ML20113A508

Forwards Addl Info Re Structural Steel Welding at Facility. Number of Unpainted Connections at Time of Insp Verification program:1045.Reasons for Unpainted Connections Discussed

ML20113A508
Person / Time
Site:	Wolf Creek
Issue date:	02/14/1985
From:	Koester G KANSAS GAS & ELECTRIC CO.
To:	Denise R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV)
Shared Package
ML20113A461	List: ML20113A496 ML20113A508 ML20113A517 ML20113A524
References
KMLNRC-85-054, KMLNRC-85-54, NUDOCS 8504100597
Download: ML20113A508 (18)

Text

i KANSAS GAS AND ELECTRIC COMPANY vm sucmc c-February 14, 1985 o6 6.c i,ea

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Mr. R.P. Denise, Director Wolf Creek Task Force U.S. Nuclear Regulatory Cormission Region IV 611 Ryan Plaza Drive, Suite 1000 Arlington, Texas 76011 KMI2EC 85-054 Ret Docket No. SIN 50-482 Ref (1) KMI2aC 84-238, dated 12/31/84 From GIKoester, KG&E to BGeYoung, NRC (2) KMI2aC 85-037, dated 1/21/85 From GIKoester, KG&E to RCDeYoung, NRC Subj: Supplemental Information Concerning Structural Steel Welding

Dear Mr. Denise:

'Ihis letter provides supplemental information requested by Mr.

Lawrence Martin of the N2 clear Regulatory C=4=nion concerning structural steel welding at Wolf Creek Generating Station. This information supplements the reports transmitted by htferences 1

'and 2.

During an inspectial exit meeting at Wolf Creek on February 9, 1985 Mr. Martin requested the following information:

1. Clarification on the nunber of joints that were unpainted at the time of the inspection verifications. performed as a result of Corrective Action Request fl9.

2. NLmber of painted and unpainted joints in each building at the time of the inspection verifications.

3. Any available information concerning the nunber of ps.inted welds that were installed by the same welders who had installed welds that were unpainted at the time of the inspection verifications.

4. Information concerning the rumber of painted joints on l

which Magnetic Particle testing had bea.n performed prior lf to painting.

Subsequent to the exit meeting four additional requests were nade. These requests were as follows:

5. Reject rate of welds with previous inspection documentation.

versus those without inspection documentation.

20.

. -ssmtwra. Kenses -Man Address:Po. soK 206 i %kNts. Kansas 67201 - Telephone: Area Code (316) 261-6451

~

9 Mr. R.P. Denise KMLlac 85-054 February 14, 1985

6. Information concerning the nunber of welds identified as having cracks, lack of fusion, undercut, and porosity.

7. Infonnation concerning thickness of paint.

8. Information concerning AWS position on secondary inspections.

The following information is provided in response to the above requests:

1. 'Ibe nunber of connections (joints) unpainted at the time of the inspection verification program was 1045.

'Ibe reason that 1045 connections were unpainted (uncoated) is discussed in Section V of the attachment.

2. See Section I of the attachment.

3. See Sectims II and III of the attachment.

Colum b 'df Section II provides the number of painted connections in N

each building that was installed by welders who had

(

installed acceptable joints that were unpainted at the time of the inspection veri *1 cation.

Section III provides additional information concerning these welders.

4. See Section II coaumn C of the attachment.

5. See Section~ IV of the atWnt.

6. See Section VI of the attachment.

Please. note that all of the connections exhibiting these charact'ristics were e

evaluated by the Architect / Engineer and found to be acaptable or use-es-is.

7. See Section VII of the attachment.

8. See Sections VIII and'IX of tte attachment.

i i

Please contact me or Mr. Otto Maynard of my staff if you have any 1

questions concerning this information.

.3 Yours very truly, Glenn L. Koester Vice President - Nuclear

+

Gm: dab I

xc: PO'Connor (2) l HBundy WGuldemond I

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Attacriment to KMLNRC 85-054 Page 1 of 17 J

I.

A.

Total Connections identified by Bechtel in CAR-19 Scope as Structural 1*Significant 2.670

=

B.

Connections Inaccessible during criginal CAR-19

~

Inspection Activities 119 C.

Total No. of Missing Connections due to No Instal-lation of Required Material or Welds 21

=

D.

. Total No. of Painted and Unpointed Connections j

Available for CAR-19 Inspection 7.529

=

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Connections l

MSSWR's Inaccessible

,k, BUILDING -

Painted Unpainted

_ Fainted Unpainted NSSWR's I No MSSWR

..e-

'1 AUXILIARY 133 502 100 382 25 23 p.s -

y,

CONTROL '

40

'172 "

40 125 17 35 '

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Page 3 of 17

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l Ill.

A minimum of forty-one (41) welders were determined to have worked on unpainted as well as painted connections in the C A R-19 scope. Each of these welder's performance on unpainted connections was evaluated to determine an individual's demonstrated capability of producing welds free specifically from lack of fusion, cracks, porosity and tight undercut. None of the forty-one (41) welders weldments applicable to C A R-19 structural connections exhibited significant deficiencies of these types, that upon evaluation by Bechtel resulted in a decision to rework the weld / connection. Therefore, each welder's work on painted connections was projected to be acceptable, and a projection made of justifiably acceptable painted connections due to these welders' performance.

IV.

Rework Rate on Connections for which all MSSWRs are retrievable = 7.396 Rework Rate on Connections for which no MSSWRs are retrievable = 2.496 Rework Rate =

Connections Reworked

• Total connections in Category Includes Connections reworked due.to exceed design stress a!!owables plus connections reworked per management direction.

V.

At the time of the CAR-19 Inspection Verification Plan, structural steel coatings were r.ot complete. In addition, structural steel that is fireproofed does not require coating. (Note: Fireproofing was removed, where present, from all joints.)

. + :.

l-I

l l

l VI.

Page 4 of 17 CONNECTIONS IN CAR-19 SCOPE EXHIBITING LACK OF FUSION FROM INSPECTION RESULTS Connection Painted Building Number Yes No Bechtel Evaluation Auxiliary A001 X

Acceptable A006 X

Acceptable A007

^X Acceptable A010 X-Acceptable A0ll X.

Acceptable

,A012

.X Acceptable A035 X

Acceptable

• ', j.. g,.

,,.A044 X

Acceptable

.. [.

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s. A 0 4 7.

x Acceptable

.-A048.

X Acceptable ph,y,).A0 51"-*'d-

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X Acceptable A073:.

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,'.."[ !;.A09 3m.m -

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-1 Acceptable

- A102 X

Acceptable

-l t :-"

',.1,A1147

.X Acceptable I

A132 '.

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X Acceptable h.. '.c.$. A.,;;.. *?g

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.,., J. cA158 X

' Acceptable

..1.i.. I l.', f i:A213;

...9A159 X

Acceptable

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3.y,.hei ).%Qv. A2'234

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'iA226 X

Acceptable.

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.a A231 X

Acceptable 23(. p"l

.fA236l X

Acceptable A+

. ?A239

'X Acceptable

. A. ~1,., ;

.o w..PrA253 X

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-W i M A259-

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.';iS

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'- Acceptable

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P s

A266 X

Acceptable

- -#f 2.

",'7 0

-A270 X

Acceptable 1

A280 X

Acceptable I

A283 X

Acceptable

. '~* r.L:- l : '.:

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A286 X

Acceptable

- e. 4.r'. '.7. M~.

./A319 X

Acceptable 4

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A370 X

Acceptable

. 5l*-

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.. 9..A439, X-Acceptable

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v. A4.5 8.. -

X Acceptnble

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I CO22' X

Acceptable

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.- CO23 X

Acceptable

. c.

CO25 X

Acceptable

? t.

/

C031 X'

Acceptable C048 X

Acceptable 1

C075 X

Acceptable

i Page 5 Of 17 i

CONNECTIONS IN CAR-19 SCOPE EXHIBITING LACK OF FUSION FROM INSPECTION RESULTS

~

Connection Painted Building Number Yes No Bechtel Evaluation Control (con't)

C085 X

Acceptable C086 X

Acceptable C087 X

Acceptable C098 X

Acceptable Cll3 X

Acceptable Cll4 X

Acceptable C121 X

Acceptable C127 X

Acceptable Cl31 X

Acceptable

'Cl32 X

Acceptable Cl33 X

Acceptable Cl36.

X Acceptable 4-C209 X

' Acceptable Pus 1 F10 X

Acceptable F17 X

Acceptable F45 X

Acceptable Rsactor RA X

Acceptable

~'

R009 X -

Acceptable

/

R030 X

Acceptable R039 X

Acceptable

.1

~ R040 X

Acceptable R043 X

Acceptable.

R078 X

Acceptable R079 X

Acceptable-R097 X

' Acceptable j,.

l R680

-X Acceptable

'.L.*

'~->

R685

.X Acceptable i

, ;;'. e -

17 61

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4-

VI.

Page 6 Of 17 CONNdCTIONS IN CAR-19 SCOPE EXHIBITING UNDERCUT FROM INSPECTION RESULTS Connection Painted Building Number-Yes.

No Bechtel Evaluation l

Auxiliary A006

.X Acceptable A007 X

Acceptable A0ll X

Acceptable A045 X

Acceptable A051 X

Acceptable A054 X

. Acceptable A061 X

. Acceptable

. X

, Acceptable A064

. 4 :;..y,. ;

1. -fu

.A065.

X Acceptable

.,.. :.. :.a..

, :4.

g.,..

s... ' :6.:r e..A067,.a..

X

, Acceptable JX Acceptable

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'..k'.':?E070'I.W~

X e.p5's.A069gyg?

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.:. Acceptable -

d.? T,$,$'S;k & l'

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, ' 17,".Igf.,,f..J. b,. e_?.. ?.... 4;c..r".g a., -

lW)~A098;,.

.'f.yiA071 a.

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'A v :, A218, :

A,-

X.

s

~,-

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fcceptable

'..A219 X

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..A224

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s 6i 9.;A251' X*

• Acceptable

...Q:

f-A266 X

. Acceptable e

(

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.A267

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l# ' A2 6 9 3 '.c, ',

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. Acceptable' jAcceptable

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[g gigy..A270'9g

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1. Acceptable',

e

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A323 c.*~.

• X1

., Acceptable -

y

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f.a,, s. c.

>c.J,,:A374 -s*n w X'

uAcceptable s

2

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- Acceptable.

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f Acceptable

s a-A505 e

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~4 T, X

Acceptable n

a

~

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I

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.X Acceptable

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Acceptable C031 X

Acceptable

- C047 '

X Acceptable f-

" C0485'-.

s X

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c

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.C090

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X Acceptable

'i.....-

Page 7 Of 17 CONNECTIONS IN CAR-19 SCOPE EXHIBITING UNDERCUT FROM INSPECTION RESULTS Connection Painted

-Building Number Yes No Bechtel Evaluation Rsactor R001 X

Acceptable R037 X

Acceptable R038 X

Acceptable R039 X

Acceptable R040 X

Acceptable R043 X

Acceptable R047 X-Acceptable R074 X

Acceptable

.R089 X

Acceptable R168 X

Acceptable R644 X

' Acceptable

..,y.

R645' X

Acceptable

'R665 X

Acceptable

R666 X

. Acceptable

.R667 X

Acceptable

• R690 X.

Acceptable R691

,X Acceptable R980 X

Acceptable RG62 X

Acceptable

's l

RG71 X

Acceptable 26 41 1

f a

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Page 8 of 17 CONNECTIONS IN CAR-19 SCOPE EXHIBITING POROSITY FROM INSPECTION RESULTS Connection Painted j

Building Nmahar Yes No Bechtel Evaluation l

Control C106

'X Acceptable C113 X

Acceptable C114 X

Acceptable

.C116 X

Acceptable C117 X

Acceptable

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Page 9 of 17 CONNECTIONS IN CAR-19 SCOPE EXHIBITING CRACKS FROM INSPECTION RESULTS Connection Painted Building Number Yes-No Bechte1 Evaluation Auxiliary A065 X

Acceptable A071 X

Acceptable A331 X

Acceptable 0

3 G

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Page 10 of 17 Section VII-2/12/85 CONTROL BUILDING MIL THICKNESS OF COATINGS ON STRUCTURAL STEEL The following is a breakdown of mil thicknesses for joints inspected in the Control Building.

t Total # of structurally significant joints 265 Total' # of joints inspected 238 Total # of joints inspected with paint 2

Total # of joints inspected with no paint 171 Total # of joints inaccessable/fireproofed ' ' '

2.0 MILS

~

65 Average MIL thickness of 2 joi6ts

% OF TOTAL OF JOINTS HIL THICKNESS

1. OF JOINTS INSPECTED WITH PAINT.

I to 4 MILS 2

100%

i e

e S

..L.

i l

3 e

0

--- ~

~

w

Page 11 of 17 2/12/85 REACTOR BUILDING MIL THICKNESS OF COATINGS ON STRUCTURAL STEEL The following is a breakdown of mil thickness for joints inspected in the Reactor Building.

i Total # of structurally significant joints in building 1300 Total # of joints inspected 804 Total # of joints inspected with paint 710 Total # of joints inspected with no paint / removed for NRC

~~

Total # of joints inaccessable' 21 73 Average MIL thickness of 710 joints 6.3 MILS

% OF TOTAL OF JOINTS MIL THICKNESS

1. OF JOINTS INSPECTED WITH PAINT I to 4 MILS 185 26.%

5 MILS 136 45.2%

6 MILS 117 61.6%

7 HILS 75 i

72.2%

8 HILS 56 80.1%

9 HILS 57 88.1%

(

10 MILS.

49 95.%

11+ MILS 3$

100%

O d

e a

(

l

Page 12 07 37 2/12/85 ESk3 PUMP HOUSE MIL THICKNESS OF COATINGS ON STRUCTURAL STEEL The following is breakdown of mil thicknessness for joints inspected in the ESk3 1,

Pump House.

Total # of structurally significant joints 36 Total # of joints inspected 36 Total # of joints inspected with paint 21 Total # of joints inspected without paint 5

Total # of joints inaccessable/fireproofed/faliranized 10'

-~

Average MIL thickness of 21 joints 2.4 MILS

% OF TOTAL OF JOINTS MIL THICKNESS

1. OF JOINTS INSPECTED WITH PAINT 1 to 4 MILS 19 90.4%

5 MILS 1

95.2%

6 MILS 0

7 MILS 1

i 100%

8 MILS 0

9 MILS 0

10 MILS, 0

11+ MILS

+-

4.

Page 13 of 17 e

2/12/85 FUEL BUILDING MIL THICKNESS OF C0ATINGS ON STRUCTURAL STEEL The following is a breakdown of mil thicknesses for joints inspected in the Fuel Building.

t Total # of structurally significant joints 277 Total # of joints inspected 203 Total # of joints inspected with paint 147 Total # of joints inspected with no paint 36 Total # of joints inaccessable/fireproofed _

20 Average MIL thickness of 147 joints 2.8 HILS

% OF TOTAL OF JOINTS MIL THICKNESS

1. OF JOINTS INSPECTED WITH PAINT 1 to 4 MILS 143 97.2%

5 MILS 4

100%

6 MILS 0

7 MILS 0

8 MILS 0

i 9 MILS 0

/

10 MILS 0

11+ MILS.

0 S-

Page 14 of 17 2/12/85 AUXILIARY BUILDING MIL THICKNESS OF.C0ATINGS ON STRUCTURAL STEEL The follcwing is a breakdown of mil thicknesses for joints inspected in the Auxiliary Building.

f Total # of structurally significant joints 694 Total # of joints inspected 616 Total # of joints inspected with paint 106 Total # of joints inspected with no paint 446 Total # of joints inaccessable/fireproofed 64 Average MIL thickness of 106 jdints

~

5.1 MILS

~'

% OF TOTAL OF JOINTS MIL THICKNESS

1. OF JOINTS INSPELTED WITH PAINT j

1 to 4 MIIS 56 52.8%

5 MILS 12 64.1%

6 MILS 7

70.7%

7 MILS 5

75.4%

8 MILS 9

i 83.9%

9 MILS 6

89.6%

(

10 MILS 5

94.3%

11+ HIIS.

6 100%

4 l

J

)

s m

Page 15 of 17 2/12/85 DIESEL GENERATOR BUILDING MIL THICKNESS OF COATINGS ON STRUCTURAL STEEL The following is a breakdown of mil thicknesses for joints inspected in the Diesel Generator Building.

Total # of structurally significant joints 98 Total # of joints inspected 97 Total # of joints inspected with paint 65 i

Total # of joints inspected with no paint 29 Total # of joints inaccessable/fireproofed 3

4 Average MIL thickness of'65 joints 2.6 MILS

% OF TOTAL OF JOINTS MIL THICKNESS

1. OF JOINTS INSPECTED WITH PAINT I to 4 MILS 54 83%

d 5 MILS 5

90.7%

6 MILS 4

96.9%

7 MILS 1

98.4%

4 8 HILS 0

i 9 MILS 0

(

10 MILS 1

100%

11+ MILS 0

i f

i I

f l

I i

S

Page 16 of 17 Sect on VIII DANIEL INTERNATIONAL CORPORATION omwict suitoinc GREcNVILLE. SOUTH CAPOLIN A 29602

.aos e z ee.asoo l

l Feb rua ry 13, 1985 Dr. Moss V. Davis American Welding Society 550 N. W. t.eJeune Road Miami, Ft.

33126

Subject:

Secondary inspection in Accordance with AWS D1.1-75 and Subsequent issues

Dear St r:

Daniel International recognizes,that AWS D1.1-75 and subsequent re-visions require that " welded Joints shall not be painted until after.

the work has been completed and accepted" (3.10.1).

Further, it'Is our understanding that 61.1 is applicable to inspections performed y

during the fabrication and erection process and does not ' address sub-sequent, secondary inspections over'.the life of the structure. There-(

fore, when It is desired to perform secondary inspections of structures, it is necessary to develop Inspection procedures, and results evalua-tion criterla speelfic to that structure.

In light of the above, we' submit the following Inquiries:

1.

Does AWS D1.1 add:ess secondary inspections over the life of the structure?

2.

If AWS 01.1 does not address such secondary IEspectlons, what parties are recomended to develop parameters for such Inspections?-

l ud.

mm hn G. Berra ce President - Operations

- _ _ _