ML19326A034
| ML19326A034 | |
| Person / Time | |
|---|---|
| Site: | Davis Besse, Oconee, Rancho Seco  |
| Issue date: | 03/02/1972 |
| From: | Brown R, Oller R, Vetter W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML19326A024 | List: |
| References | |
| 999-042-72-01, 999-42-72-1, NUDOCS 8001310608 | |
| Download: ML19326A034 (14) | |
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e U. S. ATOMIC ENERGY COMMISSION DIVISION OF COMPLIANCE REGION III C0 Inspection Report No. 999-042/72-01
Subject:
Babcock & Wilcox Company Barberton, Ohio Steam Generators for:
Ioledo Edison's Davis-Besse License No.: N/A Facility (50-346)
Priority: N/A Duke Power Company's Oconee 2 Category:
Vendor Facility (50-270)
Sacramento Municipal Utility District's Rancho Seco Facility (50-312)
Type of Licensee: N/A Type of Inspection: Special, Announced
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Dates of Inspection: January 4 - 6, 1972 Dates of Previous Inspection: N/A kb Principal Inspector:
R. E. Oller Jk72.
$ [. hcz Accompanying Inspector:
R. L. Brown 2d (Date)
Other Accompanying Personnel:
None g
Reviewed By:
W. E. Vetter, Senior Reactor Inspector 8' 2-7.2-.
(Date)
Proprietary Information: None NOTE:
See Section III for R. L. Brown's contribution to the inspection covering the Oconee Unit 2 and the Rancho Seco steam generators.
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N SECTION I Enforcement Action A.
Noncompliance: None B.
Nonconformance:
See Page 5 of the attachment to this report.
1 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 3
Design Changes: N/A Unusual Occurrences: N/A Persons Contacted Babcock & Wilcox Company (B&W) Barberton, Ohio J. C. Quinn, QA Manager - Engineering and Technology Group (E&TG) s,,
W. C. Buskey, Senior QA Engineer - E&TG J. Lang, Section QC Manager - E&TG E. J. Donaleski, Manager - Component Management Unit, Nuclear Power Generation Department (NPGD)
J. S. Gershom, Section Manager - Nuclear Equipment Quality Control (NEQC) Engineering E. Snicer, QC Engineer - NEQC Engineering D. W. Goddard, Associate Metallurgist - NEQC Engineering H. L. Helmbrecht, Manager, Manufacturing Materials Iethnology (MMI)
Management Interview The same personnel noted in " Persons Contacted" Section of this rep rt were present during the management interview.
During the. management interview, Mr. Oller discussed the details of his inspection a:tivities relating to the documentation f z tha se:ondary side shell place, used in the two steam generators for the Davis-Besse facility, and the repair of the Rancho Seco steam generato:,
Mr. Brown separately discussed his portion of the inspection activi:les, and the results of this discussion appear in Section III of this report.
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Management interviewees were informed that documentacion relating to the transfer of plate material for the Midland Unit No.1, steam generators No. 1 and No. 2, to the Davis-Besse steam generators, appeared to be com-piste and that the inspector had no further questions. With respect to the quality of the plate, the inspector commented on the fact that there i
apparently had been considerable confusion, or misunderstanding, concerning the heat treatment requirements of the purchase specifications and ultimate certification of the plate to code requirements.
In any event, the inspector said, records reviewed during the inspection indicate that both the 4-7/16" thick and the 7" thick plate have been properly certified to SA-516, Grade 70.
(Paragraphs 2 and 3)
The inspector said that a review of B&W process records appeared to establish that, contrary to previous information, radiography was, in fact, performed following ccmplete rewelding of the cracked circle weld between the lower head and the tube sheet of the Rancho Seco No. 1 steam generator, and ultrasonic inspection only was performed on repairs to the weld and preparation of both the tube sheet and lower head prior to joining the two sections with the main circle veld.
This, the inspector said, appeared to be satisfactory as opposed to earlier information indicating that the repaired circle weld had been subject to ultrasonic testing only.
(Paragraph 4) d s
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SECTION II Additional Subjects Inspected. Not Identified in Section I. Where No
. Deficiencies or Unresolved Items Were Found l
' 1.
General l
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In response to a Compliance Headquarters' letter, dated December 9, 1971, an inspection at the B&W Barberton, Ohio plant, of documenta-l tion related to the manufacture of steam generators for the Oconee 2, Rancho Seco, and Davis-Besse nuclear facilities was performed by j
R. E. 011er, Region III, and R. L. Brown, Region I.
Mr. Brown examined records for the Oconee 2 and Rancho Seco steam generators.
4 Mr. Oller examined records for the two steam generators for Davis-Besse.
In addition, the incident of the lower head circle weld I
repair was reviewed by both Messrs. Oller and Brown.
Details of Subjects Discussed in Section I 2.
Transfer of Steam Generator Secondary Shells From the Midlands to the Davis-Besse Project The details of an examination of material documentation for the Davis-Besse steam generators are as follows:
i The inspector was told by Mr. Buskey that, early in 1971, B&W determined that some shall plates, 4-7/16" thick, in the secondary
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side of the two steam generators for the Davis-Besse project, lacked evidence of having been normalized, quenched, and tempered either i
by the supplier (Lukens Steel Company) or B&W due to an error in a purchase order revision. This error was found after the plates were cold formed and welded into courses.
An attempt was then made to i
l normalize, quench, and temper the courses, but severe distortion was I
experienced and the subject courses were put in quarantine for dis-position. B&W then secured concurrence with both Toledo Edison Company and Consumers Power Company to exchange secondary shell courses of the two steam generators with those previously fabricated for the Midland Unit 1 facility. The material for the Midland courses was later considered to have been satisfactorily heat treated 1
based on a letter dated June 18, 1971, from Lukens which B&W used as a basis for certifying that the material meet the heat treatment requirements of Paragraph 4 of SA-516. A further basis for certifying the Midland courses was physical property and Charpy-V impact tests performed by B&W.
In addition to the 4-1/16" Midland plates, 7" thick plates were also received for the Midland steam generators and certified on the same basis as were the 4-1/16" thick plates.
How-ever, the 7" thick plates were subsequently properly heat treated by B&W'(normalized, quenched, and tempered).
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b A review of all available documentation for the Davis-Besse. steam generators (previously assigned to the Midland project) revealed the material is in accordance with Material Specification A-516, Paragraph 4. Grade 70, and ASME Code Section III, Article 3.
The only difference between the 4-1/16" thick and the 7" thick plates is that the former was qualified on the basis of a Charpy-V test temperatura of 700F, while the later was qualified with a Charpy-V 0
test temperature of 40 F.
Documentation reviewed to support the foregoing statements included original purchase orders, change orders (revisions), Lukens' material test reports (chemistry and UT),
a Lukens' letter dated June 18, 1971, (a copy attached to each MTR for the 4-7/16" place), B&W CTR's for both 4-7/16" and 7" thick plates, and letters of authorization to interchange secondary side shell courses from Midland Unit 1, Nos. 1 and 2 steam generators to Davis-Besse Nos. 1 and 2 steam generators.
In response to questioning, Mr. Goddard told the inspector that the No. 1 steam generator was officially transferred to the 620-0014-55 contract (Davis-Besse) but the No. 2 steam generator, including the records, were not yet officially transferred.
The inspector visually examined both of the steam generator secondary sides in the shop and established that the No. 1 steam generator was marked 620-0014-55-11T? The No. 2 steam generator still contained the 620-0012-55-1 designation.
3.
Plate Material Test Reports i
The following tabulations contain data from the documents examined by the inspector for the steam generator secondary sides designated for the Davis-Besse facility:
a.
Material Test Reports (MTR's) and Certified Test Reports (CTR's)
(1)
No. 1 Steam Generator (Officially Changed to Contract 620-0055-11)
Shell Charpy-V Basis of Course Serial Lukens' Plate Test Certification to No.
No.
Heat No.
Thickness Temperature SA-516, Grade 70 0
1.
1-212-1 C-5947-2 7"
40 F Lukens' chemical C-5947-3 7"
400F analysis, B&W heat treatment and physical and Charpy-V tests.
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.m N-Shell Charpy-V Sasis of Course Serial Lukens' Plate Test Certification to No.
No.
-Heat No.
Thickness Temperature SA-516, Grade 70 i
l 2.
2-212-3 C-5914-3 4-7/16" 700F Lukens' chemical analysis; Lukens' letter dated June 18, 1971; B&W physical and Charpy-V tests.
3.
3-212-1 C-5946-1 7"
400F Lukens' chemical analysis; B&W heat treatment and physical and Charpy-V tests.
4.
2-212-4 C-5924-3 4-7/16" 700F Lukens' chemical r
analysis; Lukens' letter dated June 18, 1971; B&W i
physical and Charpy-V tests.
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5-212-1 C-5952-2 4-7/16" 700F Lukens' chemicai
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analysis; Lukens' letter dated Jura 18, 1971; B&W physical and Charpy-V tests.
6.
4-212-2 C-5948-2 4-7/16" 700F Lukens' chemical
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analysis; Lukens' letter dated June 18, 1971; B&W physical and Charpy-V tests.
7.
6-212-2 C-5940-2 7"
400F Lukens' chemical C-5947-3 7"
400F analysis; B&W heat treatment and physical and Charpy-V tests.
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(2)
No. 2 Steam Generator (Not Officially Changed to Contract 620-0055-12)
Shell Charpy-V Basis of Course Serial Lukens' Plate Test Certification to No.
No.
Heat No.
Thickness Temperature SA-516, Grade 70 1.
1-212-2 C-5965-1 7"
400F Lukens' chemical C-5965-2 7"
400F analysis; B&W heat treatment and physical and Charpy-V tests.
2, 2-212-2 A-5140-2 4-7/16" 700F Lukens' chemical analysis; Lukens' letter dated June 18, 1971; B&W physical and Charpy-V tests.
3.
3-212-2 C-5946-2 7"
400F Lukens' chemical C-5924-1 7"
400F analysis; B&W heat treatment and physical Charpy-V tests.
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4, 2-212-1 C-5946-3 4-7/16" 400F Lukens' chemical analysis; Lukens' letter dated June 18, 1971; B&W physical and Charpy-V tests.
5.
5-206-1 C-3693*
4-7/16" 400F Lukens' CTR dated January 12, 1968; complete for all SA-516, Grade' 70, and ASME Section III, Class A requirements.
6.
5-212-2 C-5948-1 4-7/16" 0
70 F Lukens' chemical analysis; Lukens' letter dated June 18, 1971; B&W physical and Charpy-V tests.
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- Plate from 3MI-2 S.G.
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[qa Shell
- Charpy-il
. Basis of Course Serial Lukens' Plate Test Certification tc No.
No.
Heat No.
Thickness Temperature SA-515, Grade 70 7.
6-212-2 C-5965-1 7"
400F Lukens' chemical C-5965-2 7"
400F analysis; B&W heat treatment and physical and Charpy-V tests.
(3) Authorization Letters For Transfer of Steam Generators' Secendary Shells From Midland Contract 620-0012-55-1 and Contract 620-0012-55-2 to Davis-Besse Contracts 620-0012-55-11 and 620-0012-55-12 (a) B&W 1etter dated July 23, 1971, from Nuclear Power Generating Department (NPGD) - Lynchburg, to the Vice President of Nuclear Equipment Department (NED) - Barberton.
(b)
B&W letter dated December 29, 1971, from NPGD-QA, Barberton, to NPGD components management, Barberton.
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(c)
B&W 1etter dated January 3, 1972, from NED-QC
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engineering to NPGD component management.
(4)
B&W Equipment Specification CS-3-33/0570 dated May 8, 1970, tor Once-Through Steam Generators (5) B&W Purchase Orders and Change Orders to Lukens' Steel Company (a)
PO 310591 AC dated November 12, 1968, and Change Order No. 1, which substituted B&W Specification W SPE-4-102, Revision 1, for W SPE-4-102, Revision O.
Revision 0 originally designated plates in thicknesses up to ab",
inclusive, to be supplied in a ho -rolled conditi:n.
Revision 1 designated the plates as:
Type 1 - Quenched-and tempered for cold terming.
Iype 2 - Quenched and tempered for hot forming.
Type 3 "As rolled" in conrormance with SA-516 and will :on:crm to tensile properties after hot forming and quenching and tempering.
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/y OU Ihe inspector was told by Mr. Buskey that all of the places were ordered to Type 3.
(b)
Other pur:hase orcers, similar to 310591 AC and the change orders containing the B&W Specification W SPE-4-102, Revision 1, were examined by the inspec-tor.
The one exception to the Revision 1 requirements was for plate heat No. C-3693, originally destined for use in a Three Mile Island 2 steam generator which was ordered in a full heat treated condit;on with all tests performed by Lukens.
4.
Rancho Seco No. 1 Steam Generator Weld Repairs Ihe inspector reviewed the B&W process records related to complete rewelding of the Rancho Seco No. 1 steam generator main circle weld between the lower tube sheet and the lower head.
The records estab-11shed that contrary to previous information that only ultrasonic inspection was used following repair of the main circle weld, 100%
radiography was, in fact, used. The " ultrasonic testing only" infor-mation, previously obtained, applied correctly to the repair of the weld end preparations of both the tube sheet and the lower head, but the main weld, after repair completion, was radiographed and accepted on the basis of radiographic examination insofar as the B&W process records are concerned.
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SECTION III Prepared by R. L. Brown, CO:1 Enforcement Action A.
Oconee 2, steam generator 2 material does not conform with the licensee's commitment in Table 4-9, Materials of Constru: tion of the Final Saracy Analysis Report.
(Paragraph 2)
B.
Rancho Seco, steam generator 2 material does not conform with the licensee's commitment in Table 4-10, Materials of Construction in the Final Safety Analysis Report.
(Paragraph 3)
Licensee Action on Previously Identified Enforcement Action: None
, Unresolved Items: None Status of Previously Reported Unresolved Items: None Design Changes: None Unusual 0:currences: None
\\.j P ersons Centacted Mr. W. C. Buskey, B&W Senior QC Engineer, Engineering and Technology Mr. E. Snicer, B&W QC Engineer Mr. H. L. Helmbrecht, B&W Manager, Manufacturing Materials Technology Management Interview At the conclusion of the inspection, the inspection results were discussed with the ic11owing B&W representatives:
Mr. J, C. Quinn, Manager - Quality Assurance, Engineer and Technology (E&T)
Mr. J. (NMI) Lang, Section Manager, QC Engineering (E&T)
Mr. W. C. Buskey, Senior QC Engineer (E&T)
Mr. E. J. D:maleski, Manager, Component Management Unit NPGD Mr. J. S. Gershom, Section Manager, NE QC Engineering Mr. D. W. Goddard, Associate Metallurgist, NE QC Engineering Mr. E. Snicer, QC Engineer, NE QC Engineering The following subject was discussed by the inspector: O m
.m The quality control documents should be reviewed for accuracy, ccmplete-ness, and acceptability by a knowledgeable person.
In fact, the inspector noted material test reports that certify the material as SA 516, Grade 70, and the tensile strength values shown are below the specification minimum requirements of 70,000 psi; however, these nonconformances were reported by a contract variation notice to the B&W, Lynchburg engineering department and accepted "to use as is", as SA 516, Grade 65 material.
The reports should be revised :: show the correct grade of material and a cross ref-arence to the contract variation nocice would indicate B&W awareness of the noncontormance, and the material stacus could be readily determined.
Additional Subjects Inspected Where No Deficiencies or Unresolved Items Were Found 1.
Steam Generator Shell Plates for Oconee Unit 2. SG No. 2, Rancho Seco. SG Nos. 1 and 2 i
a.
Audit of the equipment specification to determine 1
(1) Material specifications.
(2) Heat treatment requirements.
i (3) Additional testing requirements.
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b.
Audit of purchasing documents (purchase order, purchase order changes, and specifications) to assure conformance with the spe:1fication requirements, Inspection of manufacturing records to assure presence of:
c.
(1) Material idencification (Mark No. and Heat No.).
(2) Material certifications including Charpy-V Notch test results.
i (3) Heat treatment certifications including shop traveler.
d.
Inspection or deviation reports to determine:
(1)
Type of de:1ation.
(2)
Recommended solution, i
(3) Acceptance of recommended solution. O)
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(4)
Cause of deviation.
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Corrective action to be taken to prevent 'a recdrience of similar deviations.
Details of Subjects Discussed in Section I 2.
Oconee 2 Steam Generator No. 2 Materials Do Not Conform With the Licensee's C:mmitment in Table 4-9 " Materials of Construction" of the Final Satety Analysis Report Table 4-9, " Materials of Construction", of the FSAR, specifies that the steam generator pressure plate be in accordance with either ASME SA 212, Grade B, or SA 533, Grade B, Code Case 1339 (SA 212, Grade B, has been superceded by SA 516, Grade 70).
Contrary to the above, this steam generator contains two SA 516 plates (Heat Nca. C-2_S3 and B6606-1) of which the tensile prop-erties are less than the 70,000 psi minimum requirements of SA 516, Grade 70.
These valves are Heat No. C2363 68000 psi and Heat No. B6606 69000 and 69100 psi.
These nonconformances were reported to and approved by the engineering department of the nuclear steam supplier, but the inspector could not determine if the deficiency has been reported to the licensee.
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Rancho Seco Steam Generator No. 2 Materials Do Not Conform With the
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Licensee's Commitment in Table 4-10. " Materials of Construction" of the Final Satety Analysis Report Table 4-10, " Materials of Construction", of the FSAR, specifies that the steam generator pressure plate be in accordance with either ASME SA 516, Grade 70, or SA 533, Grade B, Class I.
Contrary to the above, this steam generator contains one SA 516 plate (Heat No. C5952-1) in which the yield point is lower than 38000 psi minimum requirements of SA 516, Grade 70.
A value of 36,750 psi was reported, also this plate was not heat treated to produce grain refinement-as required by SA 516. Per instructions from CO:HQ, these nonconformances will be transmitted to the licensee by CO:HQ.
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DIVISION OF COMPLIANCE t
6
%J MONTHLY REPORT FOR FEBRUARY 1972
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g Bdbcock & Wilcox Company,-Barberton,l1hio - A vendor inspection __
was performed at the Eabcock & Wilco: (b&W) plant in Barberton, 2
Ohio, on January 4-6.
The inspection consisted of an examina-tion of documentation relating to the steam generator secondary ~
side shell plates for the Davis-Besse, Oconee 2, and Rancho Seco facilities, and a record review of the rewelding of a majcr circle weld on the No.1 steam generator for Rancho Seco.
The rewelding was required as a result of cracking in the original weld.
Examination"of the documentation disclosed that the reallocation of secondary side plate material from the Midland 1 steam genera-tors to the Davis-Besse units was properly documented; that B&W certifications relating to non-normalised material used in the Davis-Besse steam generators accurately described the as-fabricated
-(s state of the material; and that the remainder of the material used in the secondary side of the above units was properly heat
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treated and met the specificatlon requirements.
The rewelding of the cracked circle weld between the lower head and tube sheet of the Rancho Seco No. 1 steam generator was found to be in accordance with ASME Code requirements.
The record review further disclosed the use of a single non-normalised' plate in the Rancho Seco Unit 2 steam generator (previously reported) which also failed to meet the SA-516, Grade 70 requirement on yield strength.
The plate was recalli-fled to Grade 65 and accepted on that basis by B&W and the licensee.
A possible deviation in tensile properties was also noted in the Oconee-2 steam generator material.
This matter is currently under review.
The acceptability of non-normalised material in the steam genera-.
tors of CAvis-Besse and Rancho Secc is currently under review by DRL.
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.m DIVISION OF COMPLIANCE MONTHLY REPORT FOR JANUARY 1972 Babcock & Wilcox Company, Barberton, Ohio A vendor inspection was performed at the Babcock & Wilcox plant located in Barberton, Ohio, on January 4-6 to examine documentation of secondary side shell plates for.the Davis-Besse, Oconee 2, and Rancho Seco I
The inspection verified that the use of unnormalized plate material was limited to three steam genera-tors previously identified.
No other deficiencies were observed.
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