ML20199A497

Addendum One to Piping Analysis Calculations,Texas Util Svcs,Inc,Units 1 & 2,Part 2,Analysis of Welded Channel Box Section. Related Documents Encl

ML20199A497
Person / Time
Site:	Comanche Peak, 05000000
Issue date:	12/07/1981
From:	Beck D TRANSAMERICA DELAVAL, INC.
To:
Shared Package
ML17192A346	List: IA-85-313, Partially Withheld Transcript of Technical Review Team 840919 Interview W/Unidentified Person in Eagle Mountain,Tx Re Welding Activities ML17192A345 ML20199A477 ML20199A484 ML20199A490 ML20199A497 ML20199A503 ML20199A510 ML20199A517 ML20199A525 ML20199A531 ML20199A536 ML20199A543 ML20199A546 ML20199A553 ML20199A559 ML20199A564 ML20199A570 ML20199A575 ML20199A581 ML20199A586 ML20199A592 ML20199A599 ML20199A605 ML20199A613 ML20199A618 ML20199A624 ML20199A628 ML20199A633 ML20199A639 ML20199A645 ML20199A650 ML20199A657 ML20199A661 ML20199A667 ML20199A670 ML20199A678 ML20199A682 ML20199A688 ML20199A694 ML20199A705 ML20199A709 ML20199A715
References
FOIA-85-313, FOIA-85-59, FOIA-86-A-20 NUDOCS 8606120420
Download: ML20199A497 (28)

Text

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iFlii Transamerica Delaval ADDENDUM ONE TO PIPING ANALYSIS CALCULATIONS TEXAS UTILITIES SERVICES, INC.

UNITS 1 & 2 4

PART 2 ANALYSIS OF WELDED CHANNEL BOX SECTION i

Transamerica Delaval Inc.

Engine and Compressor Division l

550 85th Avenue P.O. Box 2161 i.-

].

Oakland, California 94621 Originator:

1.

David Beck Date December 7.1981 l

ll Checked:

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Tom Bridge Date December 7,1981

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8606120420 860604 PDR

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n Tu.5 I illili Transamerica Engine Calculations r:coi i

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El F= MENT A HA5 A 51ME55 QF:

eleePei (p4LJt_TED pNOTION) ANO IS SPz xS)z yg ANGL_e. THIS STPy=~O 15 x

ANO l H n CN PG93;CE_CTid. 6- \\AOL_. I CF THE TpenenMEacA DEL _AVAL_35MIC b

@ALJFICATlCN RF: R D AsT.

F i F: MENT B WITH A MAX STRFe=5 Op l

2!dC)A51(5 A EBOX NCTION OF TWO l

15"x40t_E CHoNNFl 9 WELDFn TO5 ETHER.

TH15 CECi ICN vvAS CW TO BE US=n IN THIS ANALY3JS EECALJ5E IT 15 A fat"__RIC.A.I c:C ~E i LONE TO ADJU'Drs._ ATE. THE. E__FFECT OF A WEI 6 55 CTlON VS A NON-WELCI il j

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CUP % i H_n EE4t( gr CR CIm - 1 C N L_'

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THe. ECpmuTY CP THE TWO l U31.- 7E:CC I MOIMEN T5 OP INEtRTIA INCKAtt-9 "a ' ~ '

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a o-g' THAT THE STPEE55 DPPEi-WE,,,,, 4 4

EETvyF:F:N TWO WELCED CHANNFI 5 4 TWO CHANNEL 5 EUTF=n TCGE D-iEf%(NOT WF ' n E Cjis NlL_.

THE WFi Nn Eox SEC_TEDN VVOUL_C f-E 6.pATF-vVITH NO WFI C'ING AT AL_L_.

CODO CONSMUC.T(CN PPETICE-AND EASE OF HAN LJNO ' Al%E T1-lE PC--CSONS THE Q-%NNELS WEPME. A t LACH F: n SY VVF:! nlN3.

EASE. OF H4NNOL_ING PATHEPs. THo N ANY tz,i RL_CTUl-yL_ Ar=^5tDN WAS THE IQF /\\

IN VVE: I nlNa iHGi Si=C.TIONS TOGET1 E THE ^PCN'E. P@P COMPAPrSON OF R.

s MOMEN IC OP JNEP nA. Sf--LOW 5 THrr WELD 5 D eF=

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TEkAS UTILITIES CN MAM

OENERATING CO.

NONCONFORMANCE REPORT (NCR)

"U i

h-82-00581 UNIT STRUCTURE / SYSTEM ITEM / COMPONENT TAG /ID NUMBER LOCATION OR ELEVATION RIR NO.

CP2-MEDGEE-01 2

DG/3000 Aux. Skids CP2-MEDGEE-02 OG Blda. 810'6" N/A NONCONFORMING CONDITION i'

Supports for ASME Class 3 piping and Components are Considered and fabricated y

by the Vendor Transamerica DelaVal as Non-NF.

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These supports should be NF as specified in the applicable Gibbs & Hill specification.

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e REFERENCE DOCUMENT-2171-MT "Id REV I

PARA 33 REPORTED BY:

,M Melanie Asmussen DATE:

5 13,82 f

1 OE REVIEW /APPROV

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ACTION A00REsSEV J. Q. Merritt/Moehlman Of:PARTMENT T

Engineering

' OlSPOSLTION:

REWORK XXX REPAIR USE AS IS XXX SCRAP See attachment.

ENO. REVIEW / APPROVAL DATE:

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$ I 2CV Bf OE E.EVIEW APPROVALds

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On 6i%D 1 "3 POSITION VERIFICATION & CLOSURE:

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CCMMENTS:

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.,;... DISPOSITION:

' Evaluation of the subject condition is separated into a consideration of design and a consideration of fabrication.

> The Vendor.- Transamerica Delaval has performed an analysis that shows that the worst case stresses fall within the allowables of the ASME Code.

This portion of 4

' the nonconforming condition is therefore dispositioned "use as is".

The fabrication records have been examined and there is insufficent documentation a

to claim NF - equivalency. A program has been developed however to qualify the li support and skid fabrication to AWS D1.1-1975 and the AISC Hanual of Steel lj Construction, seventh Edition.

,,g L s:3 All accessible welds were inspected to CP-QP-11.11, R.1.

The inspection results

'M those that had probler; such as undersize, undercut, etc, and -

M_N fall into two areas:

1 welded channel box sections where penetratica was either lacking or unverifiable.

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Welds of the first type were reworked as required, re-inspected, and found to be w m acceptable.

For those. welds in the latter group, the Vendor, Transamerica Delaval

., I t The analysis showed the TK

'%Nr:n an analysis of the welded channel box sections.

adequacy of the welded sections and their suitability for the worst case loading 3

conditions. -Based on this, the welded channel box sections are acceptable as is.

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m, These h.,;: Inaccessible welds can be neither accepted or rejected by insoection.

W a welds do not consitute a majority of the welds and are dispersed throughout the Pdoe's,not have a major impact on the overall structural integrity of the skid.

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$,,i,,,s kjd.- Based on this and the fact that the Transamerica Delaval supplied skid stress

'em-analysis yielded a' maximum stress value of 0.37, the integrity of these welds

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b Ccnsequently, the inaccessible welds may be used as is.

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h The following supporting documentation is attached:

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Weld Procedures

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Welder Qualification

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Material Certifications

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,'oiettT Es COMANCHE PEAK STEAM ELECTRIC STATION C P 1 - A1 E M7F./ 7 h.gNEATING CO.

NONCONFORMANCE REPORT (NCR) 2-dO581R-1

,[

UNIT STRUCTURE / SYSTEM ITEM / COMPONENT TAG /10 NUMBER LOCATION OR ELEVATION RIR NO.

CP2-MEDGEE-01 2

DG/3000 Aux. Skids CP2-MEDGEE-02 c, DG Bldg. 810'6" N/A NONCONFOAMING CON 0lTION Supports for ASME Class 3 piping and components are considered and fabricated by the Vendor Transamerica Delaval as Non-NF.

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These supports shculd be NF as specified in the applicable Gibbs & Hill specification.

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PARA 3.3 i f.EFERENCE DOCUMENT.

f EPORTED BY:

DATE:

M. Asmussen 5 / 13 / 82

' OE REVIEW / APPPOVAL:

DA O

ACTION A00AESSEE '

DEPARTMENT Merritt/Moehlman Engineering OlSPOSITICN:

AEWORK AEPAIR USE AS IS SCRAP See Attachment.

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/ D ENG. REVIEW /APPROVA DATE; I

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m,1..in A. A, 7,i m F f k

alSPOSiflCN VERIFICATION & CLCSURE.

DATE:

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l COMMENTS: R-1 issued to Change disposition.

F01A-85-594 e

e NCR M-82-00581 R-1

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DISPOSITION:

Evaluation of the subject condition is separated into a consideration of design

[

and a consideration of fabrication.

The Vendor, Transamerica Delaval has performed an analysis that shows that the I'

worst case stresses fall within the allowables of the ASME Code. This portion of the nonconfqnning condition is therefore dispositioned "use as is".

The fabrication records have been examined and there is insufficient documentation to claim NF-equivalency. An inspection of all skid and support welds was started in order to qualify the fabrication to AWS D1-1 and the AISC Manual of Steel Construction, seventh edition. During the inspection, various members were found to have linear indications. These findings were documented on other NCR's.

In order to resolve the problem of linear indications, the base skids and component supports shall be replaced 100%. The new skid and supports shall be fabricated in accordance with AWS D1-1-75 and the AISC Manual of Steel Construction, seventh I

edition.

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TE (As' UTILITIES g

NONCONFORMANCE REPORT (NCR)

GENERATING CO.

3 M-82-00902 thi f

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STRUCTURE / SYSTEM ITEM / COMPONENT TAG /lO. NUMBER LCOATION OR ELEVATICN RAR(NO.

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UNIT j

2 DG/3000 Skid Base FSN-00232 R.IG 813'

.N/A a

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NCNCONFORMING CONoITION i

During inspection of welds in Diesel Generator 2 linear indications were found i

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in base metal (Item G).

Indications ran the length Of West side of channel.

z Reference NDE #6166 (MT Report).

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2 3.5 CP-QP-11.11

,gy REFEREuct oOCuusNT.

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REPORTEo av:

Kirby Scott 7s 8 i82 I

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OE REVIEW / APPROVAL:

DEPARTMENT o ; /.CT:CN AQoRE5sEE J. T. Mereitt!'* ehlman Encineerine

assPcsmcN:

t REWORK REPAIR usE as is SCRAP Y'Y e

8 af Interim Disposition:

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Item G will be removed and replaced with new caterial. Old piece is to be i

E returned to vendor for analysis and final disoosition.

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~1'ork 'not related to Items G, F, J. Y, LT H. N.Tay continue.

i'aiver:

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COMMENTS: Rev.1 issued to add temporary waiver.

FOTA-85-59

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COMANCHE PEAK STEAM ELECTRIC STATION TEXAS UTitmES NONCONFORMANCE REPORT (NCR)

M.82-0902

.

• CENERATING CO.

UNIT STRUCTURE / SYSTEM ITEM / COMPONENT TAG /lO NUMBER LOCATION OR ELEVATION RIR NO.

Diesel Generator -

2 T0# 22900 Skid Base FSM-00232R.1 G 813' NONCONFORMING CONDITION During inspection of welds in Diesel Generator 2 linear indications were found in

j base i. metal (Item G).

Indications ran the length of West side of channel.

z 8

Reference NDE #6166 (MT Report).

"ag (1) hold tag applied.

eO be l*ll REV PARA

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REFERENCE DOCUMENT-DATE:

REPORTED BY:

7 8 82

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t ACTION ADDRESW b T[ bttgcp-@&w EP^T h eering O

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DISPOSITION:

REWOR:'

REPAIR USE AS IS SCRAP YYY Interim Disposition:

Item G will be removed and replaced with new material. Old piece is to be tu returned to vendor for analysis and final disposition, i

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DATE:

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' DISPOSITION YIFilEICATION & CL'OSORE:

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6166 '

QUALITY ASSURANCE DEPARTMENT MT/PT REPORT OF /

, PROJECT: COMANCHE PEAK JOB NO. 351195 UNIT PAGE /

MT R PT O N/A WDC/ Traveler #

Dr: wing $M cogg System. Net gnagg Crass 4(,Jg Welds / Item # (r LocatiordL8l 3' pfa(gyg(fqpg}

NDE Procedure Nog g g,g.,fev. 3 Mfg Stage f4 Equip / Mat'Is Mfg. g4pd y Acceptance Std.

Q4 4g[

Penetrant Batch #

A//

Cleaner Batch #

A3/$

Developer Batch # h /Ar AC Yoke @

DC Prods O '

Modei # y 6 M&TE IRC # [673 Def. 4.3M @

Diameter O

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Mst'l Type Sketch & Comments ID O OD pt

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COMANCHE PEAK STEAM ELECTRIC STATION texas UTILmES NONCONFORMANCE REPORT (NCR)

CENERATING CO.

H-82-00902 R.1 4

.i UNIT STRUCTURE / SYSTEM ITEM / COMPONENT TAG /iO NUMBER LOCATION OR ELEVATION RIR NO.,

/

2 DG/3000 Skid Base FSM-00232 R.1G 813' N/A '-

NONCONFORMING CONDITION During inspection Of welds in Diesel Generator 2 linear indications were found d

in base metal (Item G).

Indications ran the length of West side of channel.

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Reference NDE #6166 (MT Report).

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REFERENCE DOCUMENT-REV PARA 2

DATE:

REPORTED BY:

Kirby Scott 7/ 8 /82

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< dd REVIEW / APPROVAL:

DATE:

f/f/c[

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0 ACTION ADDRESSEE I

J. T. Merritt/Moehlman Enaineerina DISPOSITION:

REWORK REPAIR USE AS IS SCRAP YYY Interim Disposition:

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Item G will be removed and replaced with new material.

Old piece is to be l

E returned to vendor for analysis and final disposition.

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Work.*not relatedi o Items G,,H, J, K E L. M, N-mai codtiihbe,'

Waiver:

t zOy DATE:

ENG. REVIEW /APPROV h/Al$b D

E-OE REVIEW APPRO i

DISPOSITION VERIFIDXfiON'& CLOSURE:

T DATE:

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l COMMENTS: Rev.1 issued to add temporary waiver.

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COMANCHE PEAK STEAM ELECTRIC STATION TEXAS UTILITIES CENERATING CO.

NONCONFORMANCE REPORT (NCR)

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M-82-00902 R.2

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UNIT STRUCTURE / SYSTEM ITEM / COMPONENT TAG /ID NUMBER LOCATION OR ELEVATION RIR NO.

4 2

DG/8000 Skid Base FSM-00232 R.1G 813' N/A NONCONFORMING CONDITION During inspection of welds in Diesel Generator 2 linear indications were found in base metal (Item G).

Indications ran the length of West side of channel.

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Reference NDA #6166 (M.T Report).

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CP-QP-11.11 REV 2

para 2.5 REFERENCE DOCUMENT.

REPORTED BY:

DATE:

K. Scott 7 /8 42 QE REVIEW /APPROVA A

ACTION ADDRESSEE 'Merritt/Moehlman Engineering O

DEPARTMENT.

DISPOSITION:

XXX

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REWORK REPAIR USE AS IS SCRAP j

Final Dispo.

l Item shall be scrapped.

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DATE:

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C MMENTS: R-2 issued change disposition.

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C%en tpwo A au tra Eens sa COMANCHE PEAK STEAM ELECTHIC STATION TEX TILITIES TINC. CO.

NONCONFORMANCE REPORT (NCR)

M-8 -01207 UNIT STRUCTURE / SYSTEM ITEM / COMPONENT TAG /lO NUMBER LOCATION OR ELEVATION RI A NO.

2 DG/3000 Skid Base FSM-00232 R.0G 813' N/A NONCONFORM,NG CONDITION During the rework of the Diesel Generator support structure, the structural d

steel member referenced in NCR M-82-00902, dated 7/8/82 (attached), was y

damaged. The damage, a discontinuity in the base metal,was repaired. How-o ever, the requirements of CP-CPM-6.9B, Weld Filler Material Control, were E

not met because the filler material used for the repair was not issued specifically y

for this repair.

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PARA REFERENCE DOCUMENT-J. R. Dilling am NFPRV

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DATE:

REPORTED BY:

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ACTION ADDRESSEE

~j DEPARTMENT J. T. Merritt/Moehlman Enaineerino DISPOSITION:

REWORK REPAIR USE AS IS YYY SCRAP Use.as is. The repaired item was removed in accordance with the disposition w

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W of NCR M-82-00902.

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ITEM DEScalPTiCN iCENTIFICAT60N No.

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f. <O 6. Aux. Sub base 5Idd 2 F5m-capaa 22900 3 6 -E pio a

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g INSPECTION ATTRIBUTES QC g oaTg SIGNATURE 5

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Defect Identification

@ Base Meta 1 Da,mege {Ir mula, -f/ea,, e oof)

V O Minimum Wall violation

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00ther:

I Defect Dimensions: fy'k/%"

i Material Type / Grade: C(,yfo,f p /,,,,,, / gjr.g j,

Wall / Plate Thickness A/J O.k'y Outside Diameter:

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NRC 0...fice F (.Mb Septen:ber ik,1983 DATE :

L Iq hereby make the following voluntary statement to H. Brooks GR FFIN, who has identified himself to me as an Investigator with the U. S. Nuclear Regulatory Comission.

I make this statement freely, with no threats or promises of reward having been made to ne.

I was employed as a welder with Brown & Root from about November 1979 until December 1980, when I was terminated for failure to return to work following an automobile accident. When I was, able to return Brown & Root refused to hire me, an rown Root re tre get my Jo me in June, 1981.

I was again terminate in y,

, for excessive absences.

' because 1 required regular doctor's appointments from the automobile accident that cause me to miss work, i

During the time I was employed at Comanche Peak, there were several occasions on which I was threatened with termination if I failed to follow *. instructions from supervisors which I knew were improper.

In about April 1981 my foreman, told me to use scrap 1-beam to replace a piece in a hanaer.

cut a new piece, and attempted to weld ~it.

ine new piece was magnetized and would not accept the weld.

I told 1

e to weld it or "tnere was no rieed for me to Wit would not work, but h come in tomorrow".

I followe i

tYuctions and welded the hanger.

I made theNRCawareofthisincident,andJ1ater_heardfromtheNRCthatthishanger,had been taken out.

Most of the time that I worked at Comanche Peak I believed I was doing my work properly, until I started hel in@ prepare for her QC tests.

I realized that.

'Y

" plug' weld" that told me to perform in about February 1980 was improper.

I remembe even watched for QC while I made the weld.

I provided this information o the NRC.

Durih about 5dpicmber 1980, I remember an incident'in whic an all superintendents) threatened my super nten with terminat on.

told "if you don't finish this pipe line be ore 5:30PM, you and your crew will be icking your hats out the front gate". This particular pipe line had been in process for a long time and there had been a lot et i

problems with it.

rran ed for a lot of welders to start working and they l

" messed up" much e work.

believe the pipe was bought off.

In July 1981 iust before I was terminated,M my foreman, instructed sE to N

make a "downl

• 1" pass to cover a couge in a oita 1 was welding.

I believ M l

toldmetoenthistoprotecthisjob.

I to1 @ would rather not do it. I calledM.nd she suggested we contact anctner QC inspector to come look at the t

weld so e supervisor would not know I had notified QC. A QC inspector by the name cf came to the location, an6an caught me showing the gauce.

I was terminated the next week, bu was not.

I talked to who sa1:,

had sent a memo saying to fire me.

went to office and ta'oe: to who said tc call him the next week.

I calleo back the fo11:. r.g week and talked t told me he would check on mv story and wou,c call me. Two weet.c later, I caisec him and he got mad at me. %,

a i

i never returnt r cali. I hearo frcr cther empicyees on site that the order to Tsra r4 j

ame fro M t

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,1 Qg TEXAS UTILITIES GENERATING COMI%NY m......v s n m x...su.m wu,. m...

R. J. GARY I

'U'E " =*~

ig January 10, 1984 i

g TXX-4095 l

Mr. E. H. Johnson, Chief Reactor Project Branch 1 U.S. Nuclear Regulatory Comission Office of Inspection and Enforcement 611 Ryan Plaza Drive, Suite 1000 Docket tios.:

50-445 Arlington, TX 76012 50-446 COMANCHE PEAK STEAM ELECTRIC STATION UNIT 2 DIESEL GENERATOR AUXILIARY SKID QA FILE:

CP 82-06, SDAR-82 FILE NO.:

10110

Dear Mr. Johnson:

In accordance with 10CFR50.65(e), we are submitting the enclosed report of actions taken to, correct a deficiency regarding linear' '

indications in the Unit 2 emergency diesel generator auxiliary

. skid.

Supporting documentation is available at the CPSES site for your Inspectors review.

Very truly yours, j.

RJG:In j

cc: NRC Region IV - (0'+ 1 copy) i i

Ofrector, Inspection & Enforcement (15 copies)

I U. S.* Nuclear Regulatory Cc mission Washington, DC 20555 F01A-85-59 b

L.J.

. ; ~~

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^

^-

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E ATTACHMENT UNIT 2 DIESEL GENERATOR AUXILIARY SKID De':ription Ducing inspection by Site Quality Control, linear indications were observed in the Unit 2 Number 2 emergency diesel generator auxiliary skid (support structure).

The skid was provided by the supplier (Transamerica DeLaval) as part of the diesel generator package.

Further inspections yielded additional base metal defects which have been documented by site nonconformance reports.

Safety Implications Due to the indeterminate structural integrity of the auxiliary skids, the operability of the emergency diesel generators could not be assured during a seismic event.

Corrective Actions The existing auxiliary skids will be scrapped.

The replacement structures will be fabricated at the jobsite in accordance with drawings prepared by site engineering. All site activities will be performed per established engineering and construction procedures.

Corrective actions are currently underway.

Completion of these activities should be no later than September, 1984.

G O

e.

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NONCONFORMANCE REPORT (NCR)

M-82-01207 GaNLyTwo cO.

Attachment "I"

l UNIT STRUCTumf/ SYSTEM ITEM /COMPOhiNT TAG /lO N'JMSER LOcA,80N OR ELEVATION MIR NO.

2 DG/3000 Skid Base FSM-00232 R.0G 813' N/A NONCONFORMING CONDITION During the rework of the Diesel Generator support structure, the structural

j steel member referenced in NCR M-82-00902, dated 7/8/82 (attached), was

[

damaged. The damage, a discontinuity in the base metal,was repaired. How-ever, the requirements of CP-CPM-6.98, Weld Filler Material Control, were o

E not met because the filler material used for the repair was not issued specifically g

for this repair.

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CP-CPM-6.98

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lDaPARTMENT J. T. Merritt/Moehlman

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REWORK REPAIR Ust AS is YYY SCRAP Use..as is. The repaired item was removed in accordance with the disposition mg of NCR M-82-00902.

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