Text

Affidavit of Lockert on Evidence That Util Not Responsible for Requirements of Code of Fr Re Reporting Defects & Noncompliances.Related Info Encl
	ML20088A794
Person / Time
Site:	Diablo Canyon
Issue date:	04/10/1984
From:	Lockert S; GOVERNMENT ACCOUNTABILITY PROJECT
To:	;
Shared Package
ML20088A791	List: ML20088A790; ML20088A794;
References
	NUDOCS 8404130131
	Download: ML20088A794 (176)
	v • d • e

{{#Wiki_filter:Aftntpeu .1. A F FID A VIT ~~ My name is Steven Lockert. I am making this statement freely, without any threats or inducements, to Tom Devine, who is an attorney working with the Government Accountability Project. I am making this statement because the evidence that was available to me indicates that the Pacific Gas and Electric Company was not responsible to the requirements of the Code of Federal Regulations regarding the reporting of defects and non-compliances. Further, that the M.W. Kellogg Company made false statements regarding a weld that failed in 1977 on the steam generator 1-2 nozzle indicating that the crack in the nozzle weld was not a generic problem: when in fact, there was documented evidence to the contrary on the steam generator 1-1 nozzle. I contend that there was problems with the Kellogg Weld-ing Procedure Specification # 200 (deviation from ANSI B31.1 pre-heat requirements for P3 materials of 175'F before welding,) prob-Iems with the 1-1 nozzle weld ( Field Weld 197 welded without i I preheat prior to 12,/3/74 and again on 12/24/74,) and that there were problems with the Quality Assurance Program at the time be-l cause the nonconformance report that should of been generated l apparently did not get reported per 10 CF R 21.21. Also, I con-tend that in 1977 after a crack in nozzle 1-2 was discovered re-l examination of nozzle 1-1 revealed a similar crack that apparently l did not get reported per-10 CF R 21.21 either. e404130131 e40410 (1 of 10) PDR ADoCK 05000275 9 .PDR

Reseonse to PG&E Report 411-77.55

Subject:

Failure Analysis of Cracked Field Weld No. 212, Diablo Canyon Unit 1, Steam Generator 1-2, Nozzle-To-Pipe Weld. l After review of the failure analysis report on F. W. 212 performed by PG&E's Department of Engineering Research, I have concluded that the report was put together with gross negligence or that a coverup activity is in progress to hide generic problems associated with the steam generator nozzle to feedwater pipe welded connections. F. W. 212 was performed by Pullman Power Products Corporation (M. W. Kellog Company at that time) in May of 1974 and it is believed that the remaining welds on the other steam generator nozzles in Unit I was performed that same year. The history of the problems with these welds has extended from 1974 to 1977 to 1982 to today. PG&E's failure-analysis of F. W. 212 ~ has not put the matter to bed but has -raised more questions about l the acceptability of these weldments, the ethics of Pullman Power l Products, and the ability of the licensee to meet the requirements of-the Code of Federal Regulations for construction and operation of Nuclear Power Plants. Problems with the failure analysis report are: '(2 o f 10)

1.) The Pullman welding procedure specification (WPS) sup-plied for the report has a revision date of 6/16/76. This is obviously not the WPS that was used for the actual weld performed in May of 1974. 2.) Pullman WPS 200 has an original date of 11/14/73, the date at which time the WPS was legally in effect.

However, the accompanying Procedure Qualification Record (PQR) was perfonned on 12/28/73 over a month later.

The WPS requires a PQR before the WPS can be written or used in the field. 3.) The nozzle material ASME SA-508 Class 2 is a P3 class-ified material under ASME Boiler & Pressure Vessel Code, Section IX requirements. Pullman's WPS 200 and accompany-ing PQR (P12b-P1-K1-P4-SMAW-6G) are for welds between P12b and P1 classified materials. The WPS for the nozzle welds would have had to be for P3 to P1 materials oniv. 4.) Pullman WPS 200 states that the preheat is only required for the SMAW portion of the weld. This procedure allows the tack and root welding to be perfcrmed without the bene-fit of a preheat. This procedure has an ANSI B31.1 Power Piping Code non-compliance written into it because the very definition of a preheat means " heating the base metal before (3 of 10)

a welding or cutting operatiorf'(see paragraph 100.2,defini-tions, of ANSI B31.1 1977 edition.) 5.) Page 2 of WPS 200 has significant data on weld joint preparation written in so small that the data is illegiable. 6.) Copies of the original Certificate of Analysis for the three electrode lots of E 8018-C3 show that one of the oricinal lots L416F3AC was not even shipped until 2/20/75 nine months after the weld was performed. 7.) Figure 5 showing the crack in a macroexamination has the pipe and nozzle identifications reversed. 8.) The Certificate of Analysis for the E 70S-2 filler metal and E 70S-2 insert have not been provided. 9.) The Laboratory Sample 577.329 has been mistakenly labeled F12B material'. Note that there is no P12B material listed under QW 422 of the ASME Code, Sec. IX (see page 4 27 of the PG&E report.) 4 10.) Table I cf PG&E's report shows a preheat being per-i formed on ' May 18, 1974 when the Pullman Swindell report k specifically states that the preheat, was only from May 22, 23,. and 24 of ~1974 (Table 1 is on page 9 of report.) I believe that this is just more than sloppy report writing and a full. understanding of how bad the welds really are can be (4 of 10)

attempted only after the data appropriate for PG&E's report is found for the period of time that the weld was made. It is true that F. W. 212 no longer exists because it has been replaced but that leaves the seven other nozzle to pipe welds that were performed with the same WPS that the original F. W. 212 was welded to. Steam Generator 1-1 nozzle to pipe weld also has an in-teresting history. F.W.197 was first performed prior to a Dec 3rd meeting between Mr. J. W. Ryan and Mr. P. J. Carosella, the then Pullman Construction Manager and Senior Safety Engineer for the Department of Industnal Relations of the State of CA,..re-spectfully. Mr. Carosella makes mention of the fact that F. W. 197 had experienced a crack extending the circumference.of the pipe because Pullman production had welded with out the use of preheat. The process sheet for the second try at F.W. 197, which by the way is not marked R1, is shown with the process sheet for F. W. 212 provided on page 33 of PG&E's report. Note that the preheat for the second try is not signed of by the - MWK i. inspector and there is no reference to a preheat chart. Also note l the inconsistencies in the inspection coverage between the two weldst, the ANI checked for visual inspection but not the root pass on F.W.197 but did just the opposite for F.W. 212. I think that the DR that covers why F.W.197 was welded without preheat (5 of 10) I:

before Dec. 3 should be examined to make sure that the corrective action called for by Mr. Carosella in his Dec.18th letter address-ed to I. F. Runyan, W. M. Kellog's QA/QC Manager was adaquat-ely established. Also, some explanation for the lack of preheat l data available for the second attempt at F. W.197 during Dec. 23 l to Dec. 30 of 1974 must be provided. It occurs to me that both of these mistakes appear to be reportable per 10 C F R 50, para-graph 50.55e. l F. W.197 was subsequently radiographed and the film read by an individual named Ken Beck on 1/28/75. Mr Beck noted that tungsten inclusions were distributed through alpout 75% of the weld. i Mr. Beck did not note a drop thru that also had linearly oriented i voids. Apparently, someone requested another radiograph because the weld was reradiographed but with wider film to include a re-pair made to the nozzle. Again the weld was accepted but this time with recognition of the burn thru on 2/11/75 by Mr. Shore. The time frame for documentation of events now shifts to l March 17,1977 when the leak was discovered in F.W. 212. These events are documented in the M.W. Kellogg QA P.eport by J. P. Runyan dated 4/12/77 The radiograph for F.W.197 was again reviewed at this time and a decision was reached to now remove the drop thru present on the inside of the pipe. The repair was made per DR 3370 and consisted of cutting a hole in the pipe. (6 of 10)

and grinding out the burn thru. I think that it should be noted that the R. P. Runyan noted DR 3370 in his report dated 4/12/77 but that the letter addressed to Mr. R. H. Engelken of the U S N R C O f fic e of Inspection and Enforcement, Region V, written by a 4 Mr. Philip A. Crane, Jr. makes no mention that a condition re-quiring, repair had been found, in fact, Mr. Crane reported that PG&E's examinations revealed no rejectable indications for any of the four main steam and three feedwater welds as of 4/15/77 In DR 3370 Mr. R. P. Runyan had noted that when he had i reviewed Mr. Ken BecHs record for radiographic interpretation it was found that Mr. Beck had hired in on 1/2/74 but that he had not certified to the M. W. Kellogg radiographic Level II position until 8/9/74 and that he had accepted radiographs before he was certified to do so. However, instead of reporting the non-confor-mance via the QA system and notifying' the licencee Mr Runyan j attributed the QA breakdown to an administrative error. A problem with Mr. Beck's work was apparent as ear,ly 'as 4/5/77 as evidenced ( by the interoffice corrrespondence from S. L. Engler to R. P. Runyan where Mr. Engler states that some of the welds must be repaired. Although PG&E could find no rejectable indications in the steam generator nozzle to pipe welds as of 4/15/77 all four of the -nozzle to pipe welds were reworked from the inside of the pipe during the period from 8/31/77 to 11/28/77 Cracks were found (7 of 10)

on the inside surface of F.W.197, a grind and polish method was used to chase the cracks. One of the cracks was 5 3/8" long and required grinding below the minimum wall thickness be-fore a liquid penetrant test would yelid positive results. Of course after the minimum wall thickness had been violated a weld re-pair was in order. The grinding out of the cracks and the weld repair to F. W.197 was apparently done to an interoffice corres-pondence initiated by a Mr. Don Geske instead of the direction of PG&E as indicated in step nine of DR 3484. The welding, of course, would have required a process sheet, filler metal requisi-tions, and the full awareness of a QC welding inspector. The DR 3484 fails to include these requirements in the recomended I disposition and Mr. Don Geske was not qualified to do visual l welding inspections. l Three cracks were found that required violation of mini-mum wall thickness before they could be successfully removed. Removal of the first crack left a groove 10" long that required i grinding through about half of the pipes thickness before the crack on the nozzle side of the root pass was removed. I am not suprized _ that no one recognized that this crack was similar to the one that occured on F.W. 212 because that would indi-l cate a generic problem. In fact, the people involved were very carefull not to refer to the defect as a crack, it was a (8 of10)

j linear indication right up to and even after the weld repair. The game is over because linear indications do not require weld re-pairs but cracks do. A defect had been found, a crack extending 10" long and approximately half way through the thickness of the pipe. The crack originated on the nozzle side of the root pass under a roll over where the reentrant angle was probably less than 90. Other cracks had been observed in the land surfaces of the nozzle and pipe counterbores. Lets compare the above to a quote from PG&E's report 411-77.55 "It is believed that small cracka initiated on the I. D. of the nozzle, weld, and pipe during the thermal cycling that occured during preheating. These sma11 cracks originated at con-4 venient stressrisers such as grinding scratches and regions of lack of fusion and weld bead rollover." Mr. Runyan could not see the similarities between the two because he had already made up his mind about the failure of F. W. 212 back in April. Mr. Runyan said in his summary to his QA Report on F.W. L. "It is my be-l lieve that the crack was peculiar to F.W. 212 only and not of a generic nature. Therefore, at this time we are assuming that no further repair will be required and that when the disposition of D. R. 3370 is completed the subject will be closed." Defects had been found in steam-generator nozzle to pipe welds that had been fully inspected and accepted. F.W.197 and (9 of 1,0)

F.W. 244 revealed cracks on the nozzle side of the root similar to the crack that initiated the failure of F.W. 212 These cracks are defects which, if they were left uncorrected could have ad-versely affected the safety of the plant. The defects should have been reported to the Commission. I believe that a break down in Quality Assurance of construction has occured because the welds had been accepted and had been put in service with out discovering the defects. Additionally, after the failure of F. W. 212 when a 100% reinspection of radiographs on Class I welds had revealed prob-lems in previous interpretations, when F.W.197 required repair in April, and when extensive repairs had been made to all the nozzle to pipe welds in IJhit I the NRC had not been notified as required by 10 C F R 21 and 6r 10 C F R 50.55e. I believe that PG&E's / failure analysis of F.W. 212 is shoddy work, I believe that there has been an attempt to fix the mistakes on the sly and that there has been purposefull withholding of information from the commission. I have read the above 10 page statement and it is cor-i i rect and true to the best of my knowledge and belief. '0TY o OBNO 4/10/84_ .before me. tne undersigned. a Notary Public in and for FF - n nd State. personally appeared.... <3teven Lockert l prsonalty known to me (or proved to me en the basis of satis-tory eyw$ence) to bo the pe soru s) whose namet sl 6s/are sut> l^^^^^^^^ ^ lribed t3 the with6n instrument and acknowledged to me that g4 g f .OT/.lT( f".*60C. CAUFoANIA k p/she/they executed the same. om wts omSPO COUNTY l NTNESS my hand and offoal seat. (10 of 10) c Mr ome. W ver 9,19u \\ %, L, e

LIST OF REFERENCED M AT ERI AL ITEM DATE SUBJECT 1. 12/18/74 Crack in F.W.197 2 3/23/77 D.R. 3370 (Review of Radiographs Resulting from Crack in F.W. 212. 3. 4/5/77 Letter from S. Engler to P. Runyan regarding K. Beck. 4. 4/12/77 M.W. Kellogg QA Report on Crack in F.W. 212. 5. 4/15/77 Letter from P. Crane to NRC, Office of IE. 6. 8/26/77 PG&E Failure Analysis of F.W. 212. 7 6/23/77 Pullman Swindell Metal-i lurgical Exam of F.W. 212 8. 8/26/77 D. R. 3453 Internal In-spection and Weld Repair of F.W. 244. 9. 10/7/77 D.R. 3484 Internal In- [ spection and Weld Repair of F.W. 197. 10. 11 / 8 / 8 2 D.R. 4662 Failure to have a PQR for MT Examination of F.W.197 and F.W. 244 I 11. 10/6/75 Personnel Testing Record of Mr. D. R. Geske show-ing no examination scores for Magnetic Particle Testing i ^

FA?.TMENT OF INDUSTRIAL RELATIONS

~ veN ciiNousniat$Ar m . - Go'JEN CAM AVENut. SAN FRANCl3Co Dece:ber 12 1974 L I ,p, 4 Aur, ic, EWIStf 1. W 2.e u,.,. l..iellogg Company A1%C4%&MT l-P. O. 3cn 367 Avilc 3each, CA 932L2 Attention J. P. Amyan, QA/QC Manager l

Subject:

Qaality Assurance at Diablo Canyon helear Plant Construction site Gentlemen Cn kes:ber 3rd I discussed with you and Mr. J. 's!. Pcfan the recent wul b ycur Pred:ction Person =el of the thermowalls free the Reactor Ceolant / Leop, which had to be removed because they had been improperly invalled by ycur Cc=pany. A Hold Tag had been applied at each location and Deficie=cy Eepcrt 2L37 had been issued which outlined the corrective worx: and also clearly stated that the Quality Assurance Manager was to be notified before bech +c any currective work. Production failed to notify you and failed to fellow the D. P In doing so they violated the Ncn-Ccnfermance Section cf your Cuality Accursnes Manual. KFP-10 of your QA l'.a= cal assigns to you the respensibility to assure that its provisions are adhered to. You will recall that at the same time the repair of Steam Generator 1-1 feedwater =ce le was taking place. A crack extending circumferential17 3600 had been caused by your welders when they welded withcut the use of preheat. Die welders had been ascisned to the job by their supervision before you were in possessien cf a qualified welding procedum for P 1 to P 12-D Materials. i The installer in possession of the pmper ASME symbol stamp and Ce?.ificate of Authori.ation is nquired to operate under a controlled system by NA 4451 of Sectien III cf the Code..We would therefore request that measures be taken to. assure that conditions that-eansed,tbe Molations will be pm:rptly identified,4.:. and corrected to prae 1Me-repetitioda It is also recuested that, in acec F ance .:ith !!A L300, the identification and cause of failures affecting cuality and the corrective-actimr be damn==*.m4-s e ~ cry tre.17 y=urs P. J. Carcsella , D...., ' " Se.ior Safety Ihgineer ( ,. S .^ /aa y > -..s / J. I!. Rycn, Oc=struction Manager / ce L J. S. Guyler ~~ '.r 4 j ....v r.g. k4 j +

emsir.2. To f'@* MTAcetmewT I Psge I of 3 i THE M.W. KELLOGG COMPANY auII A navssioN of PULLMAN INCompoRATs0 0.R. No. 3370 &I 13o. No. 500146 DISCREPANCY REPORT UNIT No. I Co0E No. M/A '.,.usToMSR: Pacific Gas & Electric spec. No: 8711 CATE: 3/23/77 PaoJECT: DiaWe Canyon Joe No.: 7177 INSPECTom: 1 9. Rurrvan Q!aiPEPANT '*: Ir.W. #197. Line Kl6-6%=16-IV. Steam Generator I-I " zile to oloe A eXPLANA7 ton op osaCatPANCY-As the result of a crack in F.W. #212 at the Feedwater noule on Steam Generator I-2 (Asf. D.A. 3366) e a review of the radiographs of the same welds on the remaining three (3) generators was performed by the N.R.C. In addition, the nou le to pipe j welds on the main steam leads were reviewed. The review revealed a questionable Indication in F.W. #197 on the feedwater lead to steam Generator I-l. The indication appears to be a burn through which centains linearly oriented volds. The accompanying radiographic report accepted the weld but did not Indicate the presence of the burn through. Further Investigation revealed that a second set of radiographs, shot at a later date, exist. This set also shows the burn through which was recorded on the radiographic report as acceptable (see copies attached). (Continued on Page 2) encommeNoso oisposmoN: 8 i r i See paes 2 ,h l l NYb[E18. 98E Ild O"5/ Asween av: u.w.x. pi.w u. m r.,W^ c Yas/n C e o..e .:NA t eis,os m o N: C, - w. A4.e Com.<...i.n c.ee....... nag ~g'n x M o...d - - - w.6 c si. a.. om.: w.rkc 1.=4 in.e y - amptANATioN iin NacassAnyn Revision I see pese 3 a Reviates II see ;;;;s J g ~ MN 1 Th osse Ed /7 weemer g,g,g, piang o,4. us, C o.se tic.x. pi es cLA. wenseer O. set hN weemer . Ode b/b C o sTape To pegygNT RscummtNCE C Moe Appli.shi. 13 4e re* <!Je/ ?Mw 4%. <aau. -I~ A 5** F*r 3 ,.,,, o...u,,,,,, 4 olSTneauTioN 3 messer o,A. Pise 3 A an. Ines. 3 Sapasenne osse. O es,er i 3 consemer C neseewa, C Pises inessener i ATTACN sMETCN Ip NGCsEsanY e

Page 2 of S

THE M.W. KELLOGG COMPANY

&g l 4 osvision oF PULLMAN INCoRPo# Arso 0.m. No. 3370 61 T_ tso. NO. 8i0 0 1166 OlSCREPANCY REPORT uNiTNo. l l ,( CCcf NO. M/A /*h posific Cao a Electric pge, no: 3711 e47,; 3/23 n7 customan:_ Disele Canyon Joe No.: 7177 NspacTen. J. P. Runyan M g.ct: assemapaNTittwF.W. #197, Line K16-554-16-IV, steam senerator 1-1 Nedie to otoe Exolanation Of Olscrepancy: To determine the severity of the indications in the burn through, we have made ad-ditional radiographs of the burn through area. These radiographs Indicate that the volds are probably contained within the burn through and do not extend into the weld. There is no Indication of propagation of the Indicat.lons. U.T. of the weld by P..G.sE. does not Indicate any Indication within the weld which 4 is outside the acceptance criteria., Attachments I, 2 & 3 R ccamended Olsposition: To eliminate the possibility of a potential problem,at a later date, it is recom-mended that the burn through be removed. The following procedure is to be followed for removal and reinspection: 1. Weld a 2" threaded coupling to the pipe as shown on the attached sketch i using weld procedure 80/89 or 92/93. (Tw f 827) 2. M.T. per E50-209. 3. Post weld he,at treat th's weld - E50-2185 4 Perform a hydrotest on the weld prior to drilling into the pipe. 5. Following satisfactory completion of the hydrotest, cut the hole.through the pipe us11 with a hole saw (Ref. ESD-230) NOTE: Additional reinforcement of 2" opening is not required per P.G.& E. calculations 6. Using an entended shaft grinder with a cone shaped rock, grind the burn through flush with the pipe surface. 7. Radiograph the area to assure complete removal of unacceptable Indications. 8. Install threaded plug and seal weld (F.W. #828). This installation is to be made in accordance dith the National Board Inspection Code and ASME Section I 9 Revtowed by A.N.I., MO*st. .. r. s, m,. .a . an o~ . c ns, Q n.sshmag C P W lsumuseer i I afvaca suston is Necessanv G _ - - -. mtawm.m,w.<. m a m e.s a. m a. _ - ~

/ Pap 3 of 3

f. ' THE M.W. RELLOGG COMPANY egg a civisioN or Put.utAN INCoRPoR ATgg QA No.

3370 I?t 4 _ iso. NO. 9001/ds g'f DISCREPANCY REPORT UNIrNO. nwy . -/. CcCE NO. T/A Peeffle Gas & EIWe spge, no: 3711 garg 3/23/77 custCMER: e anyon JCs NO.' 7177 INS 7ECrCR: .I. p. Rimvan PMoJECr: oeseme**NT '7tw F.W. d197. Line K16-5 54-16-IV, Steam Generator 1-1 Nozzle et pipe RZYISION I The following action was taken. Add to " Recommended Disposition" the' following steps. A. To determine if there exists an ambiguity with other welds accepted' by the M.K. Kellogg film interpreter who accepted F.W.197, the following action was taken: 1. Review qualification records of this individual co' assure compliance with .SNT-TC-1A. 2. Review all radiographs which were accepted by the individual. NOTE: Ihe findings of the review will be reported as a separate report and attached to this D.R. before the D.R. is closed.. No revision will be required to the D.R. SUMMART , STEP 5 TO PRETCfr RECURRENCE l In addition to the above action it has been determined that a random review of accepted film from all other M. W. Kellogg interpreters was required. Twenty sets of film were reviewed from each of seven other interpreters. No rejectable indications were noted (See Q.A. report of film and doc'umentation review dated 4-22-77 Attached). Subsequent to the above a review of additional Unic I film was performed while investigating the accept / reject race of welders. Another rejectable indication l was noted in F.W. 346 Iso 1-4-500139 (Ref. D.R.3396).. Ac. this. time P.G.& E. l requested that a 100% film review be performed of all design class *I radiographs l in Unit I and II This will be performed and documented in accordance with D.R. 3 I 3400 Rev. I for Unic I and D.R. 3409 for Unit II. To further assure that all welds radiographed subsequent to this date are properly interpreted, each set o'f film will be interpreted and then reviewed by a second qualified film reader. Reference Q.A. instruction 101 Rev. I. l , y ossvaisuriom a wen,o.4.pu. 34= 3 _ _ --,o.m. O otaw a con m., ap, O Pw in n.e t m cnmanno

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} ( f } / d DIABLO CANYON NUCLEAR PROJECT JOB #7177 SPEC #8711 QUAL *TY ASSURANCE REPORT 0F ~ ACCGtPLISHED JOB TASKS (Ref: DR 3370) THE M. W. KELLOGG COMPANY AYILA BEACH, CA 'O PREPARED BY a D. Geske NDE Supervisor I APPROVED BY e=:s a J. P. Runyad Field QA/QC Manager g l l i 4 4 ee ~ p i s t I i 8
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,e y .'/ 1 -s / QUALITY ASSURANCE REPORT n OF L ACC NFLISHED JOB TASKS (Ref: DR 3'70) PURPOSE t To document all job casks perfermed as result of deficiencias notad during review of radiographic. film required by DR 3370, steps to prevent recurrence. SCO'PE This report is re.:r; t i to those items listed in our letter to the customer dated April '.' 1977 (see Attachment #1), and supplements our previous report by J.' Runya. dated 4-22-77,
Subject:
Quality Assur-ance Report of Documai ation and Radiographic Film Review. i i FILM REVIEWED K. BECK 3 'LJTST/ ISO E 4 n
../.68 803
~ V 1-4-150 1051 1-7-1
201, 204R1 1-7-4 19, 243 1-7-5 27 1-7-6 28, 31A, 32, 233 1-7-8 39A, 41R2 1-7-14 64 1-7-15 65, 66, 68, 69, 70, 71, 84A 1-7-16 72, 73 1-7-21 98, 101, 132 i
1-7-22
106, 107, 108, 109, 113 1-7-23 116, 117, 120 1-7-24 122, 123 1-7-15 166, *170 1-7-29 183 1-4-1 15, 15A, 516, 2222 1-4-41 274, 275 1-8-56
.499, 500, 372R1 1-8-61 533, 335 1-8-71 547 1-8-72 550, 552, 554, 23523 1-8-349 131211 1-4-705 1830 1-9-2 17 1-9-3 190A, 290, 293, 322, *338, 345, 348 1-9-16
279 1-9-18

123, 126R1, 127 g
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= _ - - -- l t 1-9-19 141, 145R1 1-9-21
135, 158R1 1-9-23 173, 267. 268 h
1-9-25 182, 183 1-9-37 280, 251 1-9-40 283R1 1-9-42 250 1-9-61 533, 536 1-9-209 104 1-9-216 157 149-23 102, 20R1 1-04-500136 253R1 1-04-500137 279R1 1-03-500146 1-03-500146 f.' /-3 228 229 2-03-75 532 2-04
15, 22, *28, 29 2-04-4 41, 54, 55 2-08-8 49 2-08-17

111 2-08-25

185C, 185D 2-08-31 222, 233 2-08-32

243 2-08-33 249, 249A, 2486, 2487,

390 2-08-35 266, 267, 270 2-08-36 272 2-08-548 1479 O
2-to-to
78. 385 2-10-12 110 t
2-14-63
532R2 2-04-501014 351 R. BARBER UNIT /SYST/ ISO FW 1-7-1 1, 2 1-7-10 SR2 1-7-2 7
1-7-17 78, 79 1-7-18 80 1-7-15 64 l l 1-14-81 564, 56aA, 568,' 579 1-9-38 230, 231 1-9-5 44, 47, 45, 46R1, 1-9-20 150, 131 M.5HORE UkIT/SYST/IiiO FW 1-7-5 25, 24, 295, 26,' 23 1-7-8 22 ~~ 1-7-21 100, 102, 103, 104', 105, *99,' 1-7-16 74, 75 .-V 1-9-18 124 '~ 1-9-19 138, 137, 142 1-7-29
188, 189 y
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/ R. SEARS UNIT /SYST/ ISO N 8 2-3-14 165 ~ 2-4-12 13 8 O-2-4-501016 323. 2-8-61 445A 2-8-480 848 2-9-15 117 2-9-32 196, 197 2-12-8 91 2-12-11 119 2-14-62 520, 814, 843, 861 M. COSTLEY UNIT /SYST/ ISO W 1-7-1 209, 211, 215, 213, 4 1-7-8 39, 40, 242 1-7-24 126, 129, 124 1 1-7-28 180 1-8-1 13 1-10-5 56E, 56F 1-14-35 181 1-14-81 691, 574, 583A, 576 J. RUNYAN UNIT /SYST/ ISO W 2-3-19 232, 237, 427 O 2-3-501023 333 2-4-27 294 2-4-501018 158 2-7-15 106, 115 2-8-9 55, 56, 57, 567, 569 2-8-16 105, 576, 577 2-8-63 451 2-8-65 650 2-14-62 512 J. MARTINDALE UNIT /SYST/ ISO N 1-3-500146 499, 500, 501, 502, 503, 504, 505, 506, 507, 508, 309 1-3-6 349, 348 1-7-14 62, 63 1-7-15 67 1-7-17 77, 76 , ' la 1-7-19 82, 83 i 1-4-47
501 2-8-60 437A 2-9-32 302 2-14-62 505, 517, 818 i

8aview require.d job tun.
) E s
FIIN RISHOF FOR QUAI,ITY/ CLARITY i UNIT /SYST/ ISO FV CCMMENT 1-04-500136 hl? l"} 255 Compared to original film - no defect noted. 1-04-500137 ' M ! -- 282 Compared to original film - no defect noted. 1-04-500138 < [- - 320 Compared to original ff.1m - 1-04-500139 no defect noted. t 348 Compared to original film - ~\\ geonstric difference noted, 1-07-1 see DR 3423. 201 Drop thru shot in cross-section and determined to be within , code after customer review 1-07-21 5-19-77. 99 Reshot for lighter density - 1-07-22. no defect noted 5-27-77 106 Rashot view 3-4
Original, film missing - no defects noted 5-27-77.
1-07-25 170 Rashot dua to rough surface - FW ground for inservice - no 1-07-29 defect noted 5-18-77. 188 Rashot view 2-3-4 for full coverage - no defect noted 1-09-3 5-16-77. O 388 Unconsumed insert noted during' film review. Repair included 1-09-16 with DR 3400 279 Rashot view 0-1-2 to verify root fusion - no defect noted 1-07-18 3-25-77. 123 Rashot view 8-9-0 to verify root fusion - no defect noted 5-25-77. 1-09-21 155 Reshot view 4-5-6 to verify removal of surface condition - no defects noted 5-26-77. 2-04-501013 347 Compared to original film - no defects noted. 2-04-501014 364 Compared to original film - no defects noted. r 2-04-501015 379 Compared to original film - 2-04-501016 no defects noted. 329 Compared to original film - no defects noted. 2-04-47 501 5 Rashot view adjacent to repair area - no defsets noted 5-13-77. 2-08.17' 111 + Repair completed and accepted 5-13-77. 2-08-25 185C Repair completed and accepted - } 2-08-32 ~ DR 3383, 5-20-77, h dre open. l Repair completed and acespeed - .f : / L' '243 g UR 3385, 5-26-77, hydro open. 2-08-33 390 Repair completed and accepted - p' DR 3384, 6-3-77, hydro open.
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2-14-63 532 Repair completed and accepted - DP. 3382, 6-3-77, hydro open. OTHEt~ JOB TASKS UNIT /STST/ ISO E COMMENT 1-03-500146 828 Penetrant tested seal' weld at coupling installed to repair 2-04-2 FW 197. 28 Visual inspection verified surface condition within code. CONCt,USION the above data reflects all actions completId as result of film review required per CR 3370 and constitutes final action as indicated. Defects dis-coverad during film review generated the requirement for 1007. radiographic film review. DR 3400 documents review of Unit I and DR 3409 concerns Unf t II. 1 Attachment 6 o
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y-..._..............- _..__ m., m m m .-. a u.. ~. ...._...~ ~ ......e p INTERDFFICE CORRESPCNDENCE A 70 J. ROLLE DATE APFJL 22,1977 . FRO M J. P. RUNYMi susJECT D9..Mfr.Q JQ3 TASKS...r D..L 3.3.7.Q. As result of Radiographic Film Review, conducted per D n. 3370, the ~ cttached lists present our proposed action. .' Request your rsJiew and ecmcents at the earliest possible date. ~ s. pfds J. P. Runyan Field Q A./Q.C. Hacoger JPR/&. . Attachments F-I 4 9 I h( > @\\ .\\. sN N. %. :s.' A.,%.. >.N.,N\\'is s *% %'.'s',.N'Q'.\\ .N sN N.'Ns N s.N *s,
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...~.........m.w. ,-...a.~~....- ..~.~. . ~.. __ -, _ = - -- ....s.- PACE 1 of 1 NDE WORK D.R. 3370 UNIT II p s,lT - SYSTEM ISO F.U. WORK RdDUIRED PRETARATTOff REQUIRED 2-04-501013 347 Reshoot Mainsteam 1. Scaffold at top of steam generator. 2. Not insulated. NOTE: Recommend R.T. from inside of steam generator and P.T, of I.D.,of welds. 2-04-501014 364 Rashoot Mainsteam 1. Scaffold at top of steam generator'. 2. Not insulated. NOTE: Reconstand R.T. from Inside of steam generator and P.T.' of I.D. of welds. 2'04-501015 379 Reshoot Mainsteam 1. Scaffold at top of steam generator. 2. Pull insulation. NOTE: Recoaraend R.T. from inside of steam ~ . generator and-P.T. of I.D. of welds. s '2-04-501016 329 Reshoot Mairisteam 1. Scaffold at top of steam generator. 2. Pull insulation NOTE: Recommend R.T. from inside of steam ~ generator and P.T. of I.D. of welds. ~ 2-04'-2 28 ' Visudi for surface,
2.. Pull Insulation.
1. Scaffold or la'dder. . Linear 3. Match linear ort 4. Re' shoot. ~.
2-04-47 501 Reshoot adjace'nt view 1.
Modify. existing r.caffold. .to rapsir area. 1-08-17 111 U.T. for lack of 1. None Penetration. 2-08-25 185C Repair gas holes
1.. None 2-08-32
'243 Repair gas holes 1. Erect acaffold' on top of liquid ~ hold-up tank 2-1. 2-08-33 390 Repair unconsumed ring 1. None. ~ ~ ' 2-14-63 532 Repair porosity 1. Scaffold platform for access. l. i l f l _l ,t I [
~,.a .......w. .:.s. ..m.m.m.._ ~~~ uo. PAGE 1 of 2 , NDE WonK D.R. 3370 UNIT I IIT. SYSTEM ~S ISO 7'.11. WORK REOUTRED PREPARATION 5GOUTROD 1-04-500136 255 Rashoot Mc.insteam 1. Erect' scaffold o'n top of steam II l'! generator. 2 Pull temporary insulation. NOTE: Recommend R.T. from inside of Steam Generator and P.T. of I.D. of uelds, 1-04-500137 . 282' ' Reshoot Mainsteam 1. Erect scaffold on top of steam t l generator. <'f. -3 2. Pull comporary inculation. NOTE: Recommend R.T. from inside of steam Generator and P.T. of I.D. of welds. 1-04-5.00138 320 Reshoot Mainsteam 1. Erect scaffold on top of steam-generator. 2., Pull temporary insulation. l -., NOTE: Recommend R.T. from inside Ef Steam Generator and P.T. of I.D. of welds. Q 4-500139. ' 343 ' Rashoot Mainsteam 1. Erect scaffold on top of secam ~ generator. 6 g ' -[ - @
2. ~ Pull temporary insulation.
, NOTE: Reconnend R.T. from inside of :: team / Generator and P.T. of I.D. of welds. .1-03-500146 828 Penetrant Test 1. Scaffold in place A.I. Witness-2. Pull te:cporary insulation. 3. Power bruch to clean. 1-07-1 201 R.T. Drop-Thru at 1. No scaffold required. view 3-4 2., Pull insulation. 1-07-21 99 Roshoot - Original 1. Scaffold for access. ' Density 4.0+ 2. Pull insulation. l l '-1-07-22 106 Reshoot - Original 1. Scaffold for access.. view 3-4 missing 2. Pull insulation. L,1-07-25 170 Rechoot - Original 1. No scaffold ree,uired. l Rough surface 2. Pull insulation. l L 1-07-29 188 Reshoot - Original. 1. No scaffold req. ired I-u 2-3-4 missed weld. 2. Tull insulation. t. L 9-3 338 Repair incert 1. No scaffold required. ] 2. Not insulated 3.- R.T. repaired area.' ' ~ ~ l
cm w.
.-- -. ~. _ w ~ . w w _..- .i.__,., % _ PAGE 2 of 2 i KDE WORK D.R. 3370 Os s-WRT I h T - SYSTEM ISO 7.W. UCRK nmUTRED PREPARATI0tt PE0ITTRED ~ 1-09-16 279 U.T. for possible 1. No scaffold required. lack of fusion 2. Noe insulsted. 1-09-18 123 U.T. for possible 1. Scaffold in place. lack of fusion 2. Not insulated. 1-05-21 155 Rashoot - Original 1. lio scaffold required. with possible slag 2. Pull insulation. J I O O. e e e. -.ie e i l g 4
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DIABLO CANTON NUCLEAR PROJECT JOBf 7177 SPEC.# 8711 l QUALITY ASSURANCE REPORT OF DOCUMENTATION AND RADIOGRAPHIC FILM REVIEW ( REF. D.R. 3370) O THE M. W. KELLOGC COMPANT AVIIA BEACH, CA. PREPARED BY: IM6w - J. P. RUNYAN FIELD q.A./q.C. MANacER 4/Z !71 DATE Is.. -n. <---..n..
i I j QUALITY ASSURANCE REPORT p 0F DOCUHZNTATION AND RADIOGRAPHIC FILM REVIEW (REF. D.R. 3370) PenroSE 1 To perform a comprehensive review of radiographic film and documentation l related to field weld 212 and other similar celds. E.925. To review the veld procedure, welder qualification records, heat treatment records, material certifications, nondestructive examination personnel qualification and N.D.E. results of the above mentioned welds. DISCUSSION 3ecause of the crack in F.W. 212 it was determined that a complete review of the history of the weld, including inspection and tests records, was in order. In addition, other welds of the same configuration and material combination should be reviewed to determine, if possible, if there exists a generic type problem. The result of that review is as follove. V UELD HISTORY REVIEW 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 insert was removed, however, discussions with field inspectors who were on site at the time indicate 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 root pass was made on May 22, and accepted visually May 23, 1974 Welding proceeded following Q.C. acceptance and was completed on May 24, l 1974. The veld surface was ground and final visual inspection completed on May 28, 1974 Other than replacing the insert no unusual or out of the ordinary circumstances were recorded. i FREREAT AND POSTHFAT A review of the was preheated to 200, heat charts on F.W. 212 indicate that the weld area F. min. prior to tack welding and subsequent welding. l 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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~. i Following completion of the weld on May 24, the veld was allowed to p cool and no further heating was performed until post weld heat treatment on June 24, 1974. Freheat and post heat records from other welds of the same type indicate a similar history. NDTE: Other welds reviewed were the remaining three feedveter nossle to pipe and all four main steam nozzle to pipe welds in Unit I and the main scesa nozzle to pipe velds in Unit II. The feedwater notsle to pipe welds are not welded in Unit II. i l WELDINC PROCEDURE AND WELDER PERFORMANCE OUAI,T7ICATION RECORDS Field Weld 212 was made usins weld procedure number 200. The procedure was reviewed to assure compliance with ASME Section IX. No deviations were noted. De results of the procedure qualification tests were evaluated. Included were bend test's, tension test's, and Charpy V Notch test's. All results were acceptable. Welder 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 that his performance record was good. There was no reason to suspect that welders capability or performance was below standard. NAT DIAL CERTIFICATIONS Material Certifications of the weld material and pipe-side base material was reviewed for compliance with material specifications and job specifications, including supplementary requirements. All were found l to be in compliance. The nozzle base material certifications were not I available for review by M.W. Kellogg. IONDESTRUCTIVE EIAMINATION PERSONNE
L. PROCEDURE
S Ar R2'!CRTS The original radiographs of F.W.' 212 were reviewed. There was an area along the nozzle side of the root wi:h greater density than other areas of the weld. This area is typical of c:her similar welds. ne higher density is caused by the nossle counterbers which is approxi=acely h" wide. Tbare was no evidence of linear indicatiens 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. However, the radiographs of F.W.197, which is the feedwater nozzle to pipe veld on steam generator number 1-1, indicated a drop thru which appeared to have linearly oriented voids contained within the drop thru. There were two sets of radiographs of F.W.197. The reader sheet for one set listed the drop thru as acceptable. The other reader sheet accepted the weld but did not indicate that the drop thru was present. To assure the soundness of the weld it was determined that the drop l thru should be removed. This was accomplished in accordance with D.R. 3370. l Q 4 Attached)
o. To further assure that the film interpreter, which had accepted the p weld with the drop thru without entering it on the reader sheet, had not overlooked other similar or sore serious indications, a complete re-view of all the film read by him was made. His qualification records were also reviewed. The results are as follows. J Mr. Ken Beck was employed by the M.W. Kellogg Company from January 2, 1974 to March 28, 1975. His res mo and personnel records indicates he had sufficient past experience and training to qualify him as a Level II radiographer capable of film interpretation. He completed M. W. Kellogg R.T. exams and was certified to Level II on August 9,1974. A review of the films which were read by him indicated that he had reviewed==d a===pted film prior to August 9, 197!.. It is asemmed that this was an administrative error. To assure that the film were properly interpreted and accepted by a qualified reader, all of Beck's film was re-interpreted. In general, the findings revealed that he frequently did not record all indications on the reader sheet. We found that he had reviewed one hundred twenty-two (122) sets of film, eight had indications which in our opinion should be repaired. These repairs will be performed as soon as the systems are made available. NOTE: Pour of the repairs are in Unit I, Four are in Unit II. To further confirm our findings, the Q.A. Manager and Level III N.D.E. examiner from our Paramount plant was asked to review the film which we had reviewed. His review confirmed our interpretation, a copy of his report is attached. In light of the fact that Beck had accepted welds with rejectable indications, it was determined that other film which had been accepted by other M.W. Kellogg interpreters should be reviewed. Seven people, other than Beck, had reviewed film. Twenty sets of radiographs interpreted by each of the seven were selected randomly and reviewed. Of the one hundred forty (140) film reviewed no rejectable in-dications were noted. It vae noted that occasionally acceptable minor indications were not recorded on the reader sheet. However all significant acceptable indications were apparently evaluated and recotied. Other N.D.E. reports, (i.e. M.T. and P.T.) were reviewed and found. l acceptable. This included a review of personnel and procedure qualification records. CONCLUSION It is the writers opinion that the review as recorded above has covered ( all potential areas for probleme in veldirg, heat treatment and N.D.E. related to the crack in 7.W. 212. It revealed a discrepancy in the interpretation of radiographs l which has been corrected. Procedures are in effect to prevent recurrance j of similar problems. l t No further action is anticipated at this. time. l I i =. . = - -. ~ - -... =. ~
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INTEROFFICE CORRESPONDENCE G?in1 BIT S TD ggpr TO P. RUNYAN DATE APRIL 5,1977 FRCM S. L ENGI,ER SU3)ECT.._.I'G.ER.?.RQ.U..ON, 0F,.?AD!CC?A PRS... FREVICUS LY. !;.GER,FRUp,17 K. SECK (FUL*}AN KII.*.CCC) Reviewed 24 seams tnat were previously accepted by K. Beck. These seams were reviewed by other N11=an Kellegg personnel before I arrived. They broke them into two groups: Acceptable and Questicnable. During my review of the Questic: nie Radiographs I found a lack of under-standing by the film intarpreter of the governin; acceptance standards, such as: A. Acceptable inclusions not noted on inspection report. 3. Acceptabla surface ind ic a t ic a. not marked on inspection report. C. Inclusions and surface conditions where accepted that should have been rejected. In my opinion some of the seams will have to be repaired or at least re-radiograph ed. Seme film can he accepted by ccmparison with the surface of the weld. My review of the fil :e 'r : ~ ed _ K. 3ee! that were re-reviewed by Pullman Kellogg personnel, and deter =ined to be ace-otable, ee.sisted of a i randem sample. In the pree m ;f : hat revieu no rejectable film were found. l Ouring the inscect -- i: :nd that all ether as ects of the program such as; Contrast, sensitivi:. c e n.21 - - and ?rocessing were acceptable. If you have any quest ons en :he abcve report pleaJe contact me. /2t Lv '7 h. v.n Stephen L. Engler SLE/mk 1 cc: E. 3. Curcio J. W. Ryan S. Handler 4 l l
$4tatT + To ATTACekne9T'.i. ify ^ DIABLO CANYON WUCLEAR PROJECT JOB f 7177 SPEC # 8711 QUALITT ASSURANCE REPORT OF Crack in Steam Generator Feedwater Nozzle to pipe veld (Generator No. 1-2) THE M.W. KELLOCC CO. Avila Beach, Ca. c ~ PREPARED BY / W6 - 'J. P. RUNYAf Field Q.A./Q.C. Manager MTE A /1 /9 M ,-r-_
p..._.... / \\ l QUALITY ASSURANCE REPORT 0F CRACK IN STEAM CENERATOR TEEDWATER N0ZZLE TO PIPE WELD (GENERATOR NO.1-2) PURPOSE To document eventa from the time of discovery of the leak until the completion of the repair. 1.EQ.P.E Bis report covers the on site findings, the review of documentation including preheat and postheat charts, radiographs from the defective weld, the subsequent procedures for removing the defective arcs and performing the repair. ' FINDINGS On Thursday, March 17, 1977 a leak was observed in field weld 212, line 116-555, by F.C.& E. We were advised of the leak on that date. The weld in question is where the 16" feedwater pipe ties into nozzle #4 on Steam Gererator 1-2. Visual observation revealed a weep type leak which occasionally sprayed a fine stream of water. When observed with a 10X magnifing glass there appeared to be a small intermittant linear indication approxiately 3/8" in length in the center of the weld running around the pipe. Magnetic particle exmination of the area with a D.C. converted yoke did not show evidence of a linear defect. P.C.& E. requested that we grind the area. As grinding proceeded, the' indication opened to reveal a linear defect approximately 2" long when the weld crown was flush with the pipe surface. At this point the grinding was stopped. We were requested to perform sn Ultrasonic examination to determine the extent of the indication. The pipe temperature was approximately 180* F which made it impossible to perform U.T. with the standard transducers on site. We were then instructed to " hold" until P.G.& E. Engineering Research crrived with their U.T. equipment and high temperature transducers. The weld wea radiographed at this time. The radiograph revealed evidence of a linear indication which appeared to be approximately 6" in length. On Friday, March 13, 1977 P.G.& E. Engineering Research arrived and performed Ultrasonic examination of the weld. They reported that there was a crack which j cppeared to extend approximately 2/3 of the distance around the weld. Based l ca caere findings it was determined that the welc would *ue cut. out and replaced. I i
WELD REMOVAL _._m The weld was cut by grinding approximately 1/2" frem the center line on the nozzle side and at F.W. 503 on the pipe side. The end of the pipe was then cut to remove a ring which included most of the veld and approximately 4" of pipe. The piece was examined visually and by liquid penetrant on the 0.D. and I.D. and a sketch made to reflect the observations. (Sketch Attached) The piece was shipped to.P.G.& E. research lab on March 20 for analysis. l REPAIR A piece of 16" pipe was removed from stores to replace the piece which was cut out. The pipe end preps, gamma hole and vent were machined in the P.G.& E. machine shop on March 19, 1977. The nozzle end prep at F.W. 212 and pipe end et F.W. 503 were ground in place on March 20. A liquid Penetrant examination was performed at that time to assure complate removal of any indications. ~ The new piece was moved into place and fit up on March 20. Preheat was applied prior to tack-up,(Ref. Chart # 54.7). After the fit up was approved by M.U. Kellogg Q.C. both roots were welded. Magnetic particle inspection was performed. Following magnetic particle acceptance two additional passes were. welded in each veld. Radiography was performed on March 21, 1977. The radiographs of F.W. 503 pipe to pipe wereacceptable. F.W. 212, pipe to nozzle, had excessive. porosity te the window closures. These areas were ground, reweided and re-radiographed. One area had excessive porosity, the other had a linear indication appeenimately 1/2" long and an area which appear (d to be suck back. i At this time, March 21, 1977, P.G.& E. Q.A. placed a " hold" on all work until their Engineering could review the total program and process appropriate paperwork. "This hold was not because of the difficulty in welding the window closures". No work was performed on March 22, 1977. On March 23, 1977 an on site meeting was held to review findings, work to date, and procedures. for completion of the repair. Attending the meeting were representatives from P.C.& E. Engineering, Q.A., General Construction, Division, l Westinghouse, M.W. Kellogg site Manager, Corporate Q.A. Manager, and the writer. A. It was determined that the procedure as outlined by D.R. 3366 was acceptable except that the preheat would be raised to 3000 Min, for completion of the welding. i 3. The problem of making an acceptable closure weld was discussed. It was determined _ that the positive pressure maintained in the system was 'to high ard thet weeer remaining in the gevarstor emused vapor to be carried out the window openings. i +y_ .,y _d-.m,, ,.p,y _yy ,,_,,gw.,
W ~ / C. P.G.& E. Division agreed to drain the generator and reduce the purge pressure until the closure welds could be made. on March 24,1977 'the defective areas at the closures were ground out and Nsgnetic particle performed to assure complete removal. No uciding was per-l formed since P.G.& E. had not removed the Hold. Preheat van being maintained { through the " hold" period. On March 25, 1977 the hold 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. Radiographs were shot in the hot es welded condition. No rejectable indications were noted. Post veld heat treatment was then performed. On March 26, 1977 following post weld heat treatment, the veld was ground, re-radiographed, liquid penetrant inspected and ultrasonically examined. No rejectable indications were noted. The vent line and gamma plug were completed, inspected and the system turned over to division 'for resumption of testing. SUBSECUDT INVFSTICATION Because of the unknown origin of the crack it was determined that other welds of the same type and welded using the same procedure should be reviewed i to determine if the defect could be a generic nature. Each of the remaining three feedwater nozzle velds and the four Main Steam nossle welds were ultrasonically examined. The original radiographs were re-viewed and the feedwater nossle welds were re-radiographed. There was no evidence of like indications in any of the welds and no evidence of change in cny of the noted, acceptable, indications since the original inspectiems. There was, however, an indication noted in F.W.197 on generator 1-1. The indication was present on the original radiographs but had not been noted on the radiographs report. A second set of radiographs were on file for F.W.197. This set also exhibited the same indication, however, the radiographic report did re-flect the condition as being a drop thru. The indication had app,arently been evaluated and determined acceptable at the time. Because of the problem with F.W. 212 it wa's determined that any questionable situation should be resolved. It was therefore determined that the drop thru should be removed. A D.R. was initiated and the repair was maJe. The in.ication j was removed by grinding. No welding was required. (See D.R. 3370 Attached) l l M Te date the metallurgiest analysis has not been completed of the crack sample. We had requested, from P.G.& E., a piece of the defective material for our own analysis.- This was received on Thursday, April 7,1977 and forwarded to g. F. Gerwin in Williamsport. l It is my belief that the crack was peculiar to F.W. 212 only and not of a generte nature. Tnurefore, at this time we are assuming thal no further tey.it will be required and that when the disposition of D.R. 3370 is coepicted the L subject will be closed. I.
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r l ,.2 THE M.W. KELLOGG COMPANY REWRITTEli D 4!'77 g,,5 A civistoN oF PULLMAN INCORPORATED D.R. No. _3366 Rev. I ~ 130. No..500Ih6- _ DISCREPANCY REPORT UNIT No. I CODE No. M/A Pacirle cas & Electrie _ $PEC. No: 8711 QATE: 3/21/77 Diablo Canyon JCe No.. 7177 INSPECTOR: J. P. Runvan ' l ..n.e cant 'Teu: F.V. //212. t f ne K16-qqq-16-tv. Steam Generator 1-2. Nozz le to oice t '.org ANAflOrd 05 OfSCREPANCY: A isak was detected by P.G.sE. In F.W. #212 (Pipe--Steam Gen. 1-2 Nozzle), a O I.esk occurred during Hot Functional Testing March 17, 1977, i.ine pressure was appecximately 90 psi, temperature approximately 3300F. Seo Attachnents 1, 2 and 3. s p/ CECOM14ENCEO DISPCSrT!ON: A.', Cut out weld and reweld. 8. Prior to weld cut-out: - ' A 1. Map weld area with U.T. to de'termine size and location of indict. tion. 2 X-ray for an analysis. 3. Remove weld material with Indication for furt.her analysis.
4. ' Cut out spool 58D (F.W. #5c3 to 212).
C. Reweld procedure: (,Tewri t ten) 1 Veld F.W. #503 using procedure 4/5 and 88/89 2 Weld F.W. #212 using procedure 200 or 204 (See Attached Sheet #2'for additional requirements). 3. InstcIl soc-o-let on new spool using F.W. #411 so, vent can be reinstalled.s [ noorowee Go M.W.K. Sield c. A. Mgr., oste I / 77 Cystemer,/ M# N'M9Date 8- /A - 7 7 {lNA!. DISPOS TICN: O in Acco<e ace w.in Ada,. Cather @,i.a.es.a ad...,... evi,.d>i v.,s c..i:,.a in..: _ e.e. w.,k c... r...d in., <':2>#, o.e.: 7,,/ 7 .XPLAN AT10N (IP NECEssARY!: Revision I - D.R. rewritten for clarity. Revicion II See page 2 po ague.r,oa IO.A $ '* ~ D*'s > p gcustom jjj, 76N#a* gtp 'f,,,
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1) Maintain $rehent n indiceted en Sheet 2.
2) Perform Post Weld Heat Treat irrrnediately fellowing cornpletion of weld. Field c.A.* Manage -p ISTRtsuTioN-3 Ma.t.< Q.A. File E Avin. Ing. 3 Enginee,ing Dept. O cam r e 3 custo,ner O aneivia, O Fie>d saioce:or i riACH SKETCH IF NPESSAstY
TIIE M.W. IC.ELLOGG COT. IP.-}NY EN,g REWRI A olVISION oF PULLMAN INCC APoR ATED D.R. No. '4'4 66 R ev _ f 150. No. t;nn1f.A DISCR EP ANCY. R EPORT , UNIT NO. l .. CO D E N O. N/A pnettie cas & Electric SPEC.NO. 8711 CATE: 3/21/77 [W oionfo Oanycn JCS NO. 7177 INSPECTC R: J. P. Runvan ,. e.. ..,.,trym F.V. //212, line Kl6-555 tv, steam Generator 1-2, Nozz le to pipe Recommended Disposition: 4 Crill and tap X-ray port in new spool. install X-ray plug using seal weld F.W. #298. 5. Add all information to Iso and Process Sheets. r Additional llequirements for F.V. #212 (See Paragraph C-2): 1. Preheat to 250 F minimum. 0 2. itaintain interpass at 2500F minimum, 500 F maximum until weld is ' complete and post weld heat treatment begins. ~3. M.T. root past; Esd-250. ~ 4 R.T. after root and 2 layers weld added ES0-207. Repair if required and re-R.T. before completing weld. 5. Post weld heat treat at 11000F minimum, 1150 maximum hold for I hour minimumfAr t temperature.. - 6. Following post weld heat" treatment, perform R.T.; ESD-207 and H.T.; ESD-209. 7. P'.G!?E. will perform, U.T. of final weld and maintain. records. l i A 8, I l l R vi:: ion II l I Chance para B, cub I to read "U.T.' of veld performed -by P.G.& E. personnel". 1 ' Add line S to additional Requirements.' " M.W.Kellogg will perform U.T. of final vald and incorporate results into Iso package".
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'/' j' ' ~ \\ Paga 1 of.3 ., THE M.W. KELLOGG COMPANY . at .. I .f*p/ A civietoN oF PULLMAN INCORPORATED o.R. No. 3370 hI Iso. No. 500146 .f)lSCREpANCY REPORT UNIT No. I ~ CocE No. N/A r
AusToMER:
Pacific Cas & Electric
SPEC. No:
s711 QATE: 3/23/77 M oJECT: DiaMo Canyon JoS No.: 7177 INSPECTOR: _1 P_ Rttnva n OtSC9 Ep ANT ITEM: p,y, gjg7, Llne Kl6-MM-16-IV. Stecm Generator 1-1 Nozzle to oloe EXPLANATION op OfSCREPANCY: As the result of a" crack in F.W. #212 at the Feedwater nozzle on Steam Generator 1-2 (Rsf. D.R. 3366), a review of the radiographs of the same welds on the remaining three (3) generators was performed by the N.R.C. walds on the main stcar:*. leads were reviewed; In addition, the nozzle to pipe .The review revealed a questionable indication in F.W. #197 on the feedwater lead to steam Generator 1-l. The Indication appears to be a burn through which contains linearly oriented voids. The accompanying radiographic report accepted the weld but did not indicate the presence of the burn through. Further investigation revealed that a second set of radiographs, shot at a later date, exist. This set also shows t ths burn through which was recorded on the radiographic report as acceptable (see copies attached). (Continued on Page 2) l
RECoMMENoEo olSPoGIT!CN:
Swa Paes 2 l >..) fee. PSE nL 'Sl* Doved By: M.W.K. Fief a o. A. Vgr.1 - e=# M. cate 3I M Customer cete TT 9 7 flNAL ctSPoSITtoN: C in Accorgartes With Above Q other (emplenetion end oppro el required)) loerk Cen.ststed Inse: - De,et work Cemete,ed inse: Dete: XPLANATioN (IF NECEs3ARYl: Revicion I See page 3 QC.K. Fiskt o.A. Manager Dates - U Date /N Customer TEPs T3 PREVENT RECJ'MMENCE Q Not Applieeble D b C /'* h'Y*h l Net f4khd* Pt erie s.I. A Sea Pye 3 9;etto.A.uaneeer,$ty isTMteUTtoN* 3l Master o.A. File - 2l Auth. lees. Qll Enpaaring Dept. C other_ E c temer O M-m f61Dmouw
Pags 2 of 3 / THE M.W. I;ELLOGG CO.TIPANY A DlVistoN oF PULLMAN INCoRPoRATEo o.R. No. 3370 de t) T ~ iso. No. 500 W6 _ DISCREPANCY REPORT . UNIT No. l g . coo! No. N/A ToMER: Pacific Cas & Electric SPEC. No: 8711 oATE: 3/23/77 JECT. Diablo Canyon Joe No.: .7177 INSPECTOR: J. P. Runvan f63'4_
mEpaNTITEwF.V. #197, t.ine K16-554-16-tv, steam Gener$ tor 1-1 Nozzid to oice len tirn Of Discrepancy:
To d]termine the severity of the Indications in the burn through, we have made ad-diticnal radiographs of the burn through area. These radiographs indicate that th3 volds are probably contained vtithin the burn through and do not extend into the weld. There is no Indication of propagation of the indicat. ions. .U.T. of the weld by P..G.cE. does not indicate any indication within the weld which is cutside the acceptance criteria. Atttchr.ients I, 2 s. 3 B sem:nded Disposition: ~ Ta climinate the possibility of a potential problem,at a later date,'It is recem-mend:d that*the burn through,be removed. Th2 following procedure is to be followed for removal and reinspection: 1 Veld a 2" threaded coupling to the pipe as shown on the attached sketch using weld procedure 88/89 or 92/93. (FW d 327)- 1 2 M.T. per ESD-209. l l 3. Post we'id he.at treat the weld'- ESD-218. u 4._ Perform,a hydrotest on the weld prior to drilling into the pipe. ~ l "1 5. Following satisfac' tory completion of the hydrotest, cut the hole.through l the pipe wall with a hole saw (Ref. ESD-230) NOTE: Additional reinforcement of 2". opening is not required per P.G.& E. calculations 6 Using an extended shaft grinder with a conc shaped rock, grind the burn through flush with the pipe surface. 7. Radiograph the area to assure complete removal of unacceptable Indications. 8 Install threaded plug and seal we'id (F.V. #828). This installation is to be made in accordance siith the Nacional Board Inspectiion Code and ASME Section 1 Reviewed by A.N.I. .z d e%. fb ~ suttoor. 00 Mmer o.A. Ne 2 Aven. lmo. 2 Er+n.enn, oeot. O other wme D naaniwun D zw -- n-- 1
Pqa 3 of 3 / THE M.W. ItELLOGG COMPANY A DIVIStoN OF PULLMAN INCORPORATED D.R. NO. 3370 ] ISO. NO. 500146 DISCREPANCY REPORT
UNIT NO.
OW CODE NO. M/A i h0MER: Pacific Cas & Electric SPEC.NO: 8711 ,_ DATE: 3/23/77 $ECT, Diablo Canyon JOS NO.: 7177 INSPECTon: .I. P. Rttrivan
ten!*ANTirtu:
F.W. d197, Line K16-554-16-IV, steam Cenerator 1-1 Nozzle et pipe RD/ISION I Defollowingactionwasta$en. Add to " Recommended Disposition" the' fo11cwing steps. "~ A. To determine if there exists an ambiguity with other welds accepted'by the H.K. Kellogg film interpreter who accepted F.W.197, th,e following action was taken: 1 1.' Review qualification records of this individual to' assure compliance with .SNT-TC-1A. J 2. Review all radiographs which were accepted,by the individual. NOTE: The findings of the review will be reported as a separate report and attached to this D.R. before the D.R. is closed.. No revision will be required to the D.R. Summary: ~ Steps to prevent recurrence: ? ~ ~ It has been determined that no further steps cre required to avoid recurrence o'f a similar nature. The interpretation of radiographs is always subject to be questioned after the fact. The review as required above will assure that if any ~ problimatic questions with existing installations are present, they will be corrected. "..) s NOTE: De individual mentioned above is no longer employed by M. W. Kellogg. I-e q , e e 9 6 g e )
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,. i.~.; ~-.. :.., -'~---v.,.. ...... ~ -... O w u m v -w.u.g ... v - gggy ~ April 15, 1977 gg /./77 g r 1 7 o a' / A $ Mr. R. H. Engelkon, Director 4 Office of Inspection and Enforcement N 8f T TD" Region v _ MOT l U.s. Nuc1 car Regulatory Cc=:nission - 1990 N. " California Eculavard . suite 202 Walnut Creck, California 94596 Docket No. 50-275 Unit I j l.- Diablo Canyon Site ~ Dear Mr. Engelkons on March 18, 1977 we notified the Office of Inspection and Enforce =ont, Region V, of aMe,fect in a pipe discovered during tatting,at Diablo'can' yon, which is table under Paragraph (e) (iii) i of 10 CFR 50.55. This letter is a preliminary written report of-the i cituation; On March 17, 1977, auring heatup for hot functional testing, l - a sr.all leak was discovered in the weld joining steam generator 1-2 facdwater nozzle to tho feedwater pipe. Testing was stopped to investigato the' cause and to repair the leak. .n The area of the leak was examined by nondestructive cathods which revealed that there was a thrcugh-tha-unil c: ack and that it was A 16" long ' piece of pipe, which included' confined to the leakage area. that portion of. the steam generator no==le weld containing the crack, l l j . was renoved f=cs the line. A 41/2" long section containing the crack wr.c cut from this pipe and delivered to PGandS's Departcent of ~ Engineering Research to be analyzed to determine the fciture mechanism. l The investigation is still in progress. A. comprehensive review of the weld history has been performed l including. 'the veld procedure", welder qualifications, heat treatnant l*- r* O o . e
./. e r cords, material certificat ons, nondestructive examinations, and -watcr chemistry associated with the functional testing of this squip= eat. The rendts of these investigations are still under analysis. Repair of the feedwater' pipe was made by replacing a 16". 2 angeli, of* pipe having' the same specification and physical properties as the original piece. The original weld procedure was used.with [ mi'nor changes to preheat and postheat requirements. ,Ultraconic exeinations conforming to ASME Section XI were perfor:::ed on the four main steam and the other three feedwater to cteam generator nos:la welds.,'These er.a=inations revealed that there E . ware no rejectable indications. We will sub=it, as soon as possible, a final report ~ docunenting the failure mechanism'and our intended. corrective action if such action is determined to be necessary. ~i -l t .o 1 Very truly yours, s p '~ ~* Philip A. Crane, sir.' t s t PAC / l cc: (3) Director of Inspection and Enforcement i U.S. Nuclear Regulatory Co--- 4ssion -
~
Washington, D.C, 20555 J p l. l-l f s t L f *. * * ', 3p e Q'
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4 EY.th61.7 6 "TD m 5+ [ .-g?: % 3 G and N, a'. f - = s Pacyie Gas and Electric Cennpany ; .{ .(,- s- \\.* \\ *,, - 1 r_ 4 1 ~. FAILURE ANALYSIS OF CRACXED FIELO WELO NO. 212 O!ABLO CANYON UNIT 1, STEAM GENERATOR 1-2 z / N0ZZLE-TO-PIPE WELD 4 f~l'27 ) ocme umoTo a,, p, ) mi DEPARTMEN" 0F EN 31hEEING RESE.303 a E ~~.~~:~n,-.,,, w p p b -' : : : : a../*. i-l ..JJi'.l b h. t-I p, g ;0 7.,,;. e o.- RECEIVEO i t s# t g cc .c r, u.n- - ce mu e::#-- j w, a.,... - h^L i Y / 77%T0*Y0 O
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Report Issued: Report 411-77.55 O PACIFIC GAS AND ELECTRIC COMPANY DEPARTMENT OF ENGINEERING RESEARCH B o) FAILURE ANALYSIS OF CRACKED FIELD WELD NO. 212 DIABLO CANYON UNIT 1. STEAM GENERATOR 1-2 N0ZZLE-TO-PIPE WELD o) p ~ l o D Prepared By: Approved By: l
s. p ru sonica, ens,neer

v. c. m,,r. = canurgicai enge.
(W. ,..m.e.,,.ey C. 71, .. s. . e.,, ee, b u C b'
0) n; port-411 77.55 O TABLE OF CONTENTS Page LIST OF TABLES........................... 11 ,) i LIST OF APPENDICES....................... : 11 LIST OF FIGURES 111 SCOPE 1 ,) INTRODUCTION..................'.......... 1 ,'ABRICATION AND SERVICE HISTORY 2 F Material Specifications.................... 2 3 Welding and Heat Treating History................ 2 Service History........................ 3 RESULTS OF METALLURGICAL EXAMINATION................ 4 CONCLUSIONS 6 RECOMMENDATIONS 8 i TA8LES AND FIGUR ES........ 9 ).. AP P END I CES....... '...................... 22 W 8 I 2D e 9 I i
O i l Report 411-77.55 3 i LIST OF TABLES Table Page i Fabrication and ' Service History (Sumary7........... 3 9 3 9 LIST OF APPENDICES Page g I. Material Specifications.................... 22. II Hot Functional Testing Schedule...... *.......... 34 III Analysis of Electron Diffraction Patterns........... 37 >) p p S 4 11' f \\
O Report 411-77.55 g LIST OF FIGURES Figure Page 1 Sketch of spool piece and crack path and shape of crack 10 2 Fracture surface, overall view................s 11 3 Fracture surface, area of SEM examination 12 4 SEM photographs of main fracture surface........... 13 5 Polished crdss-section of the main fracture 14 6 Cross-section of secondary cracks 15 7 Polished cross-s.ection of secondary crack 'S 8 Details of polished cross-section 17 9 Opened crack (secondary)................... 18 10 Microprebe spectrum of steel matrix 19 11 Microprobe spectrum of oxide in crack 20 12 Microprobe spectrum of inclusion stringer 21' 3-111 ) ' -. :~._; :: s; Q.;3g __
9 Report 411-77.55 SCOPE 3 This report covers the metallurgical investigation of a crack found in the pipe-to-nozzle weld of feedwater line of Steam Generator 1-1 at Diablo Canyon Power Plant. Based on the findings of thiis investigation, b recomendations are made for modification of the welding procedures, fabrication practices, and inspection of future welds made in P-3 nozzle materials. k INTRODUCTION On March 17, 1977, during heat-up for hot functional testing of p Unit 1, a leak was discovered in the nozzle-to-pipe butt weld joining the 16-inch diameter feedwater pipe to the No. 4 nozzle of Steam Generator 1-2 (Field Wald No. 212, Line K16-555-16IV). The lina temperature and pressure at this time was, approximately 300*F' and 90 psi, respectively. Visual observation at this time revealed an intermittent linear indication t approximately 3/8-inch long running in the circumferential direction near the center of the weld. During grinding of the weld crown flush with the l pipe surface the length of this linear indicati' n increased to o l e, approximately two inches. Subsequent nondestructive examination by h radiography and ultrasonics revealed a crack with a total length of approximately six inches. As a result of the above findings, a spool piece containing a. major portion of the weld, a saali section of the nozzle I.O. adjacent to the weld root, and several inches of pipe were removed for analysis. Figure 1 is a sketch of the spool piece received for analysis; included is the ). crack path and a sketch of the shape of the crack. i )
9 2 Report 4T1-77.55 3 FABRICATION AND SERVICE HISTORY Material Specifications The steam generator nozzle is fabricated of ASME SA508 Class 2 9 material. A copy of the original Material Test Report and a chemica.1-analysis performed. on the nozzle material adjacent to the crack' are included in Appendix I. The chemical and physical properties for this D' material are within the limits for SA508 Class 2 material. . The feedwater line piping is fabricated from ASTM A106 Grade 8 A' copy of the chemical analysis performed on this material material. 9 adjacent to the crack are included in Appendix I. This analys'is shows that the pipe material meets the chemicai requirements of ASTM A106 ~ Grade B. 0 Welding was performed using E8018 C-3 electrode. A copy of the original Certificate of Analysis for the three electrode lots used and a check analysis taken adjacent to the crack are included in Appendix I. p These analyses shcw the material to within the chemical requirements of E8018 C-3. Welding and Heat Treatina Histcry Welding on Field Weld 212 was.done in accordance with M. W. Kellogg procedure 200. The weld traveller and other Q.C. documents were checked along with the temperature records for preheating and postweld heat h s treatment for compliance with this procedure; no deviations were noted. l l The weld root was placed using the tungsten inert gas method (TIG) with a I consumable insert and inert gas backing. Two TIG fill passes were put in j o i the weld was completed using shielded metal are weld. The weld o
3 3 Report 411-77.55 preparatiert was preheated to 200*F prior to welding. Welding on FW 212 9 was done over a time period of saveral weeks; Table 1 is an outline of' this welding history. Postweld heat treatment was performed at 11500 ; metal temperatures F 9 were monitored on both the pipe and nozzle sides of the weld with a thermocouple placed several inches from the centerline of the weld. The temperature records were reviewed, and during heat-up there was an uneven 9 heating rate between the pipe and the nozzle, resulting in a maximum temperature differentiai.of 260 F, where the pipe was at a temperature. 0 0 0 of 680 F when the nozzle was at 420 F. This temperature differential 3 was. rectified and no further probless were; encountered throughout the postweld heat treatment. Radiography of this weld was performed after completion of welding -) - but prior to postweld heat treatment, an acceptable practice uncer the governing construction code, USAS 831.1.0-1967. Review of the radiographs showed a slight density gradient in the region where the crack occurred, but it was not judged to be rejectable nor would it be interpreted as such If this indicatton in actuality is a crack, it is at the limit of now. detectability. Service History Prior to making FW 212, a. cap wgs welded onto the feedwater nozzle of SE 1-2, a'nd a hydro test of the steam generator was performed. Subsequently, the piping hs attached and two more hydro test cycles were performed, fq11 owed by a hot functional test program. A second hot t functional was underway when the leak occurred. This sequence of events is susuarized in Table 1, the hot functional testing summary is in ) Appendix II. 1 -
g 4-Report 411-77.55 9 i During the period between the hydro test following weld completion, August 29, 1975, and the time the leak occurred, March 17, 1977, tne system was filled with water under chemical control to Ifmit corrosion or other damage to the piping or steant generator internals. The water chemistry records were reviewed and no abnormal conditions were noted. 9 RESULTS OF METALLURGICAL EXAMINATION The surface of the main fracture was almost flat, originated along the edge of a weld bead, grew approx'imately perpendicular to the surface and contained markings that ran parallel to the original edge, Figures 2 and 3. These markings appeared 'to be "beachmarks" denoting positions of the crack during its growth. The fra'cture surface appeared to be oxidized .) and was dark in color near the origin edge. Using SEM, the main fracture surface was found to be oxidized, to exhibit seme evidence of mechanical danace. (rubbing) and, at a distance from the origin, to contain secondary cracks Figure 4: The presence of the visual beachmarks and the secondary cracks indicate that cylic loading had a role in the generation of the fracture. h Examination of several polished cross-sections taken through the , crack showed the fracture initiated in 'small regions of lack of fusion along the fusion zone and in small, up to 0.015-inch deep, cracks at the root of grinding scratches adjacent to the fusion zone on the nozzle side of the weld. The crack propagated through t$e heat affected zone and then through the weld metal in the V-shaped section of the weld, Figure 5. The crack cross-section in the heat-affectec' zone was very flat and straight, i indicating l'ttle ductility; once into the weld the crack tended t.o branch
F 5 Report 411-77.55 9 and wander, indicating a material with more ductility. The heat-affected zone in both pipe and nozzle materials was tempered martensite, the pipe g material away from the weld was mixed pearlite and ferrite, and the weld material'was tagered martensite. Microhardness tests in these various regions, converted to Rockwell hardness values, were as follows: nozzle, g away from HAZ', R 96; nozzle HAZ, R 34; weld root, R 23; pipe base g g material, R 88. g Examination of the small cracks adjacent to the main fracture, g Figures 6, 7, and 8, illustrated that the cracks originate in slight depressions in the surface, grew perpendicular to the surface and at an oblique angle to the rolling direction (as revealed by the inclusion g stringers), were filled with oxide, were transgranular, and exhibited some crack branching. No evidence of plastic deformation was observed. EDXA microprobes verified that the material in the cracks was probably oxide. g , that the base metal was carbon steel, and that the inclusion stringers were manganese sulfide Figures 10-12. ~ Two small cracks were opened up for examination by impactt'ng them at liquid nitrogen targeratures (Specimens 2 and 3). The fracture surfaces k had a dark layer of oxide patches along the outer edge, Figure 9, and were in close proximity to weld heads. Each crack was actually the result of the coalescence of many cracks each having its own origin. The origin edges of the fracture surfaces were covered with a relatively uniform oxide layer. The oxide layer was present all the way to the tip of the prior existing crack. ^ f
9 6 ) Report 411-77.55 Using the plastic / carbon replica technique, the details of the main fracture surfaca were examined in the TEM. The surface was again found to g be completely oxidized; however, in some areas, the oxide formed parallel ridges which could possibly suggest prior fatigue striations. In some areas, large block-like oxide growth was found. 9 Extraction replicas were examined in the TEM to obtain the diffraction pattern of the oxide. The patterns obtained were analyzed, Appendix II, and found to be composed of a-Fe 0. 23 This oxide forms at about 3000C (570 F). 0 CONCLUSIONS The characteristics of the small cracks and the major fracture ) surface are similar'in regularity, orientation, oxidation, and degree of crack branching. The oxide extended to the tip of the advancing cracks indicating that oxidation and/or corrosion was an inherent part of the 3 c, rack growth. process. The characteristics of the fracture process; i.e., transgranular, oxidized, no plastic deformation, with some crack branching, indicated that the crack growth mode was either corrosion 4 P fatigue or thermal fatigue. The oxide resulting from ' corrosion fatigue would probably be hydrated and a lower temperature form than found on the crack surfaces in this f study. Based on this and the closely regulated water purity, it is believed that it is sera likely that the cracks in the feedwater line of Diablo Canyon Unit I steam generator resulted from thermal fatigue. The ) cracks initiated in elongated depressions in the surface of the steel which ar's believed to be grinding marks, and appar~ently acted as local stress risers, and at minor regions of lack of fusion in the weld root.
Q ~ 7. Report 411-77.55 D It is believed that small cracks initiated on the I.D. of the nozzle, weld, and pipe during the thermal cycling that occurred during j preheating. These saali cracks originated at convenient stress risers' P such as grinding scratches and regions of lack of fusion and weld bead, rollover. At the time of acceptance radiography, prior to postweld heat treatment, these crackt were below the limits of detectability for radiography. Upon heat-up for the postweld heat treatment thermal stresses from the uneven heat-up between the pipe side and nozzle side of the weld caused several of these small cracks'to link up and grow to some substantial size, most likely through the heat-affected zone (HAZ) and into the weld metal. The HAZ at this time, prior to postweld heat treatment (PWHT),.would have consisted of untempered martensite, and have ~ a hardness of about R 45. The HAZ.would have quite low ductility in g this condition and easily propagate an existing crack when subjected to differential thermal stresses. Once this crack had propagated to a substantial size during PWHT it propagated to failure by fatigue as a I result of subsequent hydro test and hot functional test stresses. i Since postweld heat treatment of the weld has tempered the heat-affected Zone, this high hardness, icw ductility condition no longer exists. The heat affected-zone now har a. hardness of R 30-35, and g would not be expected to be subject to the rapid crack growth that is - c. believed to have occurred during PWHT. e O i ,n ,,n.- ,,-n,.,
3 8 Report 411-77.55 3 REC 0letEN0ATIONS Based on the findings of.this investigation, following reconnendations. are made for future welds inade in P-3 mate 1. Specify a. minimum preheat temperature of 250 F; a maximum 0 interpass temperature of 550 F should also be specified 0 2. Maintain the preheat-temperature throughout the weld and untti ) postweld heat treatment can be initiated. If a long delay during welding or between weld'ing and PWHT is unavoidable, maintain the prehea least eight hours after welding stops, and then slowly cool to room ) temperature. dareshouldbeexercisedinavoidinglargetemperature, 3. differentials during preheating and postweld heat treatment 4 Final radiography should be dor.e after postweld heat treatment 9 1 i ~
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O 9 Report 411-77.55 3 TABLE 1 Fabrication and Service History (Sumary) 1-14-73 Preheat to attack lugs 3 '1-14-73 Preheat to weid cap '1-15-73 Preheat to weld cap 2 19-73' Hydro,1356f at 106'F ' ~ 3 4-8-74 Preheat to remove cap 4-9-74 Preheat to remove cap 5-18-74 Preheat for nozzle-pipe weld- ~ D 5-21-74 Preheat for nozzle-p'ipe weld 5-22-74 Preheat for nozzle-pipe weld 5-23-74 Preheat for nczzle-pipe wald S 5-24-74 Preheat for nozzle-pipe weld 6-15-74 Radiograph finished weTd 6-24-74 PWHT weld d-74 PWHT adjacent weld (15" away) 899-75 Second hydro, 1320f at 88 F 0 8-29-75 Third hydro, 1356'at 88 F 0 l9 12-13-75 First hot functicnal to 2-10-76 3-16-77 Second hoc functionai e p 46 6
10 Report 411-77.'55 l f *'i'*" #$ ,g s. h \\, i .k ~ S er. tra * [ p b ac$ure fkeu /YAI - ? of' na2.zle mahnal. /}licrc [< con ik : naog also.. f ~ 1 b 1 ( Figure 1. Schematic diagram of failed nozzle illustrating the locations from which senples were removed. s. e O D
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1 i 20 'N Figure 11. EDXA microprobe spectrum obtained from oxide in crack in Figure 8. T i t T, - j.... L. l .. l [ l t _. L.. i. I- ._ i. 1:... m I e l l n; f. j _ I._. ' j. a p ct I i %.m. i i c 8 -} l-t t i.e [ l. l g....: .' 43.;......:.. 4- ...j. _ j... 1 l. -l l I ! i 1 l":. (, ce l ci... -. j,,.. i p gl 1 ' l,,. :..}ii. i iI i . I.:I. I I I ..a- .s.. - (: .T.,' i.. l 9 I
47
.:t Pe a I. .(' ff j ' j. g } d '~ l-2 r-1.3 -s- .e l ,t 1: c et 4-l . i.:... g. .l.-; i:i. l; p' 3,, i ..,... i. 3,.. q... .. ; :......t... ....a: g i x
d. :4, I
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..

F :.- i- ! l
.39 2.% .J. . +- I! t ,p !:l j. .,. g
N 4
y, .l i g .a, g .p. l .. l..- ..,[..........i. .I..: i -.7. .i i i.... i_. s i i g ..r. y *, In :. .g I 6 l - 3, t C iL l .(.
-fi'@-
1l - .-l t C* 'f. f - ).'. i ^ l I l 2 g: f.
.i.
eg 3.. j,.
8. ::. l. :..
t . j ,g. .g.. ,l
h.
1,. l, : t. l.. l i w_ _e, se l l c .C ...j {. l j. _7., .... i. ,g ' i l l 3 { ,8,R,, l_ i .i.... g =.....,i .m ~ i .I ...l..=. l....!. w. ....l.. ..I i r-- m. i: l l t = t ...{..._. f i l h I if - ] a . r. gb -,G.iP ..s'.. 3.. ...l... o"* i l. .......i........I _. i 8 0 l l l!. i .,t....3 8",*_ w m. m w j6.i, .mw . ;......g_...1.....- . t..... .1....,. r t m. u i l l l l . i ..).. ..t. a i I M. 9. .i l . i. .. L.,
....... L..
i t.. i i i i i .=
=,- $
w: ~ [ g g ..i. .i.. s _h, m .__.a... y _
]
4
i ;
t 8 i b I g .C,.., ,.......i. .. l".._. ! j .l..... L _ l - 3 'a- _u.. _ -
l 1
s p ....r a I
i..
.l 1 u. + i e v>. =.,.,.7....,... ... o.... ..Q4 x, ., _... m.o. g..n. i .3 e i o. =, q l j i 6 m i. .4. i x s... +
l.....,.
g r 7...... l-i
1 i
l l g p g l l -f .,l p l i-i .n, p i ~ j. g Q, [- 'l r-t . l..... - - - Of l
J 3,.is i
i.. . l' -..!. i ...i ... l, l .. l... ....,......l.._t..... l __i._. 'I i -i r.! i ! '. l. - i t v,. r ...i..,o.,,,.. .. p. .. 1. : L ..,i_.. . 3,. t.. _. i. e f. .l-t i i i i 3,.es i i _ _ _. _ v @( i i. .,.a.. ... s.. j ....,....i i .. j... ;. o i e o ... = q (squnos y g g : stems tinJ) stuno1 uotoyd tes*x tetoj, u.
21 Denort 411 77.55 Figure 12. EDXA microprobe spectrum obtained from inclusion stringer :;ure 8. l ...l....e.. 6 . I.. ..T... i i l ' i i i I N i I .. i . _..p
t.... :[. ;..

p:
2J. p: -l
L i
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_.l.
y ..;,..{. , l.. p.- _ -l. [.. : 1. - 4. i. i ..t.*
n t-I I
e J,, m, l-l i .l l 1 h i.. T I; l' C I y' m. e c 'r: l i..~.. '. . 1 :..,7-
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. m.. :- :t: I. : I: r i . e c_ b e n i l d ~* -1 .'-l 8 I--+;-l.i'. [:
...[r g
.j'. 1:: I j (- H b 4 n. ~ ~ ^) .i. C. . l? '
: p. :
.c.g ( ' 1.:.l..p.. [ l 3'
l 1.... :.
t,, ^l~ I.
._4._ [:.4._
J h ..t-l .j. bl 1. i 't
1..
. I :i., l. '...
l..._.
x
... l.. p-1.;: :
,3 g ...Im
i:
g... ' ' :' l'! tu "d.4-i..L5t 8 t-l- i I l i .. la.._..; _ w.4 I.... l.... ;._ l4 l t ! :: t -l i-z. l.- ) l l @N ....9l;..l.-___.__........-..[...['j Ng 2 l . l i. i p.___..;..... g 2 "g'5 i j g. l _= Q .u u,
1.
1..;: 8 - -.::j..: t..a... b_:_~ '.... y - - i j .7j: ...i. g
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7, 3,. ; i .ig ; v, i. y ,. i l ..i} j. c. __.c
_ _ a... __.:
'. l t , v5* Cd r i ir I.,i 6-i f. .i t t a - _. t t ,a._a_._........__.. p. y3_._. [.. t i- - [: r- ' [. .M i .} !*] i :. l ':l l -l l' -t i [ li x o iit .. _ l..f'.l ...r.. ._.i..
l
.._l_- . b. b . b y Y. gg t. ..)- l: -. ne r-4s _e._.a a j ( g....,. P"'* '._..l.. .j,,,,.i. ........ i.. i I. l. ~~ a. C2 i g 3 .j.M M* 5 i= l l ~i- ...i. '. j:. ~ l i .:..1 1 ); 6 wr. y l f 5
l' f
,, i g ? l i @.b ..L 6 3 l .l. .;pQ;- 8gE_. , i.. i.......! _l _. c e ,j. .I
i i
,7-0 I Ei_ -.7...,.. ... 9 .. g ..e i 9 .I i s i t. ..l y , i, i c m - w .__.a.... 4a j- [ i. i a g-m. e w -.g p. .g g ....:....g " .f ..l.. .ik,. .i.. y 1 6 i, c.- i l i H \\ i s' I a .. : _l _.. _. I._ .. _.._.L: l x .. L,... . l' s = i.. ........t.... s I 8 l g 4i t t._ = l.. j 1 l 'l i i 6.1 l l p ? ~ I -l C' .j. ta + r j - 6.. r v, o, ..t*-
- ! i 1
m 1: .; a _. _. p...._ _ _-. j. i i i i ....i,..._,.....: ...i. _.a..y_.; . g e
s. -
j - a 4 i e l _a ' .= 2, c i C ...I.. ....t. (,) w :g I r,. L.t . ! y._..,. 1 _g _ u. I i t I e-gl l i i 1 ~. , g,,. i 1 g g ..i .g. .'m x' ....t.... ., _.1_ ' 7 .l 2.!...:) ..i.... .L:. p.p., h..i.. I. .. l.. l. ' Q' _d. i. .4. '2 i i I I I j y ..... i ..f... l.. . I... h. 3 ^,,, ! ~
a.....
l I I 1 i l ~ ~~
7 s
p o =m 1 g 8
i. -- -
n = e .e I. 1-
t. -~ -
) y-w vr ( ......l_ ._.J..;.. v t 6 i. j.. .g y.p. .. a.. ..p -1 i-l i I i i _a iq (stunos g
stros tin 3) stuno3 uoteyd Ath-X t#101.
w o
7 Repare 411 '7.55 9 ? APPENDIX I L Material Specifications and Welding Procedure h 80 e O
5, c,0 - .p--- ...,..... c a....;...... y; .9. g g; e '~ ?..:y.,_. g l 3 ;g. x ;.. g y g ;.; y ; g.y h,,.a.m_a - c. t
,^
~ u.u,,, ea,, a vaw,,~sM - r % 's ~- 5 MATERIAL. TEST REPORT oxyg,_ n c g o. - is 6 L {. s.'. m.. r, n,. o,4., No. g e pu,16, venu h.. no,tria ca u. N<** M N "N G oi n, c _ v c.e i c.; ro,. _ os.u;noi.,. o,d., No. t o , c.. c..se 4 Taco o Lsee Me AT ett ro*0'.ese ao as a ' = ^ *'a' v'* ., v. ..ouer caos no. 1 1 1h.75* I.n. Incart Stud Feeduster SA50s-a 4203vu holais 16500F 250F.11tr/in Air Cooked. Nossles por/ Dug. 870C217 1560 art 250F.litr/in water quccoh 1 1290 F2 250F.11tr/in Air Cooled. 0 T 0076 15 eor: 250r.uic/in v.t., 4.. w 1290*F 25'r.Ilir/in Air cool d. Tests Strcas Reloived Ats 11250F2 250F. For 20 Hours. CHiteeCAL AafALV54$ Ateo uSCHA8eeCAL F#0PERTess hermarcats arTacaso es.m ano l usas so. no. J e mes e e se en =a wo y u.v.
u. r.

o. e.
asumars m t U . kola he 42Q39W 21 .79 012 012 27 . 31s 80 68 .of Ladt, I I ~ ti. . top .79 005 015 .29 .37 80 .57 01: ch.e c o iv. a... 3o y, i ACT tests SWW D 3 . Tsusste vasto eLows. m s.a. usAt Tes.t p r e,+same ten e. essasete ess.teos an z-m
s. w.es.
antase see.mt SAveaat ei e.sa.1 msweam n. see. l o Lolab 0203vw mean Tea,. oP. 93.000 72.500 21.5 6h.9 92-109.111 .o67. 078.0aa ew-90 gaan P3 100 73.hoo 21.5 60.9 106-3c14-103 .o7h.o76.o73 85 90 85 I r. 0 Mh i. c
24 Report 411-77.55 ~ 5 CHEMETRON CORPORATION [d :h [ wsterne rneouer eivesien Certificate of Analysis .4 M. W. Kellogg Co. Customer Crder No. _ N/A c/o Pacific Gas &' Elect. Co. Daiblo Canyon Power Plan: _ Ceder No. 6285.3 Avila Bear.:h, California 93424 Shipped 6-6-73 ~ o* This meterial conforms to Specincotion _ AWS A 5.5-69 Jest Nc. 415
/X-Ray Satisfactory E 8018 C-37 Type F-7177-1269 Item A Trade Name:
/ Atom Arc 8018 ~ C Moisture @ 1800 F 0.2% aismeter Sizei 1/8" Concentricity 3% 000 lb. Let Number C315c3An Type Steel A-285 test Numbers /402K992.1,. }, Test No. Full Split Volts Amps Corban
05 /
""8"".e s e 1.01 ' Tensile & Chro*'"" Lmpacts 1 6 22 140 Nil ' Nickel .96 / 3' s:i:ca .58 ' Test AS Cilvmbium Results: Welded Tantelum %iyhdenum
12,
Yield 76,400 # Tungsten Tensile 87,500 / Coppe' Elongation 31% . Titanium Red. of Area 76.7% /- Phophorus .017 / Charpy V-Notch Impacts Tested C -40 F. Sulphur - ,018 - venodiva .02 ' T.mpacts 7 9 ', jr.. Impacts 84 # 73,,;,, Impacts 87 I j A P P R O V F. D M. W. KEL.I.oGG
o. A.
Ints cf Penna. ) P.S.St. Sietfo cassee Puesent Cou:ty of York -) 78J #-2 I"7I
". thot this repori is correct end that no sign #.. cont change hos
-$4bscribed and sworn to before m' been mode in any of the elements described
nis 22nd doy of June 19 73 in tho'quolincotion opprovol.
/ / s CHEldr*T.tcit CCRPCRATION W,Yv %.' f wetosuo moosers envisio. Q w sH l t t.o:.,, A -y comm s: 4-12-76 sy _ / _R. Stallr.wn =
25 Report 411-77.55 3 CHEIAETRON CORPORATION r") 8' J wei.ne a *acovere civi.io. Certmeate of Analysis M. W. Kellogg Company cuitemer Order No. 6520 c/o Pacific Gas & Electric Power Plant Order No* 65365 7 Miles N. of Avila Beach Avila Beach, California 93424 "jg 41 - 150 5~ 33;99*a 9-21-73 q This meterial conforms to specikation lW._S A 5.5-69 Test No. 650 /X-Ray Satisfactory Type E 8018-c3 h Trade Name: Atem Arc 8018 Moisture @'l'8000F. O.2% ~ Concentricity 3% otometer size: 1/8" Type Steel A-285 400 lb. - Lot Number: 4 328C3AD Heat Numbers 627233 f Tensilo & Impacts 1 6 22 130 p i M eng u ese .93 ' Test AS Chrom; .05 Results: Welded 1.07 'j Nidel .40 Yield 72,400 / Tensilo 86,000 / Colvebiv" Elongation 31% Tentoiva Red, of Area 75.0% Molybdenum . 15 / Tungsten Charpy V-Notch Impact: Tcsted 6 -40CI'. Copper 76l Tireniv. Impacts / Impacts 77 i Phosp,1)orus 014 / Impacts 78, swipher 022 .02 ' Fillets: OK# Vertical 1 Overhead I fren Ferrite } 3ppnovCO _ l - u. w. KC'AC"
o. A.
,, g p u cies**f'*i'd 3 ' 'i Pm
ss f g. 3-7 3 The vndsteigned certifies that this rep:rt is
,,u. s . correct and that no ugnMcorit change has Subscribed and sworn to before me _J been made in any of the elements desceibed
ii.,q,,1;&,,;,n opp,,,g, this 25th der of Sept.
1973 / 'CHEMETRON CORPORATION y 1 /AR3 sua f'af>yQ ~ \\ % e.m y
sE'aisge pares:
kd.,i. ,y l 4-12-76 gj
26 Report 411-77.5 ^@e CHEMETRON CORPORAil0N 27 wEbotN4 PeooWCTS Osv.Siem Certificate of Anclysis M. W. Kellogg Co. Castomer Order No. I 7177-2373 c/o Pacific Gas & Electric Diablo Canyon Power Plant Order No. M2_2 Mark: PO F7177-2373
7. Miles North of shipped 2-20-75 Avila Beach, California This meteriel conforms to specification.AW_S A 5.5_-69 _ & M. w. hclloqq Spec.
Test No. 558 B31.7 SFA 5.5 Cluss Il X-Ray Satisfactory Type E 8018-C3 ! 3 Trade Name: / Atom Arc 8018 Moisture @ 1800 F. 0. 2;6 0 Concentricity 456 otometer size: 3/32"' Type Steel A-285 200 lb.' tot twumtier: iLg6g Test No. Full Split Volts Ampn HcotNumben 640912l Carbon .04/ Impacts' 1 7 21 140 . ll Manganese . 75 ( Test AS Stre[s Chromium .03 Nidel + 91 y Results: Welded Relicved s 0 3;g;c, .20 / 8 hrs. @ 1125 ?. Columbium Yield 72,100/ G8,500 ' Tantalum Tensile 84,500/. 82,100 / Me:ybdenum
04 /
Elongation 30% / 3 2?f, ~ Red. of Area 77.5% 79% .aungsten copoer .03 Charpy V-Notch Impacts Tcstod C.'-200*'. r ..ran,un Phenhows .016 / f Impacts 96-109-110-112-85-99 100'-103. Sub:nur .015 / 117 venedium .02 / Lat.Exp. 73-76-83-79-e< /l-84-79-78-7 % Shear 90-85-90-85-00 75-70-80-80-7'. r,en Ferrite Fillets: CK vertical 1 ov.rhead 1 Stree of Penna. I g gern C:wney of York ) The undersigned cerrines that this rener s correct and that no signiscent enense hes O. A-been mode in any cf the elemenes descrihef subscribed and sworn to before me p.t&L p tW in the quotincetion opproval. th'.s 25th d*Yof Feb. 19 7)# W n CHEMETRON CORPORATION ws6aine Paeowcts caveseca $2AL \\ A Dh % r.ws 5 My commission empires:3 21 jg BY _N R.u. ww >/M ~-
27 iteport 4: 1-77.55 LA80RATORY CERTIFICATE ANALYTICAL Anamet la aoratories) Inc.' ast?ALLusHB8 CAL l,,,,, m,,,,, ~ - - " ' - . ~........ _....... m - -, May 25, l'377 LABORATORY NUMBER: 577.329 P.O. No. LO-879806 SAMPLE: One (1) Sample for Chemical Analysis MARX: P-12 B DCPP #1 Steam Generator Nozzle Tailure Analysis DATE SU".".!TTID: May 24, 1977 REPORT T.0: Pacific Gas & Electric Company 3400 Crow Canyon Road San Ramon, California 94583 Attn: Mr. Steve Ivy CHEMICAL ANALYSIS Requirements A-508 C1. 2 Min. Max. 0.27% Carbon (C) 0.23% Chromium (Cr) 0.40% 0 25% 0.45% hanganese (Mn) 0.81% 0.50% 0.90% Molybdenum (Mo) 0.58% 0.55% 0.70% Nickel (Ni) 0.80% 0.50% 0.905 0.025% Phosphorus (P) - 0.009% ~ Silicon (Si) 0.28% 0.15%- 0'.35% 0.025',' l. Sulfur (S) 0.012% 0.05% Vanadium (V) 0.05% r Respectfully submitted, ANAME LABORATORIES, INC. O,! r. [ By ar j 3c Si[gfrJ:fd atto. 4 ja Manager, Testing.
LABORATORY CblFICATE Rep n 77.55 ~ A N ALYTICA4 Anamet ?_. a b o r a t o r ie s, 'nc.' . :a. .A,u.. May 25, 1977
vsecac v. m g
LABORATORY NUMBER: 577.329 A P.O. No. LO-8795 SAMPLE: One (1) Sample for Chemical Analysis MARK: P-1 DCPP #1 Steam Generator Nozzle Failure Analysis DATE SUBMITTED: May 24, 1977 REPORT TO: Pacific Gas & Electric Company 3400 Crow Canyon Road 7 San Ramon, California 94583 Attn: Mr. Steve Ivy CHEMICAL ANALYSIS Requirements A-106 Gr. 8 Min. Max. Aluminum (A1) 0.03% Infornat ion Carbon (C) 0.26% 0.30% Chromium (Cr) 0.14% Information ~ Copper (Cu) 0.10% In formation ' Manganese (Mn) 0.90% 0.29% 1.061 Molybdenum (Mo) 0.04% -Information Nickel (Ni) 0.07T Information l. Phosphorus (P) 0.015% 0.04S Silicon (Si) 0.25% 0.10% k i Sulfur (S) 0.033% 0.055 Titanium (Ti) 0.003% Information l Vanadium-(V) 0.003% Inform.* tion I Y I Respectfully submitted, I ANAME 1 LABORATORIES, INC. By
s *M Il4
O f 3c S ie'g fif,.ed Ot to I j je Manager Testing _. o
29 rt 411-77.55 LA8 ORATORY CERTIFICATE Anamet a aoratories, .. n c.. ' 4 avnew
'"L m -
4se -=..asr. ..us,...,.....,,. asoa ramas=*ruas APPtJSO ASSSAACM May 25, 1977 a" men reevine i LABORATORY NUMBER: 577.329 B P.O. No. LO-879806 SAMPLE: Two (2) Samples'for Chemical Analysis MARK: Weld - Side and Crown DCPP #1 Steam Generator Nozzle Failure Analysis DATE SUBMITTED: May 24, 1977 REPORT TO: 7' Pacific Gas & Electric Company 3400 Crow Canyon Road San Ramon, California 94583 Attn: Mr. Steve Ivy L> CHEMICAL ANALYSIS Side Crown Aluminum (A1) O.005% 0.004g Carbon (C) 0.08% 0.06% Chromium (Cr) 0.09% 0.06% Copper (Cu) O.07% 0.08% Manganese (Mn ). 1.17% 1.06% Molybdenum (Mo) 0.15% 0.12% Nickel (Ni) 1.00%, 1.03% Phosphorus (P) 0.013% 0.012% Silicon (Si) 0.55% 0.60% ~ Sulfur (S) 0.022% 0.022% Titanium (Ti) 0.01% 0.01%- Vanadium (V) 0.03% 0.02% Respectfully submitted, i ANAMET ABORATORIES, INC. A t i By .i. d - / r\\ -3c ManagergdOtto Siegfr I ~ ja , Testing f w- -w-
1, t i M. V. KCLLOCG CCMrANY 30 Pass - I of 4 ~ Report 411-77.55 % Divi.:lon of Pullr.icn incorporeted Vuld Fr.>cedure ccd No. 200 ) 2:tilng Tabricaticn Spec. flu. Pl?h-PI-KI-rf.-9At p._ U llis:asport, Pa. 17701 Datu ll/14 n 3 Revis ion Dates _4-/c-pr '00CDU.ttSPECIFICATIC!lF05: Carbon Steel WE7. DING PROCESS: 'llie veldinc shall be done by ' thn GTAV insert root and SMAW wcidout l> recesses .;ng to Nickel Steel piping, insert weld- .using ennual equip =ene. The GTAl? pecccus may . GTAW (root) and SMAW (wcid out). l be ured with the filler metal type listed on ASE F.ETAL: The base metal shall conform Pace 2.for 1 iter:iictene voide, look-in holes inc specifications for ASME, Section IX, (peep holes) in the ring, or mismatch in the t's to P-1 materials, root set-up. M necessary, une complete pass may be rede chile holdin;; che purge.. craw LLIR METAL: The filler metal shall con-whlding shs11 be done usin?, a'non-con unable .i to ASME Filler Metal Specifications Num-electrode of 27. thorfaced tungsten. D?n!-2. SFA-5.5 and SFA-5JS for ferrous filter ~ J Al In Group Number F-4,and F-6.. . BASE PATERIAl. THICKNESS: This prccedure , is quellfled to allow welding of meterial cheulcal composition of the weld depos. thickness between 3/16" and 1.5" (neat shall fall within the limits of wold Metal treated). j . ys is N.mibe r A-12 b. PREPAPATIOH OF BASE' F.*.TEP.!AL: The edges S FCR TCRCl! SHIELD: Noel,nal composition or surfaces of the parts to be julr.sid by l rgon, 99.995% minimus purity (for GTAw welding shall be preparcel by flas.ie cutting, ; css). , plasma arc, grinding, s.6nchinir.g, or cr.y combination of methods to essentially form i the geometr/ of the wald 2. hewn on Page 2 i 5 Fr?. BACK'-UP PURCE:
Argon per Page 5 as detailed on the attached statches and 7
..TAVprocess). shall be clean of alI oil or grecs: as.d er.cessive amounts of scale or rust, i I 3 WELDS FCP. SET-UP: The GTAV process ELECTP.lCAL CHARACTERISTICS: Th: current 9 filler nieta. type listed on Page 2 may used shall bc OC: GTAW Strai ht Polcrity 2 Scd with or without back-up purge in 1/16, SMAW Reversc W ltritf . or 1/8 inch diameter. The weidir,9 tecik + JOINT VELDING PRCCED'!!E: nique, such as electrede t.lzes, and voltager 'ITicts: The welding may be donc in all
.nd currentr. for cach electrode, s lie.- of tFe
' i c e.. s/olding tip and filler rods. sha:1 be sub-stantially as shown on Page 2 l. ItEAT AND INTERPAS$: k00 F-g0G !* pre. APPEA.1A!!CC CF UELDit:G LAYEP.5: T!...,te i d i r.g 8 for EP.W wcld out only and 200 F minimun current and m.,nner of depcsiting th.f weld resss. metal shall be such thct there sinali ue practically na undercutting on the sic': walls of the welding groove or the adjoining ~T HEAT TRCATHENT: 1100* F - 1200* F, I base material. See job specific tler.s for j. . per inch miniemi (see job specifications speelfic undercutting lb.iltations. cycle and thicknesses requiring post heat l .t ent. CLEANING: All slag or flux ren.alnit.9 on any bend of w:IdIng shall bc removed before laying down clie next successivo becd of ' ACK!!:G STRIP: None, weldin{4 DEhr. CTS: Any cracks nr blow holes. that fi WEL $ PEED: CTAV $" - 6" pair min. cp;: car on ti.c surface of eny bcr.d <,f w Idle.n 1 ! MAW !" - 8" pie r min, stiall be rc.eved by chipping, grindint:, or r,puging befs.rt depaalting the next wecess-tve Id.ad of welding. s ^ l
31 Report 411-77.55 page 3 or 4 9 Til E !!. f. K E L L O C C C O.L! P a tt i s......... reu es s s e c s e e..ie, PlPills FAsalCATl0e a ilECOWICNDED Foni! Q-1.ilANITACTimEll'S ItEColt!! 0F WELDING I'It0CEDUllE
Heat Treated QUALIFICATION TESTS scocittenio. No. P 12b-P I-K !-F4-5MV-6C osee 12/28/73 '
Telding Procese _GIM1 f, $1*.W Heaval er W ehle. Magusa 1 leasetiel Specifiens,ien A,.5&C(2__ se,1=,101-Q., el P.No._,,12n se P.No. 1 Thickeees (if pipe, dies.etee end mell skicheren) 10" OJ,,,,,,X,,3 /14:e g l[ Thieheese Reese ihie seet geelifies,,)/J 4H t hrt, th3 )),_f,pje. 1H 194 and avec Filler Wiel Group No. F. hA A FLUX OR ATHOS!4IERE Teld Metal Analreis No. A. L2h ,Fles Trade Name et Campeelsies Npne Dreeribe Filler Wiel if net included im Table til.2 leer Gas Compeeities a_ggea er QN ll.%oc.tal2.0$m2seId ane rPn1 ft T.ede Nome Flow Rue 20 CFH Fee eeyseetylene weldias-Seese if Fille, Wesel is sil-le Beeking Suip used? No leme er eiwe'ieum killed. Prehees Temperosuse Reage200 F - 1000 F 0 TELDING PROCEDU!!E laserpees Tempereture Reage 7000 ? mi n im-a Siasle *e W3tiple Poes MultIole Pesehen Tree men 4000 F/hr fe m 6000 to siasle e, miniple Are Sinele 11000 Fe I hr at 1150* F, furnace cooled at 6c ( pe,.
rias.
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6 JJerth 28,1977 3 The fbilouing information is provided per your request to indicate tasts and transient conditions Weich influtaced tosperature and pressun on the secondary side of steen generator.1-2: a .. g afDED TE573 1st Indro I 1 his to 1 assales capped at generator)psig,9106* F 6snin steam and feedwate 2/19/74 4/29/75 2nd Itydro - 1 cela to 1320 psig 9 88* F Oty's fifted and pressure had tobereduced) g/2905 Mth present. piping ~"1356 psig 8 88* F s 3rd lydro - 1 gele to ~ g.7UNC7im usT s 12/1365 RCS heatup 100* F to 150* F 12#5/75 Rc3.heatup 150' F to 240* F 12/23/75 RCs haetup 251* F to 340* F, 62 psig to 103 psig 350' F to 450* F 119 psig to 407 psig 12/30/75 RC3 heatup 12/3165 RCs heatup 450* F to 511* F,407 psig to 750 psig 1B/75 RCS heatup 511* F to 547' F, 750 psig to 1010 psig 1/465 pressere dip 1000 psig - 940 - 1000 psfg. af < 1G* F 1/406 pressure dip 1000 psig - 925 - 995 psig. AT < 10* F 1/445 temperature drop 546' F to 523* F, 980 psig to 810 psig 1/6/75 temperature dip, 524* F - 497 - 524* F, 824 psig - 651 - 824 psig 1/7/78 temperature dip 531* F - 506 - 512' F, 900 psig - 695 - 750 psig 1/8/75 tauperature increase 508* F to 545' F,714 psig to S83 psig 1/9/75 tempersture dip-545' F - 503 - 547' F, 989 psig - 677 - 1000 psig 1/10/75 taperature dip 548' F - 526 - 542' F,1000 psig - 829 - 973 psig 1/1246 RCS cooldoom 538* ~F to 115* F, 908 psig to 0 psig 133* F to 327* F. O to 84 psig 1/1565 E3 heatup 1/17#8 RCS heatup 327* F to 528' F,84 psig to 860 psig 1/21/76 t P ature dip 528' F - 472 - 546* F, 840 psig - 501 - 982 psig p l 1/23/76 . turbine roll - 546' F - 476 - 551* F,1000 psig - 525 - 643 psig 1/34/76 temperature increase 501* F to 545* F, 680 psig - 985 psig 1/2R/75 turbine roll 547' F to 482* F, 979 psig to 563 psig 1/2B/76 ats cooldoun 482* F to 255' F, 563 psig to 20 psig 255' F to 546* F. 20 psig to 989 psig 1/2566 RCS heetup ) .544' F - 477 - 546' F, 988 psig - 537 - 993 psig ) 2/4/75 turbine rol 2/306 turbine roll 546' F - 485 - 531' F, 987 psig - 595 - 887 psig
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2/745 tasted safeties 956 psig - 864 psig several times 47 < 10* F 2/10/76 testad safeties 552* F - 531* F four times 1042 psig - 868 psig (3.4.'s 1-3 and 1-4). - 2/10/75 RCS cooldous
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549.S* F.to 100* F,1008 psig to O psig ETE: Durlog the days est itsted above, the tamperature and pressure were l velatively stable. A detailed picture of temperature and pressure is available l st the site and a drawing of the entire hot functional program. Steam pressure sham os the drawing is downstream of the main steam isolation valves and dcas not alays agree with stama pressure in the starm generator. NINI Ef RNICTIDML TEST 3/14/77 RC$ heetup 115* F to 165* F 3/15/77 RC3 heatup 165* F to 300* F, 0 psig to 52 psig 3/16/77 E3 bestup 300* F to 330* F, 52 psig to 88 psig 3/17/77 Es cooldama 330* F to 100* F. 88 psig to o psig
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n-FElmTR TO STEAM GENERATOR. Durtag both Het Functional and Mint-Hot Functional, the auxiliary feeenter systan 3 uns esed for makeup to the steam generator. Feedwetar temperature varied fras 90* F to 110*.F and fTom reta varied from 0 to 300 GPM. nie understaaf.ycu have ettnined.uuter ctemistry results from the plant chartst. 2 71E55E. HPAftSION During Hot Functional, thermal movement and potential czmonent and piping interferences mare closely annitored for each sts. ganerator. Movement of n steam generator 1-2 aus in agreement with the revenant of the remaining gamerators and accaptable by Engineering Department. lionsver, insulation on / the feeduater inlet line for steam generator 1-2 dtd_ cme in contact with the 1rissle barrier penetration, whereas feeduster ifnas en the other staam generaters did ast. The insulation cover was slightly indented. but not enough to induce a restricties to the movement of the feedustar ifne with the steam generator. Rusalts of the thersel ennaasion test during Fct Fweetional are on f.11e at the plant and Geosral Office. \\- ~. R..N. 1d000 Startup D=.;;
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2$."%A%sia DMW of Puuman incomorated h12) 562 OM Metallurgica1 Examination Cracked Field Weld No. 212 Feed Water Pipe to Nozzle; Steam Generator 1-2.
Pacific Gas & Electric Co. Diablo Canyon Nuclear Project NY Q Pullman Power Products Co. Williamsport, Pennsylvania l g s_ _ W Date: g/23/77 Prepared by: /CMO% R.H. Caug&y Chief Metallurgist i
a c ~ 4 Pullman Swindoll ~ F o m orPusmanine=, no r, 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 water pipe co the No. 4 nozzle on steam generator 1-2. The line pressure and temperature at this time ses 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) led to the conclusion to cut out and totally replace this weld. A satisfactory, acceptable replacement was completed 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 (Appendix I, pages 11-15) i h Incident with this replacement a spool piece was salvaged for subsequent labora tory examina tion by P.G. & E. It contained a conveniently large portion of the weld deposit and a representative portion of both the nozzle and pipe components. A sketch which describes the dimension of this piece; also the crack path and the i extent of the crack relative to the weld deposit is included with the Kellogg report referenced above (Appendix I). Kmllogg, for the purpose of a laboratcry examination, requested P.G. & E. to furnish representative specimens cut from this spool piece. Two-were received. The report which follows covers a description of these samples and the results and conclusions determined from this in. vestiga tion. l 1 k 1- = + - - _, - - ,,m_ .g --,..w-w.e---- e -ea-,. t e-> e-+--
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p oween at puumen inewome.o Pullman Swindell PROCEDURE & RESULTS OBTAINED A. History Pertinent to this investigation was a complete review of the records appertaining to field weld joint No. 212, namely; the weld procedure; welder qualification records, heat treatment; 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 HISTORY REVIEs1 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 insert 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 reclean the weld prep and install a new insert prior to consuming the ring. The root 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 completed on May 28, 1974. Other than replacing the insert no unusual or out of the ordinary circumstances were recorded. i 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 l tack welding and subsequent welding. The weld was preheated on May 22, 23, and 24.. The heat was. turned off at the and of each shift allowing the weld to cool. p.
g 4 Pullman Swindell 7 owan at uman incorporm.o 2. PREHEAT AND POSTEAT (Con't) Following completion of the weld on May 24, the weld was allowed to cool and no further heating was per-formed until post 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 steam nozzle to pipe welds in Unit II. The feed-water nozzle to pipe welds are not welded in Unit II. 3. TJELDTNC PROCEDURE AND ugL3gg pgpygpyjggg q,g777g;77gg RECORDS Field Wald 212 was made using weld procedure number 200. The procedure was reviewed to assure compliance with ASME Section IX. No deviations were noted. The results of the procedure qualification tests were evaluat-p ad. Included were bend tests, tension tests, and Charpy V 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 that his performance record was good. There was no reason to suspect that welders capability 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. 'O
4 Pullman Swindell F oivision or Puumen incaommed P 5. NONDESTRUCTIVE EXAMINATION PERSONNEL, PROCEDURES AND 1 REPORTS, ,a The original radiographs of F.W. 212 were reviewed. There was an area 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" wide. There was no evidence of linear _ indications in the area where the crack occurred. Review of the radiographs of other similar welds did not show evidence of linear or crack-like indications. B. Meta 11urgical Examination A description of the two (2) specimens received from P.G. & E. follows: ...._One_ represented by.about 1/2 inch of the circumference contained the full depth, " front" face of the crack as viewed O the pipe component. An enlarged photograph showing toward 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 jcint. It had apparently been re=oved from a location where crscking had not occurred. A photograph of this sample is not included. It will be discussed with relation to microscopic examinations which were conducted on both specimens. Photomicrographs of both specimens are displayed in Fig. 2 and 3*respectively. Both reprecent the existing metallic structure i in the locus of the weld root on the nozzle side of the weldment. Noteable in Fig.1, or the " front" face of the crack cross section is the distinct, variously " shaded" areas. There appears to be four in number as illustrated in the accompaning sketch.
Figure 2, Page 9 Figure 3, Page 10 c.
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Pullman Swind:ll p om or puuman incorporm o DU DISCUSSION Fractured or cracked areas showing these distinctions ara typically associated with fatique 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 weld in the forged nozzle and ultimately propagated to failure through the weld deposit in at least 3 stages as shewn in the sketch. (The l cycling involved could have resulted either from multiple hydro-testing or from cyclic exposure during hot functional testing. These facts were not contained in the reported history cited l 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 like defect. In the photograph of the fractured surfaces (Fig.1) the first distinct area is the root of the weld joint. Close lO vis=1 examinacion by =croscopic -ans shoeed sporadic sm 11 areas (light areas in the photograph) which were relatively I bright or " shined". Fig. 2 is a photomicrograph of the metallic structure 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, crack initiation stemmed from this locus; also that the initiating defects were localized, incipient root cracks threugh the land area. I l What is not clear from this examination is the cause for the defects. In the history of the field fabrication of this particular weld (cited above) the fact that, repetiture preheating and cooling was permitted to take place on four separate occassions before the weld was completed, could be one factor. Thereby inordinately high thermal stresses could have resulted in incipient cracks. ,~..
_1 j ~ l p Pullman Swindell Cheon of PuHmen incomorated ra DISCUSSION (Con't) Another contributing factor under these circumstances (which cannot be overlooked) could be the relative hardenability of the forged nozzle material the reported composition of which was a nickel, molybdenum bearing steel or A.S.T.M. A508-CL2. This is an air hardening composition. It is possible due to the noted in attention especially to cooling affects, following the root pass welding, that, air hardened, crack sensitive microstructures could have been effected and sporadic cracks on cooling promoted in the initial land area. (Micro-i structure affects in the specimens examined would, of course, be obscured by the subsequent stress-relief heat treatment.) Understanding this weld (NO. 212) was one which was completed under restrained conditions (or as a closure weld) the possible circumstances i.e., in attention to preheating and cooling and metallurgical transformations, would augment the cracking tendencies. Fig. 3 or the photomicrograph of the uncracked weld -d joint (localized at the root weld in nozzle forging) shows the normally expected microstructure; good penetration; and no evidence for lack of fusion or cracking. Certain evidence of small cracks are shown to exist in the I.D. surface of the forging. But there is no reason to believe these or like defects could have contributed to ultimate failure, once the weld was completed and stress relieved. ~ S 0
p Pullman Swindell Divieson of Pullman incorporated 'A" CONCLUSIONS
I 1.
The crack failure in the FW212 resulted from crack lika defects which apparently er:s ted in the weld bevel land. 2. The cause for the crack defects is not clear. They are believed, however, to have resulted from the welding process and probably portend the affects of repetitive preheats and cooling applied before welding was completed. Imposi-tion of high thermal stress, especially in the early stages of welding, is a plausible explanation. 3. Ultimate failure through the weld deposit was due to a cyclic fatique stress phenomenon, which it is suggested was the consequence of repetitive loading due either to preliminary hydrotesting or inherent in the hot functional i testing program. l 4. The fact that cracking was only discovdred during the hot functional testing,.and not evident from preliminary in-p process inspections i.e., ultrasonic and radiography (pro-V bably due to the inherent insensitivity of these procedures to indicate saml1 incipient cracking) the recommendation is hereby made that all like welds should be reinspected upon the completion of functional testing and before service in order to discover any evidence of crack propagation or 1 enlargement; not withstanding the fact that in process i documents failed to disclose the possibility of similar incidents. I l l i
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v: ; i. i.,.. 2,ug Lf M f, Ac R:ceived SX IEGEND l Photogra ph 1. K-insert, weld reinforcement. 2. Remanent. weld bevel land; probable crack 4 Crcck " Front" Face; Viewed Toward initiation region. Refer to photomicro-l Pipe Component. graph, Fig. 2. j 3. 2nd-crack stage. 4. 3rd-crack stage. j 5. Final stage, thru wall penetration. J l = ,...,d 4 Fig. 1 8 l
~ r, A. Remanent weld bevel land in forged noz=le. B. K-insert, weld I.D. Reinforce-ment. L s ~~ ~ Q r x s NT ^' A 7i n2. A e en l 2r' \\ Photomicrograph Cra.ek Evidence in Initial Wald Bevel Land s B ~ \\
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O p Pullman Swindell o- ~_,,_ e v APPENDIX I O d e N l/ . er ' p~ i 9 / A fa ' 8 .. v t 4 i 5 <+ = )
, t.";; { DIABIA CANYON NUCf2AR FROJECT JOB f 7177 SPIX: # 8711 QUALITY ASSURANCE REPORT OF - Crack in Steam Generator Feedus'.- Nossia to pipe weld (Generator No. 1-2) o ~ .N,.... - Co. Avila neach, Ca. ( 1 l l 5..j i maam nr G."&mmm
3. F. RUNYAf Field Q.A./Q.C. Manager
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e - l f A QUALITT ASSURANCE REPORT . v i 0F l-** CRACK IN STEAM GUEllA E FEIDWATER N0ZZLE 10 FIPE WILD (CENERATOR NO. 1-2) g f i l To document events from the time of discovery of the leak until 'the completion cf the repair. 1Gi2F. This report covers the on site findings, the review of documentation including preheat and posthest charts, radiographs from the defective weld, the subsequent procedures for removing the defective area and performing the repair. 7 FINDINGS l . On S ursday, March 17, 1977 a leak was observed in field weld 212, line E16-555, by F.G.6 E. We were advised of the leak on that date. S e weld in question is where the 16" feedveter pipe ties into nossle #4 on Steam Cererator 1-2. iisual observation revested a weep cype leak. which occasionally sprayed a fine stream of water. When observed with a 10E magpifing glass there appeared ' ~ ta be 'a small intermittant linear indiestion approxistely 3/8" in length in l tho center of the weld running around the pipe. Magnetic particle examination cf the area with a D.C. converted yoke did not show evidence of a linear defect. I P.C.& E. requested that we grind the area. As grinding ' proceeded, the indication opened to reveal a linear defect approximately 2" long when the weld crown was flush with the pipe surface. At this point the grinding was ctcyped. We were requested to perform an Ultrasonic examination to determine tha extent of the indication. The pipe temperature was approximately 1808 F which ande it impossible to perform U.T. with the standard transducers on site. We s6re then instracted et " bold" until F.G.& E. Engineering Research cerived with their U.T. equipment and high temperature transducers. The veld was radiographed at this time. The radiograph revealed evidence of a linear indication which appeared to be approximately 6" in length. On Friday, March 18, 1977 P.G.& E. Engineering Research arrived and performed Ultrasonic examination of the weld. They reported that there was a crack which cypeared to extend approximat.aly 2/3 o.f the distance around the weld. Based en there findings it was decaminad f M the weld ve=1d he cut out and replaced, y x-.. =.- .-. -. -. -. ~ - -
EfELD RZHOVAL De weld was cut by grinding approximately 1/2" from the center line on the nozzle side and at F.W. 503 on the pipe side. The end of the pipe was then est to remove a ring which included most of the weld and approximately 4" of pipe. De piece was examined visually and by liquid penetrant on the 0.D. and I.D. and a sketch made to reflect the observations. (Sketch Attached) De piece was shipped to P.G.& E. research lab on March 20 for analysis. REPATR f* A piece of 16" pipe was removed from stores to replace the piece which was est out. The pipe end prope, gamma hole and vent were machined in the P.G.& E. machine shop on March 19, 1977. D e nossle end prep at y.W. 212 and pipe end ct F.W. 503 were ground in place on March 20. A liquid penetranc examination was performed at that time to assure completa removal of any indications. %e new piece was moved into place and fit up on March 20. Preheac was cyplied prior to tack-up,(Ref. Chart # 547). After the fit up was approved by M.W. Kellogs Q.C. both roots were welded. Magnetic particle inspection was performed. Following magnetic particle acceptance two additional passes were welded in each veld. 1 Radiography was performed on March 21, 1977. The radiographs of F.W. 503 l pipe to pipe wereacceptable. F.W. 212, pipe to nozzle, had excessive porosity at the window closures. These areas were ground, rewelded and re-rae'iographed. One area had excessive porosity, the other had a linear indication appresimately 1/2" long and an area which appeared to be suck back. At this time, March 21,19h7, P.G.& E. Q.A. placed a " hold" on all work until their Engineering could review tha total progract and procasa appropriate l paperwork. "This hold was not because of the difficulty in welding the window l closures".
a No work was performed on March 22, 1977.
On March 23, 1977 an on site meeting was held to review findings, work to date, and procedures. for completion of the repair. Attending the meeting were rcpresentatives from P.G.& E. Fagineering, Q.A., General Construction, Division. i l_ Westinghouse, MJ. Kellogg site Manager, corporate Q.A. Manager, and the writer. A. It was determined that the procedure as outlined by D.R. 3366 was acceptable except that the preheat would be raised to 300* Min. for completion of the welding. 3. The problem of making an acceptable closure weld was discussed. It was determined that ene positive pressure maintained in the system was ~ ' to high. ad ther. water reminiL6 in the ganarator causad vapor to be' d carried out the window openings. 13
l iA C. P.G.& E. Division agreed to drain ths generator sad reduce the purge !J pressure antil the closure welds could be made. on March 24, 1977 the defective areas at the closures were ground out and Magnetic particle performed to assure complete removal. No velding was per-formed since P.G.6 E. had not removed the Hold. Preheat was being maintained through the " hold" period. On March 25, 1977'the hold was released. S o windows were closed and radiograph made. Both areas were acceptable and welding continued. The weld was completed on the afternoon of the 25th. Radiographs were shot in the hot as welded condition. No rejectable indications were noted. Post weld heat treatment was then performed. On March 26, l977 following post veld heat treatment, the veld ves ground, re-radiographed, liquid penetrant inspected and ultrasonically examined. No rejectable indicatioos were noted. The vent line and gamma plug were completed, inspected and the system turned over to division for resumption of testing. SUBSIOUENT INVESTIGATION Because of the unknown origin of the crack it was determined that other ~ welds of the same type and welded using the same procedure should be reviewed to determine if the defect could be a 33neric nature. Each of the remaining three feedwater nossle welds and the four Main Steam i O -e te vads - e uttras-i-117 -ined. The ori. inst radio.ra,hs were re-viewed and the fsedwatar nozzle welds were re-radiographed. D ere was no l evidence of like indications in any of the welds and no evidence of change in cny of the noted, acceptable, indications since the original inspections. There was, however, an indication noted in F.W.197 on generator 1-1. The indication was present on the original radiographs but had not been noted on the radiographs report. A second set of radiographs were on file for F.W.197. This cet also exhibited the same indication, however the radiographic report did re-fleet the condition as being a drop thru. The indication had apparently been evaluated and determined acceptable at the time. ,..) Because'of the problem with F.W. 212 it was determined that any questionable situation should be resolved. It mas therefore determined that the drop thru should be removed. A D.R. was initiated and the repair was made. The indication was removed by grinding. No welding was required. (See D.R. 3370 Attached) l To date the metallurgical analysis has not been completed of the crack I sample. We had requested, from F.G.6 E., a piece of the defective material for our own analysis. This was received on Buredey, April 7,1977 and forwarded to E. F. Gerwin in Williamsport. It is my belief that the crack was peculiar t[s F.W. 212 only and not of a y generic nature. Therefors, at this tims we ara assuming that no further repeir will be required and that when the disposition of D.R. 3370 is completed the subject will be closed. l -4.4-
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~ s \\ ]_0)PMY~N &&T $.% MTacewn g-PULLMAN PCWER PRODUCTS r \\ - EVALUATION OF DISCREPANCY REPORT IN RELATION TO REQUIREMENTS OF 10CFR PART 21 l O.R. # 3 953 Su/, to which this p.se is att.ched and become a part of, y be ) considered to be reportable to tha NRC under the requirements of 10CFR Part 21. PULLMAN POWER PRODUCTS by wh / Pacific Gas 6' Electric Company ( does oes not ) consider this - discrepancy reportable and ( has reported, not rt ) the above discrepancy. This form returned to Pullman Power Products on 3 M D DATE PACIFIC GAS & ELECTRIC Co. by V .L ~' t 7 - _,, - +,
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't PULLMAN POWER PRODUCTS EVALUATION OF DISCREPANCY REPORT IN RELATION 70.REqulREMENTS OF 10CFR PART 21 _p " - D.R. # F453 , to dich this page.Is attached and beccree e part of, may be ) considered to be reportable to the NRC under the requirements of 10CFR Part 21. MLLMAN POWER PR00t! CTS by r r { Pacific Gas & Electric Company (* does, nh)considerthis - discrepancy reportable and ( has reported, Inotrepjo ) tne above discrepancy. This form returned to Pullman Power Products on 7!M 77 . DATE 4 PACIFIC GAS & ELECTRIC CO. by h 1 y~ w ,,.a..--,-----a..v. .,,,.en- ,--e,.
h y '. ph. THE M.W. KELLOGG COMPANY Page I of 3 A civisioN op PULLMAN INCORPORATED Q.R. No. 1h6'4 ReV. I kS[ ~ iso. No. Cnnthn the_ h nf 5 DISCREPANCY REPORT UNIT No. l CooE No. N/A cuSTouem: Pacifle Gas & Electric SPEC. No: 8711 OATE: 8a26-77 PmosEcT: Olai.le Canyo"
ce No.

7177 INSPECTOR: Runyan/Scanne1I/ Guest oisenEPANv im: Line K16-556-16": Scool Piece 500: El. 154'-4M'; Area G: Sect. I ExPLAnArioN oP oisenEPANev: Reference P.G.&E. Drawing 500146, Rev. 95 Per P.G.&E.'s request, an Internal inspection of F.W. 2M on Steam Generator 1-4 Feedwater Mozzle will be performed. The line entry will be made in the folicwing manner, see Recoassended DisposItlon. 4" "i 3 F M .-n ( g ij 'y j b' i'4 ; --' " ' " ;.y 11 $ D{l RECoMMENoEo olSPoSIT1oN: 1. Measure 2" from F.W. 2M center upstream on pipe (Spool Piece 500) circumscribe the pipe using a wrap around, then prick punch the scribe line. 2 Using air-arc, cut the pipe all around maintaining less than a 400 total bevel to within approximately 1/8" from the 1.0. (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 frem cut on upstream side per Superintendent's Instruction. Install a dam in nozzle beyond F.W. 2M to prevent air frem entering Steam Generator. clean and Inspect F.W. 2M internally ad directed by P.G.&E. (Congt ogage 2) 5. care M2 Yh7 A Aoorow.d Sy: M.W.K. Pi.se CLA. Mgr. y' oste 77 Custorn.r pin AL otSPoSIT1oN: %in Wim Atme 2 oms 4.spl.a.,i.n Ud e r. It..wir.d)) n.,k c. :. a in., o..., //~ 2-U w.,6 c.
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o..., // 7"7 Expt.cNATioN HP NECsSSARYl: Revision 1 - Delete Step 6 la its entirety (access was achieved). Refer to Attach-8/# ment #1 for results of initial inspection and recommended disposition. .3 0/#7*V Z. F Revision 2 - See Page 3 of 3 and Attachment f3. Pevh h 9h/77 .h e 44 24 77 M.a.x.Pw M 'j# Cy o.,,gsh:2 cu,,,,,,,, # h % G a mir.rr(,f, % /7 7 [ U STEPS To PMEVENT RECURRENCs Appli ble ./ %J Pi.ed o.A. Man.ger l ol8TateurioN: 3 M ,o,A.p;i. 3 A,n. ines. 3 gn, nn, o.,c. O o,n, 3 ' vi.r C m __.. O Piese enesestor i i J_
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THE M.W. KELLOGG CO.TIPANY Page 2 of 3 -A otvistoN oF PUI.utAN INCQRPQR A7gm c.M. NO. 3MS3 Rev. 1 R6 1 iso. NO. 500146 Sht. 4 oT ' DISCREPANCY REPORT UNIT NO. I ~ COct No. N/A 8-26-77 customer: Pacifle Gas & Electric spge uo: 3711 cATE: Otelo Canyon Jos No.: 7177 inspacrom: Runyan/ScanneIi/ Guest pnoJacT. essensPANTITEW l.ine KI6-556-I6" Scool Piece 500: E1.1548-4 "; Area G: Sect. I RECOMMENDED DISP 051 TION: (CON'T) l 6. If access to F.W. 244 1.0. cannot be achieved, proceed with alternate instructions (See Sketch #2). 7. Upon completion of Inspection, remove dam, srind bevel to facilitate fit-up as needed, clean ar.d fit to ESD-215 and ESD-220. 8 Weld out using F.W. 549 and procedure 4/5. 9." inspect and NDE to E50-215 and ESD-206.
10. Add all Infotination to process sheet and. isometrics.
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s b., THE M.W. KELLOGG COMPANY Page 3 of 3 Uts 2. i A otvtsloN oF PULLMAN INCo#PoMATs0 Q.M. NO. 3453 iso. No. Cnn i h(, %t _ k ed $ DISCREP ANCY REPORT UNIT No. 1 n. I CCDE NQ. M /A s cusTougm Pacifle Gas & Electric SPsc.No: s711 CATE: 8 M 77 Diable canyee ,,oe No.: 7177 insPecten: Runyan/Scannell/ Guest anoacT. assenerANrstru-.Line K16-556-16": Spool Piece 500: El.154'-M"; Area G: sect. 1 0 R. 3453. Revision 2 EXPT.ANATION OF OISCREPANCY: - During the performance of ' grinding per 0.R. 3453. Revision I,' step #5, four (4) Indica-tions of heavy drop thr.ough with roll over were removed along with all of the existing root penetration. Re-inspection revealed a linear indication 11" long on the fusion line to the Feedwater Nozzle. Further ' grinding, to a maximun depth of.110", removed tho linear Indication (see Attachment #3). n u n r. n v.n m.~. n.s s ~r s $ b [N 1:, aj g w '- ., s
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h0MMENDEOOISPOSITION: Add the following to Step #5 and delete original steps #7, 8, 9 and 10. Perform the
following repair:
A. Grind the bevels to facilitate Fit-Up of F.W. 549. / f 8. M.T.1.0. of F.W. 2% using ESD-247 coil method,' and clean grooved root pass at O,4 *! F.W. 2 % per E50-215. C. Remove the das from the nozzle at F.W. 2%. 0. Preheat F.W. 2% to a minimum of 250cF* Interpass not to exceed 5500F maximum. *U b N 5,3/ Maintain this preheat until stress relief begins. f o E. Wald to procedure 200 (F.W. 2% A1), using E7052' wire with the GTAW process, to conform to blended configuration of the balance of the weld. J',0. ed iv F. Grind and polish the added weld metal to blend with base metal surfaces. G.' Inspect and NOE to E50-215 and Fr.3E bE#. To MMM 8 P. AT MM#~Wi f M t.m r s i.r M nw Ac w 7M &Py on Pcra# e 1:e 7, -NOTE: Proceed with 0.A. 3456, and X-ray wel.d, hot for Information only. j 7. Upon completion of Inspection, remove dans from F.W. 549 pipe side, clean and fit F.W. 549 to Esc-215 and Eso-220. 8 Wald out using F.W. 549 with procedure 4/5 A.O. 9. Grind F.W. 549 for X-ray. Inspect and NDE F.W. 549 to E50-215 / w"f f' - g' Q fff}ef1 ~~~~ 10 p"-'., -- ~ r-l _,,. - am l NOTE: X-ray weld hot for Information only. (,11 Stress relieve at F.W. 2% RI and F.W. 549 Il000F to ll500F per E50-218
12. NDE F.W. 24 Al and F.W. 549 o s 207.& T7 efl
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( s. ALTERNATE INSTRUCTIONS j i D
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1. Cut out F.W. 509 using air-arc and taking necessary steps to maintain the ability I to bevel the 450 oli side of the weld to 2001 210 and a 3/32": 1/16" land. Also, cut out F.W. 339 shown on iso. 3-246. 8%'*>lingorsoc-o-letA105. op 16" Pipe, schedule 80 A106 Gr 8 and a 3/4" 3000# S.W. Half 2 Requisition: Coup 3. Install the 3/4" half coupling or soc-o-let four (4) inches from the end of the 16" pipe. 4 Clean and Fit to ESD-215 and ESD-220. 5. Weld out with procedure 92/93 (F.W. 831). 6. Inspect and NOE to Eso-215 and ESD-211. 7. Upon completion of F.W. 244 l.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. 8. Reweld F.W. 339, as shown on Iso. 3-246, maintain original line configuratio'n. 9. Clean and Fit-up to Ess-215 and ESD-220. O. Weld out with procedure 92/93. 11, inspect and N0E to Eso-215 and Eso-2il. ,h 8 s* A, R G / .,**e% db g 3.% ( W j STEAM GEbl I-4 e* ,e .. ~,,., ,y-..- m_...
Findings et F.W. 2% A / NozzIe Punch Marks Pipe on 0.D. f 11" Grooved Root Pass to eliminate linear. % A V///////AV///h 3/16 % ne
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.110" %
Deep Groove Nozzle 11"

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7 riginal Root Pass 0 jl' y Ground smooth and Olended to Parent f////////// uv///// Meta l. Section A-A NOTE: Average Well Thickness =.580" to.600" Ramelning Wall At Groove =.450" Punch Marks On The 0.0. =.M7" Deep (Punch Marks are directly on the fusion line of F.W. 244 to 1/8" inside the fusion Iine.047" deep.) !V ATTACHMENT #3 DR 3453 Rev,2 e
m 1*riTECOFFICS CCRGSPCNDENCE 4 ATTACHMENT #1 OR-3453 Rev. l To J. P. RUNYAN, Q.A./q.C. MANAGER oArg AUGUST 31, 1977 FROM
0. R. GESKE, NDE SUPERVISOR sua;ecT...I. lAU..l.0 f.E.lgTME...EM.M.J.NA.T,,l 0.N.. E W,,,,2M,..I,!!S I O E,,,0_i AMETER,
on August 31,1977, F.W. 244, l.ine K16-556, Isometric l-03-500146, Feedwater piping to Steam Generator 1-4 Nozzle, was liquid penetrant examined on the inside diameter. The following Indications were noted: 1. 2" from top center of nozzle, a small faint transverse linear-nonrele-vant due to weld geometry. 2. 7" from top center of nozzle, heavy 1" drop through with roll over. 3. 9" from top center of r.czzle, heavy 2" drop through with roll over. 4 37" from top center of nozzle, heavy li" drop through with roll over. O 5. 33" from tcp. center of no zie, 8eavv i 2" droF thro oh with wire protrusion. 6. Approximately 1/16" mismatch exists from 7:00 to 9:00 facing the nozzIe. We recomend 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 1.0, with IIquid penetrant, if acceptable, proceed to " Recommended Olsposition", Step 7 of 0.R. 3453. Revision I. l Donald R. Geske NDE Supervisor DRG/js l 4 +, L. s %V A,s.N u,
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'... f-r 14 ~ t w ESR6TiTD PULLMAN POWER PRODUCTS hrTTAC8% M ( p# f. EVALUATION OF DISCREPANCY REPORT IN RELATION TO. REQUIREMENTS OF 10CFR PART 21 ..g ' - D.R. # , to which tl>is page is. attached and be.come a part of may be ) considered to be reportable to the NRC under the requirements of 10CFR Part 21. PULLMAN POWER PRODUCTS bf.hs . ap Pacific Gas & Electric Company ~( does, hoes no) consider this ~ - discrepancy reportable and ( has reported h11 not re ) the above discrepancy. This form returned to Pullman Power Products on /4 -/d - 7 7 DATE PACIFIC CAS & ELECTRIC CO. ~ by 4. v.' e mm / /V D L,,
f THE M.W. KELLOGG COMPANY Page 1 3 A osvisioN oF PULLMAN INCoRPoMATED o.R. No. %8L Rev. 1 iso. No. 500146 Sht. I of 5 DISCREPANCY REPORT uNtTNo. l "f, CooE No. M/A CUSTOMER: Pacific Gas & Electric SPEC. No: 8711 3 ATE. 10-7-77 Dielo Canyon goa uo,: 7177 INSPECTOR: RtinVan/3C3nne I I / Cue s t PROJECT: oisensPaNrirEw: 1.ine K16-554-16"; Piece #540; El 154'-5"; Area F; Section i EXPT.ANAT1oN op otsCREPANCY: Per P.G.&E. request, an Internal inspection of F.W. 197 on Steam Generator 1-1 is to be performed. The line entry will be made in the manner described belcw. A inspection conducted October II, 1977, required by Step #9 of the Recom ended Dispo-sition, revealed conditions requiring rework. (See Attachment #3, Report of Findings.: AInspection conducted October 13, 1977, required by Attach =ent #3 revealed further rework is required. (See Attachment #4, Report of Rework). Attachment #1 (Sketch) Attachment #2 (Sketch) d Attachment #3 Report of Findin A Attachment #4 ((Report of Rework)gs) RECoMMENoEo otspostrioN: 1. Remove the 2", 3000# coupling at F.W. 827 from the pipe using air-are and grinder (do not air-arc through). Clean and NDE removal area to ESD-220 and ESD-211 on j( - F.W. 197 side of hole in pipe. Close hole with fire retardant material (Reference Attachment #1). 2. Circumscribe the pipe using wrap around at the edge of hole in pipe nearest F.W. 197. This should be approximately 1 5/8" from 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 300 from 0.D. of pipe to within not less than 1/8" of the 1.0. of pipe directly below me (Con't on Page 2) 4 i Aoorav.e av: u.w.n. Pw o.A. M 7 -l ' Rm l0 b"E N*1YYO om l0 = /C * *1M I /
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i,,/, Ao,, i 1-2 > 7 f)g% , jyy w6c4 EXPT.ANATioN ttP NECE3sARYl: R: vision I - Adds Attachment' #3 (Report of Inspection Findings). P.G.&E. will Indicate rework released on Attachment #3 under Recemmended Rework. See e for other changes. Revision 2 - See page 3...(MD " / % W./4 Mu.w.n. Pm o.A. u.e.,aML oa. so/nh7 cuneme H-M40 *Al om /0
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~ ~ .... e... i tam.ssa r.. - f THE M.W. KELLOGG COMPANY Pase 2 of 3 A DeVisloN oP PULLMAN INCoRPoRATsD o.M. No. 3b8k 8.e v. l iso. No. 500146 Sheet I of 5 p DISCREPANCY REPORT ,UNifNo. l l-C006 No. N/A cum usR: Paciffe Gas & Electric ^ SPsC. No-s711 QATE-IO -77 PnoJacT: Diablo canyon Joe No.: 7177 INSPsCTOR: Runyan/SCanneIl/ Guest GlaGa* PAW 'N Line K16-554-16": Piece #540: El. 1548-5" Area F: Section f RECOMMENDED DISPO$lTION: scribe IIne'(do not cut through the pipe with air-are). Using a 1/8" blade, grind through to I.D. of pipe. 5. Locate center of F.W. 500. dsing wrap around, circumscribe weld center. 6. Prick pun'ch scribe !!ne. 7. Cut out F.W. 500 using ale-are maintaining a maximum bevel of 30 on etl side to within not' less than I/8" of the' l.D. of pipe (do not. cut through wi th alr-are). Ust'ng a 1/8" blade, grind through to I.D. of pipe.- '8. Install dam in nozzle of. Steam Generator I-I past F.W. 197. 6 9. Clean and Inspect F.W. 197 Internally as directed by P.G.&E. Report findings of Inspection before proceeding with Step #I0. A Proceed with rework require-ments as directed by P.G.&E. on Attachment #3. .10. Upon completion of Inspection,Cremove cam) grind bevels to facIIItate fit-up e as needed. ( ,w,,5 %, u4,3 i ' f' enne m, 11 Install new pup, fit-up and Inspect to ESD-215 and ESC-220.
12. Weld out F.W. '551 anS F.W. 500, as shown on Attachment #2, to process 4/5A0.
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13. ' Inspect and NOE to E50-215 and ESD-206.
14 Upon acceptance of R.T. 's of F.W. 551 and' F.W. 500, clean and fl t-up gamma plug, as inhcwn on Attachment #2, to Eso-215 and ESD-220
15. Weld out to process 7/8 using F.W. 832.
I6. Inspect and NOE to E50-215 and Eso-211
17. Post weld heat treat to E50-218 (F.W. 's 551,'500 and 832)..
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3484 REV. 2 iso. No. 500146uSht. 1 of 5 ! DISCREPANCY REPORT UNIT No. 1 Cc0E No. M/A MER: Pacific Cas & Electric "10-i4-77 SPtc. No: 8711 DATE: toJCcT: Olablo Canyon Joe No.: 71T? INSPEC*CA:' Runyan/Scannell.Cuest sene?4uTrTru: NOTED l EVISION 2: Adda Attachment #4'(Report of Rework). P. G. & E. will indicate rework released on Attachment #4 unde'r Recocanended Rework, adds rework to, Reconsnended Disposition as Stap 9a. l COMMENDED DISPOSITION: 5 3/8" Linear Removal. A. Grind to remove the 5 3/8" linear. B. P.T. to ESD 211 to insure coinplete removal. Non-metallic Inclusion Removal. Tb Bland base material to eliminate the two non-metallic inclusions. U.T. to ESD 244 to determine wall thickness remaining. B Pip:-side Rough Grind & Machining Lines. l .A. Palish the pipe-side counter-bore to eliminate rough grind edges and machining lines.- D. P.T. to ESD 211 to insure complate removal. C. Remove dam prior to Step 4. l Prchent to.250 min. 5500 max. interpass; maintain pre-heat until stress relief, i LSid the 5 3/8" Grindout to original I.D. configuration using Procedure 200. ( ' Grind 5 3/8" repair for R.T. while maintaining pre-heat. !f Wf M.T. t ESD #. or Hot P.T. by P. G. & E. D.E.R. Au P. ir. ~& E. o indicate N.D.E. to be performed (Step 7). Weld cres of inclusion removal, if needed, to original counter-bora configuration,
tcing Procedure 4/5 AO.
1 . Grind inclusion repair, if Step 8 is' used, for R.T. while maintaining pre-heat. P:rform Hot R.T.. of repair area per ESD 207. Proc :d with* Step 10 of the original D.R. 3484 Recommended Disposition. Q , w a A...n d ; t 'misuricas: 3 u w o.A. Fn. 3 Ave. in 3 an,a. win,o. O cmw I l 3 caem.c 0 neem.a. O Fw in p.etw I i Ecw stGi3H IF NM
0 2" PLUG 2'TUR'D COUP. e.orcur '"'our wsnna wem u% 500l 197l t M r c.- _ _ EC2 _ _ _ _ 1 FEEDWATEE NOZZLC-1 STEAM GEN. /-/ [ PLAN VIEW l UNE l-KE-554-16 SROOL S4D L f APPeat l9e'~ LOCATION OF CUT ITEMOVE P/PE pgggggy ygg9 SEC17DN BE7 WEEN ~5' FW-Em} CUT r O DR.3484 SdCH 1 s
NEW PUP BETWEEh! FW-500 h FW-551 ~ WITH GAMMA PLUG OM SIDE. OF PlPE. nrr. tov IT( REwELb Hgw E45TIH4 'Jool ssil 1971 M 1 L j 5 l FEEDWRTEK NOZZLE ~ 3 TEAM GEN. I-I PLAN VIEW [ LINE - l-K16-55'l-16 SRn_54D (MODIFIED) 'n' h ~ 3.75 REF. NOU^ laxJ NOTE: PLUG CAKI BE LOCATED ON EITilER SIDE _ CAI PIPrf.. M (I
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s i INTEROFFICE CORRESPONDENCE D TO J. P. RUNYAN, FIELD q.A./Q.C. MANAGER DATE OCTCSER 12, 1977 FRCM D. R. GESKE, N.D.E. SUPERVISCR $UBJEC..I I.D.I.9 P.ENETMNI.EM.M.I.M.T.I.QN.....EJ.....!.97. ..l.S.S..l.Q.E. 0.l!. MITIS On October 11, 1977, the inside diameter of F.W. 197 was Liquid Penetrant examined per Step #9 of D.R. 3484 The following indications were noted. Al! dimensions refer to a clock-wise direction beginning at the top (12 o' clock) of the nozzle. 1 8" clock-wise: 15" of mis-match with root pass roll over on the nozzle side. 2. 8" c l oc k-wi s e : 1 3/4" of heavy roll over on the nozzle side and slight roll over on the pipe side. (Previous re-work in this area removed drop-through with voids.) 3. 16" clock-wise: 1" of undercut on the pipe side of the root pass. 4 18" clock-wise: 1" of undercut on the pipe side of the root pass. 'e 5. 41" clock-wise: 3/16" crack-itke linear on the land surface of the counter-bore 3/16" from the root edge, pipe-side.
6. 416" clock-wise:
1/8" crack-like linear on the land surface of the counter-bore 5/32" from the root edge, pipe-side. 7. 41" clock-wi se: 1/16" lack of penetration at the window close area.
8. 46i" clock-wise:
1 1/2" of heavy drop-through with root pass roll over on both sides of the root. 9. The entire pipe-side counter-bore has been rough ground to facilitate fit-up. RECCMMENDED REWORK 1 Liquid Penetrant examine to redevelop the noted condition. 2 Grind and polish the root pass. Flush with the base metal from 8" clock-wise for 15", 41" clock-wise at window close, and 46 " c1cck-wise for 1 1/2". (Indications 1, 2, 3, 4, 7 and 8.) k" mcumro _s s s sm
...m .7 ;;,w ,c-. .,.,,, f.. l CCTOBER 12, 1977 J. P. RUNYAN, Q.A./Q.C. MANAGER out roi hst.satc?: 1.lqul0 PENETRANT EXAMINATION, F.W. 197, INSIDE DIAMETER pust so. 2 3. Grind and polish the land surface to remove the two (2) f inear indications in the land area of the counter-bore. (Indications 5 and 6.) 90 " o r' A M x o v t. M*A L rn'" cia" W e+cu m e, NOTE: If the crack-like linears join and grow, versus reduce in size end remove, suspend grinding and report the findings. 4 Polish the entire pipe-side counter-bore to eliminate rough grind edges. 00,NOT remove more than.010" of base metai. 5. Liquid Penetrant examine all grind areas to redevelop indications, i.e. remaining undercut (Indications 3 and h) and tack of penetra-tion at the window close area (Indication 7). 6. Grind and polish to remove the remaining icdicaticns. P o Ase r' n w us A nas., ru n, a dso " W :nse,~va.r>qi., NOTE: If the indications grow, versus reduce and remove, suspend grinding and report the findings. 7. Determine the remaining wall thickness using ultrasonic thickness measuring methods and report the findings. 8. Upon completion of rework, proceed with Step #IO of 0.R. 3484 or revise 0.R. 3484 to indicate further required rework. Donald R. Geske N.D.E. Supervisor ORG/js y ..f f =
~ _f W f / ro J. P. RUNYAN, Q.A /q.C. MANAGER .oarc CCT08ER I2,1977 'La ncT 1.IQUl0 PENETRANT EXAMINATION, F.W.197, INSIDE DIAMETER eacc w. 2 -r 3. Grind and polish the land surface to remove the two (2) l'ineer indications in the land area of the counter-bore. (Indicaticns Mesm.os.m o *.cn ~e r n oem aus.o.o r, earn u.as s&r e 5 and 6.) A c - v=. . c. - ca.uo stue Av wu no mrnse.no es.uso m w. m n m,e u.. NOTE: If the crack-Ilks Tinears join a9n grow, versus reduce in size and remove, suspend grinding and report the findings. N do n.7 4. Polish the entire pipe-side counter-bore to eliminate rough., rind edges. 0,0,N,0,1 remove more than.010" of base metal. 0 5. I.iquid Penetrant examine all
grind areas to redevelop indicar:
i.e. remaining undercut (Indications 3 and 4) and lack of p<.:. . a-tion at the window close area (Indication 7). 6. Grind and polish to remove the remaining indications. Pe Nev' n w.so n, hanes. n oeu aho* *# #es s. norm.. NOTE: If the Indications grow, versus reduce and remove, su nd grinding and report. the findings. 7. Determine the remaining wat t thickness using ultrasonic thickne:.s A. measuring methods and report the findings. Ask 8. Upon completion of rework, proceed with Step #10 of 0.R. 3484 or revise D.R. 3484 to Indicate further required rework. j b i i ..,,b bum $$$ g j.. -J - Donald R. Ceske If N.D.E.' Supervisor V. t r Q A DRG/js ? .,M / )'I ~ f r '-*l l ~ ~.. .~ , =:- . is l y j.t ~ ylfs(# i LJ . ~ c' ~ : - n s :..a...,. m... _ ,..,... a. - r ~. -~ . Q.. ..w nc V' .c. ~-- --~ ...~.... .....w,.. +_ .~ u e. ~ = _. : .w.-- '-: -' a. ...c.u -..-.-n .:-ag a . -...,.;. m.- _._.. f,. .it 3 O=~h 1- ~- ~ J a.
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s ? 'lq INTEROFFICE CORRESPONDENCE 'M l 70 J. P. Runyan, Q.A./Q.C. Manager DATE Oc ar 14, LC 7 FRCM D. R. Ceske, F.D.E. Supervisor sus;ect Re.sult of,,,aeworg,,,g.L,197_ tusid. Dt.a=.ter On October 12, 1977, the inside diameter of F.U. 197, Steam Generator 1-1 was reworked per Attach =ent 43 to D.R. 3484 At the end -f shift, the rework had not been completed. The following indications.ecained. i 1. 8" clock-wise from top center of the nozzle, 10" of roc y edge fusion line with slight weld =etal remaining above the mstal. 2. 41" clock-wise from top center of the nozzle, 3/16" ~' .: on 'he pipe-side counter-bore. The original indication ::ovt /32" laterally away from the weld. Tentative interpretati uas he open edge of a non-catallic inclusion in the pipe. 3. 41 1/4" clock-wise from top center of the nozzle,1/8' 1: ear on the pipe side counter-bore. The original indication cave ! 3/32" laterally away from the veld. Tentative interpretatio-u ? he open edge of a non-metallic inclusion in the pipe. on October 13, 1977, the indications listed above were furt.ter reworked. Neld metal was reduced to mini =um wall,.566", to eliminat. the 10" root pass edge fusion line. In addition, the area of non-cetallic inclusion was explored ultrasonically. The following are results of l rework. 1. 41" to 41 1/4" clock-wise: two non-catallic inclusions.600" fre= I the 0.D. surface, parallel to the surface. The edge of each inclusi:n was expo.cd as a result of counter-bore machining. Total surface ceasures 5/8" x 3/16" with the longest dimension parallel to the weld. l 2. 14 1/2" clock-wise: one linear indication 5 3/8" long, in the land surface of the nozzle,1/16" from the original root pass ueld =etal. [ Observation, during weld metal removal and physical =easurement, revealed that this indication was hidden by root pass roll over ) , during the first penetrant examination. J 3. Pipe side counter-bore surface was not reworked. Rough grind edges i and machining lines remain. s \\ l l s N
i s ro: J. p. Runyan, Q.A./Q.C. Manager DArc October 14, 1977 ' d s, sat::: Result of Reuork, F.tl.197 Inside Diameter pact wo. 2 Upon reaching minimum wall thickness with indicatic-r2=aining, swork was suspended and a Q. A. Hold tag applied. l RECOMMENDED RE'lORK 1. Grind to rc=ove the 5 3/8" linear indication ' A 1/2" clock-wise from top center of the nozzle. Re-weld the gr. -d-cut to original weldsent configuration. 2. Grind to re=ove the two non-cietallic inclusic .:ea.ure remaining wall thickness. tield out to original vall t' ess if required and rind to original configuration of ther e er-bor:. 3. Grind and polish the pipe-side counter-bore t elin:._ tate rough grind edges and =achining lines.
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wgy l b. /c./7-77 Y 2X-W Donald R. eske N.D.E. Suparvisor DRG/j f i k e. er
/ I INTEROFFICE CORRESPONDENCE -.d' ~ [O 70 J. P. RUNYAN, FIELD Q.A./Q.C. MANAGER o m CCTOBER 19, 1977 FACM
0. R. GESKE, N.D.E. SUPERVISOR SV8)ECT.. 3EMCEK...Qf.E 'L IC7....lfl3.lDE...Q..!MEI.53..
D.R. 3L84, dated October 7,1977, directec entry into line K16-55L-16" an-proxirrately 1 5/8" on the pipe-side of F.W. 157. Entry was required to facili-tate an internal inspection of the piping to nozzle weldment, identified as F.W. 137 Entry into the line was completed on October 11, 1977, and the initial in-spection was conducted using Liquid Penetrant methods per E50-211 The inspection revealed conditions requiring rework. These conditions were added to the 0.R. by treans of Revision 1. On October 12, 1977, P.G.&E, released the recommended rework noted in Revi-sien I to D.R. 3484 The rework was released with a modification "On not remove mere than.010" of base metal". Rework actions were begun. Two (2) linear in-dications in the pipe-side land surface of the counter-bore were not removed with removal of.010" of base material. P.G,&E. further modified Revision I to 0.R. 3484 on October 12, 1977, by indicating " Removal of.010" did not remove linears. O Continue to blend for removal. Do not remove below minimum wall requirements". At the end of shift, the rework had not been completed. On October 13, 1977, the remaining indications were further reworked. Pipe and weld wall thickness was reduced to minimum wall (.566") and both linears in the pipe-side counter-bore were explored ultrasonically, Results of these actions were added to D.R. 3484 with Revision 2 on October IL, 1977. Rework was continued on October 17, 1977, based upon 0.R. 3484, Revision 2. Further grinding of weld metal removed all of the existing indications except the pipe-side rough grind and machine lines. Wall thickness at the 5 3/8" linear wzs reduced to.350" wi th.520" at the non-metallic inclusiens. Revision 2 to D.R. 3484 was then modified by P.G.&E. to include " Grind and polish root weld flush with pipe / nozzle 1.0." Rework continued unt,il end of shift. Liquid Penetrant examination was conducted on October 18, 1977, after pre-liminary grind and polish of root pass removal and pipe-side counter-bore rough grind edges and machining lines. The examination revealed the followino con-ditions: 1 17" f rom top center of the nozzle 4 1/2" x 1/8" area of a fine network of linears on either side of the weld centerline. These two networks were lccated in the base metal on t,he face of each counter-bore. 9 A
t ro: J. P. RUNYAN, FIELD q.A./Q.C. MAtGGER cart CCTOSER 19, 1977 REVORK OF F.V. 197, INSIDE DIAMETER 0susaccT: pact so. 2 2. 31" from top center of the no::le - 2 1/2" fine linear on either side of the root pass removal area. Both conditions noted above were reported by telephone. Further rework was stopped pending review by P.G.?E. The areas in questien were examined by a representative frem P.G.55. Mechan-ical, P.G.&E. 0.E.R. and westinghouse on Octcber 18, 1977. Instruction from P.G.sE. Machanical u s to remove the indications by grind and polish. Further discussion resulted in instructica to proceed under the existing revision to D.R. 3hE4 Ra-tionale applied was that the two (2) linears at 31" was part of root pass removal and the network of linears at 17" was part of the rough grind clean-up action. Rework of the inside surface continued to the end of shif t. All noted in-dications were removed and a preliminary Liquid Penetrant examination verified re-moval. Liquid Penetrant examination per ESD-211 was re-applied en October 19, 1977. Examination revealed all previously noted discontinuities were removed and rework was concluded. Ultrasonic thickness measurements of remaining wall indicated average wall in the flush grind areas is.580". Grind areas are as follows: 1 8" clock-wise frem top center of the no::le a 10" crescent groove .350" of remaining wall.
2. 31" clock-wise feca top center of the nozzle a 2 1/2" crescent groove.420" of c:maining sail.

3. 41" c !cc k-v's: # cm tc:: conter of the no::le a 2" rounded grind-out.520" of rea.aining wall.
On October 19, 1977, rework of F.W. 197 inside surface was centinued per 0.R. 3k8k, Revision 2, Step #9A, Itse k. l l
0. R. Geske l
N.O.E. Supervisor ORG/js Atttchment - 0.R. 3484,Rev. 2
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MATERIAL CAFGON STEEL . ' 8711 Esh M'. 'N+'/"h'yd.~ig.-17. ' - EXAMINATION PRCCEDURE KMT. ~' I ".~'Y ~ ash # Id./.Nh >Nc. e A.CCEPTANCE STANDARDS . b b UX J;' W.GNETIC PARTICLE pot 7 DER BRAND ~ I' ~ MAGNETIC PARTICLE POWDER COLOR COLOR OF COMPONENT 'IIIIAI I I O s RO,I CATIONS' ., ~.. ~
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amect to,o ? ' 7 Pullman Power Products -NM 10 CPR 21 o.n. uo. 46 4 (!S) er (!S NOT1 iso. uc. enm us ATTACHED otscRE1=aNCY REPORT UNIT No. I Vp coctNo. 6
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P*effle Ga. 4 Ektric SPEC.NC: 3711 o 11*O~02
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7177 inspec;cn: ?. Eudsen/MaeCrae ESD-246 and ESD-247 - Magnetic Particle Procecure/ DI7/ con: mucus cou.*.ecnoc , 31 scat
ANT ITEMtHOD Ser SUec b7Il DtPt.ANATICN oF CtsCREP ANCY:
Internal Audit 1101, A.A.R. f1, identified that there was no Procedure Qualification Record l Or ESD-246 and ESD-247. l Subsequent investigation has revealed that ESD-247 was used to MT exanine the inside iamster of N !197, Iso f 500146, Stean Generator 1-1, DR #3h84, en two occasiens (see attached =1"ation records) ISD-247 is listed en DR 83453 as well, under Reco:cmended Disposition and s suspected to have been used (there is no:. amination record with the D.R.) to MT exanine h3 inside diameter of N #244, Iso 1500146, Steam Generator 14 The velds in question are en inns K16-554-16 I7 and I16-556-1617, both Seismic Class 1 code. The use of ISD-247 cn Seismic Class 1 pipe without a Procedure Qualification Record is a
nconfomance to Contract Specification 8711 Section 3 Table I and Notes to Table I, Section Paragraph 3.23, Section 5 Paragraph 1.2, section 2 Paragraoh 2.1 and Section 3 Paragraph 1.4.
--CONTINUED ON PAGE 2 0F DISCREPANCY REPORT-oc menoso otsposmen INDICATE APPROVAL SY CIRCLING THE APPROPRIATE " RECOMMENDED DISPOSITION" 1. Accept-as-is all work examined brESD-247 File a copy of this D.R. in the following locations: A. Docusent package for Iso 8500146 N 197 and original DR 3484 3. Document package for Iso 1500146 N 244 and original D.R. 3h" PG&E G.C. C. Criginals of ESD 246 and 247 QUALITY ONTROL REVIEWED ,,1 -- I P.G.&E. to disposition 9[ l e,,, .,...,. n e.a.n. &~ d.As KL,4'~ Ga MfM2 o, NAL alsPCsmCNt ha ? IWie '*/ * 2, - Q om.r (. tien omd.opre**i r wifed)) ' sek c =eim d in.esj C 3 w.,ii c le d t: Omos . m noo ii,..csss mi,. i d o o.,, c.,,,,,,,, o T To ** event 4EcummfuCE @ Na AroNo.We A/'4C Manager shall assure that N.D.E. proceduros have the necessary Precedure Qualification e ords perfomed and included as part of the procedure prior to submitting to P.G.1E. for ^ m a.a. M ;-m 9 t/ 7e73 ,y,u.,,_ z c o,
$l Pullman Power Producte 10 CFR 21 o.. No. (IS) er (IS NOT1 iso. uo. 5 oe~ u ATTACHED DISCREPANCY REPORT. UNIT No. I I-ccDE NQ. t ' - V % ~L cusToman. Pacifw aae a treetric spec.no:_- s711
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+ pa % J? THE M.W. KELLOGG COMPANY Page 1 of 3 A osviescos or PuttuAm inconPonATEo o.m. No. N8Il ReV. I k$i E iso. No. SIuu.ha the-h a# 5 'I DISCREPANCY REPORT UNIT No. I { cooE No. N/A cuBToasen. Peelfle Gas & Electric sPSC.No: 8711 oATE: 8-26=77 i pocascr: Osamle canyon ace No.: 7177 mspecTon: Runyan/$cannei1/ Guest ? I ossenerantim a: Line K16-556-16": Socol Piece 500: El. 15k'-44": Area G: Sect. I l expt.AMATloN oP oIACnEPANCY: Reference P.G.M. Drawing 500146, Rev. 96 Per P.G.M.'s request, an internal inspection of F.W. 2% on Steam Generator I-4 Feedwater Nozzle will be performed. The line entry will be made in the following menner, see Recomumended Dispositlon. R* s- < ^ ? d k ". $ 3 ;.*M .3 ' ~. 5 V " h '. f ' f.F-a meconsneemoso ossposmon: 1. Measure 2" from F.W. 2% center upstream on pipe (Spool Piece 500) circumscribe 8 the pipe using a wrap around, then prick punch the scribe line. 2. Using air-ere, cut the pipe all around maintaining less than a 400 total bevel to within approximately 1/8" from 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 nozzle beyond F.W. 24 to prevent air frcza entering Steam Generator. 5. Clean and Inspect F.W. 24 Internally ad directed by P.G.M. (Conytggage 2) A r e ev: M.w.n. pw c,A.up. dN# ces. fdM77 c-[/ oew #/2 9h7 4 7 emat oisposmos: 5in - El oeer 4..,l n.n L a r .r m ['" l r a c
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Revision 1 - Delete Step 6 in its entirety (access was achieved). Refer to Attach-VM ment #1 for results of initial inspection and recomunended dipsItlan. 3dW#1'88M 6#f** Revision 2 - See Page 3 of 3 and Attachmentf3. u.a.x.ri M '*]//*l - _ 9l7/?? 2,.O M.y Sed N ~ ' ' ' os,e.rkh> c_ f b'% (u.mrgetrtiih, A 1 Aen lashi.% STEPS to pagvgw? necu e r %.a Plow QA. Menecer oisTaseyTtoN 3 Manor Q.A. File 3 A m. Ines.
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~ ... a. THE M.W. KELLOGG CO.TIPANY page 2 of 3 4 omsion or put.usan inconronarso o.M. No. 3kS3 Rev. I N,61 iso. no. 500146 she. 4 of f I _ DISCREPANCY REPORT uMIT No. l I p. coor we. M/A ] y_ l custowsm. Pselfle Gas a Electrie pec.no: 2711 mara: 8 26-77 088
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7177 inspecrom: Runyan/Scanne11/ Guest moJacT. essentraut ettw Line Kl6-556-16": Soool Piece 500: E1. 154' 4 ": Area G: Sect. I RECOMMENDED OlSPOSITION: (CON'T) 6. If access to F.W. 244 I.D. cannot be achieved, proceed with alternate Instruct!ons j (See Sketch #2). e 1 7. Upon completion of Inspection, remove dam, srind bevel to facilitate fit-up as needed, clean and fit to ESD-215 and E30-220 .r ll 8. Wald out using F.W. 549 and procedure 4/5. 9. Inspect and NDE to Eso-215 and E50-206. 10 Add all Information to process sheet and. isometrics. O ~ c.:n r3 7. 6 .f'. S' I 3 ;.f ,3 ?;. n o': @i".m ;... ; a *5 -i ;; q% -' 2, tt 2 r* u < G.- <. f ~ ~.. A Q"%; M 1 'e 2 n y p p*t '.f ?,in ud % g Ti f'*h a... 4' t-U .a a p J 5,.* g "f f?g ~ t 4 %s ossenssunce 3 assero.a.pae 3 Aum. san. 3 enenswwg ossi. O omer 3 cussener Q messmens O si e im esseur a 3..
..r THE M.W. KELLOGG CO.MPANY Page 3 of 3 A otV9sloN or PULLMAN INCo#PoRATED o.M. No. 3453 &l_l2. iso. No. cnn thr, cic. h af 5 DISCREPANCY REPORT UNIT No. t n. ( CODE No. u /* cusToMan: Nifle Gas & Electrie 3pgc.No: s711 oats: E M 77 Diense canyon .los No.: 7177 Nspecrom: Runvan/5canne11/ Guest pnoascT: ossemeo u tivee U ne MI6-556-16": soool Piece SCO: El. 154'-44": Area G: sect. I O,R 3453. Revision 2 I UFt.4 MAT 10N OF OISCREPANCY; During the performence of ' grinding per 0.R. 3453. Revision 1.' Step #5, four (4) indica-tions of heavy drop thr.cugh with roll over were removed along w,I all of the existing i root penetration. Re-inspection revealed a linear indication,lif long on the fusion line to the Feedwater Nozzle. Further' grinding, to a maxi n dev th of.110", removed
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the Iinear indication (see Attachment #3)'. . ';'.g',j. % 6 W_.$ q n. W,' 2 yG r. g g @\\ NOED DISPO$lTION: G i Add the following to Step #5 and delete original steps #7, 8, 9 and 10. Perform the following repair: A. Grind the 5;v In ca *=et t f emte rie-un af F.W. 544. ,[ g a. M.T. l.O. of F.W. 2% using ESD-247 coil method, and clean grooved root pass at p F.W. 2 % per E50-215. - 4 "/ C. Aamove the das f rom the nozzle at F.W. 2%. T 5 O. Preheat F.W. 2% to a m'inimum of 2500F', interpass not to exceed 5500F maximum. [ 8 ,d, Maintain this preheat until stress relief begins o- .g g E. Weld to procedure 200 (F.W. 2% RI), using E70$2 wire with the GTAW process, to conform to blended configuration of the balance of the weld. I,0. od iv F. Grind and polish the added weld metal to blend with base metal surfaces. I G.' inspect and NOE to ESD-215 and PGf E 2HE# To mMM l A AT l'dM#~W, ( patsa.rM Moo Ac w rM ess 'y M Pera' car e 7. a NOTE: Proceed with 0.R. 3456, and X-ray weld, hot fer Information only. j 7'. Upon completion of Inspection, remove dans from F.W. 549 pipe side, clean and [ fit F.W. 549 to ES0-215 and Eso-220. [ 8 Weld out using F.W. 549 with procedure 4/5A,0. 9. Grind F.W. 549 for x-ray. L 10. Inspect and NDE F.W. 549 to E50-215 / ="<'r!' ~g'gdfl.A tff'1 y "'~ Z% ^ ~ ~ ^ ~,
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-~ ~ a-y am I NOTE: X-ray weld hot for informetion oniy. II. Stress relieve at F.W. 2% RI and F,W. 549 Il00*F to ll50*F per ESO-218 (,12. NDE F.W. 2M Al and F.W. 549 Johst207. /r; e ,,,,,,ro -w p i3 rf a u,ms. arm s prow me em a.n.e
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_ _ i_ _ Al. TERNATE INSTRUCTIONS A ( I. Cut out F.W. 509 using air-are and taking necessary steps to maintain the ability to bevel the 450 oli side of the weld to 2002 2io and a 3/32"! 1/16" land. Also, i I cut out F.W. 339 shown on iso. 3-246. 1 8%5 of 16" Pipe, Schedule 80 A106 Gr 8 and a 3/4" 3000# 5.W. Half I 2. Requisition: i Coupling or soc-o-let AIDS. 4 3. Install the 3/4" half coupling or soc-o-let four (4) Inches from the end of the 16" pipe. 4 Clean and F1t to Eso-215 and ESD-220. 5. Weld cut with procedure 92/93 (F.W. 831). 6 Inspect and NOE to E50-215 and E50-211. 7. Upon completion of F.W. 2M I.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. i 8. Aeweld F.W. 339, as shown on Iso. 3-246, maintain original line configuration, f 9. Clean and Fit-up to ESO-235 and Eso-220. i l
10. Weld out with procedure 92/93.
I. Inspect and NDE to E50-215 and ESD-211. / o. p-pr V +6 0 l / a,/ o,e,< t' ,, ~ c 144 e I . STEAMGEN 1-4 } (~. N SKETCH #2 ....OR 3463
_1 a i FindInes et F.W. 2kk ] 9 %A r3 j L' l / 1
== i e ,unch Marks PI
P on 0.0 7
11" Grooved Root Pass to eliminate lineer. % A
//////AW///h 3/16 % %
~ FF F-O .110" --> Deep a} r.raeve p- ,_,e i l 7 riginal Root Pass I 0 .i! 'y Ground smooth and Slended to Parent W/////j7// aW//// MeteI. Section A-A i NOTE: Average Wall Thickness =.580" to.600" { Remaining Well At Groove =.450" Punch Marks On The 0.0. =.#7" Deep (Punch Marks are directly on the fusion line of F.W. 2% to 1/8" inside the fusion line.M7" deep.) i V ATTACHMENT #3 DR 3453, Rev. 2
J.* t ...s..._...., .-.......,.3,.... ..1...., '.i ' e:", f%. IMEIOFf1CS CCRRESSCtlCGi?CE ATTACHNENy'#1 b' DR-3453 Rev. I i i To J. P. RIINYAN, Q.A./Q.C. MANAGER OATg AUGUST 31, 1977 FRO M D. R. GESKE, NDE. SUPERVISOR $UBJECT. I.I.SU.I..O.,,f.QETME. EM.M.J..NA,I,l.0N,,,,,E L,,2,$,,,,1,N,5,l DE__D 1 AMETER,, On August 31,1977. F.W. 244, Line Kl6-556, Isometric l-03-500146, Feedwatse piping to Steam Generator I-4 Nozzle, was liquid penetrant examined on the inside diameter. The following indications were noted: 1. 2" from top center of nozzle, a small faint transverse linear-nonrele-vant due to weld geometry. ~ 2. 7" from top center of noz=le, heavy I" drop through with roll over. 3. 9" from top center of nozzle, heavy 2" drop through with roll over, i lO 4 37" from top center of nozzle, heavy 1,i" drop through with roll over. 5. 39" fro-tcP. center of nozzie. heavv i/2" dro, throue* with wire protrusion. 6. Approximately 1/16" mismatch exists from 7:00 to 9:00 facing the
nozzIS, We recomend 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 " Recommended Disposition", Step 7 of D.R. 3453, Revision I.
~ L Donald R. Geske j NDE Supervisor e ? ORG/js 4 i \\. n .s ) 4^ Q. li *. g%. ! N%;i.:.%.6.h 1
t Response to Internal Audit #101, A.A.R. #1 l i A procedure qualification was performed in order to qualify E50-247 as l well as ESD-246 (ref. Internal Audit #101, A.A.R. #1). i As both ESD-246 and 247 have been withdrawn from use and the equipment i listed in both procedures is no longer available for use, the equipment used for these PQR's was the Magnaflux Model P-90 for the coil technique only. All other factors are the same as specified in the procedures. j As the Magnaflux Model P-90 puts)Lless amperage than the equipment listed in ESD-246 and ESD-247, and acceptable results were obtained (i.e; I.D. and 0.0. surface 1 and I.D. subsurface indications were located), the demonstration of this technique is deemed adequate to approve this method employed by the equipment listed in the above procedures. A record of the procedure qualification demonstration is hereby submitted .along with this response. The originals will be filed with the applicable procedures. g In the event that either or both procedures are re-activated in the future, ' hey _will be revised' to iiicorp' rate the Magnaflux Model P-90 into the list of equipment. ~ o As both procedures are currently withdrawn from use, no revision is deemed necessary at this time. % l A -.D,% M
i Michael S. MacCrae MT Level III 11-9-82 i
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1 j I ~ ' ENilNEERlHG SPECIFICATION ' SPEC,NO. = I 8711 ~ 23 - ENGINEERING DEPARTALENT ES 0-246 {w 4 1 MACNETTC PARTICT.E PROCEDURE OUALITICATION RECORD l Procedure Qualification No. MT-3^ + Method Dry Powder Continuous; Hal f Wave.0.C., Coil Equipment Manufacture Maanaflux coro. ] Brand-Nama Macnaflux l Model Number P-90 ~ ~ Magnetic Particles: Brand Magna flux Tyce Ory Color 8A-Red t Magnetization Current Hal f Wave Rectified 0.C. Out Put Amperes 1000 Amos. Test Piece Position . Vertical Test Material Carbon Steel Type Test Piece 3"x2" Recueer with cut fillet weld at socket end Surface Condition Bare Metal Pre-Cleaning Method None Weather 70o Orv Base Metal Color Dark Brown and Shinv Metal Contrast of Particles to Base Metal Good q Method of Particle Application Dowder Bulb q.. Method of Removing' Excess Particles Blowine
v Demagnetization None
/ Prod. Specing and Amperage: 3 Coil Loops of 5 x Pipe Diameter with 1000 Amps. / anc4%<- l 1.2. L e A ce w.t. ..I ^~] c,3 pt d g',qb EL-h. 19N s MedeA P-r w H.::AC wave. Ru.h A,e: o.n. s,4,, g 9 DC. Cacant. (im v=H 14;<.a%. f. j g 3"x 2 ~ Reducac /, LS.cc!n4.s ace. Mauce.cl %,c g 3.g.,,4. w e w7 l T:sr Piec.a. M a %-wu cd oC a D en j sa.a % ca eeessed. %eV c9 1 Coit# h % Wev au cut was M-weAdesk to f%dur.e. wu-SwMe. M tc. h oa m
Evaluation of Procedure _ Good-Indicator and defect sho'wed well.
1 Procedura: C3 Approved C3 Not Approved Test Conducted By M. MacCrae n/9/t I -""Vw.6 D % C.% l lTT', l.a.ve E. i ^ J PREPARED BY M. MacCrae DATE OP ISSUE 11/9/" 8AG5 0F DATE OF REY. APPROVED BY e
ENGlHEERING SPECIFICATION ' SPEC.NO. ~ ' ' 'l.. sw i 8711 s F 2) . ENGlHEERING DEPARTMENT ES 0-247 X ~ ~ MAGNETIC PARTICT.E PROCEDURE CUAI.I?ICATION RECORD l Procediare Qualification No._ MT-3 Method Dry Powder Continuous; Hal f Wave 0.C., Coil Equipment Manufacture Maena flux Core. Brand Name Macna flor Model Number P-90 Magnetic Particles: Brand Maanaflux Tvoe Orv Color 8A-Red Magnetization Current Hal f Wave Rectified 0.C. Out Put Amperes 1000 teos. Test Piece Position . Vertical Test Material Carbon Steel Type Test Piece 3"x2" Reducer with cut fillet weld at socket end Surface Condition Bare Metal Pre-Cleaning Method None Weather 700 Orv Base Metal Color Dark Brown and Shiny Metal Contrast of Particles to Base Metal [ Method of Particle Application ~ Good Powder Bulb jT Method of Removing' Excess Particles _Blowine J l ' Demagnetization None ~ Prod. Spacing and Amperage: 3 Coil 1. oops of 5 x Pipe Diameter with 1000 Amps. / ada:a&ce-l l 1.2. Lek t,,a, -..] 1 t K. con go3,3,_A 6% I h S a Magu,fio s. Medet P-r V_ -ww.....ml H ::AS-w.we. Rach %.ci n -. o.n. L4ar.e g' _ 9 DC. C cred'. Ge van ta & g 4 3~x2 her / l LcGca.kons are induce.:.L m.o.4c.,\\ 4 c.chs maae. by M II*
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2 J -a AMANOJT' 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 welding, procedure qualification tests, and plant modifications during the hot functional tests. In my professianal judgment, if these issues alone are confirmed as examples of general practices, the plant could not possibly be licensed to go critical under 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, Bechtel Power Corporation. Bechtel's booklet is not a bad document. Although there are a few minor errors, it describes a reasonable design control and j 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 l described in Bechtel's own handbook. The handbook will be discussed in l more detail below. (1) In reply to PG&E's letters no. DCL-84-067 and no. DCL-84-078 concerning I 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 L are many more cases where bolts have been used. I l'
. 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 I can provide the support numbers, 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 QA inspector 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., proper metallurgical properties). l l In ANSI B31.7 chapter 10723, entitled " Materials," it is stated that "all material shall be clearly identified" by "the appitcable material i specification and grade, heat number, or heat code of the material, and any. I additional markings required to facilitate traceability of the reports of L the results of all tests and examinations performed on the material." ANSI l 831.7 also states that "Certificant of Compliance with the material specifica-tions may be provided in lieu of Certified Material Test Reports unless other-. L wise required by the design specification." (Emphasis added) i
3-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 by applying his assigned symbol for permanent record in a manner specified 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 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 welding operator." In discussions with Pre-inspection Engineers, QC and QA inspectors, some 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 2 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 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 notLtrain personnel, nor did-they correct this misconception.
. Having worked on other nuclear plants, I know the importance of these sections in ANSI B31.7 and ASME SectiAn IX. At other plants almost everything in Class I systems was stamped and logged, and records were kept to insure that traceability was maintained. Per B31.7, "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 j was not done at Diablo Canyon. The practice of using "non traceable" 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 definsd in 1-723.1.2." (Emphasisadded) 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 did not have to meet the scrutiny of ANSI B31.7. (3) Deficient training reinforced the proble.ns, and perpetuated them. QA -inspectors told me that their training consisted of reading ESO 223 for one week and being given a list of suggested reading. This list contained B31.7, 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 to know what B31.7 was, not what it says." I and others thought that these codes had been incorporated into ESO 223 by management." This was, and remains, a wrong assumption. The inspectors undoubtedly performed to the best of their s ~ e g r,w --=, - .-e ,.4, ve-.- wr + -e~ -~ - r-w-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. DCL-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 criteria." I don't know if PG&E reported other modifications 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 D. 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 below of correct installation compared to incorrect installation.
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a g 3 7____ g 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. s 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 fromeither Unistrut, Superstrut, or other brand names. (6) In paragraph 5 as a remedy for possible 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 an ge. " (Emphasis added) Based on my experience in the nuclear industry, the proposed fix by PG8E/Foley would do more damage than good. To my know-ledge, there are no engineering documents presently available or in ese 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 an electro-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 I
l.- T t ' 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 yhar f exposed to adverse conditions. (7.) In reply to intervenor's Petition to reopen Construction Quality ,' Assurance, Affidavit of H.R. Arnold, F.C. Breismesiter 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, it, could not be verified that stainless steel tubing PBS number MD045 had been qualified in all braze flow positions (vertical-up, vertical-down, horizontal _ and flat) since the procedure qualitfication tests performed in 1977 did not include the vertical-up flow position. This variation was - properly documented on Foley Non-Conformance Report (NCR) #8802-675 in 's accordance with approved procedures." (Emphasis added) The statement quoted I above is in direct contradiction to the first line in Para. 1 and line, Page 1. "This allegation is completely false. The procedures in question were qualified prior to their use." (Emphasis added) To correct this problem, one worker was tested. Under ANSI B31.7 and ASME Section IX, each welder must be qualified to perform the work to which he is assigned. F31ey's solution does not correct the use of-the procedure from 1977 to 1981 for-brazing a vertie.l-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 4 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,'rince past work could be considered training thus not oualifying as acceptable work. ASME Section IX requires that the welder be qualified first before work is performed.. There is a reason for this, c - ~.. - ..v.n-.- + -,w,
8-which is to ensure that the work is performed correctly. The other point not sufficiently covered in Foley's reply is that "Neither the ASME Code nor 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 B31.1, B31.7, ASME Section IX, AWS 01.1-79 or 10 C.F.R? 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 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 i 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 l 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 remained 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 ~ w.-
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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 familiar with this Discrepancy Report (DR) on Unit 2 realized the same problem might have occurred en Unit 1. I was shown a i copy of a Preliminary Discrepancy Report listing about 15 supports in Unit 1 which the worker had determined had the same problem as the Unit 2 problem. narrated above. I can supply the DR number on Unit 2 and the author of the Unit 1 DR. This will be suppled under similar conditions listed on a 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. The title of this document is Field Engineer Pocket Hanger Reference. This document was sent to the field for issuing, but was recalled under che 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 Diablu. Had it been issued many problems would have surfaced in a relatively short time. Why 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-1ssued 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.- ~. . ~
10 - 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-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." I 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. '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 would like co point out the concise clarif.ication of weld symbol terminology. Had'this part of the' book been in effect atiDiablo,' many-questions would have been' resolved -(although many 4- + e-v w w t.- v& --e.-- e ej
11 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. Y/ S Charles Stokes l y .e p m e
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c I.-- .,l sagtlj'1 1e'llIYlne g NO TES: PIPE INSULATION CH ART 14 o ))f f kk 3Y!f'I Fittings end velves are normally insulated with pre-formed g!l g 8-ag{gggi;2[C g g t sections of thC same material as used on the pipe. However seg-a 'l Egg,[aI'((-= I' E D ggg g
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g l 3 I gggj] 3 3* The oefection of the type of jacket to be used should be modo 35 [!s aj with due consideration given to the fo!!owing: emount of abre- = g Ei l es ! sion and mechanical abuse to be encountered. Weather protection w 8 3 g g g g for outdoor installations, fire proofing, vapor barrier require-Iffi j g c3 ments, cost of applicatactn, and last but not least the finished g I i I g appearance, g aaa 3 l Most insafetion failures are caused by water entering through 2 gC hl l brooks in the finish, such as expansion cracks, or un-fleshed a ~ g 5 wE g 3 g openings, therefore, particular ettention should be given to com-1 ~ 3 piete detailed specifications in regard to weathorproofing. 1 s 3 i The usual insulating materials and jackets for heated piping g I 1 i g l t and equipment allow the moisture to escape in the form of I v{ l l j shut <fowns are frequent, moisture in the insulation is not driven = n { vepor. However in the medium temperature range, and where j I a g a off and water damage is most likely to occur. For these condi-3 g g tions, the insufstion should be thoroughly dry before applying OC the jacket, the surface of the pipe should be primod and painted, g a 7 e l TT I lation. It possible,insutstion should be applied to high tempere-a and corrosion restraint wire or bonds used for securing the insu-g l 8 ture piping while heated to insure the complete dryness of the k 3 { completed instellation. a I E The layout of insulated piping and equipment should pet > { g vide adequate cleerences for proper application of the ineutetton E [ and eleo safeguard against mechanical damage during normal operation end meintonenes ! h! k! k I !!~fl s!! ll l 8 [ Thicknesses, es shown are nominet. Actual thicknesses,which I 338 5g I I g are based on " simplified thicknesses " will very slightly from s a i esf nominal in that the outer diameters of the insulation appromi-g,"jj [j ggy l l3 mate the diameters of iron pipe sizes in order to obtain nesting 15 8I Is of layers. l ly it ah r! I Weights, as shown,are for actual thicknesses and are beood on - if [i I i densities of 11 pounds per cubic foot for 85% rnagnesia and col-I,l is t El .I g l 8 cium silicate, and 21 pounds per cubic foot for diatomeceous [ l earth (caicined disiom.eeous silice and esbestos fibers. weights
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a g 3 s a for meterials with different densities may be proportioned zj E t 1 I accordingly. l l[g5 !! ! o 5 a 0 a I At temperatures above 800 F, pipe expension is e significent 3. h 1, g gl fa-tor. For best results pipe insulation should be applied in g 2 l l double toyers with staggered joints for all operating tempere-s ga g 3 l l gl lgg 0 tures above 800 F. This construction prevents excessive heet a a I 2 losses and surface temperatures et the joints, opened by pipe l g, yt e g3 l 44! l .". expension, thus eliminating scorched or burned jackets. This Ii't I = construction also eliminates the potentist fire herard of exposing a[ l [i l g l l8 jackets to higher temperatures et the joint. Double-leyer, steg-j- m j el 8 I C gered-joint construction eiso minimizes thermal stresses in the = I* l ls-i j g E insulation by reducing the temperature differential across each lg i l 3 g layer. s a j s The recommended thicknesses in the above table are cascu-ll I j ,{ a d lated on en economic besis for heet conservation umler everage g 'llI y jg l I operating conditions for steam gene <ntion and process piping, E and secure adequate temperature control. To dstamine the most -I I I: 0 S economical thickness for any porticuter instalistion the cost of gl l 8f l* E fuel, fined therges, need for definite temperature control, or ag g 3 other special conditions must be considered. If necessary, inou-3s I 1 5 lation thickness can be increased. g sj l I{ l l - for pipe siaes up to 24-inch in calcium sificate and up to 14 inch j Generelty, pipe insulation is furnished in 3-foet half sections. 3, a, r-l g I a g pipe site for 85 percent magnesis and diatomaceous earth, g a[ g[ g I Insulation for pipe sires farger than those mentioned is usuelly g y furnished in 3 foot long segments or curved blocks. w i e
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)-- I GOVERNMENT ACCOUNTABILITY PROJECT b institute for Policy Studies 1901 Que Street. N.W. Woshington. D.C. 20009 (202)234 9382 March 2, 1984 Mr. Thomas Bishop Division Director U.S. N.R.C. Region Five 1450 Maria Lane, Ste 210 Walnut Creek California 94596 Re: PACIFIC GAS AND ELECTRIC (Diablo Canyon Nuclear Power Plant, Unit 1), Dkt. No. 50-275 i i
Dear Mr. Bishop:
Enclosed with this letter 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. Also enclosed for your use, bound separately in this package, are three documents that were not included in the petition filed on Febru-ary 2, 1984: Exhibit 4 to Attachment 2, and two Discrepancy Reports inadvertently omitted from Attachment 7. Best wishes in your continuing investigation. Sincere
yours,
__1 N o Clewett
Enclosures:
A/S l _---_-_____-_-_-_a-_--_.u-- - - - -}}

ML20088A794

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ML20088A794

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Subject:

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Dear Mr. Bishop:

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