IR 05000269/1969009
| ML19247A866 | |
| Person / Time | |
|---|---|
| Site: | Oconee, Crystal River  |
| Issue date: | 03/04/1979 |
| From: | Oller R, Sutton J NRC |
| To: | |
| Shared Package | |
| ML19247A862 | List: |
| References | |
| FOIA-79-98 50-269-69-09, 50-269-69-9, 50-302-69-09, 50-302-69-9, NUDOCS 7908030029 | |
| Download: ML19247A866 (16) | |
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U. S. ATOMIC ENERGY COMMISSION
REGION III
DIVISION OF COMPLIANCE Vendor Inspection Report PWR Steam Generators Vendor:
Babcock & Wilcox Conjany Barberton, Ohio Report No:
B&W 69/9 Components Inspected For:
Oconee 1 (50-269)
Crystal River 3 (50-302)
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Dates of Inspection:
December 16 - 18, 1969 W [. WS Metallurgical Engineer (Responsible) January 8,1970 Inspectors:
R. E. O r
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t G. W.
utton Reactor Inspector (Construction)
January 8, 1970 Licensee Representatives:
J. M. Curtis - Duke Power Company R
- Florida Power Corporation d6G/%. Bourn
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Reviewed By: H. D. Thcrnburg Se or Reactor Inspector January 9, 1970
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Proprietary Information:
Entire Report Licensee Application Requirements:
Oconee 1 FSAR - Section III, ASME Code plus Summer Addendum, 1.969, per CO:II Crystal River 3 - Section III, ASME Code - 1965, per CO:I SUMMARY Initial CO review of Barberton Works' QA and OC organization (attached Exhibits 1 and 2) showed separation of authority and respensibility in relation to activities of QA, QC, and production. All of the above groups are audited on a continuous baris by the Nuclear Power Generating Department, Lynchburg.
In-process CC is maintained by a system of process control sheets showing inspection and NDT hold points, inspection tickets, upgrading sheets, and final inspection checkof f lists. Nonconforming material is not physically segregated but is tagged and held at respective areas until cleared or scrapped.
Subvendors are inspected on a periodic basis and at specified inspection hold points.
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The Babcock & Wilcox (B5%) 0C manual was found to contain all elements of QC organization, plannic ;, control, process specifications, and record keeping, bec the included welding specifications eere only typical of those use5.
(Section II-A-1.)
Duke Power Co=pany purchase specification for the nuclear steam supply system, NSSS-201, and B&W standard specification for once through steam generators designated ASPE Code Sectior.s II, III, VIII, and 1X as controlling documents, where applicabic, and appeared to be in accordance with'these codes.
(Section II-A-2.)
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MIR's covering forgings and plate material for both Oconee I and Crystal River 3 steam generators were in accordance with ASTM A-508, C1. 2, and A-212, Gr. E, requirements and applicable ASME Codes, However, Bsrberton's Material Record Control Division had considerable difficulty in finding the Oconee records which indicated a poor record traceability system.
(Sections II-A-3-a and II-B-2.)
Welding records for selected circle welds on both Oconee 1 and Crystal River 3 steam generators showed welder operators were qualified to Navships 250-1500-1 instead of ASPE Section 17 as required.
Welding procedures WG-58 and WG-8 (fer Oconee and Crystal River, respec-tively) were noted to be qualified fo : the two selected circle welds.
However, a Navy Procedure QC-W-21 was actually used in qualifying the operators and making the welds. B&W stated the procedures were equivalent.
However, the CO inspectors considered the substitution a contractual and code violation.
A deficiency was no.ted in the qualification of Procedure WG-58 in that it was stated to be qualified for base materials P-3, SA-508 Class 2. and P-12-B.
However, the test data sheet esitted P-12-B material. B&W stated this was an oversight.
Welder operators for Crystal River work were not requalified according to Section II, Essential Variable W-1, " Change in Filler Metal." Operators had baen qualified for stainless and Inconel cladding but not for Mn Mo-Ni filler metal in Vee groove welds. B&W position was that Essential Variables did not apply to welder operators.
No hot ovens were provided in the shop for low hydrogen weld rod used in repairs.
(Sec tions II-A-4 2nd II-B-3.)
Final stress relief of Oconee 1, Nos. 1 and 2 steam generators was in accordance with Section III.
Stress relief was performed in a special furnace, usind computer controlled electric resistance elements and forced circulated hot helium gas.
Required te=perature holding times for varicus weld thicknesses were =enitored by approxi=ately 100 selectively placed thermocouples.
(Section II-A-5.)
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Rev.iew of final radiograph films on a selected circle weld for Oconee 1 showed the technique met Section III Code requirements. No unacceptable defects were noted.
(Section II-A-6.)
All nondestructive testing personnel were qualified to SNT-TC-IA Standard.
The number of personnel and equipment appeared adequate for the shop work-load.
(Section II-A-7.-)
N-1 Manufacturers Data Reports for both Oconee 1 steam generators were complete and signed by National Board of B&PV inspectors.
(Section II-A-8.)
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Manuf acturing relocations of steam system components were reviewed.
Barberton has been ASME surveyed and issued ASHI stamps for nuclear vessels, parts, and piping. Canton and Madison Works may require resurvey to secure nuclear vessel stamps.
(Section II-A-9.)
DETAILS I.
Scoce of Inspection Or. December 16 - 18, 1969, an announced vendor inspection was made of B&W, Barberton, Ohio, by R. E. Oller, Metallurgical Engineer, and J. W.
Sutton, Reactor Inspector (Construction), Region III.
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Ihe purpose of the inspection was to audit the Barberton plant facili-ties and QC performance in regard to the manufacture of steam generators for r onee 1 and Crystal River 3 nuclear steam supply systems (NSSS).
The following persons were contacted during this inspection:
Babcock & Wilcox Ceccany (B&W), Barberton C. Barksdale - QA Engineer, NPGD - Lynchburg Manager of QA J. C. Quinn
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QC Inspector C. Bourman
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G. Domalaski - Project Engineer, Steam Generators H. C. Graber - Section Manager NDT Assistant.anager Ccamercial Nuclear Co=ponents E. Hicks
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C. E. Jessen - Chief Inspector D. Kinsala QA Coordinator
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QA Engineer, NPGD - Lynchburg R. Mano11
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Assistant Specialist, Reactor Vessels E. Snicer
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Duke Power Cemoany (Duke)
J. M. Curtir - QA Engineer Florida Power Corooration (FPC)
Maintenance Engineer - Crystal Rf L.
R. Bourn
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Results of Inspection A.
Oconee 1 Steam Generators 1.
Barberton OA/OC Organization and Program The Barberton Works' OA Group ard QC Group are shown on the attached Exhibits 1 and 2.
Mr. J. C. Quinn, QA Manager, reports to the Manager of Manufacturing and is respcnsible for the research and engineering aspects of QA.
Mr. W. A.
Hansen, OC Manager, reports separately to the Barberton Works Manager and is responsible for performance of inspection, nondestructive testing, and CC engineering.
The performance of all QA/OC activities, related to B&W Nuclear System contracts at Barberton and other works loca-tions (shown on Exhibit 1), are audited by Mr. R. Manoll, QA * ;tneer, Nuclear Power Generating Department, Lynchburg.
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NPGD is the direct supplier of the system to the licensee.
In-process DC at Barberton is maintained through process control sheets accompanying each ccmponent detailing each manufacturing sequence with required inspection and NDT hold points, inspection tickets, upgrading sheet = and checkoff lists.
Provisions are made for initial and periodic inspection of material suppliers. Many large material pieces requiring 6 - 12 months' manufacturing tL=e have hold points at which B&W witness the tests. Shell and ring forgings are normally purchased in a final heat treated condition with all chemical, physical, and Charpy-V tests complete. Plate =aterial to be hot formed by B&W is purchased on a chemistry basis.
B&W performs the balance of tests.
The B&W QC Manual, which covered the Barberton and Mt. Ve rnon Works, was found to be comprehensive and contained the elements of drawing control, QC planning, base material control, procedure and welder qualification, welding process control, heat treatment, nondestructive testing, gage control and calibration, and cleaning and shipping. Welding pro-cedures contained in the manual were of a general instruction type and did not include actual shop procedures used.
2.
Specifications
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a.
Duke Soecification NSSS-201, dated January 1, 1966,
" Nuclear Steam Generating Eouipment and Nuclear Fuel" Review of the above contractual specification showed it to be a performance specification for the entire system.
All components of the Oconee 1, 2, and 3 NSSS were required to be in accordance with the latest ASME Codes and interpretations. ASME Codes designated were S.ctions II, III, VIII, and IX.
b.
B&W Specification CS-3-33, dated November 26, 1968,
" Standard Eouiement Specification For Once Throuch Steam Generaters" This specification was standard for the steam generators.
Duke requirements were added as supplements. The CS-3- 33 specification included an Equipment Specification, Functional Specification CS(F)-3-33, and General Cleaning Specification CS(F)-3-92.
Specification CS-3-33 contained the following categories:
(1) Scope (2) Reference Docu=ents: ASME Code Sections II, III, IX, and Applicable Code Cases (3) Services and Equipment tc be Supplied
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(4) Design Requirements
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(5) Materials (6) Fabrication (7) Tests and Inspections (8) Cleaning (9) Preservation, Packaging, and Shipping (10) Documents to be Supplied GD Recerd of Revisions General Cleaning specification CS-3-33, Paragraph 8.1.2.1 specified that the primary and secondary side of the steam generators would be cleaned in accordance with B&W Class C conditions. B&W's General Specification CS-5-92, dated May 29, 1968, listed four conditions of cleaning, i.e:
Class A - Co=ponents inserted into the system without further cleaning are cleaned under clean room conditions.
Class B - Surfaces of co=ponents exposed to reactor coolant, which cannot be cleaned effectively after assembly, are cleaned under near-clean
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Class C - Surface of components in contact with reactor coelant and which are capable of being cleaned after assembly or installation in a system are cleaned by standard methods as solvents, flushing, etc.
Class D - External surface not exposed to process
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fluids are cleaned by standard methods as grit blasting and then paintad.
Mr. D. Kinsala stated that, although contractual em=siements are fat Class C cleaning, B&W perfor=s a cleaning equivalent to Class B.
The CO inspectors reviewed the actual shop procedure used which confirmed Mr. Kinsala's statement.
3.
Test Records fbterial Test Reoorts (MTR's)
MTR's for Oconee 1 Steam Generator #1 were selected at randem for the upper head forging, Heat #C-25961, tube sheet forging, i
Heat #122T-127-VA1, and shell course #3 (2 places), Heats A-1773-1 a nd A-1951-1.
Records were filed in the Material Record Control Section.
Test reports for both forgings, supplied by Bethlehem Steel, were ce=plete and met the requirements of ASTM A-508, Class 2, as specified for chemistry, physical properties, Charpy-V impact properties, UT, MI, and heat trea tment.
Test reports for two shell plates consisted of Mill Test Reports for chemistry and UT dita furnished by Lukens Steel Company (basis of plate purchase) and B&W test reports on physical properties, impac t tests, bend tests, and heat tre a tsent. After considerable confusion and delay experienced Ly B&W's Material Record Control in finding B&W test records, the test data, when produced, was in pencil foru and uncertified. Both Lukens' and B&W's test reports met the require =ents of SA-212, Grade B material, as specified. The apparent lack of ready record traceability was discussed by the CO inspectors in the exit interview.
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Welding Welding records related to the circle weld joining the upper head to tube sheet of the No. I steam generator were reviewed.
The sampling consisted of Welding Procedures, Weld Control Record, and Welding Operator Qualifications as follows:
a.
B&W Procedure W-51, dated January 23, 1969, " General Specification for Submerged Arc Welding of Vessels for Several Products on Nuclear applications."
b.
B&W Welding Data Sheet WG-58 '(Supplement to W-51).
c.
Welder Operator Qualification Test Records for three operators.
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Several discrepancies and nonconformities were noted as follows:
a.
Procedure W-51 was general for numerous types of welding und was not qualified as such for the selected circle weld, b.
Weld Data Sheet Procedure WG-58, directly applicable to the selected weld, was stated to be qualified for base materials P-3, SA-508, Class 2, and P12-B.
However, the Qualificatien Test Sheet for WO-58 did not include P12-B base material. 36W personnel stated this was an oversight, 2nd the qualification tests did include P12-B base material. The CO inspectors accepted the explanation but stated it indicated a need for closer review of documents by B&W.
c.
The three welding operators who worked on the selected weld were qualified to a Navy Welding Procedure OC-W-21 instead of WG-58, and, in addition, were qualified to NavshAps 250-1500-1 instead of ASPE Section IX.
B&W stated that the QC-W-21 was a Navy procedure equivalent to WG-58 and that Navships 250-1500-1 qualification was equivalent to Section II.
The CO inspectors stated in the presence of Duke's OA Engineer tiat equivalent procedures and qualification standards were not in accordance with ASPE Codes required by the applicant's FSAR and by contractual documents. B&il has constructed a separate new welding school building.
Mr. Walker, Welding School Supervisor, stated that B&W was in the process of requalifying all procedures, welders, and welding operatiors to ASME Section IX and would provide separate ASME oualification test papers. He stated t
-8-further that all qualification records, including a checkoff sheet for updating welders and welding operators, would be centralized in the school for ready review.
5.
Final Stress Relief of Steam Generators Facilities and verification records covering the final stress relief of the two steam generators for Oconee 1 were examined by the CO inspectors. B&W had constructed a special heat treating railcar furnace building equipped with zone controlled multiple electric resistance heaters in the ceiling and floor and a forced cire :letion duct system for recirculating hot helius gas through both primary and secondary sides of the steam generators. Recuired temperature holding time for the varying co=ponent veld metal thicknesses in the vessel was achieved by eceputer control, utilizing approximately 100 the reocouple s (TC), selectively placed on and in the vessel.
All IC point re: dings were recorded on strip charts. The steam generators were stress relieved in their completed assembly with the operation being run by qualified heat treating specialists.
Mr. Curtis, Duke, stated he had witnessed final SR of both vessels.
Since examination of the many rolls of strip charts would have been a lengthy process, the CO inspectors examined an
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internal B&W memorandum dated June 2,1969, "QA to Inspection,"
verifying the successful stress relief of the No. 1 steam generator. The inspectors noted that the following welds were monitored:
a.
Inlet Nozzle and Lu~gs to Top Head b.
Top Head to Tubesheet c.
Top Tubesheet to Shell d.
Shell to Bottom Tubesheet e.
Tubesheet to Bottom Head f.
Bottom Head to Skirt Transition
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Skirt Transition to Support Skirt h.
Outlet Nozzles and Pad Buildups to Bottom Head
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-9-Location of thermocouples and hold times were verified as having been in accordance with marked-up engineering drawings.
A tabulation showed holding tLmes for each of the above welds.
All welds were verified to have been stress relieved at 11000F to 11500F, Other points monitored but not requiring SR on the
vessel did not get below 1050 F.
Structual limitations on tube temperatures to avirage shell temperature and allowable te=perature thickness gradients o'f welds, tubeshe'ets, and heads were verified as having never been exceeded. Engineering diametrical lbsits were controlled by step heating and cooling.
The memorandum concluded that all code requirements had been met, and the original tabulations would be filed in the contract file. Based on the above document, the CO inspectors conclude that the SR of both steam generators was performed in accordance with ASME Osde requirements.
6.
Rad.ioersohv To provide consistency of audit, the CO inspectors reviewed final x-ray films on the top head to tubesheet weld of the No. I steam generator.
Wald & MKS-51 W* eld thickness 8" Source CC/60 36 positions - double fibn anetrameter.80 Thirty-six films were reviewed by the CO inspectors. Wrap around technique with source in center was used. Sensitivity was good as shown by a clear penetrameter. No unacceptable defects were noted in the weld. All RT techniques and procedures wera found to be in accordance with ASME Code Section III, Appendix II.
7.
Nondestruerive Testina Personnel and Facilities The CO inspectors held a brief discussion with Mr. n. C.
Graber, Section Manager, NDT.
Mr. Graber is quali.fied to Level III (examiner) SNT-TC-IA Standard. A list of person-nel, dated September 1969, qualified to SNT-TC-LA Standards showed the following:
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Level I - 29 people Level II - 12 people
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RT Level I - 37 people Level II - 9 people E
Level I - 37 people Level'II *- 10 people MI Level I - 11 people Level II - 12 people Mr. Craber stated that the list is updated every six months.
He stated further that Barberton has a full-time instructor qualifie1 in all the above NDT tecnniques.
The CO inspectors also examined a list of NDT equipment which showed modern and adequate equipment for all types of NDT.
8.
N-1 Manufacturer's Data Reoorts The CO inspectors examined the completed N-1 forms for both Oconee Unit 1 steam generators and found then to te completed and certified by B&W and the National Board of Boiler and Pressure Vessel inspectors.
9.
Other Items Discussed a.
Manufacturing Relocation Further information was obtained.in regard to manufac-turing locations of B&W nuclear steam systems (NSSS)
componengyasofDecember 16,1969 (but subject to change).-
B&W, at present, has 11 NSSS under contract.
Locations of manufacture are as follows:
(1) Primary Piping Fabrication
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All projects
- Mt. Vernon, Indiana
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(2) Reactor Vessels All projects
- Mt. Vernon, Indiana 1 CO Report B&W 69/6.
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(3) Steam Generators All projects
- Barberton, Ohio (4) Pressurizers Oconee #1 and Three Mile Island #1
- Madison, Indiana
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Oconee #2, Crystal River
- 2, and Russelville #1 - Canton, Ohio Jersey Central #2, Oconee 3 SMUD #1, Midland 1 and 2, and Toledo Edison #1
- Mt. Vernon, Indiana (5) Reactor Internals Oconee 1, Three Mile Island #1, Midland 1 & 2, and Toledo Edison
- Barberton, Ohio Oconee #2 and 3, Jersey Central #2, Crystal River #3, Russelville #1, and SMUD #1
- Allis Chalmers, York,
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Pennsylvania (6) Core Flooding Tanks
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Ocopee #1
- Barberton, Ohio Balance of p.ojects
- Stearns Roger, Denver, Colorado (7) Reactor Vessel Nazzle Machining and Cladding All projects
- Mt. Vernon, Indiana (8) Surge Piping 2\\" & 10" All projects
- Barberton, Ohio (9) Pressurizer Heaters All projects
- Weigand Company Pittsburgh, Pennsylvania b.
ASPE N Stamo Survev Mr. Quinn, QA Manager, stated that Barberton Works had been ASME surveyed in October 1969 and had received three stamps, viz., N (Nuclear Vessels), NPT (Nuclear Parts),
and NPP (Nuclear Piping). The Madison and Canton Works were also surveyed but had not been issued stamps. The survey of these two location: tovered issuance for Nuclear Parts only, and B&W stated they may require a resurvey for the Nuclear Vessel authorization due to current plans for ecmpletion of vessels at these locations, n b1 't Ag7 z
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Shoo Insoection Tours of the shop were made on December 17 and 18 to observe Oconee 1 and Crystal River 3 work, respectively. The inspec-tors noted that portable hot ovens were not located at weld repair areas in the shop, and nonconforming materials were not segregated but identified only by a reject tag.
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following areas were visited:
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Seamless Pipe Extrusion and Plate Pipe Welding, a.
Pipe Machining and Straightening b.
Vessel Head and Shell Pressing Tube Sheet Automated Gun Drills and Support Plate c.
Breaching d.
Vessel Head and Shell Weld Cladding (Single wire and six-wire cladding)
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Main Vessel Assembly Shop f.
Gage and Tool Roon
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Steam Generator Stress Relieving Furnace h.
Various Radiograph kooms and Portable Shields (both x-ray and ga=ma ray)
11.
Exit Interview on Oconee 1 An exit interview was held on December 17, 1969, wi th Me s s rs.
E. Hicks, D. Kinsala, and J. M. Curtis in regard to Oconee 1.
The CO intpectors explained the current Compliance practice of assigning specific inspectors to audit manufacturers of nuclear components on a representative basis to gain famil-iarity with facilities and performance to determine their level of p^rformance in regard to specific licensee's work. The inspectors also noted the following items in regard to this audit of Oconee 1:
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It appeared to the inspectors that considerable confusion a.
existed in locating material recorda, and this indicated poor record traceability in the Material Records Division.
b.
The lack of provisions for physical segregating of non-conforming macerial, other than tagging, could lead to their inadvertent use.
B&W stated their system of reject tickets and clearance tickats prevented this happening.
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The lack of hot ovens at weld repair areas for care of the predominately used low hydrogen electrodes was considered poor practice by the inspectors. B&W stated they would give this consideration.
d.
Sampling of welding records shoved that welder
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operators were not qualified to lection IX.
This was in nonconfor=ance with the applicant's contractual requirements. In addition, the procedure used, QC-W-21,
.was not the procedure qualified for the specific weld and operators audited. B&W acknowledged this situation existed and stated they were in the process of requali-fying welders to Section IX in addition to their present Navships 250-1500-1 qualifications.
Mr. Curtis acated he would take action to resolve this problem as it applied to finished and in-process Cconee work.
B.
Crystal River Unit 3 Steam Generators 1.
General On December 18, 1969, an audit was =ade of Crystal River #3
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steam generators in the presence of Mr. R. Bourn, FPC.
Material records and welder operator qualifications were reviewed and in-process shop work was observed, as previously noted.
Mr. Bourn stated oa all B&W work, FPC performe their own QA surveillance.
2.
MTR's'
MIR's were selected for the lower tubesheet, the #5 shell course, and the nozzle course of the #1 steam generator.
All MIR's appeared complete and in accordance with ASTM and ASME Code requirements.
3.
_elding W
Weld ng procedures, veld data sheets, and welding operator qualifications were selected in connection witn the circle seam between the Mk 1 top shell course and the Mk 2 shell nozzle course of the No. 1 steam generator for Crystal River No. 3 generator in a manner ilmilst to the Oconee 1 selection. Welding Procedure W-51, supplemented by Procedure WG-8, were designated as qualified and used on the selected weld. Again, it was noted by the CO inspectors that Navy procedure QC-W-21 was actually used. The performance qualificatiou papers for four welding operators showed qualification to Navships 250-1500-1, instead of Section EX, ASPE Code.
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In addition, the welding operators were found to have been qualified for stainless and Inconel clad welding on low alley and carbon steel but not for butt welding. It was B&W's position that Essential Variables in ASPE Section IX did not apply in the case of welding operators. However, the CO inspectors did not interpret the code in this manner and stated that this aspect would require fur;aer
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study by Compliance. This item was discussed in the exit interview.,
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During this audit, B&W stated that longitudinal seams.
Se shells of all steam generators were electroslag welded m Mt. Vernon. ;All electroslag welding records and procedures were at Mr. Vernon and, therefore, unavailable during this inspection.
4.
Exit Interview on Crystal River A brief exit incerview was held with B&W and FPC reprt'senta-tives at which the CO inspectors again explained the recson for CO's ardit of vendors. In addition, they noted that welder operators and procedurts used on the Crystal River
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stems generators did not appear to be in accordance with ASPE Section II requirements. The FPC representative had no cc==ents to make on this item.
The inspectors stat that Compliance would follow up on this item. *
Attach =ents:
Exhibits 1 and 2 i
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