ML20148F889
| ML20148F889 | |
| Person / Time | |
|---|---|
| Issue date: | 03/07/1988 |
| From: | Baker E, Conway J Office of Nuclear Reactor Regulation |
| To: | |
| Shared Package | |
| ML20148F813 | List: |
| References | |
| REF-QA-99902007 99902007-88-01, 99902007-88-1, NUDOCS 8803280309 | |
| Download: ML20148F889 (5) | |
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ORGANIZATION: ALLEGHENY LUDLUM CORPORATION CLAREMORE, OKLAH0MA REPORT INSPECTION INSPECTION NO.: 99902007/88-01 DATE:
01/4-6/88 ON STTF Hnnpe. 9n CORRESPONDENCE ADDRESS: Allegheny Ludlum Corporation Tubular Products Division ATTN: William G. Bieber General Manager Post Office Box 948 Claremore, Oklahoma 74018-0948 ORGANIZATIONAL CONTACT: James Pepin, Technical Department Manager TELEPHONE NUMBER:
(9181 341-8711 NUCLEAR INDUSTRY ACTIVITY:
Fabricated E-Brite 26-1 alloy tubing for Engineers and Fabricators Company (EFC) and stainless 304L tubing for Yuba Heat Transfer Corporation both in 1981.
ASSIGNED INSPECTOR:
O
-88
. Conway, Progra Development and Reactive Date
. spection Section DRIS)
OTHER INSPECTOR:
C. D. Sellers, M terials Engineering Branch APPROVED BY:
E~ ~
E. T. Baker, Acting Chief, PDRIS, Vendor Inspection Date Branch INSPECTION BASES AND SCOPE:
A.
BASES:
10 CFR Part 50, Appandix B and 10 CFR Part 21.
B.
SCOPE: The purpose of the inspection was to review the QA records and evaluate the process used to fabricate the E-Brite 26-1 tubing for the shutdown cooling heat exchangers at Arkansas Nuclear One Unit 2 in 1981.
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PLANT SITE APPLICABILITY: Shutdown cooling heat exchangers-Arkansas Nuclear l
One, Unit 2(50-368).
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8803280309 8801521 PDR GA999 EMVALSC 99902007 PDR l
ORGANIZATION: ALLEGHENY LUDLUM CORPORATION CLAREMORE, OKLAHOMA j
l REPORT INSPECTION NO.: 99902007/88-01 RESULTS:
1 AGE 2 of 5 A.
VIOLATIONS:
None.
B.
NONCONFORMANCES:
None.
C.
UNRESOLVED ITEMS:
None.
D.
STATUS OF PREVIOUS INSPECTION FINDINGS:
None.
This was the first inspection at this facility.
E.
OTHER FINDINGS OR COMMENTS:
Tubular Products Division (TPD) 1.
Allegheny Ludlum (AL) fabricates tubular products at their facility in Claremore, Oklahoma, which was built in 1978.
The original TPD, located in Wallingford, Conrecticut, was phased out at the end of 1984.
The TPD produces alloy steel tubing including a number of ferritic grades designated E-Brite 26-1, AL 29-4C, and AL 29-4-2.
Based on a review of procurement and shipping records for tubing fabricated at both Wallingford and Claremore and discussions with knowledgeable personnel, it has been determined that the only nuclear tubing fabricated by AL was in 1981.
This included E-Brite 26-1 alloy tubing for EFC and stainless 304L tubing for Yuba Heat Transfer.
Tube skelp from AL's Flat Rolled Products Division is received by the TPD.
The skelp is roll formed into a circular shape on eight stand tube mills.
Continuous welding (TIG with argon-helium shielding) is done on 10 weld mills.
The weld bead is cold worked to produce a smooth surface on the OD and ID.
In-line eddy current (ET) monitoring and destructive tests (e.g., flatt?n, flare, and reverse bend) are perfonned every hour to assure the integrity of the weld.
Annealing with in-line induction heating / water quench or off-l line bright annealing guarantees that both the parent metal and weld rr.etal meet the mechanical and corrosion resistance requirements of the material specification.
Bright annealing is perfonned in a 3-zorie furnace that has an atmosphere of either dissociated ammonium i
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4 ORGANIZATION: ALLEGHENY LUDLUM CORPORATION CLAREMORE, OXLAHOMA i
REPORT INSPECTION NO.:
99902007/88-01 RESULTS:
F AGE 3 of 5 for austenitic alloys or hydrogen for ferritic alloys.
This is followed by forced atmosphere cooling.
The gages and heat treat charts on the annealing furnace are calibrated by Honeywell.
ET of all tubing is done on three finishing lines. All tubing is continuously line stenciled per the material specification.
- Heat, bundle, and ET personnel numbers are included in the identification.
The Level II examiner also performs three mechanical tests (flatten, flange, and reverse bend).
Finishing also includes cutting, deburring and cleaning and may include polishing to remove surface oxides.
Stretch or rotary straightening a;sures straight tube lengths.
Pneumatic and' hydrostatic tests are performed on a' tubes.
The gages used for these tests are sent to an outside vendor fo: calibra-tion.
Final inspection includes visual plus an OD and ID check with calibrated micrometers and ring gages.
If the tubing undergoes U-bending, the ID is cleaned if lubricant has been used.
Following bending, the tubing is electric resistance stress annealed. A temp-late is used to check the bend radfus.
The U-bent tubes are final cut and packaged for shipment.
The laboratory confims the mechanical tests perfomed by the Level II examiner and perfoms tensile and hardness tests in accordance with the material specification.
Corrosion tests are conducted if specified by the customer or the specification.
In addition to 100 percent ET, ultrasonic testing is also performed if it is required by the customer.
2.
E-Brite 26-1 The NRC inspector reviewed the QA records pertaining to the E-Brite 26-1 alloy tubing fabricated for EFC in 1981. EFC's Purchase Order (PO) 72257-D dated December 11, 1980 was for 166-3/4"0D x 16 BWG and 1332-3/4"0D x 18 BWG welded tubing to ASME SA-268 Grade TP XM 27.
I The P0 contained supplementary material requirements (SMR) and required that procedures for ET, annealing, tube cleaning, tube bending, hydrotest, marking and packaging be approved by EFC prior to manufacturing.
The SMR also designated witness / hold points and l
specified that a mill test report include "certification that material confoms to 1980... ASME Code Section III, Class 2."
A TWX dated Ja.uary 14, 1981 to the TPD indicated that EFC had approved nine procedures for the fabrication of the E-Brite tubes.
Seven TPD certified material test reports (CMTR) for the tubing were l
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ORGANIZATION: ALLEGHENY LUDLUM CORPORATION CLAREMORE, OXLAHOMA REPORT INSPECTION NO.:
99902007/88-01 RESULTS:
I AGE 4 of 5 signed by the QC Supervisor and referenced "1980 ASME Section III Class 2 and Section II SA268." During the inspection, the TPD could not produce any documentation to show that EFC had performed an audit /
survey to show that TPD had a QA program that met the roquirements of NCA-3800 of Section III of the ASME Code.
Following the inspec-tion, TPD contacted EFC and received a copy of a December 18-19, 1980 survey conducted by EFC of the TPD in Claremore, Oklahoma.
The Nuclear Survey Report was later received and reviewed by the NRC inspector, and EFC stated that TPD had "an adequate Quality Systems Program and adequate means for its implementation."
A review of the Wallingford TPD's Quality Assurance Policy and Procedures Manual, dated December 1, 1980 indicated it was patterned after the 18 criteria of Appendix B to 10 CFR Part 50.
This manual, along with the Quality System Program (QSP) were in effect when the E-Brite tubes for EFC were fabricated. The QSP sunnarized the QA program at the Claremore facility and addressed five major areas-Quality Organization; Control of Operations and Materials; Examina-tions, Test and Reports; Control of Measuring and Testing Equipment; and Audits and Corrective Action.
The NRC inspector reviewed a detailed processing plan for the E-Brite tubes which is completed prior to the issue of a mill ticket (shop traveler).
The plan is reviewed and approved by the QC Supervisor and Plant Manager.
The plan documents product information and specific activities in welding, heat treatment, straightline cutting, ET, pneumatic testing, visual inspection, U-bending ID cleaning, stress relieving, and hydrostatic test. A review of several shop travelers indicated that they included heat numbers and grade, required operations and tests, appropriate QA specifications /proce-dures, and mandatory hold and/or witness points.
The nine procedures referenced on the TPD CMTRs were reviewed.
The procedures included Heht Treating-Bright Annealing, Eddy Current Test Method, Supple ental Tube ID Cleaning, U-Tube Vi:;ual Examination Method, Process Control Dimensional Specifications (Straight and l
U-Bend Tubing), Hydrostatic Test, Stenciling Specification, Packaging, l
and Heat Treating-Stress Relieving Resistance Anneal, l
3.
Yuba Heat Transfer Corporation (YHTC)
A review of procurement records and discussions with knowledgeable personnel at TPD indicates that the only nuclear work other than the E-Brite tubing for EFC was for YHTC.
YHTC PO No. 81-3161 dated 1
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4 ORGANIZATION: ALLEGHENY LUDLUM CORPORATION CLAREMORE. OXLAHOMA REPORT INSPECTION NO.: 99902007/88-01 RESULTS:
FAGE 5 of 5 July 17, 1981 was for 690-3/4"00 x 20 BWG 304L stainless steel tubes to material specification SA249.
The material was ordered to Section III, Class 3 of the 1981 edition of the ASME Code.
TPD's CMTR dated September 17, 1981 certified that the material met the requirements of NCA-3800 and SA249-304L.
Other documents reviewed included a detailed processing plan, U-tube schedule, heat-treat charts, test report from Midstates Analytical Laboratories who performed tens 11e tests and metallographic examination, and nine tube mill test reports which showed that the flatten, flange, and reverse bend had been performed.
4.
NDE The NRC inspector reviewed TPD's "Practice for Qualification and Certification of NDT Personnel" dated August 15, 1980. The qualifica-tion records for seven examiners (2-Level III and 5-Level II) who were on the TPD payroll during the fabrication of the E-Brite tubes in 1981 were reviewed.
The records appeared to be consistent with the requirements of SNT-TC-1A.
F.
PERSONS CONTACTED
- William G. Bieber, General Manager
- James J. Pepin, Technical Department Manager James Hyslop, Marketing Manager Glenna Pennington, QA Technician
- Attended exit meeting.
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