ML19261E942
| ML19261E942 | |
| Person / Time | |
|---|---|
| Site: | Turkey Point, Crane  |
| Issue date: | 03/05/1970 |
| From: | Oller R, Thornburg H US ATOMIC ENERGY COMMISSION (AEC) |
| To: | |
| Shared Package | |
| ML19261E939 | List: |
| References | |
| B&W-70-01, B&W-70-1, NUDOCS 7910170995 | |
| Download: ML19261E942 (12) | |
Text
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U. S. ATOMIC ENERGY COMMISSION REGION III DIVISION OF COMPLIANCE Vendor Inspection Report PWR Vessels _
Vendor:
Babcock & Wilcox Company Mt. Vernon, Indiana Report No.:
B&W 70/1 Components Inspected For:
Turkey Point Unit 4 (50-251)
Three Mile Island Unit 1 (50-289)
DatesofInspepo-February 9-11, 1970 75 C.
Inspector:
R. E. Oller Metallurgical Enginee-3-2-70 Licensee Representative :
None for Florida Power & Light Company.
MPE. Associates for Metro Edison of g g i, >J + PennsyIvania.
Reviewed By:
'E D. Thornburg Senior Reactor Inspector 3-5-70 Proprietary Informstion:
Entire Report Licensee Application Requirements:
Turkey Point 4 - PSAR specifies ASME Section III,1965 Edition, and Supplements 'through December 1967.
Three Mile Island 1 - PSAR specifiesSection III, ASME Code, 1965, per CO:I.
SUMMARY
Final audit of Turkey Point 4 reactor vessel showed f abrication and NDT records were complete ar.d in accordance with ASME Code SectionIII requirements, except for the hydrostatic test not yet perfor aed.
Review of the proposed Babcock & Wilcox (B&W) procedure covering stud tensioning and hydrostatic testing showed it to be in accordance with code requirements. This vessel is scheduled for hydrostatic testing about February 20, 1970.
(Section II.A.)
1483 278 99101 "97S-
. The second audit of Three Mile Island Unit 1 reactor vessel still showed poor traceability of B&W material records.
The complete MTR's for some vessel components were still not available. The applicant's QC representative (MTR Associates) were advised that records were insufficient for the CO inspector to make a meaning-ful evaluation of code conformance at this time.
Further informa-tion was obtained in regard to the function of the current Mt.
Vernon QC Department. This vessel is scheduled for hydrostatic testing in the latter half of June 1970.
(Section II.B.)
DETAILS I.
Scope of Inspect'_o2 An announced vendor inspection was made of B&W, Mt. Vernon, Indiana, on Fabruary 9-11, 1970, by R. E. Oller, Metallurgical Engineer, Region III, in regard to the fabrication and QC activities covering reactor vessels for Turkey Point Unit 4 (TP-4), and Three Mile Island Unit 1 (3MI-1).1/
The following persons were contacted during this inspection:
W. Owens, Resident QC Engineer, Westinghouse W. F. Sanders, Assistant QC Manager, B&R, Mt. Vernon R. L. Rogers, Section Head, QC Engineering, B&W, Mt. Vernon-G. A. Walton, Section Head, NDT, B&R, Mt. Vernon W. R. Schmidt, MRP Associates (QC Representative for Metro Edison of Pennsylvania)
T. E. McSpa d de n, MRP Associates (QC Representative for Metro Edison of Pennsylvania)
II.
Results of Insoection A.
Turkev Point 4 1.
Reactor Vessel Status Shop inspection showed the vessel fabrication was complete including final stress relief of vessel and closure head. Vessel cladding repairs were nearly complete.
1/ See C0 Report Nos. 251/69-5 and 3&W 69/6 for previous inspections of IP-4 and 3MI-1, respectively.
1483 279
3 2.
Documents Audited a.
General The balance of records on work since the May 20-21, 1969 inspection were reviewed and consistad of contract variations, weld repair cycles, final stress relief, radiograph films, and the proposed Hydrostatic Test Procedure.
b.
Contract variations Twenty-five B&W in-process contract variations (CV) covering dimensional and machining variations were reviewed. All were within code allowable correction.
Two CV's involved upper and lower head dome mis-matches. An engineering evaluation was, made hy B&W in both cases and the mismatches corrected by weld metal buildup and tapering to bring them in accordance with #7ME Code Paragraph N-525
" Alignment Toleran'.e."
c.
Weld Repair Cveles Review was completed on weld repair cycles listed in C0 Report No. 251/69-5. Welds completed and RT cleared since the previous inspection were:
(1) Nozzle Course to Middle Shell Course.
(2) Middle Shell Course to Lower Shell Cource.
(3) Lower Shell Course to Lower Head Ring.
(4) Lower Head Ring to Loser Head Dome.
Repair cycles were minimal for all welds, d.
Final Stress Relief Review of stress relief instruction sheet and multipoint temperature strip charts verified that the vessel had been stress relieved for nine hours at 1100-1150 F in accordance with Section III requirements.
Temperatures were monitored by use of 24 selectively placed thermocouples.
1L83 280
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4 e.
Radiography Twenty double RT films out of a total of 60 made of the final closure circle weld were reviewed.
Sensitivity and contrast were good which was indicative of acceptable RT technique. No unacceptable defects were noted, f.
Hydrostacic Test Procedure Review of the proposed B&W Hydrostatic Test Procedure, approved by Westinghouse, showed it to be in accordance with Section III.
It specified the necessary conditions e.g., vessel metal 3
temperature of NDTT + 60 or 1100F; official test pressure of 3107 psig; demineralized water; limits of 1 ppm for combined fluoride and chloride content; total dissolved solf ds of 10 ppm; and conductivity of 20 micromohs. Stud tensioning was specified as a three pass sequence.
B&R stated that their S-178 Standard would supplement the procedure but they were unable to determine if the S-178 Standard had been revised co correct the provision for inspection at specified hydro pressure used on previous reactor vessel.
The C0 inspector advised them that this inspection pressure level, if included, would be contrary to Section III requirements.
Mr. Owens stated that to his knowledge, TP-4 vessel would be hydrostatic tested at Mt. Vernon on about February 20, 1970.
No formal exit interview was held on TP-4 vessel inspection as no items of code nonconformance were observed and all questions relevent to the inspec-tion were resolved during the inspection.
B.
Three Mile Island 1 1.
Reactor Vessel Stacus Shop inspection shewed that the vessel is essentially complete with all welds x-ray clerred except for final stress relief and final machining of the closure flange stud holes.
The only stainless steel safe ends are 0h
. two safety injection nozzles which will be welded on the nozzles af ter final stress relief of the vessel.
Balance of work on the closure head involves final machining of CRD penet' ations and installation of CRD mechanism housing tubes. B&W estimated the hydrostatic test will take place in the latter part of June 1970.
2.
Documents Audited a.
Material Test Reports (MTR's)
On February 10, 1970, during this second inspection of 3MI-1, the inspector again attempted to complete the review of MTR's for vessel material which wereincompleteorunavglableduringtheNovember 12-14, 1969 inspection._
Again the records,were found to be incomplete and not readily traceable.
The applicant's QC representative (MPR Associates) was advised that records were considered inadequate to provide the basis for a meaningful evaluation of code conformance in connection with the fabrica-tion of the vessel in question.
On February ll,1970, a meeting was held with Messrs. Sanders, Rogers, and Walton of B&R, and Schmidt and McSpadden of MPR to discuss record availability and traceability for the 3MI-1 reactor pressure vessel and other nuclear steam supply systems supplied by B&W and in fabrication at Mt.
Vernon. The QC program is discussed later in this report. At this meeting, B&R produced complete certified MTR's for all pressure containing vessel components except the following components:
(1) Upper Head. Dome - Mk 24.
(2) Lower head Dome - Mk 6.
(3) Two Core Flooding Nozzles - Mk 17.
MTR's for these three items were again incomplete as to B&W test reports for physical properties and Charpy tes t values. MPR Associates wers again advised that CO review of completed records will be necescary to evaluate vessel fabrication code con-formance.
1483 282
6-b.
Contract Variations Discussion with Mt. Vernon QC engineering personnel reveeled that prior to December 5,1969, all CV's on 3MI-l were written at Barberton to NPGD-Lynchburg and were not currently available at Mt. Vernon for review.
Since then, Mt. V0rnon had written four CV's to NPGD for applicant approval.
B&R stated that most of the CV's covered dimensional machining involved.
The variations and no mismatches s:
o inspector inquired in this matter further because of the lack of available documentation. Also, past experience has indicated that misalignment exceeding code tolerance can ta expected on head domes formed at Barberton. Afte6 some further search, Mr. Sanders produced a Barberton memorandua which stated that 3MI-1 closure head dome had two areas of out-of-code tolerance wb E:h required weld buildup, tapering, and engineering evaluation to bring them within code requirements.
Mr. Sanders stated that a production change had been aade at Barberton in February 1969, to include a final cold resizing of the hecd domes to alleviate dome mismatches.
The 3MI-1 head dome was formed prior to that date. The CD inspector stated that C0 review of all CV's on 3MI-l may be necessary to evaluate code conformance of vessel fabrication.
c.
Weld Repair Cveles Weld repair cycles on major weld seams were cis-cussed.
Mr. Rogers showed the inspector a Monthly Trend Report which Mt. Vernon makes to upper B&R management, oased on the Liaec RT records for longitudinal, circle, and nozzle welds. This record is an internal B&W information document for the purpose of rating the different types af welds.
It was started in November 1969. Due to insufficient time, the CO inspector did not perform an in-depth review of this document, d.
Radiography The C0 inspector reviewed the final RT films for the final vessel circle scam between the nozzle shell course (Mk 87) to middle course (Mk A-1).
Fourteen 1483 283
. of 66 double films were read. All films had good sensitivity and contrast indicative of acceptable RT technique. No unacceptable defects were noted, e.
Mt. Vernon QC Engineering The function of QC Engineering for organization and responsibilities (see Exhibits 2 and 3) was discussed in regard to B&W total contract nuclear steam supply system components manufactured at Mt. Vernon. This section, which has been developed within the last year, consists of 10 graduate engineers plus several technicians.
It functions as a QA support group to the Manufacturing and NDT Divisions. No one engineer is assigned to a particular applicant's work. Each engineer is responsible for a specific craponent work as reactor vessel, piping, pressurizers, etc., at Mt. Vernon and Madison.
Mr. R. L. Rogers reports directly to Mr. Sanders, Assistant QC Manager independent of manufacturing. The C0 inspector learned that Mr. Rogers is also responsible for assisting outside audit of Mt. Vernon Works.
Mr.
Sanders stated the CO inspector would have a clear channel to Mr. Rogers, who would assign specific engineers as required. This should improve the results of future CO audits of B&R total contracts.
f.
Nondestructive Testing Personnel A discussion was held with G. A. Walton, NDT Section Head, in regard to current Mt. Vernon NDT personnel training and qualifications.
(See Exhibit 1 for NDT organization.) All personnel are qualified in accordance with SNT-TC-1A Standard. Personnel attend formal courses given by NDT equipment manufacturers and are given in-plant training with progressive upgrading by examination and performance.
The following is a compilacion of qualified NDT personnel at Mt. Vernon:
(1) Radiograohv Level III - 1 l4h3 2h4 Level II - 4 Level I - 13
a
. (2) Ultrasonics Level III - 1 Level II - 17 Level I - 9 (3 ) Magnetic Particle, Dye Penetrant Level III - 1 Level II - 52 Level 1 - 17 In addition, there are numerous NDT, Class C general i vipers.
Mr. Buskey, QC Manager, has a Level III classification in all types of NDT.
C.
Exit Interview No formal exit interview was held. Audit of TP-4 was held in close cooperation with Mr. Owens, as previously noted,. and the meeting with B&W QC personnel accounted for the 3MI-l vessel audit.
Attachme~nts :
Exhibits 1 thru 3 1483 285
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