ML20081G038

Interim Rept Re Potential Deficiency 55-83-07 Concerning Pipe Shop Welds by Southwest Fabricating & Welding Co. Initially Reported on 830614.Revised Investigation Plan Being Prepared.Const Work on Pipe Spools & Welds on Hold

ML20081G038
Person / Time
Site:	Clinton
Issue date:	10/26/1983
From:	Hall D ILLINOIS POWER CO.
To:	James Keppler NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
References
10CFR-050.55E, 10CFR-50.55E, 1605-L, 55-83-07, 55-83-7, U-10103, NUDOCS 8311040078
Download: ML20081G038 (3)

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. ILLIN0/8 POWEli COMPANY p.10103 CLINTON POMR STATION, P.O. BOX 678. CLINTON, ILLINOIS 61727 October 26, 1983 Docket No. 50-461 Mr. James G. Keppler Regional Administrator Region'III U.S. Nuclear Regulatory Commission 799 Roosevelt' Road Glen Ellyn, Illinois 60137

Subject:

Potential Deficiency 55-83-07 10CFR50.55(e)

Pipe Shop Welds by Southwest Fabricating

Dear Mr. Keppler:

On June 14, 1983, Illinois Power Company notified Mr. F.

Jablonski, NRC Region III (Ref: IP memorandum Y-15971, 1605-L, dated June 14, 1983) of a potentially reportable deficiency concerning the adequacy of shop welds on pipe spools' fabricated by Southwest Fabricating and Welding Company and supplied to Baldwin Associates for use at Clinton Power Station. This initial notification was followed by one (1) interim report (ref:

IP letter U-10074, D. P. Hall to J. G. Keppler dated July 25, 1983). Our investigation of this matter continues, and this letter is: submitted as an interim report in accordance with 10CFR50. 55 (e) (3) .

Statement of Potentially Reportable Deficiency During a re-review of radiographic film, rejectable indica-tions were found in shop welds produced by Southwest Fabricating and Welding-Company (SWF)._ _The welds in question are ASME Code Class II found in safety-related piping systems. An investigation is being conducted to ascertain the scope of this problem and the potential for impact on the operation of Clinton Power Station (CPS),

Background / Investigation Results During_ examination of a field radiograph taken of a weld repair on a SWF shop weld repaired by Baldwin Associates at CPS, questionable indications were noted in the root area of the SWF

,_ shop. weld away.from the repair. The weld repair was necessary

'due to overgrinding'of the shop weld while " flat topping" in preparation for in-service inspection baseline examination. The questionable indications were also noted in a re-review of SWF shop radiographic films of this weld. Further investigation of shop radiographic film identified additional shop welds with questionable indications.

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. . l Mr.'Jamed G. KOpplar .Pege 2 October 26, 1983 These SWF:sh'op films were originally evaluated-at receipt by a Baldwin Associates Quality Assurance inspector no longer available for consultation.

Baldwin Associates performed a re-review of a sample of radiographic film originally interpreted by this inspector.

' Sixty-eight (68) welds were selected at random for. review.

Fourteen of these welds were found to contain questionable indications. The films of.five (5) additional welds showed surface conditions that possibly - could mask defects. As.a result of these findings, Southwest Fabricating and Welding reported on June 24, 1983 to the Nuclear Regulatory Commission (Region'IV),

under the rules of 10CFR21, an apparent failure to comply with the requirements of ASME.Section III, Paragraph NC-4424 for several of-the questionable welds. The welds documented in the report included four (4) piping subassemblies with.45* 1ateral branch connections, with reinforcing pads installed after radiography. Due to ~ the. presence of these reinforcing pads, it is currently not possible to determine if indications on the film are surface indications.

An Investigation Plan was developed by Illinois Power that detailed the actions.necessary to achieve satisfactory evaluation of the nineteen questionable welds. This plan called for a re-radiograph of the nineteen (19) welds in the as-found condition after a visual' inspection. The radiography technique duplicated the original SWF technique as close as possible.

.Those welds having an irregular surface were then ground smooth and re-radiographed a second time. A joint review of the radiographic film was then performed by SWF, Baldwin Associates ,

'and an independent Designated Reviewer representing Illinois Power. This review found that three (3) welds require an engineering evaluation and disposition of the indications found,

.and one (1) weld remains -indeterminate due to difficulty in interpreting the film. In addition to the original nineteen (19) questionable welds, reviews of other SWF radiographs by Baldwin Associates have identified some additional welds that contain questionable indications.

Corrective Action (Interim)

As large. bore piping fabrication is essentially complete for Clinton Power Station, Illinois Power's efforts have focused on identifying the scope of this issue and on the correction of any identified-weld deficiencies. The following actions are presently being taken by Illinois Power:

1. A revision to. the Illinois Power investigation plan is being prepared to include additional re-reviews of Southwest Fabricating radiographs for film and weld quality on piping supplied to Baldwin Associates for use at Clinton Power Station. This review will be

. performed by qualified Baldwin Associates reviewers and monitored by Illinois Power's Designated 'Reviewcr.

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l Mr. . James . G. K:ppler J .. Pege 3 " ~ october 26, 1983

2. -Illinois Power management has issue'd a~ hold on all

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construction. work on Southwest-Fabricating pipe spools and welds until further investigation of the ~ shop welds has been. performed. Exceptions.to-this hold are allowed only; on a Lease-by-case basis.

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. Safety Implications /Significan~ce

. The investigationfoffthis potentially reportable deficiency s,

continues. Once the,re-examination.is complete, it.will then be-E 1possible1to determine generic and ' specific corrective actions.

f; -Itzis; anticipated:thatfapproximately nine (9) months will be r '

necessary1to complete an' investigation'and analysisJof.this-

potentially reportable deficiency and;to~ provide a final report.

Illinois Power - intends to ' provide - an update : on - the : inves tigation di in : approximately : ninety. - (90); days .- -

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. We trust =that thi~: s interim letter provides. sufficient-information to perform'a general assessmentsof this deficiency.

and adequately describes our overall approach to resolve the .

. problem.

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Sincerely yours, '

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. . all-Vice President

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-cc: . NRC Resident Office-Director,10ffice'of I&E,,USNRC, Washington,-D.C. .20555

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Illinois Office of Nuclear Safety

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