ML20080A324
| ML20080A324 | |
| Person / Time | |
|---|---|
| Site: | Palo Verde  |
| Issue date: | 01/19/1984 |
| From: | Van Brunt E ARIZONA PUBLIC SERVICE CO. (FORMERLY ARIZONA NUCLEAR |
| To: | Bishop T NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V) |
| References | |
| REF-PT21-84 ANPP-28647-BSK, DER-82-51, NUDOCS 8402030455 | |
| Download: ML20080A324 (13) | |
Text
'
i A!N*
KCEIVED 00.C Arizona Public Service Company P.O. box 21666
- PHOENIX, ARilONA 85036
- p. t- }
January 19, 1,9,8_4.
U. S. Nuclear Regulatory Commission Region V Creekside Oaks Office Park 1450 Maria Lane - Suite 210 Walnut Creek, CA 94596-5368 Attention:
Mr. T. W. Bishop, Director Division of Resident Reactor Projects and Engineering Programs
Subject:
Final Report - DER 82-51, ReviP$0D 1 A 50.55(e) Reportable Condition Relating to Pullman-Kellog Pipe Line Failure in Unit #1 Essential Cooling Water System File: 84-019-026; D.4.33.2
Reference:
A) Telephone Conversation between J. Eckhardt and G. Duckworth on September 10, 1982 B) ANPP-21973, dated October 8, 1982 (Interim Report)
C) ANPP-22433, dated December 1, 1982 (Time Extension)
D) ANPP-22823, dated January 26, 1983 (Time Extension)
E) ANPP-23426, dated April 5, 1983 (Time Extension)
F) ANPP-23597, dated April 26, 1983 (Time Extension)
G) ANPP-23492, dated June 1, 1983 (Time Extension)
H) ANPP-24246, dated July 6, 1983 (Time Extension)
I) ANPr-27562, dated August 15, 1983 (Interim Report)
J) ANPP-28274, dated hovember 22, 1983 (Time Extension)
K) ANPP-28579, dated January 9, 1984 (Final Report)
Dear Sir:
l L
Attached is our final written report Revision 1, of the Reportable Deficiency
(
under 10CFR50.55(e), referenced above.
This Revision restates reportability under 10CFR Part 21 requirement which was inadvertently omitted $n the original final report, Reference (K).
Very truly yourg,
)
)
G L ( M t.L L m
s E. E. Van Brunt, Jr.
i 8402030455 840119 APS Vice President, Nuclear PDR ADOCK 05000528 ANPP Project Director S
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l EEVB/TRB:pt Attachments cc: See Page Two JJ - 27 x\\
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t Mr. T. W. Bishop DER 82-51 Page Two ec:
Richard DeYoung, Director Office of Inspection and Enforcement U. S. Nuclear Regulatory Commission Washington, D. C. 20555 T. G. Woods, Jr.
J. A. Roedel D. B. Fasnacht A. C. Rogers B. S. Kaplan W. E. Ide J. Vorees J. R. Bynum P. P. Klute A. C. Gehr W. J. Stubblefield W. G. Bingham R. L. Patterson R. W. Welcher H. Foster D. R. Hawkinson L.' E. Vorderbrueggen G. A. Fiorelli S. R. Frost J. Self D. Canady Records Center Institute of Nuclear Power Operations 1100 circle 75 Parkway, Suite 1500 Atlanta, CA 30339 4
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7, FINAL REPORT - DER 82-51 DEFICIENCY EVALUATION 50.55(e)
ARIZONA.PUBLIC SERVICE COMPANY (APS)
PVNGS UNITS 1, 2, 3' I. - Description of Deficiency e
While performing ; repairs to the Unit 1 Essential Spray Pond piping system (repairs for minor chips-on a flange face incurred during fit-up), the craf ts discovered delanination and peeling of the plasite 7122H Epoxy lining in three (3) 24-inch diameter 90* elbows (Spool No.'s 1-SP-030-S-042, 1-SP-030-S-043 and 1-SP-068-S-042).
Inspection by Field
' Engineering revealed that the interfor plasite lining of these three (3)
- spools had completely delamiuated from the substrate.
Nonconformance Report KY-296 documents the above plasite lining failures.
An investigation was initiated by Bechtel's Material and Quality Services (M&QS) group to evaluate this condition.
As indicated in the M&QS Trip Report dated October 14, 1982 (Reference 1, attached), it was concluded that the lining failures were - directly related to:
- 1) high L
. film thickness beyond specifications; and 2) capping the pipe with solid end caps, hence not allowing a full cure.
i As a result of = the - investigation, Bechtel. was -informed by Controlled Coatings Corporation (the coating applicator) of two other 24-inch diameter 93* elbows (Spool No. 's ISP-030-S-041. and-1-SP-068-S-040) which were coated'at the same time as the.above-spools (application commenced 12/02/80, completed 12/05/80).
An M&QS inspection of Spool No.
l-SP-068-S-040 resulted in detection of some ridges on the flange face.
Sanding of: these ridges revealed that -they contained eight (8) or nine (9) voids similar to blisters.
The voids, when iroken open, emitted a strong ester solvent type odor. The area adjacent to the exposed areas 3
exhibited poor adhesion and the coating was easily 'delaminated from the flange face into the spool approximately 1/2 inch.
This condition is documented in Nonconformance Report KY-31.
Inspection of Spool No. SP-030-S-041, after being physically delaminated, revealed a high film thickness and a very strong solvent odor.
This' condition is documented in Nonconformance Report KY-296.
Further inspection identified Spool 1-SP-068-S-041 (24" diameter 90* elbow, coated approximately one (1)
)
. month. after the above identified spools) to have similar coating failures, as documented on Nonconformance Report KY-310.
A.
plasite lining failure has also been found in Spool No.
1 2-SP-079-S-014.
However, this failure (documented in Nonconformance Report KY-315) has occurred in a 20" diameter straight spool.
The 4
failur'e differs from the above identified 24" diameter 90' elbow failures in that there were clusters of pinholes in the lining.
There was no-evidence of delamination, blistering or peeling.
For the plasite lining failures cited above, the spools had been exposed to water for approximately 20 months prior to discovery of the lining failures. No inspections were performed during this time.
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DER 82 FINAL REPORT Page Two Additional inspections were conducted by the Field Coatings Engineer in accordance with STh0 No. 19004 and NCR's KY-356 and KY-357 were issued.
NCR KY-356 d uumented minor handling damage on Snool No.'s ISP-068-S-041 and SP-030-S-041_
These spools were-repaired in accordance with Plasite Repair Procedure No.
11 of Piping Material Classifications (13-P-ZZG-012).
The condition of the lining noted on these spools does not relate to any generic lining failure noted previously.
The condician is related to minor damage (chips and nicks) which occurred during handling and installation.
NCR YY -357 documented blistering and minor handling damage to Spool No. 's 3 SP~030-S-040 and ISP-068-S-040.
Spool ISP-030-S-040 showed some localized blistering and one blister which was the result of mechanical damage. The remainder of the coatin3 is in good condition and tightly adherent.
The damage noted on Spool ISP-030-S-040 is not indicative of
-any generic failures noted previously.
This spool was repaired in accordance with Plasite Repair Procedure No.
11 of Piping Material Classifications (13-P-ZZG-012).
Spool ISP-068-S-040 was documented previously on NCR KY-312.
The failure was analyzed as being generic in nature, blistering, solvent entrapment and pliable lining.
The spool was spot repaired with Plasite No. 9009-IT. A subsequent inspection has revealed that the repaired areas are in good condition; however, the original shop lining exhibited generic failure (see M&QS Trf p Report No.
BED-083-21 attached).
It should be noted that all spools exhibiting a generic failure have been blasted and totally recoated with Plasite 9009-IT in accordance with the approved repair procedure.
Spot repairing is used only for spools exhibiting mechanical damage.
II.
Analysis of Safety Implications This condition is evaluated as reportable.
Separation of the plasite lining from the 24-inch diameter 90* elbows could potentially cause a flow restriction in the Unit-1 Essential Spray Fond System.
A restriction of this type could possibly preclude the system from performing to design intent during emergency shutdown procedures.
The subject deficiency is therefore evaluated as reportable under the requirements of 10CFR50.55(e) since, if left uncorrected, it could adversely sffect the safety of operations of the plant during the lifetime of the plant and it represents a significant deviation from performance specifications.
DER 82 FINAL REPORT Page Three III. Corrective Action The ~ failures of Plasite 7122H Epoxy lined spools documented in Nonconformance Reporta KY-296, KY-310 KY-311, KY-312 and KY-315 were investigated by the Field Coatings Engineer and Bechtel Material and Quality Services.
An inspection was subsequently conducted jointly by Bechtel Material and Quality Services, the Field Coatings Engineer and representatives of.
Wisconsin Protective Coatings (the coating manufacturer), Controlled Coatings Corp. and Pullean Power Products (the pipe supplier under Purchase Order 13-PM-201).
The following findings / conclusions regarding the cause(s) of the plasite lining failures were agreed upon by those involved in the inspection and are based upon all inspections and data gathered to date:
- 1) In the large diameter elbows, high film thickness was apparent.
Controlled Coatings Corporation stated that 24-inch and 26-inch 90*
elbows were coated with a hand-held spray gun. All other elbows and straight spools, as well as elbows shop welded to straight spools, were coated by a machine probe.
The machine probe allows a thin coat of plasite to be applied on each pass as opposed to hand spraying, which results in a heavier, less-controlled application.
This large volume of plasite may have been applied over a four (4) day period (the machine probe method of application could take up to seven (7) days to achieve the desired thickness).
Solvent entrapment subsequently resulted from capping the spools with solid l
end caps before the spools were fully cured.
Therefore, the hand l
sprayed elbows with high film thickness and less cure time, together
[
with capping the spools with solid end caps before the spools were i
fully cured, is the evaluated cause of the lining failures experienced in the 24-inch 90' elbows in Unit 1.
I
- 2) The lining failure found in Spool No. 2-SP-079-S-014 (a straight spool) showed no evidence of delamination, blistering, solvent l
entrapment or the-lining being in an uncured state.
The mil thickness was found to be thin rather than too thick and the coating was applied to a rough surface on the base metal.
An inspection of approximately 90 straight spools in Units 1, 2 and 3 (20" and 24" l
diameter) revealed evidence of pinholes and holidays in five (5)
Unit 3 spools (document in Nonconformance Report KY-332).
- However, all inspected straight spools showed no evidence of blistering or delamination and the linings were found to be hard and fully cured.
l Therefore, the coating failures found in the straight spools are considered not to be related to the problems associated with the l
large diameter elbows.
According to the coatings applicator, all cocting operations were performed indoors.
l l
DER 82 FINAL REPORT Page Four To resolve the subject condition the following corrective action has been/will be performed for Units 1, 2 and 3.
Unit 1 A representative sample of 90' elbows and straight spools (14 of each) have been inspected in Unit 1 by Bechtel Material and and Quality Services and the Field Coatings Engineer.
Results of this inspection showed one failure in addition to those previously described for Unit 1, and is documented in Nonconformance Report KY-311 (blistering and peeling has. occurred in Spool No.
1-3P-068-3-024, a 20" diameter straight spool).
Within the sample of elbous inspected, of which all were found to have hard and fully cured finings, was Spool No.
1-SP-068-S-043.
This spool is the only other large diameter elbow coated during the same time period as those identified in " Condition Description". Based upon the' coating manufacturer's evaluation that any lining failure that might occur should happen during
- flushing, hydrotesting or operational testing (as evidenced in the Unit 1 lining failures) and the absence of additional failures in the representative sample of Unit 1 large diameter elbows, no further inspection of Unit 1 was deemed to be warrante Nonconformance Report KY-296, KY-310, KY-311 and KY-312 will be dispositioned as repair in accordance with Piping Material Classifications, Drawing 13-P-ZZG-012, Plasite Repair Procedure No. 11 Units 2 and 3 Nonconformance Report KY-315 will be dispositioneo as repair utilizing Plasite Repair Procedure No. 11 referred to above.
l Separate Nonconformance Reports will be issued to disposition the Essential Spray Pond piping systems in Units 2 and 3.
All 24-inch and l
26-inch diameter 90* elbows installed in Units 2 and 3 and located in the Unit 3 laydown area are to be inspected.
Per Lesuance of these l
Nonconformance Reports, the spools to be inspected will be subjected to the following acceptance criteria:
- 1) visual inspection; 2) holiday l
testing (if applicable); 3) dry film thickness; and 4) cure test.
Each inspected spool ' will be dispositioned 'Use As Is' or ' Repair', with Plasite Repair Procedure No.
11 of Piping Material Classification (13-P-ZZG-012) being used if repair is required.
l I
- - - - - -. ~-
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t DER 82 FINAL REPORT Page Five A separate. NCR has been issued to disposition Unit 3 Spool No.
and found to have high mil 3-SP-068-S-034' which was inspected _
full with Unit 1 thickness.
This spool has been filled three-quarters spray pond water.
It has been lef t ;in the horizontal position for 59 days and has been _ visually inspected on a weekly basis 'in order to duplicate as closely as ~ possible ~the conditions experienced in the Unit 1 lining failures.
This inspection has been performed in accordance with the recommendations of M&QS Trip Report dated February 15, 1983 (Reference.2, attached).
~
After NCR's KY-356 and KY-357 were issued, an additional inspection was conducted by Bechtel Material and Quality Services, Bechtel Engineering and sechtel Field Coatings Engineer on September 14, 1983.
Spool No. 's ISP-030-S-041, ISP-030-S-042, ISP-030-S-043, ISP-068-S-040, ISP-068-S-041 and ISP-068-S-042 were inspected.
From the investigation 4
.the following conclusions were reached:
j
-1) -None of the linings observed during this inspection exhibited the failure mode seen in previous inspection, i.e.,
sheet delanination, entrained solvent, partially cured coating film.
- 2) Some localized defect were found, however these are considered minor in relation to the failure seen previously.
For details, see M&QS Trip Report _No. BED-093-16 (attached).
l In addition to reportability under 10CFR50.55(e) Bechtel PVNGS
~ Project considers the deficiency to be reportable under the requirements of 10CFR Part 21 ; by Controlled Coatings Corporation, I
the. coating applicator.
Deficiency Evaluation Report 82-51 i
addresses the reporting requirements specified under 10CFR21.21.(b)
(3).with the exception of.subpart (vi) which requires the number and
. location -(customer and/or facilities) of other possible defective equipment.
A copy of. this report will be sent to Pullman Power Products for transmittal to Controlled Coatings Corporation requesting their review for reporting under 10CFR Part 21 including number and location of.all components supplied.
References
- 1) M&QS Trip Report, dated October 14, 1982 (attached).
- 2) M&QS Trip Report, dated February 15, 1983 (attached).
- 3) M&QS Trip Report, dated August 23, 1983 (attached).
- 4) M&QS Trip Report, dated September 15, 1983 (attached).
BECHTEL GRO'p, INC.
Resear:n and Engineering Materials and Quality Services Letter File No.
DAH-102-15 Cate October 14, 1982 To:
Vas Naiarian,
From:
D. A. Mill location B49 Tel. 4392 Suoject: TRIP REPORT Date of Trio:
Project Name Palo Wrde From 10-5-82 To 10-7-82 Proje:t No. 10407-002 M&QS Log No. 2911-71 Project Spec. ha.
Destination: Palo Verde Jobsite Copies to:
/
J. W. Becker
/S. Sara Type of Trio:
W. C. Currlin B. D. Hackney D Supplier R. A. Keldel (Namej R. A. White O client
@ Jobsite Pl*EPOSE OF TRIP:
lo investigate cause of failure of the lining of some sections of the 24" spray pond piping syste=.
INTRODUCTION / DESCRIPTION OF PROBLEM:
Plasite 7122 has come off from the -ubstrate of certain elbows and spools of unit 1 cupplied by Pullman Pcwer Products Corporation and coated by Lundeen Company in coatings their shop in Fontana, California during 1980 and 1981.
CONCLUSIONS AND RECOMMENDATIONS:
The present facts indicate the cause of failure to be directly related to:
c)
High film thicknesses beyond that of our spec and the coating manufacturers reco= men-dations.
b)
. Capping the pipe with solid caps not allowing a full cure - (7 days are'needed for.12 to 15 mils).
The problem areas are directly related to high file thicknesses - over 16 mils. All spools in the lay dova area should have their caps removed at both ends and inspected. Those of 16 mils.and over should be considered suspect; those of 15 and under can be put in place efter inspection and venting.
ACTION ITEv.S 1.
Plasitt-is at present doing so e investigation for us on the chips taken from Unit 1 (a sa:ple paint chip is enclosed with this report).
2.
D. A. Mill is at present trying to get a lab analysis of the " odor" taken fro the spools in the lay down area to deter =ine if there was anything added to the coating.
3.
D. A. II111 is at present investigating the possibility of getting an inspection made of all of the Plasite lined piping 10" & 24" I.D. using closed circuit IV (since at tlie.present time we d:, not knov the extent of our proble nor where the possible failed coatec pape is locatea).
- - 4.
Since this is Q and records are available, a visit to Lundcen may give us a clue as to the extent of our problem, i.e. When was the pipe coated? A.M.? P.M.? Winter? Summer?
and What spools =ay be suspect?,
(RE: Lundeen's letter of October 5th - What is the
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batch # of the Plasite material? To what other lines was this material applied? etc.
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hECHTEL GROUP, INC.
-Resear:h anc Engineerino-Materials and Quality Servi:es' Letter File Nc.
DAu_192 13 Date October 14, 1982
-7o:
Vas Najarian Fre::.:
D. A. Eill
Subject:
TRIP REPORT (centinued)
Proje:: Name Palo Verde Project No.
10407-002 M&CS i.og ho.
2911-71 PARTICIPANTS:
NAME COMPANY OR' PROJECT AFFILIATION AND TITLES Vas Najarian Project Engineering - Bechtel' Ralph Rothenberg Field Engineering - Ecchtel Dave Crespo Steve Sara Project Charles O'Neal Inspection QEF DETAILS OF INVESTIGATION:
1.
Preliminary meeting with Vas Fajarian & Ralph Rothenberg - learned the following:
- How many feet cf spray pond piping per unit? 1500' of 24" I.D., 4 lines 10" 1.D.
2200' per unit
- All considered Q
~
- All piping canped with solid caps - af ter being " fully cured"
- Lundeen had co=e to the site with Pull =ac on Sunday, Sept. 5 and inspected " Failed" coating on 3 elbows & 4-24" I.D. lines.
i.
We went as a group tc the lay down area and uncapped 5 pipe all 24" 1.L.
- 70% of all readings were over 15 mils but none higher than 21 mils.
- A "round the clock" reading of spool #35P0pSO42 was indicative: M41 readings fer selected spool #3SP025SO42:
si
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as so
- 5,o y gu.54 9,as.
is'9 k 3M
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,jA 6 *.4 19
,5 ss.
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(This indicates that the 3600 spray used was "off' center" giving higher mileage in certain areas).
A Tooke Gauge indicated the following (Pipe 3SP-30-S-032).
l 1st application at 9 mils - grey l
2nd application at 6 mils - white Gas pockets in both coats but not extensive 4 pipe sections had a solvent cdor; the last one opened had a definite atine odor as opposed to a solvent s.:311.
(Plasite 7122 is an amine cured).
- Paint chips taken from in place spools of unit one all indicate fil: thickness over 15 mils - 95% of the readings are 'over 19 tils with many readings as high as 23 mils
& 25 mils.
3.
The last area of investigatf on was an in place 24" see:1oa ef pipe of unit 2 - this pi t.a he A Aae.n arac ure rasnad with standinc water for a cini=u. of 3 days.
General conditicn of pipe - excellent, no blisters, cracks er any sign of break-down. No odor of solvent or amine. Mil thicknesses 13 tils - ne reading over 1C mils (Thesc pipe sectient had been cappe with solid caps and had been in the.
lay down ares prior te placenent)'.
M&QS REPRE5ENTATIVE:
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Rese'ar:r an: Enginee-ing Materials an: Ouality Servi:es A etter File No.
DAH-023-08 Date February 15, 1983 To:
R. A. Keidel From: B. E. Du.' lum /D. A. Hill Location B49 Tel. 4392 subje::: TRIP REPORT Date of Trio:
Proje:: Name Palo Verde Frcm 2-1-83 To 2-2-83
[
Proje:: No.10j.07-oo2 M&CS Log ho.__n n _
Proje:: Spe:. ho.
t Destination: Palo Verde Jobsite Copies to:
W. Bingham W. Miller J. Black V. Najarian T_voe of Tric*
W. Currlin R. Rothenberg B. Hackney /R. White C Supplier T. Horst CClient
Reference:
- 1. DAH-102-15, 10-14-82, Trip to PVNGS (hame) f'
- 2. BED-013-19&20, 1-12-83, Trip to PVNGS E Jobsite, l:
- 3. DAH-013-37, 1-21-83, Trip to Lundeen PURPOSE 0: TR!*:
The purpose of the trip was two-fold:
1.
Inspect Plasite 7122H Epoxy-Phenolic lining of essential spray pond piping system in unit 2 'and lay-down storage area.
^'
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2.
kieet witn personnel from mechtel Engineering, Construction and Supplier Quality along with representatives of Controlled Coatings (Lundeen), Pull =an Power and Wisconsin Protective Coatings (Plasite).
INTRODUC~ ION / DESCRIPTION OF PROBLEM:
There is concern that a possible generic problem exists with the Plasite 7122H in the E2sential Spray Pond Piping System.
For details, see previous reports referenced above.
Methods and Pesults of Insoection:
I l
1.
The Plasite 11nin, in most of the Ells inspected indicates the material t.o have a
l excessive dry film thickness, however there is no evidence of failure or l
incipient failure in any of the Ells inspected. The exa=ination was primarily confined to visual ex=-hation, _ solvent odor detection and dry film thickness I
measurements. However, some solvent spot testing and destructive adhesion testing was perfor=ed.
2.
A straight pipe spool (No. 35079-5010) installed in unit 2 was found to be defective due to thin dry fil: and minor pinholes. The nature of the problem appears to be due to i= proper application and is not conside*ed to be related to coating failures seen previously in..u=it 1.- The defective coat:ng is to be reworked as necessary.
CCNCLUS!ONS & RECO.MMENDATIONS:
The.Plasite ' 7122H lined pipe spools inspected on Feoruary 2,1983 are expected to
,,ge perforn as designed. Based on observations and testing perforned, no failure:: of l
/. W a generic nature are anticipated.
l p.n g
,Liseussion se?
Icmediately following the morning inape tion, all participants met to discuss Eo=8 f.,
(Eee page 2)
Page 1 of 2 l
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- .. ;. v..w.. h..
Gest:-:? an: Ea.: 20t*i n; (-
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Mg';e-t a :s an: -5a'ity 5e-vi:01 Letter File NO.
D & Ce.,. 08 Date Februarv 15. 1983 ic:
R. A. Keidel Fren: 1. E. Dulluf t.
A.
v'-'
Su:.'e::: TR : RE:IF- (continued)
Pr:je:: Name Pale Wr ie Proje:: he.
1c;.G 7 M&OS Log ho.
1:21 PAR I IDANT5:
s NA"E COM*ANY OR' PROJECT AFFILIATION AND TITi"5 R. S. Rothenberg B. Oya=a Bechtel Power Corp., ALDFE - Piping i
D. Eshlenan
", Plant Design Engr.
M. Earbassian
", Supplier Quality Supv.
L Cook
", Resident Engr.
D. Crespo
", Yard Piping AFF J. Jachsen
", U-3 Piping QCE K. Carrillo
", U-3 Piping ATI AUI/IPDT D.~
", U-3 Piping LAFE j
E. Dunun Bechtel Group Inc., M&QS Coatings Coordinator A. F.endrichs
. M&QS Specialist i
J. Swanson Wisconsin Protectiw Coatings - Tech. Dir.
Pullman Power D. Ostler Controlled Coatings CON:".UEIONS & RECOMMINDATIONS '(Continued):
dispositi:n of DER 82-51. At that tine the following was agreed upon by an:
1.
The condizion of the Plasite lined pipe observed in the morning inspection is good.
However, none of the spools observed have been subjected to service conditicus. To approx 1= ate service condition, one spool (No. 3-SP-068-S-034) is to be fined 3/4 of the way fun for a period of time not less than 30 days. This spool win then be drained, inspe :ed and the results reported. Currently this is an action item for field ccustructica.
2.
Pipe spools coated by mechanical spray application are considered much less suscep-P tible to possible coating failurw. This includes an straight spools and 45 Ins.
the time of this writing there have been no documented failures of a straight A:
spool or a 450 En due to delanination or blistering of a mechanicany applied cor.:ing. The use of mechanical spray equipment anows for better control of spray application resulting in a more uniform deposition of the coating film.. Also, the, coating application process and cure is performed over a 7-day period which anows sufficient time for solven:s to release during the chemical curing of the film.
Manual application of Plasite 7122 H was performed on approximately 30-900 Ells per uni: (90 to:al). This was done to ensure that an areas of the band which may be inaccessable to mechanical application equipment are coated. In the process of hand held manuci coating there are usunny many overlaps and a tendency to overbuild tht coa-iag :1L..
Also, according to Controlled Coatings, the application period for the t.anu4Hf. applied coating was reduced to 3 days compared with a seven-day process used to cos. mechanically. Thts reduction in cure time could be critical,
=-
ME especiany in vintar:ime when chemical curing & solvent evaporation tends to be
~
D re:arded.
d. tion are cos:It was agreed that pipe Ells 24" and over, lined using a manual applica-susceptible te failure due to solvent entrapment. The condition it oI fur:h r aggravated by capping the pipe spools using rubber gaskets and unvented
.R y 1
carbon steel flange plates. Materials and Quality Services recommends that future E{
inspe:;.icas be co ' Wn d to 90 i
Ens, 24 " or larger.
&cES
&ob page 2 g 2.
t II5QS F..?.
M&QS REP
~ - -
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ATTACHME(NITODERS2-51 BEdTklGROUP,INC.
Resear:n an: Engineering Materials an: Quality Servi:es Le.cter File No.
BED-OP3-21 Date Aueust 23, 1983 To:
R.
s.
r ddel Fiom:
B.
E. nu lle.-
Lo:ation sto Tel so -am e
subject: TRIP REPORT Date of Trio:
Project Name Palo Verde From 8-17-83 To 8-18-83 Project No. 10407-002 M&QS Log ho. 1931
REFERENCE:
1.
DAH-102-15, 10-14-82, Trip to PVNGS Destination:
Palo Verde 2.
BED-013-19 & 20, 1-12-83, Trip to PVNGS Tyoe of Trio:
3.
DAH-013-37, 1-21-83, Trip to Lundeen C Supplier 4
DAH-023-08, 2-15-83, Trip to (Name)
PVNGS O Client CO?!ES:
J. W. Becker
- h. Bingham (Name) g Jobshe J.
Black D. Crespo W.
Currlin B. D. Hackney /R. A. White D. A. Hill M 7 N. Najarian
.dr/a B. Oya=a/M. Radoccia R. Rothenberg/J. Niessen PUPSOSE 0F' TRIP:
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Inspect Plasite lining of essential Spray pond piping syste= spool nos. SP-068-S-040 and CD-030-s-040.
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IN~RCDUC* ION / DESCRIPTION OF PROBLEM:
/
At the request of field engineering, Materials and Quality Services was requested to evaluate reported failures of tr.e Plasite 7122 lining of the spray pond piping system.
These reported failures are doct:=ented in Non-Conformance Report KY-357 and are directly related to previous failures noted in Deficiency Evaluation Report No.
~
82-51 (NCR's KY-296 & KY-315).
CONCLUSIONS AND RECOMNENDATIONS:
The li=ing failure of Spool No. 1SP-068-S-040 represents the fot.rth Ell to date which has been found to have a defective Plasite 7122 lining. Each Ell has exhibited the same = ode of failure, i.e.
1.
Complete dela=ination of Plasite 7122 from pipe.
2.
Excessive entrained solvent in the coating film.
3.
- he fi1= appears to be in a se=i-curad condition, lacking the integrity of a fully cured f11=.
l This failure is consistant with that encountered in previous failure analysis. The coating failure is caused by one or = ore of the following.
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l.
Premature pipe capping.
2.
Overbuild of coating fil=.
l 3.
Manual application causing irregular excessive film build.
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4.
Application of coating during winter =onths.
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~a5 Page 1 of 2.
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li.ECifiEL' GROUP, INC.
Researen and Engineering Materials and Quality Services Letter File No.
BED-083-21 Date August 22, 1983 To.
R. A. Keidel From:
B. E.'Dullum Sueject: TRIP REPORT (continued)
Project Name-Palo verde Project No. 10407-002 M&QS Log No.
io v PARTICIPANTS:
NAME COMPANY OR' PROJECT AFFILIATION AND TITLES j
i Ralph Rothenberg Bechtel Pouer Corporation, Assistant Lead Field Engineer l
Jerr-* Niessen
, Lead Field Engineer i
David Crespo
, Coatings Engineer l
Jerry Swanson Pullman Power, Engineer Stephen Engler
, Plant Superintendent Daryl Ostler Controlled Coatings i
Bruce Dullum Bechtel Group Incorporated, Coatings Specialist DETAILS OF INVESTIGATION (discussion of observations, action taken and other pertinent data):
The first Ell inspected was ISP-030-S-040. There was one blister in the invert of the pipe which was the result of mechanical damage. The da= age observed here was localized to about 4 square inches and was not indicative of the type of failure seen in the past (No solvent odor). The remainder of the coating is in good condition and tightly adherent.
Initial visual inspection of spool no. SP-068-S-040 revealed 10-15 blisters ranging in size from to 3 inches in diameter. Destructive examination revealed:
j i
1.
Total loss of adhesion.
2.
Strong Solvent Odor.
3.
Flexable Semi-Cured Film.
4.
Unknown Odor-(mushy).
1 Pipe spool ISP-030-5-040 is to be repaired locally.
I-Pipe spool ISP-068-S-040 is to be completely relined.
l M&QS REPRESENTATIVE:
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ATTACEIENT TO DER S2-51 3gC LECUTEL CEOUP, INC.
Research and Engineering Materials and Quality Services Letter File No.
EED-093-16 Date:
Seotember 15,'1983 7t. :
R. A. Keidel Fro =:
B. E. Dullum Location B49 Tel. 307-4387' Subj ect : TRIP REPORT Date of Trip:
Project Name: Palo Verde Nuelcar Gen.Sta.
From:
Seotember J4. 1983
.Proj ect No. _10407-002 M&OS Loc h,o.
2001 Proj ect Spec.No.
N/A
, Destination: Palo Verde Jobsite Copies To:
V. Najarian R. S. Rothenberg/C.J. Niessen Type of Trip:
J. Black B. Oyama/ Mike Radoccia W. Miller A. Priest B. D. Hackney / R. A. L'hite D. A. Hill Dave Crespo
REFERENCE:
DAH-102-15, 10-14-82, Trip to PVNGS: 3ED-013-19 & 20, 1-12-S3, Trip to P.V DAH-013-37, 1-21-83, Trip to Lundeen;DAHHD23-03, 2-15-83, Trip to PVNGS;
...,...EED-083-21, 8-23-83
...--.a.-.--.
PURPOSE OF TRIP:
Inspect Plasite lining in the spray pond piping system.
INTRODUCTION / DESCRIPTION OF PROBLEM:
At the request of Construction, M & QS was asked ta perform another inspection of the Plasite lininr, in six (6) spools in the spray pond piping system. The Unit I
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spools in question are SP-030-S41, SP-03G-S42, SP-030-S43, SP-068-40, SP-068-41, SP-068-4 2.
CONCLUSIONS AND RECO'NENDATIONS:
- 1) None of the linings observed during this inspection exhibited the 'nilure mode seen in previous inspection. i.e. Sheet delamination, entrained solvent, partially cured coating film.
- 2) Some loc:lized defects were found, however these are considered =inor in relation to the failure seen previously. For details, see description of investigation.
DESCRIPTION OF I!NESTICATION SP-068-42 The spool has been relined in the field with P3asite 9009-1T and the dry film thickness ranges from 13 to 18 mils. The condition of the lining is good except for one minor area. There are no blisters, no entrained solvent and no delamination.
There is ho.ever one pinpoint rust spot which will be touched up.
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... f.j' nIPTION OF INVE."TICATION (Continued)
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o rSr-068-41 g
.f Completely relined in the ficld with Plahite 9009-lT to a dry film thickness of approximately 15 mils. The condition of the lining is good.
'SP-068-40 This spool was inspected on 8-18-83 and details of inspection documented in' Trip' Report BED-033-21 date? 8-23-83. For previous inspection and repair see NCR No. KY-312 dated 1-10-83.
SP-03 0-S4 3 The Plasite 7122 coating is in good condition witt
- ers, no solvent retained and no delamination probicms.
SP-030-S41 The spool has been relined in the field using Plas.'
19-lT. The dry film
' I; is 16 mils average. There is slight mechanical dam:
the flange which is to be repaired. The Plasite lining.is in good an.
e SP-03 0-S4 2 The spool has-been relined in the field using Plasite 9009-1T. There are three (3) blisters 1/4' to 1/2"in diameter. These were broken with a knife and examined for entrapped solvent; none was apparent. Also, the coating around the perimeter of the blisters was checked for adresion and was de-termined to be good. The cause of the blistering appears to have been in
<:c-the application. -
7 PARTICIPANTS:
COMPANY OR PROJECT AFFILIATION AND TITLES Dave Crespo Coatings -Engineer, Bechtel Power Corporation
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Bruce Dullum Coatings Specialist, Bechtel Group Incorporated R. S. Rothenberg Piping Engineer, Bechtel Power Corporation
. Brad Oyama Piping Engineer, Bechtel Power Corporction, Downey Mohammed Karbassian Resident Engineer, Bechtel Power Corporation f3trin 8, 0hw (!$2 B. E. Dullum Coatings Specialist
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