ML20214P512

Final Deficiency Rept 83-08 Re Fabrication of Pullman Sheet Metal Duct Fittings W/O Approved Design Documentation. Initially Reported on 830630.Unit 1 Fitting Mods Completed on 860501.Reworking of 12 Fittings Remain for Unit 2

ML20214P512
Person / Time
Site:	Braidwood
Issue date:	09/02/1986
From:	Miosi A COMMONWEALTH EDISON CO.
To:	James Keppler NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
References
1994K, 83-08, 83-8, NUDOCS 8609230204
Download: ML20214P512 (3)

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ne First Nabonal Plaza Ctucago, Imnois kL"/ Chicago.Winois60600 07672 A&*.sves Ryly to: Poet Omco Box 757 September 2, 1986 Mr. James G. Keppler Regional Administrator Region III U.S. Nuclear Regulatory Commission 799 Roosevylt Road Glen Ellyn, IL 60137 Subj ect: Braidwood Station Units 1 and 2 10 CFR 50.55(e) No. 83-08 Final Report Duct Fitting Fabrication NRC Docket Nos. 50-456 and 50-457

References:

(a) E.D. Swartz letter to J.G. Keppler dated July 29, 1983 (b) E.D. Swartz letter to J.G. Keppler dated October 20, 1983 (c) E.D. Swartz letter to J.G. Keppler dated August 30, 1984 (d) D.H. Smith letter to J.G. Keppler dated November 28, 1984 (e) D.H. Smith letter to J.G. Keppler dated April 18, 1985

Dear Mr. Keppler:

References (a) through (e) provided information concerning a deficiency reportable pursuant to 10 CFR 50.55(e) regarding fabrication of Pullman Sheet Metal duct fittings without approved design documents at our Braidwood Station. The purpose of this letter is to provide an updated status of the corrective actions taken to resolve this issue. This letter is considered to be a Final Report.

Status of Corrective Action On June 30, 1983 Commonwealth Edison issued NCR 540 and filed a 50.55(e) Report 83-08 to document that Pullman Sheet Metal (pSM) had fabricated duct fittings without Sargent & Lundy (S&L) approved drawings. PSM had fabricated fittings based on their interpretation of the design specification and the use of standard industrial practices. This was acceptable for many of the fittings attributes such as sheet gauge, companion and stiffener angle size, companion angle joint details and sheet to stiffener and companion angle welding. However, the spacing and joint details of stiffeners was not clearly defined due to wide variations of fitting shapes.

These attributes would requiro field verification.

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4 A stop work was issued to PSM to halt installation and fabrication of

. duct fitting not covered by S&L approved design drawings. PSM was directed to

' submit design drawings as a part of their Duct Brochure for S&L's review and approval.

Based on S&L's approval of the revised Duct Brochure, PSM was then

- asked to review all fittings fabricated prior to the stop work for i acceptability. All fittings not covered by the approved Duct Brochure were to be identified for rework or submitted to S&L on a Field Change Request for approval. This review activity was performed using PSM Engineering Personnel.

Pullman Field Engineering completed its review of all duct fittings for compliance with the PSM Duct Brochure or S&L Design Drawings on February 21, 1985. This review covered a total of 2,814 fittings. Of this total, 635 fittings required "as-builts" to be submitted to S&L for further evaluation,

with 67 requiring some modifications. These modifications were completed on May 1, 1986 for Unit 1. At this time, twelve (12) fittings still require rework on Unit 2.

Of those not requiring as builts, 330 fittings require some modification to meet design requirements. These modifications and 100%

inspections by Pullman Q.C. were completed by May 1, 1986 for Unit 1.

A 95/95 confidence-reliability random sampling review program was conducted on the remaining 1,849 fittings which meet the requirement of S&L 7

approved design documents. This sampling program was used as opposed to the

i. MIL-STD-105D standard which was reported in reference (e). S&L selected the i samples from this population and Pullman Q.C. performed the actual 1 inspection. This was completed May 31, 1985. The results of this random j sample were reviewed and found acceptable by S&L.

J' Results of Review Total Fitting Population 2,814 Fittings which comply with design documents 1.849 Fittings reworked to comply with design document 330 Fitting "As Builts" submitted to S&L dispositioned use-as-is 568 dispositioned rework 67

Please address any questions that you or your staff may have concerning this matter to this office.

Very truly yours,

$t 2A A.D. losi Nuclear Licensing Administrator ADM/ pay cc: NRC Resident Inspector - Braidwood Director of Inspection and Enforcement U.S. Nuclear Regulatory Consission Washington, D.C. 20555 1994K