ML20072T473

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Rev 1 to Procedure Qualification Record PQR-047A, as Welded. Related Info Encl
ML20072T473
Person / Time
Site: Seabrook, 05000000
Issue date: 04/13/1981
From: Freed K, Martin G
PULLMAN POWER PRODUCTS CORP. (FORMERLY PULLMAN, INC.)
To:
Shared Package
ML20071K200 List:
References
FOIA-82-524 PQR-047A, PQR-47A, NUDOCS 8304080139
Download: ML20072T473 (20)
v • d • e


Text

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Pullman Power Products

~ '

<*i . PQR No. 047A DocttMLNT NO.

PREPARED BY: G.L. Martin APPROVED DY: K. J. Freed M/_ MWE 2/13/81 PROCEDURE To BE USED PAGE QUALIFICATION RECORD ONLY ON JOB # w NO. 1 Of 4 LATEST REY. DATE i PROCEDURE QUALIFICATION RECORD 4/13/81 047A-1-KI-Al AS WELDED Copyright ,1991

. PULLMAN POWER PRODU' CTS

^

UE&C .

CODE WILLIAMSPORT, PENNSYLVANIA

h. 01 R[vl580N PREPARED BY APPROvCD BY I N I T I Al. S . DESCRIPTION 2/13f81 G.L. Martin K.J. Freed kf4 Original Qualification 4nU81 G.t. Martin K.J. rreea y .

Correctea Preseat, eosition, ana Gas

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Y- g@-

Y p1 Sh50*. ... .

1 -

8304080139 830304 PDR FOIA KINDER 82-524 PDR SF 1.01 (02-79)-

1 . _ . . _ . . . . _ . . . . . . . _ . . - . . . . . . . . . . . _ . .

"1 Pullman Power Products PQR No. 047A l ,

- . DOCUMENT NO.

PREPARED BY, G. L. Martin AppRovEo oy, K. J. Freed pf){. o37g. 2/13/81 -

PROCEDURE TO BE USED -

PAGE QUALIFICATION RECORD (PQa) ONLY ON .108 # t/ NO. 2 Of 4 WPS NO. 150-1-1-KI- Al WPS DATE 2/13/81 _ , _

WELDING PROCESS (ES)

~

O TYPES Automatic

. . (M ANU AL . AU T OM AT I C. sEM I . AUTC )

' COMPOUND BEVEL BASE METAL (OW 403)

"U" GROOVE %M uATERIAL SPEC.

I

.. .. ..._ . wPE oR cRADE Gr 6 l 0F P NO. I bP 1 TO P NO. 1 Gr 1 THICKNESS (IF PlPE' DI AMETER AhV WALL fgfr THICxNEssi 24' Dia.1.565" Wall POSITION (OW-405)

,0.D. 9 / NR .

p'* gg.N PostTion oF Groove 6G Uphill & Downhill WELD PROGREsslON

~

J. / {

  • q luensu . . wiul lg' riAx 9' },

EAcu sspE { 0451.olo PREHEAT (OW 406) 500 F Min.

PRENEAT TEw.__

INTERPAss TEw. 2000F Max.

. . OTHER GROOVE DESIGN USED GAS (OW 408) '

3 TvPE or Gas oR Ase 25-40 CEH Arnon FILLER METALS (OW 404) b A 100% Arcon COMPCstTION OF G As M4 Aa uIE

- *- OTHER WELD MET AL FILLER METAL ANALYSTS A NO. I F NO. 6 TECHNIOUE PROCEDURES (OW-410) s.r. A. SPEC. 5.18 Aws CtAss E705-3 sTRiNs oR WEAVE sEAo Both osCIL u rlow See page 4 -

POSTWELD HEAT TREATMENT (OW 407) None uaTIPass oR simE Pass M y,y,k,,,,,

slNGLE OR MULTIPLE ELECTRODES Single -

. TEMPERATURE

. TiuE

~

Type: EWTh-2 OTHER ELECTRICAL CHARACTERISTICS (OW 409) See page 4 l -

WELOlNG ELECTRODE BARE FILLER CURRENT AC/DC TRAVEL VOLTS PRARITY SPEED . C04ENTs PROCESS DIA. WIRE DIA. ( AMPS)

DCSP e,

l 0 .

l

s Pullman Power Products -

yf i

, PQR No. 047A DottiMENT No PREPARF.D BY G.L. Martin APPROVED nY: K.d. Freed f.48_ $$$U 2/13/81 PROCEDURE '

To BE UsED PAGE QUALIFICATION RECORD g

9NLY CN job # I' h)

\< 4 No. ,

4 of 4 SUPPLEMENTAL PROCEDURE-QUALIFICATION RECORD

. ._ FORM FOR AUTOMATIC GTAW WELDING

, j .

Filler Metal E705-3 . E705-3 E705 Diameter Filler :1/8" x 1/16" .035" .045" Pass Type ' Root (k-Irisert) Hot & Fill Fill & Cap 1st Level Weld Current 115 Amps 160-285 Amps 265-299 Amps Low Pulse P.A. Sync-Pulse Sync-Pulse Low Pulse Frequency 1.1 P.P.S.- 0- 0 .

Low Pulse Width 50% 0 0 Background Current 60 Amps ii 65-184 Amps 190-195 Amps Out Dwell .1 Sec. li .3 .6 Sec. .4 .6 Sec. -

Excursion Time . .1 Sec.  ; .3 .4 Sec. .3 .5 Sec.

.2 .6 Sec.

In Dwell .1 Sec. -

.3 .6 Sec.

Oscillator Amplitude 0 ie .16" .27" .18" .20" Primary Wire Speed 0 40-80 Ipm 40-65 Ipm Background Wire Speed 0 30-70 Ipm 30-50 Ipm

.o {' Ist Level Travel Speed 3.2 Ipm :l 3.2 Ipm 3.2-4.0 Ipm Primary Arc Volts ' - - '

9.3y- T- 9.2-10.0v 10.2-10.6v Background Arc Volts 7.8v 7.4-8.0v 8.6-8.8v Gas Cup Size #8 -

  1. 8 #8, #10 l Torch Lead ---- 50-100 70-100  ;

l Torch Side Tilt ---- 0-70 50-100 '

300 300 Wire Block ---  ;

No. of Passes 1 ,

11 28

- t l

i i

I j

- I SF 1.o t A (4-79)

"9 pP Pullman Power Products c.

i PQR No. 047A DOCUMENT NO.

PREPARED DY, G. L. Ma r-ti n appRovco sy, K.J. Freed . .f7j}{ DATE, 2/13/81

]

r Ro ctou R E' QUALIFICATION Rtc0RD (PQRI To BE USED ONLY ON JOB a

. PAGE NO. 3#4

. TINSILE TEST (OW-150) 462.1(.8)

. OLTIMATE ' ULTIMATE, CHARACTER OF UNIT STRESS FAILURE & LOCA-

., SPECIMEN TOTAL LOAD WIDTH THICKNESS AREA LB. ESI TION j NO.

T1 - AW .746 .581 .433 33.550 77.483 Base Metal T2 - AW .737 .578 .426 32.800 76.995 Base Metal T3 - AW .740 .576 .428 32.980 77.056 Base Metal T4 - AW .742 .575 .427 32.950 77.166 Base Metal _

CUIDEp BEND TESTS (QW-160) 462.2(A) .

. TYPE AND TYPE AND *

- RESULTS FIGURE NO. RESULTS FT rtin F Mn .__

b5 - AW Bent 180 0, acceptable b6 - AW Bent 1800, acceptable .

. b7 - AW Bent 180 , acceptable b8 - AW Bent 1800, acceptable TOUGHNESS TESTS (QW -170) N/A I # " 'I * -

SPECIMEN NOTCH NOTCH TEST IMPACT NO. LOCATION TYPE TEMP. VALUES AVE % SHEAR MILS i

Welder's Name K. V. Fluck Clock No. N/A Wadgea No. 6568 Test Conducted by: MSI Testing, Inc. Laboratory Test No.81-075 Per: 8. Mockli We certify that the statemen*.s in this record are correct a'nd that the test welds were -

prepared, welded and tested in accordance with the requirements of Section IX of the ASHE Code.

Signed Pullman Power Products 2 d' &fA.

Doce_ 3/2o/r/ 3y G. L. Martin

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. March 26, 1981

- DC LAMBERT - Site SBU- 43465 File: 9.1.5 Category: REPT Ref: SB-10898 Mr. J. DeVincentis, Project Manager SB-11031 Yankee Atomic Electric Company SB-42515 1671 Worcester Road ,

P.O. Box 930 -

Framingham, Massachusetts 01701 No Response *.aquired lirM A %..k CDR emedo

Dear Mr. DeVincentis:

g l @ . OL i

Public Service Company of New Hampshire Seabrook Station - Units I and 2 Potentially Reportable UDcruau..n(e) Deficiency) \

Final Report on Homer Shankland NDE Froblem

) The purpose of this letter is to provide a final report on the

( Homer Shankland NDE problem' including the results of investigations conducted independently by Dravo and UE&C as referenced in the following:

1. Dravo letter Molvie to Case dated 1/26/81
2. UE&C memo Werner to McCarrigan dated 3/3/81 i 3. UE&C memo Werner to McGarrigan dated 3/23/81 l 4. Dravo letter Molvie to Case dated 3/3/81 This condition was initially detected by our Vendor Surveillance Representative Mr. E. Lucas on December 30, 1980 when Dravo inspector
  • Mr. H. Shankland was observed performing magnetic particle inspection j using an improper technique.. VNR-06944 was epnsequently issued and Dravo responded by re-examining Mr. Shankland's work for the day in question and five additional spool pieces fabricated earlier. Results of this re-examination, as reported in Reference 1, revealed a base metal linear indication on an ASME III Class 3 piping subassembly which does not require magnetic particle testing of base metal adjacent to welds. Evaluation of the indication showed that it was not significant and, in fact, wa's represen-tative of the type of surface indications typically found on A106 piping material. It was concluded that this was not a rejectable defect, however, it indicated that perhaps additional re-examination of this individual's work should be performed. 'l ou notified the NRC on Monday, January 26, 1981 of this potential significant deficiency and sent an Interim Report on February 23, 1981.

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Mr.J. DeVincentis March 26, 1981 Project Manager l .

l l A program was then instituted to re-examine any work performed by this l inspector which was available in Dravo's shop or in the shipping yard. As I

reported in Reference (1), seventy-six (76) fabricated piping subassemblies j (54 of which were Seabrooks) were re-examined. This expanded investigation showed seven base metal indications similar to the first and seven lack of fusion indications in a weld used to join a backing ring. Based on the results of this initial re-examination program, Dravo concluded (Reference 1) that.,

(1) although some examinations performed by Mr. Shankland have not been performed in strict accordance with their procedures and (2) although some indications found were greater than the acceptance standards would permit, none of the indications were the result of serious defects in the welds or base material l

and it was their opinion that, if the defects had not been rem 6ved, they would not have affected the safety or reliability of the fabrication. This l

was reported by Dravo to NRC also on January 26, 1981 as a potential 10CFR Part ?1 incident with the'same conclusion.

Although UE&C followed this initial investigation very closely and generally agreed with Dravo's initial conclusion, it was UE&C's opinion that these findings warranted further investigation by UE&C at the Seabrook site to reinforce or refute Dravo's conclusion based on their own re-examination program.

UE&C proceeded i with our own re-examination program, which was performed by Pullman-Higgins certified NDE personnel during the period 2/9/81 through 2/23/81, under the auspices of UE&C NDE examiners D. Reinert and J. Werner.

Results of this re-examination program, as delineated in Reference (2), revealed a total of sixteen (16) indications of which fifteen (15) were surface base metal linear indications and one (1) weld crater. These defects were identified on UE&C NCR-860. Re-examination and removal of reported indications was then performed during the period 3/12/81 to 3/17/81. Reference (3) reports the results and substantiates the fact that the indications, as witnessed during removal, were shallow in depth and considered to.be non-relevant indications.

Concurrent with UE&C's own re-examination program at the site, Dravo expanded their own re-examination program to a much larger population (see Reference 4). The results of both UE&C's and Dravo's re-examinations, as

! reported in References (3) and (4) are mutually reinforcing in their respective l conclusions. Considering the type, size and location of the indications detected to date, we can see no need to continue any addit.ional re-examination of the work performed by Mr. Shankland. Further effort of this nature would only serve to further substantiate the conclusions expressed by Dravo and UE&C. Based on the results of this investigation, UE&C concluded that the improper NDE has caused no deficiency in the design or installation at Seabrook and that this condition is not a reportable 10CFR50.55(e) deficiency. ,

l Very truly yours,

/,;G.F. Cole

% roject Manager

! GFC/RCL/Et attachment

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  • f)//f ,isu Attachmmt to SBU 43465 , MP upnwunnue OS**sE}t f Isa4) llCJ Albf pf/ncCv4 ,

BM (Mh:2J January 26, 1981 7$uelf[r.,.dfr [bMf/f]

United Engineers and Contructors 30 South 17th. Street D Philadelphia, PA 19101 3 33 E.N.cen nsJ '81 14yilD.!ER Attenti,on: Mr. E. B. Case

Subject:

Inspection Problem Report (E2936 thru E2939, E2954 and E3098)

Gentlemen:

You will find attached a report of an inspector performing a magnetic particle examination not in accordance with the Dravo procedure. The report contains' the re-examinations of this individual's work conducted by Dravo and the results of these re- .

er==inations.

In addition, the report states certain conclusions and in-house corrective action which Dravo proposes.

This report is being sent to you for your information so that you can take what action you deem necessary. Note that in the .re-examination program undertaken by Dravo, none of the rejectable indications were czused by major defects, which in our opinion, could cause a safety hazard. .

~

We are also enclosing a copy of nur letter informing the NRC of.

this incident.

Very truly yours,

.DRAV'O CORPORATION Pipe Fabrication Division -

k .

W. A. Holvie .

Manager - Quality Ascurance &

. Technical Services ,

WAM/b1w Attachments PIPE FABRICATION OlVISICM DRAVO CORPORATION 1115 O!LMAN STREET MARIETTA. OH 45750 814 373-J541 -

REPORT OF DOMER SH ANKLAND INSPECITON PR OBLEM

/

JANUARY 23.1981

1. PROBLEM *

/ On December 30, 1980, Homer Shankland was found to be conducting a ' mag

.' particle examination of a weld using a technique not in acccrdance I with Dravo Procedure. The Dravo Procedure e.alled for the area of interest to be covered in two directions 90 degrees apart where as he

~ was examining in one direction only.

This inspector has been employed by Dravo as an inspe~ctor for approxistely 2/* years, has been an inspector throuFh our Navy Nuclear Program and through all our con:mercial nuclear program. In the performance of his work he has been under observation by our customer inspectors, by our ANI and by our Level III Examiner in the normal course of performing their duties. (Our ANI witnessed hold points on October 13, 1960, and December 16, 1980, a,p which time Shankland was observed properly performing mag particle examinations). We have had no previous. complaints as to his ability to perform as a qualified inspector and we therefore conclude that he is a knowledgeable l individual with r'espect to the Code and with respect to our Nondestructive Testing Procedures. His failure to follow the procedure was not caused by his lack of understanding of the procedure.

2. INVESTICATION As soon as the problem described above was made known to Dravo,the Chief Inspector proceeded immediately to re-examine all of the work performed by this inspector on chat day. Further work consisted of approxmiately 54 operations on 19 fabricated assemblies.

Approxmiately half of these operations- were magnetic particle examinations and hal.f were dye penetrant examinations. These

~

. examinations were conduched by other members,' of Dravo's Inspection Department and some of these examinations were witnessed by the customer's inspector who had discovered this problem. There were no rejectable indications found in any of this work. There was no evidence that he was performing dye penetrant examinations in an improper manner. However, dye penetrant examinations were included in the re-examination to forestall questions concerning this inspector's actions in other NDE methods.

In ad/ition, five (5) assemblies were brought in from the shipping i

yard so that re-examination could be performed on work done by this inspector several weeks or months prior to the incident. On one (1) on these five (5) assemblies, a linear indication was founde in base material perpendicular to a weld. Class 3 assemblies do not reouire mag particle testing of base material adjacent to th,e welds and we do not consider this a rejectable defect. However,'it indicated that perhaps additional examination of this individual's work should be done.

E. ,

i ._

l . . ... . . .

a.

/

. INVESTICATION (CO :T.)

A program was then instituted to re-examine any work performed by this

',- inspector which was available in the shop or in the shipping yard,to the extent that between 50 or 60 assemblies would be examined. Over

~

the next two weeks, 76 fabricated assemblies on which this individual "

had performed examinations were brought into the shop and re-

--.-- - examinations were performed. In this group, there were three (3)

Class.1 assemblies, 13 C1sss 2 assemblies, 38 Class 3 assemblies and 22 assemblies which were Class 331.1 Critical. examination All of these to assemblies required mag particle or dye penetrant some extent. On these 76, assemblies there were 197 operations performed as tabulated below:

ITD!S RECHECKED HT DP Butt velds 2" 2 Butt welds 3" 7 4 i Butt velds 4" 13 ,,- ,

Butt velds 6" - 15 14 1 l Butt velds it" Butt velds 10" . 5 i Butt welds 12" 1 2 16" 1 Butt welds f Butt velds 24" 10 ,

Total 75 9 Bevels 6" 3 Bevels 8" 2 -

10" 2 2 Bevels I Bevels 14" 2 Bevels 16" 8 .

Bevels 24" . .9 26 2 Total 3 4 ...

Bosses 3/4" '

I Bosses 1" 4

! Bosses 1 1/2" 17 Bosses 2" 1 Bosses 3" 1 Bosses 4" -

3 Bosses 8" I 10" 1 0 .

i Bosses 31 4 Total e

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INVESTICATION (CONT.)

code Plates 7 10 Rings 16" 5 -

Rings 24" 7 Total 12 Buildupa 10 ,

Creund Areas 1 2 Fillet Welds 8 Thes'e examinations had been perforned by the inspector over a period

' of several months but do not represent all of the work that he did in that period of tizze. .. f RESUI.TS OF 15"ESTICATION The results of the re-examinations described above are as follows:

A. INDICATIOUS It! WELDS: ,

The only indications found in velds occurred in the split type backing rings that were welded. across the ring to make a solid ring. Linear

  • indications were found in seven (7) of the rings I

testied. Since it is not a Code requirement that these rings be ,

velded and since the bachin;; ring is not a pressure retcining part, we have concluded that the indication in these backing ring welda are not Code violations. Note that the construction was B31.1 Critical and not ASME III. .

5. II;DICATIONS IN BASE IfATERIAL:

.There were four (4) linear indications (2", 3/4", 3/4" and 1/4" long) in four (4) carbon steel Class 3 fabrications. The Code does not require examination of base material adjacent to welds.

These are noc considered rejectable indications . The 2" long indicatica has since been removed by grinding approximately .005" from the surface of the pipe. From the appearance of the other surface imperfections they also are not material defects as defined in the applicable material specificaiton.

. There were three (3) linear indications in three (3) stainless class 1 and Class 2 fabrications, with length of 1/16 or less.

The Code of record considers all linear indications as rejectable. However, since 1977, ASME III considers only indications with a major dimension greater Than 1/16" to be relevant. Thus, in 1974 these indications were rejectable but today they would be accepted.

e

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. RESULTS OF INVESTICATION (CONT.) t I

C. We have been holding the shipment of an order of stainless j fabrication since the first week in January 1981, until we were l able to determine the magnitude of our inspection problem.

Because of an urgent delivery requirement and in order to provide some assurance that the inspections made by Shankland in these assemblies were acceptable, we elected to re-examine one (1) assembly. This re-examination showed several unacceptable '

' linear indications on the surface of full penetration velds attaching 1" thick piste supports to the pressure boundary.

Additional penetrant examinations of these structural welds in other assemblies revealed some rejectable indications. We now propose to re-examine all of the welds previously examined by H.

Shankland on this order prior to shipment and eliminate rejectable indications. There were no indications in the girth welds in these asserblies . . This program is not complete as of this writing. - <

D. Also on Jar.uarv ?l, 1881, because of our urgent shipment requirement, we re-examined H. Shankland's work in three (3)

Class 1 carbon steel assemblies. Some unacceptable indications l

were found in base material on two (2) of these assemblies where fitting lugs had been removed. .

CONCLUCIONS:

l 1. Some examinations . performed by H. Shankland have not been done in -

strict accordance with our procedures and/or the results of these examinations have not been properly evaluated over an unknown period of time. .

2. Although~some indications found were greater that the acceptance standards would permit, none of the indications were the result of sericus defects in the welds or base material and it is our opinion that, if the defects had not been removed , they would not have affected the safety or reliability of the fabrication.

3., This problem did not occur as a result of lack of knowledge of the procedure or acceptance standards as this inspector has been observed by our customer inspectors, our AMI and our Chief Inspector performing both dye penetrant and magnetic particle in a proper sanner.

4. There is no reason to suspect that the Dravo training program, qualification program or supervision was deficient or ip any way contributed to this problem. .

er 6

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. e, 5-DRAVO ACTION The following action shall be taken by Dravo:

1. Since Homer Shankland has quit, his personnel file should reflect this fact and his name removed from our Qualified Inspectors List.
2. Provisions should be included in our inspection procedures to require the Chief Inspector (SNT-TC-1A - Level III) to monitor the work of each Dravo inspector on a weekly basis. Records shall be maintained to attest to this surveillance.

~

3. Any dye penetrant or mag particle examinations on Class 1 fabrications performed by H. Shankland on accessible surfaces be re-done prior to shipment of these fabrication from our shop.
4. This report he sent to customers for whom we fabricated nuclear piping in the past six (6) months for their information.

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