ML20137C527
| ML20137C527 | |
| Person / Time | |
|---|---|
| Issue date: | 12/27/1985 |
| From: | Conway J, Jocelyn Craig NRC OFFICE OF INSPECTION & ENFORCEMENT (IE) |
| To: | |
| Shared Package | |
| ML20137C464 | List: |
| References | |
| REF-QA-99901025 99901025-85-01, 99901025-85-1, NUDOCS 8601160343 | |
| Download: ML20137C527 (16) | |
Text
ORGANIZATION: GESELLSCHAFT FUR NUKLEAR SERVICE ESSEN, WEST GERMANY REPORT INSPECTION INSPECTION N0.:
99901025/85-01 DATE(S):
9/16-27/85 ON-SITE HOURS:
80 CORRESPONDENCE ADDRESS: Gesellschaft fur Nuklear Service MBM ATTN: Dr. Klaus Janberg Director Goethestr.
88 4300 Essen, West Germany ORGANIZATIONAL CONTACT: Mr. Reinhard Bittner, QA Manager TELEPHONE NUMBER:
(0201) 7220-160 PRINCIPAL PRODUCT:
NUCLEAR INDUSTRY ACTIVITY: Waste conditioning, packaging, engineering, cask development and transport.
ASSIGNED INSPECTOR:
.bh
/2-24.8f J
T. Conway, Re tive Inspection Section (RIS)
Date OTHERINSPECTOR(S):
S. K. Iskander, NRC Resident Engineer APPROVED BY:
1 tlf27!$6 John W. ~craig, @ief, Special Projects Inspection Date Section, Vendor Program Branch INSFECTION BASES AND SCOFE:
A.
BASES:
10 CFR Part 50, Appendix B and 10 CFR Part 21.
l B.
SCOPE: The purpose of this inspection was to conduct a programmatic evaluation of the implementation of Gesellschaft fur Nuclear Service's (GNS) QA program pertaining to the fabrication of the CASTOR V dry spent fuel storage / transport casks for Virginia Electric & Power Company (VEPC); review the QA records for the CASTOR No. 2 cask; and witness the manufacturing and testing activities at four GNS subcontractor's PLANT SITE APPLICABILITY:
Surry Unit Nos. 1 and 2 (50-280/281).
8601160343 860114 PDR GA999 EECOENS 9901025 PDR n
ORGANIZATION:
GESELLSCHAFT FUR NUKLEAR SERVICE ESSEN, WEST GERMANY REPORT INSPECTION NO.:
99901025/85-01 RESULTS:
PAGE 2 of 16 SCOPE: (continued) facilities. The subcontractors were Gontermann-Peipers (GP) and Siempelkamp (SK) which casts the cask body, Boschgotthardshutte (BGH) which forges the primary and secondary lids and trunnions, and Kraftwerk Union (KWU) which performs final machining and assembly.
A.
Nonconformances:
1.
Contrary to Criterion V of Appendix B to 10 CFR Part 50, Section 3.2 of GNS Procedure No. PV 97, and Sections 4.3.1, 4.3.2 and 4.3.4 of GNS Quality Assurance Handbook (QAH), a review of nine purchase orders (P0) to subcontractors for items and services pertaining to the CASTOR V casks for VEPC did not specify that the manufacturing activity should be conducted under an approved QA Program or that the requirements of 10 CFR Part 21 applied (85-01-01).
The nine subcontractors were GP and SK (cast body), KWU (final machining & assembly), Butting Metallwerk (fuel basket), BGH (forged lids and trunnions), Schmidt & Clemens (fasteners), Cefilac (metallic seals), Pennekamp Huesker (neutron moderator material), and Von-Roll (nickel plating).
2.
Contrary to Criterion V of Appendix B to 10 CFR Part 50 and Sections 17.3, 18.2.1, 18.2.2, and 18.3.1 of the OAH, a review of six external audit reports and QA records pertaining to persnnnel qualifications revealed the following (85-01-02):
a.
Audits of three subcontractors were overdue in that during the interval in which material / services were being controlled, the most recent audits of Butting Metallwerk (BW) and KWU were in July 1984 and SK in September 11, 198a.
b.
Checklists were not used in any of the six audit reports
- reviewed, c.
Qualifications of the auditing personnel were not documented and retained as QA records.
3.
Contrary to Criterion V of Appendix B to 10 CFR Part 50 and Section 5.1.1 of the QAH, a review of GNS Procedut e No. 91 s " Hydrostatic Test Procedure for Dry Spent Fuel Storage Cask" dated October 23, 1984, and GNS Procedure No. PV 32-1 " Helium Leak Test Procedure for Dry Spent Fuel Storage Cask" dated June 28, 1984
ORGANIZATION:
GESELLSCHAFT FUR NUKLEAR SERVICE ESSEN, WEST GERMANY REPORT INSPECTION N0.:
99901025/85-01 RESULTS:
PAGE 3 of 16 revealed that neither procedure referenced the requirement for the sequence of tightening bolts, the tightening torque and subsequent documentation on a test report (85-01-03).
4 Contrary to Criterion V of Appendix B to 10 CFR Part 50, Section 9.3.1 of the QAH, and SNT-TC-1A, a review of records for four NDT personnel (Nos. 2, 6, 7, and 9) revealed the following (85-01-04):
a)
GNS did not have a written practice or procedure for the various disciplines of NDT.
b)
Eye examinations and current copies of written examinations were not maintained on file for the four examiners.,
c)
Certifications for Level II ultrasonic testing (examiner No. 7) and for Level II leak testing (examiner No. 9) were missing.
d)
Statements indicatino satisfactory completion of training were missing for the four examiners.
5.
Contrary to Criterion V of Appendix B to 10 CFR Part 50, Section 4.5 of GNS Procedure No. 32-1, and Sections 5.5 and 5.7 of GNS Procedure No. 91, witnessing of helium leak testing and hydrostatic testing and a review of calibration records at GNS and KWU revealed the following (85-01-05):
a)
Pressure gauge No. 6 which was used for the leak test did not have a calibration : ticker, and there was no evidence of records to show that the gauge was calibrated, b)
Pressure gaugo S/N 31 which was used for the hydrostatic test was last calibrated in October 1984 by KWU. When this anomaly was identified during the inspection, the gauge was calibrated by KWU on September 20, 1985, but calibration records for the dead weight tester'used to calibrate the gauge were noted to be missing after April 1982.
B.
Other Findings or Comments:
1.
Gesellschaft fur Nuclear Service (GNS)
GNS is the affiliated company of STEAG Kernenergie (SKE), VEBA Kraftwerke Ruhr (VKR) and Deutsche Gesellschaft fur Wiederauforbeitung von Kernbrennstoffen (DWK).
SKE is engaged in all stages of the nuclear fuel cycle and performs design and project work in the planning and construction of nuclear l.
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ORGANf2ATION: GESELLSCHAFT FUR NUKLEAR SERVICE ESSEN, WEST GERMANY REPORT INSPECTION NO.: 99901025/85-01 RESULTS:
PAGE 4 of 16 facilities. VKR is the owner and operator of several coal-fired power stations.
DWK was founded by twelve German nuclear-based utilities for the construction and operation of installations of the nuclear fuel cycle. GNS is involved in the fields of mobile waste conditioning, associated engineering and services, and cask development and transportation.
Personnel Contacted Dr. K. Janberg, Director Dr. H. Baatz, Director R. Bittner, OA Manager D. Methling, Engineering Manager A. Bonifacio, GNSI Project Manager a.
10 CFR Part 21 The requirements of 10 CFR Part 21 were imposed upon GNS by VEPC for the design and manufacture of the CASTOR V dry spent fuel storage casks. The NRC inspector noted that GNS had written Procedure No. PV 97 " Procedure for Notifying US NRC or Customer of Defects and/or Noncompliances per 10 CFR Part 21" dated June 22, 1984, to satisfy this requirement.
A Notice, written in both German and English, described the regulation and identified the QA Manager as the individual to whom reports may be made. This Notice was posted in the GNS engineering department and was also sent to seven GNS subcontractors.
GNS failed to send a copy of this Notice to two subcontractors, Von-Roll (VR) which nickel plates the cask body and Pennekamp Huester (PH) which supplies the neutron moderator material, for subsequent posting at their facilities. Although GNS had sent this Notice to seven of nine subcontractors, the 10 CFR Part 21 requirements were not documented on specific P0ssent to each of these subcontractors (See 85-01-01).
b.
Nondestructive Examination (NDE)
The NRC inspector reviewed nine NDE procedures pertaining to ultrasonic testing (UT) and liquid penetrant testing (PT) of the cask body and forged lids, trunnions, and fasteners and leak testing (LT) of the assembled cask.
It was noted that the procedure for LT did not require a sequence for tightening bolts nor did it specify the tightening torque values (See 85-01-03).
)
ORGANIZATION:
GESELLSCHAFT FUR NUKLEAR SERVICE ESSEN, WEST GERMANY REPORT INSPECTION NO.: 99901025/85-01 RESULTS:
PAGE 5 of 16 All of the NDE procedures required personnel performing the tests to be qualified per SNT-TC-1A.
In a June 13, 1984 letter to the GNS QA Manager, Deutsche Gesellschaft fur Zerstorungsfreie Prufung (DGZP), the German Society for Nondestructive Testing, stated that the " Recommendation for the Qualification and Certification of NDT personnel" dated December 1983 was equivalent to SNT-TC-1A of the American Society for Nondestructive Testing.
The certification records for four GNS examiners were reviewed to verify that all personnel performing NDE were qualified. With the exception of missing certificates for examiner No. 7 (UT-Level II) and examiner No. 9 (LT-Level II), documents from DGZP stated that the QA Manager was certified to Level III for PT, UT, and magnetic particle (MT); examiner No. 7 to Level III for radiographic, PT, and MT; examiner No. 6 to Level III for PT; and examiner No. 9 to Level II for PT, UT, and MT.
It was noted that written examinations for Level II disciplines are given in a specific region by DGZP, and the Level III examinations are given in Berlin.
Copies of the written examinations or evidence of successful completion of the examination as well as eye examinations for all four examiners were missing. GNS had failed to generate a procedure addressing the training, examination and certification of NDE personnel.
Further GNS failed to designate the individual who would function as the company's Level III.
Nonconformance 85-01-04 was identified in this area of the inspection.
c.
Testing The CASTOR V No. 2 cask successfully passed a leak test and a hydrostatic test on September 17 and 18, 1985, respectively.
The leak test was performed in two stages to check the seal between the cask body and the primary and secondary lids.
Helium leak test Procedure No. 32-1 dated June 28, 1984 was used.
This procedure was reviewed and was found to be in compliance with Article 10 (T-1060) of Section V of the ASME Code.
The test was witnessed by a representative from Bundesanstatt fur Materialsprofung (BAM) and a representative from VEPC. GNS examiner No. 9 conducted the test, but a copy of this individual's certification to LT-Level II was missing from the files (See 85-01-04).
i ORGANIZATION:
GESELLSCHAFT FUR NUKLEAR SERVICE ESSEN, WEST GERMANY REPORT INSPECTION NO.: 99901025/85-01 RESULTS:
PAGE 6 of 16 The hydrostatic test, which is a VEPC requirement, was performed in accordance with Procedure No. 91 dated October 23, 1984.
The test was in compliance with Part UG-99 of Section VIII of the ASME Code. A representative ' rom VEPC witnessed the test.
The torque wrench used to tighten the bolts on the primary and secondary lids was stamped with MPA 2743.
Calibration records indicated that the wrench was calibrated on April 23, 1985 by Versuchs-und Prufanstalt fur Werkzenge Remscheid (VPWR).
However, certification No. 138122 743 from VPWR did not identify the reference standard used and that calibration was traceable to Physikalische Technische Braunschweige (PTB).
PTB is the German counterpart to the US National Bureau of Standards.'
Neither of the two procedures used in the tests identified a requirement for the tightening torque values or the seouence of tightening bolts (See 85-01-03).
In addition, pressure gage No. 6 which was used on the leak test, and pressure gage S/N 31, which was used on the hydro test, were not calibrated prior to testing (See 85-01-05).
d.
Control of Purchased Material & Services GNS utilized nine subcontractors / vendors for components with a safety function, and machining and plating services related to the manufacture of the CASTOR V casks for VEPC.
The nine subcontractors were GP and SK (cask body), BGH (forged lids and trunnions), Schmidt & Clemens (bolts),
Cefilac (metal seals), PH (neutron moderator material),
BM (fuel basket), KWU (machining and final assembly),
and VR (nickel plating),
e.
Purchase Orders P0s to the nine subcontractors were reviewed to assure that technical and quality requirements imposed upon GNS by VEPC were properly implemented and passed on to the material manufacturers and service vendors. The P0sspecified:
the scope; listed the operations to be performed; referenced the technical specifications (e.g., Material Data Sheets and NDE procedures); identified the documents to be submitted both prior to start of fabrication (e.g., fabrication and QC, welding, cleaning and packaging plans) and after completion (e.g.,
1
ORGANIZATION: GESELLSCHAFT FUR NUKLEAR SERVICE ESSEN, WEST GERMANY REPORT INSPECTION NO.: 99901025/85-01 RESULTS:
PAGE 7 of 16 material certifications, test reports, and manufacturer's acceptance and test report certificates) to GNS; specified GNS's right of access for onsite surveillance / inspection and review of QA records; and established the delivery schedule.
Although all the P0s were initialed by a representative of the GNS CA department, it was noted that GNS failed to pass on the requirements of 10 CFR Part 21 and did not require the fabrication of the item or performance of the service to be in accordance with a specific QA program that had been reviewed and approved by GNS (85-01-01).
f.
QA Manuals GNS had copies of QA Manuals for six vendors. With' the exception of KWU's manual, the manuals / handbooks for GP, SK, BGH, Schmidt and Clemens (SC) and BM all contained a document from Technischer Uberwachungs-Vereif (TUV) stating that the QA program meets the requirements of "AD-Merkblatt WO/TRD10G" which is a document similar to the ASME Code. There was no documented evidence that GNS had reviewed and approved each manual / handbook for use in the manufacture of the CASTOR V casks for VEPC.
The manuals included GP's "QA Handbook" dated February 2, 1981; SK's "QA Handbook" dated June 30, 1983; BGH's "QA Handbook" dated December 22, 1980; SC's "QA Handbook" dated March 1983; and BM's "QA Manual" dated January 23, 1984.
KWU's manual was supple-mented with a document titled "QA Requirements for Fabrication of CASTOR (s)" dated January 20, 1984. The document addressed six areas: Quality Planning, Document Control, Receipt Inspection, In-process Inspection, Documentation, and Idcntific: tion of Dcp;rt=cnt: Rc: pen:ible for Quality. GNS did not have a copy of the manuals for PH and VR.
Further, GNS is currently waiting for Cefilac's (CL) manual to be translated from French into German and English.
g.
Vendor Audits Six external audit reports whose summaries had been transcribed into English were reviewed.
All the audits were perfoi..aed by the GNS CA Manager. BM and KWU were audited in July 1 M 4, SK in September 1984, GP in November 1984, and BGH in January 1985.
There was no date on the audit report for SC. The 1985 annual audits of BM, KWU, and SK were overdue.
It was noted that the audits were performed without the use of a checklist, and the k
ORGANIZATION: GESELLSCHAFT FUR NUKLEAR SERVICE ESSEN, WEST GERMANY REPORT INSPECTION N0.: 99901025/85-01 RESULTS:
PAGE 8 of IE qualifications of the auditor were not documented and retained as a OA record (See 85-01-02).
h.
Documentation Packages (DP)
The QA records for the CASTOR no. 2 cask for VEPC were reviewed, and DPs for the eight major vendors consisted of:
Parts List - identifies the individual components by material specification, dimension and DIN No.
(if applicable) and references the drawing No.
This document is prepared by GNS-Engineering.,
Material Data Sheet (MDS) - lists the chemical, mechanical and testing requirements and the required documents (e.g. DIN No. which establishes who performs, witnesses, and signs off the test).
GNS-Engineering prepares the MPS, and it is approved by GNS-QA and BAM.
Fabrication Control Plan (FCP) - lists specific fabrication and control steps (e.g., cleaning, identification marking, inspection and testing). The FCP is prepared by the vendor but is reviewed and approved by both GNS and BAM prior to the start of fabrication.
In-process inspection is performed in accordance with the requirements
. contained in the individual FCPs. Test results are verified against procedures, drawings, codes, and standards; and tha recnits ara recordad.
The following activities are typical of witness hold points to be inspected, witnessed, and verified by the noted organizations:
UT - Cask body by GP, GNS, and BAM.
Primary and secondary lids by BGH, GNS, and TUV.
Bolts by SC, GNS, and TUV.
PT - Trunnion housing and sealing surfaces on cask body, trunnions, primary and secondary lids, and bolts by KWU, GNS, and TUV.
LT - Completed cask (primary and secondary lids) by GNS and BAM.
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ORGANIZATION: GESELLSCHAFT FUR NUKLEAR SERVICE ESSEN, WEST GERMANY REPORT INSPECTION N0.: 99901025/85-01 RESULTS:
PAGE 9 of 16 Supplemental Documents - includes certified material test reports (CMTR) and Certificate of Conformances (CC) from the subtier vendors; identification of transfer marking for material; welding, cleaning, and packaging plans; material lists showing iten traceability to heat number; and dimensional inspection and NDE reports. With the exception of the CMTRs and CCs, the remaining documents are generated by the subcontractor and are approved by a QA representative from GNS.
2.
Castor V Cask - Fabrication A finished cask goes through the following manufacturing steps:
The nodular iron body is cast by GP or SK.
Following a visual examination and UT of the rough casting, a dimensional check and layout is performed. The outer surface and cavity are machined, and 100% UT is conducted. The body is then shipped to KWU.
KWU machines the trunnion housing, drills and taps the holes.
Holes are also drilled and tapped in the bottom and lid area followed by the boring of holes in the outer perimeter to accommodate the neutron absorber rods.
Samples from the extracted rods are used for mechanical property testing. This is followed by an intermediate assembly and dimensional checkout.
The body is then shipped to VR which nickel plates the internal diameter of the cask body and the housing for the trunnions. The plated body is then shipped back to KWU.
The trunnions, and primary and secondary lids are forged by BGH.
The individual products are heat treated and rough machined. The trunnions and lids are sent to KWU. The bolts are forged by SC followed by machining to semi-finished bolts which are shipped to KWU. The lids, trunnions, and bolts are final machined at KWU.
At KWU, the internal diameters of the nickel plated cask body is final machined, and the sealing surfaces of the cask lid area are finished and then PT examinations are performed.
1
ORGANIZATION: GESELLSCHAFT FUR NUKLEAR SERVICE ETSEN, WEST GERMANY
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PAGE 10 of 16 i
Moderator material, a fuel basket, and metallic seals are fabricated by PM, BM, and CL respectively; and the furnished items are shipped to KWU for final assembly. At KWU, the unit is assembled, and a helium leak test and hydrostatic test are conducted. Painting and trunnion installation are the final steps prior to shipment to the customer.
The fuel basket is fabricated by BM in Wittingen-Knesbeck, West Germany from hot-rolled sheets out of Radionox A 18 (XCr Ni 1913).
The GNS material specification No. BS 05 included the following German DIN and GNS standards:
50 049 - Certificates of Material Testing, 17 440 - Stainless Steel, 50 145 - Tensile Test, 50 125 -
Test Coupons (Type E), 1543 - Dimensional Check, and GNS MDS No.
WB 15/1.
The MDS was signed off by GNS inspector No. 2 'and BAM inspector No. 1.52.
The Welding Plan was approved by GNS No. 9, and GNS No. 7 approved the Cleaning and Packaging Plans.
It was noted from the FCP that activities such as analysis of boron in each sheet and material stamping were witnessed by both GNS-QA and TUV.
Identification marking transfer, CMTRs from KRUPP, Creusot Coire and Thyssen, and a dimensional inspection report were stamped by GNS No. 8 and a representative from VEPC.
The neutron moderator rods are fabricated by PM in Vreden, West Germany in accordance with a Work Guide Line (designated AV) which was approved by GNS prior to the start of fabrication.
The AV addressed areas such as purchasing of raw material, material identification during manufacturing, inspection and certification. GNS MDS No. WB 23 specified the raw material
("LUP0LEN 5261 Z") which was supplied by BASF.
The manufacturing steps included forming sheets under pressure and tempercture frem raw material in granulated forP. cutting the sheets into rods, and machining into circular rods. The FPC indicated that GNS No. 7 verified material identification and a dimensional check. Material certifications (3) from Pl.
indicated that the rods meet the requirements of "3.1B-Abnahme."
Nickel plating of the internal diameter of the cask body and the housing for the trunnions is performed by VR in Klus, Switzerland in accordance with Procedure HV-3 " Galvanic Nickel Plating" which is approved by GNS-QA.
Cleaning, electrolyte composition check, and etching are performed per internal VR procedures 1
4 ORGANIZATION: GESELLSCHAFT FUR NUKLEAR SERVICE ESSEN, WEST GERMANY REPORT INSPECTION NO.:
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PAGE 11 of 16 (AV-V.R1/R2/R31/R32) which have been approved by GNS and BAM.
Internal checks such as nickel thickness testing, hardness testing, and final visual examination are in accordance with Procedure No. HV-3.
The high-tensile bolts are fabricated by SC in Lindlar, West Germany from forged rods using Material No. 1.4313 (X5 Cr Ni 134) as identified in GNS material specification No. BS 07.
Time / temperature charts for the heat treatment, CMTRs and PT and UT reports were submitted by SC. Tensile, charpy impact, and hardness testing were performed per DIN 50 145, 50 125, 50 115, and 50 351.
Visual examination and dimensional verification were in accordance with GNS Procedure PV 23,-1.
PT and UT, which were witnessed by GNS-QA and TUV, were in accordance with GNS Procedures PV 23-2 and PV 13, respectively.
Rods for trunnions and bolts and disks for primary and secondary lids are forged by BGH from Material No. 1.4313 identified in GNS specification BS 06.
For the three finished products, BGH submits a preliminary plan for heat treatment and specimen location for tensile and charpy impact tests for subsequent approval by GNS-QA and TUV.
Tensile and impact tests are performed in accordance with DIN 50 145 and 50 115, respectively. Time / temperature charts and heat treatment certifications, CMTRs and UT reports were submitted by BGH.
TUV Inspection Certificates reference dimensions and mechanical properties.
Visual examination and dimensional verification are performed in accordance with GNS procedures PV.22-1 (trunnions),
PV 21-1 (lids), and PV 23-1 (bolts). Ultrasonic testing was witnessed by GNS No. 7 and TUV No. 4, and UT was performed in accoidance with PV 12 (trunnions), PV 11 (lids), and PV 13 (bolts).
The nodular iron _ body is cast by either of two foundries:
SK or GP. The CASTOR No. 2 body was cast by GP. A review of the FCP showed that UT o the machined casting was witnessed by GNS No. 6 and BAM No. 6.21, and a dimensional check and PT were signed off by GP-QA and GNS No. 7.
The UT report dated March 27, 1985 indicated the test was performed by a Level II and a Level III examiner, and the results were accepted by a Level III examiner from VEPC.
Two certifications from GP were also reviewed. One was fer chemical analysis and the other for mechanical properties.
Mechanical testing of core samples removed by KWU was performed by BAM.
ORGANIZATION:
GESELLSCHAFT FUR NUKLEAR SERVICE ESSEN, WEST GERMANY REPORT INSPECTION NO.: 99901025/85-01 RESULTS:
PAGE 12 of 16 Finel machining of components, testing, and final assembly is pet formed at KWU. Two FPCs, one prior to nickel plating and one after nickel plating were reviewed by the NRC inspector.
Other documents reviewed included an acceptance test Certificate for the bored holes for the neutron moderator rods which was signed off by QA personnel from KWU and GNS; a dimensional inspection report for trunnion seats which was signed off by personnel from KWU, GNS, and TUV; a PT report for trunnion seats which was witnessed by TUV No. 4 and a certification to verify moderator length which was signed off by KWU and GNS-QA.
Additional accuments reviened includcJ a nickci plating, acceptance test certificate and a dimensional check after nickel plating both of which were signed off by KWU-QA and GNS No. 7.
In addition, a surface roughness check of the nickel plated surfaces and a PT report of the sealed surfaces following machining was signed off by KWU-QA, GNS No. 7 and TUV No. 4.
For the primary and secondary lids, two FPCs and the following documents were reviewed:
material identification certifications; dimensional inspection reports signed off by KWU-QA, GNS, and a individual from VEPC, and a PT report witnessed by GNS No. 7 and TUV No. 4.
3.
Subcontractors The facilities of four subcontractors were visited to assure that each manufacturer had adequate QC coninitments and was implementing an effective QA program.
During the plant visits, three of the manufacturers wcrc not cng:gcd in work related to a CASTOR V cask.
GP-Siegen, West Germany Personnel Contacted Dr. K. Schroeder, QA Manager H. Emami, QA Supervisor - Foundry H. Mehlau, NDE Examiner GP produces spin, continuous, and heavy mold castings.
The melting shops consist of four electric arc and two induction furnaces.
Weights, times, and temperatures are monitored using modern measuring and testing methods to guarantee uniform quality.
The production s
ORGANIZATION:
GESELLSCHAFT FUR NUKLEAP SERVICE ESSEN, WEST GERMANY REPORT INSPECTION N0.: 99901025/85-01 RESULTS:
PAGE 13 of 16 process, from receipt of incoming raw materials to final inspection, is subject to stringent quality controls.
Inprocess QC consists of a variety of hardness testing techniques and special UT methods.
Final inspection includes checks for dimensional accuracy and surface finish by roughness testing, MT and PT.
Chemical composition of the raw materials and finished products are controlled, and mechanical properties are verified with the aid of static and dynamic testing equipment.
The time / temperature chart for the heat treatment of the CASTOR No.
2 cask was reviewed.
It was noted that the Ni-Cr-Ni thermocouples attached to the cask body and located in the furnace ceiling were calibrated with a Pt-Rh-Pt thermocouple (transfer standard).
There was no documented evidence that the standard was ever calibrated, and the NPC inspector was told that the Pt-Rh-Pt thermocouples were purchased from a sole source supplier and that CMTRs were not required. A review of calibration certificates revealed that the mechanical testing equipment (e.g. tensile, hardness, charpy impact) was calibrated by Staatliches Materialprufungsanct (MPA) on an annual basis.
The NDE certifications from the DGZP for the Level 11 and Level III examiners who per'ormed UT of the CASTOP No. 2 cask were reviewed and found acceptable.
SK - Krefeld, West Germany, Personnel Contacted M. Rosenau, QA Manager H. Muting, Fuundry Manager SK casts products with unit weights up to 150 tons from gray and nodular cest iron and alloyed grades.
An independent QC department is integrated into the manufacturing process, and each stage of the process is overseen by the QC department.
Testing for mechanical properties, dimensional checks, surface inspections, and UT are performed by the QC department. Optical and electron microcopy are used in the laboratory, and a mass spectrometer is used for chemical analysis of both raw material and finished products.
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r ORGANIZATION: GESELLSCHAFT FUR NUKLEAR SERVICE ESSEN, WEST GERMANY PEPORT INSPECTION NO.:
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PAGE 14 of 16 The plant tour consisted of the pattern shop, core production and sand molding areas, melt shop (four induction heated furnaces),
batch mixing area, and metallurgical and testing laboratories.
A review of calibration certificates for mechanical testing equipment (tensile, hardness, and charpy impact', indicated that the equipment was calibrated by MPA on an annual basis.
However, there was no evidence that the reference standards were traceable to PTB.
KWU - Puehlein-Ruhr, West Germany Personnel Contacted K. Muller, QA Manager H. Kaufer, Electro Technician F. Schlegel, TUV Representative KWU is responsible for the final machining of several components (i.e.,
cask body, primary and secondary lids, trunnions, and bolts) as well as testing and final assembly. The NRC inspector witnessed a successful leak and hydrostatic test on the CASTOR No. 2 cask (See B.I.c).
The UT calibration block of nodular cast iron containing three flat bottom holes in three orthogonal directions was examined.
A visit to the metrology laboratories at two different sites revealed that Siemens, the parent company of KWU, calibrates the reference standards used by KWU to calibrate measuring and test equipment.
Both laboratories had posted a " Level B Test Laboratory Certificate" from Siemens which indicated that each lab meets all the requirements in controlling measuring and test equipment according to a Siemens manufacturing guideline. A review of individual certifications frem Siemens did net indicate that the et:nd:rd; were traceable to PTB.
It was noted that dead weight tester S/N 207-909/
910 was used in October 1984 to calibrate pressure gage No. 31 which was used on the hydrostatic test.
Test certi'icate No. C3/1 from Siemens indicated that the dead weight tester was calibrated in April 1982 and was due for calibration in April 1984 There was no documentation to show that the dead weight tester was calibrated af ter April 1982 (See B.1.c).
Another CASTOR cask body (designated GNS No. 02) from SK was on blocks, and two core samples for mechanical testing were being machined from the holes which will accommodate the neutron moderator rods. All mechanical testing of the cask body is 1
ORGANIZATION: GESELLSCHAFT FUR NUKLEAR SERVICE ESSEN, WEST GERMANY REPORT INSPECTION NO.: 99901025/85-01 RESULTS:
PAGE 15 of 16 performed by BAM. A decision will be made whether or not to use the cask body in a finished CASTOR cask for drop tests or for another CASTOP cask for VEPC.
BGH - Siegen-Weidenan, West Germany Personnel Contacted Dr. Biener, QA Manager J. Dilgert, QA Engineer H. Giesler, Supervisor - NDE E. Ohrndorf, Marketing Manager BGH forges the primary and secondary lids, the trunnions and stock for the bolt fasteners.
For all four products, the process consists of melting the steel and pouring it into ingots at the steel works.
At the forging plant, the ingot is warmed-up, pre-compressed in a 2000 ton press, and transferred via a roller gear bed to the forging machine. After forging, the' product is heat treated in an automated annealing, hardening and tempering plant.
The product then enters a hydraulic straightening press before being sand blasted.
Following a hardness check and an in-process UT examination, the final production steps include cutting and machining.
In the case of CASTOR V products, QC consisted of 100% UT examination. Mechanical testing (i a., tensile and charpy impact) is witnessed by a TUV representati.e.
It was noted that material identification is by impression marking of the heat number and material identification (e.g., W 310 alloy) on all products.
Traceability is maintained from the ingot, to the forged bar, through intermediate products to the #inal product which is shipped to the customer.
There are seven gas fired furnaces each with five monitored zones.
Ni-Cr-t!i thermocouples are used in ona furnace and Pt-Rh-Pt thermocouples are used in the other six furnaces.
The thermocouples are calibrated every six months against a Pt-Rh-Pt standard (two of which are in-house) which in turn is calibrated against Pt-Rh-Pt standard No. 657 which is calibrated by Eichamt Hannover No. 2 (EM-2) which is a department / division of PTB. A review of log books for each furnace verified that the thermocouples were calibrated at the required frequency, and certificate No.
657/85 from EP-? indicated that reference standard No. 657 was calibrated on July 18, 1985.
The printer charts in the control room are calibrated twice a year. A remote controlled panel is used to l
7; ORGANIZATION: GESELLSCHAFT FUR NUKLEAR SERV!CE ESSEN, WFST GERMANY PEPORT INSPECTION NO.: 99901025/85-01 RESULTS:
PAGE 16 of 16 check the temperature in the five furnace zones against the actual print-out in the control room.
The thermocouples are spaced equidistant apart in the furnace ceiling.
The inspector reviewed a calibration certificate dated 1980 from the PTB for the measuring instrument "Symetra 2D" used for calibrating the thermocouples.
The instrument is calibrated every two years and the most recent certificate from TUV-Rheinhand was dated September 24, 1982. TUV had calibrated the instrument per a contract with the PTB as noted in the certificate. No other documentation could be produced which suggests that the instrument is approximately one year overdue for calibration.
The testing laboratory was toured, and a review of QA records indicated that the hardness testers (2), tensile testers (2) and charpy impact testers were all calibrated by the MPA. A review of records for the testing performed on the items for CASTOR V indicated that the actual testing was witnessed by TUV. The UT units are serviced and calibrated by Kraut Kramer once a year. Certifications for four NDE examiners - one Level III and three Level II were in compliance with the certifying agency - DGZP.
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