ML20083M868

Metallurgical Exam,Cracked Field Weld 212 Feedwater Pipe to Nozzle;Steam Generator 1-2. Related Info Encl

ML20083M868
Person / Time
Site:	Diablo Canyon
Issue date:	06/23/1977
From:	Caughey R PULLMAN POWER PRODUCTS CORP. (FORMERLY PULLMAN, INC.)
To:
Shared Package
ML17083B313	List: ML17083B309 ML20083M848 ML20083M862 ML20083M868
References
NUDOCS 8404180373
Download: ML20083M868 (81)

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Metailurgical Ermmination Crackad Field Wald No. 212 Feed Water Pipe to Nozzla; Steam Generator 1-2.

Pacific Gas & Electric Co.

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INTRODUCTION On March 17, 1977, during hot functional testing, a water leak was discovered in the butt weld (Field Weld No. 212, line K16-555-16IV) which joined the 16 inch diameter feed weter pipe j

to the No. 4 nozzle on steam generator 1-2.

The line pressure and temperature at this time as approximately 90 p.s.t. and 300*F respectively.

Subsequent on site non-destructive testing by both ultra-sonic and radiographic means (by both Kellogg and P.G. & E. repre-sentatives) 14d to the conclusion to cut out and totally replace this weld.

A satisfactory, accepcable replacement was complaced during the period March 19-25, incl.1977.

A summary of these events are described in Kellogg's report dated April 12, 1977 prepared by J.P. Runyan, Field QA/QC Manager.

A copy of this report is attached (Appendiz I, pages 11-15)

C Incident with this replacement a spool piece was salvaged for subsequent labora:ory examina tion by P.G. & E.

It contained a conveniently large portion of the weld gleposit and a representative portion of both the cc =la and pipe components.

A sketch which describes the di=ansion of this piece; also the crack path and the extent of the cracic raic tive to the weld deposit is includiitd with the Kellogg ra;cre rafarancad abova (Appendiz I).

Kellogg, for tha purpose of a laboratory examination, requested P.G. & E. to furnish representative specimens cut from this spool piece.

T::e wers esceived.

The report which folleva covers a desc=1ption of these samples and the results and conclusions determined from this in-vestigation.

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PRCxwi.FaZ & RESULTS OBTAINED A. History Pertinent to this investigation was a ccuplete review of the records appertaining to field weld joint No. 212, namely; the weld procedura; welder qualification records, heat treat:nent; material certifications; nondestructive examination personnel qualification and N.D.E. results.

The following information was gleaned from the recorded documents on file with respect to this weld:

1.

WELD HISTCRT RE7TIV Field weld 212 was fit-up and tack welded on Friday May 18, 1974.

On Monday May 21, 1974 the tack welds and insert were removed.

A new insert was installed on May 22,1974.

It is not documented as to why the original inserr was removed, however, discussions with field inspectors who were on site at the time indicate O

that surface rust may have occurred over the weekend and the insert was removed to reelean the weld prep and install a new insert prior to consuming the ring.

The rcot pass was made on May 22, and accepted visually May 23,1974.

Welding proceeded following Q.C. accept-ance and was complaced on May 24, 1974.

The weld surface was ground and final visual inspection complaced on May 28, 1974.

Other than replacing the insert no unusual or out of the ordinary circumstances were recorded.

1 2.

PREHEAT AND POSTHEAT A review of the heat charts on F.W. 212 indicate that the weld area was preheated to 200*F min. prior to tack welding and subsequent welding.

j The weld was preheated on May 22, 23, and 24.

The heat was turned off at the end of each shift allowing the weld to cool.

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PRNAT AND POSTHEAT (Con't)

Following completion of the weld on May 24, the weld ses allowed to i:ool and no further heating was per-formed until pose weld heat treatment on June 24, 1974.

Preheat and post heat records from other welds of the same type indicate a similar history.

NOTE:

Other welds reviewed were the remaining three feedwater nozzle to pipe and all four main steam nozzle to pipe and all four main steam nozzle to pipe welds in Unit I and the main steem nozzle to pipe welds in Unit II.

The feed-water nozzle to pipe welds are not welded in Unit II.

3.

WELDING PRCCEDURE AND WELDER PERFORMANCE QUALIFICATION RICORDS Field Weld 212 vos made using weld procedure number 200.

The procedure ses reviewed to assure compliance with ASME Section II.

No deviations were noted.

The results of the procedura qualification tests were evaluat-O ed.

Included were bend tests, tension tests, and Charpy V Notch tests.

All results were acceptable.

Walder performance qualification records were reviewed.

The records were in order and the welder was found to be properly qualified.

In addition, records of other welds performed by the same welder were reviewed.

It was determined ebat his performance record was good.

There was no reason to suspect that welders capability i

or performance was below standard.-

4.

MATERIAL CERTIFICATIONS Material Certifications of the weld material and pipe-side base material was reviewed for compliance with material specifications and job specifications, including supple-mentary requirements.

All were found to be in compliance.

The nozzle base material certifications were not available for review by M.W. Kellogg. - _ "-

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NONDESTRLm.vs EXAMINATION PERSONNEI.

PROCEDURES AND 1 REPORTS he original radiographs of F.W. 212 were reviewed.

There was an afea along with nozzle side of the root with greater. density than other areas of the weld.

This area is typical of other similar welds.

The higher density is caused by the nozzle counterbore which is

, approximately 1/4" vida.

There was no evidence of linear

_ indications in the area where the crack occurred.

Review of the radiographs of other similar velds did not show evidence of linear or crack-like indications.

B.

Mecallurrical Examhm tion A description of the two (2) specimens received from P.G.

& E. follows:

,,,,,,0ne_ represented by,about 1/2 inch of the circumference contained the full depth, "frone" face of the crack as viewed coward the pipe component. -An enlarged photograph showing O

the." front" face. is displayed in Fig.1 Page 8.

This surface had been fully protected from post atmosphere affects by the application of a lacquer.

The coating was removed for photo-graphing The second (also about 1/2 inch of circumference) contain-ed the full cross section of the weld joint.

It bad apperantly been removed from a location where cracking had not occurred.

A photograph of this sample is tg, included.

IcT11 be discussed with relation to microscopic examinations which were conducted on both specimens.

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Photomicrographs of both specimens are displayed in Fig. 2 a=d 3*respectively.

Both represent the existing metallic structure in the locus of the weld root on the nozzle side of the veldsent.

Noteable in Fig.1, or the " front" face of the crack cross section is the distinct, variously " shad _e_d" areas.

There appears to be four in number as illustrated. in the accompaning sketch.

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DISCUSSION Fractured or cracked areas showing these distinctions are typically associated with-facique failures caused by the impost-tion of cyclic stress.

From this photograph the clear indication is that crack initiation took place in the root of the veld in the forged nozzle and ultimately propagated to failure through the veld deposit in at least 3 stages as shown in the sketch.

(The cycling involved could have resulted either from multiple hydro-testing or from cyclic exposure during hot functions 1 testing.

l These facts were not contained in the reported history cited above).

In such cases the causual phenomenon is usually a pre-existing discontinuity which may be either an inherent metallurgi-cal plane of weakness or a physical crack lika defect.

In the photograph of the fractured surfaces (Fig.1) the first distinct area is the root of the veld joint.

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visual e=mi-eion h7 -croscopic -a= sh-d sporadic -11 areas (light areas in the photograph) which were relatively bright or " shined".

Fig. 2 is a photomicrograph of the metallic structure t

which was found to exist in one of these areas.

The indication is that these are associated with remanent, weld bevel " land" material of the forged nozzle component.

The suggestion is that, erach iniciaeion stemmed from this locus; aiso thae the inicisting defects were localized, incipient root cracks through the land area.

What is not clear from this==4= tion is the cause for the defects.

In the history of the field fabrication of this particular weld (cited above) the. fact that repetiture prehasting and cooling was permitted to take place on four separate occassions before the veld was completed, could be one factor.

Thereby inordinately high thermal stresses could have resulted in incipient cracks.

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DISCUSSICN (Con'c)

Another contribut'ing factor unda: these circuz:: stances (which cannot be overlookad) could be the relative hardenability of the forged nozzle material the reported composition of d

which was a nickal, molybdenum bearing steel or A.S.T.M. A508-CL2.

This is an air hardening ecmposition.

It is possible 1

due to i:he noted in attention especially to cooling affects, following the root pass welding, that, air hardened, crack sensitive microst=uctures could have been effaccad and sporadic cracks on cooling prometad in the initial land area. (Micro-structura affects in the speci= ens azamined votild, of course, he obscured by the subsequent serass-ralief heat creat=anc.)

i Understanding this weld (NO. 212) was oca which was complaced under restrained conditions (c as a elesure weld) the possible circumstances i.e., in accantien to preheating and cooling and metallurgical transformations, would augment the cracking candancias.

Fig. 3 or the photomicrograph of the uncracked weld

.d joint (localized at tha root weld is nozzla forging) shows i

the normally expected microstructura; good penetration; and no i

evidence for lack of fusion or cracking.

Certain evidenes of small cracks are shewn to exist in the I.D. surface of the

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forging.

But there is no : asen to believe chase or lika defects could have cont ibuted to ultimate failure, once the weld was ccmpleted and st:sss-relieved.

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i CONCLUSICNS i

1.

ne crack failura in the W212 resulted f cm crack lika

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defects which appe=ently existad in the weld bevel land.

i 2.

The cause fc= the crack defects is not clear.

They ara believed, however, to have resulted Tien the welding process i

and probably portand the affects of repetitive preheats and cooling applisd before welding was complaced.

Impesi-tion of high thermal senass, especially in the early stages of welding, is a plausible explanation.

3.

Ultimats failtra th=cugh the weld deposit was.due to a cyclic fatiqua stress phenecenen, which it 'is suggested was the consequence of repetitive loading due either to f

preliminary hydrocasting c inherent in the het functiccal casting prog:s=.

4.

The fact that cracki=g was only discovered during the hot functional casting, and g evident f cm preliminary in-n process inspections i.e., ultrasonic and radiography (pro.

bably due to the inherent insensitivity of these proceduras V

to indicata small d~ipient cracking) the raccanandatien is hereby made that all lika welds should be reinspected upon the ecmplation of functional testing and before se:vice in order to discover any evidence of crack propagatien c:

enlargement; not withstanding the fact that in process decu=ents failed to disc 1csa tha possibility of simila:

j incidents.

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K-insert, weld reinforcenient.

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Remanent.ueld bevel land; probable crack I

Crack " Front" Face; Viewed Toward initiation region.

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3rd-crack stage.

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Final stage, thru wall penetration.

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4. 4. 01Ca 4. SCCn Photomicrograph Crack Evidence in Initial Wald Bevel Iand

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DIABIA CANTON NUCI.ZA1 PROJECT JOB f 7177 i

SPEC # 8711 I

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i QUALI1T ASST 2MICZ RE? ORT cy.

Crack in Staae Generator Feedw s'.-

Nossia to pipe weld (Generator No. 1-2)

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- _A QUALITY ASSURANCZ REPOEy g.

OF CIACE IN STEAM GENERA 1 FEZDWATER N0ZZI.Z TO PIPE WEI.D (G2NZ3Al"C150.1-2)

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M To document events free the time of discovery of the leak until 'the cecplation ef de nph.

Ei2.r a 21s report covsrs tha on sita findings, the review of de'edentatice.

including preheat and postha.it charta, radiographs from the defective weld, the subsequent proceduras for removing the defective area and performing the repair.

?MN on Sursday, March 17, 1977 a leak was observed in field weld 212, line E16-353, by F.C.& Z.

We were advtsed of the leak on that data.

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O ne -1d in 4 estto is *er th.14" feedw-er,13 tie. into -..ta a on Staan Carerator 1-2.

Tisual observation revealed a weep type task, which occasionally sprayed a l

fine stress of water.

Een observed with a 10Z magpifing glass there appeared *

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to be a small intermittant linear indication approziately 3/8" in length in the contar of the weld running around the pipe. Magnetic particia examination l

ef the area with a D.C. converted yoke did not show evidence of a linear defect.

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?.C.& E. requested that we grind the area. As grinding ' proceeded, the indication opened to reveal a linear defect approximacaly 2" long when the weld crown was flush with the pipe surface.

At this peine this grinding was stopped. We were requested to perform se Ultrasoais esamination to determine the essent of the indication.

Se pipe temperature was approximately 180* T shich made it impossible to perform U.T. with the standard transducers on site.

We were them instructed te " hold" until P.G.4 E. Engineering Research arrived with their U.T. equipment and high temperature transducers.

De weld was radiographed at this time. The radiograph revealed evidence of a linear indiestion which appeared to be approximately 4" in length.

Ca Triday, Marsh 18,1977 7.G.& E. Engineerd.ng Research arrived and performed Ultrasonia esamination of the weld.

May reported that there was a creek whiah appeared to estand approximately 2/3 af the distasse around the weld.

Based

... en there findinse it ama deterstr'=8 tha* the wid wezid is cut out and replaced.

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l De weld was cut by grinding approximately 1/2" from the center line on the nossle side and at F.W. 503 on the pipe side. De end of the pipe was then l

est to remove a ring which included most of the weld and approximately 4" of pipe.

Se piece was examined visually and by liquid penetrant on the 0.D. and J

1.D. and a skatch made to refleet the observations.

(Sketch Attached) 1 Se piece was shipped to P.G.& E. research lab on March 20 for analysis.

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l EEGL A piece of 16" pipe was removed from stores to replace the piece which was cut out. De pipe and prope, samma hole and vent vers eachine_d in the ?.C.& E.

machine shop on March 19, 1977. S e nozzle end prep at y.W. 212 and pipe end at F.W. 503 were ground in place on March 20. A liquid penetrant examination was performed at that time to assura ecepleta removal of any indications.

Se new piece was moved into place and fit up on March 20. Preheat was applied prior to tack-up,(Ref. Chart # 547). After the fit up was approved by N.W. Kellogg Q.C. both roots were welded. Magnetic particle inspection was performed. Following magnette particle acceptance two additional passes were welded in each weld.

I Eadiography was performed on March 21, 1977. S e radiographs of 7.W. 503

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pipe to pipe wereacceptable.

7.W. 212, pipe to nozzla, had excessive porosity at the wtadow closures. Dese areas were ground, revelded and re-rae'iographed.

One area had excessive porosity, the other had a linear indication appr=sinately 1/2" long and an area.which appeared to be sack back.

At this time, March 21, 1977 P.G.& E. Q.A. placed a " hold" on all. work untti their Engineering could review the total program and process appropriate i

paperwork. "This hold wee not because of the difficulty in welding the window closures".

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i No work was performed on March 22, 1977.

On March 23, 1977 an on site meeting was held to review findings, work to j

data, and procedures.for esoplettaa of the repair. Attending the meeting were representatives free F.G.& E. Engineering, Q.A., General Construction, Division, i

Weetta: Wee, M.W. Kellogs site Manager, Corporate Q.A. Manager, and the writer.

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Is was determined that the procedure as outtimed by D.R. 3364 was

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esseptable essept that the preheat would be raised to 300* Min. for esopletion of the welding.

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Se problem of making en acceptable closure weld was discussed. It

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was determined that the positive pressure saintained in the systan was ta high. 4d that water terminis4 in the seaarator cassed vapor to be v

earried out the window openings.

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7.C.& E. Division agreed to drain the generator and reduce the purge pressore antil the closure welds could be made.

J on March 24, 1977 the defective areas at the closures were ground out and l

1 Magnetic particle performed 'to assure complete removal. No welding was per-formed since P.C.& E. had not removed the Hold. Freheat was being maintained j

through the " hold" period.

on March 25, 1977 the held was released. The windows were closed and radiograph made. Both areas were acceptable and welding continued. The weld was completed on the afternoon of the 25th. Eadiographs were shot in the het j

as welded condition. We rejectable indications were noted. Post weld heat j

treatment wea then performed.

l On March 26, 1977 following post veld heet treatment, the weld was ground, l

re-radiographed, liquid penetrant inspected and ultrasonic 411y examined. No rejectable indiestions were noted. De vent line and gasssa p. lug were ecs? eced, t

l inspected and the system turned over to division for resumption of testing.

$t735 u. u,i U v u -!cA "!C't 3eesuse ' f the unknown origin of the crack it was determined that other o

welds of the same type and welded using the same procedurs should be reviewed to determine if the defect could be a generic nature.

4 Zach of the remaining three feedwater nossle welds and the four Main Steam i

O n szte weids vers 1==asonica117 eaa ined. :he ori inal radio.rs.hs were re-l viewed and the feedwater nossle welds were re-radiographed. W ere was no evidence of like indications in any of the welds and no evidence of changs in f

any of the noted, acceptable, indications since the original inspections.

There was, however, an indication neced in 7.W. 197 on generstor 1-1.

Os indication was present on the original radiographs but had not been noted en the radiographs report. A second set of radiographs vers on file for F.W.197.

nis set also exhibited the same indication. however, the radiostsphic report d..i rs-flect the condition as being a drop thru. The indication had apparently bsen evaluated and determined acceptable at the time.

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3esanse of the problem with 7.W. 212 it was determined that any questionable

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situation should be resolved. It use therefore determined that the drop thru should be removed. A D.1. was initiated and the repair was made. The indication was removed by grinding. No welding was required.

(See D.I. 3370 Attached)

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322MI To date the estallurgical sestysis has not been completed of the crack l

sample. We had requestad, free F.C.& E., a piece of the defestive material for eer own analysis. This was received os Dursday, April 7,1977 and forwarded to E. F. Gervin in Williamsport.

It is my belief that the eresk was peculiar to F.W. 212 only and not of a gemari satura.

arefers, at this tins we ars 2ssuming that as further repair Q

will be required and that when the disposition of D.1. 3370 is complaced the subject will be elesed.

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EVALUATION OF DISCREPANCY REPCRT IN RELATION TO AEqulAEMENTS OF 10CFR PART 21 9"'

1 0.R. # 3 N f3 L/, to elch this p.se is at=hed and become a part of, is not, he ) considered to be reportable to the NRC under the requirements of ICCFR Part 21.

t PULI. NAN POWER PRCDUCT3

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O Pacific Gas s'tlectric Company ( does es not ) consider this 1

discrepency rsportable and ( has reported, Ill not report ) the j

above discrepancy.

This form returned to Pullman Power Products en 9 M 77 om i

PACIFIC GAS & !!.ICTRIC CC.

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PULLMAN PCWER PR00* CT3 J

IVALUATION OF DISCREPANCY REPCAT IN AELATION TO.AEqulAEMENTS OF 10CTR PART 21 v

0.A. #

DIT

, to dich this page is attached and became a part of, may be ) considered to be reportable to the MAC under the requirements of ICCTA Part 21.

PULLMAN PCWER PR000CT3 1

by Pacific Gas & Electric Campany ( does,

) consider this

'- discrepancy reportable and ( has reported, notrecjo ) the above discrepancy.

i This form returned to Pullman Power Products on 7!M 77 13 ATE 4

PACIFIC GAS & (LICTAIC CD.

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THE M.W. KELLOGG COMPANY Page 1 of 3 A olVt00 ole op put.utafe tsetempoRAfeg 3.n. No. Th41 Rev. I IAN'

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OlSCMEp ANCY MEpCRT unit No. I C:osMc. M/A i

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Posifle Gas & Eteetrie 3,ge,3g, snt garg; 8-26-77 I

resuscT, Osasse canna ace so.:

N77 inspec; m: Runven/5canneiI/ Guest o'senerant'

• Line K16-6?6-16"? Soani plue 500t ti. !!k' ki" Area G: Sect. l j

l axpumanen ce etsemesamev: Reference P.G.M. Orswing 500146 Aav. 9s lI Per P.G.M.'s request, an Internal Inspection of F.W. 244 on Steam Generator I-4 Feeewater Mozzle will be performed. The line entry will be made in the following l

3 menner, see Aac:smeended Olsposition.

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Measure 2" from F.W. 24h center upstream on pipe (Spool Piece 500) circumscribe q

the pipe using a wrap around, then prick punch the scribe line.

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Using air-ars, cut the pipe all around maintaining less than a In00 total hevel to within approximately 1/8" from the 1.0. (See Sketch #1).

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3.

Using a thin blade grinder, cut through the center of the bevel, then dress up botn bevels (See Sketch #1).

4 Jack pipe away from cut on upstream side per Superintandant's Instruction, install a dam in nozzle beycnd F.W. 2844 to prevent air frem entering Steam Generator.

i 5.

Clean and Inspect F.W. 244 Internally ad diruted by P.G.M.

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ampumattom ier mecessanyn Revision I - Delete Step 6 in its entirety (assess was aehleved). Refer to Attach-

1. M ment #1 for results of Initial Inspection and recosumended dis sition, i

Revision 2 - See Page 3 of 3 and Attachmentf3.

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9/y/ 77.:-

24 77 l

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THE'M.W. KELLOGG CO.TIPANY p.se 2 of 3 A OfVlt*GN CP PULLA44M INc3Ryggafg3 0.3. NC.

3b$3 Rev, l

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L30. No.

5001h6 Sht. 4 of.

OfSCREP ANCY REPORT UNIT NC.

0

-1 C*05 NC.

N/A s

8-26-77 curreusar

• wff!e,casarieetris 5,se, se, s711

=4rs:

Clsale Cm JCS NC.;

7177 WS7tc"OM: Runv4n/5CanneII/0U4sI PnCJSC71 c'? cam "'m t.Ine x16-556-1688 secol piece 500: E1. I!h8488: Area G: Sect. I

!!CCM*fMDED disposition: (CCN87).-

6.

If access to F.V. 2441.0. cannot be achieved, proceed with alternate instructions (see sketch #2).

7.

Upon c::moletion of Inspectica, rencve dam, grind bevel to facilitate fit-up as needed, clean and fit to ESD-215 and Esa-220.

3.

weld out using F.V. 549 and precedurs 4/5.

i 9.' Inspect and NCE to Eso-215 and Eso-2c6 I

10. Add all Information to process sheet and.!sonstrics.

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.a, THE M.W. KELLOGG CO. IPANY Pege 3 of 3 T

o.M. No.

N$3 kk"2.

A clVtelCN oF PULLMAN INCoMPoRA rio iso. No.

ennths, o,e_

k4 5 OfSCMCPANCY RePOR1" uM4fNo.

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pselffe cas & EteetHe sPse.no:

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2-24 77 clamie canyon

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INsPECTcM: RUnVan/SCann#II/0U88I pw:

otseme*wr m.l.Ine K16-556-16": Socol Pieca 500: El. T h4W': Area G: Sect. I 0.A. 3453. Revision 2 EXPT.ANAT10N OF Of SCREPANCY!

During the performance of ' grinding per D.R. 3453. Revision I,' Step #5, feur (4) indica-tions of heavy drcp thcougn with roll over were removed alcng with.all of the existing root penetratien. Re-inscect;cn revealed a linear indication 11" l'ong en the fusion line to the Feedwater Nozzle. Further ' grinding, to a maximun depth of.110", remcved the linear indication (see Attachment #3).

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l Add the following to Step #5 and delete original steps #7, 8, 9 and 10.

Perform the

~fellcwing repair:

A.

Grind the bevels to facilitate Fit-Up of F.W. Sh9.

b3.i '!g F'f 5.

M.T. l.D. of F.W. 24 using E50-247 coil mothed,' and clean grooved rece pass at F.W. 24 per r.53-215.

3 C.

Remove the dam fran the ncz=le at F.W. 2M.

17 F Preheat F.W. 2% to a minimum of 25006 Interpass not to exceed 55CCF -nimum. 4#b ( [

D.

a'il *q 7,d Mairrcain this preheat until stress relief begins,.

c E.

Wald to procedure 200 (F.W. 2% Al), using E7052 wire with the GTAV precess, to conform to blended configuration of the balance of the weld. I.O. C d iv F.

Grind and polish the added weld metal to blend with base metal surfaces.

G.' In,spect and NCE to E50-215 and PC.3E.bEA. Tc Td4MM L P. Al" /MW#~MM, f r use ss.rsy n w K w 7M toPy +* /crer e 1:< T.

NOTE: Proceed with D.R. 3456, and x-ray weld, hoc fer information caly.

j

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7.

Upon completion of inspection, remove dans from F.W. 549 pipe side, clean and fit F.W. 549 to ESD-215 and E50-220.

8 Weld out using F.W. 549 with procedure 4/5kZ.

9.

Grind F.W. 549 for x-ray.

10.

Inspect and Not F.W. 549 to E50-215 / u"'r'a'- #--gQ fff}e(7'1 tI

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--~_.1 NOTE: X-ray weld het for information only.

(.11.

Stress relieve at F.W. 24 RI and F.W. 549 Il00*F to ll50*F per E50-218.

Not F.W. 24 Al and F.W. 549 to E50-207. /r; 12.

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s ALTERNATE INSTRUCT 10MS O

i.,, I. Cut out F.W. 509 using air-ere and taking necessary steos to maintain the ability to bevel the 450 ell side of the weld to 2000 2io and a 3/32": 1/16" land. Also, cut out F.W. 339 shown on iso. 3-2f*6.

2.

Aequisition: 8$y op 16" Pipe, Schedule 80 A106 Gr 5 and a 3/4" 300C# S.W. Half Coupling or soc + 1 t A105.

3.

Install the 3/4" half coupling or soc-o-let four (4) Inches from the end of the 16" pipe, i

4 Clean and Fit to E53-215 and Esc-220.

5. weld out with procedure 92/93 (r.w. 831).

6.

Inspect and MOE to E3D-215 and E50-211.

7.

Open complacien of F.W. 2f64 1.D. Inspection and P.G.&E.'s direction, fit-up 16",

Schedule 80 pipe and proceed with Step 7 of attached 0.R. using F.W. 549 and F.W.

509.

s 8.

Reweld F.V. 339, as shown on Iso. 3-2f46, maintain original line configuration.

9.

Clean and Fit-up to E3D-215 and Es0-220.

lo C. Weld out with procedure 92/93.

11, inspect and NCE to ESD-215 and Esc-211.

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to eliminate linear.

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3/16 % 6 F i""

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Deen Groove Nonle 11" j"I l

y Original Root Pass

f Ground smooth and l !p Blended to Parent "s.

U/////////k/////

M*t'I*

i Section A-A NOTE: Average Wall Thickness =.58c" to.6co" Romeining Wall At Groove =.450" Punch Marks On The 0.0.

=.047" Deep (Punch Marks are directly on the fusion llan of.F.W. 244 to 1/8" inside the fusion line.047" deep.)

!V l

ATTACHMENT #3 l

OR 3453, Rev. 2

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OR-3453 Rev. l 70 J. P. Rt.DfYAN, Q.A./Q.C. M'ANAGER cArg AUGUST 31, 1977 rtca D. R. GESKE, NDE SUPERVISOR suoect L.I.@l0 Pl!ET3Ajf7,,,,GA,0.J,!BI,1,0L,J,,,L 2%,,,,1,!! SIDE D lAHETER

~

On August 31,1977. F.W. 244, Line K16-556, Isometric 1 03-500146, reedweter piping to Steam Generator 1-4 Nozzle, was liquid penetrant examined on the insido diameter.

The following Indications were noted:

1.

2" from tcp center of nczzle, a small faint transverse linear-ncnrele-vant due to weld geometry, d

2.

7" frem top canter of nozzle, heavy 1" drep through with roll over.

3.

9" from top center of nczzle, heavy 2" drop through with roll over.

4 37" from tcp center of r.ozzle, heavy li" drep through with roll over.

O 5.

39" fr=m t=,. center of n.=zie, heavv > <2" dro, throu,* with wire protrusion.

6.

Approximately 1/16" mismatch exists frem 7:00 to 9:00 facing the no22Ie.

We recommend that the root pass be ground and polished to blend with base metal surfaces. Particular care should be taken to avoid the removal of base material. Then re-examine the I.D. with liquid penetrant, if acceptable, proceed to "Recomended Olsposition", Step 7 cf 0.R. 3453, Revisica I.

to

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Donald R. Geske NDE Supervisor ORG/js t

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PULLMAN POWER PRODUCTS g

EVALUATION OF DISCREPANCY REPORT IN RELATION

{

,70.REqulREMENTS OF 10CFR PART 21 J

1 p.

D.R. #

,towhichthispageis.attachedand[

became a part of may be ) considered to be reportable to the NRC under the requirements of 10CFR Part 21.

PULLMAN POVER PRODUCTS

=88 bfMu y

.g Pacific Gas & Electric Company ~( does,hees no] consider this discrepancy reportable and ( has reported,@ll not reg) the above discrepancy.

This form returned to Pullman Power Products on /4 -/c - 7 /

DATE PACIFIC GAS & ELECTRIC CO.

by E.d er-zua /96

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THE M.W. KELLOGG COMPANY Page 1 J

A ofVIsloN of PULLMAN INCoRPoMA750 0 M. No.

Ibb IeV. l

(

iso. No.

5C0146 Sht. I e t' 5 DISCREPANCY Af#dRT unit No. I l

7, c:es NC. M/A

'custonsen:

83siffe cas a tractric s,,C,3c:

s733 3,7,,

to.7 77 03888* C2"v'a e nvan/?eanne81/cuese

.ca No.:

7177 iNspec cm:

pacasct:

u eiseneraNe tt.w 1.ine K16-554-16": Piece #540: El. 154'-!"; Area F: Section i EXPT.ANA?!CN C# OtSepupANCY Per P.G.M'. request, an internal inspection of F.W.197 on Steam Generator 1-1 is to be perfermed. The !!ne entry will be made in the manner described belcw.

d Inspection c=nducted Cetcher 11, 1977, required by Step #9 of the Recctirnended Dispo-sitica, revealed conditiens requiring rework.

(See Attachment #3, Report of Findings.:

AInspection conducted October 13, 1977, required by At =-%*c <>3 revealed $2:: hor

ewo:k is requi:ed.

(See At =- % at n)4, Report of Rawork).

Attachment #1 (Skaten)

Attachment #2 (Sketch)

{

d Attachment #3 Report of Findin A Attach =ent

<>4 ((Raport of Rawork)gs) i eveeuwsNeeo eispesmCN t

1.

Aemove the 2", 3000# ceuoIIng at F.W. 827 frem the pipe using air-4re and grinder

'y (do not air-ere threugh). Clean and NCE removal area to 550-220 and $50-211 on VI.

F.W. 197 side of hole in pipe. Close hole with fire retardant materia! (Referen-Attachment #1).

2.

Circumscribe the pipe using wrap around at the edge of hole in pipe nearest F.W. 197. This should be approximately I 5/8" freni the center of F.W. 197 (Ref-erence Attachment #1).

3.

Prick punch the scribe line.

4 Using air-arc, cut the pipe all around and apply a bevel of.not more than 308 frem O.D. of pipe to within not less than 1/8" of the 1.0. of pipe directly belew

,4' I

pre,se (Con't on Pege 2) 4 ev: u.w.x. r c.A. [db -y m /e 340'? 'c on,,

M-ea m

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, it. z-77 r, e w io../

j axesANArioN isa NecassAnvi:

Aevision I - Adds Attachment' #3 (Report of Inspection Findings).

P.G.M. will Indicats l

rework released on Attachment #3 under Recommended Rework. See d for l

other changes.

Revision 2 - See pese 3...(*'8 M* %

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st.s c.A. "- _ M oestmeV?tCN: 3 mener C.A. pne 3 Aege. f ans.

3 Engineer.ie cess.

C omer

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THE M.W. KELLOGG COMPANY Page 2 of.3 A OtVIStoN cP PULLMAN INCoRPoMATsn o.R. NO.

3hSk qev, l Iso.NO.

5001% shece I of 5

,p DisemEP ANCY REPORT,

, um7 No. f CcQtNC. M/A f-Cum usM:

38seffic Cas & Electrfe spge, ue: -

3711 CATS:

M PnoJacT:

Olaalo Canyon

cs No.

7177 mspgeren: Runyan/ScanneiI/ Guest otscars.a w r m e trne t

h.16"? Piece IMkO

E l. 164 8 -?"? Area fr-tectlen f RECCMMENDED OISPOSITION

scribe line'(dC not cut through the pipe with ale-erc). Using a I/8" blade, grind through to 1.0. of pipe.

~

5.

Locate center' of F.W. 500. dsing wrap around, circumscribe weld center.

6.

Prick punch scribe IInc.

~

7.

Cut out F.W. SCO using aie-ere maintaining.a maximum bevel of 30 on eil s ide 0

to within not' less than I/8" of the 1.0. of pipe (do not cut through with air-arc). Us!'ng a 1/8" blade, grind through to 1.0. of pipe.

8.

Install dam in nozzle of. Steam Generator I-1 past F.W.

197.

6 9.

Clean and inspect F.W. 197 internally as dir eted by P.G.&E.

Report findings of inspection before proceeding with Step #10. A Proceed with rework require-ments as directed by P.G.&E. on Attachment #3.

.10.

Upon completion of inspection,G_emove cam) grind bevels to facilitate fit-up

~~

as needed.

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, 5 j

ee.vo m.

g 11 Install new pup, fit-up and Inspect to ESD-215 and ESD-220.

)

12. Weld out F.W. 551 and F.V. SCO, as shown on Attachment #2, to process k/5A0.

13.

inspect and NDE to E53-2I5 and E50-206.

14 Upon acceptance of R.T. 's of F.W. 551 and' F.W. 500, clean and fit-up garrrna plug, as 'hown on Attachment #2, to E30-215 and E30-220 s

15. Weld out ter process 7/8 us!ng F.W. 832.

!6.

Inspect and NCE to ESD-215 and ESD-211

17. Post weld heat treat to E50-218 (F.W. 's $51, '5C0 and 832.)..

1

18. Add all'information to isometric and process sheets.

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THE M.W. KELLOGG COMPANY h #5 A otVIe8o88 QF PUI.LMAN INeoRPosATED OJt. NO.

3404 RE7. 2 too. no.

500164. Sht. 1 of 5 OfSCREP ANCY REPORT.

,UN8rNO.

1 CDCE NC.

NM g gg.

Psefffe cas & E!ectric

'I b"77 SPtc.NC:

8711 Cart:

14CJCCr:

Olabio Canyon JCe NO.:

7M INSPEC=;m: Eucaran /Se an.e 11.Cu e S t

)tscRf14N? TTTSA!

N

.E7ISICN 2:

Adda Attachment #4 (Raport of Rawork).

P. C'. & E will indicata rework released on Attach =ent 14 unde'r Reconnended Rework, adds rework to, Recocz: ended Disposition as Step 9a.

ECOM'.EltED DIS? CST 7!C?i:

5 3/3" Lisaar Kar.ovs1.

~

• A.

Cri=d to remove the 3 3/S" lissar.

3 P.T. to ESU 21. to i= sura completa removal.

j Non-eetallic !=clusion Removal.

M'O. Bland base material to elimi=ata tha eso non-estallic inclusions.

C.T. to ESD 244 to datarsi=a wall thicx=ess remaining.

l

. Pipe-side Rough Grind & Y.achising L1=es.

A.

Polish the pipe-side countar-bora to eli=isata rough grind edges a=d machi=ing li=es.'

3 P.T.. to ESD 211 to insura comp 1sta removal.

C.

Remove das prior to Step 4

. Prahaat to. 250* =1=. 5500 =ax. i=tarpass; =aintain pre-heat until s tress relief.

• 4ald the 5 3/8" Gri=dont to origi=al I.D. configuration usi=g Procedure 200.

1 Gri=d 5 3/8" repair for R whila mai=taining pre-heat.

M.T. to ESD '

or Eat P.T. by P. G. & E. D.E.R.

2" P. F. 4 E. @indicats N.D.E. to be perfor=ad (Step

).

Vald area of inclusion. removal, if needed, to original countar-bore configuration, using Procedura 4/5 AC.,

Grind inclusion repair, if Step 8 is used, for R.T. while maintaiains pre-heat.

Pcrform,Not R.T.. of repair area par ESD 207.

Proceed vib Step 10 of the original D.R. 3484 Recommanded Disposition.

sp

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3 a.m. in 2 en,a na, e C oen 3c Ca C r ein er i aca suaTcw in Necassany I

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S TEli M G E N.

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UNE l-Kl6-554-6 SID O L 5'ID NY'ORff f

LOC ^TlON OF CUT ITEh3VE nne FOR Ngy wggn SEC17DN BE7 WEEN PW-55t Fiv-CO2fCUT

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.-. m yn-INTERCFFICE CCRRISPCNDENCI TO J. P. RUttfAN, FIELD q.A./q.C. MANAGER DATI OCTCSER 12, 1977 m2

0. R. GESKE, M.D.E. SUPERVISCR

$U13Ec7 klqu1O PENNNT EXAtiLgI,1,mi,,,,EJ,,,,,107 1 N5iOE OI ANETER i

Cn October 11, 1977, the Inside diameter of F.W.197 was Liquid Penetrant examined per Step #9 of 0.A. 3484 The foIIcwing indications were noted. All dimensions refer to a cicck-wise direction beginning at the tcp (12 o' clock) of the nozzle.

1 8" clock-wise:

15" of mis-match with rect pass roll over en the nozzle side.

2.

8" cicck-wise:

13/4" of heavy roll over en the nezzle side and s!!ght roll over on the pipe side.

(Previcus re-work In this area removed deco-through with volds.)

3.

16" clock-wise:

I" of undercut on the pipe side of the root pass.

4 IS" clock-wise:

1" of undercut on the pipe side of the rect pass, t <>

5.

41" clock-wise: 3/16" crack-like linear en the land surface of the counter-bore 3/16" frem the root edge, pipe-side.

6. 4th" clock-wise:

1/8" crack-like linear on the land surface of the counter-bore 5/32" fr:m the rect edge, pipe-side.

7.

41" clock-wise:

1/16" lack of penetration at the windcw close area.

8.46t' clock-wise:

1 1/2" of heavy drop-through with rect pass roll i

~

over en both sides of the rcot.

9.

The entire pipe-side counter-bore has been rough ground to fac!!itate fit-up.

RECOMMENDED REVCRK l.

Liquid Penetrant examine to redevelop the noted condition.

Grind and polish the root pass.' Flush with the base metal from 8".

2.

clock-wise for 15", 41" clock-wise 'at window close, and 46t' clock wise for i 1/2".

(Indications I, 2, 3, 4, 7 and 8.)

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J. P. RUNYAM, Q.A./Q.C. NANAGER 1.lquiO PENETRANT CAMINATION, F.W.197, INSIDE DIAMETER susate :

nos o. 2 3

Grind and polish the land surface to remcve the two (2) linear indications in the land area of the counter-bore.

(Indications wer seg,xovs. mr rwss.cs a n Wcx-sm, 5 and 6.)

aa 1

NOTE:

If the crack-like linears join and grew, versus reduce in size and remove, suspend grinding and report the findings.

4 Polish the entire pipe-side ecunter-bore to eliminate reugh grind p,0,NOT remove more than.010" of base metal.

edges.

0 S.

t.Iquid Penetrant examine all grind areas to redeveico indicattens, f.e. remaining undercut (Indications 3 and h) and f ack of penetra-tion at the windcw close area (Indication 7).

i I

6.

Grind and polish to remcve the remaining Indicaticos.

Pek="r' Mms o n hana,. n m.eto* W #ws. neowe..

I NOTE:

If the indications grew, versus reduce and remcve, suspend grinding and report the findings.

7.

Determine the remaining wall thickness using ultrasonic thickness measuring methods and report the findings.

l S.

Upon c mpletten of rework, preceed with Step #10 of 0.A. 3k8k or revise 0 A. 3484 to Indicate further required rework.

i Donald A. Gaska N.D.E. Supervi sor ORG/js

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J. P. AUNYAN, Q.A /Q.C. MANAGER

,sarc CCTO8ER I2,1977 re 1astc7: LIQU10 PENETRANT EXAMINATION, F.W.197, INSIDE DIAMETER

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3.

CrInd and polish. the land surface to remove the two (2) fineer l

Indications in the land area of the counter-bore.

(Indicat ic as 5 and 6.

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nears Joan a grew, versus reduce en size and remove, suspend grinding and report the findings.

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4 Polish the entire pipe-side counter-bor a to eliminate rough.nrind edges. g,E renove more than.010" of base metal.

5.

Liquid penetrant examine all " grind areas en redevelop indicar:

T.a. remaining undercut (Indications 3 and 4),and. lack of p.c

• J-tion at the window close ares (Indicatien 7).

6.

Grind and polish to remove the remaining Indicactens.

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If the Indications grew, versus reduce and remove, su nd grinding and report,the findings.

7.

Catermine the remaining well thickness using ultrasonic thickner.s A

measuring methods and report the findings.

e.

4Elir 8.

Upon completica of remark, proceed with Step #10 of 0.R. 3484 or i

revise 0.A. 3444 to Indicate further required rework.

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h. INTEROFFICE CCRRISPCNDENC2 l

TC J. P. Runyan, Q.A./Q.C. Manager DATE Ce

• ar 14, 14.7 r

l MICM D. R. Gaska, N.D.I. Superriser Result of Rawork. F.7.197 Inside Diame,t3r

$ w gc7 on October 12, 1977, da inside diameter of F.U.197, Steam Generator 1-1 was reworked per Attach-ant 43 to D.R. 34d4 At the end if shift, the rework had not been comp 1stad. The following indications.emained.

1.

8" clock-wise frca top contar of the noz=le,10" of roo 79Mi edge fusion 11=a with slight weld etal remaisi=; above the

.atal.

2, 41" cicek-wise from top center of the co==le, 3/16" * *

. on

• he pipe-side counter-bors. The original indicati n :evi

/32" i

latarally away frem the weld. Tentative intarpretati trac ha open edge ef a a.rne.ats1He ' e% ion 'n the 91;e.

3.

41 1/4" clock-wise from top cantar of the nozzle,1/8' 1:* ear on the pipe side counter-bore. The original indicatica =2ve ! 1/32" laterally away frem the veld. Tentative incarpretatio-t: e 'he open edge of a non-metallic inclusion in the pipe.

Cu Cctober 13, 1977, the indications listed above were fur'.:er reworked.

Teld =stal was reduced to =isimum wall,.566", to eli=inat t the 10" ruct pass edge fusion line. In addition, the ' area of cen-catallic inclusien was explored ultrasonically. The follevi=; are results of rtwork.

i 1.

41" to 41 1/4" cicck-wiset two on-catallic 'sclusions.600" fr==

the 0.D. surface, parallel to the surface. The edga of each inclusien was exposed as a result of counter-bors =achining. Total surface measures 5/8" x 3/16" with the longest di=ansion parallel to the weld.

2.

14 1/2" el:ck-vtse one linear indication 3 3/S" long, in the land surface of the nozzle,1/16" from the original root pass ueld metal.

Observation, during weld metal removal and physical measurement, revealed that this indication was hidden by root pass roll over during the first penetrant examination.

3.

Pipe side counter-bore surface was not reworked. Rough grind edges and machining lines remain.

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. ~.. - - - - -

s er J. P. Runyan, Q.A./Q.C. Manager CAft Cctober 14, 1977 To:

sasarc7: Result of Rework, F.U.197 Inside Dian:eter past m. 2 Upon reaching m4"* -' wall ehieb-ss with indicacic-r==aining, twork was suspended and a Q. A. Hold tag applied.

RECCMMENDED RE'.1CRK 1.

Grind to remove the 5 3/8" linear indicatica 7 41/2" clock-wise from top center of the nozzle. Re-weld the gr..d-out to original weldment configura:1ca.

2.

Grind to rec:ove the e:ro =cu-catallic inclusie--

.:auu're re=aining wall thick =ess.

Weld cut to original wall t'

.ess if required and e--ind to origi=.a1 configuration of the. e er-bor..

3.

Grind and polish the pipe-side c unter-bote t eli=.: ate rough grind edges cnd =achini:g lines,

k. AAlo n '*o Pot a sH ifcor= gua,s,0 pc tesi, s.. >,y pt yg w g l k.

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45-Donald R.

eske N.D.E. Sugar-risor DRC/j f W

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INTERCFMCI CCRRISPCNDINCE

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9 TO J. P. RljNYAN, FIEl.0 q.A./Q.C. hANAGER DAfg CCTCSER 19, i977 nem D. R. GESKE, N.0.E. $1JPERVl50R suanci. AE'iC81_CF F L 1CL. IRS 10.E Q.tAMT.E O.R. 3h &, dated Ceteber 7, 1977, directed entry into line Kl6-55k-16" ap-proximately 1 5/8" on the pipe-side of F.W. 197. Entry was escuired to facril-tate an Internal Inspection of the piping to nou le weldment, Identified as F.W. 197.

i Entry into the Iine was completed en Octcher 11, 1977, and'.the Inieial in-spection was conducted using 1.lquid penetrant motheds per E30-2il.

he inscection revealed ccndittens requiring rework. These conditions were acced to tne 0.R. by means of Revision I.

1 On Oct:oer 12, 1977, P.G.M. released the recemmended rewcrk notad in Revi-slon I to 0.R. 34 0. The rework was released with a modification "On not raccve more than.010" of base metal". Rework acticas were begun. Two (2) If near in-d! cations in the pipe-side land surface of the counter-bore were not removed with removal of.010" of base material.

P.G.M. further ecdified Revision I te 0.R.

34% en Cet:ber 12. 1977, by indicating " Removal of.010" did net remove linears.

O Centinue to blend for remeval. Do not remove below minimum wall requirements".

At the end of shift, the rework had not been c:mpleted.

On Octcher 13, 1977, the remaining Indications were further reworked. Pipe and weld wall thickness was reduced to minimum well (.566") and both linears in.

the pipe-side counter-bers were explored ultrasenically. Results of these actions were added to 0.R. 34% with Revisica 2 en Octcher th, 1977.

Rework was c:ntinued en Octcher 17, 1977, based upon O.R. 3h &, Revisten 2.

Further grinding of weld metal remcved all of. the existing indications except the pipe-side rough grind and machine lines. Wall thickness at the 5 3/8" linear was reduced to.350" with.520" at the non-metallic inclusiens. Revision 2 to 0.R. 34% was then modified by P.G.M. to include " Grind and polish c:ot weld flush with pipe /no n le 1.0."

Rework continued unt,Il end of shift.

L.lquid Penetrant examination was conducted on Octcher 18, 1977, after pre-Ilminary grind and polf sh of root pass removal and pipe-side counter-nore rcugh grind edges and machining lines. The examination revealed the following con-ditions:

1.

17" from top center of the noule - 41/2" x 1/8" area of a fine l

network of linears en either side of the weld centerline. These two networks were located in the base metal on t,he face of each counter-bore.

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J. P. RUNYAN, FIELD q.A /q.C. MANAGER cart CCTCSER 19, 1977 REWCRX OF F.W.197, IN$lCE DIAMETER

.bsaeater:

... 2

~

2.

31" frem top center of the neule - 21/2" fine linear en either side of the root pass removal area.

Soth conditions noted above were reported by telephone. Further rework was stepped pending review by P.G.&E.

The areas In question were examined by a representative frem P.G.&E. Mechan-ical, P.G.&E. 0.E.R. and Vestinghouse en Octcher 18, 1977.

Instructlen From P.G.&E.

Mechanical was to remove the Indicaticas by grind and polish. Further discussion resulted in instructlen to proceed under the existing revislen to 0.R. 3484 Ra-1 tionale app!!ed was tha,e the two (2) lineers at 31" was part of 'ecot pass removal and the network of linears at 17" was part of the rcugh gelnd clean-up action.

Rework of the inside surface continued to the end of shift. All noted in~

dications were remcved and a preliminar/ Liculd Penetrent examinatica verf fled re-mcval.

l.Iquid Penetrant examinaticn per ESD-Zi j was re-applied en Cctcher IS,1977.

Examination revealed all previcusly noted discontinulties were removed and rework was concluded. Ultrasenic thickness measurements of remaining wall Indicated average wall In the flush grind areas is.580".

Grind areas are es folicws:

1 8" c!cck-wise frem tcp center of the neute a 10" crescent groeve

.350" of remaining well.

2. 31" c!cck-wise frem tcp center of the nonle a 2 1/2" crescent groove.420" of remaining wall.

3. 41" c!cck-wise frem top center of the neule a 2" rounded grind.

cut.520" of remaining well.

On October 19, 1977, rework of F.W.197 Inside surface was centinued per D.R. 3k &, Revisten 2, Step #9A, item 4 l

l AA Alu L.

D. R. Gaske N.D.E. Supervisor l

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• cat. '.;cus a e.ewc.

• • • • '* N -a e t ea Seee 8711 Dip. ana?'en op etsenerency, j

I:ternal Audit 7101, A.A.R. ft, identified that there was =c Frecedure Qualifica:1cs Record l

Cr Z30-2k6 sad I53-247.

Subsequen investigation has revealed,1. hat ES:-247 vas used to !f examise ce 1: side i

taseter of T4 (197 Iso f!C0146, steam Geners ce 1-1, CF. d!kak, en two ccessi::: (see a:: ached

~

zanisation recordsh E3D-247 is listed on CR 43453 sa well, under Recommended 31s;caines a:4 s suspected to have been used (there is =c:.. azamination rec =rd with the 3.R.)

c r exa=1:e j

f to 1: side disaster of TJ J24h, Iso f!001h6, Steam Geners c; 1 h.

The velds 1: ques u: are ::

l 1:es I16-!!4-16 :7 and 116-5!6-16 *7, be:1 Seismic C* ass 1 Ocde.

• e use of E53-247 cn Seismic Cis.ss 1 ;1pe with=u a Precoct.rs cualift:st:: Rec rd is a a

j

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cc:f :r.ance to Centract Specificati:n 3711 Secti:n 3 !able : and :fotos s 7ab*e I. Secti::

Pa.sgrs;h 3 23, Sectie: ! Parsgrs;h 1.2, secti:: 2 ?arsgrsch 2.1 a:d See:::: 3 Parstrs:a 1.,-

-C02rl'"::TUZ3 C2T FACI 2 CF 3:3CRI?A:tCT EIPCR:-

i i

ecseaweNesn ciap':en'cm INDICATI APPRCVAL SY CIRC:.!NG 7HE A78RCPRIATE "RICO.TENCED l

O!!PCSITICM" Accept-as-is all verk assained 57 333-247 1

2) Tile a ce;7 cf this D.R.1: ce fell:vi:g 1cca::::s:

I l

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Occument package f r :sc f!C0146 T4197 and crisisal OR 3hik 3.

Occu=ent ;ackage for :sc jfCC146 ri 24h and crigi:a13.R. Ih" I

i PG&E G.C.

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Criticals of Ist 2h4 and 247 CUAUTY CCPC8CL i

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A/'d ifanager shall assure taa: lt.3. 2.

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Pullman Power Products i

10 CP!t.21 a.m. me.

(!S or (!S NOT1 ise. no.

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MATER!A4.

C A?.!t,f4ATl0N PROCIDURE KPT.'

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EXAM!NATlCM PRCC10URE nif. ' 07II IS0* I ' */[I'*

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DATE l.

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• F* SHEET M/A O/l"7 NUM8ER

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7177 '

JO[MTNUM8ER I'"

MATEngAL I

s EXAMINATICN PMcCCURE gpT. 8711 ISD-t l

4 l

ACCEPT.ANCE STANcAnos A3F1 s

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l MACNAFLUX DTE CH2CK LIQUl0 PENET: tant 3 gang PENEMANT DEVELOP S t

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7V. N '7

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.!QR NO.

77.77 f

.;dlNT.N.UM3gn Cannow sTtzt.

. NATut As.

'.'EXAMINATtCN PROCCURE XMT. 871L ESD-2M7

.s AEMI

• w '84I I

1 l

AcCEP.TANCE STANDAAOS i

s E" N

'hASNETIC PARTICLE POWOCR 3RANO

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..MAGNITIC PARTIC".E POWOER COLOR c.

METAL?,IC_.

.CDLOR OF C0hePCNENT INDICAT1cus 9.. s '..,,. ?,,

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THE M.W. KELLOGG COMPANY page I of 3

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4a.v.a.o,m u incon,anano a.a. no. %=1 nov. i M:

isC. No. eMM1h/n N h as # $

CISCMf*ANCY REPORT umstmo. I caosNC. /A curfcassa, eseffte cas & ffeetrfe yee, no, em cars: 8 26-77 enemicr:

Osasse cas"**

..es no.

m

.nse,cycn Runyan/$canne1I/ Guest 1

0'seneramv et ti me t f 6-4%=I 6at focal piece 800t El. 1 81+' M 't Aree Gt Sect. I expu=A7'c= ca ctsenePawev-Reference P.G.M. Orswing 500th4, Aev. et

~

Per P.G.M.'s request, an internal Inspection of F.W. 24 on Steam Generator 1-4 1

Feedweter Nozzle will be perfcrmed. The line entry will be mode in the following manner, see Reccsunended Disposition.

. c.

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ascenansenceo cispesment T. Measure 2" fress F.W. 2M canter upstream on pipe (Spool Pleca 500) circumscribe the pipe using a wrap around, then prick punch the scribe line.

l 2.

Using air-erc, cut the pipe all around maintaining less than a koe total bevel to within apprcximately 1/8" frere the I.D. (See Sketch #1).

3.

Using a thin blade grinder, cut through the center of the bevel, then dress up both bevels (See sketch #1).

4 Jack pipe away from cut on upstream side per Superintendent's Instruction, install a dam in noz=le beyond F.W. 2M to prevent air fram entering Steam Generator.

Clean and Inspect F.W. 2% intersally ad directed by P.G.M. (Congtgege 2) 5.

4 m,u.w.x.nwa.a.m.,. 9 #

e TdL47 c.,

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v m=an, eispasmont S. 4 s.4a c w i #M o. n-r.n e,,, e,w, /M.,., ne.,,, // 2.-77 Y

sou= rica n,..csssanvi Revision 1 - Delete Step 6 in its entirety (access was achieved). Aefer to Attach-

1. /*8 ment #1 for results of Init!al Inspection and recomumended disposition.

Revision 2 - See Page 3 of 3 and Attachmentf3.

30/hMM @?t*"

m.w.n.ei chf,f,,) )/L*.Q _

9/W 77

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e-THE M.W. KELLOGG CO.TIFANY pm 2 of 3 A Davistem op PuttheAas aseccaponArag 3.A. Pec.

3063 Rev. f

.TS.

tsc. peo.

500146 Sht. a of !

OlSCME* ANCY mgscaT usesT NC.

I C CE NC.

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8-26-U pielfte Gas a t?eetrie yac,ne, s711 cAfs:

maam:7:

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M insaseten: Runvan/5canne i 1/Cuest 88888* C'"**

c'scopaw1' m Lfee M16 **6-1688t secel pfece SCO: (1. I?h8 M': Area G: Sect. 1 RECOPMENDED Ol570$1710N: (C ll'T) 6.

If actass to F.W. 2% l.0, cannot be achieved, proceed with alternate Instructions (See Sketch #2).

7.

Upon completion of inspection, remove dami, grind bevel to facilltate f1t-up as needed, clean and fit to E5D-115 and E50-2:0, 8.

Veld out using F.W. 549 and procadurs 4/5.

9, inspect and Not to (ID-215 and E3D-206

10. Add all Infermation to process sneet and.fsemetrics.

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THE M.W. KELLOGG COMPANY

• *** 3 3 -

0 8 No-N'Il UO A Devision car Puuas as toscomposArso neo. no.

enntkl. w k45 DISE11tEPANCY RESCRT usesT No.

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MM t

cusfensen.

Deelfte das & Electrie spgg,no:

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7177 i,,syge7Cn: 4unven/fcanne II / Cues t PmosseT.

g e*ase m t.Ine 1(16-!$6-1688: Socol Pfees 500: El. 15h8 M ': Area G: Sect. t O.A. 1h53. Revision 2 l

EXPULNATION OF OISCREPANCY; During the performance of " grinding per 0.A. 3453. Revision I ' step #5,. four (4) indica-

~

tions of heavy drop thr:ough with roll over were removed along w,i a-l,1 of the existing root penetratica. Re-inspection revealed a linear Indication,113 long on the fusion line to the Feedwater Nozzle. Further ' grinding, to a maxind h of.110", removed yjhb the linear indication (see Attachsment #37

' "* s *

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p,. O. '.,,. --

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'g O D MENCED DISPC$1710Nt Add the following to step #5 and delete original steps #7, 8, 9 and 10.

Perform the

• following repair:

A.

Grfnd ee 52;;te es *=M 9 f ence Ff e-Ue af F 'J. tho.

[',

s.

ri.T. l.D.

of F.W. 24 using ISO-247 coil metnod,' and clean grooved root pass at F.W. 2W* eer 150-215.

4O h i_

Remove the east tre:s tae, nozzle at F.W. 2M.

C' 5 7 C.

,4@

0.

Pretreat F.W. 24 to a minimum of 25 con interpass not to exceed 55cor maximian.

E.

Weld to procedure 200 (F.W. 2M Al), using E7052 wire with the GTAW process, to.

Id L

Maintain this preheat until stress relief begins.

e conferiu to blended configuration of the belance of the weld.10. cad iv F.

Srind and polish the added weld metal to blend with base metal surfacas.

5.'

Insoect and Not to EsD-215 and Pr.;tg.bgf., l*o TesfebA S..R A1* /AM'A'I'TW.,

f so.< sa.rsv seas K wr 7M copy +*> nt e*

cs:a,7 NOTEt Proceed with 0.A. 3454, and X-ray weld, hot for Information only.

j t

7.

Upon completion of inspectlen, remove dass from F.W. 549 pipe side, clean and fit F.W. 549 to 150-215 and tsn-220.

l S.

Weld out using F.W. 549 with procedure 4/54,0.

9.

Grind F.W. 549 for X-ray.

Inspect and NOt F.W. 549 to (30-215 / w"'e"a '_~",g..Q &f1'1 tI W " '~ 'T T-M

" - ~

10.

^ -- - -- nm NOTE

X-ray weld het for Information only.

(,11.

Stress rolleve at F.W. 28e4 Al and F.W. 549 1100*F to 1150or per Eso-218.

12. NOE F.W. 2M Al and F.W. 549 u.-..

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c mens messer -

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s, ALTERNATE INSTRUCTIONS A

(, I. Cut out F.W. 509 using air-ere and taking necessary staps to maintain the ability i

to bevel the M 8 ell side of the weld to 2002 2i8 and a 3/32'T I/16" land. Also, j

cut out F.W. 339 shown on iso,3-24.

2.

Regul'sition: 88$ of 16" Pipe, Schedule 80 A106 Gr 8 and a 3/4" 3000# 3.W. Half Coupling or soc + Iet AIDS.

3.

Install the 3/4" half coupling or sos-o-let four (4) Inches from the end of the 16" pipe.

l 4

Clean and Fit to (3D=215 and (3D-220.

$. Weld out with procedure 92/93 (F.W. 831).

6.

Inspect and NCE to 13D-215 and E50-211.

7.

Upon emplet ten of F.W. 2M l.D. Insoection and P.G.&t. 's direction, fit-up 16",

Schedule 80 pipe and proceed with Step 7 of attached 0.A. using F.W. 549 and F.W.

509.

8.

Reweld F.W. 339, as shown on iso. 3-2M, meintain original line configuration.

9.

Clean and Fit-vo to (30-215 and (30-220.

C

. Weld out with procedure 92/93.

LC II.

Inspect and NCE to (30-115 and t3D-211.

4 Y

4' t

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t On August 31,1977 F.W. 24, L!ne K16-556, Isometric l-43-500144, Feedwater piping to Steam Generator 1-4 Nozzle, was liquid penetrant examined _ on the insido diameter.

The following Indicaticas were noted:

1.

2" frcm top center of nozzle, a small faint transverse 1 tnear-nonrele-vant due to weld geonstry.

2.

7" from top center of notzle, heavy I" drop through with roll over.

3.

9" frca top center of nc=21e, heavy 2" drop through with roll over.

4 37" from top center of nozzle, heavy 1,i" drop through with roll over.

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39" fr m tcp eenter of nozzle, heavy 1/2" drop through with wire protrusion.

6.

Approximately 1/16" mismatch exists frem 7:00 to 9:00 facing the nozzle.

We reconeend that the root pass be ground and polished to blend with base setal surfacas. Particular care should be taken to avoid the removal of base material. Then re-examine the I.D. with liquid penetrant, if acceptable, proceed to "Reconcended Disposition", Step 7 of 0.R. 3453. Revision 1.

Donald R. Gaske Not Supervisor t

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Response to Internal Audit #101, A.A.R. #1 A precedure qualification was performed in order to qualify E50-247 as well as ESD-246 (ref. Internal Audit #101, A.A.R. #1).

As both ESD-246 and 247 have been withdrawn frem use and the equipment listed in both precedures is no longer available for use, the equipment used for these PQR's was the Magnaflux Model P-90 for the coil tachnique only. All other factors are the same as specified in the prc:edures.

As the Magnaflux Model P-90 putsAless amperage than the equipment listed in ESD-246 and E50-247, and acceptable results were obtained (i.e; I.D. and 0.D. surface and I.D. subsurface indicatiens were 1ccated), the demonstration of this technique is -

deemed adequate :: accreve this method employed by the equi:mant'# listed in the above prccedures.

A record of the precedure qualification demonstration is hereby submitted

'1 90 *h -hi! es ense. D e originait ill be filed with the acclinble precedurer.

In the event that either or both precedures are re-activated in the future.

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hey.will be revised' to incorporate the Magnaflux Model P-90 into the list of equipment.

As both pr:cedures are currently withdrawn from use, no revision is deemed necessary at this time.

Dx Michael S. MacCrae MT Level III 11-9-82 l

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4T'TACIMft%JT" 2.

Affidavit My name is Charles Stokes.

I am submitting this affidavit to the Nuclear Regulatory Commission (NRC) to inform them of material false statements and other evidence of activities which could compromise the quality of the Diablo Canyon nuclear power plant, if it should be turned on.

The misconduct involves weldinn, procedure qualification tests, and plant modifications during the hot functional tests.

In my professional judgment, if these issues alone are confirmed as examples of general practices, the plant could not possibly be licensed to go critical under i

the NRC's legal requirements in 10 C.F.R.

In fact, the practices revealed below and others I have disclosed would even flunk Bechtel's own standards.

I am enclosing as Exhibit 1 portions of Bechtel's " Field Engineer Pocket Hanger Reference," Diablo Canyon Project, Sechtel Power Corporation. Bechtel's booklet is not a bad document. Although there are a few minor errors, it describes a reasonable design control and quality assurance (QA) program.

Unfortunately it was not issued on-site before I left.

I obtained a copy before distribution was stopped.

I can understand why Bechtel didn't want the booklet released. The plant wasn't built at all like the system described in Bechtel's own handbook. The handbook will be discussed in more detail below.

(1)

In reply to PG&E's letters no. DCL-84-067 and no. DCL-84-078 concerning welding of A-325 bolts. PG&E contends that "10 supports were identified which used welded A-325 bolt design." That is highly misleading.

In reality, there are many more cases where bolts have been used.

Because of inadequate documentation, welded bolts have been used and it is impossible to say whether they are A-325 or A-307 or anything else.

Even QA Personnel concedes not knowing.

In two specific cases, for which 7

I can provide the support n. umbers, undocumented bolts were used to connect support members to structural steel.

In my opinion, PG&E's reply is so far from complete that it does' not provide accurate information to the NRC concerning the use of A-325, A-307 or other bolts. The two specific supports do not even have a weld symbol describing how they were welded on the drawings. The QAcinspector was not able to visually inspect the connection.

(2) A second illustration of deficient documentation for welding bolts is inadequate material traceability. Material was not stamped for traceability back to the Certificates of Compliance as required. The significance of stamping for traceability is that without this traceability there existed no methodology to ensure that the material used in many hangers, or other seismic class one structures, complied with the requirements (e.g., preter metallurgical properties).

In ANSI B31.7 chapter 10723, entitled " Materials," it is stated that i

"all material shall be clearly identified" by "the applicable material i

specification and grade, heat number, or heat code of the material, and any additional markings required to facilitate traceability of the reports of the results of all tests and examinations performed on the material." ANSI B31.7 also states that "Certificant of Compliance with the material specifica-tions may be provided in, lieu of, Certifieh Material Test Reports unless other-wise required by the design specification." (Emphasis added)

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j Material traceability is only one aspect of the required traceability.

In ANSI B31.7 Para. 1-727.5.3 and para. 1-727.6, weld traceability is also required. "The welder or welding operator shall identify it as his work l

by applying his assigned symbol for permanent record in a manner specified i

by his employer. As an alternative, the employer shall keep a record of the joints and of the welders working the joints." This is also true under ASME Section.IX QW-301.3, entitled " Identification of Welders and Welding Operations," which states: "Eace qualified welder and welding operator i

shall be assigned an identifying number, letter, or symbol by the manufacturer

~

or contractor, which shall be used to identify the work-of that welder or i

welding operator."

l In discussions with pre-inspection Engineers, QC and QA inspectors, scme of whom have worked for as long as ten years at Diablo, it is obvious that neither material nor welder traceability was maintained. All that was required was that the " Certificate of Compliance" be provided. This super-ficial attempt to comply with the requirements of ANSI B31.7 and ASME Section IX does not satisfy the code requirements. This is evidenced by past and present industry practice at other plants across the United States. The abuse of traceability destroys the foundation of a valid Quality Control l

Program -- accountability and traceability.

Since many of the pre-inspection engineers and QC, QA personnel have never before Diablo worked at a nuclear plant nor othe'r heavy industry construction site nor read ANSI B31.1, 831.7 or ASME Section IX, they worked at Diablo under the false assumption that the work was being performed correctly, and that management was implementing all the necessary directives for them to do their work. Management did not train personnel, nor did they correct this misconception.

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. Having worked on other nuclear plants, I know the importance of these sections in ANSI B31.7 and ASME Section IX. At other plants almost everything in Class I systems was stamped and logged, and records were kept to insure that traceability was maihtained.

Per 831.7, "The marking or marking code

~

shall be transferred to all pieces when material is cut to make more than one piece." In my experience at other plants, this was required for all Class I material except miscellaneous material, such as " gaskets, packing, seals, springs, bearings, retaining rings, washers, fluids for hangers, etc." This was not done at Diablo Canyon. The practice of using "non tracensle" steel was widespread throughout the plant. At other plants shim stock was not required to be stamped, and I suppose shim stock was considered to be "etc."

B31.7 states in the case of miscellaneous items that "A list of such materials shall be furnished, and such materials do not require certified materials test reports or certificates of compliance as defined in 1-723.1.2."

(Emphasis added) Management at Diablo Canyon have failed to provide the chain of documentation which is necessary under 10 C.F.R. 50 before the plant can be operational. Not only did they fail to provide an "up-to-date heat number log," but also failed to publish a list of material that dH not have to meet the scrutiny of ANSI B31.7.

1Property "ANSI code" (as page type) with input value "ANSI B31.7.</br></br>1" contains invalid characters or is incomplete and therefore can cause unexpected results during a query or annotation process. (3) Deficient training reinforced the problems, and perpetuated them. QA inspectors told me that their training consisted of reading ESD 223 for one week and being given a list of suggested reading. This list contained 831.7, l

B-31.1 and other codes. In one conversation, when I asked if*the QC inspectors were required to read the suggested readings, his reply was "no, we only had I

i to know what 831.7 was, not what it says."

"I and others thought that these codes had been incorporated into ESD 223 by management." This was, and remains, a wrong assumption. The inspectors undoubtedly performed to the best of their T-

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-S-ability. However, the instruction, training, and practices necessary to adequately perform their functions were deficient. The inspectors only discovered their " wrong beliefs" through discussions with better trained, more experienced inspectors from companies other than PG&E.

(4) In letter no. OCL-84-094, PG&E states, " Pipe support number 100-111, identified for NRC review by Mr. C. Stokes, resulted in a minor modification

... This change was made for consistency with Project Standard Practices even though analysis showed the change was not necessary to meet acceptance cri teria. "

I don't know if PG&E reported other modificatiens performed during the hot functional testing to the NRC.

I do know of at least one other support which was modified during hot functional testing.

I can not give the support number here. My. informant would be immediately on the " firing" line.

I will supply the support number to NRC inspector Isa Yin, if the NRC supplies a list of supports to me for which they know modifications have been performed.

(5)

In PG&E's answer to the intervenor's motion to reopen licensing issues on Construction Quality Assurance, " Affidavit of 0. A. Rockwell, L.R. Wilson,"

Paragraph 3 states in part: "Since this contact is provided by the plate of the clamp to the Unistrut,. the plate is not necessarily horizontal and may appear ' cockeyed.'" This statement is too incomplete to be meaningful.

The use of the term " cockeyed" is not explained or supported nearly enough to support any conclusion that the clamping plates were correctly installed.

If incorrectly installed, the clamp will tend to slip off the structural steel to which it is attached. See sketches tNlow of correct installation compared i

to incorrect installation.

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m Correct. Notice Line contact at Incorrect. Line contact but not at toe and heel of plate. When bolt toe. When tongued, this tends to slip is tongued properly, clamp should off the steel marker, not be easily displaced.

In both the examples above, the plate is " cockeyed." One is correct, and if installed correctly, should not be easily moved. On the other hand, the incorrect installation could slip easily. This fact can be checked by consulting engineering manuals frem aither Unistrut, Superstrut, or other brand names.

(6) 'In paragraph 5 as a remedy' for pos;tble slipping, PG&E states, "For support type S221, U-bolts were torqued and U-bolt nuts tack welded.

For other support types, the Unistrut channel was directly welded to the beam fl ange. " (Emphasis added) Based on my experience in the nuclear industry, the proposed fix by PG&E/Foley would do more damage than good. To my know-ledge, there are no engineering documents presently available or in use that support the practice of welding Unistrut or similar material.

In fact, the material type used in making "Superstrut" and similar products should not be welded In a phone call on 3/27/84 with a Superstrut Product Engineer, I was told that Superstrut is coated with 5 eleciro-plated galvanized chromate coating (an epoxy paint) which burns when welded, giving off toxic gases.

Two problems result from welding it. (1) Air quality problems for the welder and (2) the joint corrodes. The Product Engineer said he would never

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i advise that Superstrut be welded when used as Class I supports in a nuclear plant near the ocean. He said that the material could be destroyed in one year if exposed to adverse conditions.

(7) In reply to intervenor's Petition to reopen Construction Quality Assurance, Affidavit of H.R. Arnold, F.C. Breismesitar and R.K. Rhodes Paragraph 6.

"During a planned review of existing brazing procedures for copper and stainless steel by Foley QA Personnel in September 1981, iti could not be verified that stainless steel tubing pBS number M0045 had been cualified in all braze flow cositions (vertical-up, vert.i. cal-down, horizontal and flat) since the crocedure cualitfication tests cerformed in 1977 did not include the vertical-uo flow cosition. This variation was properly documented on Foley Non-Conformance Repcrt (NCR) #8802-675 in accordance with approved procedures." (Emphasis added) The statement quoted above is in direct contradiction to the first line in Para. I and line, Page 1.

"This allegation is completely false. The procedures in cuestion were qualified prior to their use."

(Emphasis added) To correct this problem, I

one worker was tested. Under ANSI S31.7 and ASME Section IX, each welder must be qualified to perform the work to which he is assigned.

Fol ey's solution does not correct the use of the procedure from 1977 to 1981 for brazing a vertical-up joint as was originally stated in the procedure.

Nor does it resolve the issue as to whether the brazers before 1977 were qualified to perform work. The test of one worker does not satisfy ASME requirements that each worker be qualified unless the worker tested was the only person on-site who was assigned the brazing work. Nor do the present tests qualify old work, since past work could be considered training thus not qualifying as acceptable work. ASME Section IX requires that the welder be qualified first before work is performed. There is a reason for this,

(

i which is to ensure that the work is performed correctly.. The other point not sufficientlylovered in Foley'seply is that "Neither the ASME Code nor r

Foley procedures require documentation of these inspections. Therefore none were documented." Nor in.the statement that "ASME Section IX recognizes the function of independent mechanical test contractors such as Central Coast Lab, and does not requre them to witness the actual brazing." (Paragraph 3, page 6 and 7) This is an example of Management 's near-sightedness. Can they say that this documentation is not required in 831.1, B31.7, ASME Section IX, AWS 01.1-79 or 10 C.F.R7 From my previous experience in the nuclear industry, it has been the practice to test and document results therefrom for welders. This would certify that the weld was made by the specific welder and that the test results were for the welds performed by j

that individual. These logs and records were controlled and monitored by the QA. The policies at Diablo by PG&E, Pullman, and Foley are at the opposite end of the scale from what has been typical industry practice. Where documentation was in question, other plant owners considered it good engineering practice and a good policy to go ahead and provide documentation to prevent the problem of a future question. At Diablo, just the opposite 1

is true.

(8)

In a discussion with a friend, I was shown a Discrepancy Report written against Unit #2. This document listed many anchor and smaller supports which did not have acceptable full penetration welds at the stantion to pipe and were to be reworked. The problem with this work was that there had been no process sheets issued for the removal nor had the pipe been ultrasonically tested to ensure that the minimum wall [emaidd after grinding away the old material. The new stanchions were installed'without an ultrasonic test (UT) being performed. The tests were performed seven months later.

Per ASME Section IX and ANSI B31.7, the ultrasonic testing should have been conducted E

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at the time after removal and before new stanshions were welded in place.

When ultrasonically testing this type of joint, incorrect readings are possible.

A worker who was famil.iar with this Discrepancy Report (DR) on Unit 2 realized the same problem might have occurred on Unit 1.

I was shown a copy of a Preliminary Discrepancy Report listing about 15 supports in Unit I which the worker had determined had the same problem as the Unit 2 problem.

narrated above.

I can supply the OR number on Unit 2 and the author of the Unit 1 OR. This will be suppled under similar conditions listed on a i

i previous issue to Isa Yin.

(9) In closing and as the only exhibit to this affidavit, I have a copy of a document which was scheduled to be issued to all field engineers to aid them in their work at Diablo.

It was prepared by Bechtel Power Corporation.

l The title of this document is Field Engineer Pocket Hanger Reference. This i

document was sent to the field for issuing, but was recalled under the excuse that it contained errors which needed to be corrected.

I and other engineers at Diablo had copies of this document.

It contains valuable information to which an engineer could refer and rely upon during his work.

In truth, this document represents Bechtel policy at previous jobs.

Much of it is in direct contradiction to the procedures used to build Diablo. Had it been issued many problems would have surfaced in a relatively short time. '!hy is this true?

The document puts at finger tip location contradictory guides, providing typical industry practice in many areas, to the procedures and management directives issued at Diablo. There are minor errors in this document. However, I have reviewed it and have found it to be a valuable and handy document to have when working in the field.

It should have been checked, corrected, issued and used.

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Enclosed are pages 1-10 and 1-11. " Notes: pipe Insulation Chart."

In reading these two pages several points are evident which were not complied with at Diablo: (1) vapor barrier requirements; and (2) the application of a double layer of insulation on high thermal lines.

In PG&E's answers to the staff concerning stress walkdown, they tried to explain away inter-i ferences by local crushing of calcium silicate. Note, this is not acceptable on Page 1-10.

+

Also enclosed is a copy of page 1-13. " Insulation Removal Request Flow Chart" and page 1-14, " Request for Insulation Removal." NI am not aware of either of these procedures being followed at Diablo.

Also enclosed is a copy of Section 7 " Welding Instruction." On page 7-2, item 15, it is stated that there are no dihedral angle limitations for skewed T-joints.

I feel this policy will cause problems by design personnel failing to consider welds shown as fillet as partial penetration groove welds unless a note specifically stated that it should be considered otherwise.

I personally know many engineers will assume a fully effective throat for any weld indicated as a fillet. I suggest a test at site on this point before a decision is made on how to represent a skewed T-joint.

i Also on page 7-5, see " attachment I."

Either I don't understand this table or no allowance was added for the throat deduction for inadequage penetration. This last conclusion was also that of a pre-inspect engineer

?

at Diablo Canyon.

Lastly, on pages 7-7 thru 7-10, I weiild like to point out the concise clarification of weld symbol terminology. Had this part of the book been in effect at Diablo, many questions would have been resolved (although many l

e a

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4

. other questionable practices would have become evident to many field personnel).

I have read the above ll-page statement and it is true and correct to the best of my knowledge and' belief.

N Y

[h Charles Stokes i

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I GOVERNMENT ACCOUNTABluTY PROJECT b

Institute for Policy Studies 1901 Que Street. N.W. Woshincron. D.C. 2ROO9, (202)234 9082 March 2, 1984 Mr. Thomas Bishop Division Director U.S. N.R.C.

Region Fiva 1450 Maria Lane, sea 210 Walnut Creek California 94596 Re:

PACIFIC GAS AND ELECTRIC (Diablo Canyon Nuclear Power Plant, Unit 1), Dkt. No. 50-275 T

t

Dear Mr. Bishop:

Enclosed with this latt.ar is a copy of a petition filed with the Commission pursuant to 10 C.F.R. 2.206 on March 1, 1984, together with Attachments 1 through 17 thereto.

i Also anclosed for your use, bound separately in this package, are three documents that were not includied in the petition filed on Febru-ary 2, 1984: Exhibit 4 to Attachment 2, and two Diserapancy Raports inadvertently omitted from Attachment 7.

Best wishes in your continuing investigation.

Sincere 1

yours, d

onn Clawatt Enclosuras: A/S 4

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