ML19317F783
| ML19317F783 | |
| Person / Time | |
|---|---|
| Site: | Rancho Seco |
| Issue date: | 06/18/1971 |
| From: | Oller R, Vetter W US ATOMIC ENERGY COMMISSION (AEC) |
| To: | |
| Shared Package | |
| ML19317F778 | List: |
| References | |
| VELAN-71-01, VELAN-71-1, NUDOCS 8002210549 | |
| Download: ML19317F783 (10) | |
Text
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I U. S. ATOMIC ENERGY C0FFISSION REGION III g
' DIVISION'0F COMPLIANCE Vendor Inspection Report Valves
. Vendor:
Velan Engineering Company, Limited Montreal, Quebec, Canada Report No.
Velan 71/1 Components Inspected For:
Sacramento Municipal Utility District (SMUD)
Rancho-Seco (50-312)
Date of Inspection:
May 20, 1971 N [.
Inspector:
R. E. Oller Metallurgical Engineer S//7/7/
Licensee Representatives:
J. P. Jackson and W. J.
V Friedrich - SMUD Reviewed By:
W. E. Vetter Senior Reactor Inspector d~/k"7/
Proprietary Informa, tion:
None Licensee Application The PSAR specifies valves to meet Requirements:
the requirements of the ASA B31.1 Code plus the Codes Cases (per R. T. Dodds, CO:V)
SCOPE
.An announced vendor inspection was made at the Velan Engineering Company, Limited (VEC) plant in Montreal, Quebec, Canada, on May 20, 1971, by R. E. Oller, Metallurgical Engineer, Region III.
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s The purpose of the inspection was to review documentation of work, QC activities, and, in addition, to observe work in progress and the plant facilities. VEC was previously inspected by Compliance on October 27-30, 1969.
SUFFARY 1.
Preliminary to the inspection, the inspector requested that all items reviewed during the-inspection, which were considered to be proprietary, be specifically identified ~as such. No items were identified to the inspector as being proprietary.
(Section II-A.-)
2.
The inspector was told that no shop work was' started on the valves ordered by the Sacramento Municipal Utility District (SPUD) and that only a minimal amount of work had been performed on the
. valves ordered by Babcock and Wilcox (B&W), Lynchburg.
The inspector reviewed a drawing for a 6" swing check valve...
one of six over 4" in size... selected from the Master Valve List.
The drawing, contained all information relative to Velan's program for manufacturing and quality control of the valves.
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Since no material test reports or process sheets were available i
6 for the subject valve, the inspector reviewed the process sheet and shop procedures, for a similar type valve, which would be use'd in manufacturing the subject valves. The process sheet identified the valve body material, process step descriptions, required inspections, shop instructions and procedures, specifications, and inspectors.
A review of the controlling shop QC Instructions (QCI) established that they included the VEC requirements which were referenced to the ASME Pump and Valve Code and ASME,Section III, requirements. The QCI's were approved by Bechtel. The inspector commented that the QCI's appeared to represent QC Manual Standards rather than shop working instructions. -The plant manager.said working instructions were-verbally transmitted to shop personnel by supervisors because personnel were of several nationalities leading to problems in the area of understanding written instructions.
. In response to'the inspector's questions, Mr. PacLean, VEC's QC Manager, provided Shop Inspection Instruction No. 281, written specifically for the large SPUD valves. The instruction consisted of detailed requirements for controlled manufacture of the SMUD valves in accordance with SMUD specification, VEC's
. QC Standards and the ASPE P&V Code requirements.
(Section II-B.)
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The inspector inspected the documentation and work on a selection of1B&W purchased valves for SMUD, which were in preliminary f
stages of. manufacture.. Valve body forgings for two 12" 1500#
l gate valves were examined. The forgings were supplied by the
~ Cameron Iron Works plant in Scotland and were properly identified by permanent indentation stamping. Through examination and review-of the process sheets, the. inspector established that the forgings had been cleared by ultrasonic testing and that they were internally ~and externally rough machined. The MTR's traced through the serial numbers, established that the material was in accordance with ASTM A-182, F-316 material requirements as
. specified. (Section II.C.)
4.
-An inspection of-the. shop 1 areas related to welding, weld rod storage, radiography, ultrasonic testing, dye penetrant inspection, receiving inspection, hydrostatic testing end cleaning revealed that facilities were adequate.
In each area, a bound logbook
--was'kept by each supervisor. The logbooks identified the parts by:
(1)' customer name, (2) order number, (3) VEC shop order number, (4) serial number, (5) quantity, (6) size, (7) operation description, (8) procedure, (9) welder or inspector, (10) stamp,
'(11) date, and (12) materials.used.
.The weld rod was observed to.be properly identified, stored, and i
kept in hot ovens prior to issuance. The issuing record also was maintained in a logbook.
The' inspector determined that nonconforming material was identified by marking with red paint. Material found to be acceptable by NDT inspection was identified by marking with green paint and by NDT indentation stamping.
The inspector observed that the cleaning area was equipped with an'autocatically. regenerated demineralizer and~ plastic storage tanks to provide deionized water for. valve cleaning. The water was continually monitored to assure the required purity.
(. Section II-D.)
l-5.
The inspector determined that VEC is aware of the problem of sensitization of austenitic' stainless steel valve seats during stelliting and has developed hard surfacing techniques to minimize the problem.
(Section II-E-1.)'
6.;
.The inspector was told that VEC' holds ASME authorization for the N Stamp.
(Section II-E-2.)
7.
-The inspector was told that SMUD has performed two audits'of VEC and that'the resident Bechtel._ inspector provides inspection for SMUD.-
(Section II-E-3.)
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VEC's engineering requirements, according to VEC, provide for measurements and recording of wall thicknesses of pressure
.containing valve parts.
(Section II-E-4.)
- 9.
Accordi,4 to VEC, third-party inspection, witness and signoff
- where.pplicable, is performed by the Quebec Department of Labor inspector.
Nonconformance Items - None.
Other Significant Items - None.
Management Interview - A management interview was held with Messrs.
P. O. Velan, C. MacLean, J. A. Simpson, and W. J. Friedrich on May 20, 1971.
Mr. Jackson left early due to prior commitments.
1 The inspector discussed the purpose of the Compliance inspection. He
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1 then.said that the inspection was limited to an evaluation of the VEC program for manufacturing SMUD valves and that no items of nonconformance had been observed. He added that any questions which may arise during further evaluation of the results of the inspection would be communicated to the applicant for resolution.
DETAILS I.
Persons Contacted Velan Engineering Company, Limited (VEC) i I. (NMI) Velan - Marketing Manager j
P. O. Velan - Manager, Plant No. 2 C. (NMI) MacLean - QC Manager J. A. Simpson - QC Engineer A.-(NMI) St. Pierrie - Welding Engineer J. T. Kmetyko -' Chief Inspector, Plant No. 2 V. (NMI) Miller -- Receiving Inspector Sacramento Municipal Utility District (SMUD)
J. P. Jackson - QA Director.
W.-J.-Friedrich - QA Engineer 1
Babcock & Wilcox Company, Lynchburg (B&W) i
.Q..D. Overman, Jr. - QC Representative (Resident)
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II. 'Results of Inspection A.-
Proprietary Information Preliminary to'the inspection, the inspector requested that the VEC, SMUD, and B&W personnel spe:ifically identify all items reviewed during the inspection which they considred to be of a proprietary nature. During the inspection, no items were identified to the inspector as being proprietary.
B.
Work Status on SMUD and B&W Valves 1.
Work Status The inspector questioned the VEC and SMUD representatives with regard to the work status of the SFUD and B&W valve purchase orders.
Fr. I. Velan said that no shop work was started on the SMUD valves and that only a minimal amount of work had been performed on the B&W valves.
In. response to the inspector's request, a list of SFUD f
valves over 4" in size, which were of Bechtel x,
Classification NN-1A (equivalent to quality Class I of the ASME Pump and Valve Code), were selected from the Master Valve List. This selection consisted of six valves out of a lot of 15.
The inspector requested identification of the valves by systems and was told by Messrs. Jackson and I. Velan that the valves were ordered by Bechtel specification coding and that, without a P&I diagram, they could not identify the systems in which the valves were to be used. The NN-1A valves were identified to the following extent:
4 Pressure Mk. No.
Size Valve Type Rating Material 127CS 10" Pressure Seal Stop Check 1500#
SS*
221 14" Pressure Seal Stop Check 1500#
SS 14BGS 10" Pressure Seal Gate 1500#
SS 25BS 6"
Pressure Seal Gate 900#
SS 234 6"
Pressure Seal Swing Check 900#
SS 22BGS 12" Pressure Seal Gate 900#
CS**
- Austenitic stainless steel. valve body.
- Carbon steel valve body.
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- M' In response to the inspector's request to review the material test reports (MTR's) and Shop Route Process Sheets (travelers), Mr. I. Velan said that no materials or process sheets were available for the above listed valves. The inspector then selected the Mk 234 6" swing check valve for drawing review.
The drawing, according to I. Velan, represented VEC's program for valve manufacturing quality control.
It included; (1) a valve outline drawing, (2) a parts list identifying the materials, the customer's identity, the valve's description, valve class, and (3) the NDT QC requirements for body, bonnet, wedge or disc, stem, bolting, welds, and hardfacing. The inspector observed that, for the subject valve, the QC requirements were:
UT, PT, chemical, and physical material tes*4 for the body and bonnet; PT, RT, chemical, and physical material tests for the disc, and PT inspection for the welds and hardfacing. Since no MIR's or process sheets were available, the inspector requested an opportun1Jy fg to review the shop procedures and a process sheet fe'c
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a similar type valve...which would apply to the manufacture of the subject valve.
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2.
Shop Procedcres I
a.
Process Routing Sheet The inspector reviewed the process routPag sheet for a sinilar 10" - 1500# pressure sea 3 check valve body, Item 34 of the SMUD Purcha3e Orcer P-35150-2 (system not identified). The route sheet revealed that the valve body f rging was ASTM A-182, F-316 material. The process step numbers, description, Bechtel Nucitar Pump and Valve Code requirements, inspectic a, instructions, 4
specification number, and the inejector's initials were identified. Salient steps
.n the process sheet referenced specif.c shop procedures.
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Shop Procedures The contro111ng' shop QC Instructions (QCI)
- r. tranced in the above process sheet were reviewed and were determined to be the standards outlining the VEC requirements referenced to the ASME Pump and Valve Code and ASME,Section III, for the SMUD valves. _The QCI's reviewed are listed:
(1)
QCI-105 Receiving Inspection
-(2)
QCI-127 (NPV) - Nuclear Code Inspection (3)
QCI-128 (NPV) - Purchase Order Clauses (4)
QCI-1?9 (NPV) - Parts Inspection (5)
QCI-131 (NPV) - Material Review - Rejection ard Correction
-(6)
QCI-134 (NPV) - Records and Documentation (7)
QCI-136 (NPV) - Production Testing and Final Inspection N
(8)
QCI-137 (NPV) - Discrepancy Examination and Test Equipment (9)
QCI-138 (NPV) - Welding Control
)
(10) QCI-750 (NPV) - QC Audits All of the'QCI's were found to have been approved i
by Bechtel on Approval Request No. 033, Revision 1, dated April 7, 1971. The inspector commented that the contents of the above QCI's reflected QC Manual Standards, rather than shop working instructions.
Mr. P. O. Velan, Plant Manager, explained to the inspector that working shop instructions were verbally transmitted to the workers, becausa written instructions were a problem as a~ result of the varied. foreign national origins of the workers. In response to persistent questioning by the inspector, Mr.1MacLean provided a Shop' Inspection Instruction:(SII) No. 281, dated February 15, 1971, entitled, " Stainless Steel and Large Carbon Steel Nuclear'and Commercici. Valves."
-This: instruction had been written specifically for
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the SMUD valve orders and was based on a 2echtel/SMUD Specification identified as M22.1.
The inspector reviewed SII 281 and determined that it-had been approved for start of manufacture by Bechtel on April 9, 1971. This instruction included the detailed information and instructions for controlled manufacture of the SMUD valves in accordance with the SMUD specifications, the VEC QC Standards and the ASNE P&V Code requirements, where applicable. Valve types covered were:
(1) Gate: Bolted bonnet and. pressure seal (2) Globe: Bolted bonnet stop and check (3) Piston Check and Swing Check (4) Bonnetless Gate The pressure-ratings included 150, 300, 600, 900, and 1500#, Class ASA. There were 36 different valve manufacturing drawings included. The SII defined'all of the shop processes, QC and
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documentation requirements... including preparation for shipment and receipt inspection by.SMUD at the Rancho-Seco site.
C.
B&W Lynchburg Purchased Valves for Rancho-Seco The inspector discussed the B&W Lynchburg purchased valves with Mr. Overman, the B&W QC Representative, and then selected four valves for review of records and shop inspection. These valve bodies were in the preliminary stages of manufacture. The valves selected were as follows:
1.
Decay Heat Outlet Gate Valves, Nos. DH V-1 and V-2, 12", 1500#.
2.
Injection Line Isolation Gate Valves, Nos. DH V-4A & B, 1500#..
During the shop inspection, the inspector examined the valve body forgings for the DH-V-1 and V-2 valves.and determined that the identity was permanently stamped on a boss on the body and consisted of (1) die' forge number, (2)- heat number, (3) material' identification number, 'and (4) ~ serial number. lui examination of 'the accompanying
_ route sheets revealed that these large forgings were supplied by-the Cameron _ Iron Works plant located in Scotland.
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.j ~s Work completed at-the time of the inspection consisted of rough machining and gun ' drill boring of the ID by VEC and UT clearance by the Truton Inspection Laboratory for VEC. The serial number was traceable to MIR's which revealed that the 12"-body forgings material.was ASTM A-182, F-316 and that the forgings were solution heat treated and PT inspected. The chemical and physical
. properties were determined to be in accordance with the A-182, F-316 requirements.
D.
General Shop Inspection The inspector toured the shop and examined the various work and inspection areas for welding, weld rod storage and drying, radiography, ultrasonics, dye penetrant inspection, receiving
- 1 inspection, hydrostatic testing, and cleaning. Each area was determined to be adequately equipped. In each area, the assigned supervisor showed the inspector a bound logbook in which all operations were.
recorded... identifying the piece and operation by; (1) customer's name,- (2) order number,-(3) VEC shop order number, (4) serial number, (5) quantity,.(6) part size, (7) operation description, (8) procedure, (9) welder o~r' inspector, (10) stamp, (11) date, and (12) welding or inspection materials.
The inspector observed that the weld rcd was properly identified and kept in hot ovens prior to issuance. The weld rod issuance was also recorded in a logbook.
In response to questioning, Mr. P. O. Velan told the inspector that nonconforming forgings found by UT were identified with
. red-paint..The conforming Laterial parts were identified with green paint and, in addition, were stamped with an acceptance symbol after being NDT inspected. The inspector examined several valve parts and confirmed that this system was in effect. In the cleaning and assembly area, the inspector observed that a demineralizer, in. addition to plastic storage. tanks, were in use to provide demineralized water for. cleaning. The demineralizers were automatically controlled for regeneration on limits set for conductivity, pH and halogen content.
Water in the ' storage tanks were also monitored using _ conductivity cells.
E.
Miscellaneous 1.
Stelliting The-inspector questioned Messrs. FacLean and Simpson concerning sensitization of'austenitic stainless steel valve seats during ste111 ting. MacLean told the inspector that VEC uses a'hardfacing technique,-such as plasma arc or manual metal arc welding, which will f'~'g_
. expose the stainless steel base material to the least time
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[Vh at temperature over 8000F to minimize precipitation of carbides.
The' inspector asked if VEC had made tests on stellited valve material to determine the effectiveness of the technique in preventing sensitization and received 56 a negative reply.
Mr. MacLean-then provided, for the inspector review, an Engineering Instruction (No. 61) titled, "Hardfacing of Velan Valves and Sensitization of Austenitic Stainless Steels.
The instruction detailed the steps to be taken to prevent
- sensitization during welding and hardfacing. The preventative factors were:. (1) to not allow the base metal to remati above 800 F in excess of seven minutes, (2) control of interpass temperature below 350 F in welding Type 304 and 316 stainless steel, and, (3) use wrought low carbon 304L or 316L or cast CF8 or CF8M material for seat, wedges, and discs of gate, globe, and check valves 4" and larger.
2.
ASME Survey fg)
In response to questioning, Mr. I. Velan told the
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('d inspector that the VEC plant was ASME surveyed and received an NPV stamp authorization on June 10, 1970.
This authorization was subsequently upgraded to the N Stamp and is good until 1973.
3.
SMUD Audits The inspector asked Friedrich how many audits SMUD had performed at VEC and was told two audits had been made. Friedrich added that Bechtel has a resident inspector at VEC who represents EMUD.
4.
Wall Measurements In response to questioning, Mr. MacLean told the 11nspector that VEC's engineering requirements provide for actual wall thickness measurements of pressure containing valve' parts, and that these measurements are made and recorded. The measurements are made using inside and outside calipers and by using an ultrasonic technique when necessary.
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Third-Party Inspection-Mr. MacLean told the 1nspector that third-party
s inspection witness and signoff is performed, when required,
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by the Quebec Department of Labor inspector.
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