ML20107A828
See also: IR 05000219/1973001
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U.S. ATOMIC ENERGY COMMISSION
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DIRECTORATE OF REGUIATORY OPERATIONS
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REGION I
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RO Inspection Report No.:
50-363/73-01
Docket No.:
50-363
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Liesnsee:
Jersey Central Power and Light Company
License No.:
Madison Avenue at Punch Bowl Road
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- Priority:
Morristown, New Jersey 07960 (Forked River 1)
Category:
A-1
I[> cot ton:
Klockner Works, Osnabruck, Germany
Typ3 of Licensee:
1I Typa of Inspection:
Announced, Vendor
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D:tso of Inspection:
April 9 and 10, 1973
Dstes of Previous Inspection:
October 30, 1972
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Rsporting Inspector:
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Ross,L. Brown, Reactor Inspector
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-Accompanying Inspectors: M[F
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W. F. Sanders, Reactor Inspector
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Date
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Othar Accompanying Personnel:
Date
Rsviewed by:
Wh [) Jet
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E. M.'Howard, Chief, Faci /ity' Construction
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and Engineering Support Branch
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9604150145 960213
FORA
DEKOK95-258
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SUMHARY OF FINDINGS
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Cr.f( 7+ ment Action
- None
. Licensee Action on Previously Identified Enforcement-Items
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No previously identified enforcement items.
' Design Changes-
.None identified
Unusual Occurrences
None
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- Other Significant Findings
A.=
Cdrrent Findings
The inspector observed that the vendors activities were not in con-
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formance 'with the post examination cleaning requirements of the " liquid
penetrant test procedure, however, the deficiency was corrected prior
to completion of the inspection.
(Details, Paragraph 4)
B.
Status.of Previously Reported Unresolved Items
No previously reported unresolved items.
Management Interview
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A.
.The following persons attended a management meeting, conducted by
Mr. Brown and Mr. Sanders at the conclusion of the inspection.
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.Klockner Works
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Dr. W. Brohl,' Director, Quality Assurance
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Mr. W. Neumann, Quality Control
Mr. . G. Grote Quality Control Engineer
Mr. J. Kuone, Project Manager
Mr.' A. Rudolph, Quality Control
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Combustion Engineering Corporation (C.E.)
Mr. R. J. Cepluch, Manager, Quality Assurance
Mr. J. C. Moulton, Psoject Manager
Mr. G. S. Brunetto, Quality Assurance Representative
Sulzer - KSB (SKK)
Mr. B. D. Jacobsen, Manager, Quality Assurance
The items discussed and management comments were as follows:
B.
The inspector stated that the quality documents audited appear to be
satisfactory, but in some cases traceability required the use of docu-
ments written in German that will not be included in the final document
package submitted to the customer, this will create a problem at a later
date.
The management personnel present stated that this condition will be cor-
rected.
(Details, Paragraph 3a)
C.
The inspector stated that the "Klockner Heat Treatment Procedure," does
not, in all cases, specify an acceptable temperature range.
The Klockner management stated that the procedure should probably specify
a temperature range of plus or minus 250F. , but that the heat treat require-
ment will be reviewed and the procedure revised to include the acceptable
code requirements and engineering practices.
D.
The inspector stated that the management personnel present are responsible
to conduct sufficient audits to ensure conformance with established require-
ments, thus preventing a recurrence of a situation similar to that observed
where the item was not cleaned following the exanination in accordance
with the liquid penetrant test procedure.
(Details, Paragraph 4)
The C-E, SKK, and Klockner management stated that audits to determine con-
formance with the procedural requirement will be conducted on a periodic
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basis.
E.
The inspector stated that the codes and specifications may not require con-
trols against possible contamination in all materials or conditions associ-
ated with the manufacturing, inspection, or testing of stainless steel clad
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components.
It would appear to be good manufacturing practices to consider
imposing some control measures to prevent contamination in the following
areas:
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1.
Couplant used during ultrasonic testing.
2.
Surface cleaning prior to subjecting the component to elevated
temperatures; e.g. stress relief.
The Klockner management stated that the ultrasonic test procedures will
be revised to include the control of halogen and sulphur content of all
of couplants used.
They also stated that item two will be discussed with Klockner Metallur-
gical Department for recommended shop practices.
During two telephone contacts with Mr. Cepluch, subsequent to the inspection
on April 23 and 27, 1973, he stated that C-E does not believe that the
cleaning in Item 2 need be any more than a visual examination to assure that
all heavy debris and combustibles have been removed, but the need for any
solvent cleaning is not required.
The inspector stated during these telephone contacts that the situation
will be reported to R0 Headquarters for their review and recommendations.
F.
The inspector was asked if Klockner and/or their customers are permitted
to use copies of the AEC Inspection Reports or AEC letters to the utility
company as part of their sales presentation to potential customers.
The inspector stated that he did not know, and would not encourage their
use, but is unaware of anything to prevent their use, since copies of these
documents are on file in the Public Document Room.
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DETAILS
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1.
Persons Contacted
Klockner Works
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Mr. C. Maidorn, Supervisor, Quality Control-
Mr. W. Neumann,- Qualit/ Control
Mr. ~ G. Grote, Quality Control Engineer
Mr. A.~Rudolph, Quality Control
Sulzer - KSB'(SKK)
Mr. B. D. Jacobsen, Manager, Qualit Assurance
' Combustion Engineering Corporation (C-E)
Mr.'R.'J. Cepluch, Manager, Quality Assurance (MSV)
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Mr. J. C. Moulton, Project Manager
Mr. G. S. Brunetto, Quality Assurance, Representative
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2.
General
The first p' ump casing complete with seal flange, inlet and outlet nozzles is
scheduled to be shipped'to KSB in September 1973.
3.
Record Review
a.
The inspector reviewed the material test reports, heat treatmen't
certificates or furnace charts, non-destructive examination reports,
and dimensional inspection records to assure that the following
components are in conformance with the material requirements speci-
fled in the purchase ' order, ASME Codes and Standards.
(1) Pump Casing No. II, Heat No. 412340, Material SA-508-69, Class 2.
(2)' Seal Flange No. II, Heat No. 412376/2, Material SA-508-69, Class 2.
(3) Suction Nozzle No. II, Heat No. 412424/12, Ebterial SA-508-69,
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Clas s-- 2.
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. (4) Randomly selected heats of type 308L and 309L,-welding electrode.
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No violations were identified, but traceability of heat treatment
charts to the item was difficult because it required the use of
the shop travelers (which are written in Germaa and will not be
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a part of the final quality package), to establish reference to
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the item number. The vendor stated that the documentation will
be reviewed and the necessary cross references will be recorded
on.the English translation of the documents.
C-E management stated that they will conduct a comprehensive record
audit prior co shipment of the pumps,
b.
The following fabrication and in-process inspection records were
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selected to determine:
(a) if inspection hold points were being
observed; (b) if inspections were' documented by qualified personnel;
(c) if' approved inspection procedures were 'being utilized; and (d)
if the acceptable results were in accordance with the procedure
acceptance criteria.
(1) Weld history record (welder, procedure, preheat temperature,
electrode heat number and interpass temperature) ultrasonic
examination for bond report, and liquid penetrant examination
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report for the internal cladding of Pump Casing No. 1.
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(2)- Weld history records and non-destructive examination records
(magnetic particle, radiography, and ultrasonic (0-450
600))
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for the suction nozzle to safe end weld.
(3)
Radiographs for weld seam No. 3 (outlet nozzle to shell) for
Pump Casing No.1.
4. - Component Cleaning Following Liquid Penetrant Examination
The inspectors' observations of work in process indicated that the vendor
was not performing the procedure required, cleaning following liquid pene-
trant examination of cladding of Pump Casing No. 3.
The vendor took the following corrective action that was completed trior
to completion of the inspection.
a.
Issued a deviation report that required the item to be cleaned in
accordance with the liquid penetrant procedure; results were reviewed
and approved by responsible supervisor.
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b.
Written instructions were issued to the non-destructive testing
personnel, stating that the inspection is not complete and the
report can not be signed until the required cleaning has been
accomplished for all non-destructive testing methods.
Klockner management stated that in addition to the above instruc-
tion, this requirement was discussed with the responsible supervisors
and testing personnel.
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