ML20090K521

Applicant Exhibit A-111,consisting of Testimony of Jm Mcconaghy,Lr Barnes,Jp Akers,Je Cavender,Lw Rudasill,Jc Shropshire,Rp Ruth & Dh Llewellyn Re in Camera Witness 2 Allegations Concerning Lamination

ML20090K521
Person / Time
Site:	Catawba
Issue date:	01/30/1984
From:	Akers J, Barnes L, Cavender J, Llewellyn D, Mcconaghy J, Rudasill L, Ruth R, Shropshire J DUKE POWER CO.
To:
References
A-111, EXT-840130-1, NUDOCS 8405240235
Download: ML20090K521 (15)

Text

_

=

._m a

'9 Exhibit 111

/

&g q~ t I t u>y

(

Va

/k UNITED STATES OF AMERICA O

NUCLEAR REGULATORY COMMISS D0 "

s BEFORE THE ATOMIC SAFETY AND LICEN HVG BNASD D#

V DOCIT:TIIIG &

/

gravic::rmu:cu In the Matter of

)

c

'A u

4

)

\\'

DUKE POWER COMPANY, et al. )

Docket Nos.

'--~ )

50-'414 (Catawba Nuclear Station,

)

J Units 1 and 2)

).

TESTIMONY OF J. M. MCCONAGHY, L. R. BARNES, J. P. AKERS, J. E. CAVENDER, L. W. RUDASILL, J. C. SHROPSHIRE, R. P. RUTH, AND D. H. LLEWELLYN REGARDING IN CAMERA WITNESS #2's ALLEGATIONS CONCERNING LAMINATIONS 1

Q.

PLEASE STATE YOUR NAMES, BUSINESS ADDRESSES, AND YOUR 2

PROFESSIONAL QUALIFICATIONS.

t l;

3 Mr. McConaghy: My name is John M. McConaghy, Jr. My business 4

address is 422 South Church Street, Charlotte, N.C.

28242.

I am 5

a Design Engineer II, and a work leader in the Civil Engineering 6

Section, Civil and Environmental Division, Design Engineering l

7 Department.

A copy of my professional qualifications is attached 7

8 (Attachment A).

9 a

i 10 A.

Mr. Barnes:

My name is L. R. Barnes.

My business address is 11 Catawba Nuclear. Station, P. O. Box 223, Clover, S. C.

29710.

12 My current position is Planning and Control Manager for i

13 Construction at the Catawba Nuclear Station.

A copy of my 14 professional qualifications is attached to Applicants' testimony 15' addressing the Board's Question Concerning the Containment Spray

(

16 System.

I t

17

!O f

8405240235 e40130

,[

DR.ADOCKOSOOOg

i

{J 1

Mr. Akers:

My name is John P. Akers.

My business address is 2

P.O.

Box 33189, Charlotte, N.C. 28242.

My current position is 3

Quality Assurance Supervisor.

My responsibilities in this position 4

consist of supervising Quality Assurance Vendor Personnel in 5

HVAC, Civil and Electrical

areas, to include performing 6

surveys, audits and surveillance in vendor shops.

A copy of my 7

professional qualifications is attached.

(Attachment B).

8 9

Mr. Cavender:

My name is John E.

Cavender.

My business 10 address is P.

O.

Box 33189, Charlotte, N.C.

28242.

I am a 11 Nondestructive Examination Examiner (NDE)

Level III.

My 12 responsibilities include training and conducting reviews of NDE 13 results, procedures and NDE personnel. A copy of my professional O

14 qualifications is attached to Applicants' testimony addressing the 15 Board's Question Concerning the Containment Spray System.

16 17 Mr. Rudasill:

My name is Larry W. Rudasill. My business address 18 is Catawba Nuclear Station, P. O. Box 223, Clover, S. C.

29710.

19 My current position is Welding Supervisor in Reactor Building #2.

20 In the past, I have held positions as a Welding Inspector and 21 Welder for Duke at Catawba and McGuire Nuclear Station.

A copy 22 of my professional qualifications is attached to Applicants' testimony 23 addressing In Camera Witness #2's Allegations Concerning Foreman 24 Override.

25 O '

i

)

1 Mr. Shropshire:

My name is J.

C.

Shropshire.

My business 2

address is Catawba Nuclear Station, P. O. Box 223, Clover, S. C.

3 29710.

My current position is Quality Assurance Engineer.

I am 4

responsible for the Mechanical, Welding, and NDE Quality Assurance 5

Group.

A copy of my professional qualifications is attached to 6

Applicants' testimony addressing the Board's Question Concerning 7

the Containment Spray System.

8 9

Mr. Ruth:

My name is Ronald R. Ruth.

My business address is 10 McGuire Nuclear Station, P. O. Box 488, Cornelius, N. C.

28031.

11 I am Senior QA Engineer responsible for implementation of the Duke 12 Power QA Program at the McGuire Nuclear Station.

A copy of my 13 professional qualifications is attached (Attachment C).

Q 14 15 Mr. Llewellyn:

My name is D. H. Llewellyn. My business address 16 is Catawba Nuclear Station, P. O. Box 223, Clover, S. C.

29710.

17 My present position is group leader of Technical Support - Welding.

18 A copy of my professional qualifications is attached to Applicants' 19 testimony addressing Allegations of In Camera Witness #2 Concerning 20 Foreman Override.

21 22 Q.

ARE YOU FAMILIAR WITH IN CAMERA WITNESS #2's ALLEGATIONS 23 REGARDING LAMINAR-TYPE DISCONTINUITIES?

24 A.

Yes, we have reviewed his testimony.

As support for his 25 allegations the witness raises the following major concerns:

26 1.

Laminations in the containment plate are unsafe.

O a I

~

\\

Q 1

2.

Laminations in some penetration sleeves in the containment 2

are unsafe.

3 3.

A 3/8 inch deep hole in one vendor weld near a 4

penetration is unsafe.

5 e

6 Q.

HAVE YOU INVESTIGATED THE ALLEGATIONS?

7 A.

Yes. The investigation consisted of an analysis of relevant portions 8

of documents including inspection reports, vendor audits, codes, 9

standards, procedures and calculations regarding this issue and 10 discussions with inspectors, welders and welder foremen.

11 i

12 It should be noted, however, that the issue of laminations was 13 investigated before containment plate was delivered to Catawba.

O 14 Because laminations are inherent in plate of this type, Duke had

(

15 researched the issue and developed procedures to address the issue F

16 (el, CP-88). RPR, JMM.

1 i

17 l

18 Q.

WHAT WAS THE RESULTS OF YOUR INVESTIGATION?

19 A.

From our investigation we have determined that laminations in the 20 Catawba containment plate and piping penetration sleeves are 21 acceptable.

Further, we know of no existing conditions in the 22 plant that could adversely impact plant safety.

In inddition, 23 adequate controls were in effect to assure that laminar-type edge 24 discontinuities did not result in unaccer'.able welds. Also, we have 25 determined that the 3/8 inch deep hole in the weld in question did 26 not present a safety hazard.

Factors providing support for this 27 determination include those noted below.

p a

4 s

i

..r.

..._,_,--...,..__.-,+--_.-..m,..,...

.. - ~

N

O l

1 1.

Laminations in steel plate are caused by the incorporation 2

of a nonmetallic inclusion (i.e., air or gas bubbles, or 3

other foreign material) into the plate. Steel in the molten 4

state is poured into a mold and solidified.

During this 5

solidification process, gas bt:bbles and other nonmetallic 6

substances can get trapped inside the mold and become 7

part of the ingot.

The ingot is then reduced in 8

cross-section by rolling.

During this rolling process the 9

inclusions are also reduced in cross-section to the degree 10 the ingot is rolled, and they form " planes" or flattened 11 inclusions inside the plate.

The amount of the reduction 12 of the plate will dictate the resulting size and thickness a

13 of the inclusion. These inclusions are what is referred to O

14 as laminations.

Laminations are inherent in rolled plate i

15 material.

RPR, JMM.

16 a

17 2.

The containment vessel and the larger penetration sleeves 18 were fabricated from steel plate material in accordanc'e 19 with appropriate ASME requirements. These requirements 20 impose no limit on laminar-type discontinuities, except 21 when they appear at the edge of a plate. Paragraph 9.3 22 of ASME Specification SA-20 states that laminar-type 23 discontinuities on a plate edge which are 1 inch or less in 24 length are acceptable without repair. RPR, LRB.

I 25 O

i: >

h 1

The basis for lamination requirements in this ASME 2

standard is that laminations are of structural significance 3

only when they are subjected to loads which would cause 4

them to open, i.e., through-thickness tensile loads which 5

would impose stresses perpendicular to the plane of the 6

laminations.

At

Catawba, when significant 7

through-thickness loads may be applied to pressure 8

retaining plates, these plates are ultrasonically examined 9

to assure that no unacceptable laminations are present.

10 JMM, JPA.

11 12 Service loadings on the Catawba steel containment 13 including the penetration sleeves produce stresses in the O

14 viate paratiei cnot perpendicuiar) to the surface of any 15 laminations which may be present.

There stresses are of 16 no significance to the laminations since they do not tend i

17 to open the laminations. Therefore, no laminrtions in the 18 Catawba steel containment are subjected to loads which I

19 would cause degradation to the structure. JMM.

i 20 21 Even though laminar-type discontinuities are acceptable in 22 the plate, their presence may result in some unacceptable 23 defects in welds joir.ing these materials if the laminations 24 are not first :tmoved from the plate edge.

The removal 25 process (which for containment plate is as set forth in 26 CP-88) consists of grinding back and sealing laminar-type

{.O' 27 edge discontinuities.

This process is employed, when B-

)

6-

O 1

required, while joining sections of containment plate.

2 When welding items to the penetration sleeves a similar 3

process would be set forth in specific detailed process 4

control using Form F9B in accordance with QA procedure 5

M-4.

Section III of the ASME requires that these welds 6

be radiographed to assure there are no unacceptable weld 7

defects. JEC, RPR, DHL, JCS.

8 1

9 Accordingly, at Catawba welds of containment plate and 10 welds onto containment penetration sleeves were 11 radiographed.

Any rejectable weld defects caused by 12 laminations would have been identified by the radiographs 1

13 and corrected.

Indeed, in the In Camera Witness #2's 14 testimony, he attests to the thorough nature of the j

15 corrective action regarding this area by his reports on all 1

16 the corrective action which occurred on one penetration 17 sleeve weld with which he was familiar. JEC, RPR.

18 19 2.

In his testimony, In Camera Witness #2 described the i

20 repair of weld 2NI 15-1 which joins penetration 2M407 to a 21 32 'nch diameter containment penetration sleeve.

The l

22 process was fully documented in accordance with QA l

23 Procedure M-4, the weld was radiographed and all records l

24 were accepted by Duke Quality Assurance and the 1

f 25 Authorized Nuclear Inspector.

In short, there is nothing O

26 about this weld that supports any concern regarding the i

27 safety of the plant. JCS, DHL, LRB.

l i-7 L.

. ~

O

- 3.

with regard to in Camera witness,2 s concerns reg rding 1

2 a 3/8 inch deep hole in some vendor weld, we have 3

questioned each of the individuals involved and none 4

recalled the witness pointing out to them a hole in a 5

vendor weld joining a pipe penetration sleeve to a 6

containment plate section as described in the witness' 7

testimony.

However, the foreman did recall the witness 8

pointing out a pinhole in a vendor weld on a 20" 9

penetration bellows assembly number 2-M355.

This was a 10 3/16" fillet weld joining the shroud support ring to the 11 stub end of the penetration. It was in closa proximity to i

l 12 weld 2FW58-1 which the witness was working on in March 13 and April 1981. Shortly after the witness pointed out the 14 situation, the welder foreman discussed the situation with 15 a member of the Construction Engineering Group who i

16 directed that the vendor weld be repaired.

It should be I

17 noted, however, that the weld did not in any way form a 18 portion of a pressure retaining boundary.

The weld 19 simply helped hold in place a shroud which covered a 20 bellows assembly.

Th'us, even without repair, the weld 21 was clearly acceptable as far as performing the function j

22 for which it was intended. JCS, JMM, LRB, LWR.

23 24 4.

To assure that vendor welds are acceptable, Duke Power 25 Company has a rigid vendor audit and surveillance 26 program.

Duke Power audits or evaluates its vendors on O

l 27 a

periodic basis. to assure compliance with quality

a OV 1

standards.

In

addition, the pertinent Duke Power 2

Containment Plate Procurement Specification requires that 3

the vendor inspect, nondestructively examine, and repair 4

his fabrication of containment plate as required by ASME 5

III Subsection NE.

Duke QA personnel monitor many of 6

these inspections to verify that they are being performed 7

to proper codes and standards. JPA, RPR.

8 9

The welds joining penetration sleeves to the containment 10 plate are full penetration T-welds.

Paragraph 11.1.2 of 11 the Duke Containment Plate Procurement Specifications 12 requires that the weld first be welded from one side,-

13 then the root pass of these welds be back-gouged, that 14 the back-gouged area be magnetic particle examined, that 15 the first pass on the back-gouged side be magnetic 16 particle examined, and that both sides of the final weld 17 be magnetic particle examined and ultrasonically examined.

18 These examinations would have detected rejectable defects 19 in these welds, and they would have been repaired.

20 JMM, JEC, JPA.

21 22 Paragraph 7.3 of the Duke Containment Plate Procurement 23 Specifications requires that the vendor provide to Duke a 24 Vendor Quality Assurance Certification form along with all i

25 required quality assurance documen'ation.

The Vendor 26 certification consists of a

Certificate of Compliance

O 27 (signed by the Newport News Industrial Corp. QA

1 Manager) and records of

making, nondestructively examining, and repairing these welds. The Certification 2

3 was reviewed by Engineering Services Division (now 4

Technical Services Division) of Duke's Quality Assurance 4

5 Department atd found to be acceptable.

LRB, JPA.

i.

4 4

LO l

l l

O l-, - - -.

Attachm:nt A Professional Qualifications O

Of John M. McConaghy, Jr.

Design Engineer II, Civil and Environmental Division Design Engineering Department December 9,1983 My name is John M. McConaghy, Jr. My business address is 422 South

+

Church Street, Charlotte, Nerth Carolina 28242.

I am a Design Engineer II, i

and a work leader in the Civil Ergineering Section, Civil and Environmental Division Design Engineering Department of Duke Power Company.

I hold a Bachelor of Science degree from the United States Military Academy and a Master of Engineering degree in Civil Engineering from Virginia Polytechnic Institute and State University.

From June 1971 to November 1976, I served as a comissioned officer i

in the U.S. Army Corps of Engineers. From September 1978 to July 1979, I was i

employe1 as a researcher by Battelle Columbus Laboratories in Columbus, Ohio.

From August 1979 to the present. I have been employed as a structural engineer by Duke Power Company. During this period I have perfonned structural, seismic and missile analyses and design for steel, concrete and masonry components.

i My current position is Design' Engineer II in the Civil Engineering l

Section of the Design Engineering Department. In this capacity, I am currently responsible for Design Engineering support of the steel containment vessels at Catawba and McGuire Nuclear Stations.

I have coordinated and participated j

in the as-built design analysis of the Catawba steel containment vessels.

4 f

_Q I am a registered professional engineer in North Carolina, South Carolina, and Virginia.

Attachm nt B 4

~ Q RESUME JOHN P AKERS PERSONAL:

Home Address: 5443 Grafton Drive Charlotte, NC 28215 Telephone:

(704)536-7222(Home)

(704)373-8247(Office)

Age: 47 Height:

6'0" Weight:

170 lbs.

FORMAL EDUCATION:

Logan High School W. Va

'1954 West Virginia Tech W. Va.

Mechanical Engineering (3 yrs.)

ADDITIONAL TRAINING:

Duke's Philosophy of Management, Theory of Construction and Maintenance, Krautkramer's Ultrasonic Inspecting and Measuring Course, Mangaflux's Radiographic Inter-pretation Course, Duke's Magnetic Particle and Liquid Penetrant Inspection Course, Computer Programming and Operation, Steel and Concrete in Construction, plus many others.

WORK O

ExeEaleNCE:

FROM TO TITLE PROGRAM COMPANY T/74 PrHent QA Supervisor All Duke Power for HVAC, Civil &

Electrical Comp.

Supervises Quality Assurance personnel performing Quaity Assurance sur-1 veys, audits, and surveillances in manufacturing plants of suppliers of HVAC, Civil and Electrical components for nuclear power electric generating stations. Familiar with ASME codes, AWS Codes, 10CFR50 Appen-dix B, ANSI N45.2 and SNT-TC-1A with a thorough knowledge of Quality Assurance Manuals and internal procedures.

'72

'74 Equipment Specialist All Duke Power Perform Quality Assurance audits and surveillances on mechanical equipment and services for all of Duke's nuclear power plants.

1/70 2/72 Area Manager Dow Chemical l

Supervise industrial cleaning and maintenance area of five states, eight l

engineers, eight technicians, two salesmen, one mechanic, one secretary and one clerk. Raised industrial cleaning and maintenance revenue from i

$352,000 to $740,000 maintainig a field margin profit of 31.3% in first l

p 19 months as manager.

Served as maintenance consultant to chemical, si utility, paper and fiber industries.

Initiated and approved contracts l-with them.

l

f.-

4

! ()

RESUME i.

JOHN P AKERS i

Page 2 i

4 l

5/69 1/70 Service Manager Dow Chemical Directed chemical cleaning and hydro-blast operations and was responsible for all maintenance on Charlotte-based equipment. Served as consultant engineer to utility, paper, textile and chemical plants and helped initiate their preventative maintenance programs.

11/66 7/69 Project Engineer Dow Chemical Provided engineering support for construction and maintenance operations for launch pad for moon shoot. This included HVAC concrete,' steel, piping, electrical and instrumentation.

Issued field engineering orders for changes in design and served as Liaison Officer to NASA for' Apollo mis-sions.

12/63 11/66 Project Engineer Chrysler-Bendix t

O' Supervised three design engineers and seven draftsmen. Provided engineering support for Electrical, Electronic, Heavy Equipment and a Machine Shop.

Provided consulting function to outside design agencies to better utilize capabilities of these shops.

Initiated contracts to fabrication shops 1

and served on " Quality & Assurance Review Boards".

1 i

8/62 12/63 Mechanial Engineer Aerospace Corp.

Performed in Engineering support of Atlas and Titan I Missile for Air' Force. Designed and helped build hardware for missile and spacecraft checkout. Programmed and operated IBM 1620 computer.

5/61 8/62 Mechanical Engineer Pan American World Airways j

Prepared design studies and calculations for facilities additions and i

modifications. This included HVAC,= architectural, mechanical engineering and transit work.

4/60 8/61 Junior Engineer United Fuel'&

Gas Co.

l E

Prepared design calculations and layout drawings for natural gas trans-mission stations.-

()

11/58 4/60~

Junior Engineer Island Creek Coal Co.

Prepared mechanical, steel, concrete and piping drawings for modifications-to bituminous coal preparation plants.

Attachment C Professional Qualifications Of 1

Ronald P. Ruth j

Sr. QA Engineer McGuire Nuclear Station Operations Division December 9,1983 1

EDUCATION:

Bachelor of Science in Metallurgical Engineering from Mississippi State University Masters of Science in Metallurgical Engineering from Mississippi State University Duke Power Company Management Training Duke Power Company Advanced Management Training Duke Power Company Effective Management l

MT, PT, UT, RT Courses Welding Inspector Welding Inspector Instructor QA Lead Auditor Mechanical Inspector EXPERIENCE: Mississippi State University 1970 - 1971 Graduate Assistant Worked as graduate assistant on a research grant funded by NASA.

Worked 'on Metallurgical Structures on

" Skylab" or*oital laboratory.

Lenage Forge Division / Gulf & Western, Inc.

1971 - 1974 Marketing Engineer i

Lenage Forge Division was a custom forge shop that specialized in forgings for the nuclear industry.

Lenage fabricated reactor

vessels, steam generators and pressurizer nozzle forgings for companies such as Westinghouse, CE, B&W and GE. My responsibilities were to interface with the reactor vessel manufacturers and

'.]'

resolve any technical problems concerning the forgings being supplies by us.

Areas of responsibilities while at Lenage. were manufacturing, quality assurance and sales / marketing.

t i

- ~ -. - -

.-- -,,., - -, ~.

~O

~

ExrER18NCE: Duke rower Comranv.1974 - rresent (Cont'd) 1974 - 1975 Assistant QA

Engineer, Engineering Services Division (E&S)

While in E&S, one of my responsibilities was to help support field engineers in code interpretations (ASME, ANSI, AWS, etc.).

Responsible for the review and approval of vendor welding procedures to be used on Duke's products.

Responsible for assisting in answering metallurgical questions from all aspects of Duke's work, in construction and design.

1975 - 1977 QA Supervisor, Vendor Division Responsible for auditing and approving vendors QA programs to be placed on Duke's " Approved Vendor List" in the areas of electrical, engineering, fuels and services (calibration labs, chemical companies and outside consultants).

Also, I was responsible for scheduling and performing surveillances on approved vendors to check to they maintained compliance with their approved QA see program.

1977 - 1979 QA Engineer, Construction Division n

Responsible for the supervision and direction for the U

implementation of the QA program in the areas of mechanical piping, equipment and system testing, welding and NDE.

Reviewed and approved NC1's, and interfaced with NRC inspectors while on project site.

Reviewed all completed documentation to assure compliance with specified requirements.

1979 - Present Sr.

QA Engineer, Operations - Division Responsible for the implementation of the Duke rower QA program at the McGuire Nuclear Station. There are three major areas of responsibility, 1)

Q.C.

inspection

program, 2)

QA surveillance program, and 3) QA J

technical support.

s O

m 4

3 9

l l

l 1

/! l

. /

\\.

i

,r,

v'

[

/

i-d.

i \\

~

3.3 X/,/

/

a/

~

u v

/

v

{1v sb Q-

1. enj 7

$?('lz'gf n.

q,.,~

j -

ay,

/,. -

./

i.?

g

/

Q/

g& [

/g ne,;,, 0,y

/

/.. s, t1

.,/

/

/

z'.

/

y J

[

t i

l O

I f

.