ML20092C229
| ML20092C229 | |
| Person / Time | |
|---|---|
| Site: | Beaver Valley |
| Issue date: | 06/08/1984 |
| From: | Woolever E DUQUESNE LIGHT CO. |
| To: | Murley T NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| References | |
| 2NRC-4-075, 2NRC-4-75, 84-01, 84-1, NUDOCS 8406210070 | |
| Download: ML20092C229 (4) | |
Text
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2NRC-4-075 Telecopy 2
Nuclear Construction DMelon June 8, 1984 Robinson Plass Building 2, Suite 210 Pittsburgh, PA 1520s United States Nuclear Regulatory Commission Region I 631 Park Avenue King of Prussia, PA 19406 ATTENTION:
Dr. Thomas E. Murley Adminis trato r
SUBJECT:
Beaver Valley Power Station - Unit No. 2 Docket No. 50-412 Significant Deficiency Report 84-01
" Clamp Anchor Assemblies with Undersized Welds" Gentlement This Final Report is in reference to the repo rt ab le Significant Deficiency relating to the ins tallation, or rele ase fo r ins tallation, of seismic small bore clamp ancho rs with unde rs ized welds.
The pr evious Duque sne Light Company (DLC) repo rt on this subject ( 2NRC-4-012, da ted February 16, 1984) indicated that a subsequent repo rt on this subject would be submit ted by June 1,
1984.
An extens ion unt il June 8,
1984, was approved by Mr. G. Walton, NRC Senior Resident Inspector, at the request of DLC.
We ant icipa te that no additional report s will be issued on this matter.
DUQUESNE LIGHT COMPANY Ey
.tr.
Vi(c/J. 'Wooleve r E.
e President RW/wjs At t achment cct Mr. R. DeYoung, Director (3) (w/a)
NRC Document Control Desk (w/a)
Mr. C. Walton, NRC Resident Inspector (w/a)
Ms. M. Ley, Project Manager (w/a)
Mr. M. Licitra, Project Manager (w/a)
INPO Records Center (w/a)
SUB.SpRIBED AND SWQRN TO BEFORE ME THIS
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Not ary Public AfitTA ELAltlE HEITER, tt0TAfiY PtfDttC RODINSON TOWttsHIP. Al LC0!IENY Coutav MY COMMISSION EXPIRES OCT0neR 20,1rygg
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United Stctes Nuclocr R:gulctory Commicsion Dr. Thomas E. Murley Page 2 COMMONWEALTH OF PENNSYLVANIA )
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SS COUNTY OF ALLECHENY
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///[I _ before me, On this day of _
j_ g a Notary Public in and fo r said Commonwe al t h and County, pe rso nal ly appeared E. J. Woolever, who being duly sworn, deposed and said that (1) he is Vice President of Duquesne Light, (2) he is duly authorized to execut e a nd file the fo rego ing Submit t al on behalf of said Company, and (3) the statements set fo rt h in the Submittal are true and correct to the bes t of his knowledge, 21 ed t.
Not ary Public ANITA ELAINE REITER, NOTARY PUBLIC ROBINSON TOWNSHIP, ALLEGHENY COUNTY MY COMMISSION EXPIRES OCTOBER 20,1986 i
BEAVER VALLEY POWER STATION - UNIT NO. 2 DUQUESNE LIGHT COMPANY Report on Significant Deficiency No. 84-01 Clamp Anchor Assemblies with Unders ized Welds 1.
SUMMARY
Beaver Valley Power Station Unit 2's (BVPS-2) Mechanical Contractor, Schneider Powe r Corp., had the res pons ibility fo r the fabrication of clamp anchor as semb li es for small bore pipe.
These were initially to be fab rica ted in the contractor's fabrication facility local to the s ite that is subj ect ed to similar controls to tho se placed upon fab-rica t ion ac t ivities at the site itself.
Howeve r, the cont racto r req ue s ted and obt ained ap proval to sub-c ont rac t these as semb lies to Pit t sburgh Bridge and Iron (PBI) for manufacture.
During a routine inspection of installed piping on site, a QC Inspector 4o did not have direct responsibility for the ins pect ion of the clamp anchor as semblies reported that he considered the welds to be undersized.
2.
IMMEDIATE ACTION TAKEN On receipt of the QC Inspector's report, an ins pe ct ion was pe rfo rmed on similar items in the s to rage area.
This inspect ion resulted in 100%
t reject ion of the approximat e 100 clamp anchor as semb lies ins pe ct ed.
Following this repo rt, a Stop Work Order was issued by the Mechanical Contractor to pr eve nt fur t he r ins t al la t io n, and a Stop Work Order was also placed on the vendor to pr eve nt further manu facture of these assemblies.
Mr. E.
F. Kurtz, Jr., Manager of Duquesne Light Company (DLC) Regula-tory Af fairs Department, notified Mr. Glen Walton, NRC Regident ins pe c-tor, on January 16, 1984, that this matter hai be en de t e rmined to be a potentially reportable deficiency.
3.
DESCRIPTION OF THE DEFICIENCY Inspect ion by Dif Site Quality Control (SQC) reve aled that virtually all the 1100 clamp anchor assemblies cont ained unders ized welds.
The majority includes welds les s than 50% of the speci fied size.
A tot al of 515 of these as semb lies have been ins t al led.
An inves tigat ion of this incident revealed the following programmatic problems a.
It ap pe ars that the ve ndo r QC Ins pector became involved in the product ion proces s; a nd, thus, the as semb li es were not inde pe n-dently verified by the QC Inspector prior to delivery, b.
Because of the unique occurence of the Mechanical Cont r act o r placing a fabrication order for this proj ect, the s ignific ance of their return to the cont ract o r's local fab rica t ion facility was mis sed ; a nd, thus, adequate receiving inspect ion procedures were not invoked.
c.
BVPS-2's Ve ndo r Surveil lance Croup was involved at the ve ndo r's plant, but had no opportunity to independently verify a sample of the welding.
They were not given ship ping rele as e au t ho ri ty,
usually applied under normal purchasing activity.
4.
ANALYSIS OF SAFETY IMPLICATIONS DIE has de t ermined that the systems in Milch these clamp anchors are used include Category 1 systems and that multiple failures could impact on the integrity of sys t ems and on the abili ty of the sys t uns to perform their required safety functions.
5.
CORRECTIVE ACTION TO REMEDY DEFICIENCY As indicated in our previous report, laboratory testing was planned to determine the strength of the assemblies under load. A t es ting program was developed (2BVM-3324, " Clamp Anchor Test Program).
However, as the actual weld dimensions were documented on Nonconformance ard Dispos i-tion Report s (N&D's), it be cane evident that clamp anchors with such severe de fic iencies could not be quali f ied to pr es e nt des ign loads.
The re fore, the laboratory test program was discontinued.
The location of each clamp anchor assembly was detennined to facilitate rework or reassembiv.
New clamp ancho r des igns have be en issued fo r fab ric a t io n.
The new design prese nt s fewer fabrication problems and will be manufactured by a different ve nd o r.
The purchase order will placed by Stone & Webster, the BVPS-2 Architect Engineer, to ensure normal purchase controls.
The DLC Vendor Surveillance program will be applied to the select ed vendor of the new des ign pipe clamps.
This will include shippt ru release aut ho ri ty and fo rmal ve ri ficat ion by the D LC-SQC Rece iving Department.
The new as semblies will be used to replace al l 1100 clamp anchors,
which were received from PBI, including the 515 installed assemblies.
6.
ADDITIONAL REPORTS DLC does not anticipate submitting additional reports on this matter.
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