ML20087N565

Testimony of Jm Mcconaghy,Lr Barner,Jp Akers,Je Cavender, Lw Rudasill,Jc Shropshire,Rp Ruth & Dh Llewellyn Re in Camera Witness Allegations Concerning Laminations

ML20087N565
Person / Time
Site:	Catawba, Grand Gulf
Issue date:	02/22/1984
From:	Akers J, Barnes L, Budasill L, Cavender J, Llewelljyn D, Llewellyn D, Mcconaghy J, Ruth R, Shropshire J DUKE POWER CO.
To:
Shared Package
ML20087N559	List: ML20087N565 ML20087N574 ML20087N577 ML20087N582 ML20087N584 ML20087N585 ML20087N588 ML20087N594 ML20087N599 ML20087N602 ML20087N605 ML20087N609
References
FOIA-84-48 NUDOCS 8404040034
Download: ML20087N565 (15)

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I UNITED STATES OF AMERICA NUCLEAR REGULATORY COMMISSION BEFORE THE ATOMIC SAFETY AND LICENSING BOARD In the Matter of )

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DUKE POWER COMPANY, et al. ) Docket Nos. 50-413 (Catawba Nuclear Station,

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Units 1 and 2) )

TESTIMONY OF J. M. MCCONAGHY, L. R. BARNES, J. P. AKERS, J. E. CAVENDER, L. W. RUDASILL, J. C. SHROPS. HIRE, R. P. RUTH, AND D. H. LLEWELLYN REGARDING IN CAMERA WITNESS #2's ALLEGATIONS CONCERNING LAMINATIONS 1 Q. PLEASE STATE YOUR NAMES, BUSINESS ADDRESSES, AND YOUR 2 PROFESSIONAL QUALIFICATIONS.

3 Mr. McConaghy: My name is John M. McConaghy, Jr. My business 4 address is 422 South Church Street, Charlotte, N.C. 28242. I am 5 a Design Engineer II, and a work leader in the Civil Engineering 6 Section , Civil and Environmental Division, Design Engineering 7 Department. A copy of my professional qualifications is attached 8 (Attachment A).

9 10 A. Mr. Barnes: My name is L. R. Barnes. My business address is 11 Catawba Nuclear Station, P. O. Box 223, Clover, S. C. 29710.

12 My current position is Planning and Control Manager for 13 Construction at the Catawha Nuclear Station. A copy of my -

14 professional qualifications is attached- to Applicants' testimony 15 addressing the Board's Question Concerning the Containment Spray 16 System. I 17 8404040034 840222 PDR FOIA GARDE 84-48 PDR .

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e 1 Mr. Akers: My name is John P. Akers. My business address is 2 P.O. Box 33189, Charlotte, N.C. 28242. My current position is 3 Quality Assurance Supervisor. My responsibilities in this position 4 consist of supervising Quality Assurance Vendor Personnel in I 5 HVAC, Civil and Electrical areas, to include performing 6 surveys, audits and surveillance in vendor shops. A copy of my l 7 professional qualifications is attached. (Attachment B).

8 9 Mr. Cavender: My name is John E. Cavender. My business 10 address is P. O. Box 33189, Charlotte, N.C. 28242. I am a 11 Nondestructive Examination Examiner (NDE) Level III. My 12 responsibilities include training and conducting reviews of NDE 13 results, procedures and NDE personnel. A copy of my professional 14 qualifications is attached to Applicants' testimony addressing the ,

15 Board's Question Concerning the Containment Spray System.

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Mr. Rudasill:

17 My name is Larry W. Rudasill. My business address 18 is Catawba Nuclear Station, P. O. Box 223, Clover, S. C. 29710.

19 My current position is Welding Supervisor in Reactor Building #2. ,

i 20 In the past, I have held positions as a Welding Inspector and 21 Welder for Duke at Catawba and McGuire Nuclear Station. A copy 22 of my. professional qualifications is attached to Applicants' testimony 23 ad' dressing In Camera Witness #2's Allegations Concerning Foreman 24 Override.

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t 1 Mr. Shropshire: My name is J. C. Shropshire. My business 2 address is Catawba Nuclear Station, P. O. Box 223, Clover, S. C.

3 29710. My current position is Quality Assurance Engineer. I am 4 . responsible for the Mechanical, Welding, and NDE Quality Assurance 5 Group. A copy of my professional qualifications is attached to 6 Applicants' testimony addressing the Board's Question Concerning 7 the Containment Spray System.  !

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9 Mr. Ruth: My name is Ronald R. Ruth. My business address is 10 McGuire Nuclear Station, P. O. Box 488, Cornelius, N. C. 28031.

11 I am Senior QA Engineer responsible for implementation of the Duke 12 Power QA Program at the McGuire Nuclear Station. A copy of my 13 professional qualifications is attached (Attachment C).

14 15 Mr. Llewellyn: My name is D. H. Llewellyn. My business address 16 is Catawba Nuclear Station, P. O. Box 223, Clover, S. C. 29710.

17 My present position is group leader of Technical Support - Welding.

18 A copy of my professional qualifications is attached to Applicants' 19 testimony addressing Allegations of In Camera Witness #2 Concerning 20 Foreman Override.

21 22 Q. ARE YOU FAMILIAR WITH IN CAMERA WITNESS #2's ALLEGATIONS 23 REGARDING LAMINAR-TYPE DISCONTINUITIES?

24 A. Yes, we have reviewed his testimony. As ' support for his 25 allegations the witness raises the following major concerns:

26 1. Laminations in the containment plate are unsafe.

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I 1 2. Laminations in some penetration sleeves in the containment 2 are unsafe.

3 3. A 3/8 inch deep hole in one vendor weld near a 4 penetration is unsafe.

5 6 Q. HAVE YOU INVESTIGATED THE ALLEGATIONS?

7 A. Yes. The investigation consisted of an analysis of relevant portions

, 8 of documents including inspection reports, vendor audits, codes, 9 standards, procedures and calculations regarding this issue and 10 discussions with inspectors, welders and welder foremen.

I 11 12 It should be noted, however, that the . issue of laminations was 13 investigated before containment plate was delivered to Catawba.

14 Because laminations are inherent in plate of this type, Duke had

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15 researched the issue and developed procedures to address the issue 16 (eg, CP-88). RPR, JMM.

17 18 Q. WHAT WAS THE RESULTS OF YOUR INVESTIGATION?

19 A. From our investigation we have determined that laminations in the 20 Catawba containment plate and piping penetration sleeves are

21 acceptable. Further, we know of no existing conditions in the 22 plant that could adversely impact plant safety. In addition, 23 adequate controls were in effect to assure that laminar-type . edge 24 discontinuities did not result in unacceptable welds. Also, we have 25 determined that the 3/8 inch deep hole in the weld in question did 26' not present a safety hazard. Factors' providing support for this 27 determination include those noted below.

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1 1. Laminations in steel plate are caused by the incorporation 2 of a nonmetallic inclusion (i.e. , air or gas bubbles, or 3 other foreign material) into the plate. Steel in the molten 4 state is poured into a mold and solidified. During this i

5 solidification process, gas bubbles and other nonmetallic 6 substances can get trapped inside the mold and become 7 part of the ingot. The ingot is then reduced in 8 cross-section- by rolling. During this rolling process the 9 inclusions are also reduced in cross-section to the degree 10 the ingot is rolled, and they form " planes" or flattened 11 inclusions inside the plate. The amount of the reduction -

1 12 of the plate will dictate the resulting size and thickness 13 of the inclusion. These inclusions are what is referred to 14 as laminations. Laminations are inherent in rolled plate 15 material. RPR, JMM.

16 17 2. The containment vessel and the larger penetration sleeves 18 were fabricated from steel plate material in accordance 19 with appropriate ASME requirements. These -requirements 20 impose no limit on laminar-type discontinuities, except 21 when they appear at the edge of a plate. Paragraph 9.3 l 27 of ASME Specification SA-20 states that laminar-type 23- ~ discontinuities on a plate edge which are 1 inch or less in 24 length are acceptable without repair. RPR, LRB.

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y 1 The basis for lamination requirements in this ASME 2 standard is that laminations are of structural significance 1 3 only when they are subjected to loads which would cause 4 them to open, i.e. , through-thickness tensile loads which 5 would impose stresses perpendicular to the plane of the i

6 laminations. At Catawba , when significant 7 through-thickness loads may be applied to pressure 8 retaining plates, these plates are ultrasonically examined 9 to assure that no unacceptable laminations are present.

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11 12 Service loadings on the Catawba steel containment 13 including the penetration sleeves produce stresses in the 14 plate parallel (not perpendicular) to the surface of any 15 laminations which may be present. These stresses are of 16 no significance to the laminations since they do not tend 17 to open the laminations. Therefore, no laminations in the 18 Catawba steel containment are subjected to loads which 19 would cause degradation to the structure. JMM.

20 21 Even though laminar-type discontinuities are acceptable in 22 the plate, their presence may result in some unacceptable 2

23 defects in welds joining these . materials if the laminations 24 are not first removed from the plate edge. The removal '

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l 25 . process (which for containment plate is as set forth in 26 CP-88) consists of grinding back and sealing laminar-type -

27 edge discontinuities. This process is employed, when l

I required, while joining sections of containment plate.

2 When welding items to the penetration sleeves a similar 3 process would be set forth in specific detailed process 4 control using Form F9B in accordance with QA procedure 5 M-4.Section III of the ASME requires that these welds 6 be radiographed to assure there are no unacceptable weld 7 defects. JEC, RPR, DHL, JCS. .

8 9 Accordingly, at Catawba welds of containment plate and 10 welds onto containment penetration sleeves were 11 radiographed. Any rejectable weld defects caused by 12 laminations would have been identified by the radiographs 13 and corrected. Indeed, in the In Camera Witness #2's 14 testimony, he attests to the thorough nature of the 15 corrective action regarding this area by his reports on all 16 the corrective action which occurred on one penetration 17 sleeve weld with which he was familiar. JEC, I(PR.

18 19 2. In his testimony, In Camera Witness #2 described the 20 repair of weld 2NI 15-1 which joins penetration 2M407 to a 21 32 inch diameter containment penetration sleeve. The 22 process was fully documented in accordance with QA 23 Procedure M-4, the weld was radiographed and all records 24 were accepted by Duke Quality Assurance and the

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Authorized Nuclear Inspector. ' In short, there is nothing i

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l 27 safety of the plant. JCS, DHL, LRB.

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1 3. With regard to In Camera Witness #2's concerns regarding 2 a 3/8 inch deep hole in some vendor weld, we have i

3 questioned each of the individuals involved and none 4 recalled the witness pointing out to them a hole in a 5 vendor weld joining a pipe penetration sleeve to a 6 containment plate section as described in the witness' 7 testimony. However, the foreman did recall the witness 8 pointing out a pinhole in a vendor weld on a 20" 9 penetration bellows assembly number 2-M355. This was a 10 3/16" fillet weld joining the shroud support ring to the 11 stub end of the penetration. It was in close proximity 4o 12 weld 2FW58-1 which the witness was working on in March a

13 and April 1981. Shortly after the witness pointed out the 14 situation, the welder foreman discussed the situation with 15 a member of the Construction Engineering Group who 16 directed that the vendor weld be repaired. It should be 17 noted, however, that the weld did not in any way form a 18 portion of a pressure retaining boundary. The weld 19 simply helped hold in place a shroud which covered a 20 bellows assembly. Thus, even without repair, the weld 21 was clearly acceptable as far as performing the function 22 for which it was intended. JCS, JMM, LRB , LWR.

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24 4. To assure that vendor welds are acceptable, Duke Power 25 Company has 'a rigid vendor audit and surveillance l 26 program. Duke Power audits or evaluates its vendors on i

27 a periodic ' basis to assure compliance with quality

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I standards. In addition, the pertinent Duke Power 2 Containment Plate Procurement Specification requires that 3 the vendor inspect, nondestructively examine, and repair 4 his fabrication of containment plate as required by ASME 5 III Subsection NE. Duke QA personnel monitor many of 6 these inspections to verify that they are being performed 7 to proper codes and standards. JPA, RPR.

8 9 The welds joining penetration sleeves to the containment 10 plate are full penetration T-welds. Paragraph 11.1.2 of 11 the Duke Containment Plate Procurement Specificatiqps 12 requires that the weld first be welded from one side, 13 then the root pass of these welds be back-gouged, that 14 the back-gouged area be magnetic particle examined, that 15 the first pass on the back-gouged side be magnetic 16 particle examined, and that both sides of the final weld 17 be magnetic particle examined and ultrasonically examined.

18 These examinations would have detected rejectable defects 19 in these welds , and they would have been repaired.

20 JMM, JEC, JPA.

21 22 Paragraph 7.3 of the Duke Containment Plate Procurement 23 Specifications requires that the vendor provide to Duke a

! 24 Vendor Quality Assurance Certification form along with all 25 required quality assurance documentation. The Vendor 26 certification consists of a Certificate of Compliance j 27 (signed by _ the Newport News Industrial Corp. QA l

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l 1 Manager) and records of making, nondestructively 2 examining, and repairing these welds. The Certification 3 was reviewed by Engineering Services Division (now 4 Technical Services Division) of Duke's Quality Assurance 5 Department and found to be acceptable. LRB, JPA.

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Attachm5nt A

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i Professional Qualifications Of

. John M. McConaghy, Jr.

Design Engineer II, Civil and Environmental Division  :

Design Engineering Department December 9, 1983 My name is John M. McConaghy,'Jr. My business address is 422 South Church Street, Charlotte, North Carolina 28242. I am a Design Engineer II, and a work leader in the Civil Engineering Section, Civil and Environmental Division, Design Engineering Department of Duke Power Company.

I hold a Bachelor of Science degree from the United States Military Academy and a Master of Engineering degree in Civil Engineering from Virginia Polytechnic Institute and State University. '

From June 1971 to November 1976 I served as a commissioned officer in the U.S. Army Corps of Engineers. From Sept. ember 1978 to July 1979. I was employed as a researcher by Battelle Columbus Laboratories in Columbus, Ohio.

From August 1979 to the present. I have been employed as a structural engineer l by Duke Power Company. During this period. I have performed structural, seismic and missile analyses and design for steel, concrete and masonry components.

4 My current position is Design Engineer II in the Civil Engineering Section of the Design Engineering Department. In this capacity, I am currently responsible for Design Engineering support of the steel containment vessels at Catawba and McGuire Nuclear Stations. I have coordinated and participated in the as-built design analysis of the Catawba steel containment vessels.

I am a registered professional engineer in North Carolina, South Carolina, and Virginia.

.i Attachm nt 3 RESUME JOHN P AKERS j PERSONAL: Home Address: 5443 Grafton Drive Charlotte, NC 28215 Telephone: (704)536-7222(Home)

(704)373-8247 (Office)

Age: 47 Height: 6'0" Weight: 170 lbs.

FORMAL EDUCATION: Logan High School W. Va 1954 West Virginia Tech W. Va. Mechanical Engineering (3 yrs.) -

ADDITIONAL TRAINING: Duke's Philosophy of Management, Theory of Construction and Maintenance, Krautkramer's Ultrasonic Inspecting and Measuring Course, Mangaflux's Radiographic Inter-pretation Course, Duke's Magnetic Particle and Liquid ,

Penetrant Inspection Course, Computer Programming and Operation, Steel and Concrete in Construction, plus many others.

WORK EXPERIENCE:

FROM TO TITLE PROGRAM COMPANY 5/74 Prisent QA Supervisor All Duke Power for HVAC, Civil &

Electrical Comp.

Supervises Quality Assurance personnel performing Quaity Assurance sur-veys, audits, and surveillances in manufacturing plants of suppliers of HVAC, Civil and Electrical components for nuclear power electric generating stations. Familiar with ASME codes, AWS Codes, 10CFR50 Appen-dix B, ANSI N45.2 and SNT-TC-1A with a thorough knowledge of Quality Assurance Manuals and internal' procedures.

'72 '74 Equipment Specialist All Duke Power Perform Quality Assurance audits and surveillances on mechanical equipment and services for all of Duke's nuclear power plants.

1/70 2/72 Area Manager Dow Chemical Supervise industrial cleaning and maintenance area of five states, eight engineers, eight technicians, two salesmen, one mechanic, one secretary-and one clerk. Raised industrial cleaning and maintenance revenue from

$352,000 to $740,000 maintcinig a field margin profit of 31.3%-in first 19 months as manager. Served as maintenance consultant to chemical, l utility, paper and fiber industries. Initiated and approved contracts with them.

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RESUME JOHN P AKERS Page 2 5/69 1/70 Service Manager Dow Chemical Directed chemical cleaning and hydro-blast operations and was responsible for all maintenance on Charlotte-based equipment. Served as consultant engineer to utility, paper, textile and chemical plants and helped initiate their preventative maintenance programs. _

11/66 7/69 Project Engineer Dow Chemical l

Provided engineering support for construction and maintenance operations for launch pad for moon shoot. This included HVAC concrete, steel, piping, electrical and instrumentation. Issued field engineering orders for changes in design and served as Liaison Officer to NASA for Apollo mis-sions.

l 12/63 11/66 Project Engineer Chrysler-Bendix l Supervised three design engineers and seven draftsmen. Provided engineering support for Electrical, Electronic, Heavy Equipment and a Machine Shop.

Provided consulting function to outside design agencies-to better utilize capabilities of these shops. Initiated contracts to fabrication shops and served on " Quality & Assurance Review Boards".

8/62 12/63 Mechanial Engineer Aerospace Corp.

Performed in Engineering support of Atlas and Titan I Missile for Air Force. Designed and helped build hardware for missile and spacecraft checkout. . Programed and operated IBM 1620 computer.

5/61 8/62 Mechanical Engineer Pan American World l Airways Prepared design studies and calculations for facilities additions and modifications. This included HVAC, architectural, mechanical engineering and transit work.

4/60 8/61 Junior Engineer United Fuel &

Gas Co.

Prepared design calculations and layout drawings for natural gas trans-mission stations.

11/58 4/60 Junior Engineer ~ Island Creek Coal Co.

Prepared mechanical,-steel, concrete and piping drawings for modifications to bituminous ' coal preparation plants.

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Attachment C Professional Qualifications Of Ronald P. Ruth Sr. QA Engineer McGuire Nuclear Station Operations Division  !

December 9,1983 1 EDUCATION: Bachelor of Science in Metallurgical Engineering from .

Mississippi State University  !

i Masters .of Science in Metallurgical Engineering from l Mississippi State University

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l Duke Power Company Management Training Duke Power Company Advanced Management Training Duke Power Company Effective Management '

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MT, PT, UT, RT Courses Welding Inspector Welding Inspector Instructor QA Lead Auditor l Mechanical Inspector EXPERIENCE: Mississippi State University 1970 - 1971 Graduate Assistant Worked as graduate assistant on a research grant funded by NASA. Worked on Metallurgical Structures on

" Skylab" orbital laboratory. ,

Lenage Forge Division / Gulf & Western, Inc. '

1971 - 1974 Marketing Engineer l

Lenage Forge Division was a custom forge shop that l specialized in forgings for the nuclear industry. Lenage fabricated reactor vessels, steam generators and pressurizer nozzle forgings - for companies such as Westinghouse, CE, B&W and GE. My responsibilities' were to interface with the reactor vessel manufacturers and resolve any technical problems concerning the forgings being supplies by us. Areas of responsibilities while at Lenage. were manufacturing, quality assurance and sales / marketing.

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. .- l EXPERIENCE: Duke Power Company,1974 - Present (Cont'd) 1974 - 1975 Assistant QA Engineer, Engineering &

Services Division (E&S) i While in E&S, one of my responsibilities was to help support field engineers in code interpretations (ASME, ANSI, AWS, etc.). Responsible for the review and approval of vendor welding procedures to be used on Duke's products. Responsible for assisting in answering {

1 metallurgical questions from all aspects of Duke's work,  ;

in construction and design. I 1975 - 1977 QA Supervisor, Vendor Division  !

i Responsible for auditing and approving vendors QA  !

programs to be placed on Duke's " Approved Vendor List" i in the areas of electrical, engineering, fuels and services (calibration labs, chemical companies and outside consultants). Also, I was responsible for scheduling and perfoming surveillances on approved vendors to check to see they maintained compliance with their approved QA program.  !

1977 - 1979 QA Engineer, Construction Division Responsible for the supervision and direction for the implementation of the QA program in the areas of mechanical piping, equipment and system testing, welding

' and NDE. Reviewed and approved NCI's, and interfaced with NRC inspectors while on project site. Reviewed all completed documentation to assure compliance with specified requirements.

1979 - Present Sr. QA Engineer, . Operations Division Responsible for the implementation of the Duke Power QA program at the McGuire Nuclear Station. There are three major areas of responsibility, 1) Q.C. inspection program, 2) QA surveillance program, and 3) QA technical support.

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