ML19225C867
| ML19225C867 | |
| Person / Time | |
|---|---|
| Site: | Arkansas Nuclear, Rancho Seco, Zion, Crane File:ZionSolutions icon.png |
| Issue date: | 09/30/1971 |
| From: | Oller R, Vetter W US ATOMIC ENERGY COMMISSION (AEC) |
| To: | |
| Shared Package | |
| ML19225C868 | List: |
| References | |
| FOIA-79-98 NUDOCS 7908030055 | |
| Download: ML19225C867 (11) | |
Text
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C. S. ATC'MIC ENERGY COWISSIC:;
DIVISION OF CC.".PLl.GCE REGION III CO Inspection Repert No. 99900034/71-04
Subject:
Babcock and '.Jilcex Cc pany License No.:
N/A Mt. Vernen, Indiana Priority: N/A P'rT Ve s s el s for:
CateFory: Vendor Cc==enwealth Edisen Cc=pany (Zion 2)
Arkansas Pouer and Light Cc prny (Arkansas Nuclear 1)
Metropolitan Edison Co pany (hree Mile Island 2)
Sacra ento Municipal Util:ty District (Rancho Seco)
Type of Licensee:
N/A Type of Inspection:
Rout.ae, announced Dates of Inspection:
August 24 - 27, 1971 Dates of Previous Inspection:
N/A Ms 7[JO[7/
Principal Inspector:
R. E. Oller
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(Date)
Acco=panying Inspectors:
None Other Acce=panying Personnel: None p
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Reviewed By:
'd. E. Vetter
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Proprietary Infor=arion:
Section I, Enforce =ent Action - Item A Manage =ent Interview - Item A.4 Section II, Details of Subjects Discussed in Section 1 - Ites 6
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SECTIOS Er:c ree cr-Act.on lic r.c on : C rPant e A.
Three Mile Island 2 Reacter Pressure Vessel At tne tire of the inspectica, a ccepleted recirculation nc::le-te-shell veld repair, gb" deep into a 12" weld, was being stress rel:eved on the basis of a 7b hcur held time at tercerature.
This appears to be inconsistent with ASME Section 111, ' -528 anc S-332 recu:re=ents that stress telle.:ng ti=es ecual one hcur ter each inch ci veld thickness.
An ASME Code Cc== ttee ruling vill be requested by the tanufacturer en Septemte: 20, 1971.
This matter has been caferred to CO:HQ fer action.
(Paragraph 6)
Licensee Action en Previously Identified Enforcement Matters: N/A Unresolve_d iters A.
Three wile Island ? Re.ctor Pressure "essel (Paragraph 6) 1.
Radicgraph fil=s net reviewed by the authorized cede inspector.
2.
Hydrostatic test records.
3.
Post-hydro SDT inspecti:n records.
B.
Rancho Seco Reactor "ressure Vessel (Paragraph 7) 1.
The supplier's material test report and a 3abcock and Wilcox (3&W) certified test report fer tva ctre f.' coding no::le forgings were ince plete.
The vanadius content and the I
i chemical check analysis required by the ASTM Specification A-508, Class 2, were not included. The supplier'a teletype centaining the =1s:tng test data and stated a corrected MIR will be sent to B&W was received during the inspection.
Mr. Walten of B&W stated a corrected d&W CTR vill be issued.
2.
Poorly blended weld buildup area en the outside of the lower s'eli course.
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9.ro :a' u test re: orcs.
.ost-nycre NDT inspection recorcs.
C.
Arkansas Suclear 1 (Paragraph B)
The caseline 'JT weld na'pping was not cc:pleted.
Status of Previously Recorted Unresolved items A.
The 21:n 2 reac:cr pressure vessel pcst-hydro NDT inspection re crds, including 24 baseline UT veld.ap sketches, vere exa-iaed.
No ite=s of ncnconfer=ance were observed.
B.
Arkansas Nuclear 1 reactor pressure vessel hydrostatic test records and post-hydro =anufacturing NDT inspection records were exa=ined.
No ite=a of nonconfor:ance were observed.
Both A rd B, above, are no lenger considered to be unresolved ite s.
Unusual Occurrences: N/A Peraces Centacted The following perscnnel were contacted during this inspection:
Babcock and W11ccx Cc=pany (B&W), Mt. Vernen, Indiana, J. A. Van Meter, Plant Manager, Cc=ercial Nuclear G. A. Walton, Manager of Cc==ercial Nuclear Quality Control S. N. Coston, Proj ect Manager, RPV Quality Centrol M. A. Ycung, Ultrasonic Testing Supervisor R. A. Fearing, Metallurgist, Q ality Control G. R. Strc=er, Resident QA Representative, Lynchburg NPGD Westh: house Electric Corn: ration (Westinehouse)
N-,.. Roose, Senior QA Engineer. Pittsburgh e
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_Seentel Cc cratien (3echtel)
R. K. Ecyt, Resident QC Representative Sacranento Municinal titility District (SMUD)
V.
?. McMahen, QA Director Metrcpolitan Edison Co= any cf Pennsylvania (Metro Ed.)
Sene Manage:ent Interv'.aw
- bree Mile Island 2 (3MI-2)
A anagenent interview vas held cc August 25, 1971, at the conclusion of the 2-2, R-1, and 3MI-2 TOV inspection. Metropolitan Edis:n Co pany, Cc=nenvealth Edison Company, and Arkansas Power and Light Ccepany were not in attendance.
The folleving 3&W personnel vare present:
J. A. Van Meter, Plant Manager, Cc=cercial Nuclear G. A. Waltcu, Miaager of Cc=cercial Nuclear QC S. N. Costen, t roject Manager, RPV QC R. A. Feari.ng, Metallur,1:t, QC G. R. Strener, Resident QA Representative, Lynchburg, NPGD The inspector discussed the ice s inspected *(including resolution of u. resolved ite=s from previous inspections of RPV's for other ic:ilities) as well as senconfor=ance and unresolved ite=2 with regard to the 3MI-2 RPV, as follevs:
A.
~he inspector said that the Zion 2 post-hydro NDT inspection records, including baseline UT =apping of the RPV velds, had been reviewed and that no ite=s of =cccenf ormance care e-iuntered.
E.
35W personnel were infor=ed that Arkansas Nuclear hy.
astatic test records and post-hydro =anufacturing NDT inspection records
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(excluding the ince:plete baseline UT apping of the RPV velds) were reviewed and that no apparent ite=s of nonconfer=ance were identified.
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T r.e inspecter ct-ented that tne F.1-2 radiograph fil: envelope, tentaining tne it1=s c: the weid joining the % 18 recirculatica ncz:le to tne shell, did not contain evidence that the films had been reviewed by the a"thorized cede inspector.
Mr. Walton said that elk weuld take actice te assure that all veld RT fil=s were reviewed by the Ccde inspector prior to ship =ent of the RPV.
D.
With regard to the 3MI-2 R?v, the inspector said that a 7b hour stress relief hol.: ti=e for the 7h" ceep repair in a nc:cle to ahell veld =ent 12 inches thick (previously stress relieved),
appeared te be in ncncenf er ance with the requirenents of ASE Section Ill, N-52S.nd % 532.
Mr. Walten told the inspector that the ELW code representative, Mr. John Harvey (Codes and Standards Engineering Depart =ent, Barberton plant) would secure an ASME Code Cc==ittee ruling relati.e to this =atter.
Mr. Walten requested that all aspects of this matter be treated as proprietary information until after the code ce==1ttee ruling was obtained.
Later, on Septe=ber 9, 1971, Mr. Wilton infor=ed the inspector by telephone that the ASME Cc==tt ee would =eet en Septe=ber 20, 1971, after which he would advise the inspector of the ruling.
A second =anage=ent interview was held on August 27, 1971, at the conclusion of the Rancho Seco RPV inspection.
The following personnel were present:
Babcock and Wilcez G. A. Walton, Manager of Co==ercial Nuclear QC S. N. Coston, Project Manager, RPV-QC
- 1. A. Fearing, Metallurgist, QC G. R.
Strc=er, Resident QA Representative, Lynchburg NPGD Sacra = ento Municioal Utility District V. P. McMahec, QA Director The inspector discussed sll ite=s inspected, with special c=phasis en acnconfor=ance and unresolved ite=s, as follows:
A.
The inspector said the caterial test report fcr the tuo core ficoding nc::le forgings, supplied by the Mational Ferge Cc=pany, was ince=plete due to the lack of vanadim centent and che=1 cal 9
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c n e t., anoc. sis in:orna:2cn vnic.c 2r required by ASD' Specification A-506, Cl as s 2.
Thc inspec:cr add - that the B&W Certified Tes Report :cr nese two forgings was aLsc incorrect due to the sa=e c=tssien of infor:ation.
The inspector said he had reviewed a B&W written request dared Augus: 20, 1971, for the =1ssinF tes:
data and a Natienal Fo:ge 2c=pany telegra= dated A tgust 26, 1971,
/ received during -he inspecticn) which provi d the =issing test data.
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Waiten told the inspecter that S&W would secure the ccrrected S E and c:rrect t..eir CTR pric to the ship =ent of the RF't.
E.
The inspector cc =ented that Cc:pliance =ay examine the hydro-static test recorcs and the post-hydre ET inspection records during a subsequent inspection.
C.
A veld buildup area en the cutside of the lower shell course plate obstrved during visual inspection of the vessel was found to be uneven and poorly blended into surrounding netal.
Mr. M.c.Vahon requested that B&W verify the quality of the repair.
Mr. Walton said the wall thickness in the area of the repair was verified by ultrasonic neasure=eits, bat tha: he vould recheck the repair records.
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w SECTION II Additionai Subie:ts Insrected. Sat Identified in Sectic: I. Where Se Found Deficiencies Or Unresolved Ite=s Vere 1.
General OC activities and verk An inspection was cade of docu entatiot.,"4R vessels for the Zicn 2, with regard to the nanufacture of the Arkansas Suclear 1, Three Mile Island 2, and Rancho Seco nuclear facilities. Hydrostatic test and shipnant dates for the vessels are:
Facility Hvdr static Shienent 6-20-71 7-9-71 Zion 2 Arkansas Nuclear.1 8-9-71 3-27-71*
Three Mile Island 2 10-13-71*
11-1-712 9-24-71*
10-19-71*
Rancho Seco
- Estinated Mr. W. Euskey, the Mt. Vernon plant QC Manager, is transferring to '.he Earberten Plant as a Technical Advisor to Mr. J. C. Quinn, Mr. J. A. Van Meter, Plant Manager, is Sarberton QA Manager.
now also functioning as Acting QC Manc tr.
2.
Three Mile Island 2 RPV
'or pressure containing plates, Fifteen caterial test reports a.
and nozzle forgings were exa=ined.
ring forgings, for the
.-8 subasse=bly work involving the Process records b.
installation velding of the recirculation and core flooding nozzles were exa=ir.ed.
Process records for the C-8 final vessel asse=bly work, c.
including removal of stainless safe ends f rom the core flooding nozzles prior to final stress relief, and final stress relief of the vessel, were exa=1ced.
(See Section 11, for special details of stress relief nonconfornance.)
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Fin.1 radiograph fil=s ei =ajet welc' were exa.nined as follows:
(1) Fourteen of 37 fi1=s for the closure head circle veld joining tne head done and torus ring.
(2) Thirteen of 40 fil=s for the circle weld joining the vessel bette= head done to the lover torus ring.
e.
Total acer.ulated hours of stress relief for the pressure conta;ning vessel cc=penents were exa=ined.
f.
Hydrostatic test plans were exa=ined, g.
Pcst-hydro =anuf acturing NDT inspection plans were exanined, ircluding baseline UT =apping of velds, h.
Shop inspection of the closure head was =ade.
The vesse.
shell was in the stress relief furnace duric<, the inspection.
5.
Rancho Seco RPV a.
Nine =aterial :-st reports for pressure containi=g plates, ring forgings.nd nozzle forgings were exa=iner'.
b.
Process records for the 3-8 subasse=bly work, involving installation s elding of the recirculation and core flooding naz:: es were era =ined.
c.
Final radiograph fil=s of ajor veld's were exa=ined as follows:
(1) Twelve of 42 fil=s for the circle veld joining the closure head flange to the dcue plate.
(2) Fourteen of 63 fil=s for the circle veld joining the vessel lower head torus ring to the lower shell course.
d.
Total accu =ulated hours of stress relief for 18 pressure containing c.npccents were exa=ined.
e.
Hydrost.Lic test plans were exa=ined.
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Shop inspection of ori cc=pleted on the closure head and g.
the vessel was made.
1 Details of Subjects Discus ed in Sectics Three Mile Island 2 (3MI-2) 6.
packages for a Mk 18 no:zle weld in IMI-2 were a.
The fil:
found to be without signature sign of f by the code inspector.
Mr. Walten told the inspectet that all of the fil=s vculd to ship-reviewed by the authorized cede inspector prict be
=ent of the RPV.
In respcase to questioning, Mr. Coston tald the inspecter vill ce perfnraed about October 23, 1971.
b.
the hydrostatic test The inspector said Ccepliance may review the hydrostatic test records and the po st hydro S*DT records.
IMI-2 RFV, the inspector During the" inspection of theStrocer as to the whereabouts of the 3MI-2 c.
questioned Mr.
the entire vessel was in the furnace vessel and was told that 650 F for the resolutien of stress relief time holding at inlet nozzle veld repair.
for the M1 13-2 recirculatic the inspector was cold During discussions with Mr. Walten, detected that a defect was found by ultrasonge testing (not to the final stress relief of the RF7.
by RI) subsequent required grinding a cavity 8 3/8 inches Removal of the defect icng by 3 inches vide by 71/2 inches deep '4hich was subse-quently veld repaired and identified as a major repair requiring This presented a problem. Walton explairsd, stress relief.
lie'.'e d if the entire 12 inch thick weld was stress re On that for 12 hours1.388889e-4 days <br />0.00333 hours <br />1.984127e-5 weeks <br />4.566e-6 months <br /> as required by ASME,Section III, Paragraphs N-528 and N-532, the material stress relief time and te=pera-h ture qualification for the A-1 and A-2 shell courses of t e Walton said he had requested guidance vessel veuld be exceeded.
Depar: ent)
Mr. P. M. Bruster (Research and Development fre the 3&W 3arberten Plant, en and J. C. Quinn, QA Director at e
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_9-tr... :.atter ;_nc was ins:.ructed to stress relieve the nozzle i hcurs rather than 12 wele repait at a holding ti=e of hcurs. He added that Mr. Bruster had inf or=ed hi: that B&W vculd seek an ASME Code Cc==1ttee ruling in view of the fact that Paragraphs 5-528 and S-53: of ASVE Sectics 111-1968 was not clear with-respect to stress relief cf weld repa:t depth cnly or the entire thiic.ess of the veld.
The inspector was later told by Mr. Walten, during a telephone conversatien en Septe=ber 9, 1}71, that Mr. J. Marvey (Codes and Standards Engineering Departnent, 35W, 3arberton) veuld request the ASME Code Cc==1ttee ruling on Septe=ber 20, 1971, and that he would infer: the inspecter of Mr. Harvey's findings.
7.
Rancho Seco a.
MTR An exa=1 nation mate:121 test repcrts, provided by a supplier, and a 35W Certifd-Iest Report covering two core flooding nc:tle forginga, spt.-ified to ASTM A-508, Class 2 =aterial, established that neither the supplier (The National Ferge Ca=pany) nor 35W had docu=ented a chemical check analysis as required by A-508. Class 2 specification. Moreover, the reports did not include inf ormation with respect to vanadiu=
content, also required with respect to A-508 =aterial.
However, the inspector exa=ined a B&W Discrepancy Form, dated August 20, 1971, which had been sent to the supplier requesting the missing test infor=ation just pr he inspection.
During the inspection. B&W received,ior to t a teletype listing both the che=ical ladle and che=ical check analysis (including the vanadium content) for the two uczzle forgings and advising B&W that a corrected ICR veuld follev. The inspector determined that both the ladle
'd check analysis en the teletype were in accordance s.n A-508, class 2.
- Rovever, the inspector co==ented that the existing 36W CTR incorrectly certified the two nor:le forgings as =eeting the material specification A-500, Class 2.
Mr. Walton told the inspector that a corrected 35W CTR vould issued.
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Repair A weld buildup area on the outside of tha lower shell course plate, observed during visual inspection of the vessel was,
- =spector co=:ented, uneven and poorly blenced into the the retal.
Mr. McManon requestec that 35b veri:; the cuality ei the r epair.
Mr. k* alton said he would check the recorcs to ;erify the quality of the repal:.
c.
Fedr: static Test and P:st-hvd:: SDT in response to questioning. Mr. Ccston told the1 inspector the f or Rancho Seco was scheduled to be perforned hydrostatic test on Septe=ber 24, 1971. The inspector cce=ented that Compliance
=ay review the hydrostatic test records and the post-hydro NDT records.
In response to questicaing, Mr. Coston told the inspector that the baseline UI weld tapping for Arkansas Nuclear 1 was not cc plete.
The inspector co==ented that Cc=pliance may review the test results.
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