ML20054C025
| ML20054C025 | |
| Person / Time | |
|---|---|
| Site: | Indian Point, Point Beach, Turkey Point, Ginna, Robinson, 05000000 |
| Issue date: | 04/22/1969 |
| From: | Long F US ATOMIC ENERGY COMMISSION (AEC) |
| To: | James O'Reilly US ATOMIC ENERGY COMMISSION (AEC) |
| Shared Package | |
| ML20054C013 | List: |
| References | |
| NUDOCS 8204190394 | |
| Download: ML20054C025 (2) | |
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UNITED STATES Y)
ATOMIC ENERGY COMMISSION l.
DIVISION OF COMPLI ANCE
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REGION 11 - SUITE 818 230 PE AC NTREE STREE T, N OR T H W E S T f5 6 AT LA NT A. GEORGI A 30303 T m m. '.'6-4 H 7 APR 221969 J. P. O Reilly, Chief, Reactor Inspection 2nd Enforcement Branch Division of Corop11ance, Headquarters CAROLINA POWER AND LIQlT COMPANY, DOCKET NO. 50-261 CONSOLIDATED EDISON COMPANY OF NEW YORK. DOCKET NO.
50-247. 286 FIARIDA POWER AND LIGHT COMPANY, DOCKET No. 50-250, 251 ROCHESTER CAS AND RLECTRIC CGiPANY, DOCKET NO. 50-244 WISCONSIN-MICHICAN AND WISCONSIN ELECTRIC POWER COMPANY, DOCKET NO.
50-266, 301 Transmitted herewith for action are Compliance Reports covering the Westinghouse, Lester, Pennsylvania, shop inspection on March 18-21, 1969.
In addition to the subject licensees, reference is made in Exhibit E of the report to Connecticut Yankee (Haddam Neck) and Southern California Edison (San Onofre). Two items of nonconformance described in the report are significant, especially in view of prior shipment of some of the steam generators for facilities both operating and now under construction.
I recoumend that the two items be dis-cussed directly with the licensees, since Westinghouse indicated to the inspector that they plan to take followup action on all affected units.
Our metallurgist states that under certain conditions, stress relieving may not be necessary.
For example, ASME SectionIII, N-518.3, permits such welding of attachments under conditions described therein, but also allows exceptions in Table N-532.
l Copies of the report are being sent to Regions I, III, and V for information.
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CO II:FJL Senior Reactor Inspector
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Enclosure
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CO Report Nos. 50-261/69-5, ggM Q -2f /
50-247/69-4, 50-286/69-4, 50-250/69-6, 50-251/69-3,
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I 50-244/69-6, 50-266/69-4,
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and 50-301/69-3 (23) cc R. W. Kirkman, CO I B. 11. Crier, CO III R. W. Smith, CO:V 1*
8204190394 690618 PDR ADOCK 05000244
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UNITED STATES f
2 ATOMIC ENERGY COMMISSION
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l DIVISION OF COMPLI ANCE c
REGION 11 - SUITE 818
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230 PE ACHTREE STREET. NORTHWEST Nil O Temi 52 6-4 53 7 AT LANT A, GEORGI A 30303 i
APR 221969 J. P. O Reilly, Chief, Reactor Inspection and Enforcement Branch Division of Compliance, Headquarters l CAROLINA POWER AND LIGHT COMPANY. DOCKET NO. 50-261 CONSOLIDATED EDISON COMPANY OF NEW YORK, DOCKET No. 50-247, 286 FIARIDA POWER AND LIGHT COMPANY, DOCKET NO. 50-250, 251 ROCHESTER GAS AND ELECTRIC C(EPANY, DOCKET NO. 50-244 WISCONSIN-MICHICAN AND WISCONSIN ELECTRIC POWER COMPANY, DOCKET NO.
50-266, 301 Transmitted herewith for action are Compliance Reports covering the Westinghouse, Lester, Pennsylvania, shop inspection on March 18-21, 1969.
In addition to the subject licensees, reference is made in Exhibit E of the report to Connecticut Yankee (Haddam Neck) and Southern California Edison (San Onofre). Two items of nonconformance i'
described in the report are significant, especially in view of prior shipment of some of the steam generators for facilities both operating and now under construction.
I recommend that the two items be dis-cussed directly with the licensees, since Westinghouse indicated to the inspector that they plan to take followup action on all affected units.
l Our metallurgist states that under certain conditions, stress relieving may not be necessary. For example, ASME SectionIII, N-518.3, permits such welding of attachments under conditions described therein, but also allows exceptions in Table N-532.
i Copies of the report are being sent to Regions I, III, and V for informat ion.
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CO:II FJL Senior Reactor Inspector M/
Iy' Enclosures l h CO Report Nos. 150-261/69-5.
150-247/69 4, 50-286/69-4, N"
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50-250/69-6, 50-251/69-3, j'
50-244/69-6, 50-266/69-4, and 50-301/69-3 (23) 9 2179 ces R. W. Kirkman, C0:1 B. H. Grier, CO:III j
R. W. Smith, CO V
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U. S. ATOMIC ENERGY COMMISSION RECION II DIVISION OF COMPLIANCE a
Report of Inspection (Vendor)
CO Report Nos. $0-261/69-5
$0-247/69-4 50-286/69-4 50-250/69-6 30-251/69-3
'50-244/69-6 50,-266/69-4 50-301/69-3 Licensees:
Carolina Power and Light Company Robinson 2 Consolidated Edison Company of New York Indian Point 2 and 3 Florida Power and Light Company Turkdy Point 3 and 4 l
Rochester Gas and Electric Company Ginna Plant Wisconsin-Michigan Power Company l
and Wisconsin Electric Power Company l
Point Beach 1 and 2 l
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Date of Inspection:
March 18-21,1969 Inspectedbyt tw V-72 -[f J. M.~ Vdrela, Reactor Inspector (Const.)
(Date)
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F. J. Loni;, Senior We~ actor Inspector (Date) l f
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SCOPE An announced inspection was made at the Westinghouse Electric Corporation, Lester, Pennsylvania, plant. The purpose of the visit was to detetsnine the quality level of the manufactured products and the essential documen-tation. The inspection was limited to the steam generators.
(The pres.
surizers are being fabricated in Tampa, Florida.)
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SUMMARY
b' Nonconformance Items - There were two nonconformance items:
1.
Open cans of low-hydrogen electrodes were seen in the stockroom and in the shop welding area, and workers were observed obtaining a supply f rom the open cans.
(See Section G.1.)
G.3 2
The -7 nut plates on the channel heads of the steam generators i
(Drawing 679-J-442) were not stress relieved or magnetic particle (MT) inspected as called out on the drawing. The above requirement
$a.rentTy> has been overlooked on all steam generators fabricated to date.
(See Section G.2.)
6 \\.
Other Significant Items -
1.
The Manager of Quality Centrol works directly for the Manager of
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Manufacturing.
2.
No inspections are performed to verify cladding thicknesses, which, according to Westinghouse specifications, should be 1/4-inch minimum.
3.
Initials are used by inspectors to signify acceptance of an operation 3
or inspection point instead of either a controlled numbered stamp or the inspector's signature.
Management Interview - All the persons listed in Detail, Section A, except Vojtecky and Hibbert, were present for the interview.
I 1.
Quality Cont rol Organization j
The inspector stated that many authorities agree that quality control should not be a function of the Production Department. The QC people indicated their approval; however, Reynolds and Irving stated that Westinghouse has had years of satisfactory experience and success with this type organization.
The inspector did not pursue the point.
Af ter the interview, several quality control personnel indicated their pleasure over the question being raised. As the inspector was leaving i
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the plant, Jenkins stated that a similar observation was currently being made by Westinghouse in the course of their own appraisals of prospective vendors.
t In a telecon the following week, Irving and Reynolds advised the j
inspector that the minutes of the meeting, which had been distributed to top management, already had produced favorable results and indicated i
that an organization change was in progress.
2.
Low-Hydrogen Electrodes The inspector discussed the improper storage and control of low-hydrogen elect rodes; and 'Reynolds countered that since they were not using these electrodes on nuclear work, they were not the inspec-tor's concern. The inspector stated he, Earle, and Klossin had seen open cans of E7018 electrodes by the steam generators and that it was in violation of Westinghouse specifications.
Irving agreed with the inspector and added that steps would be taken to correct the condition.
3.
The -7 Nut Plates The inspector's mention of this item was accepted with only minor comment. Westinghouse stated that although it was an oversight,
,st ress relieving and magnetic particle inspections [wWd'be per'.omed),
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4.
Inspection of Cladding The inspector asked why Westinghouse did not inspect the cladding thickness. Reynolds replied that Westinghouse guarantees the cladding for five years and has never had a failure.
The inspector commented that drawings indicated the cladding should be 1/4-inch minimum thick-ness.
Reynolds' defense was, "With our cladding process, we know that we have 1/4-inch minimum."
DETAILS A.
Persons Contacted i
D. A. Jenkins - QC Engineer A.P.D.
O. J. Earle - Manager Quality Control C. W. McKee - Jt. T. D. - QC Engineer C. R. Kline - Su'pervisor QC (Receiving and Source Inspection)
R. D. Milos, Jr. - Manager Cont racts and Projects l
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E. R. Klossin - H.T.D. QC Engineer H. J. Wolff - H.T.'D. Engineering D. E. Irving - H.T.D. Customer Service F. X. Brown - Tampa S. D. Reynolds, Jr. - Manager, Metallurgy J. S. Vojtecky - QC Representative, Pressure Vessels, Pittsburgh F. Hibbert - QC Supervisor B.
Gene ral Arrangements for the inspector's visit were made by the principal j
inspectors of pressurized water reactors for Region I and II, through the respective licensees.
The inspector's initial Westinghouse contact was D. E. Irving of Customer Service.
Irving escorted the inspector to the quality control offices in the fabrication building and introduced the QC supervisors of the Lester plant and Vojecky, the QC Representative 3
f rom Pittsburgh.
QC Hanager Earle, Klossin, and Vojtecky discussed the Westinghouse I
quality control way of life in a lecture f ashion, which made it dif-ficult to note the salient items.
It became evident to the inspector that Westinghouse was unprepared and unfamiliar with Compliance-type i
inspections when Klossin asked, "What is the real nature of your visit?" The inspector outlined the Commission's regulatory program and added that in order to arrive at a confidence level of their product, it would be necessary to observe a demonstration of quality control by randomly selecting items of record, scrutinizing these i
j items, and then comparing them to the as-built hardware.
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l The inspector added that before leaving he would like to meet with l
concerned personnel and briefly review his observations in order to avoid any incorrect conclusions the inspector may have drawn.
The next day the inspector directed his efforts to the following:
1.
Organization 2.
Inspection Point Program (IPP) l 3.
Steam Generator and Pressurizer Status 4
Radiographic Inspection I
5.
Inspection of Steam Generators i
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Organization (See Exhibit A)
The organization and functions, with few exceptions, have features of the Navy Nuclear program and, in general, is better oriented to the nuclear business than most programs observed by the inspector.
Some exceptions which are on the "minus" side are the following:
1.
The Production Manager is also the Manager of the Quality Control Depa rtment. This organizational weakness has been discussed considerably in the past.
i 2
Item 5 under QC Engineering, the IPP (Inspection Point Program),
l is an excellent too1 *if the shop inspectors do not depend entirely 1
on it, thereby overlooking the unexpected.
For example, the
-7 plate was not on the IPP list, although the requirements were clearly indicated on the applicable shop drawing.
Of special interest is Item No. 10 under QC Engineering, The inspector verified that personnel are indeed periodically tested 3
and qualified for NDT as required and found that two of the "old I
timers" had recently failed to qualify when retested in accordance j
with Westinghouse requirements.
D.
Inspection Point Program (IPP)
(See Exhibit B) 1.
Upon receipt of each new shop order, an IPP is initiated in the pe rtinent inspection station and placed in a shop order folder.
2.
The shop order folder follows the work through the various manufacturing sections until the unit is completed.
3.
Responsibilities for record maintenance are:
f a.
Inspectors must properly fill out and keep the IPPt s up to date.
b.
QC engineers maintain and update programs as required, audit shop order records for adherence to established rules, and review and file the completed folders in the QC office.
E.
Quality Control Supervisor l
Duties of the QC supervisor include reviewing and checking to see that the folders are maintained by each shift and that the folders are at the proper inspection station, and delivering completed folders to the Quality Control office.
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Complete records of other objective evidence for each shop order are maintained in the Quality Control office. A folder is initiated upon receipt of each new confirming order and is placed in numerical sequence in the open order file by the clerk in the Quality Control office.
Upon shipment of each unit and delivery of the IPPand other shop records to the Quality Control office, the records are merged with the office file covering the same unig and the combined records are placed in the " shipped" file.
The following sequence permits the record information to be easily obtainable:
1.
Shop record folders a.
All appropriate IPP's b.
Welder records c.
Preheat records d.
Tube welding, Pr, gas test and repair charts e.
MT records 2.
Backup information - in chronological sequence within the following categories:
a.
Order Service or Customer Service data (1) Order sheet (2) C.0. change notices (3) Correspondent memos j
b.
Engineering shop order pages c.
Inspection memos to suppliers d.
Drawing change notices e.
H/T procedure f.
H/T records g.
UT records h.
G-Sheets
- i. EA's and EAN's J.
X-ray reports k.
Certificate of test l
1.
Field service records l
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F.
Radiography The inspector was impressed with Holmes, who is in charge of the radiographic laboratory.
Holmes has been at this post for over 25 i
years and produced evidence of his interest in this skill by the cou rs es, symposiums, etc., that he has attended in an effort to keep up proficiency. Holmes is the final radiographic interpreter. The 1
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. Lester plant of Westinghouse has two other professionals in this field, J. Gillian and W. Gibson. All three were also qualified to NAVSHIPS 50-250-1500.
Gibson and Gillian have the responsibility for examination, testing, and qualifying NDT personnel.
The film and technique selected by Holmes produced very good contrast and image sharpness which in part indicated the use of slow, fine-grain film producing the maximum resolution.
The channel head casting weldments (Drawing 794-D-219) of th.e steam generator are radiographically prepared, and examined to Section III of the ASME Code.
In this area, quality control and inspection were excellently demonstrated.
G.
Inspection of Steam Generators While awaiting to be escorted to the fabricating shop, the inspector made a cursory study of applicable steam generator drawings and specifications and observed items that did not appear to be on the IPP inspection list.
1.
Nut Plate Welds (Nonconformance).
The shop was very well organized, with the nuclear work on one end l
of the building and the nonnuclear occupying the other half. The
- first items inspected were the i_nsulation _3m1_pjaf,_e.__a.ttachments
.,,) ' (under ASME Section III, N518.3 and N518.4) on the channel heads.
The inspector inquired of Klossin and Earle if the nut plates r,.
.S on the channel heads (attachments) were inspected. Klossin i
j'45 stated that there were no inspection requirements and proceeded to check the applicable drawing. Westinghouse Drawing 679-J-442 l
indicated that the 1/4-inch fillet welds were fabricated to Specification 600923SR (stress relieve) and 60019MT-F (Magnetic Particle Inspection).
(Sec Exhibit C.)
Klossin admitted that Westinghouse had overlooked the drawing callout and Code require-ments.
2.
Electrode Storage (Nonconformance) i During the shop tour, the inspector observed workmen obtaining i
E7018 (low-hydrogen) electrodes f rom open containers. A check of Westinghouse specifications on electrodes disclosed the j
follouing statement:
"All electrodes removed f rom containers shall be baked for a minimum of one hour at 525 f 25 F prior to welding. Electrodes shall not be exposed to the atmosphere j
/ for a period longer than four hours. Wet electrodes shall be discarded." A further check by Klossin and the inspector dis-closed open containers of electrodes (low-hydro 8en) in the supply room. Klossin stated that he would discuss this discrepancy with his management.
3.
Steam Generator Cladding l
While observing work on the steam generator channel heads, the inspector saw a workman inside of the channel htac grinding weldments. The inspector borrowed the workman's extension lamp and inspected the cladding. Finding a depression in the cladding, the inspector asked Klossin and one of the Westinghouse inspectors standing nearby what the specified minimum thickness of the cladding was and how it was measured. Neither of the two ques-tions were satisfactorily answered at this time or later at the management int e rview. The most official answer was that given by Reynolds, the Westinghouse Metallurgical Manager, who stated that the integrity of the cladding is assured by a process which has had zero failures. The inspector, using a vernier depth gage, determined that weld passes had some localized depressions
.090-inch deep, and concluded that the only means of determining l
the cladding thickness would be by obtaining a core of a ques-tionable area. The inspector considers this question unresolved.
i 4.
Tube Welds (See Exhibits D) 1 l
l The inspector spent considerable time inspecting and observing the welding of the tube-to-tube plate welds. The Exhibit describes the inspector's observation. According to Westinghouse personnel, they have made over 320,000 tube-to-tube plate welds without experiencing a failure;and this is why Westinghouse now offers a five-year warranty against leakage of welded joints between tubes and tube-plate on all domestic orders.
5.
Reheater Unit (Nonnuclear) 1 l
In the course of a side trip to another section of the shop, l
the inspector observed what appeared to be deep die stamping (letters and numbers) on the head (casting) of a reheater. Klossin and Earle, when questioned about the stamping, stated that the reheater was fabricated to ASNE Section VIII, UHT-86, which specifies that only " low st ress" stamping is permissible. Klossin and Earle agreed that the inspector's observations were correct and indicated they would investigate procedures and persons res-l ponsible.
It was later learned that the tool crib had purchased I
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i the " low stress" stamps but that they had received "little or no use" as stated by an attendant. QC Manager Earle stated that the stamping on the reheaters would be ground off, NDTid, and cor-rected if required. The inspector stated his interest in this item was only as a basis for evaluation of shop performance realizing that the reheaters are not considered Class I components.
H.
Status of Steam Generators and Pressurizers (See Exhibit E.)
I Attached as Exhibit E is a list of components being supplied by i
i Westinghouse. Exhibit E shows components shipped and compon'ents which l
are pending shipment. As indicated, fabrication of pressurizers is I
being transferred to the ' Tampa plant.
Attachments:
Exhibits A through E I
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HANAGER
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MANUFACTURING f,
ii MANAGER OF QUALITY CONTROL
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9 t-QUALITY CONTROL ENCINEERING PROCUREMENT QUALITY ASSURANCE V
J.-Cuy Ass. Q.C.E. (Cond. & Mach.
C. W. McKee Q.C. Eng.
Sep. Rcheaters)
C. Patchel Inspector (Tubes)
E. Klossin Ass. Q.C.E. (Nuclear Power)
(Auxiliaries)
FUNCTIONS (Preventative)
FUNCTIONS (Preventative)
(1) Analyze contract proposals for (1) Verify quality of purchased material.
quality capabilities.
(2) Review Engineering design for (2) Audit vendors Q.C. practices quality assu rance.
and procedures.
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!i (3) Audit and analyze shop problem (3) Audit potential supplier for and determine correction thereof.
capability and controls.
(4) Determine quality adequacy of (4) Assist and advise vendors in Hanuf acturing or special processes.
our quality requirements and (5) Plan for quality by writing 1.P.P.
processes.
(Inspection Point Program).
(5) Provide feedback and improve (6) Develope new inspection controls communications.
and procedures.
(6) Evaluate vendors.
(7) Keep current with relevant trends (7) Assure that suppliers main.
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in Q.C. cont rols, tain objective evidence of
's.
(8) Maintain EAN procedure.
quality and adherence to (9) Review purchase orders for inclu-Westinghouse drawing require-sion of quality requirements.
ments.
(10) Test examine personnel for non-sb g destructive test qualification.
(11) Haintain objective evidence of quality.
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l Exhibit A Page 1 of 2
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i MANAGER OF MANUFACTURING MANAGER OF QUALITY CONTROL t
p INS PECTION RADIOGRPHIC LABORATORY Q.C.Su pe rvis ors Supe rvisors F. Hibbert 1st shif't F. Hibbert 1st shift E. Csanady 2nd shift E. Csanady 2nd shift '
ist shift-2nd shift 3rd shift 1st shift 2nd shift 1 Class A Radiog.
1 Class A Radiog.
12 7
4 1 Class C Radiog.
1 Class C Radiog.
Inspectors Inspectors Inspectors
- FUNCTIONS (Appraisal)
FUNCTIONS Assure conformance to Westinghouse (1) Establish techniques to be used -
drawings, processes, and Manufac-for radiographic test.
turing specifications by:
(2) Lay out work and set-up equip-ment for X-ray or gamma radio-(1) First piece inspection, g ra phy.
(2) Patrol Inspection (3) Complete radiographic exposure l
(3) Final inspection.
and process' film.
l (4) Dimensional check.
(4) Interpretation of radiographs l
(5) Maintaining I.P.P. program and to code specifications.
objective evidence.
(5) Conduct ultrasonic tests.
(6) Non-dest ructive testing including (6) Maintain radiographic records.
M.T.,
P.T., and gas and hydro-static test.
(7) Establish torque requirements EQUIPMENT for tube rolling.
i (1) 2 MEV Van de Craft.
l (2) 400 KVA Siefert.
(3) 200 KVA Balteau Unit.
(4) 62 curies cobalt 60.
(5) 50 curies iridium 192.
(6) 2 sperry ultrasonic.
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l 1--Three layers of Inconel weld-deposit cladding are applied to the face of the tube sheet,. providing filler metal for fusing to carbon-steel tubes.
2--Af ter finishr achining, the integrity of the Incon'el cladding is tested m
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' 3 -Tube-sheet holes are drilled with an automatic tape-controlled machine, insuring accurate spacing of the holes.
i 4--Tubes are inserted and, af ter. light rolling t6 hold the. tubes in place during the welding sequence, each tube and tube hole is counterbored. This step I
provides mechanical cleaning of welding surf ace pr.ior to welding.
5--The recessed weld is made by the automatic TIG, process, fusing the Inconel cla'd-ding toitheecarbon-st' eel tube.
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L f/NAL /N.SPECT/DN AND ACCEPI~ANCE AS /ND/CA 7"ED PVHEN A LL '
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.... b U. ...a i... 2 ' i ( STEAM CENERATOR & PRESSURIZER FABRICATION STATUS ORDEPS SHIPPED Cu stome r -- C.O. Steam Generators Pressurisers t South. Cal. Edison 16-A-4320-1 16-A-4850-1 -2 j LA-14101 S.C. -3 LA-14115 P r. Conn. Yankee Atomic 16-A-4640-1 16-A-5112-1 BS-50001 S.C. -2 -3 !f BS-50004 Pr. -4 Rochester C. & E. 16-A-5695-1 16-A-5696-1 RH-33001 S.C. -2 RH-33004 Pr. Consolidated Edison 16 A-5780-1 Not Shipped (Comp) NY-77201 S.C. -2 At Foster Wheeler -3 NY-77204 Pr. Indian Pt. II -4 Carolina P & L 16-A-6081-1 16-A-6208 -2 CH-25401 S.C. CH-25404 Pr. -3 4 Wisconsin-Michigan 16-A-6079-1 16-A-6256-1 MK-60001 S.C. -2 MK-60004 Pr.I roint Beach Florida P & L 16-A-5885-1 16-A-5883 i MI-16401 S.C. -2 Ready to Shipj -3 in W-18 i HI-16404 Pr. l ORDERS FENDING SHIPMENT Wisconsin-Michigan 02 16-A-6339-1 5/69 16-A-8216 5/69 -2 6/69 (Tampa) MK-80001 S.C. FX-80004 Pr. Florida P & L 11 16-A-6341-1 7/69 16-A-8226 9/69 -2 9/69 (Tampa) l MI-16451 Sc. -3 10/69 i, MI-16454 Pr. ) p consolidated Edison IPP III 16-A-8I73-1 2/70 16-A-8218 4/69 -2 3/70 (Tampa) I NY-78501 S.C. NY-78504 Pr. ,-g g((g ALL FUTURE FABRICATION WILL BE AT THE WESTINCHOUSE TAMRA PLANT j Exhibit E Page 1 of 1 t' I (- i c ,c _}}