ML20127B611
| ML20127B611 | |
| Person / Time | |
|---|---|
| Issue date: | 12/22/1992 |
| From: | Campbell L, Potapovs U Office of Nuclear Reactor Regulation |
| To: | |
| Shared Package | |
| ML20127B591 | List: |
| References | |
| REF-QA-99901258 99901258-92-01, 99901258-92-1, NUDOCS 9301130013 | |
| Download: ML20127B611 (12) | |
Text
.
CBCANIZATIOI:
Ram Fbtge & Steel, Irc.
Navasota, Texas RER ET10.:
99901258/92-01 NODCE ADmESS:
Mr. B. J. Gruner Vice President Ra:n Ibrge & Steel, Irc.
Navasota, 14txas 77868 GrWIIZATIGAL CDTDCT:
Pat CrarWri, Jr.
t Quality Cbntrol Manager NUCSR DIDtEIR(
AcrIVITt:
Muufactures ard supplies forgings ard other steel ptubets fcr use at ocmercial facilities ard nuclear pcuer plants.
D&wnQi CI2OUCTED:
Novmber 17 thruxp 20, 1992 b.
(f' j.dizhz m,
L.' Lv 11 [
Ente ve Inspection Secticri No.1-Venir Inspection Branch CTIHER DISPECKRS:
C. K. Battige D. G. Na' APmvFD:
3 iSlI.
,4Ap atet1 - ? 2 *) A Uldis Potapovs, Chle f ~
C Reactive Inspa:ticri iloction No.1 Venir Inspecticri Branch DiSPILTIOi BASES:
10 CFR Part 21 ard Part 50, Appendix B D&wnQi SCOPE:
'Ib review ard evaluate the Ram Forge & Steel, Irc.
(Ram Ebrge) quality assura>ce (G)'p.v:gma ard its irpleraentaticri in selected areas such as.
(1) cxxitrol of wrk ard special procemis,
.(2) purchased material ard services, (3)-inspac-ticri ard tests, ard (4) the certificaticri process..
FIRir SITE APPLICABILUY:
River Berd Staticri (50-458)
Hcpe Creek (50-354)
Janes A. Fitzpatrick Nuclear Staticr1 (50-333)
Various Duke PcM!r Plants other plants usirg Ram Fbrge prubets n
9301130013 930108
- PDR QA999 ENVRAMFO'
-99901250-PDR i
I i
1 INSPu n OJ S&t%KY 1.1 Violatiang Contrarf to the rapirrrents of Section 21.21 of Title 10 of the Oxie of Fcderal (ne sdstantive revisicns to 10 GR Part 21 that hvww effec 1991 N9901258/93-01 % see Secticn 3.2 of this report).
e Cbntrary to t% i.quirwents of 10 CFR 21.31, Pam EF e failed to invoke the reportire requirants of 10 GR Part 21 cn a purchaa order (EC) issucd for the J
quarterly calilraticn of a cirullar strip chart reoarder (99901258/92-01-02, see Scction 3.3 of this repart).
1.2 Nonconformrms Ocntrarf to the rup.tirments of Criterien V of Appendix B to 10 CFR Part 50 Ram icage Quality Centrol (QC) Marual, and the Anerican Society of 14echanical
, the Dyineers Boiler ard PImrre vase.a1 Cbde (ASd2) Secticns II ard III shop orders ard drawirgs fcr an ASd2 Secticn III, Class.1,12 irdi carbcn steel
, Ram Forge's No. EB634-2, dated Februaryelbcv, falricated to the rtquirenents of Ctonex 13,.1992, to ensure that the required mininum wall thickness was present (99901 92-01-03, see Secticn 3.6 of this report).
2 SINUS OF PRD/ICU3 DISPIETIQi FIlODGS 1his sus the first IGC irspecticn at Ram Forge.
3 DISPETTIGI FDODGS NO ODER CDfd.Dils 3.1 Intrarm ard Exit Meetinas in the entrance meeting cn Ncwmber 17, 1992, the IGC inspector *J diemceed the Durity the exit meetirg cn NcManberscope of the irspection ard established inter f11dirgs ard ccomrns with Rn Ebrge's manspet.20,1992, the 1GC inspectors diemcerd 3.2 10 CFR Part 21 1he IGC inspectors determined that Ram Forge has maintained the required 10 CFR Part 21 IXx;tirgs ar/
y Mire for'irplErentirg 10 CFR Part 21 requirements, Procedure N
- Failures to Ccrply in Respect to Regulaticn 10 GR 21 " datal Jcel-90-R, "Procxd Ru Forge infornd the imC inspectors.that they did have a crpy of IGC
- anuary 4,1992.
Informtien Notice (DI) 91-76, "10 CFR Parts 21 ani 50.55 (e)- FDIAL RULE 3 " dated.
Novtrber 26, 1991, 10 GR Part 21 into the January 4,1992, revisico of Procedure 16. N Rn Forge, hcwever, failed to revise Procedure Ib. NP-1-90-R to actiress all cf 1
-.m-W--*
,-w,,-u
c the cutstantim revisions of 10 CR Part 21 such as the 60 day limit for ccntacting the IE (the IE Operaticns Chnter).orpleting an evalt that the revisicm had not been carrectly incorpratai because Pam Foge had the text of 10 OR Part 21, reviscxi as of January 1,1990, in conjunction wit used 91-76 to upiate Pro dure Ib. NP-1-90-R.
Forge the differerres betwen the text of 10 GR Part 21 used durirq itsTh procxdure rewrite and the current requircrents of 10 GR Part 21 aM the p for issuirg IN 91-76.
Pam Farge rade a vertnl ccrnitrent to the IE irspectors to revise Procedure Ib. NP-1-90-R to c:nform with the new rtquircrents of in OR Part 21 (Violaticn 99901258/92-01-01).
3.2.1 Irr>1erentaticn of 10 GR Part 21 PiTudures The !E inspectors dienmeni sewral procurtrent and fabrication issues asscciatcd with a ronctnfaming rtrlear grade elhx fabricatai by Pam Forge follcuirg paragraphs pmsent the history of the rrnxnfamirg eltcw The Culf Statas Utilities (GSU) issued IO lb. 91-J-73927, Revisicn 1 February 24, 1991,
, dated fcot.ater pipirq to the reactor pressure vessel (RW), irc1trurg E e
n "Flhx,12 inch 90 degree, carbon steel (CS), SA-234 Type WN
. 5, rrrtin11, no weld prrp, ASE III, dam 1." tangent, 21/2 inch both erds, e u e 60 Ctnnex issued EO EE634-2, chted Feh:uary 13, 1992, to Pam Ebrge for several ita s incitriing 10 Item lb III, !G-3800, raterial requircrents cn all items ranuf
. 1, the 12 e
on e.
'Ihe !E irWa also dienmed the 10 QR Part 21 report sutnittad to the IE by GSU, Pqcrt 16. PCB-37042, dated June 18, 1992, Irvicwd Pam Forge's 10 GR Part 21 evaltaticn for the ncnctnfomiwith Pam Forge ard River Berd Station, Unit 1, RW Feed ater Ibzzle N4A, wa rq elbcu. GSU rcrital wall thickness of 0.688 int and a code minirum wall thick aea 0.535 int, lut had a neasurEd mininum ktill thickness of 0.378 int in on area.
Because GSU discoverud this deviaticn after accxptance at receipt e local inspecticn ard prior to its installaticn there was m cperational imact; hwver, GSU retal in its Part 21 reprt that "due to the gross reduction i thickness a substarttial safety bawd cruld have been created had thi n kall vessel fmchater rozzle N4A, an unisolatable porticn of s defect pressure bouMary."
Pam Forge inforud the IE inspectors that after beirg inforted by Conne rorrxnfomirg elbcw the initial cxarective acticn taken was to issue x of the Follcwirg the receipt of adiiticral infomaticn eberribirg the extent of the wall thinning frtn Ctnnex ard GSU, Rem Forge had an internal reetirg which ircitded ergineerirg, qtality acntrol, aM shcp superintendents to 3scuss the rrnxnfamiry elbcv ard to identify any problers encountered the fabricatico of the eltru.
Ram For ranufactured frm a schcdule 80 pipe, ge pcstulated that tocause the elixv was the rethod of production could have _
y
-_ -. _ _ -. - = _
required sewral heatups causing core scalirg than no It was bleniirg of surface irperfecticns to obtain the proper ocntcur aM e ard the surface finish for ultrascnic examinaticn ses the rajor centrituting cause fo a smooth the thin wall elt m.
r Pam Forge then decided to take wall thickness reastuw..da cn the out At the tim of this inspecticn, Ram Forge had reasure I
er arc of ent.
ard determined that all had an acce ar ous sizes thickness of a 45 degree eltow prn+ptable wall thickness. Also, the wall Pam Forge inforrcd the lE irqw tors that the pcstula ess was present.
durirg hot formirg, SS raterial is less likely to tulge or hrk or the a
Pam Forge further explained that the scale formed cn S er furmce is substantially thinner than the scale famed en CS mterial e in the Themfare, darity the famirg of SS products there is less tragxd s bottcra die ad a rare unifom and st:cother outside diareter (0 cale in the requiring miniral surface griniing.
r Based cn r+mvaticns durity the inspection as dimwM in Secticn 3.6 of this report, dimimions wit
, ard the ccrditicns present durirg the farmirs of the rrretnfamirg CS elbow would a
e present durire the famirg of a SS elbow.
e mterial of the renconfaming eltow, the faming ard surfaBased cn the size, thickness, a of Pam Fcrge, and the famirg cfuracteristics of CS ard SS raterialsfinishirq prac 4
ircpectcrs also acrcitded that the forgirg ard finishirg techniques
, theIE
~
Forge durirg the ranufacture of this elbcw were the likely cause of th used by Pam thickness violaticn (see Secticn 3.6 of this repart) e wall safety-relatcd fittings produced by Ram Forge for the nuclear 40 ruclear safety-related Es wre receiwd by Ram Forge durirg thi
. -A total of cnly tm of these ms were for the falricaticn of CS eltows.
s pericd ard SA-420, Grade hMG, for use at the Jares A. Fitzpatrick
- elbow, Also, irrltded in this order was a 20 irth tee, ard a 20 inch x 12 i cker Station.
pipe extrusion, teth of SA-420, Grade hMG, CS raterial.
rch large the cutside ard inside diarcters of this elbcw were rachirxd and thAccording to F thickness verified acceptable owr the lergth of the elbcw by both P e wall a representative frcn the flew York Rher Authority.
am Forge ard safety-related M for carten steel elbcss was the order for the eltow identifi The cnly other nuclear in GSU Part 21 Report Ib. RGB-37042.
e Based cn the above dim?micnc, the IE inspectors ccrcitded that the rcranfomirg eltow wall thickness identified in GSU Part 21 Report 16 was an isolated event ard that the forging and finishirq tetniques used by
. BGB-37042 fittirgs previously supplied by Ram Forge.Fcrge should rct haw c am
-related
) I y
3.2.2 OctTective Acticn The l E inspectors discussed with R m Fcrcya several ASME Cbd addressed wall thickness ard were applicable for the runufacture of t e rcqairerne tMt norronforming eih74 Ctde reglirunents rHww.ra ircitded:
e SA-234, "Specificaticn for PipirrJ Fittirgs or Wr:n]ht Cart (1) Section 12.3 of Fbderate and Elevatal 'Itrperatures," of the A92 Secticn II C dcn Steel ard Al (2) Panufacturers Stardartlizaticn Society (MSS) Stardard P t e,1986 Edition, ircltriirg the SP-87-1982"Factcry Pade Butt-Weldirq Fittirgs for Mmn 1 Nu Errata for Paragraph 3 1 ng /$plications,"
Paterial Specificaticrs,"
Products," ard 10-3690, "Dimersicral Requirtrent., ard (3) 10-2121, "Perritted Secticn III Ctde.10-4214, "Mininn Thickness of Fabricated Pats For Pipirq Oxle reqaircrents aM the rred to verify that the requir d i iThe cf fittirgs strh as elbcus sus present in areas other than the erds e
e r n rin wall thickross fittirgs.
of the Pan Forge initiated iknxnferrarce Poport 16. CS-3544-1 cn J ckarent the ball thickness problem for the rcoccnferrirg eltow s une 10, 1992, to River Berd Nuclear Staticn ard its Part 21 evaltaticn tqplial to the related cknrrnts suppcrtirg the evaluatien.inspecticn, a supple e erefre all evaluaticn for ccrpliarce to 10 GR Part 21.inferraticn and act art 21 only rarufactured cre other ruclear safety-related CS a they had ard the wall thickness cn tMt eltow was reasured alcrg its lexyth ard f e past 10 years, acceptable prior to its release for shiprent.
curd Ran Forge inferred the IE inspectors that A92 Secticn III received frcn custaners in the future will be processed in accordanand other alert the gaality control departnent of possible prchlem ce with either e ers to on the GSU Part 21 report.
evaluatico that a decisicn has been rade to irplencnt a progran w ure reportcd reqaire future eltcks fabricated far ru: lear use to be subjected to c would ultrasonic wall thickress check to provide pcsitive proof that the elbow a documented all remry regairments.
reets 3.3 Pevicv of Pan Fcm3 A:rrcrxd Sttnliers List List (ASL), dated ticurberThe MC inspectors perfcInd a limital review of Ram 10, 1992, ard reviektd selected a ditpproved Suppliers CSU 10 QR Part 21 Report 1b.10B-37042.providirg services which t
s of suppliers e
n Laboratcries, FQS Inspecticn, Irc., ard Thern>-Terp Inst The audits for CMiI Testirg ents, Irc.
voltretric exardmtiens The dccun:ntaticn was m,rgiml ard the atxiit frequency of one ya s, surface ard acccidance with the rcqairerents of Crnnex's EO.
ear was in b l
w
4 The lE irepoctors also reviewed Rn Ebtge's PCs to these sumliers ard fourd one discrepancy.
Fos, hat rather as kerk requests. Work orders to TherroJIWp were rot prwmi as femal Ru F docu entation, dated Atqust17357, which refererred Rn Ebrge IO A-857 21, 1992, chut rec:Ider, Lhit 16.12L391, used for recordirq heat treatment torperaturesfo Ikru of the cbouments presentcd to the IE inspectors referenxd rur irposcd 10 CFR Part 21 requirtrents cn the calibraticn services perforud by 'Iberro Tenp (Violation 99901258/92-01-02).
3.4 Beview of Pam Fbrue's Fairicatico Practices Pm Forge infermcd the lE inspectors that althigh there were no ruclear CS elbcus were scheduled to be formed.fittirgs schcdulcd to be fanncd durity elhcLu ard discussicos with Rm Ibrge, the lE irW, detemined that theIbilowirg a r thcce used to fom the TrnJtnformirg elbcw identified in the The lE inspectcrs infarrod Rn Ebtge that they would like to observe the famirg of these elbss in order to evaluate process cmtrol as a potential contribJtor to the wall thinnirg problcn identified in the elbaw supplied to GSU Durirg the inspecticn, the IE inspectors cbserved the famirq ard rachirurg of nirn ncn-ru:lar elbows beiry prwed in accordance to Rydrcr Alloys to 16. PA 14168, Pevisicn 0, dated Atgust 13, 1992, shidi procured 32, 90 degree, lorg radius, SA-234, Type WPC, CS elbJws, with CDs of 6 5/8 irches ard a ninirum wall thickness of 0.825 inches.
(S3) 16. S-3837, datcd AtqustThis PO was beirg prmWL cn Pam Forge Sucp Order 14, 1992, ard Ebrge Order (FO) 16. A-86568, chted
!krarber 3,1992.
'Ihe forge sirp forunan inferred the IE inSp2Ctors that in Prccadare," Pavisicn 1, dated Februaryackliticn to the FD, Ram Fbrge P
- 10. 1992, was used for guichnoe Follcuirg a review of 10 lb. A-86568 and SDP-108 ard diemions with the forge chcp foreman, the IE irspectors ccrcitded that the famiry process used for b:th rrn-ru: lear ard ru: lear pruirts was very deperdere cn the skill of the craftsman.
'Ibe formity process txgan by lmdirg 221/2 inches 1 cry sections of pipe referred to as blanks, cut frun 6 5/8 irches CD,1 inch wall thickmess, A-106, Grade B/C, reartless pipe into Rn Ebtge Ebrmee 1, a rehoat furmce tcrperature at the time of Icedity was approxirately 1600 degrecs F'Ibe furnace weru in Furmce 1 for at least 11/2 hcurs with a minirum 1/2 hour scok at The blanks 1700 ckgrees F (see Secticn 3.5 of this report for furmee cperation) blank kas rmcrxd frcn the furmee ard upset forged (ctrpresscd) frcn 221/2 The first irches to 191/2 inches in an open die which had two halves staticmry tettcn.
, a movable tcp ard rcheating was released by the upset process gathered on the 1cuer die base of the blank.ruvad durirg ard after the upset by directirn blasts of crrpressed air at the The blank was then rotated 90 degroes onto its side.
with the die, thus prcducirg an oval blank.forgirg cperatar cowed the blank to The The oval blank was placas into i
)
l 1
Funum 3 aM min +h at a soak taperature of 1850 degrees F for at least 1/2 I
i h ur.
'Ihe above scquctre o:ntitucd until all 9 blanks frun Furmee 1 kere forged into oval blanks ard placed into Furmce 3.
hhile the blanks wre soaking in Furmce 3, the < pen dies were replaced with clcced dies which have a cavity sMpcd like the finirted elbcw with the irner rMius famcd by the tcp die ard the cuter rMius forrtd by the bottan die.
facilitate the famiry pr
, a high vbmity graphite lubricant was smarcd To on the famiry surface of the dies.
After prtparirg the dies, an creal blank was rercNud frun Furm 3, descaled, checked for variaticns in its orarge calor to axes in-line with the closity directicn of the dies. verify tmmture un lcwertd thruz;h the midsecticn of the oval blank until the upper ard lcher dies
'Ibe upper die was siculy wre in contact, thus formiry a 90 elbow in cne for irg cycle.
for tMs report a famiry cycle consists of heatirg, ovalirg, reheatirg It is noted that famirg the blank.
, ard
'Ibe eltcus were allcwed to cool cn the grourd ard were then tM mchine shcp, the elbcss sure sawed to size ard stack In
'Ibe lE 1rspectors ctsermd that before processirg thrcugh the mchine strp stacked eltows were covered with a coarse scale.
, the apprtxirately 2 irrhes diareter by 1/8 inch thick of what appearcd to toOn cne eltcw, a acrpressed scale was fourd cn the cuter radius.
scale scretires nixes with the graphite lutricant ard W tngped in thera:n Forge ex dies.
scale can ahare to cr fam a flat surface cn the outer radius o that these flat surfa
, ard s are often gruni to cbtain a prcper altcw contcur.
After the eltchs were pmwi thru23h the rachire shcp, the ?E inspectors otcerad tMt rcst of the coarse scale had fallen off durirg the hanility of the eltcus.
Cn cre of the rochinal elbcus the ?E inspectors fcurd an irdentation on the cuter radius reasurirg a;prucinately 1 inch in diareter by 1/16 irth decp 3.5 Bam. Force Prheat Furmce Cteraticn_
Rrn Farge has three reheat furmces ickntified as Ebrmces Iks.1, 2 IE inWm wre infarred that the fuel-air mixtums are preset cn all three
, ard 3.
'Ihe furraces ard that the forge shcp forunan turm the furm the taperaturcs, h2t does rrrt crntrol heat up rates or fuel-air rhtures s on or off and sets the two variables crntrollad by the sMp foremn durirg the femirg pro 'Ihus, the scak terperature set paint ard the high teperature shut off point ss are Furmces 1 ard 2 are wavlled with tho, Itof rcunted, typa "R" therroccuples attacho:1 to Itmf. ell Analcque Ctntrollers.
'Ibe themaccuples are in sheaths that peretrate 8 inches telcw the roof refractories ard are approxjrately 30 irches apart.
'IM IE inspectors ciserved a 40 ckgmes taperature differerce between the therrcocuples used to crnitor Fumace 1 (1660 dcgrees F ard 1700 dcgrtes F).
Run Forge stated that thermi profiles have ret been rode for any of the fumaces.
Furmce 3 is used for high trrperature cperaticns, above 1650 degrees F controlled with a Hcmf ell Radiamtic Head truntai slightly off center cn the
, ard is 6-
- -m9' W
q m
- a.,,
,y
.r-.
--w,;
-m--6
+es
had<: kall.
'Ibe Racliamatic Head is ccnnected to two cligital ccntrollers with one ocntroller mintainiry smk ta:peratum set point and the other beirg for high torperature shut off.
Forgirgs that require close tolerarre terperature centrol durirg heat treatmnt are placcd into either Ramoe 1 or 2.
contact with the thickest secticn of the forging with the forgirg surfaceTwo tcrperature irdicatcd cn a Hcneywell !Wb1 AR-100, dual pin, cirullar strip chart recc &. 'Ihe tcrpe Quality Assurance Famger or a designee.rature charts am identified, reviemi, ard
'Ibe tcrperatum irtlicatirg ard ocntrol instrurents for the furmces here last calibratcd b 'IhcirosItrp cn ALgust 21, 1992, and had a quarterly calibration due
/
date of ikmrber 21, 1992. Cn Ncrtrier 19, 1992, to Ram Fctge ard calibratcd the furnace terperature instruments.a 'Iberr:o Itrp technician c s
inspector % dreIved the calilration of the digital contzuller cn Ram
'Ih e l E C 16, 3.
3.6 Ec412e of the tknxnfomira r1ws, Pam Forge ergineerirg prqnred Interml Ehcp Order CS-3544, dated March 26 for the cuhul of all fcmity, madlinity, grinding, ard inspection of the, 1992, noncrnfcmirg 12-irth eDxu dimmeal in Secticn 3.2.1 of this report, issue.
A-84588 ard SDP-108 for ocntrollity the famirg process, and S3 CS-3544-1 for the d EU cuttirg, codiinirg, and griniing of the forged ellrw.
Ram Forge quality-cerfJol' personnel perforred irtspecticn and pttpared their <b'wnentaticn package usirg Interm1 Grp Order CS-3544, S3 CS-3544-1, FO A-84558, Prtxxdure 16. SDP-108 Orrox IO !b. E-8634-2.
'Ibe follcui
, ard i.Wurs' review of the procuranent ard fatricaticn dmrients ard interviewsry with Pam Forge perscnnel ccrcernirg the trncrnfamirq eltcw.
3.6.1 Paterial Ram Fcrge issued PO 16. A-84195, dated Mmt 23,-1992, to Tutular Stcel Irc. for a piem of 14 int CO, 3/4 inch wall thickross, 52 int 1crg,
'Ith.tlar Steel, Irc., supplied mterial mmfactured by the t&K 03rparaticn of Ja;nn.
10Z Corpraticn's dccunentaticn package ircitded Inspecticn Chrtificate e
B 82247-02, dated Parth 30, 1991, report (CMIR).
which was b ntially a certified raterial test Pipe, API 51rX42, SIrB/ASIM A 106-B, A 53-1/ASME SA 53-B, 28760.
obtained frcn a prolongaticn of an erd of the eltcw were su ard chmical testirg.
surface and whretric examinaticn.kkiiticmily the eltcw was subjected to ncrdestructive All rtquired AME Secticn III,-Class 1, tests and e>.aniraticns were perfanned by qualificd suppliers as discussed in Section 3.3 of this report ard the results were reviewed b and found acceptable.
f the 10C inspcctors I
l' i o l
i
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3.6.2.Fomim The IE inspectors ruviewed arr' dimmal with the forge shcp foreru crders aM prcoedures used far famirq the rmocnfamirg elbcu.n the shop the rmimi dirensicns of the pipe used for famlng the elbcu The FD listed dimersions of the elbcv, the nortnliziry heat treatrent, and refererccd th
, the ncruml mterial specificaticn.
prc'vided vague diro:. tion.The famirg procedure was uscd cnly as a guide ande
'Iherefore, the IE inspectors ocxrlir'M that the ac ual faming process usal for the ncranfamirg eltru was very dependent c skill of the foremn diInctirg the famirg activities.
n the Fonya to be thin wall ard tMt Ram Forge rarely forr The IE ircpactors were
/ am s.
m2 shcp fortran inferrrd the IE inspectcrs that the renctnfomirg eltow was femed usiry similar terfunques applial to the famirg of the ron-nucle deccritcd in Secticn 3.5 of this report, with the execpticn tMt 6 to 9 f ar citow cycles were nectkd to otrpletely fcm the albcu.
a m iry the additicrul famirg cycles were rewy in artbr to limit the cxrThe shcp forcrnn ird It was explaired tMt the e>rmiw flexity outward stuld k pressive e wall.
the edge of the dies, thus fcming mrks cn the wall, ard that flex 1past would tickle the blank, rerderirg the partially forred elbcw unrepairabl rg iruard Dlrirg the 6 to 9 fcmirg cycles, the skill of the fonye strp forcran w e.
subjectcd to ard the rad for additicral famirg cycles.controllir as the ard 1cuer dies ccrpletely erricced the forgirg.ferrirq cycle the With each sucrtssive e upper Pam Fcrge sumiscd that durity the last two famiry cycles the botton of the die with ampresscd air would be scrtA os fram the rustricticn of air ficw caused by the rarrtu gap betsmn the blank e due to dies.
As cinerved with the rcn-roclear eltcw disnmni in Sectico 3 5 and the rcpart, the scale accum21ations wculd te e>pected to fem irdentations and flat spots cn the cuter art of the eltcu.
After famiry, the elbcu was nomalized at 1650 ckgrees F for two tours a d cooled.
The circular cfurt for the heat treatrent was reviewud ard acmptcd b r air quality contzul.
ard shipped it to the rnchine shcp.The forge shcp forman then mrkcd the heat
/
3.6.3 Pachinim 90 CS-3544-1, alorg with a dnreirg havity the same identification the mcture strp to control the cachinirg of the 12 Irch elbcu
, was issue to ccnfiguraticn, ard specificaticn SA-234, Type kTC. drawing list The 50 and J
to drawirg dirensicml requitwents ard the eds were rnchiredThe oltcw erds sure sam, i cff
3.6.4 grirdim 4
After rochinirg, the eltow surface ms ground to the proper contcur havi surface finish aaxptable for ultrascnic mlumtric examimticn.i ng a The tE identificd bf Pam Forge manryonent as the irdividuals win ground the elbcw f p personnel exarimtien.
surface of the eltcw.These iniividmla cxmld not reh arr/thirg abnorml abcut the or irdividuals perfom grirding with minirus supervisicn, hiumrRam Forge inforn instnettd to rutify the shop foramn when an ainormal ocnditicn is d t
, they have been The shcp fortran irdicated that the grirders usually grind heavy wall pi e ected.
haw eyrm wall material, ard that the famir pes that significant tuilt-in wall thickness tolerarce.q process, as a rule, provides a frcn discussicns with Ram Ebrge that rarrally their forged 12-irth elbaThe 100 inspx:
exrm wull thickness of up to 3/8 irth greater than ncnim1.
s have an Pam Fcrtje stated that the blerdirq in of any surface inperfecticos strh spots or scale irdentaticns to the ccntour of the eltow and grin 11ng to obtain as flat the surface finish necessary for ultrascnic examinaticn was rot consid almrm1 for their hmvy wall proirts.
ered sctw+11e 80 pipe used for the eltow blark did ret provide sufficient wallRam Fo thickness for remal surface ccrriiticning.
grirdity to remve feming defects.terrcnfamiry elbow crntained to dccunented rcqaimmnts for the grirders or their forenan to identify ard cbcun that were greurd excessimly in order for CC to detemine if the r wull was present.
irspecticn of grourd areas ard areas other than the erds of the eltcwT eqaired clnirun have reculted in a wall thickness rot roetirq the requircrents of AS9tE S a m to II, SA 234, Secticn 12 (tkxrrnformire ection 999001258/92-01-03, also see Scction 3.2.1 of this report for a dimmicn cn ASME Ctde reqaircrents for wall thickness) 3.6.5 Irsrmtion Pam Forge infomx! the tE inspectors that QC inspected the nonctnforvi to the di ensicml rcqairumnts specifitd cn the dravirg Lttached trg eltcw and pdornd a ckcurnt review to ensure that all other tests ard exrdmtico o So CS-3544-1 specificd b the custaner, the ASME (bde, ard the varicus Ram Forge work orders
/
s hxl tren ret.
The 50 and drwirg cnly rcquired wall thickness measurcrents at the ends of the cltcw, therefere any heavily groard areas wtuld not t incpectaxi.
drawirgs failed to centain sufficient regairenents to ensure that thT uve been 87-1/2 perant of rcniml wall thickness was present in the rarrnf e IIqaired (tkrocnferranJe 999001258/92-01-03).
oming elbow 3.7 Irrrccess Work Activities _
The tE irspectors perforud a review of the docu entaticn for a rmlea mnufactured in acx.ordance with Badrcr Alloys (Radrnr) P r safety-April 8, 1991.
Luke Pcw2r Ctrpany (Duke), ard inmktd several requirtrents ir
, dated _
1 1
l i
Secticn III ctde, Duke Specificatian 16. DPS-1206.00-02-002, " Specification for and Flanges,'.' Envision 5, dated Mart:hthe Prumnrent of QA Ctniiticn 1 30,1990, and 10 CFR Part 21. ' On April 11, 1991, Pedrur issued &arge }b.1 to its E0 and uWrl requirenents for dirensional tolerarces and specifieu a carten cxrttent less than 0.30 percent.
'Ihe IE 1rspectors perfarrai a limited review of Ram Forge's FO 16. A82819, Revision 0, chted lbverter 11, 1991, issued to Scot Metals Ire. (Scot) and Scot PO ?b. H-01169, chted Atypst 14, 1991, MM to Sharcn Steel Cbrporation (Surcn) for the proctuumni. of the mterial used to mrufacture the special argle flarges. 7ha material supplied, Heat 16. 339019, was certificd by Sharon on Etctrent 16. 0775-72-4029-01, dated ALgust 18, 1991, as havirg a carbon ccntent of 0.22 pert:ert.
As a result of the IE inspectors' review of the EO requirerents for the special flanges the follcwirg item were dic:m-i with Ram Forge persconel:
1.
dimnsicml tolerarres be in umrdarce with MGI B16.5. Duke Diagram,16. CS-3126-1, identifies a minirum tore of 6.0001rrhesPam Forge's Shcp 1/32 inch or nirus o irches for the special argle flarges.
, plus
" Bore of Flarges" of NGI B16.5 iniicates for rcrdnal pipe size 10 inches Section 7.6 ard smiler, the bare tolerarce is plus.03 inches or mirus 0 irches.
Ram Farge QC dimensicml irspxcticn en IbvErter A
19, 1991, for flarge C3-3126-1-#13 irdicated the bare as 6.046 irrhes.
Six other flarges in this shi diagram.rrent of ten exmad the tore tolerarcos specified on the shcp khile the safety significarce of a flarge bare 0.016 irches greater than specified ray te minim 1, the requircrents ccntractually irgced on Pam Forge by Padnor had rot teen ret.
Pam Farge perscnnel inlicated that interm1 shop dravirgs were usually specificd to tighter tolerarces than were rwmry for the castancr's order to ensure the rachinists would prubce acceptable proirts.
specified minirum bare, so these values were accxptable.Ibrther, Ram F irfA@ticn was that a tolerarre of plus or rdrus 0.030 intes frto
'Iheir NGI B16.5 was to be applied cnly cn top of the tolerance cn the shcp drawing.
Additiorally, Pam Forge irdicated that a Enke ircp& tor had perscrally perforrud dircraicml checks cn the special argle flarges ard fourd then to to accq t.able.
Althatyh Ram Farge's in+wrpretaticn of the NISI B16.5 discussicn cn the acmptability of these dimnsicns bescd evaluaticn and acceptance of the dimnsicm.
2.
'Ihe Radrer PO specified that the flarges keru to te mrufacturcd to the AEME Secticn III Cbde, Class 2 requirenants.
had tocn done to the 1989 Editicn of the AEFE Secticn III Ctde, although this was rot specified in the original ibdnar 10.
When the tE inspectors irquira3, Ram Forge irdicated that they had been vertelly instructed to use.
that allticn.
Dtzring the cx:rduct of the irspectice. Ram Forge protacrd a ctp/ of a letter to Radrrr from Duke, dated Och 20,1992, khich in11ated that the 1989 Biition with the 1989 M3errh of the AS4E
- III Ctx$e %ns to be used fat all Duke orders.
with this I w.
'Ibe irspectors kere satisfial 4
PastrNfL CaracIID Pam Forne & Steel. Inc.
S. It:Datryal, Owner / Chief Deecutive Officer B. Gruner, Vice President P. Craitck, Quality 0:ntrol Mvnger M. ecring, Forge stw Superirem S. Jefferscn, Shigpiry Superinten$erfw H. Itose, Pachine Srp Superinterdent B. Hargrave, &qireer R. Freman, Grirder C. Stqto, Grirder
'I%e Irevents. Irc._
cuy Burke, Technician
- Attended the entrance restirg an Novmber 17, 1992 ard the exit teetirg cn tb. h 20, 1992