ML100270171
| ML100270171 | |
| Person / Time | |
|---|---|
| Site: | Indian Point  |
| Issue date: | 05/07/1969 |
| From: | Reinmuth G US Atomic Energy Commission (AEC) |
| To: | O'Reilly J US Atomic Energy Commission (AEC) |
| Shared Package | |
| ML100270165 | List: |
| References | |
| NUDOCS 8111190125 | |
| Download: ML100270171 (6) | |
Text
UNITED STATES
ATOMIC ENERGY COMMISSION
- WASHINGTON, D.C.
20545 Mdy T, 1969 J. P. O'Reilly, Chief, Reactor Inspection and Enforcement Branch Division of Compliance VISIT TO INDIAN POINT 2 Mr. J. Tillou and I'visited the Consolidated Edison Company's Indian Point site on April 22-23, 1969, to obtain information about the stain less steel piping being installed in Unit No. 2. Of primary interest was the six-, eight-, and ten-inch diameter piping and fittings being supplied by the Dravo Corporation under a purchase order issued by United Engineers (UE&C).
The following summarizes our findings:
- 1. The Westinghouse equipment specifications covering the piping were made part of the purchase order to Dravo. We reviewed these specifications with care and concluded they were above average in quality.
24 Efforts to verify compliance with the purchase order and Westinghouse specifications by UE&C, Westinghouse or ConEd, was minimal. Periodic audits by UE&C havebeen essentially the only monitoring performed.
- 3. Onsite documentation of the piping is almost nil.
UE&C stated Dravo would supply mill certifications and test data after completion of the contract. This means a large per centage of the pipe will be installed before anyone but the supplier has reviewed the pedigree of the piping (our visit should result in a change however),.
- 4. Westinghouse specifications for six-, eight-, and ten-inch stainless pipe to be used in'systems with design pressures up to 1400 psi and temperatures to 6500 F. (Schedules 40 and
- 80) called for manufacture according to ASTM A-312, Type 304 or Type 316, seamless or welded.
- 5. Welded pipe marked A-312 was observed in all three sizes, Schedule 40.
Positive visual identification of all piping was not possible as the stenciled markings had been oblit erated by the Dravo fabrication processes. The use of filler metal in this pipe could not be positively determined.
Before our departure, ConEd had contacted Allegheny Ludlum 019
J. P. O'Reilly (a principal supplier to Dravo) who indicated they have a process for welding without filler metal. The extent of this capability with respect to pipe sizes and schedules was not stated. ConEd is arranging for a visit to observe a demonstration by Allegheny Ludlum. I plan to attend this demonstration.
(As of April 25, this demonstration will be performed at the Youngstown Steel Corporation rather than Allegheny Ludlumo)
- 6.
Schedule 40 welded pipe marked A-358 was also observed. This would not be in strict compliance with the Westinghouse speci fications in this grade or size*
7° The Westinghouse specifications clearly pointed out that where welded pipe was supplied, "that the weld shall have a 100%
joint efficiency. This weld integrity shall be verified by RT, UT or equivalent examination approved by Westinghouse."
No verification of compliance with this specification was available onsite.
- 8.
All fittings to be supplied in these sizes and schedules were to be manufactured in accordance with ASTI4 A-403, seamless or welded, Several fittings supplied by Flowline were observed to be marked A-312, strictly a piping specification.
- 9.
No information was available concerning the annealing or pickling history of the pipe observed. The pipe was not marked as such, records were not available, nor did anyone at the site have any/
familiarity with these aspects of manufacture. The Westinghouse specifications cautioned against the use of chloride bearing cleaning and pickling compounds.
(A combination nitric hydrofluric acid bath is frequently used by pipe suppliers for pickling.)
10, The personnel responsible for quality assurance at the site appeared to have a very limited knowledge of how the ASTM requirements fit in with the ASA Codes. For example, they were not aware of the differences between A-312, A-358, and A-376 requirements. Up to now they have relied 100% upon the supplier affidavits as to pipe and fitting acceptability, 11, Outside storage of the stainless pipe was hardly ideal. Attempts had been made to keep it off the ground and covered, Neither effort was successful.
2 -
J. P. O'Reilly
-3
- 12.
In one instance we asked that the end cover be removed from a piece of pipe so that we could read the remainder of the stenciled markings. The markings under the cover were in a new condition indicating the caps had been placed on the pipe before cleaning. It raises the question as to whether the inside of the pipe had been cleaned at all.
- 13.
During our tour of the plant, we detected four check valves in the high pressure make-up system that had been installed backwards.
In our exit interview ConEd stated that they were initiating action to determine the pipe pedigree. They were receptive, cooperative, and ex pressed a sincere desire to correct any and all deficiencies. Further more, they were "hungry" for information concerning problems experienced..
at other reactorsites. From the results of our visit, it is recommended that:
1, Region I monitor ConEd's effort in verifying compliance with the ASTM and Westinghouse requirements on all stainless piping and fittings.
- 2.
ConEd be advised that the adoption of a more positive method of-.
verifying component adequacy before installation is prudent.
- /
- 3.
Regulatory (Reactor Standards), through Code Committee par ticipation, initiate action to improve pipe marking require ments on installed piping systems.
./
- 4.
Region I assure correction of items 11 and 13.
G. W. Reinmuth..
\\
5, 7,
UNITED STATES ATOMIC ENERGY COMMISSION I
'\\
//WASHINGTON, D.C.
20545 May 7, 1969 J. P. O'Reilly, Chief, Reactor Inspection and Enforcement Branch Division of Compliance VISIT TO YOUNGSTOWN WELDING AND ENGINEERLNG COMPANY A visit to the Youngstown Welding and Engineering Company's (YW) pipe fabrication shop in Youngstown, Ohio, was arranged by the Consolidated Edison Company (ConEd) on April 29. The purpose of the visit was to witness the fusion welding of A-312 pipe, some of which was observed at the ConEd Indian Point 2 site on April 22-23.
Attending the demonstration were the following persons:
G. Wasilenko, ConEd (Engineering)
E. Dadson, ConEd (Quality Control)
C. McDonnell, U.S. Testing Ro Rapp, United Engineering and Construction Company G. Petro, Westinghouse Corporation (Service Engineer)
L. Stiles, Dravo Corporation Representing YW were:
D. Lasko, Sales Engineer Mr. Watson, Chairman of the Board My principal findings and observations from the visit were as follows:
- 1. With respect to six-, eight-, and 10-inch diameter stainless pipe, YW manufactures pipe in these sizes with both a fusion and a filler metal addition type welding process. Mr. Lasko readily admitted pipe, manufactured with filler metal, frequently was marked A-312 FMA. He stated he was aware that A-312 FMA was not a code material; however, YW's policy is to supply pipe strictly according to a customer's purchase order.
- 2. The fusion welding process without the use of filler metal is limited to Schedule 40 in diameters up to 12 inches. The wall thickness for Schedule 40, 12-inch diameter pipe, iso.407 inch.
YW stated it is technically feasible to weld heavier section pipe with the process; however, their equipment and procedures were only qualified on the above sizes.
3-It is extremely difficult to visually identify pipe welded by the fusion process without filler metal from that welded with filler metal. The only observable difference is that in the fusion
J. P. O'Reilly May 7', 1969 process, without filler metal, a fine smooth line estimated to be approximately 1/64 inch deep runs down the middle of the weld on the crown surface.
- 4.
The fusion welding is an automatic two-pass TIG process--one pass on the inside of the pipe, the other on the outside. It seemed to make no difference which pass was. made first. The process produces a weld crown on both the outside and inside.
YW emphatically stated there was no -wall thinning.
- 5.
Mr. Lasko stated that all AS2A test requirements are performed if the customer's purchase order specifies manufacture in ac cordance with a specific ASTM, Affidavits are supplied only as proof of test performance to a customer unless the customer re quests additional documentary evidence. Radiographic equipment and hydrostatic test equipment were observed. Plate material certifications (chemistry and physical properties) are supplied by the plate supplier, which is usually Allegheny Ludlum.
Copies of these certifications are retained by YW.
- 6. Shop documentary verification of the completion of the several manufacturing steps and test operations was unusual. Per forated cards with removable tabs are provided-for each order.
Each tab represents one specific operation. When an operation is completed, the foreman tears off the tab and throws it away.
The remaining card without the tabs is considered to be yeni-7 fication that all manufacturing requirements have been completed.
- 7. Annealing of the pipe after -welding was observed. The method/
employed a. continuous process wqhere the pipe is carried through a series of three burners and water spray quenched after the final burner. The pipe could be observed between the burners where the pipe temperatures were checked by use of an optical pyrometer (19000-19500F),
- 8.
Pickling of the pipe was performed by dunking in a tank of nitric-hydrofluoric acid for 10-15 minutes followed by a water bath dunking. The final step was to hose down. All water was city tap water of unknown chloride content. There was some confu sion and contradiction as to whether the acid was hydrochloric or hydrofluoric. The tanks were marked hydrochloric and Mr.
Lasko changed his initial statement from hydrochloric to hydro fluoric. Westinghouse specifications specifically cautioned agains,t the use of chloride bearing cleaning and pickling agents..
Mr. Lasko was not knowledgeable of the acid concentrations.
0 0
J. P. O'Reilly May 7, 1969 From these observations, I conclude that the following should be clarified or verified by the licensee:
- 1. Identify all welded A-312 pipe and fittings made from welded A-312 pipe at Indian Point 2 and verify that they were manu factured without filler metal.
- 2. On all welded pipe, including that supplied by YW, verify that 100 percent radiography has been performed and the radiographs have been properly reviewed.
- 3. Positively identify the pickling solutions used by XW and ex amine procedures used with respect to the Westinghouse specifi cations requirements.
- 4. Verify by direct measurement of wall thicknesses on pipe at the site, that the YW fusion welding process did not result in wall thinning below the Westinghouse requirements (sample basis).
- 5. Verify that tensile test results of the weld area were satis factory on the Yd supplied pipe.
- 6. Verify that other test requirements of ASTM A-312 were performed and that the results were satisfactory.,
These comments were discussed via a telephone conference call on May 5 with J. A. Corcoran, Construction Superintendent and E. Dadson, Quality Control of the Consolidated Edison Company, and G. Madsen, Re actor Inspector of Region I. According to Mr. Corcoran and from our observations, ConEd is engaged in a comprehensive program to trace the pedigree of the stainless piping. Results of this program will be made available to the Division of Compliance when complete.
Go W. Reinmuth, Reactor Inspector Division of Compliance