ML20054J498

Final Rept of Potential Deficiency 82-02 Re Weld Electrode E7018 Made of Nonferrous Matl,Initially Reported on 820218. Verification Program Implemented & QA Surveillance Performed at Airco.No Weldments Contain Stainless Steel Matl

ML20054J498
Person / Time
Site:	Clinton
Issue date:	06/18/1982
From:	Gerstner W ILLINOIS POWER CO.
To:	James Keppler NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
References
10CFR-050.55E, 10CFR-50.55E, U-0506, U-506, NUDOCS 8206290115
Download: ML20054J498 (2)

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1605-L ILLINO/B POWER OOMPANY U-0506 CLINTON POWER STATION. P.O. BOX 678. CLINTON, ILLINOIS 61727 June 18, 1982 Mr. James G. Keppler Director, Region III Office of Inspection and Enforcement U.S. Nuclear Regulatory Commission 799 Roosevelt Road Glen Ellyn, Illinois 60137

Dear Mr. Keppler:

Clinton Power Station Unit 1 Docket No. 50-461 Construction Permit CPPR-137 Potential 10 CFR 50.55(e) Deficiency 82-02 On February 18, 1982, Illinois Power verbally informed Mr.

Ken Ridgeway, NRC Region III, of a potentially reportable defi-ciency per 10 CFR 50.55(e) concerning the discovery of weld electrode identified as E7018 which were found to be of non-ferrous material. This initial notification was followed by an interim report dated March 18, 1982, (IP letter U-0443, W.C.

Gerstner to J. Keppler), where it was anticipated that an addi-tional ninety days would be needed to complete our investigation of the matter. Our investigation into this matter is now complete and this letter presents a final report on this subject.

The investigation into this matter was initiated as a result-of two (2) flux-covered electrodes labeled E7018 which were found to contain non-ferrous material, later determined to be E309 stainless steel wire coated with iron powder / low hydrogen flux normally utilized with E7018 electrode. A STOP WORK was immediately initiated to cease all welding on site. All AIRCO E7018 electrode was withdrawn from the field and collected together with all other E7018 electrode of the same lot number on site, and was magnetically checked. All electrodes checked in this manner were found to be acceptable. Additionally, weld electrode stubs from the power block were similarly checked and no additional improperly manufactured electrodes were identified.

A verification program was implemented to determine and confirm that similar incorrect electrodes were not used in other safety related plant weldments. This verification program con-sisted of identifying all welds known to be welded utilizing electrode from the suspect lot, drilling a sample of these welds, and having the shavings chemically analyzed for the presence of elements indicative of stainless steel, particularly chromium and nickel. MIL STD 105D was utilized as a guide in establishing a sampling plan. The results of this program showed no indication of stainless steel material in the sample of welds chosen.

B206290115 B20618 PDR ADOCK 05000461 PDR ,

JUN 2 5 1982 g O

, J.G. Kcppler June 18, 1982 NRC Page 2 A Quality Assurance surveillance was performed at the elec-trode manufacturers (AIRCO) facility to verify implementation of their Quality Assurance program. This surveillance concluded that the QA program was adequately implemented, however, recommenda-tions were provided to AIRCO management to prevent repetition of the manufacturing defect. As an additional precaution, Baldwin Associates (Illinois Power contractor) has initiated a program to magnetically check all E7018 electrodes prior to issuance to further assure adequacy of rod.

Based on the results of the verification, testing, and checks made on the unused portion of the suspect lot of electrodes, it is concluded with a high level of confidence that no weldments at the Clinton Power Station contain stainless material which could have originated from incorrectly manufactured electrodes from the suspect lot. Subsequently, a construction deficiency as defined in 10 CFR 50.55 (e) does not exist, nor is the safety of operations of the Clinton Power Station acversely affected. Therefore we conclude that the problem is not reportable per the requirements of 10 CFR 50.55(e).

Very truly yours, W.C Gerstner Exec,tive Vice President cc: H.H. Livermore, NRC Resident Inspector Director, Office of I&E, NRC, Washington, DC Director-Quality Assurance Illinois Department of Nuclear Safety