IR 05000269/1969006
| ML19319A646 | |
| Person / Time | |
|---|---|
| Site: | Oconee  |
| Issue date: | 05/26/1969 |
| From: | Seidle W, Swan W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II), US ATOMIC ENERGY COMMISSION (AEC) |
| To: | |
| Shared Package | |
| ML19319A645 | List: |
| References | |
| 50-269-69-06, 50-269-69-6, 50-287-69-05, 50-287-69-5, NUDOCS 7911180083 | |
| Download: ML19319A646 (12) | |
Text
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i# . i .. , .. ,' '- .,, U. S. ATOMIC ENERGY C0liMISSIJN ' '
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- I REGION 11 i
D1VIS10:3 0F CCMPLI/uNCE '
, .. . Report of Inspection i t CO Report Nos. 50-269/69-6 i ' 50-270/69-5 } 50-237/69-5 ' ' , i -
s< I, - . i f,l, Licensee Duke Power Corapany , ai Oconee 1, 2, 3 i License Nos. CFFR-33, 34, 35 i Category A , Date of Inspection: April 23-24,1969 t . j( Date of Previous Inspection: April 9-11, 1969 (Site) _ Apri'i 22, 1969 (B6W, Mt. Vernon) ' I Inspected By:
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_ /9.tj 26 /f/f W. B. Swan, Reac r Inspector (Construction) / Dats 24 [4) ' ' ~' " ' " "* } Revicwed By: - W. C. Seidle, !/enior Reactor Inspector Date i .: l
' -; Proprietary Information: None j j / p ' t8 , ., , i SCOPE g i An announced, vendor shop inspection was made of the Barberton, Ohio, i
manufacturing plant of the Power Generation Division of the Babcock and , Wilcox Company. The inspection was made with the cognizance of R. E.
- Oller, !!etallurgist of Region III, who is the assigned inspector for , t , B&W plants.
It was cade in the company of J. R. Wells, Principal Field .j ' Engineer for Duke Power Cotapany Oconee Station.
! ' . The scope of the inspection covered the following: 1.
Evaluation of B&W's quality assurance organization and specific implementation program for fabrication of critical equipe,. ; and piping for Duke's Oconce Station.
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Inspection of manufacturing facilities and observation of work in i.
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Inspection of testing facilities and observation of QC procedurcs, h ~ > j followed by a sampling of QC records.
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Inspectica of specific items of piping and equipment being fabri-
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SUlD'.ARY
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} Safety Itcus - None . ? - - [. j Nonconformance Items - None were noted separate from flaws already
l - detected by B&W QC and being corrected.
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.' Other Sinnificant Items - 4' . , f ' 1.
Facilities i }l The Barberton plant has been in operation for many years. It consists of old and new shop structures and offices covering a ' , -:.! large area. The shop equipment varies from the sophisticated, {' , ultramodern to the ancient and simple. It appears to average
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} about ton to fifteen years in age.
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Work Force ! .I . i
- ,i The work force is stabic, adequate, and well trained. Average f
d' }! age is probably in the forties. Production supervision is un- [ [[ -d t obtrusive but effective, and is well backed by detailed - 1?j engineering planning of all processes.
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QA and QC
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! .j The quality assurance group is well organized and trained, f adequately equipped and backed up by written procedures and a jl . good record system. Although it is not generally considered ( . l j,' a Vice President of Manufacturing.the evidence is that at this - desirable to have a Manager of Quality Assurance reporting to
, [ig plant, the QA and QC, in fact, have the authority and inde-lp
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pendence to compel compliance with quality requirements.
} ' 1 ' The QC records are kept in unusual detail for all types of tests.
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The system of preparing a separate sheet for each squawk, flaw .- . jI disposition', and process step makes tracing of the flow of QC '. , f,'. . j( ii ! .: - , ' t ' .l< , .e f ' tf - N
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, .. , I ,. , - I I work time consuming.. Also, the practice of disclosing to the ,,. ' _, .) Licensee's inspector only the records of final, acceptable tests , leaves cone doubt as to the product integrity. Recent changes in top management' of operations and in QA is reflected in some )l ~j work delay and employee attitudes. As at Mt. Vernon, QC's 'l . , zealousness in detecting and correcting flaws is seemingly not -{ -, supplemented by similar zeal in helping manufacturing avoid ' , generation of work flaws.
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l QA and QC at this plant are effective and capabic of producing
nuclear power plant quality heavy piping and equipment.
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Product ' .
l, * ' 'j one completed shepherdts hook shaped section of 36-inch steam ' line was ready for shipment, and work was nearing completion
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j on a pressurizer and on a steam generator. Visual inspection and sampling of test rec'rds indicated that completed work and
in-process work released Or the next process was flawless.
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Receiving Inspection Storage and Shipping { {' '
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..: I A walk-through inspection was made of the various areas and 1; typical forms were reviewed, but the inspection was inadequate ' , in depth to honestly evaluate the ef ficacy of controls on these
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i d % i Mananement Interview - No formal exit interview was held. The inspector q' _ : had severe laryngitis and the licenscets representative, Wells, felt that j !, interim discussions had sufficed since no items of nonconformance had / ! bcen found. Wells later expressed to the iaspector some concern about /'
l . dr y, ' N 13 schedules and the possibility of undesirable impact of B&W management / ' e'] changes on quality control. His in-plant inspector, Curtis, will monitor-(!.l - closely in the weeks ahead.
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- 'I DETAILS _
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_Pers(ns Contacted _
}- .i ' Babcock and Wilcox Company _ [i . . ' I - J. Lang, Section Head of Quality Assurance Engineering ' .J.' Cershem, Section Head of Quality Control Engineering ' ,
H.. C. Craber, Section Head of Nondestructive Testing ' p.
C. E. Jessen, Chief Inspector 3, j Jung, Project Engineer, Design, for Duke Oconee Material ]- Laver, Design Engineer, Preparation at Process Instructions ', . ' ) , . ., 3* . + g
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il Bob' Sprattling, Lead Engineer [ H. J. Hoover, Contract Supervisor (Propet Expediter) for' Duke f '
' i Cconce Material . r 0. E. Phoenix, QC Supervisor for Radiography
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J. D. Kelley, QC Supervisor for Ultrasonic H. L. Bciton, Supervisor of Magnetic Particle and Dye Penetrant
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Testing i ' ' F. W. Kane, QC Liaison between Mt. Vernon and Barberton j , ' i
Duke Power Company _ ) ' l ' J. R. Wells, Principal Field Engineer, Oconee Station t
j J. Malcolm Curtis, Resident Inspector at B&W Plants '- , - . . -
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i B. Quality Assurance Organization 1.
Management Changes - - , i .i 'l-At the time of the insoe ?' ion, the Vice President of the Manu- .l-facturing Dep,rtment, n. 1. Fragomen, had recently resigned after !( a long tenure. He has now been replaced by Gerald A. Profita.
The Manager of Quality Control, W. A. Hansen, reports to him.
- B&Wfs President, Ccorge Zipf, is also acting as head of the Power
' , Cencration Division. C. T. Smith has been elected Vice President ' and is head of Power Cencration Sales, replacing S. T. bkKenzie,
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retired. The head of Nondestructive Testing, H. C. Craber, was ll helpful to the inspector, but he was shaken up badly by a just.
announced split 'of his group with half of the personnel going ' ,:; 'to a new section designated as Quality Control Engineering to
1; be headed by Craberts long-term subordinate, J. Cers'acm. Ripples / . ' of apprehension and distraction affected the inspection on both / '
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QA Documentation
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Jim Lang reviewed with Wells and the inspector the utilization I of B&W's " Standard Practices Instructions," " Quality Assurance ' ' Manual," and a project pamphlet entitled " Codes, Design Data, .. ! and Non-Destructive Testing for Major Components for Oconee 1, . l.
2, and 3.". The inspector.was given, at the request of 'cIls, a print of , each of two reactor coolant piping assembly Jrawings, and a print of a sketch for a pipe assembly with piece numbers and weld joint identification numbers.
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10, . . -5- -f,. , e .; , ..,4 F '.,, - 1,l: , - As a placebo in lieu of permission to photograph hardware, . ' ! , l' Sprattling gave the inspector an outdated (1964) B&W brochure !- . , entitled " Manufacturing at Barberton" which pictures some of .- !- the manufacturing and testing equipment and procedures still , , ( , in use.
., , i ' A few days after the inspection, Hoover mailed to the inspector ! '
a March 1968 B&W brochure entitled "Dependabic and Economical which explains B&W's philosophy and experience '( - Nuclear Fowern
l! in nucicar power plant design, management, and supplemental , - services.
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! These documents were helpful in reviewing operations, testing, j , . ! } records and hardware. Copies are on file in Region II.
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Use of Codes in QC and QA Lang and Graber of B&W and Wells of Duke discussed and agreed on the intent during design, QA planning and QC implementation ,: ll to conform not only with the applicable ASME Boiler and Pressure
Vessel Codes as written but also to incorporate recommendations f' ' of a recent ASME Audit Team which had inspected B&W plants. In . l .,f addition to Code B.31.1 for High Pressure Piping, they are < ,. utilizing Code B.31.7, issued unofficially in February, for j
l nuclear piping.
< ~ . l t l;f C.. piscussion on Schedule for Duke Material _
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Prior to the initial shop tour, Wells held a discussion with Hoover, 's l ] Sprattling and Jung about scheduled deliveries. He was told that / L ' l ti one assembly of the 36-inch steam loop was schedu?ed to be shipped l: ' - . l !? to Oconce on June 1, followed by a section of 28-inch recirculation I , I , i's piping to be shipped on July 20, but he asserted, and they agreed, -' ' , I that these two pieces would miss those dates and that the following j more complex equipmer.t would miss their shipment schedules by two t
{ months or more. No B&W man, including the Ocone9 project uexpediteru seemed to feel guilty or apprehensive about the schedule slippages.
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Shop Tour on April 23 p t,- ' Hoover took the inspector on a shop tour in the afternoon during '*
~ ; which various manufacturing operations were obserired on pipe ex-trusion and fabrication of large vessels. including their installa-p , tion of very large number of tubes in a tube header plate.
! ! l' A' large Duke pressure vessel central section was awaiting reccf pt , )l of the heads.
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, , - . , , . .!,i, . .[.l' Part No. 4-203-59-1, a tube section, was marked " Heater Belt ShellH m i and had one head installed.
- i t Inconel penetrations were being installed on a section of core ' ' j flooding tank equipped with a spun head. The part number was / ! A12-203-61-2.
' . I ! . ' ' Tube velding to a thick cube " sheet" was being performed by B&W-
developed pulse are method which requires very precise preparation ] . l machining and arc control in tight quarters to install 15,600 tubes.
. . Equally impressive was the highly precise drilling of holes, followed ' {pl - - by complex broaching of each ' hole in the intermediate spacer plates so that each tube is in contact along four thin lines with the - l spacer plate, leaving clear areas for liquid flow past the tubes l} g j for good heat transfer and unrestricted axial movement of the tubes.
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A clever, effective, expensive, hard to control, and tedious process l
i t Steam generator for Duke Oconce No. I had its tubes in and one head
!- on, with the head under post heat while the 480 ton assembly was F ', slowly rotated. The tube sheet end head had not been installed.
- The assembly number was 203-55-1.
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'l ; A second core flooding tank center section, part, number B12-203-61-1 < , 'I was inspected.
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A massive base support skirt, part number A96-203-55-1, for the steam ' !l} generator noted above, was under final machining. B&W men were very . !! proud of the desigt of a J-weld for joining the base to the steam - -i,j generator shell. The inspector noted that a J-weld joining the liquid 'v .. j j oxygen tank forward bulkhead had been the most difficult fabrication
' ,{. problem on the Saturn 11 rocket booster vehicle for the lunar program./
, !!! ! , D! An upper head, B-203-55-1, was being readied for a second steam / n [j generator.
i4 '! , ,l' ', A Lukens' fabricated upper head, A10-203-61-2, was being dye pene-l 'l trant tested by.a technician who wat standing in the inverted head, j
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' spreading the volatile penetrants while busily smoking a cigarette.
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' ~! A hook-shaped 28-inch I.D. pipe section, B67-203-50-(?), for another
>- -site was ready for. shipment.- i .;
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Inspection of Records' ., , a . 1 To sample the QC test records, the _ inspector selected a reject sheet
I ,;! from the process records on part number B67-203-50 and one fram part , p :. number A57-203-50-1.
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. The weld had been j i, One proved to be a flaw detected by radiograph.
- - repaired and rejected a second time by radiograph F-79606, reject h '[R sheet U-7646; then found acceptable by radiograph F-79652.
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. t' The' rejection on the second part was found to have been be:cd on an ,1- ! A detailed chart which had been prepared by the [ i . .,. Ur technician precisely locating the weld flaws in three dimensions ultrasonic test.
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' The defects had been removed on a '] { I was examined by the inspector.
process variation order, and a second UT test approved the work.
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i {: Retrieval of the records on the UT was laborious due to filing of
- . f . the various types of test records and repairs and release orders in '{- t !l{ random order by dates, in several files rather than by referenceOnce retrieved f t numbers of the various types of papers.
? .. fll; were found to be thoroughly detailed. '
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' .c Composite Metal Walls on Piping and Pressure Vessels _ i
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j The designers of B&W, Bechtet, and Duke Power Company had chosen to - {- I have the pipe walls and pressure vessel walls and heads obtain their "} ! [! principal strength from carbon steel, while resistance to corrosion, . scouring and cavitation is provided by a thick layer of stainless ( The cladding is deposited by aut,ematic submerged steel cladding.
, acc process where six stringers of cladding metal are laid d j , ' '! : I - a helical pattern.
with two scam welds, at the inner and outer radii, first on the ! I On some pipe section ends and !.; carbon steel, then on the cladding.
ij ' f aces of vessel penetrations, the cladding is done with Inconel.
.l ]. Smoothing of the inner surface of the cladding is a laborious process, / /
',. - l '.! even though donc principally by machining. On pipe sections and ells / ' .,$ l examined by the inspector, precise roundness and extreme smoothness / ie i The pressure vessels can be more precisely are not obtained.
finished by large boring mills and other stationary machining.
jL I l - '. The pipe sections are started by punching a hole thrpugh nhite hot
1 ! carbon steel billet, which is then forced by a large ram through a ,{ series of ring dies dropped successively in place by a boom crane.
, 1 Reference was previously made to the use by B&W of some amagingly 1i As an example, in the pipe forming, as the .I'1' ' crude and ancient methods.
unk piece is started through each ring die, a man shovels borax out hj reads it on' top of the hot metab with his shovel.
l ' ' 'T of a barrel and - This is not precu,ely done, because of the heat, the reach he has to l~ ' The borax make, and breaks in rhythm by the crane and ram operators.
i I ' melts and runs down over the hot netal, some of it acting as lubri- ~j - cant between the hot steel and the ring die.
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Fina! QA Discussion = and Shop Tour < . .
' ' Prior to a '4nal shop tour, a discussion was held.with Lang, Jung, t ~j Spratt1'- . >over, and others of B&W, and Wells of Duke. Wells f.
, '4 discusseu licensee versus vendor contract matters with Hoover; ,, j then he and the inspector reviewed the latest revisions of' two ' j.
.i } drawings on reactor coolant piping assembly. Wells urged that the - f } drawing change approval procedure be simplified to speed incorpora- ., 'I . tion of required backfit changes without serious schedule impact.
.i Hoover explained that Mt. Vernon was soon to have a design group, }' and that the concentration of engineering functions at Lynchburg .} was being lessened by this and relocation of some design functions .; . to Barberton.
,,-j il - l A walk-through tour was made of the plate receiving and storage
.i areas, of the pressure vessel assembly area, and of the reactor [ . j vessel fabrication and rework areas. On the previous day, much
! work on fossil fuel plant b>iler tube headers had been observed.
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On this tour, a large volume of a variety of sizes of used headers I and heat exchanger tube banks were seen under repair and noderniza-
N, tion. Most of this rework was for the Navy, as was the bulk of the , < t reactor work.
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-Plant Workload _ .
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The plant appears to be operating.ncar capacity, as to area avail- {j able, machine capacity, testing facilities and manpower. An estimate g ' of the source of the work observed underway at Barberton would show i > t a distribution as follows:
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1,, [3 t New U.S. Nasy work
/ ' ., 'I Navy Repair and Moderni- - , j i ! zation
' 1-I Civilian Fossil Fuel i j-Work, including r ?t Rework
'l Duke Oconee Fabrication
- Other Nuclear Plant Effort
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ORGANIZATION CHART NO. P 4 ' - sei.i s en.r t. c ter r es t.
.r...i t.i..e e, st.f r ser. ice o.et.. THE BABCOCK & WALCOX COMPANY Pee.r G....t ie. Di.i. i... Ser ber t e..
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