ML20058B970

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Responds to 900525 Request for Updated Info Re Cracks in Reactor Vessel Head at Unit 2.Review of Fabrication History for Unit 1 Revealed Mismatches W/Manual Back Clad at Three Areas.Supporting Info Encl
ML20058B970
Person / Time
Site: Quad Cities  Constellation icon.png
Issue date: 10/22/1990
From: Taylor J
NRC OFFICE OF THE EXECUTIVE DIRECTOR FOR OPERATIONS (EDO)
To: Evans L
HOUSE OF REP.
References
NUDOCS 9010310156
Download: ML20058B970 (7)
v • d • e


Text

{{#Wiki_filter:4 4 a. i October 22, 1990 The Honorable Lane Evans United States House of Representatives Washington, D.C. 20515

Dear Congressman Evans:

In our letter to you of May 25, 1990, we committed to keep you updated on the cracks in the reactor vessel head at the Quad Cities Station, Unit 2, by sending you additional documents as they become available. In our letter of i August 6, 1990, we sent you two relevant documents. Enclosed are two additional documents submitted by Commonwealth Edison, the licensee., of August 27, 1990, contains the summary of fabrication history for the upper j reactor vessel of Quad Cities, Unit 1., of August 28, 1990, contains the inspection plan for the reactor head and upper shell of Quad Cities, Unit 1. The review of the fabrication history of Unit I revealed that mismatches with i manual back clad (similar to Unit 2) had occurred at three areas. Therefore, the inspection plan concentrates on two of these areas. The third area, which is inaccessible, will be examined in the future when the technology is better developed. Based on our current _ understanding, the licensee will perform an extensive inspection of the Unit 2 reactor vessel head at its next refealing outage. A report. of their activities will be generated, and it will be forwarded to your office at that time. We continue to believe that operatson of Quad Cities, r Unit 2, with.the-cracks poses no safety concerns. Sincerely, Original Signed Byi James M.TayloM; James M. Taylor Executive Director for Operations

Enclosures:

1. Letter from Rita Stols, Commonwealth Edison, August 27, 1990
2. Letter from Rita Stols, Commonwealth Edison, August 28, 1990.
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1 L The Honorable Lane Evans United States House of Re resentatives Washington, D.C. 20515

Dear Congressman Evans:

l'i our letter to you of May 25 1990, we committed to keep you updated on the cracks in the teactor vessel he d at the Quad Cities Station, Unit 2, by sending you additional document as they become available. In our letter of August 6, 1990, we sent you two levant documents. Enclosed are two additional documents submitted by Commonweal h Edison, the licensee. Enclosure 1, of contains the su ry of fabrication history for the upper August 27,,1990,f Quad Cities reactor. vessel o Unit 1., of August 28, 1990, containstheinspectionplanYorthereactorheadanduppershellofQuad Cities, Unit 1. The review of the fabrication history f Unit 1 revealed that mismatches with manualbackclad(similartoUnit2)ha occurred at three areas. Therefore, the inspect. ion plan concentrates on two f these areas. The third area, which is inaccesfeible, will be examined in the uture when the technology is better developed. Based on cur current understanding, the lic nsee will perform an extensive inspection of the Unit 2 reactor vessel head at its next refueling outage. A report of their activities will be generated, and it will be forwarded to your office at:that time. Sincere m ) James M. Ta lor. Executive Di ec W for Operati M

Enclosures:

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1. Letter from Rita Stols,

\\ Comonwealth Edison,. August 27, 1990 2.' Letter from Rita Stols, l s Connonwealth Edison, August 28, 1990 I.

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\\...../ The Honorable Lane Evans United States House of Representatives Washington, D.C. 20515 Daar Congressman. Evans: 3 In our letter to you of May 25, 1990, we comitted to keep you updated on the cracks in the reactor vessel head at the Quad Cities Station, Unit 2, by ser. ding you additional documents as they become available. In our letter of August.6,1990, we sent you two relevant documents. Enclosed are two additional documents submitted by Commonwealth Edison, the licensee., of August 27, 1990, contains the sumary of fabrication history for the upper reactor vessel of Quad Cities, Unit 1., of August 28, 1990, contains the= inspection plan for the reactor head and upper shell of Quad Cities,. Unit 1. The review of the fabrication history of Unit I revealed that mismatches with manual back clad (similar to Unit 2) had occurred at three areas. Therefore, the inspection. plan concentrates on two of these areas. The third area, which .'is inaccessible, will be examined in the future when the technology is better developed. We win centiad.te-keep-you yhted on thh matter 4 gg[ m, // ~ tes m F v e d e f w % o g c! o s of i P-Sincerely,ne p i - a rs d Zed. l e s knm ) 1/uk tu (A .v ex SA J L,$ Lea + 4,.J.ss(J c A' q. A k N* 3 w.'II.he }hdd ~ E 'E James M. Taylor Will' j k,-cl. j lo 'jo g for Operations Executive Director p 1 eh b. lls, f >we, Enclos6es:- t'

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r.- 1 The Honorable Lane Evans United States House of Representatives Washington, D.C. 20515 /

Dear Congressman Evans:

/ In our letter to you of May 25, 1990, we committe to keed you updated on the cracks in the reactor vessel head at the Quad Ci.1es Sta. tion, Unit 2, by sending you additional documents as they become available. In our letter of August 6 1990, we sent you two relevant documents. En' closed are two additional documents submitted by Ctenonwealth Edison, the licens' e., of e contains the summary of fabrication /of August history for the upper August 27, 1990, reactor vessel of Quad Cities, Unit 1., 28, 1990, contains the inspection plan for the reactor head and upper shell of Quad Cities, Unit 1. The review of the fabrication history of Unit 1, revealed that mismatches with manualbackclad(similartoUnit2)hadoccurredatthreeareas. Therefore.

the inspection plan concentrates on two of these areas. The third area, which

.is inaccessible, will be examined in the future when the technology is better developed, j We will continue to keep you updated on th I matter. S ncerely, James M. Taylor Executive Director /, for Operations /

Enclosures:

/-

1. Letter from Rita Stols, f

Commonwealth Edison, Au 27/, 1990

2. Letter from Rita Stols, gust /

Connonwealth Edison, August 28. 1990 / /!

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. i NAME DCRUTCHFIELD WRUSSELL l JPARTLOW TMURLEY JTAYLOR DATE- /. /90. /- /90 / /90 / /90 / /90 0FFICIAL RECORD COPY Document Name: GT 0005437

The Honorable Lane Evans United States House of Representatives Washington, D.C. 20515 /

Dear Congressman Evans:

/ In out letter to you of May 25, 1990, we committed to. keep you updated on the cracks in the reactor vessel head at the Quad Cities, Station, Unit 2, by sending you additional documents as they became available, in our letter of August 6,1990, we sent you two relevant documents,/ Enclosed are two additional documentssubmittedbyCommonwealthEdison,theljtensee. Enclosure 1, of August 27, 1990, contains the sunnary of fabrication history for the upper reactor vessel of Quad Cities Unit 1. Enclosurs 2, of August 28, 1990, t contains the inspection plan for the reactor hefd and upper shell of Quad Cities, Unit 1. The Unit I fabrication history review revealed that mismatches with manual back clad (similar to Unit 2) had occurred at three areas. The inspection plan, therefore, concentrates on two of these areds. The third area, which is inaccessible, will be examined in the futu 'e when the technology is better developed. We will continue to keep you updated on this matter. Sincerely, James M. Taylor Executive Director for Operations Enc 1 cures: 1.-Letter from Rita Stols, Connonwealth Edison, August 27 1990-

2. Letter from Rita Stols,

/ Commonwealth Edison, August 28, 1990 I "0FC I

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C:mm:n:lealth Edis n 1400 Opus Place Downers Grove, minois 63515 ? August 27,1990 Dr. Thomas E. Murley, Director NITN: Docume ' '.'ontiol Desk Office Of Nuclear Reactor Regulation Washington. DC 9.0555 Suh,iect: Quad Cities Nuclear Powei Station Unit 1 Sununary of Fabrication History for the U,por Ronctor Ve,ael N31 musks.LHoJE'M l Heference: R, Sints to T.E. Murley letter dated May 4.1990. Dr. Murley: On' April 19,1990 members of the Nuclear Reactor Regulation's (NRR) and Commonwealth Edison Company's Staffs conducted a technical meeting to discuss the ernchs identin.3d in the gun <1 Cities Unit " Reactor Vessel Head. During that - meeting,brication processes of the vessel head. Therefore, Commonwealth EdisonC to the fa tonunitled t o research the fabrication history ofits Boiling Water Reactors (BWR). The referenced letter provided the schedule for submitting the summary of the fnbriention history for ottr six (6) BWR vessels. provides the fabrication history summary for the Quad Cities Unit 1 Reactor Vessel. This sununary was developed through the review of a L limited populntion of records, however, provides the necessary information required to identify target areas for inspection. Attachment 2 provides a listing of Contract Vntiations which were identitied through the review of General Electric Quality Contiel ('heckliats. The ieview of the Contract Variations has not yet been completed and will be provided to your StafTby December 31,1990. The Quad Cities Unit 1 Reactor Vessel was fabricated entirely by Babcock & Wilcox. The summary indicates Ihat fabrication mismatches, which are considered to be significant for development of an inspection plan, were identi0ed at thn head-to-flange, tiange to shell an? uppermost shell to-shell welds. The review of limited Inbrication secords indicated that hach cladding of these welds was performed by subaic' welding; however, a more detailed review of the specific weld Inbriention records hns indiented that the back cladding operation was performed by a manual shielded metal are welding process, s (,;.., c..,.. 00 < 0 0 9een-rotryrvo0BD7 l ADOCK050gS,4 PDR g,p.

l o y l>r. T.E. Murley 2-August 27.1990 if theie nie any questions on titis topic, please direct them to me at (708) 5157283. ) Very truly yours 'J.- 7; ' ' fdkl:Y% ) Rita Stols Nuclear Licensing Adminietrat.or j i 1 ec: A.D. Davis Regional Administrator (RIII) L.N. Olahan - I'roject Manager (NRR) U. Elliot. - Technical Staff (N RR) i T. Toyini Senior Resident inspector (QC) Imw/ID202 t a

l, OAROENTO LUNDY e rNo NCEQO cmcaso ATTACHMENT 1 OUAD CITIES - UNIT 1 RPV FABRICATION HISTORY The fabrication history of the Quad Cities - Unit i reactor vessel, as detailed below, is based on the review of the six microfilm spools from B&W and the G.E. " Quality History" checklist. 1. unterial The vessel flanges were made from SA336 Code Case 1332-1 forgings (i.e, a nickel-chrome-moly low alloy steel) with a vanadium content of.02.04 percent shown on the Certified Material Test Reports (CMTR's). The torus sections, dollar-plates, and shell were fabricated from SA302 Grade B Code Case 1339 plates..CMTR's for this mancanese-nickel-moly low alloy steel did not report vanadium. Except for a plate in the top head. torus which did not show a grain size and one plate in the upper intermediate shell with a grain size of four, cll platec had a grain si:c of five or fincr. Plate thickness for the top head was 4" and for the bottom head dollar plate and lower torus 8". The CMTR's for the shell plates and bottom head dollar plate show 6-1/4" thickness but the ASME N-1A Code Data reports lists them as 6-1/8". Submerged. arc welding material is a special wire and a Linde

  1. 80 flux producing a weld deposit which matches the plate naterial. ' Shicided metal arc welds use E8015-C3 electrodes,

.a nickel-moly alloy. Most heats of E8015-C3 had.a vanadium content of.01 percent; however, a heat with the highest ^ vanadium,.028 percent,'was used on the repair and weld build-up of the top head assembly to flange weld. 2. General Fabrication Secuence Fabrication was performed by B&W, primarily in their Mt. Vernon, Indiana shop; however, the assembly of the lower vessel (i.e., the bottom shell ring, upper and lower torus and dollar plate) was field welded together'on a barge in -Madison, Indiana reportedly because of a labor dispute. The fabrication problems detailed below are summarized by location'and illustrated on the sketch in Attachment G. A. Too Head'Assembiv This assembly consists of a dollar plate, torus section, and flange. The torus section is composed'of six roll formed plates submerged arc welded (SAW) together. The torus to dollar. plate weld had a mismatch up to 5/8" and-weld gap at the_ root up to 1-3/4" (the drawing specifies ~ 3/4" minimum but no maximum). Nevertheless, the weld was; made with the fit-up condition by SAW. Preheat was maintained at 300*F for eight hours but then dropped to room temperature prior to postweld heat treatment (PWHT). f This reject condition was cleared by ultrasonically testing (UT) the weld. After a PWHT which involved an \\

w s ,w. OARGENT O LUNDY ~ ENGINEERS CM 6c ASo excessive heating rate (temperature went f rom 600*F up to 1035'r in thirty-five minutes ), UT of the circle seam was required. This revealed a deep defect which was weld repaired (see Attachment A), UT examined and then PWHT. 3' Two locations on the flange I.D. with a cumulative length of about 1/3 the circumference had undersized areas - up to 5/16" deep - which were weld built-up and PWHT by B&W, During fit-up of the top head assembly to flange weld + excessive mismatch - up to 3/4" - and weld gap at the root (the O.D. for this weld) of 1-1/2" was encountered. The weld and weld build-up on the I.D. was made using l

SAW, Upon removal of the O.D.

backing strip a crack was g detected visually in the weld. This repair and the 0.D. weld build-up were made uring shielded metal arc welding (SMAW). The I.D. and O.D. weld build-up was blend ground tc a 2:1 taper in the transition aree. B. Shell & Plance The shell consists of four rings designated as the top, C ~ uppe" intermediate, lower intermediate and bottom. Each g; g ring normally is composed of three plates electroslag 3 ,~ ' ~ i welacd together and then the ring is given a quench and terper heat treatment. However, each ring except the up',or intermediate shell had a dimensional discrepancy wh.ch Babcock & Wilcox (B&W) resolved by cutting a fourth i sr.am in the rings, expanding the diameter and making a fourth electroslag weld. Each ring also had base metal 2 weld repairs to one or m,are plates. The shell rings are .n welded together (circumferentially) by SAW with the lower intermediate t bottom shell weld being the final closure f ~ wc3d for the vessel. The shell flange was received from s the forging supplier with numerous defect cavities and low areas on the sealing face which required major weld g [,- repair. The 300'r minimum preheat was not maintained to / PWHT. Instead the repairs were heated to 400-800'T for a ./ s-minimum of two hours and then allowed to cool to room - ' ~~ /.# temperature. For the flange to top shell weld, a mismatch of up to 1-1/32" occurred at the I.D. (up to <?,f 3/B" on O.D. but this is allowablo). The weld was made N by SAW, weld built-up by SMAW on the I.D. and then ground to a 3:1 taper. The joint between the top shell (piece Mark 60) and the upper intermediate (Mk. 59) had a mismatch of up to 1-1/2" as shown on Attachment B. The ~ excess material was air are gouged away and the weld made , ~ d using SAW with additional weld deposit serving as weld build-up so that the transition was blend ground to a 5:1 taper. For the joint between the upper to lower N intermediate shell, there were two areas each on the I.D. and O.D. which were 7/16" mismatched; otherwise the joint met the 3/8" allowable mismatch. The weld was made by l _ ft, .n. j[M ' SAW in this condition. In the final closure weld, the 'gj bottom shell (Mk. 57) with the bottom head assembly + welded to it, is joined to the lower intermediate shell

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CARCENTO LUNDY r E N OIN E EQG cmcAeo r r (Mk.'58) which now has all the other"shell rings attached. As shown on Attachment C, this joint had about 7/8" mismatch on the-1.D..and O.D. with a large weld gap (almost 3"). The weld and weld build-up was made by SAW and the transition blend ground to a 3:1 taper.

However, when the weld was two-thirds complete the pre sat was' 1,

dropped during removal of the backing ring ano strongbacks. Magnetic particle testing (MT) and.UT of the weld showed no indications. In addition, after the final'PWHT this weld receives MT, UT and=RT L (radiography). Based on this it was accepted. Tne bottom shell had an o.D. weld repair about 4" deep due to removal'of a defect found by RT-adjacent to the Mk. 7 -recirculation inlet nozzle. l ll C. ' Bottom Head Assembly h The bottom head history has been obtained from the G.E. 4 checklist and the Contract Variations. The six microfilm l-spools'did not contain bottom head fabrication records for Unit 1. The bottom head assembly'is comprised of an , upper torus, lower torus, and' dollar plate. The upper. torus'is'made of six formed plates welded by SAW. The lower torus consists of four plates welded together by y SAW.1 'The dollar plate had.two weld; repairs on the 0.D. where boat samples 5-1/8" long X.1-3/4" wide X 1-3/8" deep.were taken for test purposes. The dollar-plate.to lower torusLjoint was shown to have been weld built-up by .-SAW toLcorrect for a mismatch, welded by SAW and then had L un:SMAW; repair 1toothe weld joint due-to indications found L = by UT :(reference to Contract variations CV #122-11 and - ~ L 21 not-found in'the records). A contradiction is shown ~ E Vf linrG.E.'s' summary list of.CV>s where CV #122-21 is stated-lf tolbe.for a.mismatchLbetweenithe/ upper to lower torus. ? ~The: joint between the bottom head assembly'and. lower 'shell had'a mismatch up to 1-5/6 which' required metal . removal and SMAW Weld build-up as shown on Attachment D. The weld was made also ising SMAW and the transition b blendLground to a taper.between:3:1 and 6:1. [, J3. Claddina' ![' The sealing surfaces of the.flangessand the:I.D. of the Jdollar: plate / lower. torus assembly are.SAW clad with Inconel. i The:only problem identified with Inconel cladding was two L small exposed' base metal areas in'the final bottom head [ pt assembly near'the dollar plate weld,L3-1/2" away from the cshroud leg. 'These were found after the-field hydrostatic

test and SMAW repair: welded without PWHT using a half-bead, K

Ltemper/ bead tecnnique and' invoking Code Case 1401. After . completion of the Inconci Pad Euild-ups located at the top of the upper' torus in the bottom head B-1 subassembly, the s l, preheat:was droppei. A'UT examination:showed no indications l.', [ l ~

'_h.n T Sa OARGENT Q LUNDY E N GIN EE R S cmcno f - and the variation wes accepted. All other vessel ID surfaces, including che flanges, were clad with a 1/8" minimum thickness of stainless steel. _ Contrary to'the G.E. checklist, the r, cords indicate'that through a deviation the O ' top-head dol 3a' wate and torus were clad as an assembly using the-SAW> wire method. This automatic process uses 30BL wires with welding parameters of 400 amps, 37 volts and 8 ipm travel speed. All SAW cladding was sampled (single electrode procedure WR8 and WR59 show the first bead and then every fifth bead) for chemical analysis and ferrite determination. Ferrite was required to be 5-15 percent as determined by a Magne Gage. None of the test results were ^ found in the records. The top head dollar plate / torus assembly had numerous. clad repairs with some extending up to 1/2" into base metal (see Attachment E). The top center 9" diameter of thic acccmbly is not clad automatically but by - SMAW. The flange I.D._was clad by the SAW - 6 wire method and the chemical analysis sample from bead #7 was below the specification requirements. An " accept" ticket. stated that the bead was removed, reclad 1and a new sample--rechipped with = acceptable chemistry per: Lab #6391-and 6467. The flange to , top head assembly was back clad by single electrode SAW. The wire and welding parameters for the single electrode SAW ' cladding are the same:as-the 6 wire method. The flange I.D. and circle seam back clad area had minor repairs made by SMAW using:EP 1 electrodes. All the shell rings were individp311y 1 o o s Lclad by:.ne'SAW wire method. After cladding the upper 1atermediate shell, the-preheat was dropped prior to PWHT. = This contract variation (CV #122-25 but not found in records) was accepted by G.E. Minor-repairs to the top shell cladding s a -were-made at locations shown on Attachment F. The shell i flange 1.D. and,-contrary to thelG.E. checklist, the flange-j to-top shell weld were also clad by the=SAW - 6 wire method. s Back-cladding cf the top shell-to, upper intermediate shell Me ' circle seam'weid was by SAW (WR 15.or WR'15= Alt. 1 but not- ~ ~

found in the records).-.These procedures were also scheduled

_L for back cladding the upper to lowercintermediate shell' weld > but the' records indicate that_it was back, clad.by SMAW:using = 5/32"' diameter E309.at 140. amps for the initial layer and then 5/32" rand 3/16" diameter-E308 at 115/A75 amps- ~ rospectively. Back1 cladding'by SHAW.was also used.for the-closure weld,and the bottom head. assembly' to lower shell weld. -The bottom head apper torus was clad with stainless. ~ steel by singlefelectrode SAW. Back cladding of!the upper to-1 lower torus we3d is'shown as WR 39 which is an Inconel SAW " cladding procedure.. On Unit 2 the drawing,showed WR 39'for 'back' cladding this-same weld but-actually-stainless steel -cladding using SMAW was performed. All final. clad-surfaces gr C are examined by/UT to assure proper bonding and PT (dye ac penetrant)'for-surface detects; Grinding of the cladding . preparatory to these examinations is permitted as required. Blend grinding of back clad-and repair areas-was specified. ~ l' e k

---o-CAROENT& LUNDY E N GIN E E RO CMICAeo 4. Postweld Heat Treatment (PWHT) All PWHT except the final closure weld, is performed in a furnace. The temperature range specified by procedure HT-6 is 1100-1150*F although records indicate that 1100-1130'F is used (probably because HT-6 requires the support skirt to be in.tkis narrower range). The closure weld receives a local PWHT in accordance with procedure HTL-4 which requires seven hours at 1100-1150'F. The width of heated area is to be ,9-1/2' feet. No time / temperature charts nor PWHT summaries were found for Unit 1. Information from a B&W letter to G.E. and a contract variation can establish the tota) PWHT time for the following items: (a) bottom head dollar plate - 33 hours 36 minutes 34 hours 25 minutes (b) shell flange 35 hours 18 minutes (c) bottom' head lower torus (d).lcwer intermediate shell - 36 hours 12 minutes 40 hours 36 minutes (e) bottom shell 5.- Missina Pecords-Thelsix microfilm spools contained some records from other job: numbers (e.g., Dresden - Unit 3 ASME Code Data Report). .A general list'of the' Quad Cities - Unit 1 records which were -missing is given below: (a)'Al.' PWHT data _(b)'The-enwire bottom head and assembly-f(c) Chemical analysis and Magne Gage ferrite results for the SAWjcladding (d) Many Contract Variations,~particularly CV #122-:1, 122-21, 122-25 and 122-105 i (e) Many: welding and cladding procedures but particularly WR-28 Alt. 4,'WR 74 Alt. 1, WR 15 including' Alt.L1, 2 and 4, and WR 54 \\ misc \\RPV-Fabr.wp u l n t a

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Ugr OF' C6kiitACT yARIk!I0fl Page 1 of? 6 Pages L O 5 r9 ) Checklist Ref. G.E. Disposition i Date [F - lCV drfyn # Descriptfen and ;r.orrective Action When Applic-t>!c i 12 '-1 ; Vessel. Flange:- B?d SN 48-122-1,iVariation UTWocedure .l Approved 3-lG-67 lrs 2.1, M 2.1.1-L 3-12-70,FS 2.1. M 2.1, WR 2.lC ..l D!sapproved i .12 '-3A ~ Shell Courses 122-1, 50-122-1, 60-122-1, Dimensional ' 05 2.3, M 2.3, WR 2.3 deviation - added 4th:icng. wold seam Appreved w/ccm. 9-19-70 r5 2.4, M 2.4, WR 2.4 d 122-38 'a ~*' ^ ' h 122-3C ~ Approved i 11-9-70 i 12;...S. Head Flange.~209-122 2, Weld repair . Approved 5-3 67 Approved 2-23-67 ril 1.0, M 1.3 122-6A ~ 8 Approved 12-i7-/0 ~ ~ ' 122-6B i $(i. UT indicationsJ weld repair Anproved 6-12-57 FS 2.4, M 2.4, WR 2.4C-122-7 Shell Course 122-1,- 5 a llf .58-122-1, 6-122-13, UT indications, weld i Arproved w/ccm 6-19-67l TS 2.3, M 2.3, WR 2.29 ~~ 122-8 Shell Course'- i repair t _ _. 122-9 Shell Course 122-1, UT indications, 6-122-9, 6-122-16, Approved 7-6-67 FS 2.2, M 2.2, WR 2.2 i weld repair I 122-11 Lcwer ilead Assembly 122-!, UTiindications, grourwi int.,- , Approved l. ii-9-67 i Fil 3.C WR 3.0B l l hase enetal, weld repair .l l 3, i

122-12:

' MK-17 2" Nozzle - Dimensieral deviation jApproved 11-16-67, FN 4.10 l a-l 3 UT indication, weid repair Approved 12-14-67 l F$ 2.1, M 2.1, WR 2.1 g [MXcosh611ccersa--60-122-1, ~^, _!22-p ~ ~ " ^ f,_.____ A .,,,r..,. I

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Project: Quad Cities I

. 6 L Pages.. ] Page 2 of P. O. ': .205-55599. CV cr vilf ' Description and Corrective Action Een Applicable G.E. Disposition Data Checklist-Ref. 5 122-18 Bottom Head Sub-Assembly - Al-122-1, Preheat temp' excessive. Approved 1-3-68 Fil 3.0, M 3.1, WR 3.1 g boat samples, weld repair - i 122-29 MK 1012" F'eedwater Nozzle - A10-122-2, RT indications, -Approved 2-16-68 Fff 4.4, W 4.4A, WR 4.4 -~t weld seam, weld repair 122-21 tower Head Sub-Assembly - B1-122-1, Mismatch between MK 4 Approved 4-11-68 Fil 3.0, PR 3.0A torus a' d MK 2 torus n 122-25 Shell Ccurse 122-1, Drop of preheat after cladding - Approved 7-1-68 FS 2.2, HR 2.2A prior to PWHT g 122-28 Shell ~ Flange 122-1, Dimensional deviation Approved 7-23-68 f5 2.1 122-30 Shell.Sub-A'ssembly - A43-122<1, Hismatch between MK 48 IDisapproved' l-17-69 flange and MK 60 shell Approved 10- 8-69 122-30A Approved 5-4-70 FS 2.1, WR 2.lA 122-30B 122-31 Shell Course 122-1, RT indication, weld repair -Approved 3-6-69 FS 2.4, WR 2.4B 122-38 Shell Course - A59-122-1, MK 13 riozzle opening oversize, -Approved 2-4-69 FS 2.2, FN 4.9, WR 4.9 weld repair s 4 L

A,,- gm .-p -Project: - Quad Cities I ~ P.0.: 205-55599 Page 3 of-6 Pages CV or Vfi # Description and Corrective Action When Applicable G.E.. Disposition Date Checklist Ref. 122-41; Top Shell As;embly - A43-12' ', Weld repair, drop of preheat Aporoved .6-26-69 FS 2.1, WR 2.1.1 122-41A ~" Approved 11-12 10 122-43 Lower Head Assembly :1-122-1, Flux monitor bores, Approved w/comm 5-1-69 Fil 3.0, FN 4.15 - ~ - dimensional deviation 122-47 Lower llead Sub-Assy - B1-122-1 Drop of prehea : on inconel -Approved 6-30-69 Fei 3.0, W 3.2.lc build-up prior to PHilT 122-50 Upper Shell Assembly ' A48-122-1, Cladding, weld repair Approved 7-21-69 FS 2.1. 122-51 UpperLHead Sub-Assy - A201-122-1, Temperature rise during Sunersede<1 PWHT. in excess of~ spec 122-51 A Supersede:I 122-51B Supersede 1 122-51C Approved 3-9-70 FH 1.0, W l.0 122-55 . Vessel Flange - A48-122-1'- Dimensional deviation Approved w/comm 12-23-69 FS 2.1 122-58 Closure Head Sub-Assy - B201-122-1, Mismatch MK 202 torus Disapproved 11-14-69 -to MK 209 flange 122-58A Approved 5-4-70 Fil 1.0, WR 1.0 T ~ w g m in

g, 3 ~ o m-p g7' g:-=- S ms Project: Quad Cities.I' P.O.: 205-55599 Page 4 of _ji_ Peges. a CVror VN # Description and Corrective Action Hhen Applicable G.E. Disposition Date Checl list Refl. 122-59: Upper Vessel Assembly - A48-122-1, Mismatch between 11K 60 Approved w/ corn 4-1-70 iF5 2.1, WR 2.lB shell-and MK 59 shell l 121-61 Lower Vessel - El-122-1, Shroud support jet pump penetrations, Approved 3-18-70 FA 5.1, M 5.1 dimensional deviations 122-63 Lower Vessel Assembly - El-122-1, Flux monitor penetrations, Approved w/conia 4-1-70 FH 3.0, FN 4.15' dimensional deviations 122-64 Lower Vessel-Assembly - El-122-1, Mismatch between bottom Approved w/comm 4-1-70 FS 2.4', W 2.4 0 head and MK 57 shell course ,,,5c 4 1 122-65 Upper Vessel Assembly - D48-122-1, MK 63 bushing holes, Approved 7-10-70! FS 2.1 dimensional deviation 122-66 Closure Head - D201-12?-1, Dimensional deviation Approved , 3-18-70 Fil 1.0. FA 1.3 122-67 Shell Course 122-1, 6-122-4, 6-122-6, UT indication Approved 3-18-70 FS 2.3, M 2.3, t R 2.3C plate 6-122-13, weld repair 122-68 Upper Vessel _ Assembly - 048-122-1, Stud holes in MK 48. Approved i 3-18-70 FS 2.1 -flange, dimensional deviation 122-69 Lower Head Assembly - El-122-1, shroud support jet pump Approved 4-1-70 FH 3.0 penetration, dimensional deviation T\\ ss s w% c

M v. I ll i.i.i....- ~ ~,, _ as r J ~. r .( Project: Quad Cities.I Page 5 of 6 Pages; P.O.: 205-55599 CV or:VN # Description and Corrective Action When Applicable ' -G.E. Disposition

Date_

Checklist Ref.. 122-70 Lower Head. Assembly El-122-1, Flux monitor hole, Approved 3-24-70 Fil 3.0, FN 4.15 - idimensional deviation 122-71 Upper Vessel Assembly - A48-122-1, Flange stud holes, Approved 3-19-70 FS 2.1 dimensional deviation 122-73 Final Assembly F1-122-1, Mismatch ;of MK-57 shell and Approved w/comm 4-14-70 2 MK 58 shell Approved 5-7-70 FS 2.3, WR 2.34,*< #-J'S 122-73A 122-74 Final Assembly - F1-122-1, HK 57 to MK 58 drop of preheat Approved 4-16-70 FS 2.3, W 2.38 af ter welding prior to PWHT 122-80 Final Assembly - F1-122-1,. Dimensional deviation Approved 4-22-70 FA 5.8 122-92 Final Assembly - F1-122-1, Free path, dimensional deviation Approved 5-6-70 Final checklist 122-93 Refueling Containment Skirt - B70-122-1,- Dimensional Approved w/comm 5-7-70 FA 5.9 ~ deviation 122-95 Final Assembly - F1-122-1, MK-A141 pipe welded with Approved 5-7-70 External pipe on Hi and alternate method to pressure monitor pip 1 DQ W CD

.; i S. Pro.iect: ; Quad' Cities;I P.O.: 205-55599 Page 6 of 6 Pages- 'CV or VN'# Description and Corrective Action When Applicable G.E. Disposition k Date Checklist Ref. 127-96 Final Assembly - F1-122-1, FT mge sealing surface, dimensional Approveo 5-22-70 FS 2.1 . devia tion 127-97 Final Assembly - F1-122-1, Vessel support skirt, dimensional Approved w/com 5-22-70 Fil 3.0, FA 3.3 devia tion A proved w/comm 5-22-70 Fil 1.0 122-98 Closure llead - D201-122-1, Closure head stud lioles, F dimensional deviation 122-99 Final Assembly - F1-122-1, Missing thermocouple pads Approved w/comm 5-22-70 122-99A 'pproved w/comm 7-8-70 FS 2.4, Fil 3.0, FA 5.1 122-100 Final Assembly - F1-122-1, Mislocated nozzles Approved w/comm 5-22-70 Final checklist 122-103 Miscellaneous Nozzles and 58-122-1. exceeded PWHT time. Approved 8-11-70 FS 2.1, FS 2.3, Fli 3.0 M 3.1, M 3.2, FN 4.1, Final checklist ~ ~ 122-104 Final Assembly - Gl'-122-1, Damaged bushing' thread, special Approved' 6-4-70 FS 2.1 bushing 122-109A Final Assembly and Closure Head -- Misc. Nozzles and Safe Approved 10-29-70 M 4.2, M 4.6 . Ends, Drop weight test not performed 122-115 Final Assembly - F1-122-2,' Field weld repair, lower hea'd Approved l-7-71 FH 3.0 rs N' (/ . - -. -.. -. = = -.~=.- .n- -..-

[4 ;J Downers Grove,litinNo 60515 C mmtnwealth Edistn i 1400 Opus Place i v 4 w. August 28,1990 g L, Dr. Thomas E. Murley ~ Office of Nuclear Reactor Regulation i U.S. Nuclear Regulatory Commission Washington, D.C.' 20555 ATI'N: Document Control Desk q E

Subject:

Quad Cities Nuclear Station Unit 1 Reactor Head and Upper Shell Inspection Plan NRC_IloskeLNoJ9 25L_.

References:

(a) R. Stols to T.E. Murley letter dated L May 4,1990. () (b) R. Stols to T.E. Murley letter dated August 27,1990. Dr. Murley: On April 19,1990, members of the Nuclear Reactor Regulation's (NRR) and Commonwealth Edison Com 3any's staff conducted a technical meeting to discuss the -cracks identified in the Quac Cities Unit 2 Reactor Vessel Head. Dunng that l meeting, Commonwealth Edison committed to perform inspections of the reactor vessel head at each ofits Boiling Water Reactors (BWR) Plants. j v Reference (a) provided the schedule for submitting various information to. the NRC. In reference (a), Conunonwealth Edison committed to review the . fabrication records for the upper vessel structure in order to identify target areas for . inspection. A summary of a hmited number of fabrication records for Quad Cities l H l Umt i upper vessel was provided in reference (b). ' Attached for your stafT's review is t e Reactor Head and Upper Shell i

Inspection Plan for Quad Cities Unit 1. The Quad Cities 1 fabrication history review s

-tevealed that major mismatches with manual back clad (similar to Quad Cities Unit q

2) had occurred at the head to Hange, shell to ilange and uppermost shell to shell wel<ln during the fabrication process. The inspection, therefore, will concentrate on i

-t he head-to Hange and shell to-Hange welds areas; however, the inspection plan also g' encompasses the remainder of the reactor head to verify that cracking is not occurnng in other areas. The Inspection Plan will be implemented during the-l upcoming Unit 1 Refueling Outage currently scheduled to begin November 12,1990. E l ' The plan delineates that visual examinations be performed for the reactor-1 + zhead to flange and vessel shell-to Hange welds to identify any evidence of potential - cracks. The mapection plan requires that indication be further examined by p ultiasonic examination. The liquid penetration examination for indications on the vessel shell-to Hange, e,ld is optional, due to radiation exposure considerations. ~ w k O 'i.h ooosts b J g m6sv. w ooo m F Dt L H g 9 ~.

1 x Dr. T.E. Murle : August 28,1990 The Inspection Plan does not encompass the uppermost shell to shell weld due to technological limitah.: Remote automated ultrasonic examination technology for BWR vessel welds is underway; however, the technology cannot be utilized reliably at this time. Examination of the uppermost shell to shell cannot be achieved by examination of the outer diameter due to inaccessibility, and manual liquid penetrant and/or manual ultrasonic examination from the inner diameter - 1 cannot be accomolished due to the radiation doses anticipated at that area. Commonwealth tdison, however, will perform the inspections when the technology is better developed. -If there are any questions or comments, please direct them to me at (708) 515 7283. 'l l [ Very truly yours, .) w i . Nuclear Licensing Administrator Rita Stols h 1cci - A.B. Davis, Regional Administrator (RIII)- L.N. Olshan, Project Manager (NRR) R I B. Elliot, Technical StafT(NRR) T. Taylor, Senior Resident' Inspector, Quad Cities /Imw/ID210 3 1 I l' l-s l ?: 1. T

O'. -k PROP 0 FED REACTOR READ AND UPPER SHELL INSPECTION PLAN (QUAD CITIES UNIT 1) REACTOR READ 1. Direct visual examination, VT-1, of 100% ID of the reactor head. Lighting adequacy must be verified with a 1/32 inch black line on a 18%' neutral gray card. Conditions to.; examined for and recorded: a/. Cracks or linear indications b/. Heavy / unusual rust streaks c/. Clad repair and/or clad thickness variations i d/.. Excessive grind ng 2. Photograph representative areas of the ID of the reactor head. 3.. bye penetrant test (PT) the following: c a/. All linear indications b/. All-heavy / unusual rust streaks c/. Sample of clad repair and/or clad thickness variation areas as. determined by CECO Nuclear Engineering Department (NED). r d/.. Sample-of excessive grinding areas as determined by NED. 4. Ultrasonically test (UT), from the ID, all cracks detected by VT and/or PT. t O t. iVESSEL SHELL-TO-FLANGE WELD 1. LDirect visual axamination, VT-1, the ID of the weld (360* band of. 15" wide).. Remote visual examination is also acceptable. Lighting adequacy must be verified with a 1/32 inch black line on a f18% neutral gray card. The. remote examination system, if used, must - be capable of. resolving a 0.001 inch wire, Conditions to be examined for and recorded: i g L a/. Cracks-or linear indications b-b/. ' Heavy / unusual rust streak c/.- Clad' repair and/or clad thickness variations e d/..--Excessive grinding n 0 2. PT all linear. indications, if desired for crack confirmation. h I 3.. 'UT from the ID,'directly.or remotely: all cracks detected by VT,"and all lducar indications detected by VT which are confirmed to be cracks by PT. or L l? . all' linear indications detected by VT if,PT is not performed. L L ZMAINT/311-2 l u -}}

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