IR 05000269/1968005
| ML19319A633 | |
| Person / Time | |
|---|---|
| Site: | Oconee  |
| Issue date: | 12/11/1968 |
| From: | Long F, Seidle W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II), US ATOMIC ENERGY COMMISSION (AEC) |
| To: | |
| Shared Package | |
| ML19319A632 | List: |
| References | |
| 50-269-68-05, 50-269-68-5, 50-270-68-05, 50-270-68-5, 50-287-68-05, 50-287-68-5, NUDOCS 7911180069 | |
| Download: ML19319A633 (7) | |
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U. S. ATG:IC "'~A' CY CO'VISSION DUION II DIVISION CF COMPLLU!CS Report of Inspection C0 Report Nos. 50-269/68-5 t
50-270/63-5
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50-287/63-5 l
Licensco:
Duke Power Coupany
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Licence I cs. CPPR-33, 34, 35 l
Category A Date of Inspection:
Novczber 15, 1968
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Date of Previous Inspection:
Initial Inspection
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Inspected Dy:
j William C. Seidle, Reactor Inupcetor Date
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/:b Reviewd By:
>. -cws Dito F.J.Lcng,Senioj'EcactorInspector Proprietary Information:
Nor.e SCOPE
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An announced visit was made to the Southern Boiler and Tank Works, Incorporated, Memphis, Tenneccee, where the centair.nent build 3 ng liner plate and accesrory steel including penetratien secticas are being fabricated for ihe three Oconce nuclear pcwor plants.
Tha purpoco of the visit was to review the shop QC program associated
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with th fabrication of the liner plate penetrations for Unit No.1.
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Parcutar attention was given to recent shop QC program improvements iritiated becauco of numercus wcld defects cbserved in : :veral penetration ucctions received at thc. site.
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-2-SU?' MARY Safet_v Itc.q - I'onc
!!cncenfermance Itemq - ??one Unusutil Occurrences - ?!one Status of Previously Reported Problems - Initial inspection -
not applicable.
Other Sionificant Items - Defective Southern Boiler Shcp welds in cight Unit 1 liner plate penetration cections delayed crecticn of the The wc1d defects uerc detected at
.f contain=cnt building two conths.
the sito by Dako QC perscnnel. All welds were " certified" by the shop inspector and a third party, Law En}cincering inspector prior to shipment from the shop (Scc Secticn C l..
poor wold design, QC $napection practicos, and wclder performance were Measures have since the principal causes for the defective uclds.
been adopted to correct these deficiencies, c.c., several ueld designs ('
ucro changed, additicnal third party and Duke QC welding inspcetors
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ucro assigned to the chop; wolds are new 100% radiodraph inspected; the fabricator has set up a financial incentive program for those certified uclders producing work requ ring 100% radiographic inspec-tion (Sco Section C.2.).
According to Duko representatives, the gality of weldrents in the
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steel compenents recently received at the sito has greatly imprcved (See Section C.).
Management Interview - The inspector held a brief intervicu with Lea and Jackson at tTic7enclusion of the visit. The following items were discussed:
1.
Purpoce of Insrector'n Visit _
The inspector explained to Lea that it is the policy of the Division of Compliance to spot check the QC program in many of the vender shops that fabrier.tc Class I structures and systems (Class I structures and systems woro defined).
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_3-2.
14111 Test Recorts The inspec',cr stc.t ed tht L hc.d mic a spot check review of several U. S. Steel Corporation mill test reports for stcol plate used in the liner plate and penetration scetions and fcund that nany of the reports warc not signed by a U. S. Steel representative; the certification signature line was blank. Jackson stated that Strong had advised him of his intent to notify U. S. Stoc1 of this deficiency.
3.
Record of Certified We3 der's Work The inspector pointed out that the shop QC inspectors do not g
keep vritten records that would associate a specific certi-
fied weld with the welder's name. The welder's mark stamped l
eve 17 3 8 along the weldrent is the only record. The inspector posed the question of hcw Duke cculd prove that a certified welder did, in fact, make a particular wcld in a given ponctration cyctem after that section is e:. bedded in the concrete >all of the containment building.
Jackson (
stated that this is a deficiency in the step Q0 record keeping program and that he would endeavor to correct it.
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Lea appeared to be receptive to the inspector's coaments and seemed willing to cooperate with Jackson in correcting the deficiencies discussed.
DETAIIS A.
, Persons Contacted Southern Boiler and Tank Works, Incorcorated W. Lea,. Executive Vice President and General Manager
'J. T. Roberts, Pre::idcnt and Compary cwner J. Westrarcland, Chief QC Shop Inspector 1/ uke Specification No.05-139 (Rev. 4/8/68) entitled "Specificatien D
for Reactor Euilding Liner Plato and Accesscry Stecl" requires the
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use of certified welders en liner plate and penetration section fabrication.
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-4-R. Strcng, Chief Engin eer LawEnfncerinnTestkn:r Cerrv.v (Birningham, Alabx a)
i K. E. Roberts, Department Manager - Metals Inspection Service L. A. Williams, Shop Incpcetor
.. E. Frant1, Supervisor - Metals Inspection Service Duke Power Connany F. R. Jackson, Staff F.cchanical Engineer B.
Administraticn and Organization
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Southern Boiler Shon 00 Orv.nication
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l The shop is a small ferily-ownc1 operation which has been doing business in Memphis since the early 1920's.
J. T. Roberts is the cmcr, his con T. M. Rcborts is in chargo of sales. Lea, the Cencral Manager, runs the shop fabrication operation.
Strong, Chief Engineer, is responsible for the shop-QA program. He is a graduate M.E. from Georgia Tech and has been with the ccmpany since 1959 and in his present assign-mentfor11/2 years.
Westmoreland, chief QC shop inspector (and the only Southern Boiler QC shop inspector) reports to Strong.
Westmoreland has worked at Southem Boiler for many years as a fitter, welder, and supervisor of clean-up, testing, and painting. He has been in his present ~
capacity of inspector for about one year.
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2.
Third Party Shop Inscectors The Law Engineering Testing Ccmpany, Birmingham, Alabama, has two full-time welding inspectors representing Duke in the. Shop. The inspcetorts names are L. A. Williams and W. Rosco. Willia:as has 20 ycars of welding and QC inspector experience, according to his supervisor, Frantl; the past seven years have been with Law Engineering. At one time he was associated with the Redstono Arsenal, Huntsville, Alatc; a.
Rosco is a young man with Jimited welding experience. His principal shop assignments aro QC record keeping and preparing drawings for radiograph i
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Duke Power Comnany Shoo Insnector
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Duke rccently accigncd.kekcon to the Southern Boiler chop as a QC welding inspector on a part time basis, i.e.,
two-three days every other week. According to R. Dick, Project Manager - Cconce Project, Jcekson was at one time the'princip11 M.E. for Duke Constructicn; he brings into his present assignment years of QC experience in welding.
i C.
itelti Defcet Prob 1 cms in Penetration Secticns - Corrective _
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Measures Taken 1.
History of 'deld Defect Problens l
During an inspection visit to the Duke constraction site
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in March 1968, the inspector was infctmed by J. R. Wells, QA Engineer, that the field welding inspectors had diccovered defective welds in many of the contairr.ent building steel ccmponents supplied by the Southern Boiler Shop Cccipany.
The wcld defects were in thickened sections of ficor liner
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plate fabricated in the shop. The weldmont defect details
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and the action taken by Duke to correct the defects are discussed in CO Report No. 50-269/68-2.
During the last visit to the Duke site on '9/25, the inspector learned frca Wells that the Duke en-site welding inspectors had discovered defective welds in 8 Southern Boiler shop fabricated containment building liner plate wall penetra-tions. Lack of penetration and slag inclusion were the All principal weld defects noted; no cracks were detected.
of the penctration section welds had been " certified" at the Shop by the vendor and a third party welding inspector from the Law Engineering fim (Weld defect details and the repair status are discussed in CO Report !!o. 50-269/68-4,
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SectionD.l.).
The weld inspection deficicneics discussed above prc=ulgated the inspector's visit to the Scuthern Boiler Shop on 11/15.
2.
Measures Taken to Correct Southern Boiler Shon Weld Deficiencies According to Jackson and Strong the follcwing corrective neasures were recently taken to inpreve the quality of shop velds.
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-7-an hour. Mcwever, they lose the premium wage if their wcld defects run greater than 5%. At the prosent
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time premium rates are beirr pdd to s'.x chop wlders; they are all cert,ified in HIG, TIG, gas :hielded arc, and sub=crged are uciding.
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Slag Inclusion Problem Excessive amounts of slag has resulted in the rejection of several welds.
Corrective Action The wolders are frequently re..!inded by the QC inspectors to cake a thorough c1 caning tetraen passes, l-e.
Additional QC Shop Inscactors
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a The fact that rany veld deficiencies nero found in the several shop fabricated penetration sections shipped ('
to the site would susect a breakdcwn in the show QC program.
- Corrective Action
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Duke has assigned Jackcon to the Southern Boiler shop, on a part-time basis, for the purpose of auditing the QC pro-
'4 gram, and providing liaison betrcen the shop and Duke Engineering when design and/or specification inter-pretaticn problems arise.
Law Engineering has added a seccnd full tine inspector to tho shop to assist in C: record keeping. This enables the other inspector to devote nore time to the actual inspection and testing of welds.
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Jackson stated that since the above corrective measures were imple ented a rarked improvement has been noted in the quality of shcp fc.bricated welds. The inspector will discuss these improvements with Rogers during the next
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sito visit.
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