ML20090D888

Activity Rept QC Investigation of Critical Piping Sys for Oyster Creek PWR for JCP&L,671127-671209

ML20090D888
Person / Time
Site:	Oyster Creek
Issue date:	12/18/1967
From:	Lofy R PARAMETER, INC.
To:
References
DC-14, NUDOCS 8303110169
Download: ML20090D888 (65)

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Page 1 of 19 O

ACTIVITY REPO1?T QUAIITY CONTRCL INVESTICATION OF CRIIICAL PIPI:IG 3YSTE'IS FOR OYSTER CREEK BWR FOR J"RS'IY CENTI:AL POWEN & LIGl!T Pe r i oil 11/27/67 thru 12/0/07 No. DC-14 Dcccaber 18, 1967 9 (10 magts. 52 pn ge s witi) Appt oili c e s )

AEC Contract No. AT(1I-1)-1653 PARMIETER No. 67-63, Task A Richar<l A. i.vi y .

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l'ANAMETER , Inc.

Consulting Enginctr3 C1m Grove. Wisconsin

Page 2 of 19 O

Distribution: Cooics:

ALC Regulatory Organization Division of Compliance L. Kornblith - G. W. Reinmuth -

il. R. Denton (2)

AEC Contracts Division '

Chicago Operation ; Of f ice

! II. N. Miller. D. Di >:on (1)

O P A R A >iE T " R , Inc. (1)

J. J. Chyle. (1)

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Page 3 of 19 TA3LE OF CCNTENTS: Page

, 1. "Ac t ivity Repor t - Quality Control Investigation of Cri.tical Piping Systems for Oyster Crcok", 11/27/07 thru 12/9'67 4 of 19 2 Tppendi: "A "

"Interin itcport - Inspection of Main Recirculation Sys tem - Oyster Crcek Station No. 1, Jersey Central Power and Light Company, General Electric-Co,pany - BWR; Architect Engineer -

Burns and Iloe, New York, November 29-30, 1007 A-1

3. Appendix "B"

" Table I - Inspection Itens Tenta-tively Selected for the Shop Fabri-cated Stain 1 css Steel Piping of the Henctor Itecirculation Systen". 13 - 1 4 Appendix "C"

" Table II - Insnection Tenics Tenta-

^

O tively Selected f or Recirculation Systen Piping Instn11ed Prior to Vessel Erectinn". C-1 1 Appentt i x "D"

" ra bl o III - I n spec t i on 'lopi c s Ten t., -

t i vel y Sciccted for 1:tc i rcul,i t i on System Pipi.ng Installed After Vessel Erection". D-1

{ o. Appendix "F" l "rablo IV - Insptetion Itum Tenta-tively Selected for Shop Fabricated i hecirculating Pumps". . E-1 l

7 Appendix "F" l Trip Report (dra f t ) W.E.Ve t ter 12/3/67 and "I?ccirculation Sysica -

Notts - Materi-1 by W.E.Vetter" P-1 R. Ippendix "C"

" Outline" - Inspcetion Program (preliminary) G-1 C)

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4 Pagc 4 of I9 I n t ra tic t i.on :

At the request of 1he Divislon of Compliance

( .'ir . !!. Den t on a nd .'ir . G. W.  !!einnuth), the writer participated in inspcction and evaluntion of the Recirculating Piping Systen for thc Cys ter Creek Strtion, Unit No. 1. This effort was part of a

! Intger program by Conpliance personnel to perform a quality control audit on construction of .l1 critical piping systens for a report to the Advisory Committee for Reactor Safeguards.

The imnediate objectEve of the work was to rcport on the status and eficctiveness of the contractor's

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A U inplementation of a qut1ity control program. Early results of this work are reported in the writer's Interin Report of 12 /" /6-' (Tppendix "A " ) a n < l 4 verb,1 report to the ACl?S on 13/0/67 which is sunnarized inter in this report. Salient itens requi ring resolution e re rcported in the se a reas.

Tne following sect'ons of this report are in tended to record chron il >gically the vnrious relr.ted neeting; nd - ti vi t ies , and provi rle a format (N > r 4 oa,ent,

7. n d recom,r n"la t i on; wh ic't might be considered for 7

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Page 5 of 19 ,

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(,/ incorporation in a finn 1 report by the Division of Complianch.

November 27, 1967, Monday: Pcthesda A general neeting and work session was conducted at Bcthesda. Participating were Mr. Ilarold R.

Denton, Mr. G. W. Reinmuth, .' I r . L . Kornblitn ( part tine), Mr. M. Ernst (part fine), Mr. J. O'Rcilly (part time) of the Divi sion o f Conpli; nec Staff and the writer.

Mr. Denton nrcscnted the general plcu-of-attack; using General Electric Specifications for a guide-line, to write Insucction Itens Tables for each of G the najor coaponcnts of the system.

After a review of the specification centents for the INcirculation System, inspection Tables were prepareti for the Shop Assembled Pipc, Site prc-assembly and Final Assembly stages. (Appendiccs B, C and D). These I tabics werc to be used as a guide in obtaining 1

information on construction of the system in an i

I inspection trip to Oyster Creck scheduled Wednesday and Thursday, November 20th and 30th. Par ticult r a t tent ion uru; gi ven to those i tems which vrould bring i

1

Page o of to out the fic1d erection his tory of the systca. Other arcas to be recicted vecre antc rials cert i fica t :ons a nd r.ondes t r uc t bec- t <_ s t records.

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ouc ,be r T. 1907. Thursdiy: Bethesd During the alorning a meeting was held with Dr. P.

Norr's, Director of the Division of Liscensing.

Nesscrs. Denton, *cinneth, DcYoung, Liedtr:ach, Eng1cgen, G'::c ill y and others werc in c. tcndance.

r. Denton existnined the plan for inspection of the Uys t e r Crc <. '- facility to includc the following sys te as v hic'; werc considered critical fron a safety point-of-vity:

1. The Ma in 1ccirculation Piping

1. The PriT.ary Stcan 9ysten thru the Isolation

\'a l ve ou t s ide of thc containment

3. Thc Core Soray Systen

4. Centrol ::od Ifousings and Fced weter Systems

5. Ihr Autonatic Depressuri;:ation Systen

6. The Containnent Dr. Morris expressed the nced to learn whether convcntional construction prrctices were going to be racqua.e for nuclear plants and if an effective quali-ty control systen were possible under present conditions. .

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Q The remt:inder of the morning was spent wit h .'Ir .

Denton in discussing the qui.lity control plan-of-a1 tack for sy3iems other ihan the recircuin t icn piping.

Du r ing the r.f te rnoon , the writer com.pleted an Ins;'tetion 1 tens chech 1ist for the Ma in 'tec i rcu-Intion Punps (Tabic IV - See A;)pendix "F") .

A specificaticn for the two anin shut-off valvcs in each recirculation loop vos not a vail r.bl e . 3ome t i n c v.'e s spcnt s tudying the GE specifier. tion f or the Stean isolttion Valves r.s it typified the order-ing datr prepercd for enst vr.1vc bodies.

A mceting for the foilowing week (Tuesday, December C.th) wrs p1,nncd to eview proposed sys ten inspec-tion wi.th other Division of Compliance personnel.

These representatives of the various regions would bc rissigned to the remaining systens to conduct a riuPlity audit si.ailnr to that planned for the recircul' tion systen. (See Cutline - Appcndi, "G").

"ovember 2 0 -:H ) , 1067, hedncada3 a Thuraday - t ry s t e r C r o c k . '. . J .

. Ir . O, h' . Rei.nnuth, Pir . Ccc il Jon(.s , and the v;riter I

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Page 8of 19 visited the Oys ter Cree's site to conduct the abovc

(~)h planned inspcetion. The writer's record of this visit and ini tial connen ts are contained in the Interin :eport (Appcndi:. "A") which was conpic.ted and transmitted to Mr. Denton in draft form on December 5th.

The Inspection Items Tables were used as an initial outline in interviewing the General Electric site personnel relative to field erection history and availability of records. 2= plies to most of thesc inquiries were recorded and have been left as notations in the nargins on copies of the Inspection (See Appen-p/

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itens Tables included with this report.

dices B, C, D a E). Generni comments and recoamendc-tions will be nadc in the conclusion to this report.

December 5, 1067, luesda:. : lie the s da ,

A metting was held on Tuesday morning at Bethesda to review the quality audit prograu for all criti-cal systens at Oystcr Creek. The writer's partici-pation consisted of a verbal report to thc group on the resul ts of thc previous week's inspection of the

ecirculation Sysica. Ik engaged in further discus-sions with the group on the other systems in an r

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Page Oof 19

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(, effort to di. rect inspection effort to the most important areas and to the most likely sources of information at the site.

Participating in this meeting and subsequent j

l conferences held during the day were the following Division of Compliance pt esonnel:

Mr. L. Kornblith, Divi s ion of Conplie nce Hg.

Mr . 11. .: . Denton, Mr . !!. L. Pcnton i Mr. G. W. R(inmuth Mr. R. T. Dod<?s , San iirnacisco Regitin Mr. W. E. Vetter O

V Mr. J. Fl ora . Dcnvcr i cgion Mr. J. Crews, Mr. L. D. Lon. Director, Division of Compliance i

l To outline the quali.ty control program to the group, 1

Mr. Neinmuth uscci s e r i. e'; of flip chart.; i. n hiu ini ti ni presen ta t i on. fhis outline is prrtitlly contai.ned in Appendix "G". iie explaincd t; e prtaises thst quality of the prie ry system rin<3 the e ng in. erts' ..

i s r. f e gu c r ds t"c 3 essentiel. Proof tes ts of the systens wer<: not entirely < der un to ncasures of i n i t *j r i t y .

Quality must ht " built- in". Asidc t' rom visual .

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Page 10 of 19 inspections, the principlc methods availnble to the connission to assess buil t-in quality were through the "poper work" process --

that is via material certifications, nonde s t ruc t ivt test reports, pro-cedure and welder qualifications, and of course radiographs.

Following Mr. Reinmuth's presentation, the writer gave a short verbal report on our inspection of the recirculation loops aL Oyster Creek during the previous veek.

Ensuing discussions were concerned with definiticn of the other critien1 systcms. The GE-PalD Schematics O

t/ were used to establish the boundaries of these systems generally as follows:

1. Rccirculation Piping - (covered in Interim Report dated Dectnber , 1967 - Appcndix

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i 3. S t eati System - Piping and two isolation valves, one inside end one outside the contain-ment vessel.

3. Autertatic Deprcssurization -

this systen is c or. ipr i s t J o f four (*) valve., .itach<d 1o the anin s team pi;.J ng r.nd von ted 1o the suppression chamber. The vent lines rre not considered part of the cri ti cal r;ys t en.

.:. Cors s spray 9,t; tem - Inc1udeu ; net on hea<k r ,

piping to booster pumps, pipi.ng tu main pumps, piping to re te t or ves s d, ints.rnal piping .-nd spray rings Lnd associated pumps, valves and fittings.

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Page 11 of 19

() 5. Feed water Systen - During the meeting this system was iden tifie d by Mr. Denton as a separcte iten. It had previously been listed together with the control rod hydraulic systems. The feed water systen would presumably consist of the piping and associated valves from the feed water pumps through the inlet to the pressure vessel. ,

6. Control Rod Housings & ilydraulic Lines -

After review of the flow path followed by the control rod operating water and the potential leak path in case of fail-ure of these lincs, i t was decided that this woul d not be considered a critical loss-of-coolant system. If the operating wcter lines failed, leakage from within the vessel would limited to tha t which passed a series of seals within the mechanisa itself.

The Control Rod housing itself however, is part of the fluid boundary and should bc subjected the same type of review as other primary system components. The s- housings are a purchased item supplied to the site where they are field welded into the bottom head stub tubes.

1. Ma te rials , NDT, and fabrication records generated by the supplier should be available for these housings and should be reviewed as part of the progran.

7 Containment - Drywell, Supression Chamber and interconnecting ducts.

The fabrication of this system by Chicago Bridge and Iron Company was being reviewed by Mr. C. Jones of the Chicago ll l

Region Office.

l-The GE-P&lD schematics for the Oyster Creek, plant were j

it turned over to Mr. R. Dodds for use in his subsequent site inspection.

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n Page 12 of 19 J Mr. Low joined the meeti'ig for a short time and brought out two procedurcil points regarding the Compliance QC inspection program. They were:

(1) Scope - to include evaluation of conformance to specifications but not to include evaluation of specifications per se in meeting performance or design criteria; and (2) Reports - to be written i

in an objective a manner as possibic to allow independent eva l ur. t ion .

In further discussion of the program for inspec-tion of the above defined systems, the wri ter exnlained the role of the different contractors b in fabrica ting the systcas as we had found it on V

site. Essentially these wert:

11u rn s & Roc , Inc. - OveralI responsibi1ity for detail design and procurement of all s>utems except the main recircula1 ion loops for which GE retained responsi-bility. Mainttnance of procedure and wolder r!ualification records t'or all on site vrork.

Almirall-Doyl c Corpo ra tion (joint venture)

1. Field sub-assembly t.nd final i

! assembly of rceirculation 1(> ops.

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() 2. Core Spray System

3. Rod Ilydraulic Systen (would probably not include housings)

4. Automatic Depressurization Valves Almirall Corporation

1. Main Sten System Chicago Bridge & Iron

1. Containaent (no longer on-site)

Mr. Dodd's and Mr. Vt t ter reported on their inspection trip to GE-APED at San Jose. Manufacturing and test procedurcs, inspections and test records and materials records for control rods nd the recirculation t%

(-) systen were reviewed in considerable detail. (See Draft Report of Appendix "F").

In the Gencral Elec tric specifientions for the recirculation piping the attachment of internal flow restricter nozzles wns mentioned. Dt. sign infornia tion on the nozzles or thcir method of ettachment to the recirculation piping was not given. Nr. Vetter indicated that they did not learn any additional information about these connections.

Mr. Vetter mentioned that he wns surprised to 1 carn n

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Page 14 of 19 i

that for purchased parts, GE depcnds more on an (a~)

inspection procedure " audit" concept than on

] actual inspection. They do however witness arny l inspcctions.

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Mr. D0nton suggested that repor ts on systems to be inspected be as detailed as possible. The type and extent of the records review should be stated. In other tvords --what was lookcd at, percentage samp-ling taken, what ques tions were asked and what were the replics.

Mr. Dodds explained a real problem in following up records for items procured in quantity by GS. A

() production lot would include duplicate i tems going to a number of different reactor. sites. The problem is how to find out which individual inspection records apply to the items which went to n certain site. This could be important; if deviations occurred during manufacture of an item, its final location would not be recorded.

During the afternoon, the tvriter discussed general details of our piping inspection with Mr. Flora and Mr . C rev's . A suggestion by Mr. Flora that cloride i

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piping should be f ol ' owed .

December 7. 8, o, 1967 - AEC IIr adouar t ers . Was hington ,

D. C.

The writcr wa s askal t o a t tend meetings he l d at AEC licadquartcrs on the above dates and to be avail-abic to present resul ts of our quality control inspection at Cyster Cree's to the ACRS comaittc6 which was accting concurrently.

As the presentation of the Divis ion of Coupliance was delayed on Thursday afternoon, the 7th, the opportunity was taken to discuss various detail s of s the Oyster Creek inspection with Compliance person-nel.

Mr. Reinmuth talked to GE personnel f r o., t he Oys te r Creek si to about the practice of stud welding pias to the cast SS pump and valvt bodies. GS conf irned that this was not an approved practice. The pins w i. l.1 probably have to bc removed and surface inspec-tion performed to be surt that nc. damage has occurred.

Mr. J. Chyle concurred in the opinion that the stud welding could cause cracking and provide a crevict susceptible to corrosion. This item should be followed up and GE's technical disposition reviewed.

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Page 10 of 19 A genera 1 discussion on t I tc t roslag wel di.ng w .s ht!d in anticipati.on of this subject being heard by the ACHS. A'IC R( gula tory Organiza t i.on personnc1 wno p;rticipated werc: Mr. L. Porse, Mr. 3. Levine, Mr. SS Pawicki, Mr. DeYoung and Mr. .1. Ilo1 * .

The writer reviewed a copy of Amend.ncnt No. 28 to the Licensec's Applice tion which described the Quality Control plan at Oyster Creek in between ncetings.

On Friday, December 8th, additional informal dis-cussions were held with Compliance personnel.

Perticipating a.t various times in thcse di.scussions

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,) wcrc Mr. J. O ' I!c il 1 y , Mr. Roberi Carlson i.nd

. ir . Glen Madsen of the New York region, Mr. Denton, Mr. Reinnuth and Mr. J. Chyle.

Mr. J. Chyle and Mr. Carlson discusied their inspection of the Ningera Mohnwk reactor vessel on December 4th. Mr. Chyle is summarizing his obser-vations on tii; trip ina separate report. (PARANCTCR Report No. DC-16).

The weld process for controlled shrinkage of the closure scans in the recirculation piping at Oyster O

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v Creek was discussed. (This process uses T1G and

'i.'La wc l d ' ng sel ec t i ve ly to control shrinkage.}

Nr. Chyle concu rrel in the opinion that changing the proportions of the weld aetal deposited by the different processes would not affect the integrity of the all stainicss steel we1J. It was noted that the wel d wns finishal by the TIG process to obtain r-smooth surface for radiography with a minimum of grinding. Mr. Chyle was of the opinion thet tais change in process would reluire a new procedure qualification. Our intervIcws at Uyster Creek would indicetc that the process was not requal i f i.e d.

La te in the day on Friday, December 8th, the prcsen-tation by Comp'i.'nce ptrsonnel was made to t he .\CRS.

Mr. G. W. Rcinmuth outiined the plsn as described earlier in this report. Tht writer summarized the salient factors rtsulting from our inspection of the Recirculating Piping at Oyster Creck for thc group. His comaents art generally contained in l the interim report (Appendix "A"). Therc wcrc no questions rcquiring additional expla na t ion unde by the committce.

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1 Page 18 of 19 (9

V On Sa turday , December Oth, the ACRS coaulittee made inquiries in t o t he s tuhl tube problem at Oyster Creek.

Mr. Chyle represented PARAMETER, Inc. in rendering his opinions rega rding welding and welding metallurgy.

The writer represented our interest in the design-analysis considerations. Rcsults of our study on this subject and any technical recommendations will be treated in another report.

It is recoimended that the design criteria and analyses prepared by GE for the Main Recirculation System piping he reviewed. The effect of piping mi s al i. gnu n t and col d pull- up on piping upcrati.ng stresses can then be evaluated more thoroughly, nnd U

a qualitative technical opinion rendcred. As back-check on the al ignmEH t of the piping Cr pu:P.p S , thO huilt-in " tilt" of the pump; could again b (_ mos-O ured for all loops in the field. Thc effect y a ument rcaetion of the t:lted pump body upon rightin.; itself under oporrting condit t ena on the pipe should be deternined.

"r vi ct1 of Materi.Is Certific.ations Tn1 Nondestructive Test records for all critical system components should I

r Page 19 of 19 be foll owcd up for t ivo reasons . First, to verify thc quality control of the itects and sccondly, to determine if the proposed r e c o r d 'c. c p in g s y s t e") can be made to work.

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Richard A. Lofy.h.Eh J

P ARAMT:TER , Inc.

Consul t ing 'Ing int.crs Elm Grove. 'di s c on s in k

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Task A, Compliance December 4, 1967 Interim Report: Inspection of Main Recirculation System - Oyster Creek Station i

] No. l jJersey Central,' Power and Light Company, Ceneral Electric l, Company - BWRJ Architect Engineer - Burns and Roe, New York h

t November 29-30, 1967 f f

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Introduction:

l . The writer accompanied Mr. G. W. Reinmuth, AEC Division of Compliance Head-  !

g i i f' Quarters, and Mr. Cecil Jones, AEC Chicago Region Office on the subject j e

inspection trip to the Oyster Creek plant. l The primary purpose of this trip was to conduct Quality Control " audit" of the construction practices and supporting records pertaining to the main

{ socirculation loops for the reactor. Of primary interest were the non-1 t destructive test inspection records and practices, material records, welder l! I and weld procedure qualifications and installation procedures.

! I l The secondary purpose of the visit was to ascertain the availability of r

similar infonnation for subsequent inspection of other critical systems

! I by AEC personnel. These systems are: ,

The containment, l (Inspection of the containment was performed by Mr. Jones),

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The Main Steen System thru the second isolation valves, and The Automatic Depressurization System.

Personnel contacted during the course of our tour and discussion of those l

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[ systems were:

General Electric Cosmany APED Mr. William Royce

. Mr. Charles Smith i

Admiral Doyle Corporation Mr. Len Wasson Mr. W. Taylor Discussion:

1 Upon arriving at the site on Thursday morning, in overall tour of the plant was made including a detailed inspection of the recirculation piping.

Particular attention was focused on the recirculation pipe to nozzle welds,

' and the pipe to pump and value connections, the hanger support system, i and the construction of the valves and pumps.

t During the afternoon, in a meeting with Messrs. Royce and Smith, the extent

• • and availability of records was reviewed and the general site fabrication

- history was discussed. To act as a guide in this discussion, TABLES I thru IV Woro l

of " Inspection Items" which/ prepared at Bethesda on Monday and Tuesday were

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used. These tables were prepared from the General Electric specifications co.

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for the various components and fabrication stages required to complete the recirculation loops. These were:

1) " Shop Fabricated Stainless Steel Piping of the Reactor Recirculation System." Ref. G-E Specification 21A2104, i Rev. 1, Table I of Inspection Items.

1

2) " Recirculation Piping installed (or subassembled) prior to vessel erection." REF. G-E Specification 22A2102, Rev. 1 - Table II of Inspection Items.

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3) " Recirculation System Piping Installed after Vessel Erection."

Ref. G-E Specification 22A2107, Rev. 0 - Table III of Inspection Items.

O 4) " Recirculation Pumps." Ref. G-E Specification 21A1202, Rev. 1 -

Table IV of Inspection Items.

5) " Reactor Recirculation System Valves'.' Ref. G-E Specification 21A2305, Rev. 1. (Note: The specification was received at the site and thus an " Inspection Items" TABLE had nottlr been prepared.

However, as a main component of the system, it will be treated similarly to the other elements in this discussion).

The general correspondence and receiving records folders for these components were made amtilAhleto us for study on Wednesday evening. From review of 4

these records and discussion with Mr. Smith, Mr. Royce, and Allmirall Doyle (continued) m

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4-i personnel, the following background history and status of information envolved :

A. Recirculation Piping. - Shop Pabrication

1) Straight sections of pipe were formed, welded, and heat treated' by National Annealing Best Company under subcontract to Grinnell ,

Manufacturing Company. Material certifications and radiographs for longitudinal seems are presumably on file with NABC0 and duplicated at SRx G-E-APED, San Jose.

2) Pipe formed elbove were made by Crane Company. Records on longitudinal

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weld seems would be maintained by Crane and similarly forwarded i

to G-E, San Jose through the fabrication contractor. [

0; 3) cri 11a f =riEPrPrea a 6 m=14ea eri=*e ei -

and elbows into the shipping pieces. Records (radiographs, weld material certifications, and welder qualifications would be expected i

to be maintained by Grinnell for the 5-year period required by ASME Code and also duplicated at San Jose) . '

0' a) Grinnell was responsible for the Code calculations for pipe sizing and reinforcement. Some of the reinforcement calculations were performed by Pipe Fabrication Institute in Pittsburgh.

+i Calculations required by the fabricator were of & routine l Code naturef 'tak6ng into account pressure and steady state l ,

temperature only. The flexibility analysis and the thermal s transient work (if any) were by C-E.

ti (continued) e I

'I

')

- - =.

1 I

k-5 t'

I j .

)

i 4 " The

4) Most piping was 316 SS. / type of SS - for individual pieces can be 3

ascertained from Grinnell sketches which were for the most part i

included in the job folders.

5) Conformance of all material to chemistry and physical requirements t

would have to be ascertained'through mill reports. No mill reports were currently available at the site.

I jf._0.T.[: General Electric plans to move copies of all records to the site

, within the next few weeks. There is a question of whether they will be able to get copies-of all radiographs due to ASME requirement i

that fabricator retain these. It could be recommended that, in the interest of an effective safety program, an ASME ruling be obtained to allow maintenance ok all radiographs of plant components at the L t%A

6) With regard to minimum ferrite composition of weld metal, G-E (Mr. Smith) indicated that material was not accepted at the site i

I 4 unless it met specifications as tested by the supplier.

a

7) Records of repairs to components are maintained by G-E, San Jose.

8) Detailed drawings of the recirculation loop fabrication were not t

, available. Thus it was not possible to review the attachment of

, theflow restrictor nozzles on thermal sleeves.

(continued)

O

n.

l .

A-C 4

D

9) Receiving reports consisted of routine acknowledgement of delivery. A visual inspection for damage was made at the site. We did not get a good feel for how the components were

~

protected during shipment or storage. As-built dimensional d records are apparently ayailable at San Jose.

i B. Recirculation Piping. - Field Fabrication

. 1) This work was performed by Almira4Doyle on-site. The breakdown of work indicated by Part I and Part II (work before and af ter vessel installation was not always followed. They tried to do as much work "on the floor" as possibla. We see nothing I

wrong with this practice.)

0: 2) Early in the erection process, they found that they could get a man inside the recirculation pipe for its entire length. Thus,

' the need for the elaborate blind welding, baffling, and inspection procedures was voided. Visual inspection coe11d be performed on all main welds. (access was allowed wiseux when I

ptanp rotors were removed). This is a definite benefit to

.\.

1 process control l

3) There was an issue within 0-E as to the desireability of using I s$

i, t the poening process to influence joint shrinkage and subsequent alignment. Thus the field representatives chose not to use

,i peening. Minor control over alignment was accomplished, by 1

(continued) lI l . t L e-  % A p.- = .m. , , , - .,- ___ __ __

_1-l A-7 I '

Ia 1

~I~

(-

y selective application of TIG and Metal Arc weld and by varying weld depth around the circumference of a groove. We believe this to be the preferred method.

4) Weld historys were being prepared by Almira11-Doyle for trans-mittal to G-E and were in good shape. We asked that an entry be made to the effect that peening was not performed and selective welding used for dimensional control where allowed by the specification.

I

5) Walder qualification records were being maintained by Burns and Roe on site. We did not review these records, but it is

, suggested that they be spot checked in the future.

V

6) From discussion with Mr. Smith, it was concluded that they approached fit-up and final closure welding of the loops very cautiously. They met all alignment tolerances and had no real trouble. Again, this is an operation which should be documented in the future as it affects the installed stress condition of the loop.

l l

7) It was noted that some hangers supporting the pumps were disconnected. Mr. Smith explained that on these pumps, the motors had not been installed and thus the hangern were relieved l to more accurately simulate the load on the loop.

8) It was learned that the main loop hangers must be blocked when i i  !

(_s) the pipes are empty. They are designed to support the pipe {

(continued) i I l

Q_ .. ___,,r=. -

.. . - = . - - - - - - - - - -

- f, A-D i

0: .

full of water and will over stress the empty pipe. (If this

, is true, can such adjustments be made if it required to drain the (i q loop after operation!)

J

, 9) The suction and discharge lines are approximately 10-11 feet different in length. do accommodate the differential thermal t

expansion resulting, the pump is cocked about 1/16" when the closure welds are made. It was indicated that this procedure was i

3 followed carefully and the ficup tolerence was met on all loops.

Initial deflection was maintained during welding of the closure (l '

senne by selective weld deposit. (The preset described above should minimize stresses with the loop hot, However, it would be expected that some bending moment would be transmitted through the pump as the' expansion occurred. Such a scannt

'] was not specified in 'the pump design requirements. If should

]

'. l be determined if this moment is a faaeor in pump performance.)

f 6

i 10) Only stainless steel wire brushes were allowed for cleaning l of welds.

, C. Recirculation Pumps

, 1) Files reviewed contained general assembly drawing of the pumps,

'~

performance specifications and test results.

, 4 i

t e

r (continued)

>O i

L I

t .

4 'I 9

O 2) The pump drawings showed detailed end prepawcions for welding to the pipe. By visual inspection it was noted that the 3/4" blend radius and tapers specified were not held. On some pumps, sharp tocled corners existed at the transitions of the weld

)

prep to the taper and from one taper to another. General k Electric has taken actien to grind these transitions on the basis of comments during a previous AEC inspection trip. This should be followed-up.

3) Pumps were manufactured by Bylon-Jackson. Housings were cast by General Electric in Schenectady. Only one set of radiographs for the pump castings are maintainadat Byron-Jackson.

4) The correspondence files reviewed at the site included many

{'

trip reports on in-process inspection of the pumps. Approval of radiography, and penetrant inspection by GE-APED was 1

recorded in the reports. Close follow-up of these units by G-E i

was in evidence.

5) During inspection of the pumps, it was noted that many pins were stud-welded to the casing to hold insulation in place.

It should be determined if this weld could possibly oe a crack starter on the casing itself.

1 -

(continued) f

O

. - - -- =

A-to .

3.

6 .

J; .s .

g D. Recirculation System Valves a

) 1) Valves were made by Chapman. Bodies are cast stainless SA-351 J

l similar to the pump bodies.

1

+

2) The above comments of paragraph C-2 on abrupt transition i

j .l sections mentioned si for the pumps also apply to the valves. '

4 i .

l -

l 3) It was noted in the correspondence that some deviation from

, l 100% radiography was considered on the valve bodies. The I 1

extent of this lack of coverage and significance, if any, should be determined.

t

4) The location of records for the valves was not determined.

O -

General V

General Electric has started to assemble all records en site by system.

+

We were given a copy of the index to this filing system as it has progressed to date. None of the tilee on the six critical systems are yet in process. After learning which systems the AEC will be interested in, G-E personnel indicated they would work on these first.

l, Although records on the recirculation system were at a minimum, we were able to get a good feel for how the job was handled. Subject 66 future spot checking of records and correction or resolution of the l items listed above, it can be concluded that the components were built

, and system assembled in good agreement with the General Electric l

Specifications.

(~h i V (continued)

.,-.._-m- . _ , . _ _ _ _ . _ . _ _ _ _

(

,u- ,

A-li y, , . > ' ' ,.,

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Probably the most important geestion to be answered is "are the l , specifications adequate for the operational requirements?" The primary considerations in design of the reactor itself are thermal transient

- i conditions. These cycles limit the life of the vessel. The design

( rules are spelled out in Section,III of the ASME Code and well

? -

q , l accepted. This Code does not apply to the recirculation piping.

\ ,' Our review of the specifications for the pipe, valves, pumps and I appurtenances show no consideration for thermal stresses or fatigue t

i-

'l life. Service under these conditions can only be based on thermal

, analysis or on operation controls which preclude severe transient conditions.

i

! Ua recommend that the design basis be investigated for assessment of this I

r i i

plant and for informational vahse in future applications.

{  !

l l

• \j . 71 l Richard A. Lofy, P.E.

l ,

Parameter, Inc.

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r .

TABLE I INSPECTION ITEMS TENTATIVELY SELECTED FOR THE SHOP FABRICATED STAINLESS STEEL PIPING OF THE REACTOR RECIRCULATION SYSTEM i

Reference:

" Specification For Reactor Recirculation System I

Piping"; 21A2104, Rev. 1, dated January 9, 1965.

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1. Sheet 1 of 1; Section 3.4 - Is shop a ASME code certified shop? '6RIN i

s

2. Sheet 1 of 1; Section 3.1 - Establish who was responsible for 3dlN

/

qs deta_il design, G-E or vendor?

. s.,

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3. Sheet 2 of 15; Section 3.3.5

,Itacablish that f exibility stress [ra N' p

'T .

analysis and weight balance calculations were performed.

z }7 1

(Tentative : To be reviewed for adequacy by Parameter, Inc.) [sia"1.a) .

4. Sheet 2 of 15; Section 4.1 - Establish which editions of Section 7

[ ' I I and which revision and addenda used. he#'

l

!. 5. Sheet 3 of 15; Section 5.1 - Review representative mill rePors from f[

)

each supplier to ensure a minimum carbon content of 0.04% (Code would allow 0.08% - lower requirement reduces susceptability to sk

.s e sensitization). *

[ p, ,gf f f'D

- 6.

Sheet 3 of 15; Section 5.1.1 - Establish type of material, type 304 S h '

1 .

- g t<d j or 316, used in all parts of system. Perhaps indicate on drawing. g.5 6 .

. '!. 7.

~

t Sheet 3 of 15; Section 5.1.2 - Establish compliance with Sectfoiii

%E ec h -ose seh th bonneN

,, j I, including acceptance standards and sensitivity'yst level.s - a w e s d at fag g e.

4 (sk y..Jr - w. g%s b ua\6-

sN O ede

8. Sheet 3 of 15; Section 5.2 - Review representative a h epors from

.s ,

b >'

each supplier to ensure a minimum carbon content of 0.04%.

i he 'jr Establish for each fitting whether wrought, forged or cast, and the g.

, Gv availability of radiographs if cast. Welder qualification if weld- ,,

.Q '

ing employed. , . . - -

/,'p r- -

(continued) l__ - [ _

a .

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> 9. Sheet 3 of 15; Section 5.2.2 - Establish whether G-E or vendor

-p.'1 * ...

l '

q responsible for detail design.

j -

J , 10. Sheet 4 of 15; Section 5.2.2.3 - Review representative mill certi- $.<d ficatiots to ensure that chrome-nickel ratio is a minimum of 1.9 to ,

Sea i 1 (affects weldability) .

u

11. Sheet 4 of 15; Section 5.3.1 to 5.3.5 - Tentative review of drawings ", g.a by Parameter, Inc., to ensure that drawings conform to design re-6t "3g, **' q\e quirements. Compliance to determine if equipment conforms to draw. w e l}

1 ing. 6~

yeE8#

d dwY'

! -+

12. Sheet 4 of 15; Section 5.4 to 5,4.2 - Tentative review of drawing 58 and weld procedure by Parameter, Inc., to establish effect, if any, , c of flow nozzle attachment on' pipe integrity. p. lab *}c..

13. Sheet 5 of 15; Section 5.7.1 - Review dimensional records, or Vy' certified drawings, to ensure compliance with requirements (See ASA 6vff*$s g

s t-B 31.1-1955, Appendix D to Section 6,. page 125) . } {g., fa

14. Sheet 6 of 15; Section 5.7.2 - Review dimensional records of cast"

(.? }", Ne fittings to ensure compliance with plus 3/16" or minus 1/8" from v. -

nominal wall thickness. .

s. ~ 3.= ad .

I

' y d 9,ke )7 go i L "i. Q ob;es (continued) $k. d b M .

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e

15. ""

- Sheet 6 of 15; Section 5.8.1 - Review certification records to Af /

2es /$

• r ensure required heat, treatment.(Essential for proper material j. ,

properties). -

16. Sheet 6 of 15; Section 5.8.2 - Review fabricator records to d ,,,

g 5*5 C ensure that either pickling or passivation operations performed

,' (Sand blasting alone prevents' successful liquid penetrant tests) .

i

17. Sheet 6 of 15; Section 5.9, - Review records of all repairs which p required C-E approval for type and extent of defeats. N fasc.

saw O~

18. Sheet 7 of 15; Section 5.10 - Review records of all repairs which 7

required G-E approval. .

19 Sheet 8 of 15; Section 6.1.- Review all reports of substitutions,

. I modifications, and relaxatiors of specified materials, procedures, and N design for type and extent. fof ~

20. Sheet 9 of 15; Section 6.4.3 - Review representative records of g

ferrite tests to ensure ferrite content requirements met. (Por g T056 clarification see Section 6.4.4 of " Reactor Recirculation Piping Installation Part II, Work After Vessel Erection," dated April 27,

/ 1967).

Dq (continued)

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21. Sheet 10 of 15; Section 6.4.5 - Review records of repairs requir-l ing G-E approval for type and extent of defects. 'fs 5 V j ,

22. Sheet 10 of 15; Section 6.5.4 - Review of drawings by Parameter,

,,,, ht"

N= g Inc., to determine effect of thermal sleeve installation on pipe 2W

,i

< (, integrity (Thermal sleeves a priorievidence of high thermal stresses) .

r *

,. 23.

Sheet 11 of 15; Section 7.2.1 - Tentative: Review representative ,gqvg

, number of radiographs to ascertain compliance with sensitivity 2} Giaa' i

2.1 Sa-requirement and certification.

24. Sheet 12 of 15; Section 7.4.1.2 - Review drawings to establish that

.y sc.

i , films identified for each lengt,h of pipe.

' e

25. Sheet 13 of 15; Section 8.0 - Review receiving reports to determine g condition of pipe and fittings upon arrival and during on-site ' 'Y insg* *-

2 3 4_. v.e < 6d~c, " 6 * *Md*5* w@sh. c'"I f 6'C#

scorage, g 4,uev s - %We ,y C

%ew..wa\ 9ec= 5 * [, s 3*5"-

26. Sheet 14 of 15; Section 10.2 - Audit drawings.and determine low

$oGC compliance with drawings established.

3,J- -

27. Sheet 14 of 15; section 10.3, 10.3.1, 10.3.2, and 10.3.3 - Review '

fra

all items listed to determine type and extent of all specification deviations and, tentatively, adequacy of code calculations.

28. Sheet 14 of 15; Section 10.4 - If not covered above review records for completeness and adequacy. .

b _

, m. _m-.- --,.-_-- - _ - - .- ~

n. -

'q, C -l

/I996W Oit . C" .

O TABLE II 1

I INSPECTION TOPICS TETfATIVELY SELECIED POR RECIRCUIATION SYSTEM PIPING INSTALLED PRIOR TO VESSEL ERECTION

Reference:

" Reactor Recirculation Piping Installation, Part I, Work

1. Prior To Vessel Erection," 22A2102, Rev.1, dated May 10, 1967.

'(.

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g 15 k-9 li 1

1. Sheet 5 of 22; Section 6.3.1 - Review representative number of b g

• 'd2 i C1.E h b

i weldor's certificates of qualification. Al-$'"8\ 3*/(. e a 2. e<'""

l Sheet 5 of 22; Section 6.3.2 - Establish that written and approve 4*Y sb'(*4 Q His .% b~9 W'\

1 procedures were used for all welding. -

t g

j $ .ce b

• Vg a # b v j 3. Sheet 6 of 22; Section 6.3.4 - Review representative results of g fic[- g[

i i <

(%v. 9A\ee dw e) 66 gu,.c g tests to establish that weld deposits meet requirements. Identify *** g .-ga.-

v}t* 6 any welds for which chemical analysis of wire or rod substitutedby 2"y7 (;5 I i d for weld deposit analysis.

qet .

4. Sheet 6 of 22; Section 6.3.6 - Establish which method used to p.N'/

ortf

',f -

had f e i

q determine adequacy of purge 'and type of problems encountered, if

, U.c. d G y 40 a l any. g s. g hy

5. Sheet 7 of 22; Section 6.3.7 - Visually inspect for compliance with surface requirements.

hfl' g' 4ee s ,

2Y .

'6. Sheet 7 of 22; Section 6.3.8 - Verify that peening was not used . pc. (*#,.g for dimensional control (Peening is expressed prohibited here but A use4*

6eb /Q

(** g T1 V is required in Section 6.2.4 of Part II of the specification) . g3o sb" g-N j

4 , gH B 7.

Sheet 7 of 22; Section 6.3.9 - Verify by visual inspection where$'f keds cYg possiblethatcoatedelectrodeswerenotusedoninsidesurfaces.05[g,f.<(

f b.o d w.k he a c.-c % eweegk k=w M w h 4. sU q, 8. Sheet 8 of 22; Section 6.5 - Establish whether any solvents other than acetone used in cleaning. - - -

, ' C) .-

n (continued) ,

f t

a. - .- , . _. -- _

T. . ,

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9.

i ,

Sheet 8 of 22; Section 6.6.3 - Determine whether brushes used in e.S ' S S cicaning intermediate weld pases were of stainless steel.

k 10.

Sheet 9 of 22; Section 7.1 - Review proceduresand acceptance k b5 f( standards to ensure compliance with PW-51,Section I. Review V' .

e representative number of filmsfor sensitivity and weld identification. kvf-11.

Sheet 9 of 22; Section 7.2 - Review procedure to determine compliance with acceptance standards. Determine whether standards comparable to Section III Code requirements.

12.

Sheet 9 of 22; Section 7.3 - Identify the welds subjected to 5X visual examination in lieu of a liquid penetrant test.

}w#e (is

' uc Id.8 Ge cr*50 1 Cb ' bgg 8

g c

/c b 13.

Sheet 10 of 22; Section 3.2 - Review representative records to determine 7 compliance.

, s.

14.

Sheet 10 of 22, Section 3.3 - Determine that each weld history signed

\ '

by APED representative. Review type and extent of all repaism and re-inspections.

g,,_ c T L2-4,64 f y;J. :es f. , .

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u.,by*-}'1....&f, O. c\es -T' JaeUs r#a;s.jg.

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AP9E N D e'Y -D.

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a 1 .

'O' TABLE III INSPECTION TOPICS TENTATIVELY SELECTED FOR RECIRCULATION SYSTDi f PIPING INSTALLED AFTER VESSEL ERECTION

Reference:

" Reactor Recirculation Piping Installation, Part II. Work After Vessel Erection," 22A2107, Rev. O, dated April 27 1967.

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j 77

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1. Sheet 4 of 43; Section 6.1 - Review records to determine type and E

gm hoS extent of each modification. '

! Sheet 6 of 43; Section 6.2.3 - Determine if d'ischarge and suction m+/

i

2. c t

g u-

, , riser pipes installed within tolerances shown in Figure G. 7aC .g Identify any pipes for which G-E rsviewed and approved deviations. sy.,ni Q)'/&

i i

, +. 3. Sheet 7 of 43; Section 6.2.4 - Determine if pump casing flanges were

/c % -

~

installed within tolerance of Figure 7. Identify any instances in hara'd

, which peening was necessary. -

V"'44-T&'"s.y l I .

4. Sheet 7 of 43; Section 6.2.5 : Verify on at least one hanger that f od '

g , . tolerance requirement is met.

Vi ,

5. Sheet 9 of 43; Section 6.3 - Identify any deviations from sequence Af/***[,)se procedure specified in Appendix A'. (e# ,

1

6. Sheet 10 of 43; Section 6.4 - Items listed in Sections 6.3, 6.4,

'6.5, 6.6, and 6.7, of CO Table II are applicable. In addition, ,

l determine that pipe has minimum engagement in the socket as speci-~

~'

- " ~

fied in Figuc. 15. , . . . .

~

7. Sheet 17 of 43; Section 6.7.1 - Identify any detergent used and its chemical composition.

q

8. ' Sheet 19 of 43; Section 7.0 - Items listed in Section 7 of CO Table II are applicable. 9 iV ho se e gqd; j ~V (continued) fab ". g., h, b, j .

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d l 9. Sheet 19 of 43; Section 7.3 - Identify method used for inspecting W5 8 l W[*

j .

loop closure joints and type and extent of any defects found. gc( (

l

10. Sheet 20 of 43; Section 8.0 - Items listed in Section 8 of C0 i

Table II are applicable. In addition, determine if record of peening

- (" "

• S w.h osek - k 7 dh i

'  ; included in weld joint history.

C = W e av d i% u d ksh des.

i j

{ 11. Appendix A - Identify procedura'l controls used to assure Compliance

with requirements.

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- r TANA IV

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44

.- f DGP!IS' ION THD6 TBffATIVELY SE2EC'HO

'.~- '. .

s POR SHOP FAIRICATED RECIRCUIATING PtrPS

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A Ref%simoes 0.E. Spoo. 21A1203, new.1, "spectricattai ter Re-

, +d > - - . '

cizulating Pumps an6 Drives with Mechanical Senis,"

e-

,. fn., dated Octcher 22,1964 _

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, Sectim 4.0 Codes j 4.1 Detemine certification of den! En, cmstruc-tion und test to applicable codast t

k

- Standards of the flydraulio Institute

- Section VIII - ASlE Code j - ASA = Prwssuzw Piping Code a-( Secticn 8.0 Design Analysis - Review calculaticns to insure that i twquirwoonts of 7.1.4 (eart.typahr acceleration) and j 7.2.5 (desien prwesure rating) have been net.

1 3

Section 10.0 Matorials Determine that approved enterials were used.

]

.'q s"/

10.1 i Check chemical analysis - verify solutim f

j heat tnstment of castings nnd forging:n.

a

. Section 11.0 Pabrication ,

b

) Review - Weld Procedure Q1alificaticns j

1 Welder Qualificaticas s

?

!!ent Treatinr Procedures q Repair Procedures Cleaninr, Procedurws l

j Sectim 12.0 Inspeo tien and 'Ibsts Review dimnsional recotti sheets ces as-tuilt drmrine:S for ecnfermity to pro.iuot drawings. ,

{) Ccnfim inspecticn of puep after test.

u 1

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2

-3

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p 3 12.1.4 Review certificat1ms of carolimee with all i

j y, , constructicn codes.

1 i 12.4.1 Review liquid penetrant inspection procedure.

.f . Determine that acceptance stardards were mt.

4 c

12.4.2 Verify t1st ultrasonic testing was performd.

l Detemine procedure used and acceptance standants.

l 12.5.1 Determine that pump castin23 were 100% radio-grephed hfter heat treatment. Verif5/ cco-I j femance to AE'IN E71, Standards for Class 2

ex! tings and 25 sensitivity level. -

1 V Prdew railographs of pressure centaining.

, 12 5.2 J WPt ter parg. W-51, Secticn VIII, ASW. Code.

12.6 Verify hydrostatic test.

l Section 13.0 verify clemanr. and packadng in accorrtece with specificaticn.

1 u

i' Secticn 14.0 Review these submittal iterm of this section necessary to ascertain cmformance to above listed requirwnents.

Ma data is required by the buyer tod includes the

, follcwings l

l N.,l .

u- .

n

< ,.' E-4 h

1 i -4 O

- Drawings i

- Deviations from Specification

- Desifyi Analysis Calculaticna

- Material Deviations or Substitutims

- lleat 'ihattant fYooedums l - Welding and licId Repair Procedures i

- Feld and Welder Otalificaticn Procedures l - Cleaning and Preserving Procedures (with chemical ocupesition or. solutions or enmts)

- Ultrasonic Test Procedures

- Pagnetic Particle Test Procedures l - Liquid Penetrant Test Procedures

- Radiographic IUonninetion Precedure l - Ilydrcetatic Test Procedum s _ _ _ . _ . , _. _ . _ _ _ _ - .

L Accewo,x *F" h 5 F-1 i

J DRAFT

!,o - e=

12/5/67

, I. 192EE, i The General Electric Atemic Products Equipment Department (APE 3 pleet, located at San Jose, California, uns visited by R. T. Dodde and W. E. Vector em November 21, 22, 27, 23 and 29, 1947. The yearpose of the visite woe to (1) reviar 0-E's quality esourance efforts as they f[ relate to the Oyster Creek reester core sprey sentre.1__ red and roeire,u-lation systems and (2) review G-E's APED "g- "uf material" and "on-ette fabrication" gestity eestrel prograses in detail.

11. jggggy, Oma area of the quality assuranee program, in the epistosa of the

- writer, appeared to justify ariticias. As far as could be determined

[ h desting the visit, a forumlined. faileste analysis psegram uns nomeaistent.

The flow diagram ebensa em Figsre I uma foswalated by the writer. It is based on discussions with the Managers of eesh of the sis Quality Centrol f

groeps shouse and a review of programa precedures. The flow diagrees has not been reviewed by 0-E.

( In any case, the met reeutta of the visits indicated that the APED Quality Assestanse Programs, both with regard to etrueture and ataffing, are adegaste. (See Figste 1, attashed.)

1.

111. DEIAILS The mechanimos, precedentes, plans, etc., listed below are the primary eemstituents of the G-E APED quality Asseeranse Progrense. For additiesial information with regard to the control god drive systems, seet 1. T. Dodds' report, that subject, dated 1967. For more detailed information O

l

F-1 s

1 1

l

-=-

JO e with regard to the sore spray and reciramistion systeess, ese W.E. Teaser's g .

2 report, that subjest, dated 1967.

3 o,. .,

A. Quality Control Maast-th-Eite Fansaarenant f 1. Insterhtl andler Emaiammat paenest Foxus GIhEN)

N

- ar. - .. a. p,,.ah,.. .f 7, the Psodnet and IIsehenisal Ensimmering .eenpe. The fenes

}

sentata all of the intensation and imetractione eensidered

{

f necessary for prosessing by the qiss11ty Centrol subeesties i

k and purehmetas Operaties, i.e., spesifications, special f

a 1.en.stie.e,ete.

l i

5 The IIIsar's are regissed by the quality Centuel Mrect-to-Sita

]O ,r.e u e.,e i.eere. Th. i r d.te - time d .-- y of theIns W's. If they are foemd to be inadagsate, i :1 ij, they are deausmed k the initiator with appegriate cessenate.

lP For example, if the specifiaattees appear to pre-emmpt a satie -

] <

W factory gestity eentrol psegrams Begissering and Quality Centrol i

~

F1 meet to malso the regstred adjustmente.

1 J . 2. Quality Centrol inesentian }metmoetissas (QQ1) m _ -. ._

i; qc11's are p , M by quality Centrel Begineers in the Qeality

'd i . Centrol Direct-to-Site Group. The QCII's are prepared for the i .

q .

esclusive mee of the vender. The G-E field inspector only sendW i .

j the vender'a perfemenose - he does not nahe phyateal inspeetione,

'J -

, only audits, by observaties.

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a

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y The QCII's containt

• C g a. A scope section.

.,c e

g h. A process specification sectime.

(?

g c. Code requirements.

y w-

d. Defect classification secties.

4' 3. _ Quality Centrol Test Instructi-f (OCTI) f,+

The QCrl's are similar to the QCII's sacept that they are g

concerned with product and ognipment testing procedures and requirassents.

S

[ 4. Aseestable esality Level Plans (AGJ

h. When appropriate the Quality Centrol emaineer dentsas and i

AWL plan which is to be followed by the vendor. The Quality

O Co trei airect-to-site Fr.c res t field ins,e t r a. dita the d, vendor's operation to insure comformense to the AqL plan.

j 5. Trip genorts - Consumisatiemp The results of inspection-endit visits to the vendor's plant by the field inspector are sent to the Qsality Control engineer.

1 These reports, plus telephone commersations between the field l

inspector and the Qaality Centrol engineer and occasiceal visits 1

l 1

to the vendor's plant by the Quality Centrol engineer, are the emethods to insure a eactsfactory and product.

B. Daality Centrol San _% P _%turina The Quality Centrol Programs somociated with products snamesfactured at APED San Jose are essentially the same sa those discussed under A above, 1

for the Quality Control Dirwet-to-Site Procureement.

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b f; 1. Pipina - Crinnel ce.. Warren. Ohio '

{. Reviewed Grimmel final report of all_ of the required mill tests h

p and material certifications and other tests as required by the i

g' purchase order for all of the pipias. This incluhdi i

d.'

a. Chemical Amelysis 1. (,,.

h{: .

+

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b. Mechantaal Ladies -

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p (1) Tessile (91,000) '

(2) Tield (53.800) d)

$ (3) Eleagatlas (67%)

e j (4) Flattentag (GK) (ASD1 Code) "

=

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(5) Itydroetatic (2500 # - ASDL - 5) /

t

s. Inspection Remorta 3

(1) Neat -

l '

(2) chemical-Physical properties (3) X-Ray results

! (4) Welding seaterial analysis

!I L. (5) Hartford Boiler Inspection reperca i

d. Inspection *--tructicas l '

I; Quality control Inspection Instruction Quality control Test Instruettens i

l 1

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(1) Indicate pipe ps. by dreming so. and whether accepted l- er rejected.

U ,

(2) Copies of inspect _i_ee reemit_s slips idaich autherine g

shipment to site.

I (3) Indicate onesceptable material by dranias/SM, reemen b ',

unacceptable and regstred degree and type of rework

• g .

g d.d.

b g 2. Yalves * -- - . Divis tem of ci_ a Co.

fi T a. Smindlw

[ All spindles were 100% tasted for flaws with an Eche L Ultrasonis instrument. The tests were made by time j g Magnailum corp.

fe

b. Racerds poviewed 2 Escords of tests and inspecties, as shown in 1, a, b, c, and d

?

! ' above were reviewed in detail.

f .

c. Casimas (Bodies) Beamets. Discs Radioarainhy b

(1) Total of 15 valves 1

i Five suetten ,

t j,

rive dischar&*

e Five bypass i

+

a (2) Reviewed radiographic results

.1 Rattegraphy was perforsned using 1 Mov X-Ray - 1000 KV.

X-Ray No. is stamped in casing and appears on X-Ray fils for identification purposes.

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.s

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4 i 3-h (3) Meterial = conde, cast type 316 steinless steel (Creet).

0 (4) 1:r g-Ule etendard for reading film - ASTM E71 - CL.11 *

(xe >. .

(3) Technigne = amable (tes ille eevering total area).

{ (6) Redingssphy covemods

$ . All hedies v

f . All hennete

{h . All diese

'J

% (7) Final andiegraphy taperte.

J' i . Showed me re M te 2 . Of 452 filme, the fellenrims -x::;-sla defecte sore noted

[

, (a) Sea incleetene - ~ 140 K (b) See inclesteme - ~ 78 1 O.

f (e) serimes defeete - ~ 45 0=

(d) shrieke (Claes 11 AS M) - S '

)

d. $terial Certilisatime f The meteriet eertificattees for eneh of the 15 valvee unee reviseed. Typiest eartificatismo are atteehed.

5

8. IFit M A roeise of the trip reperse dieeleeed that the inoposter witnessed variese in-peesees teste end all final performance teste.

3. Punes and 7 pun Metaire - Egann Jaskaan

e. Rom-in, Beliability, Peraensense Teste sore perfonned en each L of the 5 resisselaties ponye. The run-in test paneedoree called for a 500 beer-test en the first of 5 peanye end a 20D-K heer ames en the halense. Aseerding to the review af records, 3

4 e

hfr F ~i I ,

t

@ -4 y O 10 peepe were purchased by the same yearchase order - 5 for fi e Oyster Creek and 5 for Wine Mile point. My QC contact v

t';

g stated that only the first of 10 pumps received the 500-c Itl W run-in test and the rest were sedybt to a 200-hour

,1.

O i test. My (c; contact said that the change in test precedure 4.l. .

fd uma approved by all of the rogstred persoanel.

f b. lacatise of Pynn Teetg i, The pump run-in tests were perforused at the Los Angeles, s

.{ Dyrom Jacksom plant. Typical'reemits of testa performed IL en taso of the pumps are atteched. Also attached is a

) diaar== showt s the test .etup.

c. Purrhase Enesineg133g

{

l O 'a '** 5't =t i d ' ac 6-

$ typical of G-E NED perchase specs. The specs include e < 1. sco,.

A C 2. Responsibilities

?

A

3. Gemaral description of material q 4. Applicable sedes 1

i ..

l'

5. systaus arrangement F

!i 6. System head loss l*

!' 7. Design requireements l

S. Design analysis

9. Construction r3quireunents O

11 l

0 1 FG l

h 9

a .

3

10. Iseterial identificatism

{l 11. Fabrimmei== regstruments

• i <

12. Inapecciam and test regnarements i

13. Cleaning - ebapping instructions h 14. Schmittels j l The pump castleg material tests, h iemi smalysis tests, h ,

radiographie, process line and penetrattee test reemits were met available for review at San Jose. $ contact, however, k esid tlaat time test sueelta had been ordered as a rossit of h

g my visit and that they would be stored at San Jose. De said f that he had witnessed several of the tests and that this and other contacts with the vender ladicated a coupletely metis-

. t , p t.

1 O . '

d. Trin Bemerts h '

l A review of the laspecties trip reports indicated that the e

field inoposter observed y

( '

(1) Radiographie and dye penetremt testaat of the puey

casti g..

3*

(2) Aandited physical and chassical test data.

i (3) Audited test reports of welding mediumns and observed welding operations to tasure that technispaes matched

~

regnirements.

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,, e. purshmee Seasilientians The pesehnee speetfiesttees were meted to be tyydcolly g.

i eenysokeenive. ,

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i The trip reports were w ily Amiemmetive and indisesed h

d i edspete sheeuvottom and fenneusy by the insposter. The test 1

-

• reselte are on file at G-E's Noter Generator pleet in l

i sehneeste4, New 3erk.

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s. r4p unemers .ertemmi ca. h ah e 1

e. har % Amen 111aatimas d A review ei the parthsee apose, espy attached, and a review of a semplete set of desige dreutege, indieeted fell oesplimose to the design eriteria se desarthed in the FHSR.

b. Tria haastas f > The toepeater's arty supoete indiented fait eempitense with the quality centret toepeatsen testzuseten.

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( FAutCATION DRAWING 8 4'-

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DEVIATION ANALYSES III. FABU CATION AND EXECTION 2 WELD W WELDOR QUALIFICATIONS 4

l WELD HISTORIES 1 =ruu ASS MBLY FAOCEDURES FITUF RECORDS i

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$ INSFECTION OF STEAM SYSTEM

AND A.D.S. 12/11-12 2 t

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