ML19322B505
| ML19322B505 | |
| Person / Time | |
|---|---|
| Site: | Oconee  |
| Issue date: | 07/28/1970 |
| From: | Brown R, Crossman W, Seidle W US ATOMIC ENERGY COMMISSION (AEC) |
| To: | |
| Shared Package | |
| ML19322B498 | List: |
| References | |
| CAMERON-IRON, NUDOCS 7912030391 | |
| Download: ML19322B505 (18) | |
Text
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6 S. ATO' TIC EUERGY COT ISSION If,
, )I
.u DIVISEU:1 LF CC:'.t LIA!!CE D0't IF. 11iarriU.:1 !El U.tT.
11 pe C
u<,a Tren W rbt, Tncoc; 3ra tod W iz' a :
I'c alon, Toyas r.wccn Tron 1."orka '40-1 ilupct "o.:
s D 2ke Pe.:ce Compluty c<. p mta Tr:p uted For:
C.: cave Ca. L F1y 26-27, lc/70 0 des of In;j r.etten:
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W. A. Cco:n.an, Reactor Inapector, CO:II (In Charge)
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Date R, L Prairn, Emtetor Insp egfr, 00:I J. L. L, Ostertag, Engineer Liennsco P.oprecontative:
Duke Power Cc:npany D
3, Przewki Senior Engincer, QC Ct.har Purcens Contacted:
P. R. Davic litwager, Technical Pipo Marketing V, M, Spiller, Jr Supervisor, f;DT R. E, !!odgin - QC Engineer, Tubula Sales Engineer, Sales Department R. Clark - Chief Chumiet, Chemical Tcat laboratory T. A, McDenald Application 3 Engineer, Product E. P. Rchert Gales Engineer, Galec Dapartuent r.n;pcoc cing J Kiefer "anager, Heat Treatrr.ent Departrc.ont
- h'.cf Engineer L,l!arvey Accislant i
lI 79120303 f/
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V I Rpt. No.-
Cracron Iron Uorku '/0-1 ZA
~d c6S"jd
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9qnrt Reviewd Ev:
W. C. CcidlQ cait,r N ; tor r,,,>,e 0
[hf/fd v
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..% w a v Dato G. W, Reinmuth, Reactor Tnepector (Program Stawhtda)
The vandor considera "cet$ ona D, F, H, and K Proprietary Information:
ao proprietary.
!TF10$
An announced inspection was rado of Caerun Iron '. forks, Incorporated in Hounten, Tou.s, on !hy 26-27, 1970, as a rart of the Ccaplianco vendor inapcetion program.
The crecific purpose The visit was arrarced thecugh Duke Powr Company.
of thic inspectica uas to exar.iino pipe and revicu available records ' for i
couponents supplir ' th: Cconce project, 4
An ev11uation of the CDI QA program and plant production capabilitics are included in the detailo of the report.
SLM1ARY i
Significant Items -
CEI employs approximately 3,300 people in its Katy Road and Cypres 1.
- plants, It alloya its own steel.
- . tely ' 5% of its production.
(Sco Section A,)
u
- Pipo is the only finiched CD1 deco not have code stamp authority,)
2, product manufactured.
(Sec Section B.
Pacilities for UT examination of forged and extruded componenta are RT is contracted to Conam Incpection, Incorporated.
3, excellent.
(Sco Section C.)
- 4.. The Manufacturing Process Instruction cycto:n utilized by CDI for prowa The control was found to be adequato to produce a quality product.
(Sco system outlinos all control points, procesacs, and procedures,
(
Section D. )
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. V1 Rpt l'o.
Camercn Iron Worka 70-1 cwp:ntnt iM irl-,H en to mintained by rectamping the serial nur. Lee
("a "at' - E.)
on the part af ter cach femang ur cutta..g om 4.ien.
5, Document centrol procedurea place the renpen 6.
mont cu p rvicors.
(Soc Section P.)
CUT does not have a form 1 precedure for centrol o' wold filler aetal, h only a very rmall count of welding 7,
Erzowcki indicated that althcu6 is performed, CEI anam cut will mint to catablish a contr ol precedu (Sec Sectica G. )
Heat treatment prccedures are generated by the engineering departm and accenpany the lhnufacturing Procons Inctructions.
l 8,
T Repairs to one acetion of Dako pipo was adequate and well docum 9,
(Uco Secticn K.l.)
CEf furnished dccumentation which verified Volan Engirieering Ccmpany had been provided nolution heat treatment recorda of valvo forgings 10.
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for Duke valves, (Geo Sectica K.2. )
21nggent Interview - Drcowcki and Perrmd met with the 5napectors f Four major areas ucro discussed:
the debriefing, The inspectors reitorated that CEf chould exploro the neccc 1.
partial N stamp authority.
to ncet all provisions for crection certification of the Oconce min loopa utilizing CD1 pipe and valve bodies, Duko must cortify that the components were manufactured in accordance with ASME code.
Erzowski and Pornoud indicated that Davis would follow up on this poi Brova pointed out that the need for a formal wcld meta 2,
wolding, the need to govern icsue and return of wcld filler metal is cedure existed, casential.
Erzoucki restated his position that ho believen that CDi management Alco that will want to 'establich a control procedure in this area.
CDI will bo in contact with Dako. In this regard.
Althou'gh no formal control proceduro 3,
Document control was discussed.exista, the department sup their responaibilities concerning doccment control, that a possible weakness lo that cach supervisor is reopensible for
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recall'and/or destruction of the obsoleto copics of process control f
procedures.from the operation floor, b
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C;u oren Iren Worka '/0-1
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Drzowski socced to think the method worked very ucl1 tut Indicated he l
reuld mpinre formli ntion of the process.
h.
The inspoctors ccc:nonted thst the weld repairs to the sectlon of i
Cecnco pipo to Le used in the core flooding syste a nas well deemntod.
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Ilezowski stat rd that the requeut for waiver of final heat treatncnt l
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<;1s mdo becauco the relnirs ucro to a t n11 trea and were aballow, Alro, the danger of i.nvalidating the di: miens by addition,1 Leating i
uau ir ainent, f
OETAII:3 i
j A.
D cytytion of the Facility, i
l CIU produces its own steel (carbon, lut-alloy, stainleas, and various j
high-nickcl alloys) for its product line of pipe, valves, aul apccialty l
l items.
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CDI is a young plant as foundries go - 47 years.
Annual producticn j
d is approxinatc3y 120 nillion dollars. Spleyrwnt is arproxirately 3,300 in the Special Frolucts Division, l
The phnt is presently expmding to a new sito (approximtaly 1,600 acres) at Cypress, Terts, which is just rorthwest of Houston.
The l
plant at Cypress has assumed the utcol production and testing (product i
i centrol) reaponsibilities, Equipncnt installed at the Cypress facility includes a 50-ten air nelt i
furnace and a 60-ton vacuum inducticn furnace. Testing equirc;ent includes
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a computcrined X-ray luaineccence analyzer. This instrument was capable of analysis and printout of the composition in percent by weight of at l
i least a dozen chemicals.
The test equipment is utilized for centrol rather than certification of raaterials.
i Pornoud stated that CDI is the largent prolucer of rotating parts for Jet engines. Roughly, divided equally b? tween valve bodies (15 to 20% production cndeavors areforged stainless steel), o l
alther the closed die forging or special items which are produced by% of its production volume is for extrucion, process. Approxirately 5 j
nuclear application.
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i VI IQ,0. I!o. j Cruci.rcn Tron Worku '<0 -l CIW has been extruding pipo for a}proxirately five years.
Targo diameter pipo for main coolant loops is precently being extruded at the Houston 4
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yhnt ta a :Of. m, ul p M.
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.o f ' d ' St a 1 T g r a
press, 35,000 pai, is being inatalled at, the Cypress plant.
B.
QdLjRmp_Aulhed ty, 1
Davis repLled to th: quection ro;;nrding ClW s pocition regarding codo strunp authority, l!e aated that he hwl raced the question to coveral of the b31 Executive Oc eittco < tinea (n;;cifically W. R. chll) and was informed that it was not ucoccary ninco CIW does not unnfacturo a eampletud ptr luct.
Davis stated that he,cas very.intermted in cctablishing the necessity of an !! stamp since C1W ulll cui ply.in increasing number of ccmponents to the nuclear induntry.
The incpectors co n ented th2t he chould check again with the cedo comittees to be accured that they do not nced a partial N stamp, sinco i
the ayates containing CIW pipe must be code atamped by their customer and, connequently, all materials must ricet all cedo requirements.
91.Cre0@'gJfyn Anf J!nPhnt NDT C,rabi)ifE t
C.
The ClW QC organization is tbo came as that experienced by Compliance inspectors during May 1%9.1/ A plant organization chart and a QC organination chart are attached as Exhibit A.
Wycho, Manager of QC, was not availabic at the time of the inspection.
Fernoud and Hod in wure on hand to accompany the inspectors and desig-d nato individuals of the correct dicciplines to provido inforcation.
1 Administration of the facility is divided betwoon two managers who report to a vice president.
One manager heads what is escentially totallegraphic research, tecting, and control. The second manager supervices plant activities which includo manufacturing, sales, and quality centrol.
Many of the in-proccos product centrols are directly related to and overlap quality controls. For examplo, chemical analyscs are performed as outlined in Scotion A and are also perforced for certification in the chemical test laboratory facilitics at the Houcton plant.
In-process.
dimensional checks are inado by the product control personnel who work out of the product metallurd cal control group.
i 3/C0ReportHo. 50-275/69-5.
j
VI !!pt. "o.
Camoron It on Works 'iG-1 All nondectructive testing is the responsibility of the QC deFtrtment.
CiU ;4 cim:
m1y.TT
.;d UT u r. W ar preducts.
Tf RT is perform d, Inspection, Incon ernud (~J. a:'..f it is usualh centracted to Cvnwa
)
of Autentien Industrics, Incorporated, of Operry Laboratorica.
Liquid pnotrant tenting I roceduros and testing n connel are quali fied to HM/ SHIP 3 250-1500.
Ultrasen'c testing procedures and perne: nel are qualified to E'G All cxaulnera are Lovel II, 3H1'-TC-1A excupt t
Gection I]I, Apper. dix 1X.
Opiller who is fonrilly quali ricd to the applicable SMT TC-1A requirc-rents as a Level III ultracenic instructor.
i D.
Procens Control CIU utilizes a cyctm referred to as Manufactur.ing Prcccas Instructions An MPI is prepared by tho (t:PI) for centrol of rreduct and quality.
The en3 neering departn ent for each ccaponent to be ranufactured.
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The ceaphta d MPI is revicued by the mnufacturing and Q i
Finally, the customer receives the MPI i
depart =nta for production.
in a pwkage ahich accempanies the rough machined part.
The !1PI identifies the part, An MPI form is attached as Fahibit B.
customer, drawings (internal), e.g., rou)ch mchine or farging, refer Procedures and specifica-specification (s), and raterial (CIN code.tions which pertain to Those process operations which as cpocial heat treatment proccus).
are gcnocalized are designated by Operation No. such as S-1 for caving ratlts, W53 for welding identificatien plates, or I-53 for final The letter designates the department perfoming the inspection.
operation.
The MPI accccpanies the part to all work stations during production.
After cach cperation is completed, it is documented on a " Travel Ticket" Two " Travel Tickets" (Exhibit C) and sent to the next work station.
are ccepleted; one is cent to production control and the other accom-panics the part to the next work station.
E, Coru,onaut Identification Coaponent identity through the various stages of manufacture appears Each item frca a heat of material to be satisfactorily controlled.
is assigned an individual serial nunbor (S/N). ThisS/Nisrestamped on the part after cach forming' or cutting operation before it is por-4 This identity centrol is by.
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mittcd to progress to the next operation.
the MPI, " Travel Ticket," and "Scrial Checkoff Sheet.'?
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1 V [ Rpt, No. Carcron Iron Works 70-1 A S/H is assigncd to the cenronent at the timo it is saw cut and the heat number is correlated to the S/N by use of the " Serial Checkoff
.t."
This c! ;keff
- t L! atifk a th; ;.rt n N.:, or& c
'. e r,
i prv3uct claur, in addition t.o the CIU S/N "mult" weight (also by i
uhNa cut) beat number, etc. Thece are reproduced and scnt to all dotartments which have an input to these records.
Peta 11urgical certi fication of the rnterial in the retal Mat is entered on an lFM founat and correlated to the heat nurder.
The ic.ctallurgical derartrwnt is recrensible for entering the che.dcal nalysis and machunical test results into the ccaputer. Ccntinuing 3dentity is maintaino.1 by the production control group Oich roceives the second copy of the " Travel Ticket. "
I F.
Docun nt Control i
Doctw. ant centrol appr ars to bo *:ati sfactory.
Although the progrma does not include a pcocedure for inplemntation of docummt control, every deputnant cupervisor cppears to kncu all control procedures are originated and distribt. Led by the engineering department.
l The weakness in this cyctora is that each departrent cupervisor is responsible for recall and/or destruction of the cbsolete copies fron the op; ration floor.
a Pmisions to the lfPI's are sent to all departments and the supervisor l
in cach departrent is designated to te responsible for insertion of the revision and destruction of the old co (Erneuski stated that this pericd is approximately eight hours. )py.All departments have an l-input for nodification of MPI's.
G.
Welding According to CIW management, the only welding it performs in its nuclear production is reiv.tir wolding.
A repair weld procedure for each defect repair cccurrence is established by the engincering department. Each repair procedure and the woldor is qualified in accordance with ASME Code,Section IX.
A wcld repair record for defect repair is attached as Exhibit D.
Wold electrodo control is a very questionabic area.
CDI does not have a formal proceduro governing electrodo issue and return.
It.a handled r
by word of mouth only between the engineering department (which has I
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-i VI I?pt. No, Cmrecon Ircn 'dorka 70-1 the material cortification of the electrode) which is responsibic for repair to nuclear components, and according to Itarvey and Brzowski,
- n the only 'qart;.:nt authorind to innue electicka f u.a.elcar re pair.
The need for a formal control proceduro dcas exist; however, C1'.1 appears to be abic to centrol the minor amount of repair wclding that l
- la performed by the infonn1 word-of-rcuth approach.
This would not bo locciblo if the proccas required more than ene woldor or a rajoe woont of repair ucidir.g or any production fabrication uclding, Bracunki otated he paroon d ly belicves that CD1 rear,mc.ent vill cant J
to catablich a control proccdure in this area.
He further stated that j
CD1 will bo in contact with Duke in this regard, 4
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Revleu of the rcrair welding preccduro established for defect repalr in i
a length of 34-inch Schedule 140, Tyro 30411 pipo, proceduro qualification, I
l and vc1 dor qualification rccords 3 rylicated they were acceptable and in j
accordance with ASMF,Section IX,1968 Edition, t
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l Egrt Treatment i
CDI furnacco are natural gas (demostic) fired, I
i The furnace heat la recorded from 18 thermocouples:
l'6 TC & 1 (master TC) meauuring chamber temperature and 1 (alarm TC) measuring the tem-porature in the area of the product.
Alarm TC is set 25'F abovo nominal heat treat temperature and is capablo of activating an alarm and chut-l ting down the furnace if e>cessivo teq crature is encountered.
Thermocouples are replaced routincly every 30 days, or noro of ten if
.l necessary, with new calibrated thermocouples.
According to Kiefer, the traximum elapacd timo for transfer of a part from the heat treat furnace to the quer.ch pit is ene minut'e, but in most casca the average is thirty coconda, l!aat treat procedures are acnerated by the engineering department and accompany the mnufacturing process instructions.
Tcmperature of the part during the extrusion or forgirig operation and the transfer time from furr ace to quench pit io contir.ually monitored by a member of tho' netallurgical department.
This person does not have the authority to mako metallurgical decisiens but he can stop an opera-(
tion ~(forging or extrusion) if.the temperatures are not as specified..
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VI Rpt. ?!o. Crur.oron Iron Works 70-1 I.
Maintenance and Calibration of Inapection Equipment
" ' gin d.ii d u it uit m ronic f u t e qu i ;
-n t, 's e M i,!.
, y 00 daja tud the tent plates are resurfaced annrally.
Dbcnolonal digital readout equi wnt is calibrated overy 90 days.
l J.
Costraars for INc1 car Cn:32onnnts C1'I cupplies enir.ponunts to the follcuing mjor nuclear contractors:
B],,-Knox Ccgany, Cores -Volcan Divi nion Crano Ce:.pany, Chapnan Valve Diviaion Volan Paginecring Company i
Chcmetron Corporation, Tube Turns Division h*ectin;houac Elcetric Corporation Dabecek and Wilcox Ccarany, Tubular Prcducts Diviaien (for KAPL)
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Ccgyncnts for Oconeo 1.
Pipo The inspectors reviewed the repair of ono 148 8-1/2" length of pipo to be used in the core flood system (System I!o. 53 ).
The pipe is included in Custcmcr Order I!o. 32196 and identified by Forgo Scr.lal 17o. 5190 as follows:
14" 00, S-140, T-304H, A-376, Heat I!o. F 2143 Certification of chendcal analysis and mechanical properties are attached as Exhibit E.
Records indicato that the acetion of pipo nas rejected bccause the vall did not neet alnlaum thickncss requirements in three areas.
Repairs were accomplished by building up the areas with weld metal, finishing, and then PT and RT examination to determino if the repairs were effective.
Inacmuch as the three veld repairs were relatively shallem and small in size, CDI requested that Duke waive the requirement set forth in Wold Repair Proceduro L 57, which requires heat treatment fol-lowing completion of welding.. (Soc Exhibit F. ) Subsequent infor-mation revealed that Duke waived the heat treatment.
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V I Rpt. No.
i Caine rr.t Iron Works 70-1 j
Weld Repair Procedure W-57 was ccvicticd by the inspectors and assessed t
j for nacqur.cy, The procerbiro nas dated October 16,19/>9, and revised Nove.mber 12, 1969, The pruccN i..
.as guc1 i fled
- n
- c a 'an
- th ASME 1%PV Code Section IX, Ucidors utilizing the procedure w re Paco r etal is P-No. 8 required to be qualified by the cano code.
rntorial; filler.atal is to bo E 308-15 in accordance with SA-273.
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l Inspcetten rcTtire uts ucro described as follcus:
Ucld areas are to be prepar ed bygrinding or mehining mvl l'r l
j exandned to insure rcrovat of durcet.
a.
l Tho entiro area :. hall be PT m nined for one-half : inch on o'ch 4
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b.
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side.
(1) l'T af ter each weld paus for noninjuricus defects.
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j (2) PT after ccmpleted wold beforo RT for injurious defcets.
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(3) PT por ClW Pcceedoro P-13.
l (4) PT acceptance standard for the wcld and surrounding base j
retal:
l (a) RT of injurious weld defects shall be applied to those encroaching in excess of one -fourth inch I
min 11r.um wall.
(b) Either RT or pro;;.acsive PT shall bo perforr.ed on those injurious defects which encroach cn 3 css than i
ono-fourth inch minir:;um wall.
j RT of the throo repair arcas was by Conam Inspection, Incorporated.
The acceptance standard was by USASI B31,7, "l!uclear Piping."
Technique was in accordance with AS'IM E94 utiliv.ing an 86 cu Ir-192 cource for five minutes.
The inspectors reviewed three X-ray fila (14" x 17") labeled 5190-1, 2, and 3.
The sensitivity was P.T using a !!o. 25 penetrameter.
Film type D-7 was utilized with a front screen of.005" Pb and a back screen of.010" Pb.
!!o defcets woro obeerved.
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VI Rpt !!o.
11 Camoron Iron W rks 70-.1.
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2.
Valves t
I'rzo ski providul the imi c i ora 4G at m entat.;c.n concerning t,ho j
colution heat treatment of va tvc forgings shi ped to Volan End ncering Coccpany (Volan).
(See Exhibit G.
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The letter statc3 opecifically that recorda furnished coverad all l
valvo forginga shipped to Velan fcr Duko valves in the paut mtd will be included on valyca shipped 3n the future.
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Exhibits A thru G i
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- 'it i:. N. C..?'708 ay 22, 1970 Dai o Powr Co-rany rout Office Du 2178 Ch.u-l et',o, . C.
Attuatica:
'f r. U. !!.
O., n/R. E. IM llor Gentle; :n:
O n'oj o e t: Cs:enco 1 ft 2 Coro 71oo:1 Cyutuat riping Systun j$3 Cedar Gill 32196 Dy referring to wr 1iny 6th letter to Cr; aron Iron 'clorks you win recall that the foD ce:tng pir a in Leing repared at their Heunton, Texas, plant:
3 h" C -]h0 T 0 0ld! A-376 Heat //F21h3, Carial $190, length 3h' 1/34 Ir.c.c Nh na ' ho.> eld repair is relatively shallou and amall in sico, Cr;.eren requented that you watvo the requirement cet forth in their Iron L'ocks h:3
' old Repair Proceduro '! $7 calling for heat treatnant followind completion of welding.
Cauoroa anelarct aniu that the repatred area la to be ranctrant and X-Eny testad, and that the entiro J ength of pipe is to be tcstod Ultrasonically prior to rc-shipment to Oconce.
Would you cenfira nico that you now feel it will not b3 necessary for our hncinor frut Grinnell R & D, Providenco, R.
I., to rc--inopect this piccc of pipo und witness the conic inspection.
'lery truly yours, GRII;TEIL
.1PMiY, INC.
vus' d
.x C. S. Fullian IP partncnt Iianager
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Industrial Piping Division CSP 4thu CC: Mr. A. S. I.aurenoon (2)
Exhibit F l
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Ibly 25,1970 lir
.ti.hn 11 B l.ii 'a nn til T.
. r. D. IUC.
Iti p r Ve1.ni inyin.cring t h. : r 1( >l i e,
f.' ir I h C.iro l i n.
1:1 Ot. u ic e l3 tti'S( o 1 U c? f3 I o r y I S t e l V. i l '/ ",
l Ve1an Ref P - 31, Ol'O Q'ality Contiol inf.' lition thJ e l'ile OS -- 2 / - E De ir fir. Bl act ien:
c r.. t ion of liay 22, 1970 This is to a:nf i ria our telephone c<u" reg.irding heat t reatu :n t rccords of the volve forgings for the vendor
.af Velan I:ngineering.
Please refer to our previous let 1.c r of l',rr.h 31 and your let ter of / pri l 29, 1970.
We onderstanil Ihat the Cm.cron I ron k'or ks of th.us ton, Texas her. provided Velan Engineering the re:1uested documentation on beat t r es t r.ie n t for forgings.
The records covered all valve forgings < hipped to Velan for Duke valves in the past and will be incluiled on f o r g i ngt. shipped in the future.
We further undor. tant th..t Velan is prou < sing t his information and it wilI he t ranmi t ted 1o Duke in osder for it to be incluled in our valve records.
Should this i n f o rnia t i o n cc,w to your office please tran:.mit to us as early as possible.
Ue appreciate your ef fort:> in obtaining thic information.
Very truly yours, l
W.
II. Owen, Principal licchanical Engineer t
l g.
t.
tly:
D. S. itobbins
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DSR/JMC/cf Copy to:
11r. it. F. Smith lir. J. t..
I., Ostertag i
lir. J. 11 Curtis Exhibit G I
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