ML19261E925
| ML19261E925 | |
| Person / Time | |
|---|---|
| Site: | Crane  |
| Issue date: | 05/18/1970 |
| From: | Oller R, Thornburg H US ATOMIC ENERGY COMMISSION (AEC) |
| To: | |
| Shared Package | |
| ML19261E922 | List: |
| References | |
| B&W-70-02, B&W-70-2, NUDOCS 7910170980 | |
| Download: ML19261E925 (7) | |
Text
e U. S. ATOMIC ENERGY COMMISSION REGION III DIVISION OF COMPLIANCE Vendor Inspection Report PWR Steam Generators and Reactor Vessel Vendor:
Babcock & Wilcox Company Barberton, Ohio Report No:
B&W 70/2 Facility Inspected For:
Three Mile Island Unit 1 (50-289)
Dates of Inspe,ction*
April 27-29, 1970 kb Inspector:
R. E. Oller Metallurgical Engineer 5 70 Licensee Representative:
None for Metropolitan Edison
~
of Pennsylvania C C. hw Reviewed By:
H. D ornbur Senior Reactor Inspector 5-18-70 Proprietary Information:
Summary and Section II of report Licensee Application Requirements:
Three Mile Island 1. PSAR, Section 4, Table 4-2 Reactor Vessel and Steam Generators designed and constructed per ASME Code - Section III - 1965 Class A, plus addenda through Summer of 1967.
Summary As a result of Babcock & Wilcox's (B&W) management reorganization, Mr. J.
Lauer is now Project Manager for all B&W commercial nuclear steam supply system co_ponents.
Mr. J. Black is Project Manager for special nuclear vessel contracts.
(Section II.A.)
The record retrieval system at Barberton was unsatisfactory, and would not meet the requirements (24-hour retrieval) of ASME Section III, Appendix IX, IX-225(b) for record review by a third party inspector.
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,e
. Although this requirement was not contractually binding on the Three Mile Island (3 MI-1) project, B&W's lack of cooperation in providing records for Compliance review was unsatisfactory.
(Section II.B.)
Review of material test records f r the 3MI-l reactor vessel was completed. All pressure boundary component materials appear to have been manufactured, fabricated, heat treated, and inspected in accordance with ASME Section III.
(Section II.C.)
Material test records, belatedly provided for Compliance review, in regard to selected components of the No. I and 2 steam generators, were incomplete.
(Section II.D.l. and 2.)
Welding procedures and welder qualification records were found to have been recertified to ASME Section III and IX since the prior Compliance inspection in December 1969.
(Section II.D.3. )
Review of radiograph films of one 8" thick circle seam in the No. 1 steam generator showed the RT technique was minimal. The No. 80 pene-trameter image was barely visible.
(Section II.D.4.)
The final stress relief of welds in the No. 1 steam generator was verified as having been successfully completed.
(Section II.D.S.)
The N-1 Manufacturer's Data Report for the No. I steam generator was complete except for the Hartford Insurance inspector's signature due to his uncompleted review of records.
(Section II.D.6. )
Shop inspection of tube-to-tube sheet welding on the No. 2 ste.am generator revealed the welding was being done in clean room facilities. Completed welds appeared acceptable.
(Section II.D.7.)
B&W stated that a program of removing sensitized stainless steel nozzle safe ends from B&W nuclear vessels was initiated about a year ago.
On subsequent ressels, the safe ends are installed af ter final stress relief of the vessels.
(Section II.E.)
Lynchburg NGPD QA is assigning a resident QA representative at Mt. Vernon j
effective June 1, 1970.
(Section II.E.)
i DETAILS i
I.
Scope of Insoection l
On April 27-29, 1970, an announced vendor inspection was made of l
Babcock & Wilcox Company, Barberton, Ohio, by R. E. Oller, hetallurgical g
Engineer, Region III.
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. The purpose of the inspection was to complete the material record review of 3 MI-l reactor vessel found incomplete at the Mt. Vernon shop,l/ and to audit the fabrication and quality contro' activities of B&W in regard to the two steam generators for 3 MI-1.
The following persons were contacted during this inspection:
B&W - NCPD. Lynchburg R. Manoll - QA Engineer C. Thompson - Assistant QA Representative B&W - Nuclear Equipment Department, Barberton J. Lauer - NSS Components Project Manager F. Perrera - Nuclear Equipment Department QC Manager J. Gershom - QC Engineer R. Allison - Welding Engineer J. Marshall - Supervisor of Welding School G. Emmanuel - Senior Metallurgist E. Domaleski - Nuclear Components Specialist M. Hoover - Assistant Nuclear Components Specialist C. Jessen - Chief Inspectar F. Gear - QA Test Report Clerk II.
Results of Inspection A.
Current Barberton Management The C0 inspector was informed that with recent reorganization at Barberton, all B&R commercial nuclear steam supply system's components manufactured are now headed up by Mr. J. A. Lauer. All special vessel contracts, as for General Electric (GE) and Westinghouse, are headed up by Mr. J. Black.
B.
Record Retrieval On April 27, 1970, the C0 inspector gave the Barberton Works QC Engineer a list of material, welding, and inspection documents covering selected components of 3-MI Nos. I and 2 steam generators.
In addition, a list of material test records on reactor vessel components unavailable at the Mt. Vernon shop were given to the Assistant Fuclear Component Specialist.
These documents were selected by the C0 inspector as a representative sampling for code conformance evaluation.
The lists were given to B6W early to allow adequate time (24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br />) for their retrieval, as prescribed in Section III, Appendix IX; paragraph IX-225 (b ). Although Appendix IX is not a contractual requirement, cooperation on B&W's part in producing the records was unsatisfactory.
-1/ Report BER 70/1.
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. Welding records shown the CO inspector on the following day were the wrong records and considerable time was lost before the correct records were found. No attempt was made by B&W to locate the material test records until the af ternoon of April 29 (when the C0 inspector was due to leave). At this time, copies of the necessary records were retrieved for the C0 inspector (approximately 48 hours5.555556e-4 days <br />0.0133 hours <br />7.936508e-5 weeks <br />1.8264e-5 months <br /> af ter originally requested). It appeared to the inspector that an uncooperative attitude was expressed by B&R.
This situation was discussed with the Manager of Quality Control - Barberton during the exit interview, since the applicant's QA representative was nut present during the inspection.
C.
3 MI-l Reactor Vessel Material t st records for the reactor vessel which were found
. incomplete during the January 9, 1970 inspection at Mt. Vernon were reviewed and found in accordance with ASME Section III and ASIM Standards.
These records covered the upper head dome (Mk 24), lower head dome (Mk 17), and f.wo core flooding nozzles.
This review completes the Region III material review of the reactor vessel. The CO inspector considers the reactor vessel material to have been manufactured, fabricated, heat treated, and inspected in accordance with the code.
D.
Steam Generators No. 1 and 2 On April 27, records related to ti.2 following steam generator components were requested for review, for the purpose of code compliance evaluation. These vessels are being manufactured under ASME Section III, Class I, through 1967 Summer Addenda. The records retrieved after 48 hours5.555556e-4 days <br />0.0133 hours <br />7.936508e-5 weeks <br />1.8264e-5 months <br /> were partially incomplete as noted below:
1.
Incomolete Material Test Reports Test reports for the following components lacked B&W data for physical properties, and Charpy impact values and were not certified by B&W as meeting ASTM and ASME Section III requirements. Only supplier data for chemistry and ultrasonic tests (basis of purchase) was included, a.
Mk 3 - Nozzle Shell Course, No. 1 Steam Generator, b.
Mk 5 - Shell Course, No. 1 Steam Generator.
c.
Mk 6 - Shell Course, No. 2 Steam Generator.
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e
, 2.
Acceptable Material Test Reports Test reports for the following components were complete for supplier and B&W test data and B&W certification to applicable ASTM and ASME code requirements.
a.
Mk 8 - Upper Head, No. 1 Steam Generator, b.
Mk 50 - Lower Tube Sheet, No. 1 Steam Generator.
c.
15 Random Heats of Inconel Tubing, No. 1 Steam Generator.
d.
Mk 51 - Upper Tube Sheet, No. 2 Steam Generator.
e.
Mk 3 - Nozzle Shell Course, No. 2 Steam Generator.
f.
Mk 7 - Lower Head, No. 2 Steam Generator.
Tube sheet forgings were certified to ASTM A-508, Class 2; beads were certified to ASME SA-533, Grade B, Clacs 1; shell courses were certified to ASME SA-212, Grade B; and steam generator tubes were certified to ASME SA-163.
All plate and forging materials were certified to ASME Section III for acceptable Charpy impact values and other specified tests.
3.
Welding Records Welding procedures and welder qualification records, and weld control records (daily) related *o four majcr circle seams, one primary inlet nozzle to head, and tube-to-tube sheet welds in the No. I and No. 2 vessels were reviewed and found qualified in accordance witt ASME Section III and IX.
This represented improvement by B&W since the prior Compliance inspection in December 1969, when procedures and welders were found qualified only ta Navships 250-1500 Standards.
4 Radiograph Films Twelve out of 36 final radiograph films for the circle seam joining the Mk 8 head to the Mk 51 tubesheet for the com-pleted No, I steam generator were reviewed. All code required information was noted on the reader sheet, film envelope and films,
powever, in viewing the films made 1483 215
, with the cobalt 60 source, the C0 inspector noted that the No. 80 penetrameter outline and 2T hole were barely visible. This condition indicated the RT technique to be minimal to ASME code requirements. Although both B&W and the Hartford Insurance inspector signed off on the films as being acceptable, the C0 inspector questioned the reliability of these films to detect potential defects bordering on 2% of the 8" wall thickness.
This item was discussed in the exit interview.
5.
Final Stress Relief The CO inspector was informed that the procedure used for the final stress relief of the 3-MI No. 1 steam generator welds was similar to that used for two steam generators for Oconee Unit 1, and that the stress relief treatment was successful and met the requirements of ASME Section III.
In lieu of reviewing numerous rolls of strip chart temperature records, the CO inspector reviewed a B&W internal memorandum dated March 23, 1970, from the QA Engir.aering Department, which verified the acceptability of the final stress relief of the No. I steam generator we lds.
6.
Manufacturer's Data Report The ASME Section III Code required N-1 Manufacturer's Data Report for the completed No. I steam generator was reviewed by the CO inspector. All code required informa-tion was filled out and signed by B&W engineers.
The Hartford Insurance inspector had not yet signed the report.
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B&W stated that this was because he had not completed his review of records at the time of this C0 inspection.
7.
Shop Inspection A brief shop inspection was made of the in-process work on the No. 2 steam gaaerator. Work in process was the tube-to-tube shest welding using automatic gas shielded tungsten are with filler wire which produced a double bead fillet weld. Welding was being performed within a plastic enclosure under clean rcom conditions.
The C0 inspector observed welding being done and examined several welded tubes. All welds appeared to be of good quality.
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. E.
Miscellaneous Discussion B&W's position in regard to sensitized stainless nozzle safe ends was discussed with Mr. Lauer. He stated that B&W initiated a program about a year ago to remove all sensitized safe ends on B&R contract vessels, and that subsequent vessels are scheduled so the final stress relief of the ves,el is performed before the welding on of the austenitic safe ends.
In some cases Inconel safe ends were used.
Mr. Manoll, QA Engineer, NPGD-Lynchberg, was closely questioned by the CO inspector concerning the depth of his QA audit of B&W nuclear project work at the many shops.
The CO inspector stated that it appeared to him that Mr. Manoll's itinerary was rather extensive for one person to achieve a meaningful QA surveillance.
Mr. Manoll stated he was attempting to 1mprove conditions. Starting June 1,.1970, Mr. C. Thompson would be NPGD resident QA representative at Mt. Vernon and he was also attempting to get authority for a resident QA repre-sentative at Barberten.
Mr. Thompson is a qualified walder and also a,ualified SNT-TC-1A Level II technician for all NDT techniques.
F.
Exit Interview An exit interview was held with Mr. F. A. Perrera, Manager of QC-Barberton, Mr. Lauer, NSSS Project Manager, and Messrs. Manoll, Thompson and Hoover.
The C0 inspector clearly stated that he considered B&W's record retrieval system was less than desirable and would not meet current requirements of ASME Section III Appendix IX, paragraph IX-225 as it applies to an authorized inspector. B&W staced that the 3-MI contractual commitments did not include Appendix IX.
Also, that they were currently setting up a new filing system to alleviate delay in record retrieval.
The C0 inspector stated that copies of records provided at the last minute would require review and any deficiencies noted would be called to the applicant's attention for resolution.
The CO inspector stated thst review of RT films indicated the tecnnique was marginal to code requirements as the penetrameters were barely visible.
Mr. Perrera stated he would take action to correct this condition.
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