ML19329E634

Interim Deficiency Rept Re Defective Pipe Support Fillet Welds.Addl Work Needed to Accept ITT-Grinnell Conclusions That Welds Will Not Fail in Svc.Meeting w/ITT-Grinnell to Be Held in Apr 1978 to Determine Future Actions

ML19329E634
Person / Time
Site:	Midland
Issue date:	03/30/1978
From:	Howell S CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.)
To:
References
HOWE-36-78, NUDOCS 8006160415
Download: ML19329E634 (9)

Text

{{#Wiki_filter:a T.I Consumers Power St.ph.n H. How.el

m. ,,._ , / Company s n.r.: ome..: nia w e usenigen Avenu..a.ca on. wicnigen emoi March 30, 1978 .

Howe-36-78 - gj .; q w _ Ra! Mr J. G. Keppler

• P Office of Inspection & Enforcement ,

Region III ., da E3 US Nuclear Regulatory Cc= mission s w 1 799 Roosevelt Road  ?

                                                                                                   "       g          e Glen Ellyn, IL 60137                                                                      -

MIDLAND NUCLEAR PLANf - UNIT NO. 1, DOCKET NO. 50-329 THIS DOCUMENT CONTAINS - UNIT NO. 2, DCCKET NO. 50-330 P00R QUAL.ITY PAGEg PIPE SUPPORP FTim WELDS Reference 1) Letter, S. H. Howell to J. G. Keppler, Midland Nuclear Plant - Unit No. 1, Docket No. 50-329; Unit'No. 2, Docket No. 50-330; Pipe Support Fillet Welds, Serial Hove-197-77, dated November 21, 1977

2) Letter, S. H. Howell to J. G. Keppler, Midland Nuclear Plant -

Unit No.1, Docket No. 50-329; Unit No. 2, Docket No. 50-330; Pipe Support Fillet Welds, Serial Hove-211+-77, dated December 22, Igrl7

3) Letter, S. H. Ecuell to J. G. Keppler, Midland Nuclear Plant -

Unit No. 1, Docket No. 50-329; Unit No. 2, Docket No. 50-330; Pipe Support Fillet Welds, Serial Hove-ll-78, dated February 10, 1978. The referenced letters were interim reports. This letter is also an interim report. Attachments 1 and 2 provide Eechtel Associates' interim reports in response to the Management Corrective Action Reports (MCAR-1 Report No.18 ard MCAR-1 Report No. 19). Attachment 3 is Eechtel's Quality Assurance Program Manage =ent Corrective Action Report (MCAR-21) which addresses undersized field welds. The Project Engineering response to MCAR-21 vill be included in our next 50 55(e) report-ITT Grinnell submitted to Bechtel Associates' Professional Corporation two engineering reports for review, one dealing with stress analysis of as-built veld configurations as found in a field survey and the second one providing the results of specific testing and a general history of Grinnell's experience with the type of welding in questien. These reports support a conclusion that the hanger velds vill not fail in service. Consumers Power and Eechtel, after review of these reports, agreed that additional work is necessary to strengthen the justification for an " accept as is" disposition. A meeting vill be held by early April with ITT Grinnell to determine the further actions required. g

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5. Howe-36-78 Another interim or final report vill be sent en or before May 31, 1978. nW Attachments: 1) Interim Report No. 4 dated February 24, 1978, MCAR-18

2) Interim Report No. 4 dated February 24, 1978, MCAR-19

3) Quality Assurance Program, Management Corrective Action Report, MCAR-1, Report No. 21 CC:> Dr Ernst Volgenau, USNRC (15)

Director, Office of Management Information and Program Control, USNRC (1) e 9 e \

                                                                     , , - _ . -     , - , . .  --4 --. --

   *         -                                                                   Attschme~nt 1 Howe-36-78

['**

SUBJECT:

MCAR # 18 (Issued /o-7J-77 ) INTERIM REPORT # 4 DATE: 2- 24-78 PROJECT: Consumers Power Company Midland Plant Units 1 & 2 Bechtel Job 7220 Status of Corrective Action and Investination Grinnell is proceeding with preparation of the test report. Three additional load tests will be included. To establish the actual quantity of underspecified fillet welds, Bechtel

            . is reviewing,all ASME hanger sketches originally engineered prior to May 1, 1978; the date Grinnell acknowledges full compliance with the code fillet veld size requirements.             ,

For'ecast Dates on Corrective Actions Grinnell has committed to submit a preliminary copy of its test report by the end of February. The recent severe weather that paraly::cd the east coast forced Grinnell engineering at Providence to shut down for nearly 10 days which will probably cause some slippage in concluding this MCAR. BechttelwillcompletetheunderdesignatedweldcalloutsurveyinFebruary. s  %-t/,6 4 Submitted b'f: F. Approved by: A#/A ed'~uC;a . Concurrence by: Ed M 4_ i

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~ ' Attachment 2

SUBJECT:

MCAR # 19 (Issued //-7-77 ) Hove-36-78 1

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INTERIM REPORT # 4 DATE: 2-24-77 ,

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PROJECT: Consumers Power Company Midland Plant Units 1 & 2 Bechtel Job 7220 Status of Corrective Action and Investigation On February 13, 1978, Bechtel received Grinnell's analytical analys'is report on the 36 shop welds found underfabricated by Bechtel field OA personnel on random sample of 125 hangers. This report is presently being reviewed by Bechtel. . Bechtel is currently - an estimate of the number of underf.ibricated shop welds existing _. nangers shipped by Grinnell to the field through August 1977. sais estimate will also include the cost of reworking and the factors on uhich the estimate was based. Forecast Date on Correcti'.e Action Bechtel's estimate of the number of underfabricated shop welds and the cost of their rework will be completed by ,the end of February 1978. Review of the Grinnell analysis on underfabricated welds will be completed with.a disposition on applicability by March 17, 1978. Submitted by: [[ ym/3 Approved by: fic[M &I4 u b M Concurrence by:

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                                                      'm                                                                 Attichment 3 How3-36-76
                '.                                           QUALITY ASSURANCE PROGRAF.1 h
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   .-p MANAGEMENT CORRECTIVE ACTION REPORT MCAR.1 REPORT NO.            21 P.O. 7220-M-106 a no, Various                         DATE             2/28/73 JOB NO. 7220 1 *DE .':RIPTION (Inctuding references):

As part of the investigation to determine the extent of fillet veld size discrep-ancies associated with hanger fabrication and identified in MCAR 18 and 19, a reinspection, using a weld fillet gauge, was conducted by Quality Control of a sanple of 80 completed hangers consisting of 300 field ucids. This sa=ple represents 10". of the Q-listed hangers uith field fillet welds installed to date. The reinspection was for the purpose of determining the actual field weld size conpared to Grinnell design and shetches. It was discovered that contrary to the specified field veld size required by Grinnell drawings, the actual field weld size

         ' RECOMMENDED ACTION (Optional)

1) Determine the cause of the deviation.

2) Request Project Engineering to evaluate the nonconforming conditions and deter-mine whether er not the worst probable case for undersized confiCuration has been identified. If not, instruct Quality Control accordingly to expand their sample to include the vorst case configuration.

3) Have Quality Control conduct additional reinspection of the field welds of the

                 . remaining installed hangers depending on Project Enginecring's disposition of (con t ' d. )

REFERRED TO ENGINEERING . QA MANAGEMENT [ CONSTRUCTION

               *Potentially Reportabic
            ** Reported by CPCo as part of fillet veld proble= ISSUED B                                              "'    S      v8          f by letter (Hove-197-77) dated 11/21/77 to NRC.                                              ,
                                                                                                                   ; g A ,,,,         oate NO        IED Cf LENT    T   -F/'W' 11 REPORTABLE DISCREPANCY NO

• YES x -m' N CJte

                                                                                                                                            /ME/ 73 8                                   Protect f.iJmMe,                            /

lli CAUSE

                                                                                                                                      /

CORRECTIVE ACTION TAKEN AUTHORIZED BY oate DISTRIOutloN. ,iolette P,o3ect Maoage, FORMAL REPORT TO CLIENT T. M. Leverette tir section 84 Applies) oate Q"'",',',*,", ",*" *y' P,oin t C h0' ate, G. L. Richardson

           'o, yay. P,1,., "eI."u'e',         J. Amaral (Caithersburg) CORRECTIVE ACTION IMPLEMENTED
      **'U. I,7 *2e"I."70' u ,,.              J. E. Bashore (Norwalk)
        ^S"'*'

t VERIFIED CY eroi.ci or co,-e., o.ie o.x, ... . .-. ,,.. 4 . .. ..cn ,,,,,,oc e ooco ,m. .. 1 t e.' I Q1

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          !! CAR Report lio. 21 February 28, 1978 Page 2,                          ,

I DESCRIPTIC'T (Cont'd.) for 26 hangers, representing 9 field welds, were undersize. As a result, the attached I'CR r71222 has been issued. d REC 0!!}D'DED ACTION (Cont'd.) the identified nonconforming conditions coordinating the action with MCAR 18 and 19. 1

4) Have Quality Control evaluate the methods used to inspect the field fillet veld si::e and revise the QCIs as necessary to provide clear instructions for inspecting pipe support field fillet velds.

5) Determine and clearly identify what action' to be taken to assure quality

• of field fillet welds on hangers to be installed.

6) Coordinate with Project Engin:ering and determine reportability under 10 CFR 50, Section 50.55(e). Request Project Engineering to prepare an

                        ' interin report and issue to the Project Yanager within 15 dt.ys, containing all available infor=ation, together with a statc=ent as to whcn a complete report will be issued. The interin report is to address clearly the question of reportabilit).

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QA F E f; 2 3 'S70 "dw gQ NONCONFORMANCE REPORT

1. PROJECi NAME JOli NO. 10. 20.

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2. UNITISI 3. DRAWifJG/PART NO. -

REV 4. ITEM DESCRIPTION 5. ITE.'.1 LOCATION

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7. SERI AL FJO.

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16. NONCONFORMING CONOlTlON: 21. DISe'OSITION CONCURDEr.'CE .

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Of g REGULATORY INFORMATION DISTRIBUTION SYSTEM (RIDS) DISTRIBUTION FOR INCOMING MATERIAL g/50-329/ 30 REC: KEPPLER J G ORG: HOWELL S H DOCDATE: 03/30/78 NRC CONSUMERS PWR DATE RCVD: 04/03/78 DOCTYPE: LETTER NOTARIZED: NO COPIES RECEIVED

SUBJECT:

LTR 1 ENCL 1 FORWARDING CONSTRUCTION DEFICIENCY REPTS CONSISTING OF BECHTEL ASSOCIATES" INTERIM REPTS IN RESPONSE TO MANAGEMENT CORRECTIVE ACTION REPTS (MCAR-1 REPT NO 18 & 19) AND QUALITY ASSURANCE PROGRAM MANAGEMENT CORRECTIVE ACTION REPT (MCAR-21) WHICH ADDRESSES PLANT NAME: MIDLAND - UNIT 1 REVIEWER INITIAL: XJM . MIDLAND - UNIT 2 DISTRIBUTER INITIAL: DL

  ***************** DISTRIBUTION OF THIS MATERIAL IS AS FOLLOWS ******************

CONSTRUCTION DEFICIENCY REPORT (10CFR50.55(E). (DISTRIBUTION CODE BOO 4) FOR ACTION: ASST DIR VASSALLO**LTR ONLY BR CHIEF VARGA**LTR ONLY PRO.' "'" "on**LTR ONLY LIC ASST SERVICE **LTR ONLY INTERNAL: REG FILE **W/ENr NRC PDR**W/ ENCL

                           - , C- GrT~EfIdL OELD**LTR ONLY GOSSICK & STAFF **LTR ONLY         MIPC**W/ ENCL BOYD**LTR ONLY                     DEYOUNG**W/ ENCL HELTEMES**W/ ENCL                  R. MATTSON**LTR ONLY KNIGHT **LTR ONLY                  ROSS**LTR ONLY TEDESCO**LTR ONLY                  EISENHUT**LTR ONLY STANDARDS DEV.**W/ ENCL            K SEYFRIT/IE**W/ ENCL EXTERNAL:          LPDR'S MIDLAND. MI**W/ ENCL TIC **W/ ENCL NSIC**W/ ENCL FERD DREHER/IE**LTR ONLY ACRS CAT A**W/16 ENCL DISTRIBUTION:        LTR 41        ENCL 28                       CONTROL NBR:   78095000; i

SIZE: 2P+1P+6P ) l I

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