ML20083D995

Interim Deficiency Rept 55-83-06 Re Structural Steel Welds by Rockwell Engineering.Initially Reported on 830427. Reorganization of Baldwin Assoc Vendor Surveillance Group Effected to Increase Program Effectiveness

ML20083D995
Person / Time
Site:	Clinton
Issue date:	12/09/1983
From:	Hall D ILLINOIS POWER CO.
To:	James Keppler NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
References
10CFR050.55E, 10CFR50.55E, 1605-L, 55-83-06, 55-83-6, U-10110, NUDOCS 8312280390
Download: ML20083D995 (4)

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)/$h 1605-L ILLIND/S POWER 00MPANY g.19110 CLINTON POWER ST ATION. P.O. box 678. CLINTCN. ILLINOIS 61727 December 9, 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:

10CFR50.55(e) Deficiency 55-83-06 Structural Steel Welds by Rockwell Engineering

Dear Mr. Keppler:

On April 27, 1983, Illinois Power Company verbally notified Mr. F. Jablonski, U. S. NRC Region III, (ref: IP memorandum Y-17046, 1605-L, dated April 27, 1983) of a vendor concerning potentially shop report-welding able deficiency per 10CFR50.55(e) deficiencies on certain structural steel members supplied by Rockwell Engineering. This initial notification was followed by two (2) interim reports (Ref: IP letter U-10060, D. P. Hall to J. G. Keppler dated May 31, 1983, and IP letter U-10085, D. P.

Hall to J. G. Keppler dated August 31, 1983). Our investigation has determined that this issue represents a reportable deficiency This letter represents an under the provisions of 10CFR50.55(e).

interim report in accordance with 10CFR59.55(e)(3).

Statement of Reportable Deficiency Vendor shop welding deficiencies were identified on certain structural steel members supplied by Rockwell Engineering (struc-tural steel fabricator) to Baldwin Associates (CPSThe contractor) structural for installation at Clinton Power steel members in question are columns used Station (CPS'.

to provide lateral Investigation of this support for concrete block walls at CPS.

issue continues, to determine the full extent of the condition into other types of structural steel members supplied to CPS by this vendor.

Background / Investigation Results column During on-site modifications to a block wall support by Baldwin Associates, a deficient weldThe was found that was made deficient weld was one by the structural steel fabricator. The of three used to attach a connection angle to the column. (FCR 17033) column was being modified per a Field Change Request which, in part, required removal of the connection angle.

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Mr. James G. Keppler Page 2 December 9, 1983 Inspection of the deficient weld revealed that there was no fusion with the base metal. An investigation was initiated to determine the scope of this problem.

A review of the applicable purchase order was performed and those columns received with unmodified welded connections were identified. This review identified fifty-eight (58) columns. An inspection by Baldwin Associates Technical Services was performed and found that fifty-seven (57) columns contained welding defi-ciencies that varied from cosmetic to structurally significant.

Deviation Reports (DR) 5815 and 10303 were generated to document the welding deficiencies identified by the inspection.

To evaluate the root causes of potential welding defi-ciencies, and to eliminate cosmetic deficiencies from the eval-uation, the welds on twenty-two (22) erected columns were field ground to sound metal, and another inspection was performed.

This second inspection provided detailed information and sketches of the remaining welds for on-site evaluation. The thirty-five (35) columns that were not installed were returned for evaluation and were repaired in the vendor's shop. The evaluations indicat-ed a trend in inadequate connection angle welds parallel to the column flanges on 6' and 8" columns. This trend is believed to be caused by lack of accessibility to properly position the elec-trode during welding of the connection angles. As a result of this adverse trend, the scope of the investigation was increased to address all safety-related blockwall columns to assure adequa-cy in meeting design requirements.

All installed safety related blockwall support columns fabricated by Rockwell Engineering which have the potential for welding deficiencies were identified. Those column connection angles that are accessible are being inspected and repaired as necessary. Those columns and connection angles that are not accessible (due to being encased in block walls or concrete walls / slabs) have been referred to the Architect Engineer for an engineering evaluation and disposition.

In parallel to the above inspection effort, an inspection of a random sample of other accessible assemblies welded by the fabricator under other purchase orders was performed. The results of this inspection did not indiccte any additional adverse trends. However, several isolated cases of deficient welding were identified. As a result, an additional sample representing 20% of the safety related structural steel members shop-welded by the fabricator is being inspected to further investigate the extent of this condition.

Corrective Action (Interim)

1. In-process installation work on the subject blockwall columns was ceased until further investigation into this potential deficiency was performed and repairs made to the columns.

Mr. James G. Keppler Page 3 December 9, 1983

2. Blockwall columns that were not installed were returned to the vendor for repair in accordance with approved welding procedures. Baldwin Associates Vendor Surveillance person-nel witnessed a representative sample of column weld in-spections and repairs.

3. Blockwall columns installed at CPS that are accessible are being inspected and repaired if necessary. Those which are not accessible for inspection and repair have been referred to the Architect Engineer for an engineering evaluation and disposition.

4. Welding deficiencies noted during the random inspection are being documented on Nonconformance Reports (NCRs) and the members are being reworked by Baldwin Associates to the original designer's requirements.

5. Where possible, Illinois Power and Baldwin Associates have constrained future orders of structural steel to stock material. Fabrication of required members will generally be performed on-site by Baldwin Associates using the stock material. This action has resulted in minimum purchases of shop-fabricated structural steel assemblies.

6. Structural steel vendors performing work or supplying material for CPS (past and present) were notified, advising and stressing that they have responsibility for their work.

This includes correctness of design, proper completion of work, implementation of QA/QC programs, and reportability in accordance with the Code of Federal Regulations.

7. Enhancements have been made to the Baldwin Associates vendor surveillance and receipt inspection programs since the affected members were received. These enhancements include the following:

a. intensified in-shop vendor surveillances in both scope and number.

b. a reevaluation of Baldwin Associates vendor surveil-lance inspection / receipt inspection points was performed, with more hold / inspection points estab-lished.

c. a reorganization of the Baldwin Associates vendor surveillance group from the Quality Control to the Quality Assurance Department was made, to increase overall program effectiveness.

Mr. James G. Keppler Page 4 December 9, 1983 Safety Implications / Significance The blockwall columns in question provide lateral support for concrete block walls at CPS. It can be postulated that the shop welding deficiencies on blockwall columns could adversely affect the performance of the block walls under seismic loading conditions and impact the safe operation of CPS. Although further inspection and engineering evaluations of the structural steel members supplied by the vendor are being performed, this issue is considered to be reportable pursuant to 10CFR50.55 (e).

We trust that this interim report provides you sufficient background information to perform a general assessment of this reportable deficiency, and adequately describes our overall approach to resolve the problem.

Si cerely yours,

. . Hall Vice President REC /dkr cc: NRC Resident Office Director - Office of I&E, USNRC, Washington, DC 20555 Illinois Department of Nuclear Safety INPO Records Center l

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