ML20080B155

Forwards Info on Welding Inspector Concerns Re Unit 2 Containment Dome Pitting (Nonconformance Item 9092), Containing Nonconformance Item,Evaluation Calculations & Ref Correspondence,Per D Demart Request.Related Info Encl

ML20080B155
Person / Time
Site:	Catawba
Issue date:	03/17/1983
From:	Mcconaghy J DUKE POWER CO.
To:	Van Doorn K NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II)
Shared Package
ML17214A749	List: ML20080B155 ML20080B166
References
FOIA-83-200 NUDOCS 8308040632
Download: ML20080B155 (95)

Text

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l l I I I  !  ! I l si e,is. = l i.:,t. I  : I I i i i l 1  ;;,=;,. Attachment (1) to NCI 9092 Surface defects are judged not to be significant based on engineering judgement gained by prior experience in containment vessel and pressure vessel design. Site QA and QA Vendor surveillance shall address and evaluate why defects were not discovered during shop inspection and receiving inspection. Repairs to be done in accordance with Section III, Subsection NE, of the ASME Code. b.E.be bad E-ZhI k. E Yaw,/yg 7-W-9/ i [ l . e l. Attachment (2) to NCI 9092 4' Response to Attachment (i) to NCl 9092 Vendors supplying safety-related materials or components have an approved QA Program. This program includes QC and inspection that we are confident I is satisfactory. Duke Power QA performs survelliance on their program to maintain a good confidence level. The surveillance does not include 100% inspection of the material or component. Minor or extremely small irregu-larities can go unnoticed depending on inspection or NDE requirements. i Shipping damages and normal oxidation are factors to consider in reviewing the containment plate. 4LW 9'-/ - P/ 38 4 vj-3 desceaBes THE eszpvitzeD Estc/vM4 Fo2 0D)IllM$ ?L6 TG, TW IO ECTibbi msuxcmas dde: It w w dg A da g ... Cop ld a Tze_ Cood . acesTmo f s A od w ~creosm c>3 e o.ande, {T' ws. OA')CKJ15- W ' h 3_ b 0 U> LJ% , ' dbW . s u ll dahe i ik wsseh doe. 6 A c m e rec M 1Lis clocs De ork,uleg v4 6 oe. bepeuww-se r used puuca. . i see A (L p, C74Hf s 8 t 1 Attachment (3) to NCI 9092 j This attachment provides additional guidance to the resolution of original NCI dated 7-28-81. Surface defects have already been judged not to be significant based on engineering judgement (see attachment (1)). This attachment provides additional criteria for the surface preparation and inspection of pitting I and surface roughness less than or ha been P egug"l to 1/8 I N ltEp inch in"fC V}n[tt depth. lI hlOI The containment dome plate 2' 5: sand blasted to a " white metal surface"- in accordance with Surface Preparation Procedure DPSP5-I. This process w+44 h s reesd reeve all surface foreign debris, scaling, rusting, etc. to sound metal. ASTM A20, paragraph 9.2.1.1, requires all imperfections to be removed to hfms,,fr/ar o j,g' sound metal and to be well faired. Procedure MSS SP-55 shall be used as a guide to detennine well faired conditions. Type II, Type VII and Type VIII 7E ////7/a photographs shall be used for representative acceptable surfaces. All pits greater than 1/8 inch in depth shall be weld repaired in accordance with ASTM A20, paragraph 9.4. k By: bl Yk //h8/ fMB t'// f/* Technical A3 proval: bS. - ///f/2/ QA Approval: , f$ ll7-$l s  ? Attachment (4) to NCI 9092 page 1 of 2 , Previous resolutions have proven to be very difficult to implement without damaging the containment plate. The following procedure shall be followed to detennine 'which defects are acceptable and which require repair. Details concerning the development of these criteria are contained in calculation file CNC-ll44.09-01-0003.

1. Surface flaws with a depth of 1/8" or greater shall be weld repaired according to ASME procedures.

2. Surface flaws with depth less than or equal to 1/32" are acceptable if they do not interfere with other flaws as outlined below.

3. The remaining flaws shall be inspected to determine their acceptability using the attached Figure 9092.1. The acceptability of a given flaw will be determined by the size of the surface which it covers, the depth of the flaw, and the proximity of the flaw to other flaws. Surface defects failing this criteria shall be weld repaired according to ASME procedures.

4. The following definitions apply to the variables used in Figure 9092.1:

a. d (flaw diameter): The dimension of the surface flaw in the direction of the next adjacent flaw. For circular pits surrounded by a circular pattern of smaller pits, d shall be taken as the distance across the circular pattern,

b. D_ (spacing between flaws): The minimum clear distance of unflawed surface between adjacent flaws. If D_ is greater than 13/8", D is to be taken to be equal to 1 3/8".

c. _t, (flaw depth): The maximum penetration of the flaw measured from the uhflawed surface.

5. In applying Figure 9092.1, the two surface measurements D and d should be made first. With these two measurements, one point on tee figure is determined.

This point will lie between two flaw depth lines. The flaw depth indicated by the line imediately below the point given by D and d_ is acceptable, while the flaw depth given by the line imediately above the point is unacceptable. For points lying on a given flaw depth line, the flaw depth given by that line is acceptable. For example, a flaw with D=l/2" and d=5/8" is acceptable for a flaw depth of 5/64" and is unacceptable for a flaw depth of 3/32". The actual flaw depth should be compared to Ge acceptable value to determine whether repair is required. Repairs may be made either to the flaw in question or to an adjacent flaw to arrive at a combination meeting this criteria.

6. Figure 9092.1 assumes an identical flaw on the opposite face of the dome plate.

If it can be verified that in the area of a given flaw no surface flaws are present on the opposite face, the allowable depth given by Figure 9092.1 may be multiplied by two. 1

7. Surface flaws with a maximum dimension d greater than 13/8" shall be weld repaired according to ASME procedures except as noted in 2. above.

8. Surface flaws with a maximum dimension d less than 1/8" are not required to be repaired except as noted in 1. above!

9. Repairs are to be done in accordance with Section III, Subsection NE, of the ASME Code. ,

O Lj\,W ENY bdL Y. $b Yl3o/tz. 2 At 2 M /~ x' u B8: IMM A-29-82 LHElKEb' fdYl3 4/50l9i Attachment (4) to NCI 9092 page 2 of 2 yg e 3 3 ( For D> 18, Use D = 18 i I iT I i i I i I _ 9t_ / / h - OI REPAIR /

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• Attachment (3) to NCI 9092 This attachment provides additional guidance to the res'olution of original NCI dated 7-28-81.

Surf' ace defects have already been judged not to be significant based on engineering judgement (see attachment (1)). This attachment provides additior.al criteria for the surface preparation and inspection of pitting ' and surface roughness less than or h.u been I' eoug"l to 1/8 inch in depth. flIlII l** ' & I-lnltI 'fi' II The containment dome plate :'ul' i: sand blasted to a " white metal surface" in accordance with Surface Preparation Procedure DPSP5-1. This process w4M Ac5 nmued r: :, e til surface foreign debris, scaling, rusting, etc. to sound metal . cg ../nf ASTH TO, pa ragraph 9.2.1.1, requires all ' imperfections to be removed, to l sound retal and to be well f aired. Procedure V.SS SP-55 shall be used as a h D l'[11 guide to cetennine'well faired conditions. Type 11, Type Vil and Type

• Vill 7E ////

photocrip'.s shall be used for r'epresentative acceptable surfaces. /11 piti creater than 1/8 inch in depth shall be weld repaired in accordance l with ASTP. A20, paragraph 9.4 1 By: - brY&sh -  !!)lh8/ g'HB s'n/W / . Technical Aoproval: S. NM - //ffl2) ,, QA Apprcval. $ A /b 7-dl' Attachment (4) to NCI 9092 page 1 of 2 gg S ih

• Previous resolutions have proven to be very difficul MIN J

= the containment plate. The following procedure shall. M.yTM N 3famaging ne r which defects are acceptable and which require repair g he development of these criteria are contained in calcul. nd M 7 11-0003. Kap b.

1. Surface flaws with a depth of 1/8" or greater shal . ,. u occording to ASME procedures.

2. Surface flaws with depth less than or equal to 1/32" are acceptable if they do not interfere with other flaws as outlined below.

1

3. The remaining flaws shall be inspected to detehnine their acceptability using the attached Figure 9092.1. The acceptability of a given. flaw will be determined by the size of the surface which it covers, the depth of the flaw, and the proximity of the flaw to other flaws. Surface defects failing this criteria shall be weld repaired according to ASME procedures.

4. The following defin'itions apply to the variables used in Figure 9092.1: -

a. d '(flaw diameter): The dimension.of the surface flaw in the direction of the next adjacent flaw. For circular pits surrounded by a circular pattern of smaller pits, d shall be taken as the distance across the c.ircular pattern. -

. b. D (spacing between flaws): The minimum clear. distance of unflatted surface between adjacent flaws. If D is greater than 1 3/8", D_ is to be taken to be equal to 1 3/8". . .

c. t 7 (flaw depth): The maximum penetration of the flaw measured from the unflawed surface.

5. In applying Figure 9092.1, the two surface measurements D_ and d should. be made first. With these two me surements, one point on the figure is determined.

This point will lie between two flaw depth lines. The flaw depth indicated oy the line inmediately below the point given by D and d is acceptable, while the flaw depth given by the line immediately above the' point is unacceptable. For points lying'on a given flaw depth line, .the flaw depth given by that line is acceptable. For examplet a flaw with D=l/2" and d=5/8" is acceptable for i a flaw depth of 5/64" and is unacceptable for a flaw depth of 3/32". The actual flaw depth should be compared to the acceptable value to determine whether repair is required. Repairs-may be made either to the flaw in question or to an adjacent flaw to arrive at a combination meeting this criteria.

6. Figure 9092.1 assumes an identical flaw on the opposite face of the dome plate.

If it,can be verified that in the area of a given flaw no surface flaws are present on the opposite face, the allowable depth given by Figure 9092.1 may be multiplied by -two.

7. Surface flaws with a maximum dimension d, greater than 1 3[8" shall be weld repaired according to ASME procedures except as noted in 2. above.

- 8. Surface flaws with a maximum dimension d less than 1/8" are not required to be repaired except as noted in 1. above!

9. Repairs are to be done in accordance with Section 111, Subsection NE, of the ASME Code.

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gym..L ; . . _ _ . - ~ ENCONTR_ . 7y7 c . . , . ,! . .._s...-<._ . . . . - . . . . . . .L . '~---~~1--~_____~____. I - ~ - ~ " 'Ii "--~~~^*"*~^-~7--~I'~~~1 FOR RSSOLUT70s) INFORMATIQ1 TO BC BedSHED . DIRY Ub Cg~ Ntf == N3D}B& 7 Attachment (4) to NCI 90 2_ U Previous resolutions have praven to be very' difficult to implement without damaging' the containment plate. The following procedure shall be follcmd to determine which defects are acceptable and which require repair. Details concerning the development of these criteria are contained in calculation file CNC-ll44.09-01-0003.

1. Surface flaws with a depth of 1/8" or greater shall be weld repaired according to ASME procedures.

2. Surface flaws with depth less than or equal to 1/32" are acceptable if they do not interfere with other flaws as outlined below. ,

3. The remaining flaws shall be inspectedi to determine their acceptability using the attached Figure 9092.1. The acceptability of a given flaw will be determineGB by the size of the surface which it covers, the depth of the flaw, and the proximity of the flaw to other flaws. Surface defects failing this criteria shall be weld repaired according to ASME procedures.

~) The following definitions apply to the variables used in Figure 9092.1: Q=====4. a. d (flaw diameter): The dimension of the surface flaw in the direction of y* the next adjacent flaw. For circular pits surrounded by a circular pattern , of smaller pits, d_ shall be taken as the distance across the circular pattern. O 4' b. D (spacing between flaws): The minimum clear distance of unflawed surface between adjacent flaws. If D_ is greater than 1 3/8", D_ is to be taken to , be equal to 1 3/8". ( r

c. t f (flaw depth): The maximum penetration of the flaw measured from the unflawed surface.

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5. In applying Figure 9092.1, the two surface measurements 0 and d should be N made first. With these two measurements, one point on the figure is determined.

, This point will lie between two flaw depth lines. The flaw depth indicated by the line inmediately below the point given by D and d is acceptable, while --) the flaw depth given by the line immediately above the point is unacceptable. For points lying on a given flaw depth line, the flaw depth given by that line O H is acceptable. For example, a flaw with D=1/2" and d=5/8" is acceptable for a flaw depth of 5/64" and is unacceptable for a flaw depth of 3/32". The actual flaw depth should be compared to the acceptable value to determine whether repair is required. Repairs may be made either to the flaw in question or to an adjacent flaw to arrive at a combination meeting this criteria. ,

6. Figure 9092.1 assumes an identical flaw on the opposite face of the dome plate.

If it can be verified that in the area of a given flaw no surface flaws are l present on the opposite face, the allowable depth given by Figure 9092.1 may be multiplied by two.

7. Surface flaws with a maximum dimension d greater than 13/8" shall be weld repaired according to ASME procedures except as noted in 2. above.

8. Surface flaws with a maximum dimension d_ less than 1/8" are not required to be repaired except as noted in 1. above.

- 9. Repairs are to be done in accordance with Section Ill, Subsection NE, of the ASME Code. By: Technical Approval: QA Approval: ~ ~ -..- = - n,an a ?0R gg 4-29-82 INFORMATION ONLY- m "" " #"" * "^ v ENCONTROLLEID For D > 13 d, Use D = 13 8 l l l l l l I l _ 18 3 a REPAIR _ O ALL FLAWS Jd . W/ ft 218" y E n ~ g ,# . { (n 3 3/_ v' g

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.. z.%]c' $4:Q L. .y . c < . . . , . . 3 :. q., . . , - .w r . g.-- ,n, a n :_ ._ .. k_,.  % o?. .__e . .'m .. o f _,___,_f'*p _ s1 g ,,b., n , pn Cl- 9 - -- W W ;'[ j ".~d i r.i X ( ', d [ C., ~ civil EinT:Oilt,'.t;ii .L t .. ~ *. April 1, 1982 c;yll PR0tCia 0.iid.1 IWO f A:1: : a r?.,? L. C. Dail , j S. K. Blackley, Jr. CEllTR %UC{ t10 tilfM "%I [S 5 Hage6 TILE fl0' C. J. Wylie - ~ - - - Re: Catawba Welding Inspector Task Force Design Engineering Response Scope File: ELD-0201 9 A. P. Cobb's letter to W. H. Owen dated March 30, 1982, transmitted Vol. I, Rev. I of the Task Force Effort to Evaluate Technical I Concerns of Catawba Welding Inspectors. A review of Vol. I. has been conducted and the list of resolution items requiring a response from Design Engineering is included as Attachment I. W. H. Bradley, Management Implementation Coordinator, agrees the list defines our scope for responses. 1 . I will be working with the appropriate folks in the line divisions over the next few days to review response needs. The Specific Concerns (I) in Att. I reouire a resoonsible_. individual and a l comoletion date and the implementation Objectives (11) require a l , date by which actions will be defined and a date by which actions will l be complete. These resoonsible individuals and dates should be - _ defined bv Aoril 6. 1982 for response to W. H. oradley. . I After assignments and schedules are defined, a response to each item will be made and any required action will be followed to completion. R. B. Priory, Principal Engineer Project Management Division ( By: D. F. Mitchell Engineer Associate RECEIVED civil Elri m;lt.1LiliAt Olvisl0i1 DFM/lmr ClllEF EllG!t'EER'S OFFICE Attachment APR 0 21982 cc w/atta: W. H. Bradley CErlTRAL RECORDS lDiVIS10!! ' ..  !!0 ATTACH:.1EHT TO FILE t'O. - ___. .=1 n- CONCERNSWiTHDESIGNENGINEERINGDEPARTMENT RESOLUTION INVOLVEMENT

1. Specific Concerns A. Table 11, 8) Revise Design Specification and CP432 to define.

acceptability for overlapping fillets. (R-9) B. Table 11, 9) Evaluate " weld on edge of plate" question. (R-34) C. Table 11,16) The disposition of weld INIl62-27 is. dependent on the resolution of NCIR 13955. (D-30) i<.- l',

' .. D. Table 111,3) T ,

I" immediately. Determine (K-2) a workable resolution to NCIR 909? i I . .\i - ~1. Table I, 18) Follow through on completion of NCIR 14033. .s.1 (R-64) - ..I r# 1 F. Table IV,1) Identify the specific weld in question and document problem to Design Engineering for evaluation. (R-24)

11. Implementation Objectives

• A. Sec. 9.0, (3)e. Continue emphasis in training on proper method of NCI resolutions.

This speaks to NCIR Resolution Recommendations no. 1 and no. 3. 4 no. 1 - Review adequacy of present requirements and controls for documenting technical resolutions, especially those by Design Engineering and Construction, insure that written resolutions are concisely stated, cite specific documen-tation as basis, and answer obvious questions. no. 3 - Review process for NCIR resolution by Construction and Design Engineering to insure adequacy of the following: a) Resolution documentation b) Adequate site inspection before resolution is issued. c) Workable . repairs are issued for craf t implementation. I d) Any significant level of NCIR occurrences in specific areas is factored into procedure and performance reviews appropriately. e) Any significant level of acceptance of."as is" conditions which do not meet Design or Construction original requirements are reviewed for procedure changes and personnel performance evaluation by appropriate management. f) Upper time limit for resolution of all NCIR's is adequately defined and enforced. . , .u . : ...a - .f , . . B. Sec. 9.0, (3) 9 Clarify method of handling NCI's that have resolutions that are questioned. 6 This speaks to NCIR Resolution Recommendation no. 3g. no. 39 - Returned NCIR's which have resolutions that are problems are tracked in the same manner as normal NCIR's received for the first time. Also insure thit such returns are trended for procedure and performance evaluation purposes. C. Sec. 9.0, (3)m. Standardize welding symbols in design documents. This speaks to Design Drawing Recomendation no.1. no. 1 - Review clarity of present standards used for weld callouts on drawings. Consider using more general specification vs. providing extensive joint geometry. Ill. Addition Items Used for Inputs in Addressing Items I. and II. above. A. Sec. 5.3.2, (7) Design Specifications, QA procedures, or Construction procedures are not always revised to' clarify certain practices accepted by supervision. , B. Sec. 5.3.3, (1) NCIR evaluators do not always provide a complete and obviously substantiated resolution to the NCIR's. C. Sec. 5.3.3, (8) Standardized methods for presenting weld requirements on drawings for individual weld joints may b,e ' needed. D. Sec. 5.3.3, (9) Some NCIR's are not being resolved in a reasonable time frame. E. Sec. 5.3.4, (1) Questions have arisen in the field concerning the validity and clarity of certain weld symbols. F. Sec. 5.3.4, (2) Additional emphasis may be needed in Design Engineering to emphasize importance of good drafting to eliminate drawing clarity problems. . G. Sec. 5.3.5, Discussion Non-Standard procurement and specification of materials by various organizations in Design Engineering leads to many degrees of material segregation at sites. H. Sec. 5.3.8, (6) NCIR evaluations are sometimes not being adequately written. Sufficient detail concerning acceptability or rejectability of the item is not included in the evaluation text. I. Sec. 5.4, (4)(i) Poor documentation of discrepancies and resolutions on NCIR's by QA, Construction and Design. . ". l' age Ilir ce - ~ ' .= _ J. Sec. 6.0, (3)(d) Guidance within each Department for propar NCIR .. processing including such areas as documentation of problem, description and evaluation, adequacy of resolutions, and timing of resolutions. K. Sec. 7.1, (2) More specific adminis'trative guidance appear.s needed . to insure completeness and consistency in wgrk performance but such guidance does not belong in a QA manual. i 9 1 1 4 . OFM/Imr 4-1-82 s L447a u ,:, . & J3( . (5@ L & aLi~ AJ -77 " o? OC? April 2, 1982 m ' U' RECElVED I . f-/(o CML. ENVIRONMENTAL DIVISION Clylt PROJECTS SECTION S. 3. Hager .* APR0 51982 Attn: I. W. Pearce , CENTRAL RECORDS / DIVISION USE NO ATTACHMENT TO FILE Catawba Welding Inspector Task Force Re: Design Engineering Response Scope FILE NO. File: ELD-0201 1 l A task force headed by A. P. Cobb has recently' completed an effort to evaluate technical concerns expressed by Catawba welding inspec-tors. A portion of the Design Engineering response falls under - your scope of responsibility. , A. Specific Concerns Item 9 from Table II - Welding Inspection,of Volume 1 Jd 1. of the report recommends - Evaluate " weld on edge of plate" question. (Inspector concern R-34) i Please review R-34 (attached) and determine what actions are required to respond to the recommendations as stated in R-34. NCI 11486 was cleared by Construction in 5/81 but a copy is being sent to me and I will forward it to you upon receipt. DM 2. Item 3 from Table III - NCIR Resolution, of Volume 1 of the report recommends - Determine a workable resolution to NCI 9092 immediately. (Inspector concern K-2) Please review K-2 (attached) and work toward a rapid, , workable completion of this NCI. I believe NCIR9092 has previously been cleared but requires additional action. Since these are Specific Concerns, please advise me by April 9, 1982 a schedule date for completion of all action for each concern. The schedule dates and a confirmation that these are within your scope is all I need by April 9. All further action to resolve NCI's, define criteria, coordinate with others and revise appropriate design documents will be required as of the schedule dates you provide me. gr S. B. Hager Attn: 1. W. Pearce April 2, 1982 Page Two - B. Implementation Objectives ~llid- Item 1 of Table IV - Design Drawing, of Volume 1 of the report recommends - .... Consider using more general specification vs. providing extensive joint geometry. A. P. Cobb has indicated this item deals with not providing. detailed joint preparations on design drawings and leaving preparation up to Construction and their procedures. Please review this recommendation for impact on Design practices and possible actions required if changes are - needed. You may need to review this item with D. M. Collings and others. Since this is an Implementation Objective, please advise me by April 9, 1982 a schedule date to complete the impact i review and, if actions are fully identified, a schedule . date to complete the actions (an action completion date might not be possible until after the review is complete). These concerns requiring action all directly affect on-going site work. As such, they should be resolved as expeditiously as possibie. In addition, these concerns and their resolutions will be reviewed by the flRC for complete and prompt responses. If you have any questions, please call me at extension 2892. R. B. Priory, Principal Engineer Project Management Division, . Q, $. NW-_ By: D. F. Mitchell Engineer Associate DFM/imr Attachment cc w/o atta: D. M. 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-% e = .. .O .:a7sm.,2r .9hm z. , . . .! r: J.a.rL .2. r,.n o , ; 2,. ,a9,5.O SIGN-OFF - EVA LU ATION PERF0RMED BY W,.9,<.[()} "YV' .?!),piu l , (l,, , l nerr- 9-2t-94 , -/ # l ..::. v. /. . VERIFICATION-lNDIVIDUAL CONCERN - f-- AyJ y, -w :p FILE NO. X-t- $ mb7A ww e. l fj ,. $nq.emem. enfitemma@/uin & Albm wilt EkludiLNud * *n if,'.' . I) 74chnirad adtgtatg-$b%.PU $ N on oMn (f@f?%7 ;.kh tad q tww toff 6 M# Exp. peumnC.7in ' y k.Y{$  ? ..sfuQ mawL imovarat inyt asakk and mydano Qli,A - 'J Jednital WalackN fb asedath adiyaf ,Rphrk Ihdkn. $  ?!;' T. ard y w itom/pt u a i t &cmb%/xo lL \ % , Any)nu$2SL _L L' . - -6af k con 6e.>nw{}kmenkd.

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}.{f, p@ew' srppant hit shetA kvehoulud y .t/= . Nerdor , >J Ei$ eW f 5) 1sgl &qn , shatl& telWe Rdoltat gown %t hfj' '?.: oced r 6 Tht p act */a appropd s+;ps 4 g fn In h ht u adgnet g ' L,i A p: a) TedmusL uschekk brn@mn - -1hd%1 wa.w msoN& bone m pymuit aiifhat &mtp in oppndy xy . anspL duc b) % % L po 4 appan.y,e g g a  % 2Epeanut- okad at he. perinTib@ cLi ns .. t 3, AwLogtua. c) lachehrL m nbt IGvLfL /y .;((? d) 3andaulf kt/fa ctmb% Bpr-$rgiQ ati.il(; gb% .adog ag a y k k h k F O L' ,d' Ti3 n. ' O lhilivi__[LU ~ SIGN-OFF . _ _ yER1FICATION PERFORMED BY: h[I/kb DATE: _ - - - EM M U ll,9 r ' r-i . )L'Wu \lTnp>LL.CU[... . .. 'v i ih . ' fa t .J J 1,7 .. m s .2 4 - . . . . . A1 e. . .. 'hj. Y is .cm m m.d .w7.O yih in . K . anif. E .........em h h.>~ A ..pl le... . ik..AnL..<aiJ A. /s: ..: s ........ A ... w /7 /.s 8 0.. .. n.F . wa s . 4IJ H. -h ;f a ,PA .CN,,. . . l b. . .. . . . P<p< w N L ...: n i.%I iJ u> ... , va kj aup < d. J ~..;l_. l:';.[ .. ^ .. %u. . pIo ko % .  % . m. 1a d.'> /a e /r,- .P //< ~>s. , j;.}. .. /> /A eh4 ; 9 a& n.4 2I Q% -A>  ? /6 s'.'d m/ ,Ge/ < 7- 4 471 >p,,iaJ .;}sllb aa kwn. fII f, tf-6%{., '!' n L k f& J K ,,.%q, / a~ n a ,.A Af & a~s L . A ,. 4 y+ A His 4 L. c6 .as n +& - .?;.  ! p <. 6 L . . s I ' . s' f ki<. s . !< z.- r, c.-( .rM/ A /n L. en k ,L./ <2.-L P. g& mLJ J K ph k o ~J $,.be p .-e . . T. l y w y a LJ n ~ , .  % o c.c rf.o czyog2 a H~.L.J 'Y af ivi, . .r 9  ;.> ~/ Li x << ., , L. ,G, 4 x.: > ocr . 4 6 g // U 6 ';400 < > > m -s . /3 iv. ~ a o;- es,- . '~.1+4f p to /< s L 4<e 4 n s, /- . y 4 s.c ^" O m s.<. p.% 4 .L t~'9 yD if K7 - Jy -4 6+-! A .sp J. .~~/ .4y A.rp~.6a/.o# p 26 ver e m') f cj - a / G M . .E- y ' J. 6 .'/ L I -i L p><p.,-- .JLL LJ w y .~ 4 vL p,. L . ac 4/f mo ~ < y nq >4 .a.Mu . n. . - . h h ', * . g .a. ,, a.i. n u 4 "'" .. & p ro U . . . . . . e. . .. .. . . . _ . . . . _ . . . . . . . . . . . . . . . _ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . _ _ __ . l '~ . /,1,%dJ. rzT ..s..sc z ...-90 9 2.._.. p / , v..abc.<. , %.'K .. '. ;}. .;t ..p~ G n n ...- . p .. f n ,/s .4 ~ ... G . m <.. . O;i ' n8.(; . S- w -o .1/:// n sJ sk:_./ .. r,-. . ft.~-f.. M ss SP-5.sT . :1 ,;,X,. . f .s.c & fv. <,. & . i.s . 6 < ~Mysig. r & + ~' <m Lin J ,e 4.d... ' ,14 ,. 7-Ly -M -Q n /so f<. I f A d w ,*/ O < as - I ~> V'f.-< 15y- f /a. A &4e , , , /A j E./A:p p vi j;l.]. ke pase.:b.3 ~pa /L.l n y & ~ >sc/<. ~ L/ ~f & // A +-G po i h. -/ L-. a. L l t ~ Lo.y n e z. , cG s .p .a~. ; , l~; fo/a 4 x/ 5 p %We L & /.'<J % , a.9 6 ' A1< . 7< ly . /k sJ VL y ./f ,~u L l . gin . .. u .ry LJ m p J cnu'~t . ,i- w /x . A c,3 ~~ # / f ,_ ~ h . c u l u G i'i l m p.<.~ 4 v J . ' :.~. 1 . 1 .,+ ~ & y-~ol #1 <. Ir y> m a .~ < m ~~t. is ~ k kJ /, a s /c 6 a-enLa G . A f ,% K / L /e' m lu. b e /ro 4 a. )- K ' p/> h .T . . .. . h.g y e q f h $ s.e m..ap., emymw s -- . , m .. . .- __ __ _____ 3... __ /- .O .. . .. . . .M . . . , h R. @. p..g . r,.-  ;. ) % ~.- .y , ) -.W- .u >r P . ..s. s. .............y,.,... .. . , , , , . . . . . . . .  ;.4 ,, . ,, , . . , . , . , . . g.. ...

c. .gj.rs, 1982% W M M j. M !.7:d,'.9 p v.;#.c o d.9% M7i.e:.W a.99!.h. g '

. ... .. ~ . , ,, s. 3.... 1. . ..  :, . . a a * * . , . r *. ,~.ig 1.',.,. . * . u. . . ..m '~ ?.'; . . t. . ,4  ; . ,. 4 . w; *. : . ?q, .. 'm*r. .y .i. ~. y y..^ : ' ~ : ', ' ' ':-.';.~. . mfr.' . ifc. . f.3 '..- .c.cf..- Mr. Gary E Chenault . W4 . .. ..+.....,......:... . Newport News Industrial Cor ration.,. /t. , '. .*. . , ,,W .'

• 4

< - 2 ., .. .f . .- 230 41st Street .. . . . . . - . . . . . ~ Newport News, VA 23607 . . . . . .. . . . .; .. . . , * '4 4 h. .Jb ,,.: ~ . ' -t. .Subjectt' Catawba Nuclear Station. . Unit; 2.'.'.W.M. . . . . ,,. . . >. 'w .,. e .,< +% .4.... ....w.~ .... v Containment Vessel . Dome . .u. . .. . ..a....--.. ~ . w@ W/ . :_ File.No:. CN-ll44.0.9 - ,. g ... w q. . .. . ._ . < ,,,_,,,,g . . .'. . $. :i . .se .,; .. 't.g. ..s~~- .. . . . . . z . . ,. . .. . , ,  ; 7, q ;p. ;p.

Dear. Gary,

_. . . .., c _q,y ; ,,, .. Enclosedarefive(5)photoswhicharerepresentativeofthesurfaceconditionsj,,..[3 which I described in our phone conversation last Thursday. As I mentioned, we :/ . , are most hopeful that your staff will. be able to assist us in determining the nature; , { and origin of these surface conditions. Your efforts to solicit input from -

                                                                                                                                                                                                                                                                                                           . , .,i ..

Phoenix Steel are also appreciated. . . ,.

                                                                                                                                                                                                                                                                                                                   ....1  .....
        '-' Please contact me concerning any-assistance you'can provide in this matter. g., e,.h-3.gJ                                                                                                                                                                                                                         .
  ' D'*. Your's tru3y, $25.' . s.=:i *<.

y .% , .. 4.4r,%.._.:. C.. 'R,:h.'?A**$::i. :.*NMb M$l24.?i.+;+M% s ,

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                                                                                                                                                                                                                                                  .:                                                   6      .       n -%L S. B. Hager, Chief Engineer                                       ..                                    . . . ..                        .                                                                                                                                                - ' y,..

Civil /Enviromental Division . ,... .. .

                                                                                         ~                                                                                                                                                                                                                                    s. 'i .

l By: D. E. DeMart, Supervising. Design Engineer . 42.kbED/ks'!".'.n:N!.k#C'I53$d EE-D..N. D [.hb N M NM@ .N h Attachment _. .. xc: 1. W. Pearce J. M. McConaghy . R. H. Benoit . R. F. Sm1th ..',

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                                                                                                                                                                                                                                               ,  ,Q Re: Catawba Welding Inspector. Task Force                                                                                   *        - ;.                    ~

4 IN. Design File: Engineering Response Scope **9 'YET ELD-0201

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                                                                                                                                                    . :.                                                                                       s:. pc Please reference your letter of April 2, #1982 reg r5~ ding #our response '.to the-W
             "'-       Catawba welding inspector task force. evaluation of . technical conceras.pxpressed:2$, . .

g -qby welding. inspectors..

1. Specific concern item 9 from Table II Volume 1 (Inspector concern R-34). A' response . Welding to Inspection..of this concern hasreport . j f.. ' [,lIihj{

   .                         already been sent to you in a separate letter.                                                                                                                                              ._.              : . 93,,

4 . .w.

2. Specific concern item 3 from Table III - NCIR Resolution, of report - '.

            -                                                                                                                                                                                                                      'y. -[,[7
            '        ' ,.,, (Inspector Volume lconcern   regarding                       an        expeditious,lworka'ble.

K-2)._We expect.to complete work mquired to support resolution .to' NCI 9092.'i.'6.5 This .has.. required a review J. p'p'.a

              '# A .,,;.our resolution and release by April,30,1982.of the contaiment stress,and ultimate 1

1 influence of vatious degrees of. repair. ,

                                                                                                                                             . . . . . ,           .                 ..                                                              +;

3. Implementation objective' item 1 of Table IV - Design Drawing, of report #

Volume 1 recomending consideration for more general specifications for [ i ' welded . joints on drawings. Per our telephone discussion today, we will . ,,.. e],.,f reviewitthe

                             'when               response you have is received.                                              prepared based on imput from us and others .. . b,p" i i
                                                                                           , ; .3 ,. .. , g,, ., , f                                         -             -

m .9 .:Q S.B.Hager'ChiefEngiide'r 9).Nh,b3[3DP,)'),f'W,MIMEM'5"j?+j,k, Civil / Environmental Division. . . . ... . . ll.

                                                                                                                                                                                                                                                ~ m.

By: 1. W. Pearce, Principal Engineer IWP/ks ,

        " ,-  ;.. xc:            D. E;'DeHart-                   .
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                                .J. B. Reeves.             -
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C. L. Ray , A. P. Cobb

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Dev./ Stain.o h4M. . S'77 dbh 4td 4 ,a m. ', Subjeci 1  : . OG-Z k . 3 0, s,,u mo r.; t.. . . a . . .

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uA k M . NI/. 2121.5 hiinim im 'I histnew of Alastriah. f a) MsII finulcritoirstum e. Plane suutesi.d shall hc ordered not thinner than the design thickncu. Vewels ,l l i i{ l l l l l * l made of plate furnished with an undertoicrance of. not more than the smaller value of 0 01 in. or 6 per. NE-2124 Material Size Ranges and Tolerances ' cent of the ontered thicknew may be used at the full g ;g g g; g; g;g . desien pressure for the thicknew ordered. 11 the i given in any specification in Section Il may bc.used if specification to which the plate n ordered allows the material is in compliance with throth@lfh- ^ a Ercater undertolerance. the ordered thickness of ments.of-th'e;:specificatiorCan~d%7%lirnitation is the material sisall be sulhciently greater than the de- i s in sign thickness so that the thicknew of the material . E vent!@lfPSWstettS6dri40ieseUpecifigps - whiebhemical comM. echanicihg Irties furnnhed is not more than the smaller of 0 01 m. or 6 percent under the dcugn thicknew.

                                                                                                                                      ,,gggg                          ~

gg g' material out's'ide!'!hejpe"cifiTaTi~di88fihNsh c .I' be Ih).. I'i tse Unclertaleram e. ; If, pipe orflohe is 33ggn;_ order r'd ,by;,ite nommalgvall thick ness- the; manu- , neare'st specified range' facturmg undertoleranceion,. wall thiqknen.jhall che

                                                                                                                            '[                                      gggg
   ,                takenijnin;accounigilic,ngxt heavier commercial    ,                                                                                (b) Plate material shall be ordered not thinner than .'
   %                wall thickness may.thes(igu,wdgl,,lp manufactyting                                   :                             the design thickness.Wessels, except for piping, 'made
   $                underloterances arc given in the several pilgand tube
                                                 ~              ,

of plate furnished with an undertolerance of not more 5 1.ycifkali8iiQtc'djngthe gap;licabl4.tabl3 ni Ap- . than the lesser value of 0.01 in. (0.25 mm) or 6% of

                 ' mined Pendih.lMiegh(jperc)murnj;va[@I l#itbshalt.bq rgn                       S oligtj@pjatt!1tutbunKsQllicienty
                                                                                                                                                              $l$p$,$ter , .
                                                                                                                                'the ordered thickness may be used at the full design                                                        I

{ pressure for the thickness ordered. If the spec to which the plate is ordered allows a greater DPMIUh'[pc3.I.kIk.I!pi'r$Mitidfit'dl6HM owc,d,' the,ps gby,fpd. $'

                                                                               .                  dh           -             all".i
                                                                                                                              .        undertolerance,          [              the ordered thickness of the material
                                                                                                     ,              ll.shall be sufficiently greater than the design thickness l       l               .                                                                       ;. so that the thickness of the material furnished is not ,

NIC-2124 Siir Itant:es . f. more than the lesser of 0.01 in. (0.25 mm) or 6% under the design thickness. .', h.Ekqmptv%il. Materials outside the limits' N.[sIEe. oblhicknes[p lc) II P IPe or tube is ordered by its nominai wall thism67lNfThisTTgl . Ema

                                              .r-4gJ1 thuWh'ual n~m_.
                                                                           - comn

_- hanegy]n)ge h'I trilh

                                                                                                                              . thickitess,pht.pp%fRnitin'g3n*de'rtBleranePon*

gg gggj .g. l. wa D.I . ( ,.ipaikgikca,.laathisJuhssclion. (ST.'Ilf t$5411indblN5eblUidi$liMNMY!!314'C In those speci. i4,'. turi.n~'Ju~islErtolsr$ces '.'are given'in tt$e several pipe !. licationwin .whic6erhosujoaluompmitmnc and/or - 1$ g -g ...m gg j

                                                                                                                                            . .. ,A:.,i mechanicakprnpertic= rare 4ndiented-in vary Eith' size                          ,           ' Ani Pgngi,xj %g.gt.e. g e_smnungun,waH;.gh;$ ness                                                              is
                                                                                                                             ).'determmed,f itqshallu.befincria'edi                                s                 by an amount orathicknes.'<nny siintVrbl outside the specification I

range shall be tcymred to conform to the composi- .; 5uff Ctent t Provide for the manufacturing undertoler. tion and mechanical properties shown for the nearest - ' ""** "i1 w in the pipe or, tube specification.- a specified range.* * ' l . . j

VIf Tv idt.mhecd ' ' ' -

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Fos ni co l.. Da v.l!.n..t . . . j tI..s. .i.. i l

   #            Subjeu yd                                                                                                                            o,                   i s.. . .

Sh u u s f .'. * * * ** '

                                                                                                     .c i

NE 2500 EXAhtlNATION ANI) REPAIR NE 2500 MAIERIALS HEPAlHS @d OF PIMsSSUHI' IMITAINING , NI:-2510 Gl;NI.H Al. Ill f)UlHl:MlWl.'s f j blATERIAL f NE 2510 PRESSURE RETAINING . Defects in material may he repaired provided ap. [ h!ATERIAL prmal of the inspector is first obtained for the method and catent of sepairs (sce Ni!-4621.1). De- Pressure retaining material shall be examined and feetive maicrial that cannot be satisfaciordy repaiicd shall be rejected'

                                                                                                *)j '

repaired in accordane: with the material specification and us otherwise required by this Subarticle. MO b.gh itt

• Z .

NE-2540 11 '.PAllt OF Dl;FiriS IN *} FOltGINGS *' N 2530 EXAhllNATION AND REPAIR OF g,g,g.g.g NE 254N Eliminatinn nf Defects  ; l NE 2531 Itequired Examination (a) Surface imperftetions such as chip marks. h!cmishes nr other irrecularitics shall be remnved by , g'.

                                                                                                ;'                     Plates shall be examined in accordance with the !l requirement's of the material specification.

grinding, or machining and the surface expmed shall i,! I he blended smoothly into the adjacent area where N[

             ,                                                                                "l                                                                              I!

sufhcient wall thicknew pernuts thin areas m comph. 3! NE 2537 Time of Exumination , ance with the requirements of Nii-42231henD f b) Thinning to remove defects beyond those per-f (. Acceptance examinations shall be performed at the p j time of manufacture as required in (a). (b), and (c) j mitted in NE-4223 may be repaired by welding. only

                                                                                                  ;.              below.

l af ter approval by the impccior. l i , j p, . (u) Examinations required by the ' material speci. - i NE-2549 Hepair by Welding j' fication 'shall be performed at the time of manu. - 7l facture as specified in the material specification.

                                                                               .i       i         i                (b) Radiographic examination of repair welds.
                                                                             ./ '                               when required. may be performed prior to any i

I  !

                                                                          /             !          I rcquired pustwcld heat treatment.

i l' t ,' (c) hlagnetic particle or hquid penetrant examina-l ' ' '

                                                                 ./,

tion of repair welds shall be perfortned after any l 1 required postweld heat treatment, except for P No. I ' 1 i e I i

• i maternal which may be examined before or after any *I

                                                         ;fe.tr
                             ,                                                                     i            required postweld heat treatenent.                             i l  l                3,, d                                 i i      i                   /.                                                                                                                       .l' l       l             ,/ .                                                            bNE 2538                Elimination of Surface Dciects j
                                 '      './        ,     i i

(a) Unacceptable surface defects may be removed i l " . .- i by grindmg or machining provided the requirements ' of (I) and (2) below are met: (!) the tcmammg thickness of the section is not

                                 ,    {                  ,

raduced below the minunum requued by the design; i 1 - l

                                             '                                                                          (2) the depression, atter defcet ehmination, is 3                                                                                                            blended uniformly into the ,urroundung sunface (b) When the clumnation of the defect reduces the
              'f , 'l b                               r ID M I M ' g h 6-2, Q Q\                                thsekne>> of the section below the minimurn reymred i i                                                                                              by NE-3000, the maierial shall be repaired in accor-I l

g i M to W 5 dance wiih NE.25g -

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                                                                                                                                                            *              !                            l           l         l           l                      !       l NI:.41.UI                       I l.l.\ll N A ll O N AND lti.I'Allt 01' k                                                    NE-4k30 ' R$ PAIR'OP M ATERI AL '  ' ' 'I If 1 ,'

t Elimination and Repair of Defects , W81 I 0 IH i l CIS NE 4131

                                                                                                                                  )
            . NI: 41.li                             Ituin Goscaning 1.lirnination and                                                l                                   .

Matenal on. .ginally accepted on deh.very in which

                                                                                                                                                                                                                                                                                                        . 4 {..
                                                                                                                                  'h                                                                                                                                                                 

II'P^" j i defects exceeding the process the limitserof NE.2500 are k Defects in materials which were accepted on de. y discovered during of fabrication instal .. lation is unacceptable. The material may be used ,.{,* ' ' ,

           ] livery or which arc distmcred during the process
          ' of fabrication or imtallation may be climinated or $                                                                                    provided the condition is corrected in accordance with repaired by welding, prmided the defects are re-                                                                J97 h gimm d E500 h & Wi@ 'm'N -

nuncil, repaired amt csamined in auordance with : product form except:(1) the limitation on the depth I.' ' . the ruguisements of NI:-25titlior the applicable pital. ,I nf the weld repair does not apply; amf(2) the time of uct form. cucp that the limitation on the depth of { ,.aamination of the weld repairs to weld edge prepara-repair does not apply. lions shall be in accordance with NE-5130. ,

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l c i i l.: . i I .L_ r NE-4220 NF. 4220 1 O R hllN G 'lapr ut.F H A N Cl S = teoilN1ING TOI.ERANCES NE 4221 '" gNE 21 .f Tolcrance for Vessel Shells $ 42 'Interance Inr Veuct Sheik y ,, l  !  ! b l

                                                                                              .h                              _ _ _ . _ . . . .
                                                                                                -t N E-42 21.1 Masimum Hillerence in Crnu Sec-                                  .                         NE 4221.1 hlaximum Difference in Cross Sectional j                                              '

tinnal liiarnticts. Q Diameters. '* ' ' ' '[ i ' NE 4221.2 Stanimum Deviation from True 't he. .f, I nrotical l'nt m O '

                                                                                                                !             NE-4221.2 hf aximum Deviation From True Theo-O'                        retical Form for External Pressure. "-

t l l NI:-4 22 I ..) Desiations from Tolerances.

                                                                                                }.                        e i

1 , I l , {'! , NE 4221.3 Deviations From Tolcrances. I i . NI: 4221.4 Tolerance Deviations for Vtuel l' arts i NE-4221.4 Tolerance Deviations for Vessel Parts Fa!nicattil from l'ipe. " Fabricated From Pipe. I . I - f 8 NE 4222 Tolerances for Formed Veuct licads [r ,, 3 NE 4221.5 1.ocalized Thin Areas. Localized thin <j

                                                                                                                    " ' " PC'*itted if the adjacent areas surrounding
  /                                 The tolcrance for formed vessel heads shall be as each has sullic.ient thickness to provide the necessary set forth in the following subparagraphs.
           ,                                                                                    ,.,                 reinforcement according to the rules for reinforcement g NE-4222.1 Desiation for Specified Shape.                                         iis NE.3330.                                                                                                  .

l In) 'lhe inner surface of a head shall not desiste p f IICS b

• from the specified shape by more than I % percent of i  ; I l l

the inside diameter of the head skirt. Such deviations t i l ., g : shall not be abrupt changes, shall be outside of the [f. il design shape and shall be measured perpendicular .ai j NE-4222 Tolerances for Formed Vessel IIcads ., to the specified shape. j (b) 'I he kiris of heads shall he sulliciently true ; 4 The tolerance for formed vessel heads shall be as set . . j forth in the following subparagraphs. ,)' to round so that the dillerence between the masimum ' Y  ! l NE-4222.1 Staximum Difference in Cross Sectional and minunum diameters shall not exceed I percent . 1 1 of the nominal diameter (sce Fig. NE-4221.I-I). Diameters. The skiit or cylindrical end of a formed .} . head shall be circular to the extent that the difference ,( l NE 4222.2 'Interance on Forged IIcads. Forged i in inches between the maximum and minimum diame. Ei heads sh.dl be as true as is practicable to inake q)) ; them to the shape shown on the design drawings. } ters doeswhere

                                                                                                                       + 12)/lDi).         not enceed                      the lesser of(D D is the nominalinside                          diameter   + 50)/200 in -

er (D ] Any deviations therefrom shall merge smoothly into g inches and shall match the cylindrical edge of the the general shape of the head and shall not evidepe. adjoining part within the slignment tolerance specified 3 a decrease of strength for the sections as requag in NE-4232.g; .g by the formulas for design. k NE 4222.2 Deviation From Specified Shape

                                                                                                                                                                                                                                    'd F                                             ,                           t                                                                                            ,

NE 4223 I.ocalized Thin Areas 't { po g i

   =               __     ,

Localiied thin areas are permitted if the adjacent }, g j p _ arcas surroumhng each has sulh,cient tinckneu to ; ' A ,

     \.                         provide lhe neccuary reinforcement according to thef, ','                                                                 g                                          ,                       j                i es for reinforce, ment in NE-3330.                         'f                                               Q                                                                          i                i l        c
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Af April 23,1982 Ekmo To File Re: Catawba Nuclear Station, Units 1 & 2 Steel Containment Vessel Dome Pitting,' Unit 2 . NCI 9092 ' File No: CN-ll44.13 On April 23, 1982, I received a call from Mr. Jim West, Quality Assurance Manager at Newport News Industrial Corporation. NNI's technical staff has reviewed photographs of the surface conditions observed on the dome plate, and Mr. West wanted to advise us of what.they believe is the source of these conditions. Mr. Jerry Cobb, a metallurgist for NNI stated that they have experienced similar surface conditions as a result of exposure of plate to the environment. Near 4 the Chesapeake Bay, where the atmosphere is considerably more brackish than , this area, up to 25 mils of corrosion pitting can be experienced in one year. These conditions are aogravated by standing water on the plate. Localized effects are generated by dirt spots on the surface allowing the fonnation of oxygen pockets which accelerate the effect. NNI does not believe that.this would be caused by inclusions, since these would be more elongated and indicative of rolling directions. Mill scale would probably not be the source of these problems, but the presence of scale could accelerate formation of localized oxygen pockets. In summary, NNI does not believe the conditions existed when the plate left NNI, since an inspector would have to be totally negligent to miss the conditions. Mr. Cobb stated that if the plate were sandblasted to white metal prior to coating, the condition would be stable. 1 Mc. Jo M. McConaghy, De i n Engineer I Civil / Environmental Di i ion JMM/ks xt: I. W. Pearce D. E. DeMart

Form 847 MEMORANDUM

                                                                                                                      ~        ~

DATE

         .o                ftt 6 ADDRESS FROM                                          OMMNy                                     SUBJECT    K# F !d#8              - Nb1 iOiZ i

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May 7' 1982 AL DIVISION

            '                                                                                            PMD-82-017 CNL f'RollCTS SECTION 4-MAY 101982 g              W. H. Bradley CENTIM.WEC0RDS/ DIVISION USE ED ATTACHMW 10 fitE Re:   Catawba W M in @lns3 ecto tTask Forq e Design Engineering Response                                                     "

File: ELD-0201 Attached are the Design Engineering responses to Specific Concerns DD-1 and NCIR-3. HCIR-3 is complete but the specific weld in question in DD-1 cannot be identified by QA for evaluation by Desicjn as agreed in our 5/6/82 meeting. Design considers 00-1 closed unless ' further instruction is provided by the Task Force. . As identified in Volume 1, Revision 2 of the Task Force report and our agreements in the 5/6/82 meeting, Design accepts responsibili.ty-

               ' for review of WP-10 and WP-11.                                                       -

l Scheduled Action ) Item - Assigned Individual Completion Dat'e

             ,           WP-10                                                            C L Ray            -

6-15-82 WP-ll D M Collings 6-15-82 Please provide documentation sheets for these items.

            . To update our current status, with the attached responses and excluding 4             WP-10 and WP-ll, our only outstanding item is PC-18. The NCI involved I

was partially resolved by 4-30-82 but requires aooitional information ' for completion. PC-18 will be resolved by 7-1-82 as outlined in my 4/14/82 letter to you. Please advise if you have any questions. , R. B. Priory, Prindipal Engineer Project Management Division By: D. F. Mitchell Engineer Associate a DFM/lmr - Attachment cc: 1. W. Pearce (w/NCIR-3)

l s l l Specific Recommendation tio. t1CIR-3 Assigned to k. f f7l O D/ I Determine a workable resolution to NCIR 9092 immediately, f Di scus sion/Ana lysi s/Addi tional i nfo rma t ion: PE4tto$ (ZE6cLOTiot46 TD ticI 9cO. HME. R?.04FA TD CE. OWPic0LT 'fo trnPLEMEt4T u.)tTm0T DRmReMS TAE. C.oMTPcts ifEAT PLArc_. Action to be taken: 0' CfdTE44 A 3RRLL SE. AFPLIED TO ETErcmlM8. eMic_H 4 CEFfLT5 AE Ru_e.PrR8tc. AND (d41CH IEEQOlf2E. faE9N(t. . c,rttTE#_t A l$ R20VIDED ert% Eis0Tiod Tb (4CC 9CC.

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fjI . 55.3 Attachment (1) to NCI 9092 Surface defects are judged not to be significant based on engine.ering judgement gained by prior experience in containment vessel and pressure vessel design. Site QA and QA Vendor surveillance shall address and evaluate why defects were not discovered during shop inspection and receiving inspection. Repairs to be done in accorda'nce with Section III, Subsection lie, of the ASliE' Code. . .

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I Response to Attachment (1) to NCl 9092 Vendors supplying safety-related materials or components have an approved QA Program. This program includes QC and inspection that we are confident is satisfactory. Duke Power QA performs surveillance on thei r prograrn to maintain a good confidence level. The surveillance does not include 100% inspection of the material or component. Minor or extremely small irregu-larities can go unnoticed depending on inspect ion or NDE requi rements. Shipping damages and normal oxidation are f actors to consider in reviewing the containment plate. ,

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e O 4.:_ N Attachment (3) to NCI 9092 This at'achment provides additional guidance to the res'olution of original NCI dated 7-28-81. Surf' ace defects have already been judged not to be significant based on engineering judgement (see attachment (1)). This attachment provides additior.al criteria for the surface preparation and inspection of pitting ' and surface roughness less than or has b ee,s N eaug"l PU' b to l*ln[t1 1/8 inch in "/E depth.

                                                                                                                                                                                                                                                      // f/I/U The containment dome plate chd' it sand blasted to a " white metal surface" in acccrdance with Surface Preparation Procedure DPSP5-1. This process @ Ac5 remued r: : e 111 surface foreign debris, scaling, rusting, etc. to sound metal.                                                                                                                                                                                                      cc ../nf ASTM A2:i, paragraph 9.2.1.1, requires all ' imperfections to be removed, to sound etal and to be well f aired. Procedure F.SS SP-55 shall be used as a hD l'[11 guide to cetermine'well faired conditions. Type 11, Type Yli and Type

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photogriphs shall be used for r'epresentative acceptable surfaces. All pits creater than 1/8 inch in depth shall be weld repaired in accordance

• with ASTP A20, paragraph 9.4.

S.. . By: - 0/Y&sh b t'f4l8/ g'HB llt i/W . Technical Aoproval: hE.bl%/- iih/s,_. - QA Apprcval:

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Attachment (4) to NCI 9092 page 1 of 2

        - Previous resolutions have proven to be very dif ficult to implement without damaging
   =-     the containment plate. The following procedure shall be followed to determine g     which defects are acceptable and which require repair. Details concerning the development of these criteria are contained in calculation file CitC-1144.09-01-0003.

1. Surface flaws with a depth of 1/8" or greater shall be weld repaired according to AStiE procedures.

2. Surface flaws with depth less th'an or equal to 1/32" are acceptable if they do not interfere with other flaws as outlined below.

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3. The remaining flaws shall be inspected to dete'mine r their acceptability using the attached Figure 9092.1. The acceptability of a given flaw will be determinez by the size of the surface which it covers, the depth of the flaw, and the proximity of the flaw to other flaws. Surface defects failing this criteria

• shall be weld repaired according to ASt<E procedures. ,

4. The following defin'itions apply to the variables used in Figure 9092.1: -

a. d (flaw diameter): The dimension.of the surface flaw in the direction of the next adjacent flaw. For circular pits surrounded by a circular pattern of smaller pits, d_ shall be taken as the distance across the circular pattern.

               . b.                             D_ (spacing between flaws): The minimum clear distance of unflavied surface between adjacent flaws. If D is greater than 1 3/8", O is to be taken to be equal to 1 3/8". .

c. t 7 (flaw depth): The maximum penetration of the flaw measured from the unflawed surface.

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    $      5.       In applying Figure 9092.1, the two surface measurements 0, and d_ should, be made first. With these two measurements, one point on the figure is determined.

This point will lie between two flaw depth lines. The flaw depth indicated by the line imnediately below the point given by D and d is acceptable, while the flaw depth given by the line immediately above the* point is unacceptable. For points lying ~on a given flaw dcath line, .the flaw depth given by that line is acceptable. For example; a flaw with D=l/2" and d=5/8" is acceptable for a flaw depth of 5/64" and is unacceptable for a flaw depth of 3/32". The actual flaw depth should be compared to the acceptable value to determine whether repair is required. Repairs-may be made either to the flaw in question i or to an adjacent flaw to arrive at a combination meeting this criteria. L . l 6. Ficure 9092.1 assumes an identical flaw on the opposite face of the dome plate. If it can be verified that in the area of a given flaw no surface flaws are present on the opposite face, the allowable depth given by Figure 9092.1 may be multiplied by two.

7. Surface flaws with a maximum dimension d areater than 13/8" shall be weld repaired according to AStiE procedures except as noted in 2. above.

8. Surface flaws .with a maximum dimension d less than 1/8" are not required to

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be repaired except as noted in 1. above! Repairs are to be done in accordance with Section 111, Subsectiory NE, of the

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Palmetto Allianca Press Re..ase e Arcid recentl. discovered NHC documente. shoving Duke Poeer Company quality assurance employee complaints of harassment, nrders to falsify records and a " Duke whitewash", Palmetto Alliance and Carolina Cnvironmental Study Group have gained l the assistance of the Government Accountability Project in their challange to the Catauba Nuclear Station operating license. GAP is e Washington, D. C. caued organization which monitors government and industry practice througn the use of whistle olowers - vorkers who expouc fraud, uante and improper pcectices. CAP has helped expose videspresd quality control problems at

  .       the Zimme;- nuclear plant in Ohio, where the NRC has nalted cansLruction.                      M:   . Billie Garde. GAP staff investigator, vill be present at the April 21 press conference. CAP agreed to assist in investigation and moni toring of the QA-QC programs at Catsuba based on evidence of serious, systematic and tidespread problems at the pinnt.and indications that NRC cfforts in correcting the problem have been ineffective.

In the NRC licensing case, ... based on information proviceo by two former Catawba workers - including a Q/C inspector - Palmetto Alliance charged that company pressure on i.upecters to approve faulty workmanship and subvert the NRc required C/A program p roduced sy stematic defi cie.:c; es in plant construction...

        .             R t s h w a ri u g y.p x a p a r u k t a u x x During prenearing preparation,                            Palmetto Alliance found.QfA-0/C crublems had caused Duke Power Compans to conduct its osn investigatica f rom December, 1901 to ri a r c h , 1982, hecently released documents show that Q/C inspectors h u 'j compiained as early as Feuruary 1, 1962, to the NRC that Duke A ver C o m p a n :. vaald sttempt to " whitewash" investigurion that the QC peruonnel nac bovn " harassed on ': h e ,t o b  cnd t.hn t they aad beer. " told to falsify leecrds".

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Group.To Accuse Duke ,

j. Ei In Nuclear Plant CW Free Page 1A Records acce director, said the NRC "

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           Wa have thoroughly reviewed a.m. press confermes in Chariotta to rmalNRC W they my ontes in=tisation of ths.e aDe- wlB support their chstges.' .
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gations and we conclude it was a wiB siso aanmar= socod la. 1--+'a= and we do not Ea$oS that ald5 mM. m that an and

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Ity nasarance or goalfty control Govenunset AeocustabGity Pto. ems at Catawan. We do not there was a whnewash.-

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{gj niental Study Group coerend there quiry into construction problems

                                                                                                                                                   @E                          T are "serlons syntasnade and wide-                    at the Zitamer socient plant in
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g "NRC afforts la correcdag the pedered work as the plant hartad - - rr a have been Iceffecove.' . a r--fo re*w. L , g - yg ,$4- {3 2 g u ~.. m.

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