ML20032C077
| ML20032C077 | |
| Person / Time | |
|---|---|
| Site: | Satsop |
| Issue date: | 10/29/1981 |
| From: | Kim C, Leddick R, Sluka J WASHINGTON PUBLIC POWER SUPPLY SYSTEM |
| To: | |
| Shared Package | |
| ML20032C059 | List: |
| References | |
| 10CFR-050.55E, 10CFR-50.55E, GO-81-2676, NUDOCS 8111060675 | |
| Download: ML20032C077 (35) | |
Text
{{#Wiki_filter:._ 6 Washington Public Power Supply System Box 1223 Elma, Washington 98541 (206)482 4428 October 29, 1981 G03-81-2675 U.S. Nuclear Regulatory Commission, Region V Office of Inspection and Enforcement 1450 Maria Lane, Suite 210 Walnut Creek, CA 94596-5368 Attention: Mr. B. H. Faulkenberry Chief, Reactor Constructie. Projects Branch Gentlemen:
Subject:
PROJECT NOS. 3 AND 5 ' DOCKET NUMBERS 50-508 AND 50-509 FINAL REPORT OF 50.55(e) LINEAR INDICATION IN ASME PIPE SPOOL Re erence: Letter, G03-81-2473, R. S. Leddick to B. H. f Faulkerberry, dated September 11, 1981. Attached please find the Engineers' final report of a 10CFR50.55(e) i condition of linear indications disc' overed in ASME pipe delivered to the WNP-3/5 Site. Should you have~ any questions or desire further information, please contact me directly. Very truly yours,. fp c - 4 R. S. Leddf Program Director, WN" 1/5 Attachment cc: J. Adams - PP&L-WO/A D. Smithpeter - BPA -WO/A Ebasco - New York -WO/A l WNP-3/5 Files - Richland -WO/A t I SIIIOGo67F
s s-WASilINGTON PUBLIC POWER SUPPLY SYSTEM WPPSS NUCLEAR PRO,IECTS No. 3 ANDJ ENGINEERING FINAL REPORT 10CFR50.55(e) - D/N #032 LINEAR INDICATIONS IN ASME PIPE SPOOLS - IIEAT NO. WE 218 October 26, 1981 Prepared by: f' weSjuxa Eb4L C M Kim -b R C T4Ffor /; - i
M-INTRODUCTION On May 15, 1981 the installing contractor observed a crack-line indication in the veld end preparation of pipe spool #3-3AF3-111SB-12 as it was being installed in the Auxiliary Feedwater System of WNp-3. This piping is designed to the requirements of ASME Section III Class 3 and the pipe in question is three (3) inch Schedule 40, carbon steel SA106 Grade B. Examination using liquid penetrant methods disclosed a tight crack-like indication running essentially the full length of the pipe. Attempts to remove the in<lication by grinding and blending reduced the wall thickness below minimum requirements (0.189 inches) for Schedule 40 pipe. NCR 251-4546 was issued against this spool and an investigation was initiated to identify cnd inspect all piping produced f rom the same heat of material (IIcat No..WE218). On August 13, 1981 the NRC was notified of the deficiency under the requirements of 10CFR50.55(e) and an Interim Report was submitted on September 15, 1981. This Final Report summarizes the results of the investigation and the actions taken to resolve the deficiency. It must be noted that material from lleat No. WE218 has been used by the fabricator to produce pipe spools for both ASME and ANSI systems, however this report addresses only that piping produced to the requirements of ASME Section III for Safety Related Systems and ANSI B31.1 Fire Protection for WNP-3/5. r d
4' A. DESCRIPTION OF DEFICIENCY 1. Original Finding of Deficienev and Notification to NRC On May 15, 1981 the piping installation contractor, Peter Kiewit Sons, observed a crack-like indication in the weld end preparation of Spool #3-3AF3-111SB-12. Further investigation disclosed a tight hairline crack running essentially the fuit length of the pipe and NCR #251-4546 was initiated. Attempts to remove the indication by grinding and blending resulted in a reduction of the wai1 thickness be3sw minimum requirements of Standard Schedule 40 pipe. The pipe was rejected and the entire length was removed f rom the spool for further detailed examination. This pipe is three (3) inch Schedule 40, SA106 Grade B, designed to the requirements of ASME Section III, Class 3 as part of the Auxiliary Feedwater System, and is located inside the Radioactive Pipe Chase at Elev. 352'-3" of the WNP-3 Reactor Auxiliary Building. The minimum wall thickness requirements for three (3) inch Schedule 40 pipe produced in accordance with SA-530 is 0.189 inches. Since the oefect exceeds the allowable and the pipe is installed in a Safety Related System, the deficiency was judged to be significant. Accordingly, on August 13, 1981 the NRC was notified of the deficiency under the requirements of 10CFR50.55(e) and on September 15, 1981 an Interim Report was issued. 2. Additional Findings Since the defect in Spool 3-3AF3-111SB-12 ran the length of the pipe, it was indicative of a basic flaw that could exist in other piping. It was therefore decided to inspect all piping in the field and in the shop that was fabricated from the same heat of material, and to conduct a metallurgical examination of the crack found in Spool 3-3AF3-111SB-12. The heat number was identified as WE218 and a careful search was made of the QA records to identify all materials produced from this heat. a. Material at Pipe Fabrication Shop The fabricator, Associated Piping and Engineering Incorporated (AP5E) was directed to identify all piping containing material from Heat No. WE218 categorized as shipped, in process or in stock. They were also directed to conduct a metallurgical examination of material removed from Spool 3-3AF3-111SB-12, to stop shipment of all Heat No. WE218 material, and to perform nondestructive inspection of all piping containing material from this heat. The inspection was to be performed.
s TABLE A.2.a (1) RESULTS OF IN3PECTION PERFORMED BY ASSOCIATED PIPTNG AND ENGINEERING ON FABRICATED-BUT NOT SilIPPED SPOOLS (Total of 16 Spools) Linear Encroachment of Shop Sheet No. Indication Minimum Wall Thickness 144 599 1604 1788 1789 Positive Yes, 0.183" 1790 1791 1872 Positive No 2135 2136 2137 2139 Positive No 2140 Positive No 2141 2142 2144 Positive No NOTE: Full circumferential inspecti^n performed at maximum of ten (10) foot intervals using LPE, plus 100% MPE. All blended areas re-examined with LPE and MPE to confirm removal of indication. UT readings taken on all blended areas to measure remaining wall thicknesses..
_m a t I A. DESCRIPTION OF DEFICLENCY (CONT'D) 1 (3) Spools Shipped to the Site (71 Total) This total includes both ASME III and ANSI B.31.1. See Section A.2.b below for description. (4) Metallurgical examinations were conducted by both AP&E and US Steel Corporation. The defect in Spool 3-3AF3-111SP,-12 i was measured at 40% to 45% through wall by AP&E. US Steel i Corporation concluded that the linear condition existed in the billet prior to piercing or occurred during the piercing operation, and that such a condition is related to the product of this billet and is not a function of the heat of stecl. See Attachments 2 and 3 respectively for these i reports.
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The piping produced from Heat No. WE218 was subjected to hydrostatic tests at a minimum pressure of 2500 psi as evidenced by USSC's Metallurgical Test Report. (See ) i 1 b. Material Delivered to the Site The sev6aty-one (71) pipe spools identified as containing =aterial from Heat No. WE218 and delivered te the Site consist of thirty-seven (37) ASME Section III Class 3 (AP&E Job No. 17948) and thir'ty-four (34) ANSI B31.1 (AP&E Job No. 17950). NCR's have been issued against all of these ASME III Class 3 and against one ANSI B31.1 spool. Only one ANSI B31.1 spool is to be installed in a Safety Related System (Fire Protection) in WNP-3. These spools with their designated NCR and status are as shown in Tables A.2.b-1 and A.2.b-2. 1 Each spool will be inspected by LPE cr MPE as described in Section A.2.a above and is being properly controlled and j dispositioned through the NCR process. Rewerk and repair will be in accordance wich the requirements described in Section 3 of this report. i ) At.the time of this report, twelve (12) spools have been inspected l and except for Spoo 3-3AF3-111SB-12 no rejectable linear indications have been found.. v-,-- .-_,-.,..-_,r-r-.., m._,~,.., ... ~. ..-.,-......,-..-_m ...c.-.,- - ~. -g
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11. ANALYSIS OF Tile SAFETY IMl'LICATIONS Piping produced from material of lleat No. WE218 has been fabricated into spools for the f ollowing - stems: Design No. of System Pressure Temperature Sp_o_ols Fab'd Aux. Feedwater 150 psi 125 F 37 Component Cooling 150 psi 2000F 16 Fire Protection 167 psi 800F 1 Total Fabricated 54 The design pressure for these systems is extremely low compared to the 2500 psi minimum hydro pressure reported by US Steel Corporation in. However, the 40% to 45% through wall crack depth reported by AP&E in Attachment 2 gives rise to serious concerns for the long term integrity of the piping systems under the most adverse design loading conditions considering pressure, temperature, thermal expansion and dynamic effects. In consideration of these loads over the long term duration of the plant design life, any defect of the magnitude found in Spool 3-3AF3-131SB-12 would have to be judged detrimental to the overall plant safety. 1
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A1TACilMi:Nr 1 linited ugs States Steel l 01}70111tlO11
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INTim uOUNT AIN DISTRICT S ALES to E AST SOUTH Tr u PL E *1200 $ a L T L A u f CIT Y, UT AH 8 4133 DENvt, oLoRADo: 303/623 2001 Oct. 7, 1981 Associated Piping & Engineering Co. 851 South Freeport Industrial Pkt y Clearfield, Utah 84015 Attn: Frank Corjat
Reference:
Mill Order AB 48850, Mountain West Pipe 5 Supply Surchase Order 0474, 3k O.D. x.216 W ASTM A-106 Grade B Heat # N56659
Subject:
Linear Indication Gentlemen: i sie sample submitted.to you from the spool fabricated from the referenced pipe has been inspected by Mr. Archer, Metallurgical Engineer. ' After this preliminary inspection it is concluded that the linear condition existed in the billet prior to piercing or occured during the piercing operation. Such a condition is related to. the product of this billet and is not a function of the heat of steel. I This condition did exceed the minimum wall tole'rance and the length of pipe is properly rejectable. A portion of this sample a,long with another piece randomly selected from your stock is being forvarded to the laboratory of our producing mill at Lorain, Ohio. An in depth investigation will be made and their conclusions reported. Very truly yours, /N R. E. Meier Manager of Sales Intermountain DSO A3-1
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INDEX Page Introduction. 1 Conclusion. 2 A. Description of the Deficiency 3 B. Analysis of the Safety Implication. 11 C. Corrective Actions Taken 12 Site NCR 251-4546 Johnson Controls IOC " Metallurgical Evaluation. Attachment 2 of APLE Code-WE218" f rom Bob Hipley to K C Jones dated October 8, 1981 United States Steel Corp Letter to AP&E " Linear. Attachment 3 Indicatiens" from R E Meier to Frank Corjat dated October 7, 1981 United States Steel Corp Metallurgical Test. Report dated 11/21/77 (carked for WE218) e 11
c CONCLUSION The crack-like indication found in pipe spool 3-3AF3-111SB-12 has been subjected to detailed metallurgical examination by the piping fabricator, Associated Piping and Engineering Corporation and by the material supplier. US Steel Corporation. AP&E has reported that the pipe contains a mill processing defect that extends 40% to 45% through the wal' from the OD surface. US Steel Corporation has reported that the linear indication existed in the billet prior to piercing, or occurred during the piercing operation. Further, that such a condition is related to the product of this billet and not a function of the heat of steel. All piping prcduced from this heat (WE218) for WNP-3/5 has been identifed and is being examined for similar indications using liquid penetrant or magnetic particle inspection methods. Inspection has been completed by AP&E on all WE218 piping in their facilities, including fabricated pieces and material in stock. This inspection has disclosed additional indications, some of which cannot be removed without wall thickness reduction below minimum requirements. Directions are being given to AP&E that such defects may be removed as long as Schedule 40 minimum wall thickness of 0.189 inches is maintained, and that if removal results,in a reduction of the pipe wall below minimum wall thickness, repairs may be made in accordance with ASME Section Ill Subsection ND-2550 and ASTM A106 for AS12 and ANSI pipe respectively. For all piping delivered to the Site which contains material from Heat No. WE218, Site NCR's have been issued and nondestructive examination using liquid penetrant or magnetic particle methods is in' process. No additional def ects have been found to date. Should indications be found in this delivered material, they will be reworked by grinding and blending. If such rework infringes on the minimum wall requirements, the material will be replaced, or repaired in accordance with the ap-propriate requirements of ASME Section III and ANSI B31.1 as stated above. All such inspection, rework, replacement or repair will be documented on the NCR's. It is therefore concluded that a) with the identification of material praduced from Heat No. WE218, b) the detailed inspection program described herein, c) the documented dispositioning of all delivered spools in accordance with the NCR procedure, and d) the controls established at the AP&E fabrication facilities, the deficiencies associated with Heat No. WE218 will not Le present in the piping as fi, ally installed at WNP-3/5..
A. DESCRIPTION OF DEFICI,ENCY (CONT'D) using liquid renetrant methods, applied over a full circumferential band at maximum intervals of ten (10) feet with at least one band on each length of pipe. In response to this direction AP&E has reported as follows: (1) Spools fabricated but not shipped (16 Total) (See Table A.2.a.(1)) (a) No linear indications found. 11 spools (b) Linear indications found. 5 spools (c) Indications removed by blending within minimum wall thickness requirement. 4 spools (d) Indications removed by blending below minimum wall thickness requirement. I spool *
- In one small area a thickness reading of 0.183 inches was obtained after removal of indication.
(2) Material In-Stock (30 Total) (See Table A.2.a(2)), (a) No linear indications found. 12 pieces (b) Linear indications found. 18 pieces (c) Indications removed by blending within minimum wall thickness requirements. 2 pieces (d) Indications removed by blending below minimum wall thickness requirements. 15 pieces ... l
TABLE A.2.a(21 RESULTS OF INSPECTION PERFORMED BY ASSOCIATED PIPldG AND ENGINEERING ON _UNFABRICATED PIPE STOCK (Total of 30 pieces) Pieces with no linear indication found: 1, 2, 6, 20, 21, 22, 23, 24, 25, 26, 27 and 28 (Total 12) Pieces with linear it.dication found and removed within minimum wall thickness requirements: 5, 8 and 17 (Total 3) Pieces with linear indications found and removed with encroaclunent on minimum wall thickness (0.189") requirement (Total 15): Pieces No. No. of Areas Lowest Reading (inches) 3 34 0.173 4 1 0.187 7 4 0.183 9 1 0.182 10 2 0.182 11 14 0.175 12 7 0.181 13 3 0.178 14 17 0.173 15 45 0.173 16 1 0.175 18 12 0.181 19 1 0.185 29 3 0.181 30 2 0.131 NOTE: All pieces 100% inspected by LPE and MPE. All blend areas re-inspected with LPE and MPE to assure removal of indication. UT readings taken on all blended areas to measure remaining wall thicknesses..
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S K R AM E R 2 - 1 l .f 2 o l ,I I l A1 3 l. l i:i I. Mte B e S Ah U TS TAT S I S T, I U S E R it0 I TC E P S 1 t I l .i 2 iI 7 R / C W 1 f ) / l l W J a 1 t 0 s 9 n I 'n, i T M AC w 9) O L 8.y, S u 1 0 ) ( g,e B /- R G p 6 6 0 0 e 1 3 A y; L O ~ 0 (p O b P S 4 l a i / P C S /. f '3 38 d n O os ~6# i s t aY T pl Il 7 i C i r /S 8 c e sdbP 2 eo O DCAS Sc l1 llL l1l l1\\
?' C. CORRECTIVE ACTION The def ective material found in Spool 3-3AF3-111SB-12 has been scrapped and repaced with conforming material. The inspection of all piping produced from Heat No. WE218 as described in Section A of this report will provide assurance that all non-conforming material from this heat has been identified. All similar linear indications will be reworked by grinding and blending within the limitations of the 0.189 inch minimum wall thickness requirement, or by repair in accordance with ASME Section III Subsection ND-2550 for ASME III Class 3 pire and ASTM A106 for ANSI B31.1 pipe, or the pipe will be replaced, all subject to the Engineer's prior approval. Welding end preparations produced at the AP&E shops are subjected to visual examination by the operator performing the work and by an independent inspector. Effective October 13, 1981 AP&E has intensified their visual inspection of all weld end bevels prior to the application of the deoxaluminate coating. Close scrutiny of the weld end preparations will continue to be performed by the installing contz ~ tor.
wNr.3/* NITM:llMI{N I l PAGE / _ OF /1' '(} m.4546 -[EPO d i No of SITL NONCONFORM ANCE REPORT g'#j (t i Al'IT Y CL A S S t r > INSTRUCTIONS ( E E E B AC K Or F OR M) P90 JECT NO (3) cascagion os cowac=t=, past. ca systt u t a r Loc at io n i s i t+a.i=ss setc i cuot s tancaa s p i. ; a - s~ r3 -/43 - / 2. & r> a' p '., e L s <. .hs f -s si - c ' n. y-was o=sente co=rascv tr> a.: r eo = r a n t = T o c c = t a c t no=consonwa nce ic i suostost ar.itws ca antas irrecTcc (s ) 3:-vo -?rt +4c/ Jy'
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EBasCO st:VICESINr00PonttD CN P. S /$ REC EIV ED. / b REDISPOSITION - 9~ i931 'PAGE 8 0F REPORT No. _ gy'f SITE NONCONFORMANCE REPORT i QUALITY CLASS INSTRUCTIONS * (SEE 9 ACK OF FORM) { K $.$Q$gROJECT No. I II G 3 5 385 otsC::lPrios. or COWPO%ENr Paar C# sYsitM loc M ion / om a wing / s PtC1coDt /st a NDanD l A -2 RF3 -///Stf_ /2 K 4 2 ('A B l'. 2M -&f/- 62 /Erv6~ misecg attcomia t actiowhtaa = is comrax noncomrommanct,4b FAY # 727 -EN~~hoV7 lsuestNtwr ita us on anta J M O-d6"/ LLason roa at oisposition _ao6%w/own e'emdheo /
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(!ASHINGTCN DUBLIC POWER SUPPLY SYSTF M E9 ASCO SERVICES INCORPORATE NUCLEAR PROJ ECTS 3 ti 5 REPORT OF NONDESTRUCTIVE EVALUATION CONTRACTOR CATE V rVCR 0Q - VW C 79 U CONTRACT NUMBER CONTROL Na OR REPORT No. 3M6"DO U 100T P32 Y o ~s P JCB OR P90 JECT LOCATION P. O. No. PLAN OR WG No. 00 #
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Wop-3 SURFACE CONDITION HEAT No. HEAT T R EAT. TYPE C MAT'L TEMP. OF M AT' L. 3 mgof f etFoot C svTER Q k W Y* * *1l 'INOARD { NDE PROCEDURE No. TYPE OF EX AMIN ATION EXAMINATI N STANDARD ACCEPTANCE ui G ur Q nf g) [ h$ff g l ffb ULTR ASONIC EVALU ATION EQUIPM N TRANSDUCER TEST BLOCK METHOD USED SCANNING METHOD SENSmVITY LEVEL M MAGNETIC PARTICLE EVALUATION ""#E"#8E P OLCR EQUIPM NT oRy O viSi e tt O AC Q oC Q p a OQ SPAC:NG fv WET C FLCUR ESCENT C 9 EC'IFito O EsoO Coil O LlQUID PENETRANT EVALUATION 7~ M ETHOD '.tN ET R AN T CLEANER DEVELOPER l ) e ANO No. 9 OwELLTlWE B RANQ ho. SATCH BR ANO No. BATCNNo. CEV. Tl WE ORY C *eQN. fb' W [fblu q _ hypy cci jf -)] () y p,, y 94.p Q $ 17 j,r th Ar chaxousq PART No. TOTAL L ENGTN EX AMINED TY8E OF wCRK WS OFI u b ') h ? $ '~ ll} & ~ NEw Q RLP AIR C ~ ]/- TYPE OF DEFECTS CODE C=CRACMS P = PO ROSITY NF
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AASHlfM ON iuPi1C PCWER SUP LY SYSTEM ES ASCO SERVICES II4CORPOR ATED NUCE r. ar? PROJ ECTS 3 8 5 REPORT OF NONDESTRUCTIVE EVAL.UATION CCNTRACTOR CATE 7 (C(o 3 Sms c h lW CCNTRACT NUMBER ^^NTRCL Na OR DEPORT Na 2270/2 rl V 32*o-am -O P JCB OR P90 JECT LOCATION P. C. No. PL AN OR OWG. No. f(t v L7)(r bLJV 3 Odd *7I/~ 6 Mb SURFACE CONDITION HEAT No. HEAT 7REAT. "Y:E OF MAT *L T EM P. OF M AT' t g c.h g} 8 tFC R ArTL R Q h hG* TYPE OF EX AMIN ATION EXAMINATION STANDAR0 ACCEDTANCE STANCARD NCE @ROCEDURE No. U' O
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' Al idCIL*tLN1 J inter Offica C:rt:spond:ncs . CON M S Date . October 8, 1981 Subject Metallurgical Evaluation of AP&E Code WE-218' From Bob Hipley To K. C. Jones I Upon your request, I have evaluated the section of A106, 3".216" wall pipe (U.S. Steel Heat #N56659) returned from the WPPSS sit'e. A macro (5 magnifications) section revealed that there is a longitudinal scam approximately 40% to 45% t.irough the wall thickness. This seam appeared to be a mill processing defcct. After visual examination of the outside diameters of the straight lengths remaining at AP&E, three additional samples from the ends of pipe numbers 15, 17, and 18 were selected for further examina'.on. Micro examination (50 and 100 magnifications) of all three showed only surface conditions, such as, cold laps, folds, and grooves. No evidence of the seam found in the returned pipe was detected. ~ Photomicrographs of'these various indications are attached. All these samples were join,tly reviewed with the district metallurgist (Bud Archer) from U.S. Steel, and he was given samples and photos to send back to U.S. Steel for their comments. If we can be of further assi' stance, let us know. g i C' Te hnical Services RLH/vm A2-1 O
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~ ' ATTACle!Ehr 3 UNITED STATES STEEL CORP LETTE4. TO AP6E "LI:1 EAR INDICATIONS" FROM R E MEIER TO FRANK COPJAT DATED OCTOBER 7,1981 e
.. ' {~ ATTACFliENT 4 UNITED STEEL STEEL CORP METALLURGICAL TEST REPORT DATED 11/21/77 (MARKED FOR WE218) t e J}}