ML20099H721
| ML20099H721 | |
| Person / Time | |
|---|---|
| Site: | Limerick  |
| Issue date: | 05/07/1984 |
| From: | Kemper J PECO ENERGY CO., (FORMERLY PHILADELPHIA ELECTRIC |
| To: | Grier B NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| References | |
| OL-A-128, NUDOCS 8411280273 | |
| Download: ML20099H721 (8) | |
Text
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United States ??.clea: les:1 story C- 'asion , Cffice of I spectics s=d 2=forcement, 2egion I 631 ?a== Avenue King of .'5-e.ssia, ?1 19hC6 SUL*IC": u d II Regio Letter dated.?ebraa.-/ 27, 1931 SI: Site I=apection of Januarf 5-30,1981 4 Inspecties Esport ::o. 50-352/31-01 & 50-333/31-C1 Limeric's Generating Station - Units 1 a=d 2 J- m ri GAL 1-2-2 (352/3t-01 a 353/31-01 r - zea= r.=. c=ie= < ) {'. ' respc=se to the subject letta= regarli=g ite=s identifisi durist- the subject inspecti = of cc=structi;= activities autt:ori:ed ' I by II:10 Lizenze : os. var 1CS a=1 -1C7, we tri d t herewith the fa%t.g: 1:ta=h=s=t I - Eespe=:e to A;;e=di= 1
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-J0F.3 S.:KIMPIR, being firs: duly sworn, deposes and says:-
Tha: he'is Vice President of Philadelphia Ile ::1c Company, the holder of Construe:1on Permits C??R-106 and C??R-107 fc:'Li=erick, Generating Stat.. ion Units 1 and 2; tha: he has read the foregoing Response to Inspection Repor: No. 50-352/81-01 and 50-353/31-01 and knows the con:ents the: eof; and tha: the statenants and natters se: forth therein are ::ue C and cc :ect to the best of his knowledge, infor.9ation'and belief. O , [: s v hd $~ W
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.... ATTACEMINT -
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- 10C7R50, Appendix 3 Cri:erion 7.VI, states, "...condi: ions adverse-to_ quality, such as...nonconformances, . are pro:p:17 iden:1fied. ...
that the cause of the condi: ions is determined and cc: ective-action taken to preclude repetition...and :he corree:1ve action
-taken shall'he documented and reported to appropriate levels of mar.agement.".
The Line:1ck ?SAR, Appendix D, paragraph D.A.12, s:a:es, in par:, that: "...The program shall provide input for the initiation of -* cc ee:ive ac:ica and follow-up as appropriate.". Project Special Provisions Noti'ce,_ST/ PSP C-3.1, Revision 3, paragraph 3.1.5,' states, "If a deficiency to the code requiremen:s
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-are identified within.the code boundary of an ASMI 1:en,' it.shall be con::olled by the use of nonconformance reports.".
l Con::ary to the foregoing, on January 15, 1981, :he NRC inspector discovered through observation and document review tha: rej ect able nondestructive testing indications were identified and disposi:ioned
=cn In-process' Rework. Notices instead of Nonconfor=ance Reports as
.rs required. Specifically, an ASMI Nuclear Class I pipe weld, DLA-
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(7 107-1/FW 11, was liquid-penetran: tested and rejectable linear
'. indications-were.iden:ified, "outside the areas of interest,"
(the adjacent base material). The indications were dispositioned on In-process Rework NoticeRNo. W655. _This is a Severi:y Level V Violation (Supple =en II). Resoonse to Violatied Nonde,structive testing indications.docu=en:ed on In-process Rework Notice No. W655 was subsequently docu=enced on a Nonconformance. Report. In addition, a review of open Rework Notices was performed. Several addi:1onal instances where In-? ocess' Rework Notices were employed in lieu of Nonconformance Reports were . identified. These were then incorporated in:o Nonconformance Reports. To prevent recurrence the following actions were taken:
, 1. Supervisior and production personnel were instructed to perform no work on ASMI boundary co=ponents without proper authorization. Ihe instrue:1ons were reiterated by the superintendent in a subsequen: memorandun to the responsible personnel.
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I 1/4 30-352/31-01 50-353/81-01 T.;E O
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- 2. LThe'Q.C. depar:sen: held a ::aining class on January 23,.1981
,. for :he1 responsible personnel on the requirements for the luse'of Nonconfornance Repor:s.
{~}i f' . . c 'yu11, co=pliance was achieved cn 'd 'bef ore March -17, 1981. In addi: ion, the valve. described in In-process Revork Notice Mo. W652 (noted Jin :he " DETAILS" ~sec:Lon of the NRC's Inspection Repor:,) was also subsequently _docu=ented on a Noncenformance Report. The-valve.in In-processLRework Notice W652 and.:he pipe spool in
'In-P:ccess Rework Notice **655 were both: f abricated in accordance with the' code and received and-passed the required nondestructive .
exanina: ions. The code _does not require.pene:: ant examinations during the fabrica:Lon/ manufacture of these componen:s. Any-renoval of liquid pene: aut indications, outside the area of interest of the-liquid penetran: :est performed during installation , is in ex:ess cf-code require =ents and, therefore, the valves ve:e accep able for installation as received'from the manufacturer. Violation - 3
.10CTR$0, Appendix 13,' Criterion V, states, in part, that, " Activities
-affecting quality shall be...acco=plished in accordance with these instructions, procedures, or drawings.".
The Limerick p5AR, Appendix D. paragraph 6.4, states, in part, that, "Bechtel Construction Department...is responsible for cons: ue: ion of the plant to approved engineering specifications...". Bechtel Specification for yorming. placing, yinishing and Curing of Concrete, 8031-C-36, paragraph 14.0, states, in part,'that, "Imperfee:1ons in formed concrete shall be repaired as soon as
. practicable but no later than 28 days after forms removal.". ,
Contrary to the above, on January 15, 1981, a concrete imperfection
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was observed on approx 1= ate elevation 279', in Reactor Builcing No. - 1, in the Wes: slab construe:1on joint 15-y-1-4, measuring-
.appronimately 2" deep by 1" high b'y l' in length. The Quality Control Inspec: ion Record No. C-Ja0-RS-y-1-4, executed on oc:obe
, 10, 1977, did not record this condition.
This is a Severi:7 level V Violation (Supplement II). , Ressonse to violation 1: NCR 4551 was issued :o identify : hat th2 concre:e vall imperfee: ton had not been repaired within 28 days after form removal. The NCR was dispositioned "use as is" because the structural integrity of.the vall vill not be adversely affected by failure to =ake , repairs within 28 days. I 2/4
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(' 'g j 3echtel QC inp1'e=ented Quali:y' Cont:cl !sspection Record JC-140-RS-r- ?-1-43 for inspec:1on of the sub j e c: area and issued In-? :cass
\ Rework no:1:e C-2229 which iden:ffies tha: repair is required a:
the loca: ion dese:1 bed by :he Violation. The repair loca:icn has
' been chipped to sound concrete and disposi:1cned "ninor' per.:he requirements of.See:1on 11.0 of Specification C-36. The repair vill be_ce=ple:ed before March 31, 1981.
w - QC reinspected.approxi=ately 100 o:her concre:e place =en:s origina11yf inspected by the personnel who inspec:ed the place =en: . in question. The~rainspec: ion docunested on QC-C-1-C-36-SI-1-1, identified 5 =inor def ec:s 'which have been repaired. Actions taken to. prevent recurrence were 1) a class held on 2/17/51 after the Violatics was identified; and 2) reissue of PCM-187, dated 6/16/80 (P roj ec t Construction Manager =eno) to all responsible personnel to re-emphasi:e the requirement tha: concrete repairs are to be made within 28 days of for renovaal.
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Violation - C
-10C7150, Appendix 3, Cri:erion II, states, in part, that,
"... Welding... (is) controlled...in accordanct vi:h applicable codes, standards, specifications...".
,- The Limerick PSAR, Appendix D, paragraph D.6.4, states, in p art, that, "3echtel Construction-Department...is responsible for s C/ construccion of the plant to approved engineering specifications...".
Welding Procedure Specification F1-A-1H (Sheet), Revision 0, requires that valding be performed in accordanca with the General Welding Standard, GUS-Strue: ural. The GWS, in paragraph 5.1 and Table GSW - Structural - 1, requires tha: for E7018 elec: odes and =a:erial thickness in excess of 1h" through 2h", the velding preheat be main:ained at 150 T.. Contrary to the above, on January, 21, 1931, the velding on the safety-related electrical supports Wald No. R-431-4, consisting of a 5/8" plate velded to a structural bea= flange grea:e :han-th" chick, did not have prehest applied to a' enperature of 150 T. .
. This is a Severity Level V Violation (Supple =ent II).
Response to Violation We have dete==ined that veld K-431-4 perfor=ed without prehea:ing-to 1500 is acceptable based on tests perfor=ec for certain Welding Procedure Qualification Repor:s. The applicable PQR's are 606, 633, 689, 690, 691, 705, 706, and 707. These tests were perfor=ed using E6010 ,and E7018 veld elec:rodes and they de=ons::a:e that t' *
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>(U 79sa:isfactory welds..can be-done on'l-h to 2. inch base =a:erial 1 . . " ' ' 60 .us ing 'significan:ly . las s _- p reheat :han :he'15C07 required by the
. ../~"p J!' General Welding :Specifica:Lon. The-prehea: te=perature for-the-L 's/ '~l' above'tes:s were -either 50c7 a; ge cy, indicating tha: no preheat was.perfor=ed and :ha: :he ambien: :e:perature was recorded during
.iC c :-he' cast. The 500 to 60 ? ambient is approx 1=a:ely.what exis:s throughout the hea:ed plan:, therefore, weld R-431-4.was perfor=ed under. essentially thesa=etcond1}ionsasLtheabove ?qR's.
-*) ~ -; ; Turthermore, codes o:he:~chan AWS base prehea: requirements.on weld.si:e, using the throa: thickness of a fille: weld as measure-- .
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. .- - = e n't instead of thickness of~the base =etal. For exa ple :Of regard
' O. ;to preheat, ANSI 3 31.1 sta:es, "The thicknes's of socket, fille:-
4 ' %l land. seal velds is defined as throa: thickness for pressure non-3 'i ' ' p~ressure welds". (See ANSI 3 31.1 - 73/U74, table 131, note 4.)
.- ' 'Si=ilarly, where the ASME code offers guidelines for p aheat of
;t ,P1 steel, the code states that-the guidelines do not apply to
'i 7 "...Tillet. Welds 1/2 inch and under in size that are-used to at:ach insulation clips and o:her parts no: carrying loadings
- due..:o internal pressure." (See ASME,III - Div. 1, 1974, sc Subsection NA, Appendix 0, parag'raph D-1210.2). The position that the fillet veld threa: thickness should be used to deter =ine preheat requirements instead of base =ecal thickness is suppor:ed by the ?QR's noted above.
Our pisition is that =ini=u= preheat. require =ents should be deter =ined as outlined-above, however, the actual work' prae:1ce: i? .:bs the f uture will =eet the preheat requirements in the General' Welding J Specifications which are = ore conservative. hc(g[t E~ W
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?. - To prevent a recurrence the following actions. vere taken: a) A training session was held on January 22, 1981 for all
- elec::ical welders, forenes, general fore =en, and. electrical h j_ t superin:endants ~ :o discuss prehea: require =ents.in AWS codes.
p- i b)l On the same date, a training., session was held for 3echtel j ,. welding Quality Control Engipeers on the same subj ec: . - , , J . c) 4 The Job' Rule'for Welding,-Job Rule,G-16, was revised on h.f March 20, 1981 to clarify and e=phasize s uctural preheat ., 3 require =ents. i :5: .1 Full Compliance was achieved on or before 3/20/31.
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