IR 05000312/1971005
| ML19317G047 | |
| Person / Time | |
|---|---|
| Site: | Rancho Seco |
| Issue date: | 01/20/1972 |
| From: | NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V) |
| To: | |
| Shared Package | |
| ML19317G034 | List: |
| References | |
| 50-312-71-05, 50-312-71-5, NUDOCS 8002210748 | |
| Download: ML19317G047 (17) | |
Text
_ _ _
.
_ _. _ -
.
,
s
.
.
..
,
U. S. ATOMIC ENERGY COMMISSION DIVISION OF COMPLIANCE
REGION V
INSPECTION REPORT C0_ Report No. 050-0312/71-05
'
Subject Sacramento Municipal Utility District Docket No.(s)
050-0312 Rancho Seco Unit No. 1 License No.(s)
CPPR-56 Location Clay Station Priority-
--
Sacramento County, California Category A-2 Dates of Inspection December 13-17. 1971 & Januarv 7.
1972 Dates of Previous Inspection July 21-23. 1971 Type of Licensee 963 me (2772 Nt) PWR. B & W
'
Type of Inspection Construction, Routine Announced Principal Inspector
/M
R. T. Dodds, Reactor Inspector
/ Date i
Accompanying Inspectors I
//fd
A. D. Johnson, Reactof Inspector
/ ate D
,
Date Other Accompanying Personneli G. S. Spencer, Sr. Reactor Inspector on January 7,1972
/2/2 neviewed By G. S. SpencerV Senior Reactor Inspector Date Proprietary Information: None een m 977
.
....
-
-
- -- -
.
_
'
<
.
s
,
J SECTION I Enforcement Action The following items of noncompliance with 10 CFR 50, Appendix B were identified.
A.
Manufacturers procedures for 125-volt DC system battery chargers did not incorporate acceptance limits (Criterion XI).
(Paragraph 13.a.(2)(c).)
'
B.
Inspection plans were not prepared prior to construction activities (Criterion II & SMUD QAP No. 6).
(Paragraph 14.)
i
C.
Conseco's QC manual failed to reference or provide necessary documented l
instructions for quality activities (Criterion V).
(Paragraph 15.)
D.
Audits of special processes were not being performed (Criterion IX and Conseco QC program).
(Paragraph 15.d.)
E.
Insufficient records were being maintained for work governing the construction of field erected tanks (Criterion XVII).
(Paragraph 15.e.)
Licensee Action on Previous 1v Identified Enforcement Matters None required V
Unresolved Items A.
Examination of all Class I valves disclosed that some of the valves supplied by Velan Engineering had thin walls. Usage and testing of the valves were being reviewed by the licensee.
(Paragraph 12.)
Status of Previcusiv Reported Unresolved Items A.
Instruction to Welders It was verified that the instructions to welders now include the essential variables.
B.
Identification and Control of Class I Carbon Steel Pipe. ASTM A-53.
Type S. Crad e B '
'All but 174 spools of' carbon steel pipe have been traced to heat numbers.
Of these.174 spools,-two specimens from each size of pipe (4, 6, 8, 10, 12, 18 and 20 inch) have been destructively tested for chemical content, yield strength'ani tensile strength. Tensile properties were determined before and after heat treatment. It was verified by a review of the test records that all of the spools tested complied with code requirements.
-~s x/
J
,
a
_ _ _
-.
_ _.. _ __
_
_ __
~
O'
^
2-Persons Contacted The following personnel were contacted during the inspection.
M D. Raasch Project Engineer
-
V. McMahon Quality Assurance Director
-
W. Friedrich Quality Assurance Engineer
-
J. Hiltz Resident Engineer
-
L. Kielman Senior Mechanical Engineer
-
-R. Wilson Senior Nuclear Engineer
-
L. Smith Mechanical Engineer
-
Bechtel Corporation (Engineering and Construction Management)
W. Stinchfield Project Manager
-
C. Blum Office Engineer
-
J. Walker Project Quality Assurance Engineer
-
W. Chapla Quality Assurance Engineer
-
W. Taylor QA Engineer
-
J. Wait Senior QA Technician
-
'
R. Franquero Field Engineer (Electrical)
-
Bechtel Corporation (Construction)
J. Vander Knyff.
Project Superintendent
-
B. Boyd Welding Supervisor
-
A. Priest Senior Electrical Engineer
-
E. Callaway Electrical Engineer
-
I. Glorit
.
Electrical Engineer
-
E. Callaway Electrical Engineer
-
J. Cornhan Field Engineer
-
A. Rogers Receiving Inspector
-
W. Bagley Welding Inspector
-
Conseco a Division of Chamberlain Manufacturine Corporation H. Hollowell Foremen
-
-
C. King Welder
-
QC Services Incorporated J.'S. Spacke, QC Inspector for Conseco n/
,
~--
--_.
.
_
,1_.
_
. _.
..
. -..
..
..
.
.
- -_
. -.. - _ _ _ - - - - - _ -
,
'
.)
.
,
,
4 1-3-
,
Management Interview The results of the ~ inspection were discussed with Messrs. Raasch, McMahon and other members of theirs and Bechtel's staff at the conclusion of the inspection. A subsequent management interview was held with Mr. K. Davis, General Manager, SED, Mr. Mattimoe, Chief Engineer, SMUD,and Mr. McMahon
on January 7,1972. Pertinent responses to inspection findings were as
.follows:
A.
The need for additional testing and/or additional documentation to show
'
the acceptability of the use of unnormalized SA 516 steel for one of the shell rings in steam generator No. 2 will,be reviewed. To clarify the docummutation, the cause of the design contract variation will be
' included in the nonconformance report.
(Paragraph 11.)
,
B.
A manufacturing data report will be obtained for circuit breaker No.
52-4A01-1200A. Further, the electrical equipment records will be examined to assure that all applicable manufacturing data reports have been
received.
(Paragraph 13.a.(1) )
C.
A nonconformance Report will be prepared for station battery charger No.
633-1H4BD' requiring corrective action because of the excessive time required to trip the output breaker for pole No. 1.
(Paragraph 13.a.(2)(b) )
D.
The manufacturer's tests of the battery chargers will be reviewed to assure independent inspection of performance tests and that the records adequately identify the inspector in accordance with AEC Criteria X and XVII respectively.
(Paragraph 13.a.(2)(a) )
E.
The procedures provided by Babcock and Wilcox Company that have been proposed for receipt, inspection, handling, storage and installation
'
of the reactor vessel and.the steam generators will be implemented by Construction Management as applicable.
(Paragraph 10.)
_F.
The quality control program governing the construction of Class I field errected: tanks will be evaluated to determine if the implemented nondestruc-
'
tive test program is adequate to assure quality consistent with the safety importance of the tanks and the procedure controlling weld filler material
.will be_ changed to limit the duration of time low hydrogen filler material may be used after disbursal from the holding ovens.
(Paragraph 15.)-
G.
In regard to the items of noncompliance, the entire QA program will be
~ reviewed and corrective action taken as necessary to meet all requirements
for a total program that will be consistent with the AEC criteria.
e Matrix diagrams will' be developed for Class I activities as a management
<
l tool,'to assure that QA' activities will be performed in a timely manner.
' H.
SHUD's examination of vendors to determine their respective program for checking the wal1 ~ thickness of all Class I valves was acknowledged and where an acceptable program was not available, independent meesurements were made by SNUD. These measurements disclosed that some of the valves
/.
supplied' by Velan Engineering, Quebec, Montreal, Canada had thin walls and
,
l
,,s
-
that all of the valves had undersized valve seats. The valves will not be L
Lused unless engineering review and/or testing show them to be acceptable I
for~their intended service.
(Paragraph'12)
h L
ll,
,-
., -
- -.,
-
- - -
-
--
---
- ~ ~ ~ ~ ' - - - ~~ ~~~~~
'
,,
_.
_
_ _ _ _.
_ _ _ _ _ _ _.. _ _
_ _ _. _
'
.
-4-Additional Subjects Inspected. Not Identified in Section I S Where No Deficiencies or Unresolved Items Were Found t
~1.
Status of construction Project construction was estimated to be 57% completed as of December 16,-1971.
Construction progress was behind schedule because of a six week strike in August and September,1971. However, Bechtel has been working two shifts a day and claims that the scheduled completion date will be met.
However, it was later acknowledged by ShDD management
that the December 1972 fuel loading date is unrealistic and a new completion date will be published in January 1972. The last of the concrete for the containment vessel dome was placed on December 14, 1971.
Nhjor work for the erection of the 230 kv switch yard has been completed.
,
The first of the Bechtel startup personnel are on the job and working with SMUD test personnel on startup and test' of electrical systems.
Checkout and test work has been concentrated on the 4160-volt switch-j gear and station lighting systems.
The reactor vessel and steam generator No. 2 have arrived at the site.
The No. 1 generator should arrive in-January, 1972. Their installation is. scheduled for January-February 1972.
2.
Instrumentation (Completion of Examination of OC System)
a.
Use of expertise installation - N1.1 contract requirements, b.
Inspection and Testing Provisions - Quality Control Instructions and Construction Inspection Data Report (Inspection Plans)
i 3.
Electrical (Completion of Examination of OC System. Record Review, and Observation of Work)
a.
Relay Coordination Study I
(1) Load Design. Data Sheet 125-volt DC system (2) Load Design Data Sheet for 4160v bus "4A", includes Diesel-Generator (3) '" Coordination of Protective Devices" (480v, 416v, 277v
.
lighting, and 120 volt systems)
,.
N
'
l I
...
.
.
_.-
_
..
- -
._
.n
./l
'
5-
-
b.
Nhterist Certifications (1) Diesel-Generators (Bruce GM Diesel, Inc.)
(a) Test Sunnary and Test Procedures (b) Report-of Tests c.
Installation Techniques (1) Diesel-Generators
'
(a) Inspection Plan No. NE.1-71-2 (b) Quality Control Instructions No. 318A (c) Construction Inspection Data Report (d) Rotating Equipment Installation Field Inspection Checklist d.
Protection of Installed Comoonents (1) QCI No. 205, Storage Inspection Requirements for Electrical Equipment (2)
M ggering Records of Diesel Generators e
(3) Cell tests of batteries - 11/15/71 to 12/14/71 (4) Daily ammeter checks of switch gear heaters, October -
December 1971 (5) Verified existence of plastic sheet covering over equipment for dust protection. Checked switch gear to assure heaters were operating.
e.
Ouarantine of Nonconformine Comoonents (1) Observed proper tagging of equipment in quarantine in storage area.
(2) Nonconformance Report :;o. - 928 for Diesel-Generator Control Panels (Requires Rework)
(3) Receiving Inspector's log of tags issued for quarantined equipment 4.-
Cables and Terminations
.
a.
OC Program for Site NDT on Cables (1) ' Quality Control Instruction No. 208, Testing of Electrical Cable and wire, dated.1/13/71'
.(2) Construction Inspection Data Report No. M1.1 (7N.21)-2. dated 12/17/70
~
m
.
--n---
,
,
,
,
, -
...e
-
,
,
,
n--
'
'
K.
{G
.-
i l-6-b.
Record Review (1). Vendor NDT on Cables (a) Certified Test Reports (Approximately 15 examined)
(2) Ouarantined or Nonconforminst Material (a) Receiving Inspection Data Report No. 93 (b) Nonconformance Report No. 747-(c) Checked other Receiving Inspection Reports (about 5)
and verified quarantining of cable as appropriate.
(Most quarantined because of damaged cable ends as a result of handling and shipping.)
5.
Steam Generator No. 1 - Report of Weld Repair on NK 50 Tube Sheet and A-7 Head 6.
0C System for Prestressed Concrete a.
Material Certification on Hardware (1) " Quality Assurance Program for VSL Post-Tensioning System Installed in Nuclear Containment Structures" approved by Bechtel 5/19/70 (2) Material Certifications required by P.O.12.lA, Paragraph 5.26A i
b.
Chemical Analysis on Greases (1) Purchase Order No. 12.lA, Paragraph 7.06B (2) Sampling frequency specified in Paragraph 6.01 B.7 c.
Installation of Tendons l-(1)' See item 6 a. (1) above. However, manual was being revised _
at time of. inspection.
(2) Crew qualification.
7.
Weld Repair on Steam Generator No. 1 Examined reports and contract variation approval for. repair of the tube sheet to heed weld for steam generator No. 1.
.
.
-
.
.
.
.
_
_
.
m
)
i
-7-l 8.
IEELs l
Coastruction site including welding shop to check for material and tool segregation. Observed placement and protection of electrical equipment.
9.
Class I Field Erected Tanks a.
SMUD approved Conseco QA Manual b.
Contract specifications and approved drawings c.
Quality Control procedures for:
(1) Qualification of weld procedures, welders, NDT technicians and NDT techniques.
(2) Visual inspection of completed welds.
(3) Radiography, vacuum box and hydrostatic testing.
(4) ' Weld material control including receipt verification, pre-issue storage, issue control and disposition of unused
,
material.
(5) Identification, receipt, and storage.
d.
Records examined included:
(1) As-built drawings showing:
(a) Weld procedure (b) Welder and date of weld (c) Radiography including repair shots (d) Material identification heat numbers (a) Deviations-from design drawings (f) Vacuum box tests
- (2) Stamped radiographs-showing examination by the construction management inspector.
(3) Qualified weld procedures.
(4) Welders performance qualification test results.
(5). List of qualified welders.
(6) Welding tickets used to control weld filler material.
(7) Radiography inspection reports showing radiographer, film number correlated to weld location, applicable code,-and acceptance or rejection.
(8) 'NDT technicians qualifications (9) Job description and operations sequence plen i"
-(10) ' Material receipt inspection (11) : Concrete batch plant reports b)
\\.s-
.
.-
.
.-
_-
.
-..
_
-
..
__
_
._
_ _. -
_
.
.
-s
,
.,
_,
-8-
,
(12) Concrete placement reports (13) Preparation for concrete placement repsets (14) Phterial certifications for:
(a) Steel plate (b) Nossier and fittings (c) Eye bolts, studs and nuts (d) Bottom gussets (e) Reinforcing steel (15) Results of user tests of installed reinforcing steel, e.
Observations included:
(1) QC inspector visual examination of completed welds.
(2) Welding operations pursuant to qualified procedure.
'
(3) Weld filler material controls including storage and adherence to the approved procedures.
(4) Material storage including the use of the material identification
'
and status procedures.
10.
Reactor Pressure Vessel and Steam Generators a.
Proposed procedures for receipt, inspection handling, storage installation and cleanliness of the vessels b.
Examined reactor vessel on rail car at site.
Details of Subieces Discussed in Section I
11.
Use of an Unnormalized Plate in Steam Generator No.__2_
'
The documentation from B & W to SMUD and the Rancho Seco nonconforming report for support of the use of an unnormalized plate in steam generator No. 2 were examined. The documentation only addresses the question of changing from CA-516-GR 70 to SA-516-GR 65 because of low yield strength (i.e., 38,000 psi vs. 35,000 psi - actual of 36,750 psi) and increasing
,
the nil-ductility transition temperature from 40 F to 70 F.
The
'
documentation failed to include the cause of the design deviation (i.e.,
the change from normslized to unnormalized steel).
A boat sample was removed from the corner of the plate in the steam generator and the material tested to meet the minimum requirements of che ASME Section III Code. These included a tensile test and the breaking of a set of 3 Charpy impact specimens. Additional tensile and NDT tests (
were performed on samples obtained from the plate trim rings. Results of all of these tests were as follows*:
3s c* Adequacy of the testing program and acceptability of material is currently being investigated by C0 Headquarters.
-
.
-
-.
...
.
.-.
.-
.
-
- -~
.
_
,
.
.
-9-l Mt. Vernon Results - Test Rinns T.S. (psi)
Y.P.(psi)
E1. (7.)
R.A.(%)
Temp.(%)
CVN(ft-lbs)
Top 76,000 39,000
64.4
+40
+50
+60 10,15,23
+70 27,32,37 Bottom 74,000 38,500 30.5 64.7
+60 17,20,22
+70 32,37,37 Barberton Results - Removed from Vessel Top Not removed from vessel
!
Bottom 77,000 36,750
51.9
+40 15,26,30 12.
Measurements of Class I Valves All vendors of Class I valves were surveyed by Bechtel to determine what procedures had been established to ensure that design requirements were being met.
Two suppliers, Velan and Aloyco, were found not to have acceptable programs. Therefore, measurements of valves received from these venders were performed by a Bechtel Receiving Inspector.
The Aloyco valves were within specifications. However, it was determined that two 12-inch and two 14-inch valves supplied by Velan Engineeristg, Quebec, Montreal,' Canada that were ordered prior to the proposed issuance
of the ASME Pump and Valve Code, had " thin" walls. For example, the minimum specified thickness for the 12-inch valves was 1.963-inches whereas a minimum thicknesslof 1.438-inches was discovered; on the 14-inch valves the required thickness was at least 2.156-inches whereas
'
a minimum thickness of 1.35-inches was disclosed by ultrasonic testing.
One of the valves has been returned to Velan Engineering for a hydro test at 6400 psi which could then qualify it for service. The Nonconform-ance Report on these valves had not yet been dispositioned. Design eval"~ tion may find them acceptable for service.
'
i During the check of the wall thickness it was learned that the waterway
bores of valves supplied by Velan were'considerally smaller than the valve size as illustrated below:
v i
r
!
,
_
...... -
_
,
...
...
. -
__., _ _ -
.. _,,, _.
, _
.
..
-~s
.
- 10 -
Tvoe Valve Valve Size Waterway Bore Diameter 11obe 2.5" 1.75" 3"
2.00"
-
"
4" 2.50"
"
6" 4.25"
"
8" 6.00"
"
10" 6.00" Cate 10" 8.00" Stop Check 10" 6.00" Cate 12" 10.50" Check 12" 10.50" Cate 14" 10.50" Check 14" 10.50" i
System performance analysis has shown that the pressure drop across two 10-inch stop-check valves in the decay heat supply line to the reactor vessel would be excessive and therefore the valves have been rejected. All other valves were found to be acceptable.
~
13. Electrical Systems and Components
'
a.
Nbnufacturing Records of Critical Components (1) A check of the records disclosed that there was no manufacturing cata report for the tie breaker (No. 52-4A01-1200A) between the diesel generator and the 4160-volt system, bus 4A.
Originally there had been a nonconformance report on all of the 4160-volt switch gear because the data reports were missing. They were subsequently received but apparently the data report for the above breaker was left out.
The omission was not detected by Quality Assurance before clearing the nonconformance report.
(2) Bat t ery charners.125-volt DC System The manufacturing test data for the nine 125-volt DC system battery chargers and the respective Bechtel Source Inspection Reports were examined. The battery chargers were manufactured by AVTEX Systems Incorporated. The following deficiencies were identified during the review of the records.
(a) 'The test reports contained sign off spaces for each test-entitled " Accepted" and in addition " Certified by" following a series of tests. The " Accepted" spaces were noted to be initialed or signed. However, the " Certified by" spaces were not always signed off.
.
1%.
.
.
.
...
\\
- 11 -
Mr. West, Senior QA Technician, contacted AVTEX and was informed that " Certified by" was suppose to be signed by the Bechtel source inspector. This was not consistent with the observed practice since the Bechtel inspector initialed the bottom of each page of the test reports and someone from AVTEX had signed " Certified by" a number of times.
(b) In reviewing the test data it was noted that the output breaker for pole 1 on charger No. 633-1-H4BD did not trip for a time period of 680 seconds when a 190% overicad was applied. The test was performed and certified by "W.M."
on 10/3/71. A check of the manufacturer's data shows that the breaker should have tripped in less than 480 seconds.
It was observed that the other breakers tripped in less than 400 seconds, usually approximately 300 seconds for 200% overload.
(c) The examination of the procedures, which were an integral part of the test data report, disclosed that they did not g
incorporate " acceptance limits" as required by 10 CFR 50, Appendix ' B", Criterion XI.
0A Program - Inspection Planning SMUD QA Procedure No. 6 requires that inspection planning be prepared for
'
construction inspections of Class I items. Contrary to this requirement, the examination of the records for the installation of the 4160-volt evitch gear and the 125-volt DC battery chargers and for the construction of Class I field erected tanks disclosed that " Inspection Plans" had not been prepared prior to the initiation of construction activities as follows:
a.
The first cf the 4160-volt evitch gear was installed on July 16, 1971.
The Inspection Plan" (CIDR) was issued on November 18, 1971.
-
b.
Installation of the battery chargers started on October 24, 1971.
The " Inspection Plan" was issued on November 15, 1971.
c.
Construction activities for the field erection of Class I tanks j
started on November 10, 1971, with the first weld being made on November 18, 1971. The " Inspection Plan" was prepared during the inspection and was approved for issue on December 17, 1971.
)
15.
Class I Fleid Erected Tanks Conseco, a Division of Chamberlain Manufacturing Corporation, was awarded the' contract to install the three 450,000 gallon QA Class I tanks for
.
storage of condensate,-borated, and demineralized water. The carbon steel condensate storage tank is to be constructed to meet the requirements of American Petroleum Institute (API) Code 620. The stainless steel
!
borated water and the demineralized water storage tanks are required to meet-the code requirements of API 650. The Conseco construction activitie.,
c related to these tanks commenced on November 10, 1971.
i
...
, -,
-
..
.., _
.-.s,.
-..,,.,
. - -
. - -.,
g
_. ___
- _
_
..__
_.
.
._
. _
.. _. _
__
.
....
- 12 -
l
'
Based on the inspector's review of the contract specifications, the SNUD QA program manual, the Conseco QA program manual, the Conseco
onsite QC manual and the records of QC activities, deficiencies in the
- Quality Control procedures and activities 'were identified as discussed below, a>
Conseco QA-0C Program Instructions
The Conseco QA Manual was reviewed and approved by the SMUD QA
>
Organization prior to the. sward of the contract to Conseco. The manual provides general policy direction for Conseco activities;
however, it appeared to be primarily directed toward QA-QC activities at the Company's fabrication facilities located in San Leandro, California.
Mr. Taylor, Bechtel-QA Engineer, stated
,
that site activities are more specifically controlled by the l
.on-site QC Manual approved by Bechtel. The inspector called to the attention of Messrs. Taylor and Freidricks that the Conseco QA Phnual references a procedure for handling nonconformance items and that the procedure had not been included in the Conseco QC
Manual.
Mr. Taylor explained that whenever nonconformance items are found by the Conseco QC inspector he is to notify a Bechtel
~
QC inspector and then a nonconformance report is to be initiated,
&
.
if appropriate, pursuant to the Bechtel nonconformance reporting j
procedure for resolution.
,
Mr. Spacke,- Conseco QC inspector,. informed the inspector that l
anything he. thought was a significant deviation or deficiency he would call to the attention of the Bechtel inspector. However, he
,
,
added upon questioning,'that his written instructions did not
'
include a specific procedure to follow for reporting and resolving
identified deficiencies or nonconformance items.
In addition, the QC hhnual failed to provide written instructions j-concerning control of weld repairs and dye penetrant testing. The i
approved weld procedures did, however, contain a sentence to the.
- effect that defects were to be removed and the affected-area rawelded.
,
Mr.:Spacke explained that defective weld areas are normally ground out and. rewelded by the same welder using the same weld procedure
'
as used for the original weld. As for dye penetrant testing, Spacke stated that he has a Level'II classification and performs the tests to standard procedures. Spacke pointed out that-dye penetrant testing is not required by the contract or the code and is only performed as an ~ additional check when desired.
d
,
l
'
.. u
.
..
.
.-
.
~
. _ _ ~., ~. _.
.
-, - _. _..., _
,. _ _,...
.
.
'
OU
- 13 -
b.
Weld Pflier Material Controls A detailed procedure to control weld filler material has been included in the Conseco QC Manual. The procedure provides a system whereby the QC inspector issues weld metal to the welder and provides a duplicate ticket to the welder showing heat or lot number, amount,
'
type, welder, weld procedure and date metal was taken from oven.
In addition the records showed the time rod was issued. Also a check with a welder confirmed the procedure was being followe:
.
The welder, C. King, indicated that the ticket system was not too inconvenient except that he had problems finding it when various inspectors came around to check on him.
Although the records appeared to be complete and a random check showed that welders were generally issued only enough rod for about four hours of work, the inspector pointed out to Messrs.
Spacke, Friedrick and Taylor that provision had been omitted to limit the time rod could be used after disbursal to the welder.
Mr. Spacke said he makes checks to assure weld rod is either returned to the ovens or discarded at the end of a work shift,
'
and that this possibility has not been a problem to date, c.
Nondestructive Test Pronram The nondestructive tests that have been prescribed include spot radiography pursuant to AP.I code 620 (condensate storage) and 650 (demineralized and borated water storage),1007. vacuum box test of floor area, and hydrostatic test (fill tanks with water and look for leaks).
A reading of the code provisions indicates that 107. of the welds are required to be examined by radiography. If under API-620 a weld defect is identified, excluding the sections 3 inches from each end, the defect is repaired and reexamined. No additional radiographs are required even if all radiographs were to show defects. However, if a defect is found within 3-inches of the radiograph end another radiograph adjoining that end is required to assure that the entire defect is shown and repaired. As for the requirements of API 650, if a defect should be located, additional radiographs are taken on each side of the spot radio-graph until the weld seam shows free of defects. When questioned concerning whether or not additional radiographs would be made on the condensate tank (AFI 620) if many defects were identified, Mr. Spacke indicated that only insofar as required by the code
.
since that is what is called for by the contract.
a,
i l
L
.
-
-.
-.
- ~
--
.
.
....
-
.
.
.
N
'
'
i
,
- 14 -
d.
Audits of Weldina 'oerations D
Section 4.1.1.1 of the Conseco QC manual reads " Welding operations shall be audited to assure conformance to the applicable procedure.
Results of audits to be logged in inspection planning sheet (operation
sequence)".' To date, no entries had been made in the record to show that the prescribed audits had been performed.
Nk. Friedricks stated that to his knowledge audits had not been performed,
s e.
Records-(1) Weld Repairs
.
Mr. Spacke stated that the only record of repairs to welding l
is the radiograph. He explained that whenever a repair was made a reshot of the repaired weld would show an "R" after the radiograph number; with 2 "R's" shown if it were the
,
second repair of.the same area, etc.
Other than this no records are maintained. As for the welder. performing the a
'
repair, Spacke stated the same welder that originally welded the seam is required to do the repairs. However, Spacke indicated that if a different welder did the repair his initials would also be shown on the as-built drawing.
(2) Dve Penetrant Tests Spacke. stated that since there are no requirements for dye penetrant testing, no records are maintained.
'
(3) Visual Inspections-Spacke explained that he is responsible for the continual inspection of work being performed. He stated that he v:'.sually inspects weld fitup, root passes and the completed welds. He
,
also stated that he frequently checks the ovens that conte,
I the low hydrogen electrodes. Spacke showed the inspector
'
that when he has completed the visual inspection of the complete
welds he stamps.the entry on ene operation sequence. However,
- provisions for inspection of the fitups and root passes have
-
not been included in the sequence form as a necessary step even though the' QC Manual requires that "all fitup, welding, etc., shall be inspected for workmanship and quality". Other i
.than stamping the operating sequence form when items are i
inspected no other records are maintained of visual inspections.
'
,
.
--
.
. - - - - -. ~. -., -
.
,
..
.
[A)
s
,
U 15 -
-
t Nk. Spacke indicated that he also observes welder performances
.on a continuing basis but does not record his observations.
(4) Radiograohv Records.of radiography performed by QC Services are shown on the as-built prints, and on inspection reports. Also, the Bechtel inspector punches the radiograph with an identifying symbol to show that the radiograph was acceptable to the Bechtel inspector.. QC Services inspection report identifies the radiographer and inspector. However, this record is not referenced in the QA manual and provisions have not been included
,
in the manual to assure that NDT personnel performing a test
!
are identified as required by AEC Criteria No. XVII.
In addition the program is silent as to the final disposition of
.the records being generated. The Conseco QC inspector said he would turn over his records to the Conseco foremen who in
- .
turn plans to send them to the home office unless given further direction.
(
.
l
'
,
.
.
..
.
.
..
_
.
.
.
a
>
.'.. y
.
.n
%
- p'l
..
.t
!s j DIVISION OF COMPLIRICE
'
MONTHLY REPORT FOR JANUARY 1972
,
.
.
.
.
.
Sacramento' Municipal Utility District (Rancho Seco)
.A
. management meeting was held at SMUD's Sacramento office on January 7 for the cArpose of discussing the results of the-inspection of December 13-17 (December Monthly Report).
The licensee stated that corrective action was being implemented on all of the identified deficiencies.
The licensee haa previously informed CO by phone that one ring of' the-shell of the No. 2 generator had been mistakenly
. fabricated with SA 516 hot rolled, rather than normalized plate.
The vendor.had' requested the licensee's approval to change the
.{v specification-requirement to permit the use of the unnormalized
. plate.. The licensee informed CO that the engineering tests and analysis indicate that this material substitution is accept-able-for-its intended service.
SMUD. stated that the State'of California Chief Code Inspector.has been fully informed concern-ing this matter, and that B&W's. Code. Inspection Agency
.(Hartford ~ Insurance) has confirmed that the vessel complies with ASME Code and;has signed off the Code Data Report.
'
CO is conducting an investigation of this matter, but has not yet come.[to a decision concerning the acceptability of the vessel.
.
g
.
v
,
.
.
.
.
~
s o'
-.
-. -,.,
,. -.
,.e e
,.
,