ML20129E786

Responds to FOIA Request for Documents Re Deficiencies Associated W/Polar Crane Box Girder of Units.Forwards App a Documents.Documents Also Available in Pdr.App B Documents Already Available in PDR

ML20129E786
Person / Time
Site:	Perry
Issue date:	05/09/1985
From:	Felton J NRC OFFICE OF ADMINISTRATION (ADM)
To:	Hiatt S OHIO CITIZENS FOR RESPONSIBLE ENERGY
References
FOIA-85-234 NUDOCS 8507170069
Download: ML20129E786 (5)

Text

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'% ,,,,,+ May 9,1985 Docket Nos. 50-440/441 Ms. Susan Hiatt OCRE Representative 8275 Munson Road IN RESPONSE REFER Mentor, OH 44060 TO F01A-85-234

Dear Ms. Hiatt:

This is in response to your letter dated April 1,1985, in which you requested, pursuant to the Freedom of Information Act, all documents concerning deficiencies associated with the polar crane box girder of Units 1 and 2 of the Perry plant.

The documents listed on the enclosed appendices A and B are responsive to your request. Appendix A documents are enclosed.

Appendix B documents are inspection reports. As you are aware, these inspection reports are routinely placed in the Nuclear Regulatory Commission's Public Document Room and the Local Public Document Room for the Perry plant. The inspection reports listed on Appendix B are available for public inspection and copying at the LPDR which is located at the Perry Public Library, 3753 Main Street, Perry, Ohio 44081, telephone (216) 259-3200.

Access to these inspection reports may be acquired by contacting the Reference Librarian, Mrs. Shirley Morgan, either in person or by phone, and giving her the accession numbers for these inspection reports.

Sincerely,

. . Felton, Director Division of Rules and Records Office of Administration

Enclosures:

As stated l

8507170069 850509 PDR FOIA i HIATTB5-234 PDR 7 -

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APPENDIX A

1. October 17, 1981 Morning Report and evaluation sheet (2 pages)

2. November 12, 1981 Interim 50.55(e) report to Keppler from Davidson

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Il j 3. November 20, 1981 Minutes from NRC Exit Meetin9 (1 page)

!! 4. February 26, 1982 Final 50.55(e) report to Keppler from Davidson t

(2pages)

L' 5. April 23, 1982 Corrected 50.55(e) report to Keppler from Davidson (2pages) i

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APPENDIX B DOCUMENTS IN PDR/LPDR

. 1 Inspection Reports Accession Numbers No. 50-440/81017; 50-441/81017; 8204050165 50-440/82006; 50-441/82006; 8207200287 50-440/83010; 50-441/83009 8304220568 i

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,,} P O Box 5000 o CLEVELANo. oMio 44101 o TELFPHoNE (216) 622 9800 e ILLUMIN ATING BLDG e 55 PUBLIC SOU/4E iwyn R. Davidson # #

vlCE PRE 5soENT SYSTEM EPsGINEERING AND CoNSTRUCfloN November 12, 1981 Mr. James G. Keppler Director, Region III Office of Inspection and E iforcement U. S. Nuclear Regulatory Commission 799 Roosevelt Road Glen Ellyn, Illinois 60137 RE: Perry Nuclear Power Plant, Docket Nos.

50-440; 50-441, Interim Report on Unit II Polar Crane Girder Weld Deficiencies (RDC 39(81))

Dear Mr. Keppler:

This letter serves as an Interim Report pursuant 10CFR50.55(e))oncerningweld defects in the Polar Crine Box Girder for the Uni I L eontainment . This was first reported by Mr. V. Higaki of The Cleveland Electric Illuminating Company to your Operations Center, Bethesda, Maryland, on October 17, 1981.

This report includes a description of the deficiency and the method planned to com-ylete our evaluation.

Description of Deficiency The Polar Crane Box Girder which will support the Polar Crane in the Unit II contain-ment was fabricated in ten sections by Newport News Industrial in their Greenville, Tennessee facility under procurement specification 660-4549-00.

1 Visual inspection of full penetration welds in these sections was performed during receipt inspection. Visual defects were identified and Nonconformance Report 17-136 w2s initiated. During excavation to prepare the unacceptable velds for repair by our Site contractor, Newport News of Ohio (NNICO), additional linear indications (lack of fusion) were discovered.

Evaluation Method

,I l All major structural welds in the Unit II Polar Crane Girder are being ultrasonically

. inspected (UT) by NNICO. The Perry Project organization is monitoring the UT inspec-

,l tion. After Non-Destructive Examination is completed, all necessary repairs will be made to assure compliance with the specification requirements. Preliminary results of the UT reflect a high rate of rejectable welds.

Newport News Industrial of Virginia has been requested to conduct an analysis / study to determine the level of quality of the existing shop welds in the Unit II Polar ll Crane Box Girder. To accomplish this, a task force under the direction of Newport I

1. NOV 16 1981

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Mr. James KepplGr Noyemb:r 12, 1981

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) g2 Two News' Director of Engineering has reviewed manufacturing and field repair inspection reports. Additionally, they are duplicating in their Newport News, Virginia, facility the shop processes employed at their Greenville plant to study the effect of parameter variations for travel speed, amperage, etc.

Once Newport News has completed their investigation, a full report will be submitted to the Cleveland Electric Illuminating Company.

All evaluations should be completed by February 26, 1982, and we are presently planning to submit our Final Report at that time.

Sincerely, 8 L Dalwy R. Davidson, Vice President System Engineering and Construction DRD/llp cc: NRC Site Office i Mr. Victor Stello, Director Office of Inspection and Enforcement U. S. Nuclear Regulatory Commission Washington, D.C. 20555 U. S. Nuclear Regulatory Commission c/o Document Management Branch i Washington, D.C. 20555 I

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PEERY NOCLEAR POWEE PLANT

-LS. NRC EKIT MEETINC

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ATTENDCEN:

U.S. NRC PROJECT ORCANIZATION C. M. Erb R. L. Farrell M. k. F4olman J. P. Eppich P. L. Cibson C. F. Rubbuch ,r R. P. Jadschew '

T. P. Keaveney J. S. Kerr J. M. Mehaffey

5. P. Tulk 1, D. Us1rath M, E. Combs COMMEKrs:

Mr. Erb Tne princLpt.1 ot,)cctive of this inspection was to rev.tw corrective action relativt to cht KKICO 10::FE21 report on covering up defective welds and to the j Unit #2 Polar Crane Cirder veld deficiencies. Other areas were also inspected i cod art discussed melow.

Mr. Erb stated chte hc had identified no ne.- itass of noncocpliancq and tho i followin two issu would be reported at concerns :

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Resolution of the Unit 1 Containment floor place weld probles; Mr. T. Bond ,

of NKICO had presented their corrective ection program to him and he stated that it' appeared to be adequate. He onderstood that a UT investi-

, gattor, of the welds was in process.

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... Protectior. cf thost Dcit 2 Conttirment individuct quencher floor plates W.lcl. cro Inr, t s. l l ed. ha ecc:.::ntd th:t tir.cc Ur.it 2 It c :. L i l opos., sou prottetior. should b:. provided to avoid possible pitting of thc stainless

steel free wa tar or saw. (

r Er ther. -nted or. other areos which twe coverod.

... buring his review of the Unit #2 Polar Crane bor girder wald defect .

probles., he noted that the Unit #1 girder had also been Identified on a nonconformance report. It was explained that they were fabricated in different shops, and while the problem with the Unit #1 girder was mainly 1

surface weld defects, during fabrication of the Unit #2 girder the Creenville Shop had used a lower heat input during the MIC process dich had caused lack of fusion, t

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Semog The Best Location on the Na:ce; Daiwyn R. Davidson viCE PAESIDENt SYSTEM ENGINEERING AND CoNSTRUCTeoN February 26, 1982 Mr. James G. Keppler Director, Region III Office of Inspection and Enforcement U. S. Nuclear Regulatory Commission 799 Roosevelt Road Glen Ellyn, Illinois 60137 RE: Perry Nuclear Power Plant, Docket Nos.

50-440, 50-441; Final Report on Unit II Polar irder Weld Deficiencies (RDC

Dear Mr. Keppler:

This letter serves as a Final Report pursuant to 10CFR50.55(e) concerning weld defects in the Polar Crane Box Girder for the Unit II Containment. This was first reported by Mr. V. Higaki of The Cleveland Electric Illuminating Company to your Operations Center, Bethesda, Maryland, on October 17, 1981.

This report includes a description of the deficiency, analysis of the safety impli-cations, and corrective action.

DESCRIPTION OF DEFICIENCY The Polar Crane Box Girder which will support the Polar Crane in the Unit II Con-tainment was fabricated in ten sections by Newport News Industrial in their Green-ville, Tennessee (CMM) f acility under Procurement Specification SP-560-4549-00.

During visual inspection prior to erection, a number of surface weld defects such as undercut, porosity, and insufficient leg were identified and documented on Nonconformance Report No.17-136. The Perry Project Organization directed Newport News Industrial of Ohio (NNICO) to proceed with the repair of these nonconforming welds. During the repair of these weld defects, it was determined that a number of sub-surface linear defects existed in the shop welds.

ANALYSIS OF THE SAFETY IMPLICATIONS Ilad the deficient welds in the Unit II Polar Crane Box Girder remained undetected and a section of this girder failed to perform its design function, it can be postulated that the safety of Polar Crane lifting operations might have been adversely affected.

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Mr. J:mes G. K2ppler Fabru ry 26, 1982

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CORRECTIVE ACTION TAKEN TO DATE In order to determine the extent of weld defects present, an information ultrasonic test examination was conducted on all welds identified as strength welds per the design basis utilized by Newport News Industrial of Virginia. These welds are as follows:

1. Face plate to top flange

2. Face plate to bottom flange

3. Tee stiffener veld to top flange The only welds not UT examined were the excavated joints undergoing repair which were identified on Nonconformance No.17-136.

Newport News Industrial has stated that approximately 90% of the total length of welds which were UT examined are rejectable and will be repaired and brought into full compliance with specification requirements. All rejectable areas shall be excavated in order to remove defects. The excavated areas shall be magnetic particle examined prior to welding. Once the repair weld is completed, it will be visually inspected and MT examined in accordance with approved procedures. All repair weld activities will be monitored by NNICO weld engineering section.

Anticipated completion of this activity is July 30, 1982.

Sincerely, I

Dalwy R. Davidson, Vice President System Engineering and Construction DRD/llp cc: NRC Site Office Director

! Office of Inspection and Enforcement U. S. Nuclear Regulatory Commission Washington, D.C. 20555 U. S. Nuclear Regulatory Commission c/o Document Management Branch Washington, D.C. 20555 i

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y P O Box S000 e CLEVELANQ_OHlo 44101 e TELEPHONE Q16) 622-9800 e ILLUMINATING BLoG. o 55 PUBLICsOUAIE

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SYSTEM ENGWEERWG AND CONSTRUCTION A Pril 23, 1982 Mr. James G. Keppler Director, Region III Office of Inspection and Enforcement U. S. Nuclear Regulatory Commission 799 Roosevelt Road Glen Ellyn, Illinois 60137 RE: Perry Nuclear Power Plant, Docket Nos.

50-440, 50-441; Unit II Polar Crane Girder Wel eficiencies

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REF: Final Report dated February 26, 1982 to Mr. James G. Keppler

Dear Mr. Keppler:

This letter serves to correct our Final Report of the Unit II Polar Crane girder veld deficiencies. Subject Final Report is dated February 26, 1982.

In the portion of the report entitled " Corrective Action Taken to Date", we described the following action to be taken:

"... Once the repair weld is completed, it will be visually inspected and MT examined in accordance with approved procedures ...."

This statement is incorrect.

Nonconformance Report No.17-136 which identified the weld deficiencies was dispositioned to include a visual inspection and an ultrasonic examination (UT). The Final Report inadvertently specified a visual inspection with an MT

) examination. It is the intent of The Cleveland Electric Illuminating Company to perform a UT examination as specified in Nonconformance No.17-136.

4 This matter was discussed with Mr. E. H. Nightingale of your office during his l inspection conducted at the Perry Nuclear Power Plant on April 22 and 23, 1982.

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Mr. J mes G. Kappler April 23, 1982 4

The above information supplements our Final Report on this matter.

If you have any questions, please call.

Sincerely, d  %,

, Delwyn Davidson Vice President System Engineering and Construction DRD/llp cc: Mr. M. L. Gildner NRC Site Office Director Office of Inspection and Enforcement U. S. Nuclear Regulatory Commission Washington, D. C. 20555 U. S. Nuclear Regulatory Commission c/o Document Management Branch Washington, D. C. 20555 l

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