ML19276H315
| ML19276H315 | |
| Person / Time | |
|---|---|
| Site: | Crane  |
| Issue date: | 12/10/1969 |
| From: | Cantrell F, Moseley N, Whitesell D US ATOMIC ENERGY COMMISSION (AEC) |
| To: | |
| Shared Package | |
| ML19276H275 | List: |
| References | |
| 50-289-69-05, 50-289-69-5, NUDOCS 7910160656 | |
| Download: ML19276H315 (11) | |
Text
{{#Wiki_filter: ) "$,Ys5 9 U. S. ATOMIC EN"RGY COS!ISSION REGION I DIVISION OF COMPLIANCE Report of Inspection .) CO Report No. 289/69-5 Licensee: Metropolitan Edison Company (Three Mile Island Unit 1) License No. CPPR-40 Category A Date of Inspection: November 3-5, 1969 Date of Previous Inspec ton: July 23-25, 1969 Ingpected By: / e>I. /2/c/I(9 D. E. Whitesell, Reactor Inspector'(Construction) Date Wn }\\ h J.2 hlh 9 9 F. S. Cgntrell, "Jr., Rcp';;,6r, Inspector (Principal Inspector) Date /1//(/[ / [,4 // Reviewed By: N. C. Moseley,'Se'nior React f Inspector batd Proprietary Information: None
SUMMARY
Approximately 340 feet of 21/2" and 3" ASTM A-312 stainless steel pipe purchased for the radwaste system was rejected for suspected incomplete fusion and use of filler metal. Met-Ed has sent samples to three independent laboratories for evalua-tion (paragraph III, 4. a.(5)). A strike by the bvilermakers has stopped all work on the containment liner (paragraph III. 7.). Concrete placement cannot proceed until known defects in the liner are repaired. The paper trail for the completed work was reviewed. The pre-stressed concrete QA procedures and the mill certificates for on site pre-stressing equipment were reviewed. The QC procedure for " Pipe Welding Control" was reviewed and found adequate. An in-spection of the velding shop showed that, the procedure was being implemented. gor of six 4" stainless steel valves received from Alloyco for the radwaste system cc.ained a crack in the machined weld prep area (paragraph III. 6. c. ). All six valves were rejected pending further evaluation. 1,g y.. 98 7910160 f
-Vt'h i 9 ' 1. SCOPE A routine, announced inspection was made to the site of the pressurized water reactor being built on Three Mile Island, near Middletown, Pa. The purpose of the inspection was to audit records, to observe the progress of work, and to transfer the primary inspection responsibility to F. S. Cantrell. N. C. Moseley, Senior Reactor Inspector, Region I accompanied the inspectors on November 3 and 4, 1969 to review the organization and construction progress. . II. PERSONS CONTACTED 1. Met-Ed Mr. Gene Hreczuch, Resident QA Engineer Mr. Vern Stuebner, Resident Engineer, Unit 1 Mr. Will Shepard, Unit 2 Mr. E. Allen, NDT and '* ;1 ding, QA Engineer Mr. G. Kopp, Electrical, QA Engineer Mr. Bud Avers, QA Manager (GPU) Mr. Neil Goodenough, NDT-{Telding QA Engineer (GPU) 2. UE&C Mr. Milo Prisuta, Site QC Manager Mr. H. A. liardy, Asst. QC Supervisor Mr. K. J. Branch, Liaison Engineer, QC Mr. Paul Dailey, Civil Engineer, QC Mr. Lon Haley, Instrument Engineer, QC Mr. Dave Lambert, Mechanical Engineer,. Receiving, QC Mr. Tom Diarmit, Structural Engineer, QC Mr. George Kenny, Welding, Piping Engineer, QC 3. PTL Mr. B. D. Bryant, Field Supervisor, QC III. DETAILS 1. Pre-stressed Concrete a. Inland-Ryerson QC Manual was reviewed. The manual provides for the re-ceiving, handling and storage of the tendon hardware and stipulates the materials of the various components. The records and documentation re-quirements, relative to the stressing operations, are specified. No deviations from the PSAR commitments were noted. (4705.04) (1) In addition to the QC manual, Ryerson's " Installation and Tensioning Instruction Manual' was reviewed. This provides detailed instruction for unpacking and installing the tendons and the required equipment and duties of the tensioning crews. { 4 l ') lgg
- 2. ~2. [
. b. A review of the material records was made. The only hardware received to date are the base plates and grease. (4705.05 a.1) (1) The base plate mill certificates show the plates to be in accordance with ASTM A36, hot rolled, 3 3/4" thick fine grain with chemical and physical properties. (2) The chemical analysis for the grease showed the chloride to be less than 2 ppa, nitrates less than 1 ppm and sulfide "not detectable". The placement of the bearing plates, trumpets, ducts and spiral reinforce-c. zent under the plates and around the trumpets were noted to be in accord-ance with the drawings and details. (4705.06 a.1 & 6) (1) After the concrete has been poured and the forms stripped, all exposed surfaces of the base plate are cleaned and grease applied to prevent oxidation. (4705.06 b.) 2. Containment Liner a. The boilermakers have been out on strike since August 1, 1969, and CB&I work has been stopped since August 16', 1969. Copies of C3&I's nondestruc-O tive procedures were reviewed previously*,except for qualifications.- (1) The inspector was informed by Mr. Dave Lambert, UE&C Quality Control, that he had reviewed the qualifications of these procedures and the qualification certifications of CB&I's NDT personnel. These records are on site in CB&I's field office. (4805.04 a.3 & 4) b. The "as-built" drawing of the containment liner is being compiled on a stretch-out drawing that identifies each plate, heat number, weld number, welder and shows the location of radiographs made, LP examination, visual examinations, leak tests, etc. (4805.04 b.1, 2, 5 & c.6) (1) Any defect that is found is mapped to show the location and kind of defect. The defects are then ground out, repaired, and re-inspected for acceptance. (4805.04 b.6; f.2 & f.6) Plates are shipped with their number and heat number stamped on them. The c. mill certificates are also checked to verify the numbers and materials. (4805.04 g.i & 5405.04 d.2) (1) The purchase order for some of the plates required them to be ultrasonically tested before shipment and the test results are sent en the site with the mill certificates. (4805.04 e.5 & 5405.04 b.3)
- C0 Report No. 289/69-3 f419 200
q, sz L 4-G d. The mill certificates were reviewed and the plate numbers, heat numbers, ASTM standards, chemical and physical properties were noted together with required grain refinement and notch toughness test results. (5405.05 a.2) The ultrasonic test results relative to the plate materials was reviewed. e. The UT records note ;ne equipment used, transducer size and frequency, the melt and slab numbcrs, specification number, inspector's name and date. No deficiencies were noted. (4805.05 a.3 & 5405.04 b.3) f. A review was made of CB&I's records and UELC's surveillance reports relative to soap film tests, air pressure tests, halogen leak tests of cover channel welds. Records of the liquid penetrant and leak tests of the welds of 14" stainless steel lines to the containment sump liner, and the welds of the cover channel were also reviewed. Repair of defects and reinspection and test for acceptance were noted. (5405.04 f.5) g. Logs for the installation of 16 strain gages, installed to date, were re-viewed. These icgs note the type of ga,ge, location, date installed, balance and resistance, moisture protection, etc. (5405.04 f.3) 3. Bleed Tanks (PDM) a. The PDM file was audited relative to the work on the three bleed tanks, fabricated on site to Section III, Class C of the ASME Code. (1) The welders' performance qualification records were reviewed, and five were found to be in accordance with the requirements of Section IX of the ASME codes. Two are still unacceptable for the same reasons re-ported previously*. This item will be followed on the next visit. (4805.05 a.1) (2) The "as-built" drawings are stretch-out drawings and sections of the shell and heads. The heat number of the plate, weld number and loca-tions of the radiographs are noted on these-drawings. (4805.04 b.1 & e.6, & 5405.05 a.3) (3) The daily inspection reports covering from 1/27/69 through 4/18/69 were audited. The reports include the inspection of the welds, grind-ing welds, and dye penetrant examinations. (4805.04 e.2 and c.4, and 5405.06 a.3) (a) Deficiency reports were audited. These reports note the drawing number, purchase order number, and the serial number of the tanks. The deficiency is described and repairs accomplished by dressing out the defect, rewelding and re-radiographing. The deficiency reports are duly signed off, after repairs are accepted. G
- C0 Report (4805.04 f.2.
f.6 and 4805.05 a.41 (540;.04 f.5 and 5405.06 a.3T 289/69-2 4 '417 201
. (4) The reports and results of the LP examination of welds in tanks lA, IB, and 1C were reviewed. The reports noted the cleaner, penetrant and developer used and the tem erature range; no deficiencies were noted. (4805.05 a.3 6 5405.04 f.5) (a) The UT reports for checking the material thickness after grinding out are strikes, weld grinding, etc., were reviewed. These UT examinations were also made for verification of radiograph inter-pretations along selected weld joints. The report listed the equipment used, transducer size and frequency, transducer angle, couplant, operator's name and qualified to level II SNT-TC-1A. (4805.04 c.5, 4805.05 a.3, 5405.04 f.5 and 5405.06 a.3) (5) The material certificates for the plate and electrode materials were ~ reviewed. (a) The plate material was noted to conform to ASTM 240 type 304; the heat numbers, chemical and physical properties were noted. (b) The material certification for the 308-16, 309-16 and 308 bare filler wire, noted the heat number, lot number and the che=ical analysis of the filler metals. 9 No deficiencies were noted in any of the material certifications. (c) (4805.04 g.1, 5405.04 b.1, b.2, d.2, 5405.05 a.1 & a. 2) (6) It was observed that these tanks are protected from the weather by plywood covers. 4. Pipine (UE&C) UE&C's Quality Control Procedure #QC-8 for " Pipe Welding Control" was re-a. viewed. This procedure references 19 additional QC procedures, and the UE&C " Welding Specification Nuclear Plant Piping." The procedures define the responsibilities and duties of the A&E's Site Engineer, UE&C's Welding Supervisor, UEEC's Quality Control Engineer (Welding and Radiography), The procedures Quality Control Inspectors, and the UE&C's Piping Supervisor. provide for the following: All welding, including repair welding, to be performed by qualified (1) welders using qualified procedures in accordance with Section IX of the ASME B&PV codes. (4805.04 a.1 & a.2) (2) All NDT operators and interpreters are to be previously qualified to the applicable SNT-TC-1A section. (4805.04 2.4) O 1419 202
1 g [- 6-Numbered spool sheets are correlated to the work by identifying the (3) system, the system drawing number, the section number, the weld map number, pipe schedule, weld procedures, required nondestructive tests, weld number, welder's number, base materials' heat numbers, and the A weld joint history record is prepared for each weld joint. date. This record notes all the information contained on the spool sheets with the addition of the sign-off of the various QC and NDT require-A copy of the front and back of this hist.ory record is enclosed ments. as Attachment No. 1 and No. 2. (4805.04 b.1 thru f.6) Receiving inspection of pipe and 5ittings for conformance to the required (4) material pedigree and standards, as assigned to the Field Supervisor This effort is stipulated to conform Quality Control Jr his designees. with the following: QC 2 " Receiving and Inspection" (4805.04 g.1) a. b. QC 3 " Storage Control" (4805.04 g.2 & 5405.04 d.2) QC 17 " Control of Nonconforming Materials" (5405.04 c.5) c. that The inspector was informed by Mr. T. Hrec uch, QA Engineer, Met-Ed, (5) approximately 200 feet of 21/2 inch, and 140 feet of 3 inch, Schedule 9 40, 304 stair.less steel pipe specified to be ASnt 312, fusion welded, The receiving inspection had alerted the had been received at the site. QC Supervisor that part of the pipe was suspected of having filler metal added and part appeared to have a lack of fusion at the center of the weld. As a result, the entire shipment of pipe has been quarantined, and sampics have been sent to three independent laboratories for analy-The lack of fusion for approximately 1/4 the wall thickness in sis. ASn! 312 pipe could cause grave. concern, because it not only reduces the wall thickness along this weld, but also creates a stress raiser. ASTM A312 does not require any nondestructive test other than hydro-This static pressure to produce a stress of 507. of the minimum yield. item will be closely followed by Compliance. All of the suspected pipe has been ident ified by clearly marking (a) each section "Not to Be Used for Nuclear Service or Seismic I or II". The pipe has been quarantined by placing it in the " Temporary Piping" storage bin, and will be replaced with ASri A376 pipe. To prevent a re-occurrence of this condition, the piping specifica-(b) tions are being revised to eliminate all ASni A312 references and specifying ASTM A376 for seamless pipe, and ASTM A358 for welded pipe. O I419 203,-
t U[ . The qualifications of UE&C's welding procedures and welders' performances were b. reported previously. (C0 Report No. 289/69-4; 7/23-25/69) the welding procedures, The welding shop was visited where it was observed that weld rod control, and QC-8, " Pipe Welding Control" were being followed. c. (4805.06 a.1) or interpass temperature is required, the temperature is con-(1) When preheat, Examination of the purchase trolled by "Tempilstiks" indicating crayons. orders and QC records show that the Tempilstiks are certified by the manu-(4805.05 a.3) facturer to be lead free, sulfur free and halogen free. the weld history records are affixed to each weld It was observed that (2) until the final weld has been radiographed and accepted, af ter
- joint, which the weld number and the welder's identification mark arc stamped on In this manner, the inspection and test status of each weld the pipe.
is maintained, from the start of the weld, through the repair of any (4805.05 a.4 & 4805.06 joint defects, to the final radiographs and acceptance.
- a. 3)
It was observed that when the shipping container is opened, all coated (3) electrodes are placed in holding ovens located in a controlled storage G area in one corner of the shop. Each type of electrode, e.g.; stainless Electrodes are issued in steel and carbon steel, have separate ovens. There small quantities by the attendant in charge of the storage area. No electrodes are smaller individual holding ovens in the weld areas. (4805.06 a.5) other than the ones being used were observed in the area. 5. Records All the mill certificates and NDT reports and results mentioned above are main-tained in steel file cabinets located inside a fireproof vault. Any QC records a. maintained in field offices are maintained in steel filing cabinets that are encased in approximately 3/4" asbestos cement board that has been tested in the field to have a fire rating in excess of 2 hours, In addition to the normal field generated QA-QC documents, records are also b. the site relative to the evaluation of the QC programs available for review at Trip reports are also available relative to the sur-of some of the vendors. veillance and audits of vendors' inspections, e.g. ; Chapman Valve Division of Crane Co. 6. Implementation of procedures j 204 Bud Avers, QA Manager, GPU, and Mr. Milo The inspectors were informed by Mr. that a school was being held for all of a. Prisuta, Field Supervisor-QC, UE&C, the construction supervisors and craft foreren, to acquaint each of them with O the procedures and instructions applicable to their specific field of respon-The supervisors and foremen are then held responsible to enforce in their ex,ecution of the work. sibilities. strict adherence to these pracedures by the craft
ny b ,. During this visit six 4" stainless steel gate valves were received from A11oyco b. for use in the radwaste system. Upon receipt inspection, a crack was found in the machined weld prep area, and also evidence of grinding dust indicating un-satisfactory cleaning. The Supc. isor-Quality Control ordered all the valves in the shipment to be tagged as rejuted and left in their shipping crates until a vendor's representative could be brought to the site relative to their re-placement. The inspector was informed by Mr. Hreczuch, Met Ed, QA Engineer, that UELC has been instructed to develop procedures for proof testing of hoisting equipment, c. including slings, yokes, chokers, etc. While this is primarily a safety item, it will reduce the probability of damage to critical equipment, through mis-andling or dropping, by reasons of the use of inadequate or substandard equip-ment. It was observed that rotating equipment that is now stored in place has a 1c3 d. attached showing the date that the equipment had been rotated. The frequency of such rotation is in accordance with the manufacturer's reconmendations. 7. Concrete ancrete work on containment has reached a standstill due to a strike by the boiler-rakers. Defects in the containment liner must be repaired before any more concrete is placed for the shell of containment. The batch plant was operating to provide for Unit No. 2. concrete for the flumes from the cooling tower, and for the mud mat The inspector inspected concrete for the above two placements, Prenlacement OC Insocction (4605.06 a.3) s. An inspection form is used to show that the site has been properly prepared Attachments 3, 4 and 5 show the form used. (The for placement of concrete. same form is used for both Units 1 & 2.) The forms were filled out and signed by the UE&C crafts and the Job Engineer. A separate but similar form was filled out and signed by PTL to authorize the batch plant to manufacture concrete for that location. The inspector checked the location prior to placement of any the area was clean and free of concrete and noted that the forms were secure, water, and was in proper condition to receive concrete. b. Slumn, Strength, and Entrainment Test (4605.06 a.5) (1) Slump tests were made on the contents of each truck at the site. The pro-cedure (QC-1) requires a minimum of one test per 50 yds. of concrete placed. A set of ten cylinders were cast from the second bucket of the first truck (2) unloaded. The procedure requires that the cylinders be made and cured per 9 ASTM C31.66 for each 100 ya&d.; cf concrete placed. The procedure requires all cylinders be prepared from the middle 807. of one truck load of concrete. The field practice is to make a set of cylinders for each 50 yards of con-crate placed. 1419 205
V31 - The ten cylinders cast included two extra cylinders required because of the The procedure requires these two anticipated overnight low temperature. cylinders to be field cured at the site of the pour when there is a possi-0 0 bility of air temperatures below 40 F or above 90 F. (3) A check of air entrainment was made on the first four truckloads delivered The first two trucks were rejected by the PTL inspector because to the site. of low air entrainment - <,47.. ( 3. 67, & 3. 8*/). An addi.tional gage was ob-tained and the third truck was accepted based on an average of the two gages (3.9 and 4.17.). An adjustment of the air entraining agent and water content The air entrainment was was made to the fourth truckload at the batch plant. checked and found satisfactory before the truck was unloaded. The procedure least once for each 50 yards of requires checking the air entrainment at concrete placed. c. Proper Placement (4605.06 a.6) During 'Tremies were set up on ~ 6 feet centers prior,to the start of placement. the placement of the first load, the UE&C inspector noted that excessive horizon-tal movement would be required to reach one corner of the form and he had another The crew size was adequate to handle the place-tremic set up for that corner. 9 ment of concrete, set up another tremie and operate the two vibrators used for compacting the concrete. The work observed was satisfactory. d. Deliverv of Proper Mix (4605.06 b.5) The inspector observed that concrete identified as 3000 psi concrete was being The PTL in-the batch plant and delivered to the site as required. prepared at spectors were concerned and were checking times and mixing speeds to be sure that overmixed concrete was not used as a result of the delay caused by the batches rejected because of low air entrainment. e. Quality Control Insucctions (4605.06 b.8) the site UE&C QA and Pittsburgh Testing Laboratory QC personnel were observed at of the pour. One UELC QA Engineer was at the site auditing the testing and place-PTL had three inspectors and a supervisor following the test-ment of concrete. Af ter the initial problem of low air entrainment, ing and placement of concrete. the placement proceeded in a satisfactory manner. f. Implementation of'OA Procram UE&C is the construction contractor and is constructing the concrete portion af Quality control surveillance of the manufacture and placement of the plant. concrete is performed by an independent testing organization, Pittsburgh Testing G Laboratory (PTL). !419 206
, A PTL inspector observes the preparation of cadweld splices, and must approveu the finished splice. Selected splices ar. The recults are re- .d on the site. the testing laboratory that has been erceThese reports, together with the mill certi-ported to UE&C's QA organi: ation.ficates and receiving inspection reports This file is available for inspection by the owner and his QA are kept by UEEC. organization. PTL has one or more inspectors at the concrete batch plant. The principal in-the proper materials spector is responsible for checking that PTL checks the moisture content of the proportions required by the batch design. aggregate and is solely mix. PTL inspectors at the pour site have an inspection check sheet that must be com This inspection in-pleted prior to approving the placement of any concrete. ur base, and the loca-h , cludes verification of the condition of the forms, t e poThe PTL inspector performs slump tion, size, and splicing of reinforcing steel. the truck revolution the batch temperature, tests, checks the air entrainment, At least one other counter, and prepares test cylinders as required by procedure. i t inspector observes the concrete placing operation for compliance with requ re 9 of the procedure and good practice. or the UELC QC auditor can The PTL inspector, the UE&C concrete superintendent, A record is main-reject a load of concrete for failure to meet specifications. Records of the above test tained of the disposition of each load of concrete. l reports, inspection and audits are maintained by the UE&C QA group, a able for inspection. Quality assurance audits of the concrete manufacturer and placement a quality control surveillance are made by the Architect-Enginee Associates (GA). PTL and GA are made by the owner, Met-Ed, and MPR Associates, for the owner. A weekly quality assurance meeting is held at the site to review p all areas, including concrete. A monthly meeting is held at the home office of required on specific problems. UE&C to review overall progress. A review of records and discussions with personnel at the site show that th This organization exceeds the re-QA-QC organization is functioning as described. d quirements for QA-QC outlined in the PSAR, and meets the intent of the pr 10 CFR 50, published April 17, 1969. QA Criteria in Appendix B, O lb'li 207 O
.t g[U 8. .Cqd"ri s Certificates for cadwelding powder and sleeves were reviewed. The powder was certified to meet "cadweld spccification." Analyses were not included with the certificate. The sleeve analyses vece satisfactory. (Min. tensile strength 70,000 psi.) Re-The inspector discussed the problem with cadweld powder found at Oconee*. cords did not indicate any of the defective batches at TMI.. Mr. Dave Lambert stated that during the summer of 1968, one batch of powder did not appear to be The firing properly and the batch was discarded after two splices tested low. powder is stored in a low humidity trriler. A minimum amount was noted to be on hand. IV. EXIT INTERVIEW An exit interview was held with Mr. Gene Hreczuch, Site QA Engineer, Met-Ed, l. Mr. Milo Prisuta, QA Manager, UE&C, and their respective QA staff. A discussion was also held by phone with Mr. Vern Steubner, Resident Engineer, Met-Ed, subsequent to the inspection. The inspectars -stated they had not found any deficiencies in the records' audited 9 or noncompliance in the work observed in the field. The suspected problem with the 21/2" and 3" stainless steel pipe. that was re-3. jected was reviewed briefly. Mr. Hreczuch reaffirmed that Met-Ed would send Compliance a copy of their report of their investigation. e g g ' 419 20g}}