ML20083K477

Final Potential Deficiency Rept 55-82-11 Re Incorrect Identification of Base Matl & Improper Weld Procedures on Piping Hanger Travelers.Initially Reported on 821120.Issue Not Reportable Per 10CFR50.55(e)

ML20083K477
Person / Time
Site:	Clinton
Issue date:	04/04/1984
From:	Hall D ILLINOIS POWER CO.
To:	James Keppler NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
References
55-82-11, U-10139, NUDOCS 8404160190
Download: ML20083K477 (4)

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ILLINO/S POWER 00MPANY f3 3 9 500 SOUTH 27TH STREET. DECATUR, flijflOIS 62525 April 4, 1984

' Docket No. 50-461 Mr. James G.'Keppler Regional Administrator

. Region III .

U.S.-Nuclear Regulatory Commission 799 Roosevelt Road

-Glen-Ellyn, Illinois 60137 Subj ect: Potential Deficiency 55-82-l'1 10CFR50.55(e)

Incorrect Identification of Base Material and Weld Procedures on Piping Hanger Travelers

Dear Mr. Keppler:

.On October 20, 1982, Illinois Power Company notifi.ed Mr. F.

Jablonski, NRC. Region-III, (Ref: IP memorand im;Y-13999, 1605-L,-

dated 0ctober 20, 1982) of a potentially reportable deficiency .

.per 10CFR50.55(e) concerning.the-incorrect identification oftbase material and_ improper. weld procedures on piping hanger travele'rs.

This' notification was followed by six.-(6) interim reports'(IP letter.D. P. Hall to-J. G. Keppler U-10010, 1605-L, dated tiovem ;

ber-19~,:1982,.IP letter D. P. Hall to J. G.T Keppler U-10023,

• 1605-L,EdatedJJanuary 17,-1983, IP. letter D. P.; Hall to J: G.

Keppler U-10051, 1605-L, dated April 27,'1983, IPxletter D. P. s ,

Hall to'J..G. Keppler U-10078, 1605-L,' dated 7Auguct 5, 1983 IP letter'D. P. Hall to'J. G. Keppler U-10106 dated-November 14, c1983, and IP; letter D. P. Hall-to J. G. Keppler-U 10129 dated _

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February. 22,:1984).- Our investigation into;this matter . . -

hasidetermined'that theiissue does not repressnt a r reportable X V?

1d e'ficiency under 10CFR50.-55(e) .- This letter 1 represents a. final .s* _

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report:.in accordance with 10CFR50.55(e)(3)., y , N _

.STATEMENTOFPOTENTIALLY'REPORTABLEDEFICIENCY(WITHDRAWN)}

2 Duringifinal. review of piping'hanghrlinatallation travelefs,

-it{was: discovered that incorrect base materials?and improper weld -

t procedures were identified on the travelers'.' Although.some ~ _i

cases ' of incorrect welding : resulted . from the :docuter.tation .

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- errors ', no adverse impact -on the. safety of Tuperation of CPS ;wod1dD ' i-'

have occurred had.the hardware errors gone ' uncorrected.

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INVESTIGATION RESULTS/ BACKGROUND

~ During a Baldwin Associates (IP Contractor) Technical

M - Services Department final review of piping hanger installation travelers, it was realized that the wrong embed plate base

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material and improper procedures for welds between embed plates and piping hangers were identified on the documents. This error resulted in the issuance of a Nonconformance Report (NCR-7725).

.As a result of NCR-7725, the Baldwin Associates (BA) Quality Assurance Department issued Corrective Action Requests CAR-105

-and CAR-121 which addressed improper initiation by BA. Engineering

-and improper initial review by BA Technical Services on an unde-

-termined number of piping travelers.

Upon investigation by Illinois Power into the problems identified by NCR-7725 and CARS-105 and 121, the following information was obtained:

1. Sargent & Lundy (CPS Architect-Engineer) design drawing S21-1001 allows the use of both ASTM A-36 and ASTM J A-572. Grade 50 as embed plate material.

7Q 2. The,BA Piping Department did not realize that an v^ alternate type of material was allowed for embed plates. It was errcneously assumed that all embed y<-_ plate material was ASTM A-36, subsequently, pipe hanger 2-travelers were prepared identifying the embed base material as ASTM A-36. In reality, both ASTM A-36 and ASTM A-572 Grade'50 material were used.

3. The initial pipe-hanger traveler review by BA Technical Services assigns a weld procedure to the traveler, based on1the base materials identified on the document.

Therefore,.if erroneous. base material information is

-identified on travelers,' the). possibility of assigning

. _ -anEincorrect welding procedure exists.

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L 4. . The; weld proce' dure for welding?ASME SA-36 (pipe'h' anger

9. material) to ASTM A-36~(embed material) is desighatedl

- as N-1-1-A-lM. The~ weld procedure for welding n ASME 2SA-36 to ASTM A-572 Grade 50.(embed material) is-

designated as N-ASTM-A-SP. 'As~ ASTM A-36 material wass

< identified.onithe travelers, weld procedure N-1-1-A-lM 1 was subsequently indicated on the travelers;by?BA; J c sTechnical Services.: .Itcshould=be notedithat since i 7 3the'se.two welding proce~dures. utilizez the?same fillerE

~_ ,_ . material'and the same essential variables, the welds; p . ;are acceptable 1even though.anlincorre'ctiweld procedure hc 1, 3wasjspecified.- '

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whoperformedthewek.ds;in.questionLwere:

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-Mr. Janes G. Keppler Page 3 April 4, 1984 q

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e ;6. A review of traveler programs in the electrical, C -

instrumentation, mechanical equipment, and HVAC disci- l plines for weldments to embeds disclosed no welding I procedure errors.

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7. Investigation revealed that an ASME Code Case, N-71-10, states that an ASME weld procedure qualification (such g as N-1-1-A-lM) with a base metal in one P-number and

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1. Group number (for ASTM A-36, P=1) qualifies for all other base metals in the same S-number and Group number

_. -(for ASTM A-572 Grade 50, S-1).

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• A review of nearly 9000 pipe hanger travelers and addendums x .

was_ completed to determine if similar problems existed in pipe up hanger weldments to other base materials, such as structural ym ' steel. . 0f these , .pproximately 3600 travelers required revision y to correct.or' clarify base materials and/or weld procedures.

Although a large number of base material identification errors

, J weresidentified,.it was generally found that the assigned weld

, - Tproc'edures were adequate for the actual base materials used.

<y :In1some cases,.'it was identified that the weld procedures used m were inappropriate for the: combination of base materials used.

.Nonconformance Reports'-(NCRs) or Deviation Reports (DRs) were

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written to-document these problems and obtain disposition of the

~1[f welds. ;However, only threef(3) hanger welds were identified as requiringiphysical-rework?due to the use of an unacceptable weld procedure.

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fAnotherJ: issue thattwascidentified through investigation of

~: - .this1 potential" deficiency concerns the materialsz used for bJ @f", q.f Ifabricationtof(reari bracketis M Engineersiforiuse~at Clinton Power; 'fo.r pipe 3

hangers The Station. supplied vendor's by Basic detail j '

ddrawings? indicateJASMEjSA-36: material for"these brackets,. how-

-.ever, morenrecenttLoad~ Capacity Data. Sheets. indicate that-alter-W" ; ; ' - > 1nate materials G ASMEiSA-105,"ASME SA-515 Grade '70cand-ASME SA-516

'y . Grade 970~,imay'havelbeen 'used. . However,~ pipe-hanger travelers-O z

s W jenerallyDidentified(the' materia 1lasDASME SA-36 or.asfP-l' ~

[A%- ' Ofieldsweld prdcedures;used,werercorrectLeven material.T7Sincetthe mat'erials arelalliof;P-l? group number, the

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though; alternate x 2 -k > .*

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. -CORRECTIVE ACTION. _

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G. n 1 idocumentation ,e(The?following>actionsxare;b'eingiraken to correct identified L y;j~ i J - m ,

problemsVand.tosprevent> recurrence:1

, , ~ < v. s y%; x pl s ^/ N* iBA(Piping 1 Department $has[conduc Nd departmental (

% ,f* strainingjrelevantitoltraveler initiationiand:thei iimpo'rtance r ofcsupplyin fcorrect material idehtificationi-

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h-% MC; W/ Y '~+wa's?completedton? December 322 W1982.3 ' ,

f informa tioMoniworkiref ate d a do cumen t s . ?This4 training #

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MQ dk W df 24 9& SJD ' ' L?For3thoseipiping

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ravelers 'iniwhichtwelds to.

T 11 g % d embeds'havecnottbeiensatarte'd DBAjPipingaDep'artmentihas; l hi LW D4 5 findicatedEthattembed; base materials;arefeither ASTML T g m M. M ,N J~ T ~ < /A-36

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.5 .Mr.' Jam 2s G. Keppler Page 4 April 4, 1984 y-R , weld procedure is either N-1-1-A-1M or N-ASTM-A-SP, to show that alternate materials and weld procedures

• exist. For those travelers where welding to embeds has been ntarted cr is complete, a copy of NCR-7725 was included to correct the documents.

3. In those cases (other than welds to embeds) where an incorrect base material and weld procedure were identified on a traveler and the weld is in-process or complete, an NCR or DR has been written to obtain disposition of the weld and a copy was included in the traveler to correct the document. In those cases where documentation errors were identified through the investigation review process and the welds have not been started, the travelers were revised to identify the correct or alternate base materials and correct weld procedures that apply.

4. The Piping Specification, K-2882, has been amended to allow the use of Code Case N-71-10.

5. Baldwin Associates Procedures BAP 3.2.5 and BAP 2.6 will be revised to clarify methods of documenting the materials of pipe hanger rear brackets on travelers.

. SAFETY IMPLICATIONS / SIGNIFICANCE 4 * ~ ..

Although

documentation errors have been identified, it has P

ebeen: generally found that the associated weldments are

%s acceptable. In;the three (3) cases identified where tinappropriate weld:. procedures were used and the hangers. require i ~

' rework,\ an evaluation determined that no adverse. impact on the

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safety of operations?of CPS would have.resulted had the. hardware

pgone. uncorrected.- On this basis, the issue'is considered to:be

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- -non-significant, and'therefore,Enot reportable under

10CFR50.' 55 (e) . '

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.[ We trusththatithisifinalmreport:provides you. sufficient W Oi~formationLtofperformfafgeneralfassessment'of thisiissue:*

f(.  % n 4 '( % (andiade^quatelyf describes':our Loveralloapproach= to -resolve _ the. '

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s _- l Sincerely; yolurs , :

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