ML20091A588

Forwards Nonconformance Rept M01-92-074 Re Welding Defects on Structural Support Steel,Per 840515 Request.List of Defective Welds Encl

ML20091A588
Person / Time
Site:	Midland
Issue date:	05/18/1984
From:	Kinne J CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.)
To:	Carter G STONE & WEBSTER, INC.
References
CIO-0051, CIO-51, NUDOCS 8405300023
Download: ML20091A588 (7)

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- Lt:t M "AO 303 DOCUMENTATION TRANSMITTAL 3GA

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-File g To: Stone & Webster - CIO Transmittal No:

CIO- 0051 PO Box 1963 Date:

May 18, 1984 Midland, MI 48640 Attention: Geroge Carter The documentation listed below _ is provided herewith, X_ was previously provided on 5-15-84

as requested by George Carter Documentation

Description:

Nonconformance Report - M01-9-2-074 CIO has X has not been placed on routine transmittal for the described documentation.

Spature 8405300023 840518 PDR ADOCK 05000329 PDR g

e CC RJCook,'NRC Site (w/a, unless volumineus)

JJHarrison, NRC Region III (w/a, unless volumineus)

DDJohnson, SMO (w/o)

JGKeppler, NRC Region *III>(w/a, unless voluminous)

BHreck, SMO (w/o)

NIReichel, SMO (w/o)

MAY 241984, RAWells, MPQAD (w/o)

CMThompson - File 24.2 (w/a, unless voluminous) jM ! \\ \\

M10384-0001A-Qt,06

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\\ ONCO \\20RMANCE RE-)0F A~'

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g,e7.o PnoJacts.ENGINEERRG AND CONSTRUCTION M01 2-0 711 2.

STAPT.t;P SY!*Dt:

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FRICBITT CCIE:

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TRD D CGLE L 5.

ACTION ITD4 50:

NTS000 1

H-7 S-1566 6.

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BOECORPORMIEG PAR" BOr 6.

NCNCCBFORMIEG PART EAHE:

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MfE IALD 6-19 -82 See Block 17 SUPPORT STEEL 10.

5CBOC8FORMI5G PARY 11.

MSPONSIBLE CRCAEIZATICE 12.

14 CATION IE FLANT:

L3 DATE OF REVISION:

SERIAL Nt.MBERt N/A Bechtel See Block 17 n.

DI=RInurIcs: LEDavis16-885"""""f 2 ACTIONEE.

MADietrich Bechtel Technical Specification 7220-C-233, Rev 23, Section 7.2 Dehorn requires the following:

" Welded joints shall be made in accordance JARutgsrs JAHorsch with the Code for Welding in Building Construction, AWS D1.1-72, RDJohnson and the section on Welded Joints of AISC Manual of Steel Construction."

INFO:

(See page 2 )

BWMarguglic LAkirs 17-

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REMcCue JBico Bechtel NCR 935 identified welding defects found during receipt inspec-DBMiller lWRBird tion on vendor supplied structural beams which had been released by SQR BHPeck

JEBrunn;r Inspector No. 335. Consumers Power Company letter 66FQA8 0, W R Bird to ESmith L A Driesbach dated March 6,1980 requested a reinspection of beams lJWCook DATaggert HMCollins, Jr released by SQR Inspector No. 335 to determine if similar problems MLCurland RAWells existed on other structural beams.

Bechtel QC identified approximately LHCurtis JLWood 2400 beams associated with SQR Inspector No. 335 and purchased on P.O.

DJDapip h g g B (See page 2)

Yrs to 16.

MCCDOENCED PART CCRRECTIVE 4CTICE:

Bechtel QC to 100% reinspect all beams purchased under P.O. F-3103 and g,

DISro:ITIon uar X

repair or obtain Project Engineering disposition for any defective we.lds ro.

e-L!n EauIr.

found as a result of the reinspection.

rsvel.vnt X

$***s$ nACE)

(See page 2)

X 22.

mg Taos 23.

tocATI:5 CF TAC 8:

See Attachment A

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REPf RTABLE FEB 2$.

REPOR'!TD 81:

26.

REPolfrED TCt

27. LATE CF REPORT:

26. TIME CF REPCMT:

50 * * "

To t e doternined

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0;i : IATED 3 30.

WRITTER REPLY REQUIRED:

3r t!FLevIscR'S $!0NATt.1tE/DATE:

July 15. 1982 hd 3J.

FAFI *!,RRECTI1E ACTION PPCFOSED:

33 QA CCNCL1ULINCE.31G/CATE:

3b.

PART CCPPECT!VE AC" TION VERIFIED:

35.

VERITIED BY-SI;/CATE:

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MID TAJ3 RD*;VEC &Y.3133AltRZ/LAIIs 37.

BCR CIASED BY = SIGRATtlRE/LAIIs

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\\0\\C0\\ 20HVA\\CE RE30R. PRa' JECT:

IGINEERING AND CoNSTEUCTioN-a===

Power Mo,_,-2-07 umM nCn sum. numus PROCESS 'COR RECTIVE ' ACTION Fa 2 cr 6

% QA A33E33)GJi? CF 3007 CAU5E(8):

TO BE DETERMINED BY PROCUREMENT SUPPLIER QUALITY IN BLOCK 39

39. AC1tAL RAT CAUSE(3), 3 Duruua? FRm ABOVE (20 BE COMF!2MD BY ORG. AE370N3DLE FOR PROCESS CA) t

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60 Fn0 Cess cA aBauDED ram DESI3 FABRICAMON CON 5 3UC MON PROCURDENT DSECMON na Procurement Supplier Quality

41. GA AZCol9eJf3ATICAI FOR FROCESS CA D]termine root cause and formulate process corrective action based upon actual root cause(s) including assuring that there are no generic supplier related problems of a similar nature cnd that the current supplier quality system is effective in preventing snipment of dsfective material.

J.

PROCESS CA 10 BE TAXEN ET ORG(8) QECIED D BLXE 41 & DAM OF CONF 12TICA:

3.

EDCD OF F10 CESS CA VERUICATION:

313. CF ChJ. RESPONSI3:2 FOR PRCCESS CA SIGNIFTD3 COMFLETIon 45.

ROCE33 CA CWF12TICE WE BY/ DAM:

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M01 2-074 "CTIOi

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S-1566 Block 16 (REQUIREMENT) cent.

Page 3 of 6 1

AWS D1.1-72, Section 3.6.4, requires "For buildings and tubular structure undercut chall be not more than 0.01 in. deep when its direction is transverse to primary tensile stress in the part that is undercut no more than 1/32 in. for all other situations."

AWS D1.1-72, Section 2.7.1.2 (2 ) requires "The maximum fillet we'ld size permitted clong the edges of material shall be 1/16 in. less than the thickness of base metal, for metal 1/4 in or more in thickness unless the weld is designated on the drawing to be built out to obtain the full throat thickness."

AWS D1.1-72, Section 8.15.1.6, requires " Fillet welds in any single continuous weld chall be permitted to under run the nominal fillet weld size required by 1/16 in.

without correction provided that the undersize weld does not exceed 10% of the length of the weld............"

Block 17 (NONCONFORMANCE) cont.

numbers F-3043, F-3091, F-3103, F-15765, F-16781, F-17119, F-17306, F-17626, F-19753, and F-24897 and reported this data on FQCL-962 dated January 21, 1982.

In order to provide a reduction of the original request, MPQAD conducted an overinspection on 78 structural beams purchased on one order only (P.O. F-3103) to determine if nonconformances existed in the field.

Contrary to the requirements listed in block 16, 66 weld joints were nonconforming out of 146 overinspected.

This represents 41 of the 78 structural beams over-W lding defects and beam locations are listed in Attachment A.

inspected.

e Block 18 (RECOMMENDED PART CORRECTIVE ACTION)

Project Engineering to devise a plan to determine the acceptability of welding on beams purchased under purchase orders:

F-3043, F-3091, F-15765, F-16781, F-17119, F-17306, F-17626, F-19753, and F-24897.

NOTE:

It is expected that many of the beams are totally inaccessable or will at least be difficult to inspect and repair.

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M01-9-2-074 ACTION J0.

S-1566 Page 4 of 6 ATTACHMENT A Number of Defec-Beam 10 Location tive Weld Joints Defects 2B2 A

4 Undersize welds-1/4" specified 1/8-3/16 actual 74H1 A

1 Lack of fill, are strikes, pinhole porosity 8AH1 A

1 undersize welds-3/8" r aecified 1/4" actual 1082 B

2 1/16" undercut 1381 8

2 1/16" to 3/32" undercut 1081 C

1 1/16" undercut 1082 C

1 1/16" undercut 1083 D

1 Insufficient throat 10B2 D

4 1/16" to 1/8" undercut 1381 D

1 1/16" undercut 1082 D

2 1/16" undercut 1081 E

2 1/16" to 3/32" undercut 10B2 E

4 1/16" to 1/8" undercut-1 joint also has undersize weld 1381 E

2 1/16" to 3/32" undercut 10B2 E

2 1/16" to 1/8" undercut 1081 F

1 1/16" undercut 1082 F

1 1/16" undercut 13B1 F

2 1/16" to 3/32" undercut 10B2 G

3 1/16" to 3/32" undercut 13B1 G

1 1/16" undercut 10B3 G

1 Insufficient throat

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NCF M:

M01-9-2-074 ACTION

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S-1566 Page 5 of 6 ATTACHMENT A (cont.'

Number of Defec-Beam 10 Location tive Weld Joints Defects 1082 G

2 1/16" undercut 10B2 H

4 1/16" to 3/32" undercut-I weld joint also has undersize weld 10B2 H

2 1/16" to 3/32" undercut-I weld joint also has undersize weld The following nonconforming welds are undersize from the weld specified on the vendor drawing but meet the minimum weld size requirement of AWS D1.1-72 Section 2.7.1.1.

Actual hbid Beam 10 Location Number of Weld Joints Specified Wold Size i Size 10B4 B

1 1/4" 3 /16 " to 1/4 "

10B4 C

1 1/4 "

3 /16 " to 1/4 "

'10B3 C

1 1/4 "

3/16" to 1/4" 10B3 D

1 1/4" 3/16 "

10B3 F

2 1/4" 3/16" 10B4 F

1 1/4" 3/16" 10B4 F

1 1/4" 3/16" 10B3 F

2 1/4" 3/16" 10B4 G

1 1/4" 3/16" 1083 0

1 1/4" 3/16" 10B3 H

1 1/4" 3/16" 1084 H

1 1/4" 3/16 "

1084 H

1 1/4" 3/16" 10B3 H

2 1/4" 3/16" to 1/4" 1083 I

1 1/4" 3/16" to 1/4" 1084 I

1 1/4" 3/16" to 1/4" 10B3 I

1 1/4 "

3/16" to 1/4"

NCR M01-9-2-074 ACTION

..s.

S-1566 Page 6 or 6 ATTACHMENT A (cont. )

LOCATIC?! 0F BEAMS WITH DEFECTIVE WELDS A.

Aux. Bldg. - Elevation 675' 0" - column lines 5.1 & A B.

Containment 1 - Elevation 688' - 9" - near column 10 C.

Containment 1 - Elevation 688' - 9" - near column 12 D.

Containment 1 - Elevation 688' - 9" - naar column 16

- E.

Containment 1 - Elevation 688' - 9" - near column 17 F.

Containment 2 - Elevation 688' - 9" - near column 2 G.

Containment 2 - Elevatien 688' - 9" - near column 2 H.

Ccntainment 2 - Elevation 688' - 9" - near column 6 I.

Containment 2 - Elevation 688' - 9" - near column 8 t

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