IR 05000275/1970001

Insp Rept 50-275/70-01 on 700416-17.No Noncompliance Noted. Major Areas Inspected:Review of Primary Loop Spool Piece Fabrication

ML20195D082
Person / Time
Site:	Diablo Canyon
Issue date:	05/26/1970
From:	Long F, Potapovs U, Reinmuth G, Seidle W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II)
To:
Shared Package
ML20195C961	List: IA-88-156, Forwards 700917-18 Feeder Insp Rept IR 05000275/1970001 ML20195C957 ML20195C972 ML20195D272 ML20195D322 ML20195D405
References
FOIA-88-156 50-275-70-01, 50-275-70-1, NUDOCS 8806230030
Download: ML20195D082 (12)

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e U. S. ATOMIC ENERGY COM4ISSION

REGION II

DIVISION OF CCMPLIAN2 Vendor Inspection Report Pipe Vendor: Southwest Fabricating and Welding Company Houston, Texas Report No.: Southwest Fabricating and Welding Company 70-1 Components Inspected For: Diablo Canyon (50-275)

Date of Inspection: April 16-17, 1970 Inspectors: M ,#' -

$-IO-70 U. Potapovs, Reactor Inspector (Metallurgy) Date

/ 5l O F. J. long, Senior R(actor Inspector bate Persons Conta:ted: P. E. Wecker, Sr. QA Engineer, Pacific Gas and Electric L. Iswell, Sr. QA Engineer, Pacific Gas and Electric G. H. lockwood, President, Southwest Fabricating ,

and Welding B. A. Grahm, Assistant Vice President, Sales, Southwest Fabricating and Welding F. E. Sewell, Manager, QC, Southwest Fabricating and Welding R. C. Green, Chief Engineer, Southwest Fabricating and Welding R. D. Page, QC Representative, Westinghouse l

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8806230030 880615 IL B-156 PDR l

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VI Rpt. No. Southwest Fabri- -2-cating and Welding Co. 70-1

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Report Reviewed By: .

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W. C. Seidle, 4. Reactor Inspector Date

.W S*c?d-fp G. W. Reinmuth, Sr. Reactor Inspection Date Specialist Proprietary Information: Entire Report SCOPE On April 16-17, 1970, U. Potapevs and F. J. Iong visited Southwest Fabricating and Welding Company, Houston, Texas, as part of the Compliance vendor in-spection program. The visit was arranged through the Pacific Gas and Electric Company and had as a specific objective the review of Diablo 1 primary loop spool piece fabricatio St.HMARY Southwest Fabricating anu Welding Company is a wholly-owned subsidiary of International Utilities Ccopany and is one of the largest manufac-turers of fabricated piping assemblies. Nuclear work constitutes approximately 10 to 15% of the gross production. The plant has no design or stress analysis capability. (See Section A,) Westinghouse is the largest nuclear customer. At the time of the Coc'pliance visit, Southwest Fabricating and Welding had completed 25 Westinghouse primary loops of the original ortler for 28. A new order has been placed recently for 55 additional loops with option for 15 -

more. Extruled pipe (ASDI A376) was used in fabricating the spool pieces under the original order while the new order will be fabricated using mostly centrifugally-cast pipe. (See Section A.) Southwest Fabricating and Welding has no pipe manufacturing capabilit The large diameter primary loop piping and fittiags for Westinghouse contracts are supplied by Westinghouse (from other sources). The branch nozzle fittings and small diameter pipe are procured by South-west Fabricating and Welding. (See Section B.)

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VI Rpt. No. Southwest Fabri-cating and Welding Co. 70-1 -3- Southwest Fabricating and Welding has been recently surveyed by ASME and has , reportedly been recommended by the surveying team for the issuance of nuclear stamps in piping, pressure vessels (limited), and nuclear parts. (See Section C.) The plant has a QA manual and the responsible personnel are cognizant of the nuclear code requirements. In-plant NDT capability includes radiography, MP, LP, and UT. No laboratory facilities are availabl (See Section D.) The pressurizer surge line piping is hot formed followed by solution annealing, spray quenching, and sand blasting to remove scale. The fonning and heat treating procedures were considered satisfactor (See Section F.)

7 Welding procedures and procedure qualifications were reviewed and found to be satisfactory. Welding material control was considered goo (See Section G.) Identification marking is accomplished using low stress interrupted dot stamp (See Section H.)

9 The Diablo 1 piping was approximately 40% completed at the time of the visit. The spool pieces are being fabricated in accordance with Westinghouse E Spec. G-676343 which references ASA B31.1 and Code Case N-7 as the applicable code requirement . The large diameter piping for Diablo 1 spool pieces (and all Westinghouse contracts) is purchased by Westinghouse from pipe suppliers and deliv-ered to Southwest Fabricating and Welding with the appropriate mill certification. These do not include NDT documentation, which is re-tained at Penn Center. The Diablo 1 primary loop pipe was purchased to WAPD E Spec. G-676341, which designates ASTM A376, TP 316, with several supplementary requirements. (See Section I.) Hydrotest of the individual pipe lengths has reportedly been waived by the Westing-house purchase orde . Other Westinghouse supplied items include large cast fittings (27-1/2-inch I.D. and larger) and temperature detector bosses. The fittings are purchased to WAPD E Spee. G-676342 which designates the material as ASTM A351 GR CFSM, with additional supplementary requirement (Section I.1) and requires the fittings geometry to confora with USAS B16.9. Again, the shop hydrotest has reportedly been waived by the Westinghouse purchase orde . --

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i ( ( l VI Rpt. No. Southwest Fabri-cating and Welding Co. 70-1 -4-12. The branch nozzles a.re procured by Southwest Fabricating and Welding to ASm A182, GR F316. For nozzles two inches in diameter and smaller, ASm A276, TP 316, bar stock may be used. (See Section I.l.)

13. Other Southwest Fabricating and Welding 1.rocured items incluce thermal siseves -(ASTM A312, TP 304), pressurizer spray scoo WP 316) and surge line (ASM A376, TP 316 + S2,(See ,

S6)pSection elbowsI.l.)

(ASm A403 1 Observation of work in progress on the Diablo 1 spool pieces did not identify any significant problems or causes for concern. The welding procedures conformed to the applicable requirements, workmanship was satisfactory, and identification of the individual components and weld seams was adequat (See Section I.2.)

15. Radiography of two butt welds was reviewed. Radiographic quality was good and in accordance with the applicable requirements. No rejectable defects were identifie The weld condition did not significantly surface impair film was not ground,(but readabilit this See Section I.2.)

16. Westinghouse E Spec. G-676343 does not specify shop hydrotest of the fabricated spool pieces, although a warranty of 3,750 psi hydro capa-bility is require (See Section I.2.)

17. Westinghouse and Pacific Gas and Electric quality control surveillance in the Southwest Fabricating and Welding shop appeared to be above average. (See Section I.3. )

Management Interview - A short management interview was held at the conclu-sion of this visit with Green, Sewell, Page, Wecker, and Iswell. The gen-eral findings were summarized, and no particular problem areas were identi-fied with respect to the Southwest Fabricating and Welding operation. The inspector expressed concern over the omission of shop hydrotesting the indi ,

vidual pipe lengths and fittings since this could be a technical violation of the applicable ASW standards, but since this was Westinghouse rather than Southwest Fabricating and Wolding responsibility, no Southwest Fabri-cating and Welding action or response was required. The inspector also noted that some of the material certifications for small diameter pipe did not specifically state that hydrostatic test had been perfomed. Although the manufacturer's certification of compliance with the applicable AST!!

specification implies that all requirements of that sycification have been met, the inspector suggested that it is the buyer's responsibility to assure that this has in fact been done and that some pipe fabricators have been known to omit hydrotesting as standard practice. Green indicated that their vendor qualification program to date had not encountered this condition and that they would watch for i _ _ _ - _ .

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VI Rpt. No. Southwest Fabri-cating and Welding Co. 70-1 -5-DETAILS Plant and Product Description. Product Distribution l

Southwest Fabricating and Welding is a wholly-owned subsidiary of International Utility Company, who also owns Delta Southern Compan Southwest Fabricating and Welding fabricates piping spool pieces and assemblies, headers, and small pressure vessels mainly for the petroleum industry. The plant employs 400 to 450 people and does approximately

$15 to 20 million business annually, of whien approximately 10 to 15%

is for nuclear assemblies. There is sn engineering department of LO to 50 people, but the plant has no design or stress analysis capabilit No piping is ranufactured at Southwest Fabricating and Welding. Fabri-cation is limited to cold and hot forming, welding, and machinin Seamless and welded pipe is obtained from outside source Westinghouse is by far the largest nuclear customer. As of the time of the inspection, Southwest Fabricating and Welding had fabricated 25 primary piping loops for Westinghouse and had 3 additional loops to fabricate under the original contract (Westinghouse P. O. 54Z 70499B).

Westinghouse has recently placed an order (5546-CRW-ll6871 BN) for 55 additional loops with an option to buy 15 more. No work has been done on the new contract. According to Page, Southwest Fabricating and Welding will be the only supplier for Westinghouse primary loop spool sections. It was also learned that most of the piping to be used under the new contract will be centrifugally cast - probable supplier:

U. S. Pipe and Foundry Company, Surlington, New Jerse In addition to the Westinghouse contact, Southwest Fabricating and Welding will supply recirculating loop piping sections for two G-E facilities: Edwin I. Hatch and Shoreha They are also supplying auxiliary system spool pieces for several facilil ties including Maine Yankee, Beaver Valley, and Palisades plants.

l' Most of the nuclear work is currently done in a restricted bay area of

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the shop, but future plans include a separate building for this wor Subcontractors Since Southwest Fabricating and Welding has no pipe fabrication capa-bility, all piping is procured from outside source The large-diameter pipe, as well as the cast fittings for Westinghouse primary loop spool pieces, are purchased by Westinghouse from the pipe mill or foundry and surnjied to Southwest Fabricatina and Waldino with the original materia)

certifications. The material certifications do not 2xlude .'iEr reports. These are sent

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VI Rpt. No. Southwest Fabri-cating and Welding Co. 70-1 -6-to end retained at Penn Center and eventually delivered to the licensee as a part of the complete data package. Westinghouse is responsible for the quality conformance of this material. Westinghouse is also supplying all thermal well bosses for the spool pieces. Up to now, all the large-diameter primary loop pipe has been obtained from Cameron Iron Works and the cast fittings from Esco Corporation. It was indi-cated that on the new Westinghouse purchase order at Southwest Fabri-cating and Welding, only four projects will use Cameron pipe; the balance will utilize centrifugally-cast pipe (U. S. Pipe and Foundry).

It was also indicated by the Westinghouse resident that the last Westinghouse order for cast fittings was split between Esco and Mitsu-bishi Atomic Power Industries, Japa All branch nozzle fittings and small diameter pipe are procured directly by Southwest Fabricating and Weldin The larger nozzles are forged while smaller (unde, three inches) are generally machined from bar stock. The major forging suppliers are:

Cameron Iron Works, Houston, Texas Green River Steel Corporation, Owensboro, Kentucky Texas Metal Works, Incorporated, Beaumont, Texas Beaumont Well Works, Houston, Texas Bonney Forge Division, Allentown, Pennsylvania Some pipe suppliers are:

U. S. Steel Corporation, Pittsburgh, Pennsylvania Swepco Tube Corporation, Clifton, New Jersey Cameron Iron Works, Houston, Texas Tube Associates, Incorporated, Houston, Texas Cupitol Pipe and Steel Products, Incorporated, Bala Cynwyd, Pennsylvania Only light-wall seamless pipe (schedule 10 and less) is reportedly being purchased from Tube Associate No Tube Associates pipe was observed in spot checking typical material certification. When pur-chasing material from supplier stock, the original mill certifications are always requested. There is a program for auditing of material suppliers, and all material sources have reportedly been audited unless the supplier is in possession of the ASME N stamp. In such cases, audit may be waive No fabrication or welding work is subcontracted. Mechanical testing and chemical analysis, when required, are performed by outside source .-_ __

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VI Rpt. No. Southwest Fabri-cating and Welding Co. 70-1 -7- Code Stamp Authority The Southwest Fabricating and Welding facility was originally surveyed by the ASME in January 1970 and approved by the surveying team for code stamp issuance at that time pending some revisions to the QA manua ASME, however, made the issuance of the code stamp subject to a resurvey at a later date. Southwest Fabricating and Welding reportedly rewrote the QA manual and requested an imediate resurvey. This was completed on April 15-16, 1970, the last day coinciding with the Compliance visi A favorable recommendation was reportedly mad Southwest Fabricating and Welding has requested three stamps: Nuclear piping, nuclear vessels (limited to 48-inch diameter or 5 tons), and nuclear part Orranization. NDT Capability The plant has a QA manual. Because of the very recent ASME survey and reportedly favorable findings, the QA manual was not reviewed in detail during this inspectio The Southwest Fabricating and Welding general organization chart and QC organization chart are attached as Exhibits A and B, respect $vely. A breakdown of the quality control department, showing the personnel qualification level.a, is shown in Exhibit In-house capability exists in radiographic, dye cenetrant, magnetic particle, and ultrasonic examinations. L ray (250 kv), as well as gamma radiography, is performed in the shop. The radiographic proces-sing and reading laboratory is well equipped and organize The shop has no mechanical testing or metallurgical laboratory. This work, when required, is subcontracted. A hydrostatic test facility is available, but no hydrotesting is required on the Westinghouse spool piece The QC personnel appeared cognizant and up to date on the applicable codes and quality control requirements. The Chief Engineer, Green, who also takes an active part in quality assurance, is on the B31 Executive Committee and is the Chairman of the Committee on Fabrication, Assembly, and Erectio Standard Procedures. Records The nuclear and nonnuelear work though tne shop is handled in a similar manner, except that the inspection and documentation requirements may differ considerably. Standard procedures are used. These are supple-.

mented when additional requirements are contained in a specific contract.

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A standard manufacturing record sheet has been recently adopted. This becomes a permanent record for each spool piece and contains provhions for signoff by Southwest Fabricating and Welding QC inspectors, as well as code and customer inspectors on all phases of fabrication and testin A copy of this record sheet is attached as Exhibit . . . - - - _ _ _ _ - .

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VI Rpt. No. Southwest Fabri-cating and Welding Co. 70-1 -8-

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Each spool piece has on file a complete package of records - material certifications (including welding material), dimensional checks, NDT results, and heat treatment charts when applicable. The records were readily retrievabl The spool piece drawings are prepared by the Southwest Fabricating and Welding Engineering for each individual assembly and are submitted to Westinghouse for approval prior to fabrication. The only items not requiring a spool piece drawing are '.5' cast elbows which are shipped as individual units and receive no fabrication effort at Southwest Fabricating and Weldin Forming. Heat Treating. Descaling Hot forming of austenitic stainless steel pipe is done at temperatures between 1600 and 1950*F as detemined by optical pyrometer. The pipe is packed with comercial iron-free sand and heated to 2050*F in a natu-ral gas-fired clamshell furnace adjacent to the work area. The forming is done by bending the pipe around a contoured shoe. The bending pro-cedure has been qualified to produce less than 6% ovality and assure no thinning below the minimum wall thickness. The wall thickness is checked ultrasonically when there is any reason to suspect excessive thinning. Following the hot forming ope'.ttien, the sand is removed and the entire pipe is solution annealed in a natural gas-fired annealing oven at 1950'F followed by spray quenching. The annealing oven has six control zones and is reportedly capable of maintaining set tempera-ture within 25' tolerance throughout its length. A temperature record is generated for each heat treatment cycle and placed in the spool piece file. The temperature controlling and recording instrumentation is calibrated yearly by ou', side source Spray quenching is perfomed using a manifold with multiple spray heads.

i This system is reportedly capable of cooling the pipe from the annealinr ,

temperature to less than 300'F in 2-1/2 to 3 minute Following the heat treatment, the pipe is sand blasted using iron-free sand and steam detergent cleaned with halogen and boron-free detergen The cleaning is followed by a deionized water rins No acid cickling j is done at Southwest Fabricating and Welding.

l The only Westinghouse pipe sections subjected to hot foming at Southwist Fabricating and Welding are the pressurizer surge line piece Welding and Welding Material Control Tungsten are, manual metal are and submerged are welding, or combinations of these processes, are used at Southwest Fabricating and Welding. A

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VI Rpt. No. Southwest Fabri-cating and Welding Co. 70-1 -9-review of applicable welding procedures showed these to be in conformance with applicable ASME anl ASA requirements, A sheet showing up-to-date weldor qualifications anc identification was available in the fabrication are The control of welding material (receiving snd in process) was very good. Upon receiving, the electrodes are quarantined and not released to the storage area until the material certifications have been checked by QC, Open containers of all low hydrogen electrodes are placed in drying evens at 250-300*F in the locked storage area. From the storage room, the electrodes are removed to rod boxes located near the fabrica-tion area. The rod boxes are maintained at 135 to 150*F and access to these is supervised by the welding foreman. Only one type of electrode is placed in each rod box, and no more than a two-hour supply of covered electrodes is issued to the weldors at any time. All unused welding material at the end of a shift is either discarded or returned to the drying ove Cleaning. Marking. Packaging Following the fabrication, all spool pieces are washed with acetone and steam cleaned, A visual inspection is perfomed at this time to pick up arc strikes and surface irregularities not previously remove Such areas are marked and reworked by localized buffing follow *d by a second steam cleaning cycle and deionized water rinse. End co ers are then put in place and the spool pieces are strapped to the bracin Carpet strips are used to protect the spool pieces from steel strappin A recently adopted practice on Westinghouse contracts involves coating all cast fittings with a wax-type clear liquid to protect the somewhat coarse-textured casting surface from exposure to environment. The material, which is painted on, solidifies as a clear fil It was identified as TECTYL 131 and has reportedly been analyzed ard approved .

by Westinghouse as meeting their chemical restrictions with r3spect to halogens and other impurities and having no effect on weldin All identifiestion marking on the spool pieces and the individual com-ponents is applied using low stress interrupted stamp Diablo Canyon 1 Piping Status of Completion. Applicable Criteria The Diablo 1 piping was estimated as about 40% completed at the time of the visit. The primary loop is being fabricated in accord-ance with ASA B31.1, Sections 1 and 6, plus Code Case N-7. The applicable Westinghouse E Spec. is G-676343, Revision 1, "Reactor Coolant Piping Shop Fabrication. " The design conditions are 2485 psig at 650*F (680*F for the surge line).

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VI Rpt. No. Southwest Fabri-cating and Welding Co. 70-1 - 10 -

The large diameter pipe (27-1/2 inch I.D.) furnished by Westinghouse confoms to WAPD E Spec. G-676341 which designates AS'IM A376 TP 316 -

except that defects referenced in paragraph 10.3.1 of that speci-fication are restricted to 3% nominal wall thickness, supplementary requirements S2 and S6 are invoked, and a complete LP examination of all surfaces is required on each length of pipe in accordance with ASME Code Section VIII, Appendix VIII, with acceptance per Code Case N-9. According to Page, the shop hydrotest is waived by the Westinghouse purchase order in lieu of as-fabricated system hydr The large cast fittings supplied by Westinghouse confom to WAPD E Spec. G-676342. The fitting geometry is required to confom to USAS B16.9, and the material is designated as ASm. A351 GR OF8M with supplementary requirements S2 and S4. One hundred percent volumetric radiography is specified in accordance with Westinghouse PS 595141 and acceptance per ASTM E186, severity level 2, except that defect categories D and E are not pemissible. Again, the hydrostatic test is reportedly waived by the purchase orde The branch nozzles (Southwest Fabricating and Welding procured)

are required by the E Spec. to confom to ASTM A182, CR F316. The i

basic purchase order, however, pemits the use of ASTM A276 TP 316 bar stock for nozzles of two-inch diameter and smaller. UT of the har stock is require Thermal sleeves are specified as requiring ASE A312, TP 304 or Westinghouse approved equivalen The pressurizer spray scoop elbows are specified as ASTM A403 GR WP316 or WP30 The surge line is required to confom to ASm A376 TP 316, Schedule 140 wall plus S2 and S6 supplementary requirements with the 32

requirement applicable to each length and the S6 requirement being i

100% volumetri . F=ination of Hardware. Review of Radiograchy thterial Certificatien, and Fabrication Procedures i Shop fabrication of the Diablo spool pieces was observed during the visit. The general workmanship appeared good, and no signifi-cant problems were identified. Identification of the individual components was maintained during fabrication. The pire segments are supplied by Cameron Iron Works with square ends with identifi-cation stamping on the ends. The marking (heat number and serial)

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is transferred to the pipe 0.D. at Southwest Fabricating and Welding using interrupted dot stamps. The fittings are marked with the heat number and pattern number on nameplates. All welds examined were identified with the weldor symbol. Butt welds in the large diameter pipe were made using a combination tungsten inert gas and automatic submerged are welding procedure (SW-P8-HA-1). The welds were left in the as-welded condition (unground) on the 0.D. and blended smooth by manual grinding at the I.D. The weld profile and reinforcement appeared good. The 0.D. weld ripples were generally smooth and even and contained no sharp discontinuities. Dimensional checks were being made during the machining of the weld end prep, fitup, and I.D. grinding to aid in maintaining the minimum wall thickness. Although not observed on the Diablo spool pieces, eccentricity resulting from the extrusien process has caused some difficulties in machining concentric weld preps and maintaining the minimum wall thickness. In some cases, buttering of the weld ,

prep area has been required to maintain the dimensional tolerance The branch nozzles were generally welded using tungsten inert gas and manual metal are procedure (Procedure SW-P8-HA3) and ground smooth after weldin The welding procedures were reviewed and found to be in confomance with the applicable ASMS Code requirements. A Westinghouse supple-ment to the Southwest Fabricating and Welding procedures specified ferrite contents of the deposited filler metal between 5 and 15%

and required that the weld interpass temperature not exceed 350*F  !

as checked by contact pyremeter. The use of tempilsticks was prohibite Two primary loop butt welds were completed and radiographed at the '

time of the Compliance visit (Serial 7524F PGE loop 1-1). The radiographs were taken using 7" x 17" Kodak AA film (single film technique) and 19 curie Co-60 source. The film was reviewed and showed satisfactory technique and good quality. No rejectable defects were identified. The delineation of the submerged are weld beads on the pipe 0.D. did not significantly impair radiographic interpretatio It was noted that the applicable Westinghouse E Spee. (G-676343)

does not require shop hydrostatic testing of the fabricated spool pieces, although a Southwest Fabricating and Welding certification is required stating that the spool pieces are capable of 3,750 ,

psi hydr A spot review was made of material certifications applicable to the Diablo piping. No items of nonconformance were identifie .__ _ _ _ _ . _ _ _ _ _ _ _ _ _ _ _ _ _ . _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ - _ _ _ _ _ _ _ _

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VI Rpt. No. Southwest Fabri-cating and Welding Co. 70-1 - 12 -

3. Westinshouse and Pacific Gas and Electric QC Coverare Westinghouse has a resident inspector (Page) in the Houston are Besides Southwest Fabricating and Welding, his inspection assign-ment includes Cameron Iron Works; Delta Southern Company; Engineers and Fabricators, Incorporated; Wyatt Industries, Incorporated; and Esco. He reportedly averages approximately one to three days per week in the Southwest Fabricating and Welding shop. He appeared to be knowledgeable in the applicable codes and specifications and thorough in approach. The Westinghouse resident is responsible for signing off on QC release of all spool pieces shipped from South-west Fabricating and Welding. Highlights of the inspection effort required to sign the QC release on the spool piece were sumarized by Page as follows: Radiography of Shop Welds - 100% review of all radiographs, LP of Welds - spot review (approximately 10 to 20%), Dimensional Inspection - based on review of critical dimension Westinghouse inspector reviews the data sheets and picks out critical dimensions for verification in his presence, Visual Inspection (100T) - for are strikes, weld spatter, rust, contamination, stress raisers, surface finish, weld transitions, mechanical damage, and identificatio Cleanliness - Examination for confomance to cleanliness requirements specified in WPS 292722- Mill Certifications - Review of all material certifications for conformance with the applicable specification .

The Pacific Gas and Electric Company has six senior materials in-spectors in the eastern United States working out of their private homes. Their assignments are principally based on geographical considerations and include fossil as well as nuclear plant equircen The inspectors appear to be well qualified and experienced. Iswell has been recently hired by Pacific Gas and Electric and will relocate in Chattanooga, Tennessee. His background includes QA engineer positions at Westinghouse and at Babcock and Wilcox Ccepany. The current visit was reportedly the third Pacific Gas and Electric inspection at the Southwest Fabricating and Welding sho Attachments:

Exhibits A thru D