ML20093P205

Interim Deficiency Rept 84-15 Re Gk Newberg Welding Program Defects.Initially Reported on 840810.Structural Steel Traveler Packages Reviewed to Identify & Correct Defects & Will Be Part of Final Gk Newberg Document Review Program

ML20093P205
Person / Time
Site:	Braidwood
Issue date:	10/22/1984
From:	Danni Smith COMMONWEALTH EDISON CO.
To:	James Keppler NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
References
84-15, 9370N, NUDOCS 8411060183
Download: ML20093P205 (2)

Text

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, / Chicago, lilinois 60690 October 22, 1984 Mr. James G. Keppler Regional Administrator U. S. Nuclear Regulatory Commission Region III 799 Roosevelt Road Glen Ellyn, IL 60137 Sub ject : Braidwood Station Units 1 and 2 10 CFR 50.55(e) Interim Report G. K. Newberg Welding Program Deficiencies {

NRC Docket Nos. 50-456/457 References (a): D. H. Smith letter to J. G. Keppler dated September 10, 1984.

Dear Mr. Keppler:

On August 10, 1984, the Commonwealth Edison Company notified your office of a potential deficiency reportable pursuant ,

I to 10 CFR 50.55(e) regarding deficiencies in the Gust K. Newberg l welding program at our Braidwood Station. Reference (a) provided l information concerning this matter to fulfill the thirty day i reporting requirement. For tracking purposes this deficiency was l assigned Number 84-15. The purpose of this letter is to revise the  !

description of the deficiency to include Shielded Metal Arc Welding l (SMAW) and update the status of corrective actions.

l OESCRIPTION OF DEFICIENCY A review of Gust K. Newberg welding has revealed some inconsistencies in the Gust K. Newberg welding program.

inconsistencies can be categorized as 1) Gust K. Newberg These engineers specified AWS weld process specifications (WPS) that had not been incorporated into the Gust K. Newberg welding procedure for flux core welding, specified improper WPS's, or did not specify WPS's for all joints, 2) Gust K. Newberg ironworkers welded to AWS pre-qualified details that were not approved by Sargent & Lundy for the flux core procedure or were not specified by the Gust K. Newberg engineer, and 3) Gust K.

Newberg ironworkers listed procedures on traveler packages as being used that they did not use or did not list all WPS's used.

Investigations indicate that the problem is confined to cover plate installations in Unit 1 and Unit 2 Containments, and box beam end connection modifications in the Unit 1 Containment.

Based on applicable Structural Steel Traveler Packages (SSIT) reviewed to date, documentation problems occur, in varying combinations, in approximately 82% of the Flux Core Arc Welding (FCAw) SSIT's and 18% of the SMAW SSIT's.

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, . w i-STATUS OF-RESOLUTION To date,-320 SSIT's have been reviewed.-

Based on the results'of these reviews, Commonwealth Edison continues to believe that the problems relate to-documentation physical defects only and that no associated exist. This belief, as previously stated in Reference (a), is based on the.following:

1.

The welders involved were qualified according to American Welding Society (AWS) to use all welding processes involved.

2.

The weld. joints detailed by engineering and installed in the field conform to AWS pre-qualified details.

3.

The welding processes used were pre-qualified by AWS and the size and type of electrodes used were limited, limiting the variables available to the welder. thereby 4.

Electrode wire size, voltage, and amperage carameters are the same for all FCAW and ~SMAW welds regardress of joint detail or orientation.

5.

All welds were visually inspected and in some cases, Nondestructive physical defects Examinations (NDE) were conducted.

were identified. No SSIT review to identify and correct document deficiencies will be part This program, of the Gust K. Newberg final document review program.

Newberg Procedure which29,will be conducted in accordance with Gust K.

Program completion is scheduled for January1985. 15,should be initiated by A status report will be submitted following completion of the SSIT reviews. ,

concerning this matter to this office.Please address any questions that you Verytrulyyoufh, dd m th&

Day d H.

Nuclear Licensing Administrator cc: NRC Resident Inspector - Braidwood Director of Inspection and Enforcement U.S. Nuclear Regulatory Commission Washington, D.C. 20555 9370N