ML20126M610
| ML20126M610 | |
| Person / Time | |
|---|---|
| Site: | Satsop |
| Issue date: | 05/29/1981 |
| From: | Leddick R WASHINGTON PUBLIC POWER SUPPLY SYSTEM |
| To: | Faulkenberry B NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| References | |
| 10CFR-050.55E, 10CFR-50.55E, GO3-81-2056, NUDOCS 8106190292 | |
| Download: ML20126M610 (54) | |
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P Washington Public Power Supply System A JOINT OPERATING AGENCY P O 80X 1213 ILMA. W ASHINGTON 96$41 PHONt t2061249 5001 May 29, 1981 G03-81-2056
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Nuclear Regulatory Commission, Region V ' %. ' M Suite 202, Walnut Creek Plaza ,, c. ,WW N 1990 N. California Boulevard Walnut Creek, California 94596 Attention: Mr. B. H. Faulkenberry Chief, Reactor Construction Projects Branch 0 A Gentlemen: p
Subject:
WPPSS NUCLEAR PROJECTS 3 AND 5 NRC INSPECTION OF WNP-3 AND WNP-5 3 /(( 7'd b '? DOCKET NUMBERS 50-508 AND 50-509 2 4 N Y,2g N k9; FINAL REPORT OF EMBED PLATE STUD WELDS CA 4 8
References:
- 1) G03-81-861, Letter, R. S. Leddick to ' y B. H. Faulkenberry, dated March 25, 1981. pp
- 2) G03-81-979, Letter, R. S. Leddick to B. H. Faulkenberry, dated April 28, 1981. ,
On February 26, 1981, your office was notified by telecon of a problem consi-dered potentialTy reportable under the requirements of 10CFR50.55(e). The problem was identified as failure of the stud welds when studs were bent to 300 as required by AWS. The studs in question were welded to embeds manu-factured by Chicago Bridge And Iron in Salt Lake City, Utah. When the problem was discovered approximately 80% of the embeds had been received at the site and 42 had been embeded in concrete. Site Corrective Action For those embeds that were on site, NCRs were written identifying those em-beds that had been installed and those that had been received and were in storage. For those embeds not installed, the NCR was dispositioned to test 20% of each plate type, bending 50% of the studs 300 on plates selected at random. The acceptance criteria was establishci where those embeds with 5% or less 81061902827 THIS DOCUMENT CONTA s POOR QUAUTY PAGES I'/
, - . Letter to B. H. Faulkenberry May 29, 1981 Page 2 G03-81 -2056 failures were acceptable, those with greater than 5% failures required all studs on that plate to be tested and all failures repaired.
After completion of this testing program, a review of the results revealed that the majority of the failures were on non-safety related embeds. All of the safety'related embeds met the acceptance criteria established by the NCR disposition and were accepted. The plates failing to meet this criteria were dispositioned " Repair." The embeded plates were dispositioned "Use As Is" based on the design intent and the percentage failure rate established during the testing program. Supplier Corrective Action The embeds fabricated but not shipped were placed on hold by CB&I. CB&1 established a test program where every third stud was tensile tested to the load specified by AWS. Any failure of welds on a plate required all studs on that plate to be tested and all failures to be repaired by fillet welding. Cause Of Stud Failures The cause of the welding problem was identified as a defective stud welding gun in the CB&! shop. Conclusions Based on the design intent of the type of embeds where studs failed to meet the testing criteria and the acceptance of all other embeds, this problem is deemed not reportable as required by 10CFR50.5Y(e). Attached please find a copy of the Engineer's Report for your information. Should you have any questions, or desire further information please feel free to contact me. . Very) truly yoyrs, V R. S. Leddick Program Director, WNP-3/5 cc: D. Smithpeter - BPA /wo/a Ebasco - New York /wo/a WNP-3/5 Files - Richland/w/a
+
MEMORANDUM DATE: May 28, 1931 LETTER NO: WPPS-ESSI c.:c.il-330 FILE NO; 3240-113 A a Cu:rona / L A sas: TO-FROM: R She::y SU BJ ECT: washinzton Pudhe Power sucoiv sys:ern
%7PSS Nuclear Pre,e:ts No 3 & No. 5 Significance of Nonconformance Repor: No. 12825 For Reportabili:y per 100FR50.55(e)
The' following repor: evalua:es the non-conforming conditions in CBLI Contract 3240-ll3 Stud Welding and Resolution. Since non-conforming condicions are found, basically, in non-cri:1 cal plates and the problem is rec:ified before
- the embedment of these plates (except 42 plates). we consider, for the purpose
~
l of reportabili:y per 100FR50.55(e). The problem is not significant designwise. RS:mef-Attachments: 1. Report la.S:stistical Table
- 2. CE&I Le:ter No. 245.
- 3. CB&I Let:er No. 253
, 4. CBEI Letter No. 206 ' '
- 5. WC?. 12825 6~. CBit Report on S:uds (Prelimicery)
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L'ASl!INGTON PU3'!C ?O' ER SU? FLY SYSTEM NUCLF.AR F0i??.R CENEFJ. TING STATION UNIT i:3 DEFECTIVE STUD bT.'_ DING REPORT Con::act 3240-113 By R. Shetty O e e6 amo m eaa < me= "* 9 ^**** ~
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L7PSS Nucle 4r Projec: No. 3 and :'.o. 5 OwM r : Washington Public Power Supply Sys:e=' (h7PSS) A/E: Ebasco Services Inc. (Ebasco) 1 Subj ec t : Stud Welding on Embedded Plates for Rese:or Building ! Supplier: Chicago Bridge and Iron (CMI) Problem: Defective Stud Welding i 1 DESCRIPTION: Chicago 3 ridge and Iron Company supplies embed plates for Unit #3 and #5 under Con:rac: 3240-113. CB&I ships these plates from its shop at Salt Lake Ci:y, Utah, after testing Cne studs for AWS D-1,1 S:ructural Welding Code acceptance cri eria. on 25 Feb S1, WPPSS-Ebasco Quality Serveillance, in a spot check, found out cer:ain studs 5.ere failing at 30 bend test. The f ailure was identified as bri:cle f ailure in the weld :eno. 30 bend test is AWS Dl.1 See: ion 4.25 Quality Coenrol require-men: .for production weld. NCR-12625 was genera:ed :o*1 den:ify the problem. CODE REOUIRDIENTS: , l S:ud welding is done ,accordin; :c American Welding Society D1.1 S:ructural Welding Code Parr. T and project procedure 3240-448. Code re::w.res a 30 bend tes: cn firs: :wo s:uds (AWS Dt.1 - 4.25.1.1 & 4.25.2) o for :he er.2;ue: ton weld and a 15 band tes: of one s:ud for every 100 s:eds c.s ar. I i insg c:1... .r:.:erion (AWS 31.1 .27.1 6 4.26.2).
.CWPLIAN"E:
l l ! C34: sta e><ns h:.ng to :hese recui;-:.en:s. C2.L I w a s a l s and testing over 30 p e r c e r. ' ? ! the studs to 15 cri:erien. All :hese s: ads noseared :o nave p m ed I l' l
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i (Compliance cont'd.) the nor a1 requirements of the Code. PROBLIM: In a detailed CB&I investigation, it was found out that.one of the stud welding guns were malf unctioning. According to CB&I, they had been using Nelson and KSM stud welding guns. KSM stud welding guns have veltage regulating circuits. It was discovered that'one of the stud welding gun's circuits was not functioning correctly. It was concluded that stud welding done by this particular gun was defective. CBLI had already delivered 80 :: of the places to the site for Unic #3. 42 plates were already es edded in the concrete. Some of the plates were up on the forms;
- the :est were in the storage yard.
TESTING: Since it was not possible to. separate those studs which were welded by the de-fective gun from the rest, it was necessary to test stu.d.s in each plate to estab-lish a definitive-trend of failure. The following sa:pling program was set up to accomplish this goal: .
- a. Test-by group identified by mark numbers,
- b. Test minict:m 20!; of plates in each group.
- c. -Test cir.imum of 500 of studs in each plate to be tested.
- d. Test the studs to 30 bend test per A'O D1.1.
ACCEPTANCE CRITERIA: l '. rec-p- up to 5: C:ilure pet piste.
- 2. : f 1:e .- than E fcilure in any plate, test all th studs.
- 3. i,alace all brv.:n studs. .
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Def. S:ud Weld. Rpt Fage 5 ef 7 JUSTIFICATION TOP. 5% A00E?TANCE: ** Confidence interval for Proportion ?: A - - - ^ - .. """
?-E xf l'J "71#- ( }' P + b ,. ! %f_S.-
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of defec:s in the random sample of si:e n. We A I" 2,,7valueofstandardnormalcurveleavinganareaof~4/2 to the righ:. No. of samples n = 100 No. cf defec:s x=5 s p =x = % = 0.05 13 100 a 9, = 0.95 iL,/, = 1.96 f or 95% confidence in:erval From :he Chart
? ,= 1.64 f or 907. confidence interval A::achment I Suos:itu:ing the values:
90% confidence interval: /
,/
0.05 -1.64 0.05 x 0.95 sP 0.05 - 1.64 0.05 r .95 -- 0.014 ( P (0. 086
\ 100 \ 100 95% ::.nfidence interval: -
c_ 0.05 - 1.96 0.05 x 0.95 g0.05+1.95 l0.05x.95 = 0.007 ( ? ( 0.093
** deference: Prebabill:) and 5 :a:is t .:= for Eny,ineers and Scientistn by I.onald P l11 pole and Taymond H. Myers p y - - - - - - p
Def Stud b* eld Rpt
' ' ? age 4 of 7 CORRECTIVE ACTION: )
]
For corrective action the embed plates were catagorized as follows:
- 1. Essed plate immediately needed for construe:1en and those were already up on the forms.
II. Eched plates in the st:rsge yard at site, l!! E Led plates in CB61 shop.
!Y Inced plates already embedded in concrete.
For catagory I & II a f ailure trend was established by the field bend test progra=. Send test results showed that Type I, Type II and Type F1 plates are the plates which were failing bad. All these plate groups which had f ailure less than 5% were accepted to "Use As Is". Eroken studs in the sample were replaced. All the rest of the plate groups were rej ec t ed . Every stud in rejected plates were tested and the f ailed studs were replaced. All Catagory III plates were reinspected and studs were tension tested by CB61 ond accepted on the basis of allowable tension values. Testing and approval has been documented in SCR 12885 and NCR 134NS. Catagory IV plates were embedded bef ore the proble: was identified. The following places were used as noted below: See A:tached Chart Following Page -- a m
Def. S:ud Wald Rp: 5 of 7 Con:, Mark Type Plate No./S:uds Purpose - Tail Rate Da :'e ' Pour tio . Plate Q:y Size per Pla:e :o Support by Tes: No.' ( inch) 1/26/81!038 I i 82A Type : 1 4x%0-4 2 Handrail ., 8 .,
. 75 ,.
Pos: , 2/4/81 ' 039 82A Type I 13 4xbO-4 l2 Handrail 18% 75% I Post 2/ 6 / S '. l059 78F Type PS 1 - I- - 0%
! i 2/6/S1 ! 059 82D Type IV 1 10x1x0-10 l !. 5%
I 2/6/81 ! 059 82G TvpeVIIl1 C '.' l ! 2/13/81 82A Type I 2 4xirx0-4 2 Handr il 18* 75% 038A li Pos: I 2/13/81 033A 74D Type F3 4 - C'; 2/13/81 039A 82A Type I 2 4xtrx0-4 2 Handrail 18 *. 737. Pos: 2/13/81 039A 74D Type F3 4 - - - 0*; 2/18/81 041 823 Type *I 4 6750-6 2 Ladder 54% 2/18/S1 041 82G Type VII 6 - - - 0*; 2/18/81 041 82A Type 1 3 4xbO-4 2 Handrail- 18', 75 Pos: M m l l l 1 l l 1
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Def Stud Weld Rp: Page 6 of 7 Only Type I and Tyee II Plates had more :han 5T. failure rate. Type IV had a 5%
. failure race. All other types had CI; failure rate.
Type I plates are exclusively used to support handrail posts on :he top of slabs. Type I! pla:es are used to support ladder,also en the top of the slab. These plates basically serve as means for attachmen:, There is no load carrying criteria for these pla:es in this application. A::achment is not safety related and failure of these plates vould not create any safety hazard. Moreover, the bond berween concrete and plate is more than sufficient for :he intended purpose. Type IV pla:e is a par: of pipe rupture restraint. This plate supports a knee brace f or support RCH-16-K-8 shown on drawing G-3535Sl. Plate is shown in Sectier. 1. AI & A? on Drawing C-3535 53. The loading on :his brace is 2" tension. The pla:e capacity is as given below: Tension 14.3" (reduced capacity f or 2" eccen:rici:y) Shear (Vert.) 27 Shear (Horiz) 23.3 Homen: 90" Factor of safe:y in tension = 14.3 =c 7 2 or 700?; Failure ra:c for this palte is 5%. Since only one plate is used and loading is small, this pla:e could be used as 13. All c ncr ple:es proved to ce good 10'y. Hence a separ.cc analysis for :hese pla:es is no: required. t - .- g,. - ., ,.
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t CORRECTICNS EY CEi! C31*.'s Lc::er No. S1-213, 81-253, S1-206 (A::achments 2 thru 4) explain the C3&I corrective actions'under:aken to rectify the problen. C3&I corrective steps are as f ollows:
- 1. Comple:ely diccon:inue K5.9 stud weldin; gun an: s:ar: using Nelson stud welding guns for all s:ud welding.
- 2. Inspect 100?. of all welded studs to AW$' Di.1 criteria before shipmen; from the shop.
- 3. Tension tes: every third stud in every plate.
- 4. If one stud fails, test every s tud.
- 5. Continue tension testing for fu:ure 5000 studs :o assure the adecuacy of welding gun and process.
CONCLUSI0": Field testing programme demons::a:ed specific pattern of f ailure. Three catagories of plate types and three specific mark numbers were iden:ified as the failing ca tago ri es . They are as follows: 4b rk No . Tvoe Failure 82A I 75% 823 II 54%
~
70A P1 13%
~
The following pla:es ;Nru already embedded: Tv;: I - 21 pla: u Te,,- II - . p la r a.. Al- abeve plate :y p e.4 tr+ used fer supper.in; n-critiual 1:< s em.h as handrati 1.; ~. c . x , e tc . Thert ;< ne safe:y ha:srd ever 2i :he pi c.- Ca:1 .a impac: k '.' . i. d. F.o : be nifnific
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A::en:icn: D. L. Quemme .u
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- m n: a2w-13 -.4 Washington Public Power Supply System WPPSS Nuclear Projects 3 and 5 .
Satso:, Wasning en CBI contrac: 03270/80, 04020/30 E5ASCO letter E5113-81-25 Gentlemen: )
. .we reviewed our operating and cuality assuran:e procedures relative co the stud welding being perfomed under Contrac; 3240-113. We find that s uc welding and inspection perfomed to date is in confoman:e with the spacifications, the applicacie ASME and AWS code re:uirements, the procedures .>.pproved for this contract, and tne 05: Quality Assurance Program.
Knile performing the above review it was found thbk one of the stud weiding guns used on this work has perfomed in an ancmalous .anner. 'Ae believe that removal of this particular stud gun fr:m service will resolve an.y concerns .vou may have. _ 1r. reply to your .reques to upgrade the presen: contractu:1 insce:: ion I cro:ecure, you may wisn to cons 1cer ne f ollow.>ng program: l
- 1) All plates which have Neison studs atta:hed, both at site and i
i l those presentiy ready for shioment shall ce insce:te: oy Tensiie loading every third stud on every plate to the loac specified in AWS Fig. 4.2.5.2 and AS{ se:: ion IX cara. OW '.?2.3.
- 2) Should any one s ud fail uncer such i:icir; on try :le e, a :1 stucs on that olate shall be suojec to the ension tes .
2} Notwitnstancin; the above, any stud w .i:r has :eer :revi ui .' ben more than 15 snail no: ce tension ioade:. 1 C5: Oc;::ra: ion NO 223-CS-C iC-2 5-;;- t n.
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Chica;c Eridge & Iron Cor.cany ;
,Ma-:a .1, 1981 .
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Page Tac ) i l 4). A11 failed studs shall ~be manual filie wei:ec.tc the pla e and
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ension tes ted.- This tension test shall :e in addi:icn to an~v tas _w hich may be required on failed.st;ds :y .he AWS code. We propose that the Nelson stud oiates meeting' nt. above cri eria be censidered as accepted and suitable for your needr. j 1 Per your direction we are perfoming certain chemical and mechanical tests I on failed test studs and plate materials from 5ai; Lake and the jobsite -l if. 'necessary, and we will forward the results in a -imely manner, j 1 We await your direction as to the implementation of the above suggested . 'l rehe.oection procedure. Reply requestec by March 17, 1951. I Sincerely, . 7 i
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. NEiuM Project Manager CBI Seit' Lake i
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Washington Public Power Su.=.lv Svstem . . WPPSS Nuclear Projects f3 & !5 Centrac: 3240-113 CBI Centract 03270/80 Nonconformance Report Ccncerning Tasting of Studs In the March 10, 1981 meeting between Ebasco and C3&I at C3&I Salt Lake facili:v.o stud welding and testing cf studs was discussed a: length. As a result of this discussion, Ibasce requested C3&I i.ni-iatn the suggested, stud testing procedure outlined in C3&*'s letter 113 E3-El-245 dated March 13, 1961 , This procedure is to be applied to sufficient number of studs to assure a quality stud weld is provided consistently. To initiate these new testing guide lines, it was suc.c.ested bv Eb,asco that C3&I submit a Ncn- . conformance Report to void Nonconfermeance Report 24NS and the addi:icn testing specified therei:r. Accordingly please find - enciesed the C3&I prepared Nonconfermance Report dated .u. arch 18, 1931, which euc. lines the revised testing procedure. A: Ibasco's request, C3&I is now testing ctuds to be shipped to tne site per this Noncenfermance Reper . chis progra:. will be c^..*.."".in
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l it REcowa f.h0 E0 or5PO$iT10N ' ' ' (Jub,nst Shesch si Applicoble) Con'- 2) Should any one stiud f ail under such loading on any plate, all studs en that plate shall be sub]ect to the tensien test. 1 3) Notwithstandine the above, any stud which has been nreviously bent mere than 15'shall net be tensien loaded.
- 4) All failed studs shall be manual fille: welded to the nlate and tensien tested. This tensier test shall be in addition to any test which may be reruired on failed studs by the AMS code.
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letter ill comfirm the discuss,jons beween CSI and ESASCO con &1ne. 5:vd wei ing and inspection of 5:.Desced asse : lies for the 3240 113 centra::. 1 e suoject discussions occurred a- - .e EEASCO-C51 meeting cf - March 17, 1941, at CBI's Salt Lake f acility. Tne followin., is a su mary of tne areas cf :n:ern and dis;0sition of each
!w pl - Embedded Assemolies Already .: acticated. ..
A. Assem lies at site. ESA500 site eerscanei nave or will test anc repair as require: all embed assecolies ex:e: 'the 0-1 embeds. Tnese P-1 ecceds will be leaded by E3ASCO cr a CBI-Oroviced truck, returned t: Sal: Lake wnere all s:ues will :e tested and efe::ive ~ stu.ds replaced per :ne non-conf r .ance re:0-; dated 318-31 crepared by s.: 1. -
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'.?II, and ,.e wiii teie :py these to you tne day r.e> are received here a- 541: 1. ate. Similar Tes:s for stues shot wi n :ne 'ielson gun will ce avaiitole at a later cate.
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i ..aw E; is :o ;roceed on stud welding and insce: . ion of 5:J s. If you have any cuestions , please tail me. Our snco.is proce.e.cing now cer the above; so . , de re0'Jes* your rasponse to *his ay r,.pr11 0, I ,s, c i .
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SITE NONOONFORM ANCE REPORT OUAurY class m f o, :o.,owt c. .. r. ou syse t - t . ) f INSTRUCTIONS (SEE EAct Ce FCaul i uoc ariei. 6 s i PROJECT NO. (3 ) m*-iaw s".:.mt ma ca u u . . ,
- s s,:=ie r ici E.ceccec Pla:es
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3240-!'3 I: Hold Tac Attached I ?? Cenerate 51 ace e-- **:.060.013. 045,100,0-6, & 111
~. DESCR;FTION 0: NONCON rOR M ANC E : iic)
Identified a:oaren: bri::le failure of Selson Studs en cer:ain embeds suc: lied by C55. uncer con:rac: 113 1 ti a c .:,'.2:v a .m . car a:: ac iiu y / a: 2 t .lo.
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.-' . REC OM M END E D 0lS PO SITIO N - (it ) CEStGN DCOU M E *i~ C H A NG E R EOUIR E D (13 ) C YES G NC. . I ( 14 ) C USE.AS IS C REPAIR C REWORK CN PREPUR0HASEO ITEMS WITHOUT APDROVED PAOCEDURE I DE N TI FIE D (is) C R'Jre- -' O r=m.m eg .newnsv r M ;:;,rit w :,, ras 7.5 2 0; w,. c I a.. e:Dec t y r,e s .,c r ea ch Ma t e rial ,r,,eceio : n,eport l t isi CORRECTIVE ACTION ) 0 M.FJ vill have a =ini=c: ef 50*. cf Nelsen 5:uds ben atorex. 30 fren an axis between the attach:en: poin: and tne center of stud head (1) only studs unich have no: been previous.) cen sna . oe penc :es ec. u) Vnen adiacent s:uds are bent, s:uds shall no: be cen: towarcs each c her (3) E beds which have s tucs that fail the spec:.iled bend tes:s shall be segregated and failed studs retained vi:h each embed plate. (4) Those plates with failed studs shall be repaired in accordance with an approved procedure. l ACTI O N TO PREVENT R EOOOV A R E N C E (I F A P P LIC AS LE ) ' prj f.--,,ge ,,5 f,ff; A44/.jpg/g sps g/,a,"g g.cyg increased f re:;uene . of inspections. Ayyd Cen:rae:cr Quality Con:rcl and Ebasco VCA have Additional sanoling and testin; to be perfer:ed for additional placements as required. N01ItUt'lhL UJ.'EST7JAMW A CC:0kE.'ETEWFA$df MH ff %Qi &* 4.NpgStiz~=" r/u9)(y4(f g ,{fz. 7;i.C Kg:ouw t h:t : v(aiFiCATIOh ST i (le ) CONTa&CTOR -QC S4' C CTes ta C mc7 Provingc C LB AS 0 0 A C E B AS00 ENGINE 18iNG C OchTAA
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,very other stud shall be cen. Over to an an;.i e ,i: anc returned t: ; ;s originai .
2 :. posi: ion using the cene ada ter as showr i . ne sketch. The bend ada::er is recessed to orovide tne :rcoer radius cf :e..c in each diameter of stud. A 155 sicae is built int: tne bene acaster to os sure the proper amount o cene is l actem:lished. When testing 5 uds with heads first burn off the heic and grind off any dross to ac: r. : ate the bend ada;;er. 3 '/isually inspect the ber.t studs after re u ning t original position and all - shall be free to visicie separation or fra.::gre.
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