ML18017B340

Final Deficiency Repts 400/79-14-01,401/79-14-01, 402/79-13-01 & 403/79-13-01 Re Procurement,Fabrication & Insp of Engineered Plates for Concrete Embedment & Support of safety-related Loads.Corrective Action Taken

ML18017B340
Person / Time
Site:	Harris
Issue date:	02/27/1981
From:	Chiangi N CAROLINA POWER & LIGHT CO.
To:	James O'Reilly NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II)
References
10CFR-050.55E, 10CFR-50.55E, 400-79-14-01, 400-79-14-1, 401-79-14-01, 401-79-14-1, 402-79-13-01, 402-79-13-1, 403-79-13-01, 403-79-13-1, SH-N-2-18, NUDOCS 8103110600
Download: ML18017B340 (11)

Text

REGULAY INFORMATION DISTRIBUTI(SYSTEM (RIBS)

ACCESSION NBR: 8103110600. DOC DATE; 81/02/?7 NOTARIZED:"'O DO

'0

~

FACIL;50 000 Shearon Harris Nuclear Power Planti Un) t ii Carolina 001 Shearon Hart is Nuclear Power P) anti Un) t ?'i Car ol)na 0500000.f 50-40? Shearon Harris Nuclear Power Planti Unit 3i Carolina 05000002'5000403~

50'03 Shearon Harris Nuclear Power Planti Unit Qi Carolina AUTH ~ NAME" AUTHOR AFFILIATION CHIANGIiN~ J, Car ol ina Power 8 Light Co.

RECIP ~ NAME RECIPIENT AFFILIATION O'REILLYiJBP ~ Region 2i Atlantai Office of the Director

SUBJECT:

Final Deficiency Repts 900/79 10-Oii401/79 14"Oii 402/79"13"01 8 403/79-13 01 re procurement). fabrication insp of engineered plates for concrete embedment 8 support of safety elated loads, Corrective action taken, DISTRIBUTION CODE: B0198 COPIES RECEIVED:LTR TITLE! Construction Deficiency Report.(fOCFR50 ~ 55E) j ENCL j SIZE: +

NOTES!

RECIPIENT COPIES RECIPIENT COPIES ID CODE/NAME LTTR ENCL' ID CODE'/NAME LTTR. ENCL ACTION; A/D LICENSNG 04 1 YOUNGBLOODiB 05 1 1 RUSHBROOKiM ~ 06 1 AULUCKiR~ 07 1 1 INTERNAL: AD/RC I/IE 17 1 ASLBP/J'SHARD 1

'1 D/DIR HUM FAC15 1 EDO 8 STAFF 19 1 1 EQUIP QUAL BRil 1 1 HYD/GEO BR 22 1 1 IS,E 09 1 1 LIC QUAL BR 12 1 1 MPA 20 1 1 NRC PDR 02 1 1 OELD 1 1 P n ST REV13 1 1 QA BR 10 1 1 Of 1 RUTHERFORDiN ~ IE 1 1 STANDRDS DEV 21 1 1 EXTERNAL: ACRS 16 ie LPDR 03 1 f NSIC 08 1 MAR 12 88 TOTAL NUMBER OF COPIES REQUIRED: LTTR 38 ENCL 38

V P tt Q

k

'I p L,

~ %I g

'l K

t t

f '1 l

,n

FORM 21 Caroffna Povrer 8 Ught Company Raleigh, N.C. 27602 File: SH N-2/18 Item 12 February 27, 1981 Mr. James P. O'Reilly United States Nuclear Regulatory Commission Region XI 101 Marietta Street, Northwest Atlanta, Georgia 30303 SHEARON HARRIS NUCLEAR POHER PLANT UNITS 1, 2, 3 AND 4 DOCKET NOS. 50-400, 50-401, 50-402 AND 50>>403 DEFXCXENCXES IN THE PROCUREl&NT, FA33RXCATXON AttD INSPECTXON OF ENGXNLERED PLATES FOR CONCRETE EQ3EDMENT AR SUPPORT OF SAFETY RELATED LOADS OPEN ITE".fS 400 AND 401/79-14-01, 402 AND 403/79-13-01

Dear Mr. O'Reilly:

Attached is the final 10CFR50.55(e) report on the subject deficiency which describes the problem and the corrective action taken to accomplish resolution.

fB.th this report, Carolina Power 6 Light Company considers this matter closed.

If you have any questions regarding this matter, please do not hesitate to contact me.

II NJC/mt (7236) Yours very truly, Attachment 01"Igi.""::I Sl;" 1"-'; By cc: Mr. G. Maxwell M/A Mr. V. Stello (2) H/A N. J. Chianti N. J. Chiangi Manager Engineering 6 Construction Qua1.ity Assurance 8

'gg (g 1'ifqg g 0 )g

'

fh

) ~ a ~

<<~

~ PS>>

g rt,)

J n t

Carolina Power 6 Light Company Shearon Harris Nuclear Power Plant Units j, 2, 3 and 4 Final Report February 26, 1981 Reportable under 10CFR50.55(e)

Prepared by: Carolina Power 6 Light Company

J 4

SUBJECT:

10CFR%.55(e) Reportable Item Shearon Harris Nuclear Power Plant (SHNPP)

Docket Nos. 50-400, .50-401, 50-402, 50-,403 Deficiencies in the Procurement, Fabrication, and Inspection of Engineered Plates for Concrete Embedment and Support of Safety Related Loads SUPPLIED BY: DuBose Steel Company Industrial Mechanics ALFAB Inc.

DESCRIPTION On or about July 6, 1979, during the repair of a damaged engineered plate, it was discovered that the anchor bolts w'ere welded with a fillet weld rather than a full penetration weld with a reinforcing fillet as required by the weld symbols on the design drawings. An investigation revealed that 238 engineered plates received from the same fabricator (Dubose Steel Company) on four (4) purchase orders were welded with fillet welds of the size specified for reinforcing welds. The investigation also identified =that documentation associated with the fabrication and nondestructive testing .(NDE) of the materials was also missing.

The findings from this investigation prompted an investigation of field procurred items requiring welding. This investigation revealed missing documentation associated with fabrication and nondestructive testing from two (2) additional fabricat'ors. Plates were fabricated in accordance with design requirements but in many cases nondestructive testing was not accomplish-ed or else not documented. Approximately 231 engineered plates from these two additional fabricators were missing some documentation of the required NDE.

SAFETY IMPLICATIONS Engineered plates were not fabricated.and/or tested in accordance with design requirements. All suspected plates were evaluated and corrective action, if any was required, was completed.

All the. plates identified have been analyzed. In the worst case one plate (identified on PW-C-789) was overstressed 17X from that allowed by the applicable standard review plan. The standard review plan requires a cross section 1.6 times the normal section calculated from A.I.S.C. The'normal code calculation utilizes approximately .6 and .45 of the yield strength for tension and shear respectively. The standard review plan provides approx-imately 300/ safety margin relative to the material yield strength. The before referenced 171 is an, encroachment into this required design safety margin.

In addition to engineering evaluation destructive tests were performed. A pig was fabricated where by a plate was put in a tensile test machine to evaluate how it would perform since it was originally designed with a full penetration weld and fillet reinforcing, but was installed with only a fillet weld. Test results were documented in PW-C-789 and transmitted to the A/E for use in his evaluation. This information along with weld sizes provided to the A/E allowed them to evaluate the plates to determine their acceptability (the weld size of plates embedded in concrete was determined using ultrasonic testing). Of

~ ~

C

all the plates evaluated (embedded only) nine (9) plates had to be modified (pei FCR-C-869 Rev. 2) while all the remainigg plates were accepted as is.

In the accept "as-is" category the original -$ " tolerance in reference to the load attachment point had to be decreased to -1" in several cases. By decreasing the tolerance the plates in this category will not be overstressed.

CORRECTIVE ACTION The cause of the problem was due to misinterpretation and misapplication of design documents by both siteand vendor personnel.

Each engineered plate installed prior to problem detection was identified and evaluated relative to design requirements. The required corrective action, if any, was taken on an individual plate basis.

Engineered plates not installed prior to problem detection were placed on QA hold. 'The required corrective action, if any, was taken on an individual plate basis. As a secondary check to the QA hold, special interim procedures were implemented with the concrete placement activities to ensure individual engineered plates were in accordance with design requirements. These interim procedures required the field construction'nspectors to identify each engineered plate and obtain written confirmation from QA that documentation, NDT, and/or repair work was complete.

Site inspection and field procurement personnel were made aware of the problem. Training on weld symbol identification and weld inspection was conducted.

Site specifications utilized,to procure fabrication steel was reviewed in detail and changes were initiated to ensure fabricators and inspectors could readily ascertain welding and NDE requirements.

Fabricators working on site structural steel orders were individually con-tacted to ensure specifications were understood and change orders were issued where necessary to clearly define requirements.

Site personnel associated with procurement or inspection have been instructed to ensure that vendor requests or questions are properly documented and processed through purchasing to site engineering in accordance with standard procedures. Site personnel have been cautioned to use standard prospect pro-cedures (RCI) for requesting clarification of design requirements on an individual basis.

Ebasco reviewed engineered plate details associated with ident3,fication nomenclature and welding symbols and initiated changes where required to minimize any confusion that may have existed.

Ebasco has provided an alternate fillet weld design to repair existing fabricated plates. This detail requires increasing the fillet weld size to develop the full strength of the associated anchor bolt.

Since the incident no engineered plate material has been accepted by the site QA receipt inspection unit having incorrect welding details. In addition, individuals involved with the ordering, receiving and inspecting of engineered items have been instructed to pay particular attention to welding details and raise questions if there is any doubt as to correctness.

~ r ~ ~ REFERENCES FCR-AS-40 1/16/79 FCR-W-011 3/9/79 FCR-AS-79 5/23/79 FCR-AS-84 6/25/79 Ltr to Dist from Loflin (PPED) PPED-79228 7/6/79 FCR-AS-90 7/11/79 FCR-AS-91 7/12/79 PW-C-789 7//12/79 Ltr to Dubose Steel, from C. Rogers, CPGL PLS-2152 7/12/79 DDR No. 269 7/13/79 FCR"AS-94 7/13/79 FCR-AS-95 7/16/79 Ltr to Carl Rogers (CP&L) from Dubose Steel 7/16/79 FCR-AS-97 7/17/79 FCR-AS-101 7/31/79 FCR-AS-102 8/1/79 Ltr to Forehand (QA) from Lucas (Res Eng) MS-6513 8/6/79 Ltr to Dist from Chiangi (QA) QA-1213 8/7/79 Ltr to Dubose Steel, from Harrington (CPGL),PLS-2204 8/14/79 Ltr to Dubose Steel, from Harrington. (CP6L) PLS-2214 8/23/79 PW-C-868 8/23/79 PW-C-867 8/23/79 PW-C-866 8/23/79 Ltr to O'Reilly(NRC), from Chiangi (QA) 9/5/79 PW-AS-123 9/10/79 Ltr to Forehand (QA) from Whitehead (QA) 9/20/79 PW-AS-143 10/24/79 Ltr to O'Reilly (NRC) from Chiangi (QA) 11/2/79 PW-C-1043 ll/13/79 Ltr to Forehand (QA) from Lucas (Res Eng) MS-6859 "

12/6/79 Ltr to Dist from Chiangi (QA) QA-1412 12/11/79 Ltr to O'Reilly (NRC) from Chiangi (QA) 12/27/79 Ltr to O'Reilly (NRC) from Chiangi (QA) 2/29/80 PW-AS-225 5/21/80 Ltr to Forehand (QA) from Lucas (Res Eng) MS-7383 5/27/80 Ltr. to O'Reilly (NRC) from Chiangi (QA) 5/30/80 PW-AS-265 8/19/80 Ltr to Forehand (QA) from Lucas (Res Eng) MS-7606 8/25/80 Ltr to O'Reilly (NRC) from Chiangi (QA) 8/29/80 Ltr to Forehand (QA) from Lucas (Res Eng) MS-7816 11/12/80 Ltr to O'Reilly (NRC) from Chiangi (QA) 11/14/80 Ltr to Forehand (QA) from Lucas (Res Eng) MS-7950 12/24/80 Ltr,to O'Reilly (NRC) from Chiangi (QA) 12/30/80 PW-C-869, Rev. 2 2/4/81 PW-AS-416 2/5/81 Ltr to Lucas (Res Eng) from Forehand (QA) 2/19/81 Reference Drawings Showing Location of Plates Embedded in Concrete:

2168-G-156S01 Rev. 9 2168-G-221 Rev. 3 2168-G-163SOl Rev. 9 2168-G-227 Rev. 3 2168-G-164SOl Rev. 5 2168-G-172S01 Rev. 3

.r