ML20154E908

Insp Rept 50-275/69-05 on 690506-07.Nonconformance Noted. Major Areas Inspected:Review of QA-QC Programs Maintained Re Plant Reactor Primary Piping & Welding & Radiography Problem Areas

ML20154E908
Person / Time
Site:	Diablo Canyon, 05000000
Issue date:	05/13/1969
From:	Spencer G, Vetter W US ATOMIC ENERGY COMMISSION (AEC)
To:
Shared Package
ML20154C370	List: ML20154C367 ML20154D294 ML20154D425 ML20154D452 ML20154D528 ML20154D575 ML20154D594 ML20154D647 ML20154D736 ML20154D846 ML20154D855 ML20154D869 ML20154E066 ML20154E143 ML20154E188 ML20154E240 ML20154E258 ML20154E356 ML20154E392 ML20154E431 ML20154E484 ML20154E507 ML20154E577 ML20154E597 ML20154E600 ML20154E634 ML20154E666 ML20154E684 ML20154E762 ML20154E785 ML20154E809 ML20154E821 ML20154E871 ML20154E878 ML20154E908 ML20154E958 ML20154E967 ML20154E977 ML20154F001 ML20154F024 ML20154F073 ML20154F094 ML20154F104 ML20154F116 ML20154F123 ML20154F135 ML20154F145 ML20154F153 ML20154F156 ML20154F390
References
FOIA-88-156 50-275-69-05, 50-275-69-5, NUDOCS 8805230026
Download: ML20154E908 (9)

Text

._ - . .. .__

C C U. S. ATOMIC ENERGY COMMISSION DIVISION OF COMPLIANCE REGION V .

Report of Inspection CO. Report No. 50-275/69-5 Licensee: Pacific Gas & Electric Company Diablo Canyon No. I License No. CPPR-39 Category A Date of Inspection: May 6-7, 1969 ,

Date of Previous Inspection

April 30, 1969 i

Inspected by: h* 6 {#i'5/ f"# / 5' d /

W. 2. Vetter Reactor Inspector r

Reviewed by:

'f / i n v i i s- 0 IO 4 G. S. Sidencer i Senior Reactor Inspector Proprietary Information: None i SCOPE i

4 i

Type of Facility: Pressurized Water Reactor .

i gue r 1,e wl : 32 50 :;'ic Location: San Luis Obispo, California Type of Inspection: Vcndor Inspection j Accompanying Personnel: G. S. Spencer (lCGION V)

W. A. Crossman (REGION II) ,

Scope of In.1pection: The Cameron Iron Works (CD1) and l j the souchucat Fabricating and Weldina Company (SWnlCO) facilitics, both located in llouston, Texas, were visited on May 6-7, 1969. The purpose of the visits was to:

8805230026 800510 l PDR FOIA MCMILLANBO-156 PDR i

(

2-

1. Review quality assurance-quality control programs maineatnod by CIW and SWFWC0 relative to the Diablo Canyon Unit , reactor primary piping.

2. Review welding and radiography problem areas associ....cd with the Palisades reactor primary piping at the request of C0:

Region III.

Mr. Spencer accompanied the inspector to make a performance appraisal and to become familiar with vendor inspection activitics in general.

Mr. Crossman participated in the visit activitics primarily for the purpose of becoming acquainted with CIW and SWFWC0 QA-QC programs.

SD' MARY The results of the visit indicacc that adequate QC progra;.m exist, in the case of both CIW and SWFWCO, but that essentially no formal QA programs have been provided (see sections A and B of this reporc) .

A review of the Palisades reactor project uciding and radiography prob 1 cms ind: ates that adequate and timely resolution has taken place (see Section C. of this report) .

DETAILS A. Cameron Iron Works The Cumcron Iron Works (CIW) was visited during the morning of May 6, 1969. The visit included a tour of the pipe manufacturia portion of the plant, a sampling of QC records and a short diset.

session concerning QA-QC program provisions. Personnel contacteu ,

during the visit included: l Mr. J. L. Wyche - Manager , QC , CIW Mr. R. B. Hodgins - Supervisor, QC, CIW Mr. R. D. Page - QC ncpresentativo. Westinghouse ~

Mr. P. E. Wccke t - Senior Material Inspector, PG&E Following the tour of the pipe nanufacturing portion of the plaat, Mr. Hodgins produced a QC file containing a sampling of QC records )

pertaining to the PG!d Diablo I reactor facility. By way of review, the inspectors "followed" oac section of the Diablo I primary pip,ing throagh the Lunufacturing process by reference to:

3

1. Westinghouse purchase orders

2. Mill certifications (check analyses)

3. Purchase specifications

4. Dye penetrant inspection procedurco (MIL-STD-767)

5. Ultrasonic testing procedurcs

6. Processing instructions (code requirements)

7. Processing instructions (heat treatment)

8. Processing instructions (torchcut cults)

9. NDT results (production travelcr shocts)

Based on a limited records and procedures sampling effort, it appears that the primary piping for Diablo I (now stored at SWFWCO) has boca fabricated in compliance with applicabic codes and in conjunction with adequate QC and production coritrol procedurcs. The records estabiished the existence of programs to assure (1) proper approval for changes in the processing programs, (2) review of N;,T results and (3) final, complete review of manufacturing records by Wcscinghouse personnel. Shi p.c.ca t of the pipe to SWFWC0 appears to have been consistently coatingcat upon Westinghouse written approval. Mr. Page said that, in addicion to the review of manufacturing records (traveler chects) and review of NDT results , he periodically reviews NDT equipaent calibration results and techniques. Mr. Weckor added that his activitics at CIW were similar, although not quite as intense, to those described by Mr. Page.

As a final item of discussion, Mr. Wycho deceribed the CLi QC program and responded to several questicas by the inspectors, Mr.

Page and Mr. Wecker. According to Wyche, the CIW QC staf f totals approximately 130 persons, headed by himself as the QC Manager. He said that in addition to a QC supervisor, the QC staff consist of 12 floor supervisors. The balance of the staff, he said, are inspectors assigned to the following QC Groups. -

j

a. Quality Control Procedures

b. Measuring and Test Equipment

c. Tool and Dye Inspection *

d. In-Process Inspection

c. Magnetic Particle Inspection f, vioonnecat reo e m. 7a 7e ec t oc,

g. Dy< ;' coe l t . ;n t !n.:y etloa

h. Radiographic Inspection

1. Ult rasonic Inspection J. Hydrostatic Testing

k. Source Inspection

1. Final Inspection When questioned about the existence of a QA program to suppor'c the CIW QC progra..t efforts, Mr. Wyche said that such a program in the formal sense of the words, was not provided. He explained that, while he was

• t

, aware of the existence of such programs elsewhere and of their potential ,

value, he did not consider them to be necessary at CIW. A strongly  !

cmphasized Process Control Program effort, plus almost hourly contact ,

with the QC staff by himscif and/or Mr. Hodgens, Wyche said, climinated any need for a formal QA program ef fort. l As a result of Mr. Wychc's comments , cocraents by Messrs. Page and Wccker and observations by the inspector during the visit, it appears that: (1) the CIW total QC cffort includes, intrinsically without conscious programming, the basic constituonts of an adequato QA program and (2) that the licensec - contractor QA offorts are reason-ably consistent with acceptable practice and the critoria of PI 3300, i

B. Southwest Fabricating and Wolding Company (SWWCO)

The SWWC0 was visited during the afternoon of May 6, and again on May 7, 1969. The visit included a tour of the portion of the plant  ;

used to fabricate stainicss secol piping and the plant radiography i facilities, a review of the plant pipe fabricating procedurcs, a  !

l' review of the plant QC programs and discussions with the fallowing persons.

Mr. G. L. Lockwood - President & Chiof Executivo Of ficer, SWFWC0 '

{ Mr. C. L. Skidmore - Vice president & General Manager, SWWC0 j Mr. R. C. Green - Chief Engincor, SWWC0 l Mr. F. E. Sewell - Chief Inspector & Radiologist, SWWC0

Mr. B. A. Grahm - Sales Administrator SU WC0 l Mr. R. D. Page - QA Representativo, Westinghouse j Mr. P. E. Weckcr - Senior Material Inspector, PG&E Mr. J. L. Day - Inspection-Radiography, Bechtel Corporation *  !

Mr. B. McDaniel - Inspection-Radiography, Bechtel Corporation )

Mr. C. Q. Hills - Senior Engineer Consumers Power Company ]

As a first order of business it was determined that, although pipo .

from CIW and pipe fittings from the Electric Stocl Company (ESCO) 1 Portland, Oregon, were on plant , fabrication efforts had not been j started relative to the PG&E Diablo Canyon No. I reactor. For this 1 reason, QC processing records other than rocciving reports for the i pipe and fittings, were not available for review. In the absence i of such records, the inspectors reviewed records and/or documents i listed below.

I j 1. SWWC0 Quality Assurance Procre.m 1 This is a ninc page document delineating each of the l programs and/or steps to be followed during pipe j fabrication activitics. l

)

l

1 1

2. Weld Rod Control Procedures  !

5 This procedure was found'to bc. consistent with standard good practice. 1

3. Wolding Inspection Record .

This record. is a 15" x 24" blueprint which includes a I spool piece drawing and a history of cach wcld performed.

The veld history includes wcld procedurcs, wolder '

idantifications, NDT performanco signof f (cxcept final X-ray signof f) material requirements, heat numbers and i other information which may be considered pertinent at the discretion of QC personnel.

4. Purchase Specificacions Typical - not related to the PG&E Diablo Canyon No. I reactor.

5. Warehouse Receiving Reports Typical - as well as related to Diablo Canyon No. I.

6. Mill Certifiestions For Diablo Canyon No. I piping.

7. Radiographic Inspection Reports l SWFWC0 format for internal use as well as for submittal

• to customers.

i

8. Liquid Penetrant Inspection Procedures i

- These procedures appeared to be adequately consistent with f standard, acceptabic practices. l

8) . Un.1 i ogph i e r to c_. m .

The procedurca wrc provided to SW7.iCO by Ucstinghouse and are to be followed by SWi%'CO during fabrication of Diablo Canyon No. I primary piping. According to Mr. Lockwood, ,

the SWFUC0 radiography procedures arc more demanding (QA-wisc) than any of the customer supplied procedures.

10. Ucid Repair procedures These procedures appeared to be consistent with code f requirements.

l

1 1

i e

11. Welding Procedures ,

4  :

These procedures include detailed instructiono for each of the several types of welding performed; i.e. , TIG, MIG, etc.

12. Qualification Tests of Welding procedures and operators l 4

These forms were noted to be conventional in appearance and to contain the usual information.

the resu;ts of the document-records review and comments by SWWCO, l Westinghouse and Bechtel personnel indicate that the SWWC0 QC program

! is ucli documented and more than adequately comprehensive. The revicw, '

l and comments by Westinghouse, PC&E, Bechtcl, and Consumers Power Company 4 personnel, indicates that adequate Licensec-Contractor QA program 4 techniques (per PI 3800 criteria) have boca establis,hed ar will bc  :

applied to the PC&E Diablo Canyon No. I reactor project. Specifically, '

Westinghouse plans to provido purchase orders, purchase specifications, fabrication instructions and inspection coverage designed to assure i

desired quality. Mr. Page said that hc plans to look at all of the weld radiographs and to sampic all of the QC records generated during

] the course of the project. Also, Mr. Weckcr plans to make a similar,  !

j) but less intensified effort. l Following a question-and-answer session concerned with the SWWC0 a

QC program QA provisions, which are discussed in general terms in the SWWC0 Quality Assurance Manual, the inspector stated that therc

! appeared to be a singular lack of both verbal and written definition. l Further discussion and connent by SWWCO, PGSE, CP and Bechtel personnol l l 1ed to a consensus on the part of SWWC0 people that written clarifica' tion j of the QA program functions and responsibilitics was needed. At the conclusion of the visit Mr. Lockwood said that appropriate measures would be taken on a priority basis, a .

i C. Palisades Reactor Primary pipin; i

At the request of CO: Region III personnel, potential probicm areas relative to the Consumcrs Power Company (CP) Palisades reactor project ,

worc discussed with SWWCO, Dechtel and CP representatives.

a 1

1. Primarv Pipina nust Deposite 1

l As a result of an examination of an interior weld scam on a

! 14 inch diameter shop fabricated "T" and elbow fitting fo,r s

( (  ;

7 l

r

' the Emergency Core cooling system (ECCS) Cor.sumors Pmzur (CP)

• personnel became concerned about an apparent veld defect (see  ;

C0 Report No. 50-255/68-9, Section B.) . Further examination -

i of the weld seam disclosed significant deposits of rus e on the inside of the pipe. .. restricted to an area about 3/4 inchus l wide and common to the veld scam only. An investigation into the problem by CO, Bochtel and CP resulted in a conclusion on the part of Cp that, although not particularly desirabic, tho rust deposits did not present a significant probicm insofar as i primary coolant contamination was concerned. At the conclusion ,

i of the investigation, all parties concerned agreed that the  ;

source of the rust was most likely one of the following:

a. Brushes and grinding tools of improper material. i

b. Brushes and grinding tools of proper material but contaminated,

c. Carbon steci particles in the hydrostatic test water.

3 d. Although not identified as a possibic source of the rust, SWWC0 stated that they planned new construction so that .

it would be possible to isolate the plant carbon steel

. and stainless steel fabrication facilitics.

During the current visit, the inspectors obtained the following  ;

information relative to the rust problem.

l First, CP still feels that the extent of the rust deposition is relatively insignificant and strongly rejects any program 4

of pitling and passivation of the affected fittings. ,

i Second, test programs at SWWC0 conducted by SWWCO and 3cchtc1 personnel indicate tha*. the rust occurs as a result of moisture

• l which precipitates out of the air inside of the pipe as a j function of diurnal ccmporature changes. Mr. McDaniel said j

i that he had witnessed several tests involving the scaling of j

"dry" pipe sections (normally donc as a condition for storing finished pipe) and unncaling the sections 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> later. He 4

said that, upon unsealing the pipe scetions, significant quantities of water were found at the low ends of the pipe.

] Third, the rust deposits appear to be directly related to the welding operation in that no other areas of rust have been found..either as a result of routine examination of finished pipe or as a resalt of the tests.

I i

8-Fourth, no further tests or ovaluations relativo to the rust deposition are planned except on a possible "for interest only" basis.

2. Quality of Radiography A review of radiographs associated with the wold deiccc identified in 1., above, led to concern on the part of CP that the SWFWCO radiography procedures may be substandard l in the area of density control. Subsequent investigation revealed that film densitics varied from a low of 0.9 and a high of 4.0 by reference to Eastman Kodak filmstrip density comparitor (code limits-are 1.7 to 2.5). Morcover, during the review of film densitics, CP personnel noted two apparent weld defects which had not been previously detected, q As a result of the apparent discrepancies, in film density control and additional wcld defects, a Bechtel metallurgist was sent to the SWFWC0 plant to review a number of radio-graphs. About 400 radiographs were reviewed and several questionable wolds were detected. Conscquently, agreement was reached that the production rc.diographs for the palisados ECCS piping assembled by SWFWC0 should be 100 percent reviewed.

Approximately 5300 radiographs were reviewed by Bechtel personnel and 400 of these were tagged "questionable" and sent to Bechtel's San Francisco of ficos for further review.

i i

on May 7,1969, the inspectors requested a "current status" discussion session with concerned personnel. The results of the discussion session which included the following participants, are listed.

Mr. G. L. Lockwood - President , SWFWC0 '

Mr. C. Q. Hills - Consumers Power Company (CP)

Mr. B. McDaniel - Bechtel Radiologist Mr. J. L. Day - Bochtel Radiologist (Inspection) .

j Mr. F. E. Sewell - SWFWC0 Radiologist (Inspection)

a. of tim 4te0 mdio.p : pies s e n t: co .:..a F rancisco for review as sunpect substandard, ucchtel confirmed that 66 of the radiographs did, indeed, exhibit substandard character-istics to some degree. The substandard indications included t such items as improper penetramotor positioning as well as weld defects,

b. Of the 66 radiographs showing possible substandard , ,

characteristics, 22 have been tagged as showing wold '

i defects and are to be field repaired (spot repair) by  ;

Bechtcl.  !

1 4

5

.c 9

c. In addition to che 22 radiodrophs indicating defective wolds , 5 more e i che 66 radiographs have anomalouu indications to the extent that Bechtel has requested re-radiography. The balance of the 66 radiographs (39) as well as the remainder of the initial 400 subject to review, are considered to be well within code by San Francisco Bechtel personnel.

d. Mr. McDaniel pointed out that essentially all of the questionabic radiographs were related to 4 to 6 inch diameter thinwall (schedule 10-20) pipe and that piping of this l size presents dif ficulty both in the area of radiography j and film reading. Most of the radiographs , he said, I required a maximum of "judgement" during review due to the inherent difficulties involved. Mos s rs . 11111s ,

Day and Sewell agreed with McDaniel's cor. cents.

3. corrective Acti,cn Corrective arcton, relative to each of the iteras discussed above, is as follove:

a. As stated earlier, no further activitics are scheduled in conjunction with the rust probico discussed in C l., above,

b. SWFWCO has purchased a densitometer (McBeth) which is used to detcenine the density of all radiographs.

According to Mr. Sewell, the densitometer is calibrated several times during each day of usage by reference to '

an Eastman Kodak film strip density comparitor,

c. Although SWFWCO management personnel feci strongly that their radiography personnel are well qualified and that de fec t detection is and has been at a better-than-average level, plans have been completed to bring in "outside experts" in an effort to develop maximum capability on the part of the 9WFWC0 NDT staff. Mr. Green said that the outside experts are persons employed in a full time capacity as radiography instructors.

.