ML19317F795
| ML19317F795 | |
| Person / Time | |
|---|---|
| Site: | Rancho Seco |
| Issue date: | 06/24/1971 |
| From: | Oller R, Vetter W US ATOMIC ENERGY COMMISSION (AEC) |
| To: | |
| Shared Package | |
| ML19317F787 | List: |
| References | |
| B&W-71-02, B&W-71-2, NUDOCS 8002210558 | |
| Download: ML19317F795 (11) | |
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U. S. AT0 HIC ENERGY COMMISSION REGION III g
DIVISION OF COMPLIANCE Vendor Inspection Report i
Pumps Vendor:
Babcock & Wilcox Canada, Limited Galt, Ontario, Canada Report No:
B&W 71/2 Components Inspected Fort Sacramento Municipal Utility District i
Rancho Seco (50-312) i Dates of Inspection:
May 17-1971 0E M
Inspector:
R.
Oller 5.29-7/
Metallurgica Engineer Date j
Licensee Representatives: J. P. Jackson and W. J. Friedrich Sacr o Municipal Utility District 0
J 6,29-//
Reviewed By:
W. E etter Senior Reactor Inspector Date Proprietary Information: None Licensee Application Requirements:
According to R. T. Dodds, CO:V, the PSAR specifies that Class A pump casings will meet the requirements of ASME Section III, Subsection A.
SCOPE An announced vendor inspection was made at the Babcock & Wilcox Canada, Limited (B&WC) plant, located in Galt, Ontario, Canada, on May 17-19, 1971, by R. E. Oller, Metallurgical Engineer, Region III.
The purpose of the inspection was to review the documentation of work, QC staffing and QC activities, work in process and to observe plant facilities.'
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SUMMARY
'1.
The B&WC and Sacramento Municipal Utility District (SMUD) representa-tives were told by the inspector to identify all inspection items considered to be of a proprietary nature. During the inspection, no such items were identified.
(Section II-A.)
- 2. The inspector was told by the B&WC QA Manager that the manr
.re of pumps for nuclear facilities is a relatively new opera B&WC m.
currently has nuclear pump orders from five utility companies in the United States.
A. review of the QC manual disclosed that it provided for a documented, controlled manufacturing system in accordance with the ASME Pump and Valve Code and ASME Code,Section III. The quality assurance organization was determined to function in parallel but independent of the manufacturing department.
(Section II-B.)
3.
The SMUD specifications, prepared by Bechtel, were comprehensive and I
reflected applicable code requiremento.
(Section II-C.)
4.
A-record review revealed that the manufacturing status of the quality Level I SMUD pumps was in a preliminary state. Only selective requirements of the ASME P&V Code applied. The material test reports g
for only.one of three pumps, selected out of the order of 24, were
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all available, due to the fact that no work was in process. Some omissions of signoff by B&WC on supplier process sheets were observed.
(Section II-D.)
5.
An examination of the shop facilities revealed that the B&WC plant contained a separate-clean room for nuclear pump parts receipt inspection, weld repair, PT inspection, and cleaning. An examina-tion of botton and top castings for two nuclear service water pumps.
revealed that the castings were made by the B&WC foundry and were properly marked. The route sheets with these castings listed all steps of processing but lacked. provisions for witness signoff.of inspection points by the Ontario Department of Labor (OD of L) inspector (third-party inspection) or the resident Bechtel inspector.
(Section II-E.)
6.- The welding procedures, applicable to pump manufacture, were deter-mined.to be written and qualified in accordance with ASME Code Section IK and were approved by the OD of L.
(Section II-F-1.)
.7.
A review of welder performance qualification records revealed that i.
welders were qualified in accordance with ASME Section IX.
The welding tests were witnessed and approved by the-GD of L.
The per-
- formance records were maintained on record cards. A system for notifying the shop to requalify welders when required was determined to be in effect.
(Section II-F-2.)
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8.
The B&WC QA Manager told the inspector that the OD of L examined and i
certified the NDT personnel for all tehniques to SNT-TC-1A, Levels I and II.
The Level III equivalents are. the OD of L examiners. The inspector reviewed a sampling of examination records for the B&WC NDT personnel and verified that personnel were qualified in accordance with the SNT-TC-1A standards.
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To evaluate the RT technique of both B&WC and one of their major suppliers of pump parts, the inspector reviewed a random selection of pump casting RT films for pumps ordered by unidentified purchase *.s.
The B&WC films reflected conformance with ASME Code requirements.
However, the films made by.the supplier's contracted inspection laboratory were of marginal code conformance for sensitivity of the penetrameter 2-2T hole. The inspector observed that various types of portable MI equipment was located in the work areas of the plant.
Examination of the UT facilities revealed that the storage of ultra-sonic test equipment and housekeeping of the UT laboratory left much to be desired.
(Section II-G.)
9.
The B&WC QA Manager told the inspector that B&WC had not been ASME surveyed for an N Stamp authorization but that they were planning to request a survey hrough the OD of L in the near future.
In response to questioning, the QC Manager told the inspector that B&WC makes and records actual wall thickness of pressure containing pump castings when the minimum wall is specified on engineering drawings. If only internal or external dimensions are specified, these dimensions would be measured and recorded as accept or reject.
(Section II-H.)
Nonconformance' Items - None.
Management Interview - A management interview was held with Messrs.
Harvey, Juccolo, Hesslip, Young, Jackson, and Friedrich on May 19, 1971.
The inspector scussed the purpose of the Compliance inspection and then reviewe
...e inspection findings as follows:
1.
The inspector said that, since the amount of work completed on the SMUD pumps was minimal, the inspection had been limited to an evaluation of B&WC capabilities and QC program relative to the manufacture of nuclear quality pumps.
2.
The pump QC manual appeared to L comprehensive and to represent a controlled manufacturing system for nuclear pumps.
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' ;3. The inspector said a more thorough review by B&WC of supplier's records was indicated by the fact of omissions of signoff (by B&WC) on subcontractors' process sheets and some of the MTR's l
for pump casting were not available.
In response, Mr. Haaslip said that the subject casings were still in process at the supplier's plant and.that this was the reason for the absence of some of the MTR's.
Haas11p said that the subcontractor's process sheets would be reviewed for omission of signoff.
4.
The inspector said that storage of ultrasonic test equipment and
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housekeeping of the UT laboratory was less than desirable.
Mr.-
l Haaslip'said he would review this condition.
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5.
The inspector said the RT technique of the testing laboratory, used by one of B&WC's major casting suppliers, appeared to be marginal with respect to ASME Code requirements.
Mr. Hesslip said he would investigate this condition.
6.
Provisions for witness inspection hold points for the OD of L and Bechtel inspectors' signof fs, the inspector commented, should be shown on the shop traveler sheets.
Mr. Jackson said he would take
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action to resolve this. item.
s Mr. Hesslip said that B&WC appreciated the inspection comments and welcomed the inspection.
DETAILS 4
I.
Persons Contacted' Babcock-& Wilcox Canada. Limited (B&WC)
J. R. Harvey
- Vice President of Operations J. L. Juccolo
- Project Engineer for SMUD Project F. E. Hess11p
- Manager of QA A. A. Young'
- QA Section Head E. R. Williams
- NDT Supervisor J. (NMI) Roberts - Record Clerk Sacramento Municipal Utility District (SMUD) 1 J. P. Jackson
- QA Director i
W. J. Friedrich - QA Engineer 1
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. l II.
Results of Inspection
'A.
Proprietary Information Preliminary to the inspection, the inspector advised the B&WC
.and SMUD personnel that all items reviewed during the inspection, which
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they considered to be of a proprietary nature, should be specifically identified as such. During the inspection, no items were identified to
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the inspector as being proprietary.
B.
Quality Control Program and Organization Through discussions and observations, the inspector determined that the B&WC plant is engaged in manufacturing fossil fired boilers, power piping and a variety of pumps.for conventional and nuclear power plants. The plant includes a foundry for the production of castings.
The manufacture of nuclear facility pumps is a relatively new function.
Mr. Hemolip told the inspector that their current nuclear pump contracts included pumps for five utility companies in the United State..
A review of the QC manual for nuclear pump manufacture disclosed that it provided for a comprehensive, documented QC program to assure
\\s-code conformance with the ASME Pump and Valve Code, ASME Code Section III, and other codes, standards and specifications where applicable. The organization chart revealed that the QA Manager, Mr. Henslip, reported directly to thri Vice President of Operations. The groups reporting to the QA manager were:
1.
The QA section supervisor, who is responsible for QA engineering, audit and survey, and gage control.
2.
The QC section manager, who is responsible for metallurgy, process control, welding development, nondestructive testing, and shop process inspection.
The QA section consisted of fe analysts plus the QA supervisor, and the QC section consisted of 33 ins; tors plus the,QC manager.
C.
.SMUD Purchase Specifications The inspector reviewed the SMUD pump specifications, prepared by Bechtel Corporation, as follows:
1.
Specification 29.1. dated February 25, 1970 i
" Horizontal Centrifugal Pumps and Related Auxiliary Pumps"
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Specification M30.1.' dated January 23, 1970
" Nuclear Service Raw Water Pumps and Auxiliary Equipment" 3.
Specification MS.6, dated April 20, 1970
" Auxiliary Feedwater Pumps and Related Equipment" The three specifications each contained the following requirement categories:
1.
Equipment to be furnished.
2.
-Quality program.
3.
Control of special processes.
4.
Calibration of measuring and test equipment.
5.
Nonconforming material control.
6.
Quality program records.
7.
System audit.
8.
Symbols for vital characteristics of Class I pumps.
9.
Design conditions.
10.
Parts description of single suction and double suction pumps.
l 11.
Materials of construction.
12.
NDT codes.
13.
Qualification of NDT inspectors.
14.
Factory performance tests.
15.- Inspection documents.
16.
Surface. preparation and coating.
Each of the three specificat.ons referenced the applicable portion of Bechtel appendix, The appendice/, which were reviewed by the inspector, are listed.
1.
Appendix 71
" General Welding Requirements For Shop
~ Fabricated Equipment" 2.
Appendix 73
" Metallurgical Requirements For Types 304 and 316 Stainless Materials" A review of the appendices revealed that they included standard Bechtel requirements which supplemented the SMUD specifications. Both of the appendices represented elements of good practice.
D. ' Record Review In response to questioning, Mr. Jackson told the inspector that Bechtel' qua*ity Level I was equivalent to Class I of the /.SME Pump and Valve Code.
Mr. Hesslip said that the SMUD pumps were ordered only to f
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' 1 certain requirements of the P&V Code and that all of the pumps on the SMUD order.were in preliminary stages of manufacture. G the 24 pumps on the SNUD order, the inspector selected six QA Level I pumps for a parts material record review. The selected pumps were:
- 1.. Reactor Building Spray, B&WC Serial Nos. 68570 and 68571 4
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-Boric-Acid Pumps, B&WC Serial Nos. 68650 and 68651 3.
Nuclear Service Water Pumps, B&WC Serial Nos. 68550 and 68551 The review of the material record packages established that complete records were available for the nuclear service water cooling pumps only.
Some omissions of signcff of suppliers' process sheets by B&WC were observed. The receiving inspection records and material test reports for the casings and back covers of the Reactor Building Spray (RBS) pumps.were.
not available. The inspector commented that the B&WC manufacturing step process correspondence for these items was dated April 1970 and, therefore, it appeared that material reports should be available considering the time lapse invo3eed.
Mr. Hesslip explained that the castings were still at the supplier's plant and, therefore, the subject reports had not been received.
Only a fes material records for the boric acid pumps were available for review, due to the fhet chat no work was in progress.
E.
Work-in Process and Shop Inspection The inspector toured the shop areas and observed that B&WC had a separate clean room for nuclear pumps parts receipt inspection, weld repair, dye penetrant inspection, and cleaning with deionized water.
The bottom and tcp castings and shop route sheets.for the two nuclear service water pumps were examined.. The castings were made in the B&WC Galt foundry. The castings in the "as cast" condition were properly markeJ. Examination of the route skeets (travelers) established that all steps of receiving, mac! ining and ss.ap instructions were listed.
The travelers did.not, however, provide for witness signoff of inspection by the Bechte1' inspector or third-party inspector. This. item was dis-cussed with Messrs. Jackson and Hess11p. Mr. Heaalip said that the third-party inspection at B&WC was performed by the OD of L inspector who normally: reviews NIR's, witnesses. hydro,-and reviews spot checks of in-process work. Mr Jackson said the only witness point which required signoff by the Bechtel inspector was the hydrostatic test. The inspector j
said it appeared that the route sheets were incomplete with respect to provisions for witness and signoff. Both Jackson and Heaslip acknowledged
.that the route sheets should be corrected to provide for witness signoffs where required.
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Welding 1.
Procedures The inspector reviewed a sampling of six welding procedures which would be applicable to pump work. The majority of the procedures were for use of a combination of processes. For example: " Procedure for Groove and Filled Welding of P-1 to P-1 Material by Submerged Arc on Shielded Manual Metal Arc and Gas Tungsten Arc Root Passes." All of the procedures contained the essential variables and were qualified in
'accordance with ASME Sections III and IX.
The procedures and qualification records were approved and witnessed by the OD of L.
In addition, they were signed by the B&WC chief metallurgist.
2.
Welders The inspector reviewed the system for welder qualfication updating; the welder qualification summary, and a sampling of welder qualifications.
i Mr. Roberts, Record Clark, said there were 219 qualified welders and demonstrated the use of a card file system through which welder qualifications are kept up to date with respect to the various welding processes. Roberts said that he gives - the shop a one-month notice 'of a need for updating qualifications.
Mr. Hesslip seki that the routine for qualifying welders is to make out a form request for a welder performance test setting forth all required information. The weld test plate is then stamped by the OD of L and the test made.
After successful completion of the test, all of the information is tranferred to a " Performance Qualification Record" (card). On the back of the card, provisions L.e made for the test number and signatures of the welding foreman, person giving the test, OD of L inspector, and date.
The inspector reviewed the qualification records of four welders and determined-they were qualified in accordance with ASME Section IX and that the records were signed by responsible personnel, m
d 9-G. -Nondestructive' Testing
- The system for qualification of NDT personnel was discussed with.
- Mr.-Haaslip. Hess11p said that RT personnel are examined and certified
' by the Department of Energy and Resources (part of the OD of L) located in Ottawa, in accordance with an RT-48GP standard. This reandard quali-fios personnel as Junior and Senior Level radiographers. equivalent to SNT-TC-1A' Levels I and II (respectively). The SNT-TC-2A Level III equivalent is the provincial examiner. The above meth)d of qualification by the OD of. L also applies to ultrasonic, dye penetrant and magnetic particle inspection.
The' inspector reviewed a sampling of qualification examination records for'RT, UT, PT, and MT inspection personnel and determined that they were qualified to the requirements of Levels I and II of the SNT-TC-1A standards.
Since no 3DT inspection-had been performed on the pumps for SMUD, the inspector randomly selected pump ' casting radiographic films (associated with unidentified. customers) to evaluate the RT techniques of B&WC and the Visi-U-Ray Inspection Laboratory used by Wilmet Limited, who is a major supplier of castings to B&WC. The review of the films revealed that the
- B&WC technique reflected code conformace. However, the films made by Visi-U-Ray were of marginal code quality with respect to penetrameter sensitivity of the 2-2T hole.
The inspector examined the UT facilities and observed that the storage of crystals, reflectoscopes and standards was unacceptable in terms of equipment protection. Moreover, housekeeping in the UT labora-tory was less than desirable.
Adequate portable MT equipment was available in the plant for use in remote work are s.
The marginal RT technique of the supplier's inspection service, i
questionable storage of UT equipment and UT laboratory housekeeping shortcomings'were discussed during the management interview.
H.
Miscellaneous 1.
ASME Survev The inspector asked Mr. Hess11p if B&WC had been'ASME surveyed j
for N stamp authorization. Haaslip said that B&WC had not been surveyed but that they anticipated making an application through the OD of L chief inspector. The CD of L inspector will request.a survey by the Canadian Standards Association
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If, as a result of the ESA survey, the OD of L approves the plant, an ASME survey will be requested by the OD of L.
For nuclear equipment used in Canada. Haaslip said, Canada does not require an ASME stamp but does require an equivalent to that required by the ASME.
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Casting Wall Measurements The inspector asked Mr. Haas11p if B&WC made and recorded actual wall thickness of pressure containing castings. Mr.
Haaslip said that, if the engineering drawings specify a minimum wall thickness, actual measurements are made and recorded. If only the internal or external dimensions are' specified, Hesslip added. these dimensions would be measured and recorded only as acceptable or rejectable.
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DIVISION OF COMPLIANCE MONTHLY REPORT FOR JUNE 1971 l.
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60'8 Babcock & Wilcox Canada, Ltd. (B&WC) - Galt, Ontario, Canada A vendor. inspection,,was performed on May 17-19, to examine the fabrication of pumps for the Sacramento Municipal Util1~ty District (SMUD) Rancho-Seco facility.
The inspection disclosed
~no items of nonconformance.
This was the first CO inspection-of B&WC.
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