ML19319C157
| ML19319C157 | |
| Person / Time | |
|---|---|
| Site: | Davis Besse  |
| Issue date: | 05/30/1972 |
| From: | Oller R, Vetter W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML19319C150 | List: |
| References | |
| REF-QA-99900019 NUDOCS 8001310517 | |
| Download: ML19319C157 (8) | |
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U. S. AT051C ENERGY COMMISSION DIRECTORATE OF REGULATORY OPERATIONS REGION III Vendor Inspection Report i
RO Inspection Report No. 999-019/72-01 S ubj ect : Grinnell Company License No.: N/A Kernersville, North Carolina Priority:
N/A Balance of Plant Nuclear Piping for:
Category: Vendor Davis-Besse l
n Type of Licensee:
N/A Type of Inspection:
Routine, Announced Dates of Inspection:
May 10 - 12, 1972 Dates of Previous Inspection: N/A
$ $. h h P rincipaa Inspecto**
R. E. Oller (Date)
Accompanying Inspectors: None Other Accompanying Personnel: None Reviewed By:
k'. E. Vetter, Q11ef
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/ 2--
3 Reactor Construction Branch i
Proprietary Information: None i
e 8001310$~/7
n, SECTION I Enforcement Action A.
Noncompliance: None B.
Nonconformance The partial data report Forms NPP-1, for three lots of completed and shipped nuclear Class III service water and component cooling piping, were found to be incomplete. The omissions were in Item 7 of the subject forms. This information is required by the ASME Code, Section III-1971, Paragraph NA-8415, to which the piping was purchased.
(Paragraph 14)
C.
Safety Items: None Licensee Action on Previously Identified Enforcement Matters: N/A Unresolved Items: None S tatus of Previously Reported Unresolved Items: N/A Desian Changes: N/A Unusual Occurrences: None Persons Contacted The following personnel and others identified in the Management Interview Section of this report were contacted during the inspection:
Grinnell Company (Grinnell)
J. G. Skander, QC Manager D. R. Giguere, QA/QC Manager (Davis-Besse Site) 9 Toledo Edison Company (TECO)
W. G. Moring, Field QA Engineer Bechtel Corporation (Bechtel)
- 11. A. Ablondi, Field QA Engineer (Davis-Besse Site)
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Management Interview The personnel at the management interview were as follows:
Grinnell J. L. Fread, Plant Manager of Operations J. S. Cole, Plant Manager of Central Engineering K. E. Wilkinson, Project Engineer (Davis-Besse)
D. R. Giguere, QA/QC Manager (Davis-Besse Site)
J. G. Skander, Plant QC Manager TECO W. G. Moring, Field QA Engineer Bechtel H. A. Ablondi, Field QA Engineer J. M. Boland, Inspection Area Supervisor R. C. Hoody, Inspection Area Supervisor H. A. Crotts, Resident Inspector The following item was discussed:
A.
The inspector discussed the omission of information in Item 7 of the Form NPP-1, which includes the " Class of Piping" and Remarks, Manufacturer's Data Form.
." Mr. Skander said he would recall t?e data packages to the shop for correction of the subject forms.
He cided that he was uncertain whether the " Remarks.
." portion should be filled out by the Grinnell shop.
(Paragraph 14) 1 O I
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V SECTION II Additional Subjects Inspected, Not Identified in Section I, Where No Deficiencies or Unresolved Items Were Found 1.
General The inspection was performed with regard to the fabrication of balance of plant nuclear classes of piping for the Davis-Besse facility. The Bechtel Specification No. 7749-M-190, Revision 2, required that the 7
nuclear piping be designed, fabricated, inspected, and tested in accordance with the requirements of ASME Code,Section III, Classes I, II, and III. The inspector was told by Skander that, in addition to the nuclear piping, the order included critical piping and noncritical piping (B31.1.0) and that over 2000 subassemblies were included in the order. The piping was observed to be in the initial stages of fabrica-tion.
The inspector was told that no Class I, ASME Section III, piping was currently in the fabrication stage.
2.
Proprietary Information Prior to the inspection, the inspector advised Grinnell, Bechtel, and TECO personnel that any information on items inspected which they considered of a company confidential or proprietary nature should be i
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identified. During the inspection, no such items were identified.
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3.
Shop Inspection An examination of the plant facilities established that the plant was organized in a direct work flow-through type manner with separate bays for work on carbon steel, low alloy, and austenitic stainless steel i
pipe. The stainless steel piping bay was isolated by a permanent wall.
For each bay, the flow of work starts at one end with receiving inspection and storage and is finished at the other end with final cleaning, inspection, and preparation for shipping.
An examination of a shop equipment list established that the shop was adequately equipped with welding machines, grit blasting facilities, machine tools, other required pipe fabricating tools and facilities, rail car heat treating furnaces; and NDT equipment for UT, MT, PT, and RT.
The RT is performed using cobalt 60 and iridium 192 sources con-tained in external buildings.
The inspector observed that there were no demineralizers to provide required cleaning and rinse water.
Skander i
said a demineralizar had been purchased, was being delivered at the time of the inspection, and would be in service when required.
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Welding materials were found to be stored in a heated storage room and are issued directly to portable hot holding ovens in each of the welding areas.
An investigation disclosed that a log is used to record weld rod issue to each oven, but that there were no provisions to account 0
for leftover rod nor was there an 800 F bake out oven available for treating leftover rod.
In response to questioning, Skander told the inspector that a baka out oven was on order and would be installed in the storage room.
The inspector examined numerous Class II containment spray subassemblies of stainless steel piping in various phases of fabrication and determined that the piping was marked as required by code and that partial and completed welds showed acceptable workmanship.
Examination of in-process traveler documents for one assembly established that it consisted of a "QC and Acceptance Data Sheet" on which all work, specifications, materials, welders, and NDT were recorded as work progressed. A fabrication sketch and a work step sequence sheet, which identified each operation to be performed on an assembly, was also included.
4 Quality Control Manual A review of Grinnell's shop Quality Control Manual (QCM) established that the manuel was complete and was in accordance with Appendix IX of the ASME Code,Section III. The manual contained copies of ASME "N" type stamp authorizations for Subassemblies (NPT) and Nuclear Piping Os (NPP) both of which were dated March 3, 1970.
5.
Bechtel Purchase Specification 7749-M-190, Revision 2 An examination of the subject specification established that Revisions 1 and 2 updated the nuclear riasses of piping to meet the requirements of the ASME Code, Section III-1971, Classes I, II, and III, in place of USASI B31.7 which was specified in Revision O.
6.
Record Traceability In response to questioning, Mr. Skander told the inspector that traceability of each piece of piping, fitting, and appurtenances was maintained by assigning a registry number at the time of receiving inspection (for shop traceability) and a subassembly number for field traceability. He added that all identification is transferred when a length of pipe is cut into several pieces.
The registry numbers and subassembly numbers are also recorded on each related fabrication sketch, traveler, material record, etc.
During the shop inspection, the inspector examined several lengths of pipe subassemblies and travelers and found that the 'ientification was as described.
a m
,s 7.
Typical Record Package Sent to the Site The inspector examined three record packages for completed and shipped service water and component cooling piping.
(Paragraph 14)
The following is a typical list of records sent to the site for nuclear classes of piping:
a.
Statement of conformance.
b.
Partial data reports NPP-1 Form.
c.
Examination and document checklist.
d.
Index of material certifications.
Shop sketch and bill of materials for each subassembly.
e.
f.
QC acceptance data sheet.
g.
Copics of all NDT reports, h.
lieat treatment charts.
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Supplier's certified test reports.
8.
Shop Procedures and Specifications Reviewed a.
Standard Fabrication Specifications Four standard shop fabrication specifications for carbon steel and austenitic stainless, and supplemental specifications to the standards, were examined in detail. The supplements contained special requirements of the Bechtel Specification M-190.
All of the specifications and supplements were approved by Bechtel and were in accordance with Bechtel Specification M-190.
b.
Standard Shop Welding Procedures An examination was made of 19 welding procedures and their qualification records.
All of the procedures were determined to contain the essential information, the essential and non-essential variables, and were qualified in accordance with the AStiE Code, Section IX-1971.
In addition, an examination was made of two material specifications for weld filler metal and one for t-1 der qualifications.
These two were determined to be -
4 acceptable. All of the procedures and qualificata n records were approved by Bechtel.
"he inspector commented that weld repair l
procedures were nor.ncluded.
Skander replied that these are being sent by the 'Jrovidence, Rhode Island, office to Bechtel for approval.
c.
Standard Shop Inspection Procedures Sixteen nondestructive inspection procedures for the techniques of PT, MT, UT, and RT were examined.
All of the procedures were determined to be in accordance with Appendix IX,Section III of the ASME Code and were approved by Bechtel.
d.
Standard Cleaning Procedures Six cleaning procedures, all involving the use of grit, solvent, or steam, for cleaning carbon and stainless steel pipe, were reviewed. All of the procedures were in accordance with Bechtel Specification M-190 and were approved by Bechtel.
9.
Radiograph Film Reviewed An examination was made of RT films for five welds in three component cooling piping subassemblies.
The radiographs were made using an
.s iridium 192 source. The weld and penetrameter contrast, density, and sensitivity of the film were acceptable.
. indicating that a proper radiographic technique had been used.
Some code acceptable slag inclusions and porisity were observed.
10.
Welder Qualifications An examination of eight welder qualification records (for both manual and automatic welding processes) established that the welders were qualified in accordance with the ASME Code,Section IX.
In addition, examination of a welder qualification monthly check off sheet established that control was maintained to assure that welders used processes within the period required by the ASME Code,Section IX, Paragraph Q-26, for renewal of qualification.
Skander told the inspector that the shop currently had 48 qualified welders, 11.
Nondestructive Testing Personnel An examination of the certificates of six NDT personnel qualifications for PT, MT, RT, and UT established that they were in accordance with SNT-TC-1A standards. The shop personnel were qualified to Levels I and II.
Skander told the inspector that Level III personnel were a
-s, located at G e Providence, Rhode Island, office and that they s,
served as examiners during qualification of shop NDT personnel.
12.
Supplier Surveillance In response to questioning, Skander said that all suppliers are audited and approved by the Providence office and that a list of i
approved suppliers is furnished to the shop.
He added that a documented program for supplier audit and surveillance is maintained in the Providence office but not at the shop.
13.
Material Certifications Reviewed An examination was made of several suppliers' certified material test reports for 4",
6", and 3" stainless steel containment spray piping lengths, stainless steel fittings, and Class III welding materials.
All of the information and test results were detarmined to be in accordance with ASME Sectica III-1971 requirements.
The test reports were properly certified, signed, and dated, i
l Details of Subjects Discussed in Section I i
14.
Partial Data Feport NPP-1 During exar' nation of record packages for three lots of nuclear Class III
'e vice water and component cooling pipe, previcusly shipped to tna site, the inspector determined that the partial data report Forms NPP-1 omitted information required in Item 7,
" Class of Piping" and " Remarks, Manufacturers' Data Reports Mr. Skander said the emission of the class of piping was an oversight.
However, with regard to omission of information in
" Remarks, Manufacturers' Data Form.
.," he said he was not certain that this was required to be filled in.
A subsequent review of the ASME Section III-1971 Ccde, established that Paragraph UA-8415 requirements, referenced in Article ND-4000 piping subassemblics by fabricators and excludes only the certification af the destgn portion of the form.
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