ML20039A845

Interim Deficiency Rept Re Masking of Certain Weld Indications During Unit 1 Suppression Pool Clad Floor Plate Installation Activities,Initially Reported 811112.All Suspect Weld Joints/Areas Will Be Reworked by 820331

ML20039A845
Person / Time
Site:	Perry
Issue date:	12/11/1981
From:	Davidson D CLEVELAND ELECTRIC ILLUMINATING CO.
To:	James Keppler NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
References
10CFR-050.55E, 10CFR-50.55E, RDC-40(81), NUDOCS 8112210370
Download: ML20039A845 (8)

Text

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TliE CLEV E L A N D ELECTRIC ILLUMIN ATING COMP ANY P o BOX 5000 CLEVELAND, oHIG 44101 e TELEPHONE (216) 622-9800 e ILLUMINATING BLDG.

e 55 PUBLIC SoVARE Daiwyn R. Davidson YCE PRESIDENT SYSTEM ENGINEERING AND CONSTRUOTION December 11, 1981

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Mr. James G. Keppler

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Director, Region III Office of Inspection and Enforcement U.S. Nuclear Regulatory Commission Q

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Perry Nuclear Power Docket Nos. 50-440; 50-Interim Report on Unit 1 Suppression Pool Clad Floor Plate Installation Activities [RDC 40(81)]

Dear Mr. Keppler:

This letter serves as our interim report pursuant to 10CFR50.55(e) concerning the masking of certain weld indications during Unit 1 Suppression Pool Clad Floor Plate installation activities.

Mr. L. McGregor of your office was first notified on November 12, 1981, by Messrs. E. Riley and G. Leidich that The Cleveland Electric Illuminating Company was investigating this deficiency.

Subsequently, on November 18, 1981, Newport News Industrial Corporation of Ohio (NNICO) filed a 10CFR21 report with your office.

Our report includes a description of the deficiency, information concerning completed and planned corrective actions, and the planned date for our submittal of the final report.

Description of Deficiencz NNICO Quality Assurance personnel received information on November 10, 1981, that their craft welding personnel had been instructed and were performing welding operations to mask indications from detection during inspection.

Specifically, this concerned indications created during semi-automatic produc-tion welding related to installation of some Unit 1 Suppression Pool Floor Plates.

NNICO immediately stopped all work in the affected area and conducted an investigation to establish the validity and extent of the deficiency.

Non-conformance Report 17-316 was issued to document actions taken to resolve this l

problem.

Please refer to this Nonconformance Report (attached) for all details of NNICO corrective action known to date.

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Mr.-James G. Keppler:

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The Cleveland Electric.11'luminating Company concurs with the NNICO Quality Assurance and Engineering disposition and justification.

We.are. planning to submit our final. report on this subject when rework has been completed. The i

dateL projected at; this time will be March 31, 1982.

If you have any questions, please do not hesitate to call.

Sincerely,.

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A Dalwyd Davidson t

Vice President System Engineering and Construction DRD:pab Attachment NNICO NR 17-316 cc: NRC Site Office j

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Director l

Office of Inspection and Enforcement U.S. Nuclear Regulatory Commission Washington, D.C.

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. 'e, PERRY NUCLEAR POWER PLANT f

NONCONFORMANCE REPOR r REVIEW / REVISION N 7.1523

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ATTACHMENTS ygS NO IF TH3 PROPOSEO DISPOSITION WA'S REJIfCTED. THE RESPONSeBLE ORG ANIZ ATION SH ALL COMPLET85 THE SECTION BELOW AND R'78UBMIT THE NR TO COS QU ALITY ADMINISTR ATION.

I CISPO3 TION REVISION NO.

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PROPOSED REWORK 425 USE AS IS I 4) 9 DISPOStTIC 4 JU STI FIC ATION

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PttoonAut g-covEnNiNo' t INCLUDE ACCEPT ANCC g, nEQUtnEME N1 CRIT ERI A AND DOC *MT. NOS. ) ACME Nuclear QA Manual, Cubacetion 16.1000

" Identification of Nonconforming Conditions" l-f Y fff4 NC

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NONCONpoRMANCE f/j

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craft vellinr[p'croonnel End been irintruc'ted'ruid vero performing velding operations En cuch-

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During_inctn11ation of Aron 6 clad floor plnten in Unit 1, it vna diceovered that

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n manner to mank_ __indi, cati,onn_from dctec_t.1,on during inn,pe_c,ti,on.

Specifically, indications created during semi-nutomatic production velding vere velded ever manually prior to turnover for innpection.

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l Please refer to attached Justification, plus Attachments 1 and 2.

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~ All perronnel. direct y nanoeinted vi h the suspect veld joints 50 have beeri icanci~gned to otlic~r' 'uoik Wi cha or Vem5v'e'd ~rroni'lli6 ~j6E '6iTc.

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We_Wng_1.'ngineering pornonne.l. have conducted indoet.rinntio.n/, training ceanionc_ concern.-

ing techniquen to be employed for unbnequent velding cperationu in the suppression pool ~are t for nll_.pernonnul, including nupervi,ulon.;urrent1y nau.que.1 to thin _vork nr.ca,., _

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Proposed Disposition:

RWORK Justification:

A detailed investigation of all activitics asnoeinted with Unit 1 suppression pool (area 6) clad floor plato installation han been performed.

As a result, it was determined that two welders (1.D. I's 272 rutd 637) performed stainless steel repair operations in such a manner as to mask indications from detection during inspection.

A review of all welding documentation was performed to identify weld joints /arcas w:rked by the welders involved. This review included wcld history records, wcld metal isnue records, inspection reports, daily time-chargo logs, and other applicable docu-mestation associated with normal installation activitics.

It was determined that three categories of stainless steel repair work were involved - root layce, inter-1 mediate laycr, and final layer repairs. represents 100% of suspect wcld joints /arcas worked by the two walders noted above. These areas shall be reworked in accordance with the requirements of applicable drawings, procedurcs, and instructions as specified below:

1) 14ak-chase items (where installed) shall be removed from the wcld joints /arcas

'ntified on Attachment 1 in accordance with Instruction 465-NC-W001, taking extreme caa to minimize <1amage to the leak-chase.

Imuk-chase items shall be appropriately identified and stored in accordance with the ASMR Nuclear QA manual.

Areas of leak-chase removal-shall be ground flush with the clad floor plate base metal.

Removal, ctoragc, and " grind-flush" operations shall be documented on inspection reports by QC personnel.

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All stainicas stool wcld metal shall be removed from the wcld joints / areas

-identified on Attachment 1 in accordance with Instruction 465-NC-W001. Extreme carc is to be taken to ensure that adjacent clad floor plates-are not damaged.

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All areas of wcld joint removal shall bc Vr-inspected in accordance with 4

Inceruction 948-N-N002 and Mr-inspected (carbon-steci areas) or PT-inspected (stainless-cecol areas) in accordance with Instructions 465-NC-N004 or 465-NC-N003, respectively.

4) Wold metal removal and excavation NDE operations chall be documented on tho cppropriate wcld history records in accordance with Instruction 701-F-S004.

5)

Upon satisfactory completion of excavation NDE, all excavations shall be re-welded and inspected in accordance with the original requirements of Manufacturing /

Installation Instruction (M/II) 701-NC-1030-1, as supplemented by the specific limit-ations of Attachment 2.

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Upon satisfactory completion of stainicas steel wcld rework, Icak-chase items che.ll be re-installed and inspected in accordance with the original requirements of

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WlsI,D lileMOVAT. AtlD EXTI:lPP CitTTI:ltI A (2.ce NUITS below)

1) Itemove the 1:frPTI(1: ve_1.1_in the roll ow i ng n ee3ul.

Weld joint # 1-3 between Az. 225" & 235 nnit between Az. 270 & 285.

Weld joint # l *( between quencher baue pint,c #'s 'fl9-1 & $80-1.

Weld joint # l-8 between quencher bane glat.e #'n '/(0-1 & '/(9-1.

Weld joint #1-10 betveca Az. 2'j')

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2) Remove etninlcon nteel veld metal to the enrbon nteel root nu follova:

Note that etching for determination of complete at,ninlecc removal is required.

Weld joint #1-167 (around entire guencher bane plate).

l Weld joint # l-11 between Az. 210 & 270".

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3) Demove ONT.Y ' rill < 1/T1. AT. T.AY1?R (3/16" minimum removal ) of ntninlenn nteel veld metal:

Wold joint # 1-3 between Az. 195 & 225 and between Az. 235 & 270.

6 between Az. 195 & 225 and between Az. 255^ & 285 Weld joint # 1 1 Wold joint # 1-5 between Az. P10 & 270.

Weld joint # 1-6 between Az. 210 & 270.

Weld joint # 1-7 between Az. 210 & quencher base plate #579-1 and betvoen quencher base plate #580-1 and Az. 270.

Weld joint # 1-8 between quencher base pinte #'n 579-1 4 580-1 and between quencher bane glate #580-1 & Az. 270".

Weld joint # l-9 between Az. 195 & 270.

Weld joint #1-10 between Az. 210 & 255 and Az. 265 & 270.

Weld joint #1-11 between Az. 210 & 2'(0.

l Weld joint #1-12 between Az. 210 & 2*to.

Weld joint #1-13 between Az. 165 & 270.

l Weld joint #1-116 between Az. 210 & 2l0.

t Weld joint #1-59 (radinl veld joint ndjacent to quenchor bace plate #580-1).

Weld joint #1-96 (radial veld joint at Az.15 ).

4 Weld joint #1-166 (around entire quencher base plate).

Weld joint #1-168 (around entire quencher base plate).

Held joint #1-169 (around entire quencher baue plate).

NOTFB:

1) Any rejectable indicstiono chall be completely removed.

2) The followinrr, azimuths are nominal locat.ionu where a radial veld joint inte ocetn n nunpect, circin.irerentinl veld joint:

165, 3 80,195, 210, 225, 2! o, 255, 270, and 285 i

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1 Kl"rAQlMI'.NT #2 NCR 17-316 REVISION O 2

RIMORK TEGINIQlif.S, i

l Rework shall be accomplished as applicatale in accordance with the following:

i Reference Instructions e.)

465-C-EdOl and 701-F-W002 (Welding) n b.)

948-N-N002 (VI) l c.)

465-NC-N004 (Mr) j d.)

465-NC-N003 (PT)

.lil c.) WPS's (as noted)

'I Rework of Entire Wold j

I 1.)

Err.avate wcid to metallic backing (Figure IA) 2.)

Pctform VI and Mr.

3.)

Deposit C.S. root layer: WPS 1.2.3 - 001 Rev. 2 or 1.1 - 014 Rev. 3 (Figure 2) 1 4.)

Perform root Mr 5.)

Deposit second C.S. layer: WPS 1.2.3-001 Ecv. 2 or 1.1-014 Rev. 3 (Figurc 2) 6.)

Deposit final weld layer (S.S.): WPS 1.2.3-001 Rev. 2 or 1:8.1-005 Rev. 0 (Figure 2) 7.)

Perform final Vr & PT Notes:

a.)

No section of wcld greater than threc (3) feet in length shall be excavated until at least an equal portion of the C.S. root has been redeposited.

Rcwork of Interim Tayern 1.)

Excavate wcld as shown in Figure 111. (F.li,uro1D.,Quenchornonly) 2.)

Perform Vr and Mr.

3.)

Deposit C.S. layer: WPS 1.2.3-001 Hav. 2 or 1.1-014 Ecv. 3 (Figure 2) 4.)

Deposit final layer (S.S.): WPS 1.2.3-001 Rev. 2 or 1:8.1-005 Rev. 0 (Figure 2) 5.)

Perform final vr & PT.

Rcwork of Final Tayer 1.)

Excavate wcld as shown in Figure 1C.

(la'iguro 1M., Quonchcra only) 2.)

Perform Vr & PT.

3.)

Deposit final layer (S.S.) : WPS 1.2.3-001 Rev. 2 or 1:8.1-005 Rev 0 (Figure 2) q 4.)

Perform fhal Vr & PT ll

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