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Parry Nuclear Power Flent - Unit 1 and 2 Construction Quality Section l Surveillance / Inspection Report (SIR) Continuation . , | Parry Nuclear Power Flent - Unit 1 and 2 Construction Quality Section l Surveillance / Inspection Report (SIR) Continuation . , | ||
SHEET 4 - OF 4 I LK COMSTOCK 33 ' | SHEET 4 - OF 4 I LK COMSTOCK 33 ' | ||
g p_. 5 E -13 &3 Contractor Spec. No. SIR Number-IMPACTONCURRENTWORK-N/A ACTIONS TAKEN/PIANNED A. This concern was a misinterpretation by the Task Force of the Pullman Power Products Program. Attached is the Pullman letter dated July 19, 1982, address-ing this concern. The letter states that the date by the QA approval on form 7026-102 is for the date the rod is returned. This date should be regarded as being part of the " return" column and not the row showing QA approval. | g p_. 5 E -13 &3 Contractor Spec. No. SIR Number-IMPACTONCURRENTWORK-N/A ACTIONS TAKEN/PIANNED A. This concern was a misinterpretation by the Task Force of the Pullman Power Products Program. Attached is the Pullman {{letter dated|date=July 19, 1982|text=letter dated July 19, 1982}}, address-ing this concern. The letter states that the date by the QA approval on form 7026-102 is for the date the rod is returned. This date should be regarded as being part of the " return" column and not the row showing QA approval. | ||
B. The Pullman letter also addresses this concern. At the time of the Task Force Review the field weld process sheets were for "information only". The information is filled in during final QA Review. | B. The Pullman letter also addresses this concern. At the time of the Task Force Review the field weld process sheets were for "information only". The information is filled in during final QA Review. | ||
ATTACHMEFIS | ATTACHMEFIS | ||
#1 LKC IR 5195 1 page | #1 LKC IR 5195 1 page | ||
#2 Pullman letter dated July 19, 1982 2 pages | #2 Pullman {{letter dated|date=July 19, 1982|text=letter dated July 19, 1982}} 2 pages | ||
#3 7 pages weld rod storage requisition forms | #3 7 pages weld rod storage requisition forms | ||
#4 7 pages PF. field weld process sheets - | #4 7 pages PF. field weld process sheets - | ||
| Line 5,030: | Line 5,030: | ||
This letter is to acknowledge receipt of Inspection Report Number 50-440/ | This letter is to acknowledge receipt of Inspection Report Number 50-440/ | ||
83-06; 50-441/83-06, attached to your letter dated March 16, 1983. This report identifies areas examined by Messrs. P. A. Barrett, K. R. Naidu and P. R. Pelke during their inspection conducted February 6-11, 1983. | 83-06; 50-441/83-06, attached to your {{letter dated|date=March 16, 1983|text=letter dated March 16, 1983}}. This report identifies areas examined by Messrs. P. A. Barrett, K. R. Naidu and P. R. Pelke during their inspection conducted February 6-11, 1983. | ||
Attached to this letter is our response to the three Violations described in the referenced Notice of Violation, dated March 16, 1983. This response is in accordance with the provisions of Section 2.201 of the NRC's " Rules of Practice", | Attached to this letter is our response to the three Violations described in the referenced Notice of Violation, dated March 16, 1983. This response is in accordance with the provisions of Section 2.201 of the NRC's " Rules of Practice", | ||
Part 2, Title 10, Code of Federal Regulations. | Part 2, Title 10, Code of Federal Regulations. | ||
Revision as of 18:26, 26 September 2022
| ML20080K422 | |
| Person / Time | |
|---|---|
| Site: | Perry  |
| Issue date: | 10/11/1982 |
| From: | Packy T COMSTOCK ENGINEERING, INC. |
| To: | Bower R AFFILIATION NOT ASSIGNED |
| Shared Package | |
| ML20079G896 | List: |
| References | |
| FOIA-83-199 NUDOCS 8309290151 | |
| Download: ML20080K422 (137) | |
Text
{{#Wiki_filter:, .;,w rW cousTocx Perry Nuclear Power Plant o E sence 1904 L.K. Comstoc ( Engineering Com 3any, Inc. A COMSToCK GAoVP COMPANY October 11, 1982 Richard L. Bower Q. C. Manager Task Force #40
Dear Sir,
A review of all Equipment Packages was performed to evaluate the major concerns expressed by the Task Force during and after completion of their equipment package review (i.e. , Task _ Force #32 dated 8/6/82 and Task Force
#34 dated 8/13/82, Attachments 1 & 2) regarding Inspectors performing inspec-tions outside the area of their certifications.
The intent of this review was to evaluate the entire situation as to the full extent of the problem so that corrective action-can be implemented-immediately. All Inspector signoffs related to Equipment Inspections were evaluated to the following criterion: Were they certified in that specific area on the date indicated, and if not, was there a certified Level II signature or initials present attesting to the acceptability of the installation and documentation. The uncertified inspections performed fell into 3 major areas.
- 1. Uncertified Installation Inspections performed - Hardware (Checklists, N.R. 's, Hilti, heeiving, etc.)
- 2. Uncertified implementation insiections performed - Maintenance l
Verification, Inspection Repor:s, Megger Form Review, etc. l l 3. Certified Level I Inspectors - no co-signature of Level II Inspector. NOTE: It should be noted that L. K. Comstock policy in the past was to have the Inspector Trainee complete the Inspection Report t_s a. part of training under the direction of a certified Level II, who l , would sign the report also. This policy appears to have been abused l in the case of W. G. Morris, simply because of the sheer numbers of Inspection Reports authored (initialed or signed) during this equip-ment receiving, installation time period (1/81 ' throagh 4/81)' . A Q These inspections were not included in this report in the uncerti-fied catagory but should be analyzed for potential credibility problems at turnover. 8309290151 830622 T 199 PDR ( 324, PERRY, OH 44081 l (216) 259-3755 fm,
Akb. 5!E/
~~
O Task Force #40 Attachment 3 to this report lists all equipment numbers, inspectors, type of inspections involved and the date of the inspection documentation. In closing, it is my recommendation that all of these specific inspections be reviewed again, by Quality Control, and the following corrective action implemented.
- 1. All Uncertified Installation Inspections that are verifiable should be totally re-inspected and documented as such on the appropriate checklist. The specific instances should also be recorded _on a Generic I.R. to document corrective action and to clarify existing documentation. Corrective action should also include training.
(Reference Item #3 below)
- 2. All Uncertified Installation Inspections not verifiable should be documented on a Nonconformance Report.
- 3. All Uncertified Implementation Inspections should be documented on an Inspection Report for corrective action, which should include detailed training of all present Q.C. Personnel stressing the importance of their O signature on Inspection Documentation, performing only work certified b in, and Level II co-signature requirements of ANSI N45.2.6.
- 4. All Level I signatures and documentation should be reviewed and co-signed by a Level II certified in the area of review.
4A. A standarized method of Level II co-sign should be established and adhered to, with no exception. It is my strong recommendation, made in an effort to forestall future problems of this nature, that the Level II signature be made independently of the review signature currently being utilized. (i.e. The Level II co-sign and date should be on the same line as the Level I.) If there are any questions concerning the content of this report, please feel free to contact the undersigned. W b Thomas W. Packy Task Force TWP: sad W/ Attachments , cc: R. Marino T.F. File
, , gg ATTACHMENT 1 Page 1 of 4 (Tank Forca #40) TF-32 cousTocK Perry Nucl=r Power Plant
.O - . .
L.K. Comstoc( Engineering Com Jany, Inc. A COMSTOCK GROUP COMPANY August 6, 1982 William G. Ladochy Eastern Regional Manager, QA/QC Services L. K. Comstock Engineering Co., Inc. 920 Fort Duquesne Blvd. Pittsburgh, PA 15222 Subj ect: Concerns as a Result of the Review of the Equipment Installation Packages Bill, The following are major concerns as a result o'f a partial review of j Equipment Installation Packages performed by the Task Force. Concern 1A. L. K. Comstock inspectors have been performing and signing j , for acceptance of inspections outside of their areas of cert-s- ification. As a result of these findings all personnel and inspections performed prior to January 1, 1982, must be held in suspect. This is to include Switchgear, Termination Cabinets, Rotating ! Equipment and Penetrations #1R72-S001 thru 1R72-S029. A par-tial list of examples is as follows:
- a. Brian Palmer has made inspections on the Class 1E Switch-gear and Termination Cabinet Installation Checklist (?orte
#32). He was never certified to perform Equipment Instal-lation Inspections. Example: 1H13-P706, P710, P711, P712, P713, P714, and P715.
- b. G. Young has verified inspections on the Class 1E Switch-gear and Temination Cabinet Installation Checklist (Form
#32) before his certification date of 4-7-81. Material Receiving Report indicate verification of Material Recet-ed before he was employed. Exanple: 1H13-P706, P707, P710, P711, P712, P713, P714, and P715.
- c. G. Hagler has not been certified to perform Equipment Insal-lation but has performed inspections and documented such on Form #32. Example: 1H13-P710, P711, P712, P713, and P714
- d. L. Samosky has documented stud welding on Form #100 but has never been certified to Stud Welding. Example: 1H13-P706, h e.
P710 P711, P712, and P713. M. Bires was not certified to Level II Stud Welding on P.O. BOX 324, PERRY, OH 44081 l (216) 259 3755
-., ATTACHMENT 1 (Task Force #40)
C Oes t IOt . O Concern IA. e Continued 2/14/80. There is no co signature. Example: 1H13-P707, sad P715.
- f. H. Ennson was only a Level I and has signed Inspection R'aports (Form #118) without a Level II co-signature.
Example: 1H13-P711, P712, P713, and P715.
- g. Phil Romano inspected Class 1E Switchgear on 2/11/81 (Form #32).
He was not certified until 4/13/81 and only as a Level I. Example: Package OR24-S023.
- h. Lucille Cleary received material since 8/13/80 (Form #39A).
She was not certified until 2/23/81 and then as a Level I. Example: Package 1H22-P030.
- 1. Brian Palmer signed off Form #32 Class 1E Switchgear and Termination Cabinet Installation Checklist on 1/8/80. He was no't certified for Equipment Installation. Clarence Hart co-signed this form.
! Additional examples available.
- j. R. L. Coffman co-signed Inspection Report #356 for Phil Romano who was not certified on 2/11/81. He was not certified himself f until 4/7/81.
I
- k. Approximately six (6) people were certified out of 22 people who '
were signing off various Inspection functions and were not , certified to do so at that particular time. This partial list of uncertified individuals was taken from the personnel I files and based on the information available. The necessary Site ! approval letter for certification was not noted in most individual l personnel files at the time of review for specific activity certification l l
- 13. The 1R24 packages are in .the process of being turned :'ver to Site and !
were reviewed for Velidity of Inspections prior to transmittal from l the Task Force. The reeults of this review t.lso indicated inspections i performed by individuals not certified to specific activities. The l documentation in question consists of Nonconformance Reports, Inspection 1 Reports, Material Receiving Reports and Checklists for documenting electrical equipment installation.
"IC.
In reference to electrical penetrations, 1R72-S001 - S029, all inspections performed and documented on form #39A, Material Receiving , Reports, and Form 4116-A & B, Installation Checklists hase been I generated by inspectors who were not certified on the date the inspections were performed. O Page 2 of 4 l b
I.
- jg ATTACHMENT 1 (Tezk Forca #40) c o.n o .
Concern 2A. There appears to be no standardized method to filling out Form #21 Insulation Resistance / Continuity Test Report. The foms have been altered by the craft to suit their own interpretation. Often, the results are indecipherable. SP 709-4549-00 Section 1:05.10 Control of Inspections and Tests Paragraph 1 states:
- 1. A program of inspections and tests shall be prepared for all activities affecting quality, and shall identify those inspection and tests points to be verified for conformance to documents such as instructions, procedures, drawings, specifications, etc., that are used to perform the activity.
The inspection and tests shall be performed by individuals other than those who performed the activity being inspected or tested and who do not report to the supervisor who directed the original WORK. There shall be an adequate number of inspections and tests performed to assure that all operations of the activity fulfill the predetermined quality requirements. The CONTRACTOR shall describe the system which he will utilize to identify, implement and verify HOLD POINTS, or WITNESS POINTS which will assure that inspections and tests are performed as required. Paragraph 1:05.10 3.C. states:
- 3. c. What written instruction the person performing the inspecticus and tests will be working to, including the specific acceptance criteria, tolerances, etc., which must be verified.
- 23. Craf t has been using the infinity symbol (ef) extensively. The i Procedure states that the reading should be in ohms, megohms, etc.
Procedure 4.3.18, Meggering and Continuity Testing, paragraph 3.1.9 states: "A record shall be made and kept for all tests governed j by this procedure. The record must indicate the following: (Use
- Form #21, Attached)"
l
3.1.9 states
" Test Measurements obtain6.', with units identified (i.e. ohms, megohms, etc.)." l 3.2.1, under acceptance criteria states: l "Unless otherwise specified by the Project Organiza-tion Engineer, values in Figure 15 (Page 12) shall be used." It is a requirement of Spec 33-4549-00 that 100% of all Class 1E and Non Class 1E cables have a Megger/ Continuity Test and the results be documented: This activity is performed solely by the construction department. (Testing and Documenting). The Quality Control Dept. O has accepted these test results in accordance with procedure 4.3.18 prior to this procedure being approved. At this time, per the Task Force Document Review of Electrical Equipment Page 3 of 4
se a 46 h { Qeg g f O( g ATTACHMENT 1 (Teck Forcs #40) Installations and as a result of these findings, all inspections performed prior to 1/1/82 should be considered invalid and the lack of certification of the individuals performing these inspections should be addressed innediately. Additionally, all Megger/ Continuity Tests should also be considered invalid, as a result of the acceptance of test results without an approved procedure. Also, all inspections presently being per'ormed and all personnel certific.ations should be reviewed at this rise because of tho fset that some of the inspectors identified as being not certified in specific activities are currently employed by L. K. Comstock at the Perry Site. Cordi y, (. . V. A. Eichler Leader, Task Force cet R. E. Marino L. G. Seese D. Friend
- R. L. Bower ,
! J. Zilka, ECI t O Page 4 of 4
, . ATTACHMENT 2 Pc82 1 of 5 (Tcek Forcs #40) TF-34 cousToca Perry Nuclear Power Plant r
o . . . . . L.K. Comstock Engineering Com Jany,Inc. A CoMstoCK GAoup COMPANY August 13, 1982 ,
Subject:
Identification of Concerns as a Result of the Electrical Equip-ment Documentation Review performed by the LKCE Task Force The following is a summary of the five (5) major areas of concern identified as a result of the Equipment Package Review conducted by * ' the Task Force. Also, a list of Generic Items is also attached. A written response to the following concerns is requested. Co dially 1 V. A. Eichler Leader. Task Force VAE/bb cc: R. E. Marino W. G. Ladochy R. L. Bower L. G. Seese D. G. Friend J. R. Zilka, ECI File A - O . P.O. BOX 324, PERRY, OH 44081 l (216) 259-3755
m_. -m - m _. _ . . _ _ - _m.. _ _ _ _ _ . _ m.m._ _ _ _ _ _ . _ d
- , . pg ATTACHMENT 2 (Teck Forca #40) i O Co*C=S iS A =S=T or EtEcrucit E==E=T t=STittmo RENEW i i
Concern #1 L. K. Comstock Inspectors have been performing and signing for acceptance of inspections outside of their areas of certification. This is to include Switchgear. Termination Cabinets, Rotating Equipment and Penetrations #1R72-SC01 thru 1R72-SO29. A list of examples is as follows: A. Brian Palmer has made inspections on the Class 1E Switchgear and Termination Cabinet Installation Checklist (Form #32). He was never certified to perform Equipment Installation Inspections. Example: 1H13-P706, P710 P711, P712, P713, P714,, and P715. B. G. Young has verified inspections on the Class 1E Switchgear and 3 Termination Cabinet Installation Checklist (Foru #32) before his certification date of 4-7-81. Material Receiving Reports indicate verification of material received before he was employed. Example: 1H13-P706, P707. P710, P711, P712, P713 P714, and P715. C. G. Hagler has not been certified to perform Equipment Installation
! but has performed inspections and documented such on Form #32.
Example: 1H13-P710, P711, P712, P713, and P714. D. L. Samosky has documented Stud Welding on Form #100 but has never
- _ been certified to Stud Welding. Example
- 1H13-P706 P710. P711,
. P712, and P713.
if E. M. Bires was not certified to Level II Stud Welding on 2/14/80. There was no co-signature. Example: 1H13-P707, and P715. F. H. Hanson was only a Level I and has signed Inspection Reports (Form
#118) without a Level II co-signature. Example: 1H13-P711, P712, P713, and P715.
G. Phil Romano inspected Class LE Switchgear on 2/11/81 (Fom'~irJz). He was not certified until 4/13/81 and only as a Level I. Examole: Package OR24-S023.
, H. Lucille Cleary received naterial since 8/13/80 (Form #39A). She was 4
not ::ertified until 2/23/81 and then as a Level I. Example: Package l 1H22-P030. I. Brian Palmer signed off Form #32 Class 1E Switchgear and Termination Cabinet Installation Checklist on 1/8/80. He was not certified for Equipment Installation. Clarence Hart co-signed this form. Addition-al examples available. J. R. L. Coffman co-signed Inspection Report #356 for Phil Romano who ' was not certified on 2/11/81. He was not certified himself until 4/7/81. K. R. L. Coffman co-signed Insulation Resistance / Continuity Test Report (Form #21) with Zack Space on 4/30/81. Mr. Space was not certified in any activity until 3/26/82. L. Ron Gillette signed Form 39A - Material Receiving Report - on 6/19/81.
- s. At this time he was' certified as a Level I and the report was initialed only, not co-signed and dated.
Page 1 of 5
._ _ . _ _ ~ . . . _ _.. . _ _ -_ , _ . . - - --__----- - _ _ - - _ . - - - - - - - - - - - - - - -- - --
ATTACHMENT 2 (Tcak Forca #40) b W Concern #1 Continued M. M. Imhoff verified Item #1 on Form #32 for Installation of Equipment on 8/8/80. He has never been certified in Equipment Installation. N. J. Ruff t signed for acceptance of welds on Form #107 on 8/11/80. He was certified in Visual Inspection as a Level II on 8/26/80. O. T. Ross and C. Skarupa co-signed verification of Item #2 of Form #32 en 2/28/80. Neither one was certified for Equipment Installation. P. P. Romano and B. Erwin co-signed an Insulation Resistance / Continuity Test Report for verification of FSMR Requirements date 3/24/82. Mr. Erwin was certified Level II on 3/26/82 and Mr. Romano was certified Level II on 5/4/82. This partial list of uncertified individuals was taken from the personnel files and based on the information available. The necessary Site approval letter for certification was not noced in most individual personnel files at the time of review for specific activity certification. The certification dates referenced are L. K. Comstock only. Spec-709-4549-00, Dated 5/24/79, Paragraph 1:05.2-2, page 7, states in part
" Notification of all new or upgraded qualifications / certifications of Con-tractor QA/QC'and NDE personnel assigned to the Site shall be submitted to 3 the Owner's QA Element for review and concurrence prior to assignment of ; the individual to Safety-related work. The Owner's QA Element Review shall 1 be comleted within two working days after receipt of Contractork notifica-tion."
l The documentation in question consists of Nonconformance Reports, Inspection l Reports (Form #118), Material Receiving Reports (Fom #39A), Weld Documen-tation Records (Form _#107), and Checklists for documenting electrical equip-ment installation, Form #21, 27, 32, and 128. In reference to electrical penetrations, 1R72-S001 - S029, all inspections performed and documented on Form #39A, Material Receiving Reports, and Form
#116 A&B, Installation Checklists have been generated by inspectors who were not certified on the date the inspections were performed.
Concern #2 There appears to be no standardized method to filling out Form #21, Insula-tion Resistance / Continuity Test Report. The forms have been altered by the craft to suit their own interpretation. Often, the results are indecipher-able. SP 709-4549-00 Section 1:05.10 Control of Inspections and Tests,. Paragraph 1 states: -
- 1. A program of inspections and tests shall be prepared for all activities affecting quality, and shall identify those inspection and test points to be verified for conformance to documents such as instructions, pro-cedures, drawings, specifications, etc., that are used to perform the activity. The inspection and tests shall be performed by individuals other than those who performed the activity being inspected or tested
% and who do not report to the supervisor who directed the original WORK.
There shall be an adequate number of inspections and tests performed O , to assure that all operations of the activity fulfill the predetermined quality requirements. The CONTRACTOR shall describe the system which he will utilize to identify, implement and verify HOLD POINTS, or WIT-Page 2 of 5
ATTACHMENT 2 (Tezk Forcs #40) b h. W.-- s honcern#2 Continued NESS POINTS which will assure that inspections and tests are performed as required. Craft has been using the infinity symbol extensively. The Procedu're ; states that the reading should be in Ohms, Megohms, etc. Procedure 4.3.18, Megger-ing and Continuity Testing, paragraph 3.1.9 states: "A record shall be made and kept for all tests governed by this procedure. The record must indicate the following: (Use Form #21, Attached)."
3.1.9 states
" Test Measurements obtained with units identified (i.e. Ohms, Megehms, etc.) ." 3.2.1, under acceptance criteria states:
"Unless otherwise specified by the Project Organiza-tion Engineer, values in Figure 15 (Page 12) shall be used."
Paragraph Spec-709-4549-00, 1:05.10 3C states: C. What written instruction the person performing the inspections and tests will be working to, including the specific acceptance criteria, tolerance, etc., which must be verified. It is a requirement of Spec 33-4549-00 that 100% of all Class 1E and Non Class a 1E cables have a Megger/Continuit This activity is performed solely by t'y Test and the results he construction be documented. department. (Testing and Documenting). The Quality Control Department has accepted these t'est results in accordance with Procedure 4.3.18 prior to this procedure being approved. Concern #3 The following pieces of Electrical Equipment were not listed in Spec-33-4549-00 Equipment Furnished by Owner (FBO) List. The concern is what documents address installation of this equipment by L. K. Comstock, if any. The list is as j follows: OH51-P094, 2H13-P624A, OH51-P095, 2H13-P731, 1H13-P74, 2H13-P732, 1H13-P619, 2H13-P736, 1H13-P621, 2H13-P822, 1H13-P630, 2H51-P056, 1H13-P632, 2H51-P846A, 1H13-P634, 2H51-P864B, 1H13-P680, 2H51-P847, 1H13-P731, 2H51-P848, 1H13-P732, 2H51-P849, 1H13-P864, M40-C001B, 1H13-P865, 2P42-R22, 1H13-P866, l OR24-S012, 1H13-P867, OR24-S013, 1H13-P870, OR24-S032, 1H13-P872, OR42-S006, 1H13-P902, 1R24-S026, 1H13-P904, 1R24-S036, 1H22-P022, 2R24-S012, 1H51-P056, 2R24-S015, 1H51-P846A, 2R24-S028, 1H51-P846B, 2R24-S037, 1H51-P847, 1R24-5033, 1H51-P849, and 2R42-S007. Concern #4 All Equipment Packages reviewed by the Task Force had numerous inspections i that had not been performed. Concetu #5 It appears that a large number of original Material Receiving Reports have been lost. It also appears that an attempt has been made to re-document . the Receipt Inspection without any back-up information. At this time, per the Task Force Review of Electrical Equipment Installations and g .c a result of Concern #1, all inspections performed prior to 1/1/82 should be consid-l cred invalid and the lack of certification of the individuals performing these inspec- ! hionsshouldbeaddressedimmediately. Additionally, all Megger/ Continuity Tests should l elso be considered invalid, as a result of the acceptan.e of test results without an ! cpproved procedure. Page 3 of 5
. 46 h ATTACHMENT 2 (Task Forcs #40)
( Oen%I(M s Also, ali inspections presently being performed and all personnel certifications thould be reviewed at this time because of the fact that some of the inspectors iden-tified as being not certified in specific activities are currently employed by L. K. Comstock at the Perry Site, as previously identified in part on 8/6/82. s .l i O . i l O Page 4 of 5
i l
. . 1
.I gg ATTACHMENT 2 (Teck Forcs #40) co.um.
k ATTACHMENT 1 LIST OF GENERIC ITEMS l l
- 1. There is a lack of IEEE Certifications or NR# CQC 1226, to document the lack of the smae. There is also a problem with tracing the Con-ditional Releases to the panels since most C.R.'s are also missing.
- 2. Forms were not properly filled out (i.e. all blanks not filled in).
- 3. All Form #62 - Warehouse Issue Tickets were poor Quality Reproductions.
- 4. Many forms were missing from each equipment package.
- 5. Field Storage Maintenance Requirements were not performed properly and all temperatures and pressure readings recorded showed no evi-dence that calibrated equipment was used.
4 l 1 l l l l l l 0 l l Page 5 of 5
(Task Forco #40) ATTACHMENT 3 Pega 1 of . 7
. INSPECTORS INVOLVED.
O' M.S. = Max Sorensen R.G. = Ron Gillette P.R. = Phil Romano J.R. = John Rufft B.E. = Barry Erwin T.R. = Tim Ross B.P. - Brien Palmer R.B. = Richard Britanik G.H. = George Hagler M.I. = Mike Imhoff R.C. = Ralph Coffman G.Y. = George Young EQUIPMENT NO. INSPECTOR TYPE OF INSPECTION DATE OHS 1 - PC77 A&B P.R. Maint. Ver. Level I 3/23/82 0H51 - P077 A&B M.S. Maint. Ver. Level I 2/24/82 OR24 - S020 P . R. /R.,C . IR 2/11/81 OR24 - S020 G.Y. AFR 4/03/81 OR24 - S025 P.R./R.C. IR 2/11/81 OR24 - S035 P.R./R.C. IR 2/11/81 OR24 - S036 P.R./R.C. IR 2/11/81 OR24 - S037 G.Y. Installation 3/12/81 I OR24 - S037 P.R./R.C. IR 2/11/81 1E22 - P001 & P002 P.R./RC IR Level I 2/10/81 1H13 - P70,1,2,3,4,7, 10,11,12,13,14,15,17, R.C./P.R. Maint. Ver. 2/11/81 () 30,40,41,42,43,44,45, 46,47,48 1H13 - P701 G.Y. Installation 3/23/81 IH13 - P702 G.Y. Installation 3/24/81 , 1H13 - P702 B.P. Installation 1/07/80 l IH13 - P703 G.Y. Installation 3/24/81 1H13 - P704 G.Y. Installation 3/24/d1 1H13 - P706 G.Y. Installation 3/24/81 l ,1H13 - P707 G.Y. Installation 3/24/81 l IH13 - P710 G.Y. Installation 3/24/81 1H13 - P710 , G.H. Installation 10/07/80 1H13 - P711 G.Y. Installation 3/24/81 l 1H13 - 2711 G.H. Installation 10/02/80 l 1H13 - P712 G.Y. Installation 3/24/81 1H13 - P712 G.H. Installation 10/02/80 1H13 - P713 G.Y. Installation 3/24/81 1H13 - P713 G.H. Installation 10/02/80 1H13 - P714 G.Y. Installation 3/24/81 1H13 - P714 G.H. Installation 10/02/80 1H13 - P714 B.P. Installation 1/08/80 l 1H13 - P715 G.Y. Installation 3/24/81 1H13 - P715 B.P. Installation 1/08/80
(Task Force #40) ATTACHMENT 3 Page 2 of 7 O EQUIPMENT NO. INSPECTOR TYPE OF INSPECTION DATE 1H13 - P717 G.Y. Installation 3/25/81 1H13 - P717 G.H. Installation 10/02/80 1H13 - P730 G.Y. Installation 3/25/81 ~ 1H13 - P740 G.Y. Installation 3/25/81 1H13 - P740 B.P. Installation 1/07/80 1H13 - P741 G.Y. Installation 3/25/81 1H13 - P741 G.H. Installation 10/07/80 1H13 - P741 B.P. Installation 1/08/80 1H13 - P742 G.Y. Installation 3/25/81 1H13 - P742 B.P. Installation 1/07/80 1H13 - P743 G.Y. Installation 3/25/81 1H13 - P743 G.H. Installation 10/07/80 1H13 - P744 G.Y. Installation , 3/25/81 1H13 - P744 B.P. Installation 1/07/80 () 1H13 - P745 IH13 - P746 G.Y. G.Y. Installation 3/25/81 Installation 3/25/81 1H13 - P746_ B.P. Installation 1/07/80 1H13 - P747 G.Y. Installation 3/25/80 1H22 - P007 G.H. Installation 10/25/80 1H22 - P008 G.Y. Installation 12/22/80 IH22 - P030 R.C. NR 2/18/81 1H22 - P033 R.C. NR 2/18/81 1H51 - P054 A&B R.G. Receiving Level I 9/23/81 1H51 - P174 A G.Y. Receiving 1/28/81 1H51 - P174 A J.R. M.T. Level I 1/19/81 IHS1 - P174 B G.Y. Receiving 1/28/81 0H51 - S002 P.R. IR Level I 2/15/82 1R22 - S006 B.P. Installation 1/28/80 1R22 - S006 B.P. Installation 10/22/80 1R22 - S006 M,I, Installation 8/08/80 1R22 - S007 M.I. Installation 8/08/80 1R22 - S007 B.P. []) Installation 1/28/80
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, * (Tcak Forca #40) ATTACHMENT 3 Pega 3 of 7 EQUIPMENT NO. INSPECTOR TYPE OF INSPECTION DATE 1R24 - S018 T.R. Installation 3/05/80 1R24 - S018 P.R./R.C. IR 2/11/82 1R24 - S018 G.Y. IR 3/13/81 1R24 - S019 P.R. IR Level I 2/26/82 1R24 - S019 P.R./R.C. IR 2/11/81 -
1R24 - S019 T.R. Installation 3/05/80 1R24 - S021 P.R./R.C. IR 2/11/81 1R24 - S022 P.R./R.C. IR 2/11/81 1R24 - S023 P.R./R.C. IR 2/11/81 1R24 - S023 .P.R. AFR Level I 2/11/81 1R24 - S024 G.Y. Installation 3/13/81 1R24 - S026,28,29 P.R./R.C. IR 2/11/81 1R72 - S001 P.R./R.C. IR 1/16/81 1R72 - S001 R.C. Installation 2/26-3/03/81 1R72 - S001 R.C. NR 2/11/81 1R72 - S00jl R.C. Installation 2/26-3/4/81 1R72 - S002 R.C. .NR 2/11/81 1R72 - S002 P.R. NR Level I 3/02/82 1R72 - S002 P.R./R.C. IR 1/16/81 1372 - S003_. -. G.Y./R.C. Installation 2/11-2/25/81 1R72 - S003 P.R. IR Level I 2/16/82 1R72 - S003 G.Y. IR 2/11/82 l 1R72 - S004 R.C. Iastallation 2/20-3/25/81 1R72 - S004 P.R. NR Level I 3/02/82 1R72 - S005 R.C. Installation 2/13/81 1R72 - S005 P.R./R.C. IR 2/24/81 1R72 - S006 R.C. Installation 2/20-3/24/81 l 1R72 - S007 R.C. Installation 3/09-3/11/82 1R72 - S008 R.C. Installation 2/19-7/09/81 1R72 - S008 B.E. AFR 12/01/81 1R72 - S009 R.C. Installation 3/03-4/03/81 1R72 - S010 R.C. Installation 3/09-4/07/81 1R72 - S011 R.C. Installation 2/24-3/25/81 1R72 - S011 P.R. hR Level I 3/02/82 i 0
,_,,,..,-_m.- ,. . . . - _ . _ , _ _ _ , . _ _ _ _ _ , , _ _
(Tcck Fcres #40) ATTACHMENT 3 Pzga 4 of 7 EQUIPMENT NO. INSPECTOR T7PE OF INSPECTION DATE 1R72 - S012 R.C. Installation 2/17-3/11/81 1R72 - S013 R.C. Installation 2/18-3/06/81
*1R72 - S014 R.C. Installation 3/11-4/06/81 1R72 - S015 R.C. Installation 3/09-4/06/81 1R72 - S016 R.C. Installation 3/10-3/18/81 1R72 - S017 R.C. Installation 2/24-3/11/81 1R72 - S018 R.C. Installation 3/16/81 1R72 - S019 R.C. Installation 3/11-3/18/81 1R72 - S020 R.C. Installation 3/17-4/02/81 1R72 - S021 R.C. Installation 3/19-4/01/81 1R72 - S022 R.C. Installation 3/19-4/07/81 1R72 - S023 R.C. Installation 3/17-4/01/81 1R72 - S024 R.C. Installation 3/19-4/07/81 1R72 - S025 R.C. Installation 3/11-3/25/81 1R72 - S025 R.C. Installation 2/20-3/31/81 IF.72 - S027 R.C. Installation 2/23-3/31/81 1R72 - S028 R.C. Installation 2/24-3/18/81 1R72 - S029 R.C. Installation 2/16/81 2E22 - P001 P.R. ID Level I 2/15/82 2H13 - P701 G.Y. Installation 3/30/81 2H13 - P702 G.Y. Installation 3/26/81 2H13 - P703 G.Y. Installation 3/26/81 2H13 - P704 G.Y. Installation 3/26/81 2H13 - P706 G.Y. Installation 3/26/81 2H13 - P707 G.Y. Installation 3/26/81 l
2H13 - P710 G.Y. Installation 3/26/81 j 2H13 - P711 G.Y. Installation 3/26/81 l 2H13 - P712 G.Y. Installation 3/26/81 2H13 - P713 G.Y. Installation 3/26/81 2H13 - P714 G.Y. Installation 3/26/81 2H13 - P714 G.H./R.B. Installation 10/21/80 2H13 - P715 G.Y. Installation 3/30/81 2H13 - P715 G.H./R.B. Installation 10/21/80 , 2H13 - P717 G.Y. Installation 3/30/81 2H13 - P740 G.Y. Installation 3/30/81 2H13 - P741 G.Y. Installation 3/30/81 2H13 - P742 G.Y. Installation 3/30/81 2H13 - P743 G.Y. Installation 3/30/81 l
(Tr,ck Forco #40) ATTACHMENT 3 Paga 5 of 7 EQUIPMENT NO, INSPECTOR TYPE OF INSPECTION DATE O 2H13 - P744 G.Y. Installation , 3/30/81 2H13 - P745 G.Y. Installation 3/30/81 2H13 - P746 G.Y. Installation 3/30/81 2H13 - P747 G.Y. Installation 3/30/81 2H13 - P748 G.Y. Installation 3/30/81
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2H22 - P007 G.Y. Receiving 12/04/80 2H22 - P008 G.Y. Installation 12/22/80 2H22 - P030 G.H./R.B. Hilti 12/12/80 2H22 - P030 G.Y. Rilti 1/07/81 2H22 - P030 G.Y. Receiving 12/04-2/06/81 2H22 - P030 G.Y. Installation 1/07/81 2H22 - P030 R.C. NR 2/18/81 2H22 - P031 G.H./R.B. Hilti 12/08/80 2H22 - P031 G.Y. Etiti 1/07/81
~
2H22 - P031 R.C. NR 2/18/81 2H22 - P031 G.Y. Installation 1/07/81 2H22 - P031 R. C. NR 2/18/81 0 2H22 - P031 2H22 - P032 G.Y. G.H./R.B. Receivin, 12/04/80-2/0e/81 Hilti 12/08/80 2H22 - P032 G.Y. Hilti 1/07/81 2H22 - P032 R.C. NR 2/18/81 2H22 - P032 G.Y. Installation 1/07/81
- 2H22 - P03? G.Y. Receiving 12/04/80-2/06/81 2H22 - P033 R.C. NR 2/18/81 2H22 - P033 G.Y. Hilti 1[07/81 2H22 - P033 G.Y. Installation 1/07/81 2H22 - P033 G.H./R.B. Hilti 12/12/80 2H22 - P033 G.Y. Receiving 12/04/80-2/06/81 2H51 - P054 B R.G. Receiving Level I 10/01/81 2H51 - P055 B R.G. Receiving Level I 10/01/81 2R22 - S006 M.I. Installation 8/08-8/12/80 2R22 - S007 M.I. Installation 8/08/80 2R24 - S018 G.Y. Installation 3/12/81 2R24 - S018 P.R./R.C. IR 2/11/81 O
(Terk Fcres #40) ATTACHMENT 3 Psga 6 of 7 EQUIPMENT NO. INSPECTOR TYPE OF INSPECTION DATE~ O 2R24 - S019 G.Y. Installation 3/12/81 2R24 - S019 P.R./R.C. IR 2/11/81 2R24 - S021 G.Y. Insta11aiton 3/12/81 2R24 - S021 P.R./R.C. IR 2/11/81 2R24 - S022 G.Y. Installation 3/12/81 2R24 - S022 P.R./R.C. IR 2/11/81 2R24 - S023 G.Y. Installation 3/12/81 2R24 'S023 P.R./R.C. IR 2/11/81 2R24 - S024 G.Y. Installation 3/12/81 2R24 - S024 P.R./R.C. IR 2/11/81 2R24 - S026 R.G. IR Level I 10/12/81 2R24 - S026 P.R./R.C. IR 2/11/81 2R24 - S026 G.Y. Installation 3/12/81 2R24 - S028 G.Y. Installation 3/12/81 2R24 - S028 P.R./R.C. IR 8/11/81 2R24 - S029 G.Y. Installation 3/12/81 (] 2R24 - S029 P.R./R.C. IR 2/11/81
~
2R24 - S030 P.R. Installation Level I 1/15/82 2R24 - S031 P.R. Installation Level I 1/15/82 2R24 - S032 P.R. Installation-Level I 1/15/82 2R24 - S037 P.R./R.C. IR 2/11/81 2R42 - S012 P.R. Maint. Ver. Level I 3/25/82 i 2R42 - S012 Unknown Maint. Ver. 6/01/81 l 2R42 - S013 Unknown Maint. Ver. 6/01/81 2R42 - S013 P.R. Maint. Ver. Level I 3/25/82 2R42 - S013 P.R. Meg. Level I 3/25/82 2R42 - S014 P.R. Meg. Level I 3/25/82 2R42 - S014 Unknown Maint. Ver. 6/01/81 2R42 - S014 P.R. Maint. Ver. Level I 3/25/82 2R42 - S015 Unknown Maint. Ver. 5/29/82 2R43 - S001 A P.R. IR Level I 2/26/82 2R43 - S001 A P.R. Receiving Level I 3/04/82 l 2R72 - S001 P.R. , Installation Level I 11/18/81 2R72 - S002 P.R. Installation Level I 11/19/81 2R72 - S011 M.S. Maint. Ver. Level I 7/09/82 l l 1
- . ATTACHMENT 3 Pag 2 7 of 7
_. (Tc k Fcres #40) EQUIPMENT NO. INSPECTOR TYPE OF INSPECTION DATE 2R72 - S019 M.S. Maint. Ver. Level I 7/08/82 2R72 - S025 M.S. Maint. Ver. Level I 7/09/82 2R72 - S028 M.S. Maint. Ver. Level I 7/08/82 o O 0 . 9 l l l 0
.V.. -
7 Puilman Power Products
- I
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e SECTtoN No. PREPARED Sy, J. E. Miller A,,povgo sy, E. F. Gerwin W- oATE: 11-22-82 Quaufv assumascs ORGANIZATION PAGE 2 of 14 P904Ran go, 1.3.3 Senior Vice President, Diping and .wechanical Graue The Senior Vice President, Piping and .veenanical Group reports to the Executive Vice President of Pullman Power Products. He has the authority and responsibility for administration of all Piping Fabrication and Mechanical Construction lines of business. He delegates authority for administration of Mechanical Con-struction to the Vice President, Mechanical Construction Operations. 8-30-82 1.3.4 Vice President, Quality Assurance The Vice President, Quality As'surance reports to the President. He is responsible for establishing Corporate policies relating y to Quality Assurance and for assuring their effective imple-mentation by the Director of Quality Assurance at various field sites. He shall have overall responsibility for indoctrination
,V and training of all personnel affecting quality, k 1.3.5 Vice President, Mechanical Construction Operations 1
The Vice President, Mechanical" Construction Operations reports to t*.e senior Vice President, Piping and Hechanical Group. He has the authority and responsibility for the administration and execution of all mechanical construction projects. This includes i selection, indoctrination and training of personnel assigned to specific field sites and evaluation of their performance. He l delegates authority for administration at each field site to the Resident Construction Manager. l l 1.3.6 Director of Quality Assurance The Director of Quality Assurance, reports to the Vice President, f Quality Assurance on all technical and functional matters relating to quality assurance. }ie . reports..,a6 1 tni,s trat,ivel.y,,to
- Q Vice President, Piping __and_ Mechanical Group.__
3 . SF 1.06 r3
Pullman Power Products A SECTfoN No. PREPAAEo BY, J. E. Miller lAPPAavEo sy E. F. Gerwin #)7 leATE 11-2?-82 f QUALITY assuR&aCs PAGE Peossam ORGANIZATION so. 6 0F 14 1.3.12 Supervisor of Quality Assurance, QEG The Supervisor of Quality Assurance, OEG reports to the Director of Quality Assurance. He has the authority and responsibility for acministering the quality assurance program and coordinating the activities of the Project QA Engineers Document Control Specialists, clerks and other personnel assigned to the Quality Engineering Group. He shall have responsibility for t5e review of Quality Assurance, Quality Control, Project QA Manuals and Procedures as required By various codes and Customer spectfications. 1.3.13 Resident Construction Manager The Resident Construction Manager reports to the Senior Vice p President Piping and Mechanical, through the Vice President, 2 Mechanical Construction Operations. He has the authority
^
and responsibility for the administration of all required a functions at the field site. This includes selection, indoc-
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C trination and training of personnel, other t5an QA personnel, in cooperation with the Quality Assurance Manager as outlined
%l' in $ection II, Para. 2.5.4, as required to effect a quality g
installation. His compliance with QA requirements are con-trolled as described in 1.3.15. The Resident Construction Manager has the authority to cause any Su6centractor personnel to be removed frcm the site. 1.3.14 Quality Assurance Manager The Quality Assurance Manager reports on all technical and functional matters relating to quality assurance to the Director of Quality Assurance. Je recorts administratively to the Resident Construction Manacer. He is responsible to the Director of Quality Assurance for the effective in.plementation of Quality Assurance and Quality
' Control procedures (as applicable) at the field site to which he is assigned.
8-30-82 He has the authority, responsibility and organizational freedom for implementing Quality Assurance or Quality Control Programs as directed by the Director of Quality Assurance. In cases of conflict in matters
- relating to the function or technical aspects of quality or adminis-tration of Quality Assurance personnel, he may report directly to the President, through the Vice President of
\
Quality Assurance and Director of Quality Assurance. l' - ) . l !- i' ' SF 1.06 l
1 Pullman Power Products
} A I
sEcTicN No. b' PREP AREo BYr d. E. Miller l APP 9avEo BYr E. E. Ge Win' _ N loA Er 11-22-82 ou Au ry AssusAsec ORGANIZATION PAGE ,7 p 3 FROGRAN NO, 1.3. 14 Quality Assurance Manager (Cont'd) Once a Project Quality Assurance Manual is established by virtue of an acceptable ASME site survey, the Quality Assuranca Manager will be responsible for its revision, maintenance, control and distribution. He will. obtain approval for all revisions from the Vice President of Quality Assurance, through the Director of Quality Assurance.
~
He is responsible for the control and distribution on site of the Quality Assurance Procedures established for the job and other duties relative to such procedures as may be de-legated to him by the Director of Quality Assurance. This includes se'lection, indoctrination, training, cualification and certification of QA personnel who may be hired in the field. i
# He cooperates with the Resident Construction Manager by coordin-ating the activities of the QA Cepart=ent in the field with 7
F~ + production activities as necessary to assure the attainment [ji 4 of the desired quality levels. He has the authority, respon-sibility and freedom to identify quality problems and to ( . initiate, recomend or provide solutions and to verify implement-i
~
ation of solutions and control of further processing of any nonconfaming item or condition until proper disposition is made. 1.3.15 Assistant QA Manager i l The Assistant QA Manager reports to the QA Manager. He.is responsible for the implementation of the QA Manager's responsibilities in his absences and other duties as assigned by the QA Manager. 1.3.16 Tra.ining Engineer The Training Engineer reports to the QA Manager. He is responsible for the coordination and administration of all field training. It is the responsibility of the Training Engineer or his representative to conduct training using the various materials and aides made available and to develop additional materials and aides necessary for the implementation of a complete Training Program. Classroom Training shall be-conducted by the Training Engineer or qualified personnel v (< designated by him. On-the-job training may be conducted by
,~ .,
the responsible supervisor. All Training shall be documented. 1.3.17 Field QA Supervisor The Field QA Supervisor reports to the QA Manager. He is responsible for the accumulation, evaluation, ratenticicentrol
^
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e , Pullman Power Products 1
, SECTION NO.
PREPARED BY: J. E. Miller APPROVED BY: E. F. Gerwin N DATE: 11-22-82 QCALITV ASSURANCE PAGE PROGRAM ORGAflIZATI0f4 no. 14 of 14 I _ _ _ l : l
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' Ao k Wy c 0l 'b9 {&3 p COMSTOCK P rry Nuclear PowcrPlant J'
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gx' #e 4g L.K. Comstoc< Engineering Com 3any, Inc. A CoMSToCK GAouP COMPANY a 2 January 19, 1983 Pullman Power Products Perry Nuclear Power Project Perry, Ohio 44081 Attn: Mr. R. Walter, Resident Construction Manager Mr. J. Miller,/ QA Manager
Subject:
Electrical Penetration Weld Documentation CONTROL NUMBER: Q-83-1-71
Dear Sirs:
A review of the electrical penetration weld documentation submitted by Pullman Power Products to L. K. Comstock has generated concerns. Please review the attached list of concerns and provide the corrective action needed to clear said items. Since the electrical penetrations are an NRC concern please submit your response by January 28, 1983. It is also recommended that Pullman Power Products provide a Q. A. ( - individual who is familiar with the L. K. Comstock electrical penetration l packages and the Pullman Power Products Q. A. program to review the concerns l identified. This meeting is requested by January 21, 1983.
= ^ "L R. L. Bower QC Manager, LKCE l
RLB:ecs w/ Attachments cc: T. Woodman - E. Yockey J. Hubbuch D. Fike QC File 1 f P.O. BOX 324, PERRY, OH 44081 l (216) 259-3755 [ f4
- Page 2 CONTROL NO: Q-83-1-71 CONCERN #1 Pullman 1-72R Series Isometric Drawings do not contain the same information as Westinghouse E-40047 and E-40048 Drawings. Pullman's procedures do not call out any additional acceptance l criteria for fitup inspections. Specification 33-4549-00 Para. 5:08/1.4a " Inspect fitup...to assure that the installation and field weld can be accomplished per the requirements as indicated on manufacturer's drawings..."
#2 j ullman and Comstock Procedures state that all welding on the
. electrical penetrations are to be performed per ASME Section a
m *, fT III Div. I 1974, MC Subsection, however Westinghouse Drawings E-40047 and E-40048 state that the penetrations were designed per the 1977 Code (same Section and Division).
#3 Pullman failed to properly identify control and address noncon- -
forming conditions, as .follows_:. _ _ _ - - . -
.- ' A) Pullman did not address any nonconforming condition to theh customer-client (L. K. Comstock) . \
/ / g.g -
The following are nonconformances which were addressed via Q [ another contract not L. K. Comstock Requisition #2329 and Spec. 33g4549-00.
\
/, (689 /
NR #584 & NR #PO 44-204. These NR's address penetrations ' 1 1-R72-S008 and 1-R72-S019. h
\ Pullman QA Manual Section XV Para. 15.2.7 states: "Appro-I
\
priate resolution of nonconformances will be determined by , the Field Engineering Department in conjunction with Quaity Assuranc tomer..." B) " Field Weld Process' Sheet for~ base delal buildup" (Form #19) for' penetration 1-R72-S002 does not establish any of the y parameters which dictated repair to the nozzle. There is no way of evaluating this repair to base metal because of (fjlf. a lack of documentation. N, The Field Weld Process Sheet (Form #19) does not reference g g the base metal buildup document.
- p. - 4 19 U3 PL 4)6/ Specification 709-4549-00 Para. 1:05.14.3 "These conditions dispositioned. . . repair require owner approval.
*A yW .a. (i '
y4/
. Page 3 CONTROL NO: Q-83-1-71 CONCERN #3 C) Pullman's NR #PO 44-204 R-3 does not document the size of indications for 1-R72-S008, as required by Project Organization Engineer.
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#4 Medium voltage penetrations 1-R72-S001 & 1-R72-S002. Two medium voltage electrical penetrations nozzles were welded to containment nozzles per Pullman Power Producta Isometric Drawing LR72-3 Rev. OC and LR72-4 Rev. 0A (respectively). These drawings do not detail f
backing ringscas required.
/
Procedure used by welders, IT12A, does not require backing ring or any of the other methods established by the reference ASME Paragraph to assure full penetration. Soecification 33-4549-00 Para. 5:08.14.C and ASME Section III, Of 6
) Division I, MC Para. NE 4242j(1977), Westinghouse Drawing Spec.
g E-40045. Pullman QA Manual Section III Para. 3.6.1. 9
#5 Pullman's " Fabrication and Installation Specifications for Nuclear Power Plant Components. . . . ASME Section III" (1X-3) Para. 7.9.3
" Reinforcement of butt welds other than ISI allows 3/16" weld p reinforcement when the base metal is an inch or less.
a ASME Section III Div. I, MC (Subsection) (1974 & 1977) Para. NE 4426, pl ' {" allows 3/32" weld reinforcement when the base metal is an inch or less.
\P' ullman Procedure (1X-3) Para. 7.5.1.3 ../
states: " Prior to making the
#6 final' connection to equipment the following conditions must be met:
\
h4S $ 8
" Final fitup hold point. . .is an owner hold point owner acceptance o h aiver must be obtained..."
g&g * - N This hold point was not-applied to the electrical pene-7 (yf p
/ trations.
#7 Pullman Power Products to cut nozzle to proper length, if required, g and prepare and inspect the nozzles for welding in accordance with hQ Reference 1.3 (Westinghouse Manual / Instruction Book) and Drawings B-224-301 & B-274-301.
. #8 Pullman's inspection documentation (Field Weld Process Sheet) does p,p not consistantly establish what procedures and revisions or 4 / criteria was used by Pullman's Inspector's and Craf t.
#9 No ASME Data Report was submitted for the nozzle penetation weld.
,,/ Specification 33-4549-00 does not waive Data Report.
b 1 Y l A Q'&
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It e e Page 4 CONTROL NO: Q-83-1-71 Concern #10 ThereisnoevidencethatFullmanIT12A-III(WeldirhSpecification)' y/ procedure was presented to L. K. Comstock for approval. L. K. l Comstock does not list this procedure on Attachment #4 of Procedure
} 4.3.10.
-l p/ Speicification SP-33-4549-00 Para. 4.06.5 and SP-709-4549-00 Para.
1.04.6.
#11 Improper documentation practices. were found during the review, examples follows:
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Improper changes, see package 1-R72-1, 2, 3, 4, & 5. Weld i I Rod Requisitions.
,-A
/t B) ' Rev sio'nsnumb'e e h of' SIsometric Drawings are not idsnt.ified o iiibpectk docSnents'. Sq,e Form' #,19 's.
l * #12 There is no evidence Pullman completed Form #10 (Final Inspection po Cover Sheet) as required by their QA Manual, Section III, Para. 3.8.
//ff
#13 On electrical penetrations 4, 5, 14, 19, 21, 23 and 26, the fitup and tack was signed off by the Quality Control Inspector before the rod was signed off by the Quality Assurance Process-Specialist frou the Process Sheet / Weld Material Distribution
. Center. (See Attachment A)
[o Pullman Power's Document VIII-3, " Control of Welding Materials (Field)", Para. 6.2 states:
"Each Distribution Center shall be staffed by a Quality Control Sepcialist-Process who shall have total control over all activities involving the distribution and return ',
of welding materials."
#14 heview of Penetrations 1-R72-S003, indicates a base metal buildup performed on 3/30/81. Pullman Power's Document IX-14, Section 3.3,' states:
'j " Base Metal - Repairs which. exceed the lesser of 3/8" or g ,
10% of the'section thickness and cracks shall be documented as a nonconformance. , Welder Repair (i.e. Weld Metal Buildup) of weld edge preparation, which is necessary prior to the issuance of Installation Process Sheets shall be addressed as nonconformances.". Pullman Power has not included a nonconformance in their veld documentation. ' '-
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GOVERNING (INCLUDE ACCEPTANCE 5 REOUIREMEN CRITERI A AND DOC'MT. NOS. ) SP-33-4549-00 PARA. 5:08.1.4 B & C, PARA. 1 5:08. & C. PARA _4_.106.5.1,VESTINGHOUSE DRAWING E40048 AND ASME CODE SEC. III MC(FOR CAT .B) O ESCRIPT IO O NC IRELATE TO 7 NoNCONFORMANCE; y . J CODE LINE NO. 61 CONTRARY TO THE ABOVE DOCUMENTS, WHICH i 0)5l INDICATES USE OF A BACKING RING, MEDIUM VOLTAGE ELECTRICAL PENETRATIONS WERE WELDED USING AN OPEN BUTT WELDING PROCEDURE IT12A (BACKING RING NOT REQUIRED) INSTEAD OF 1T8A (WHICH IS QUALIFIED FOR USE WITH A BACKING RING).
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" CAUSE OF CAUSE . . .
sNONCONFORMANCE CODE -0, 3( 4' DOES NOT MEET SPECIFICATION REQUIREMENTS 9 IS OSIT ON j SCRAD I ?) A7wCRK (2) ; REDAIR (3) . 'USE / S IS ( 41 5 JU STI FIC A fION:
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PNPP R EVIE W "1EO'D. C YES R NO D Ect SION - ACCFAT AF tFt T REVIEW ENGINEER DATE Q A /Q C O_A/ 5 T2 BOARD j:{ }-[
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. . . Q U A L I T Y ' C 011 F 0 llH A N C E REPORT -
y . j LK COMSTOCK DEC N ER 22,_1981 10 CENTER ROAD
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PERRY, OHIO 44081 . kfg
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_ 91710_01-7001
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. TYPICAL CERTIFICATION AIRCO CODE-ARC.7018 MR -
. STOCK NUMBER 1318-7183 . .
ITED TEICHT (L85) SIZE TYPE HEAT Ho.
- LOT 3
2,50 POUNDS , 3/32 , 7018 MR .
, 111-19B5B 2 550 POUNDS' 3/32 .
7018 MR 110-23B5A
's .200 P'dUNDS 3/32- . '7018,MR 110-22B5A __ 'HDflCAL ANAt.TSIS la TYPICAL ELD METAL - ',
To e un P s sl
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** 0.04% 0.65%
0.011% O.013:; 0.55:; . 2 3.04k 0.65%, 0.011% 0.0130 0.55:: 0.011% 0.0130 0.55::
.p . 3.04% - 0.65% .
llECHAMICAL PROPERTIES . TYPICAL V*.LD i METAL.
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lTED TENT lLE P.3.'t.- YIELD P.S.I. 5 EL. 5 R.A. . *0THER
.70,000 58,000 24
' 2 70,000 58,000 24
;'3 70,000 . . 58,000 24
- A 0 6-I-T 10 H A L" T E S T S S
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. =s lgaraandSubscr"0N' e ' 'y$ thi - 24th l'cartilF the chemical snelysis and physical or machenlesl tes t l
reported above meet the specifiestlens en the described material
. *'* Ma y -. - are correct as c ned in the records of the Company, t
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a ha- SED l I Perry Nucl ear Power Pl ant - Uni t 1 and 2 Construction Duality Section Surveillance / Inspection Report (SIR) SHEET,1 OF L. K. Comstock 33/Rev. IV
.. Contractor i /.3b 3
, Spec. No. SIR' Number L. K. Comstock Task Force #29 - Eauirment Th' 1 System / Component Name MPL Number N/A 2/20/83 Location Date C 5:08.1,2,3,5,6,7 6 28 33/Rev. 2 Inspec. Type Area of coverage SIP Number-Rev.
(A. B. C.) (Code No.) DESCRIPTION of SURVEILLANCE /INSPEChEON:.. N Concern #1 There appears to be no standardized method to filline out Form #21, Insulation Resistance / Continuity Test Report. The forms have been altered by the craf t to suit their own in t e rp re t a t i on . Often, the results are indecipherabis. Corrective action documentation - (NRs - ARs - CARS) Heasuring/Inspecti on Tools I.D.: N/A _ _ Remarks: frispector ' y ] x.nY-f hl- Zf21f8b Reviewed - RespU DE Date Approved - Lead DE Date J7 m
r i O Perry Nuclear Powcr Plant - Unit 1 and 2 Construction Duality Section Surveillance / Inspection Report (SIR) Continuation SHEET - OF
. i L_ K_ cnn= rock SP- 11/nov_ Tv 8 /303
. Contractor Spec. No. '
SIR Number l 2.) Trpact on current work: None - corrective action annent en havn honn -
..i e nk en _ # riirche r inprncons nuaire nre renuirna en en = iiro rh n e ernin ng described below has been e f festive.
I 3.) Actions taken/ planned: LKC Procedure 4.3.18 Rev. date 5/06/80. item 3.1.9_ {. addresses a standard method on information that must be indicated in the I filling out of Form #21 (Insulation Resistance / Continuity Test Records) to st'andardize form fill out. LKC craft training was conducted on 8/02/82, 9/23/82, and 10/08/82 (see attached) to assure that LKC craft performing Megger/ Continuity Test understand proce'dcre s requirements. In addition, a rec'ord check '.;y CQS was performed on eight (8) Form #21'~s,(see attached) _ to verify the effectiveness of the training, the results of the trainine _ and CQS check were found to be acceptab1'e. As a result of the LKC Task Force concern LCK QC issued IR #5407 (see .
' ~
attached) which addresses the review and assessment of -all previous D Form #21's for acceptability to procedure requirements and the initistkn_ of NR's where required, This SIR will. remain open until all IR Corrective _ _ Action is complete and evaluated by CQS. . - 4.) List of Attachments: Attachment #1 - IR #5407 Attachment #2 - LKC Procedure 4.3.18 rev. 5/06/80, item 3.1.9 Attachment #3 - LKC craf t training documentation . i Attachment #4 - Form #21 (Records check) - k kb o n)$ Cr gm nkd o n (*qu a y g h f-$,* - 64(P . f
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QA/0C SECT O INF0lIMATl3N ONLY - L 3.1.7.3 ch= meter-resistancelessthan100 Ohms. ' 3.1.7.4 Phone - clearly audible co=munication established. 3.1.7.5 Megger - needle shall deflect sharply toward low resistance end of scale upon discharging of conductor to ground. 3.1.8 Automated test equipment, designed to perform required functions, may be used in lieu of =anual testing, provided that the machine is in current calibration and performs , a self-check of its functions. Use of. automated equipment shall require PROJECT approval prior to application.
. s 3.1.9 A record shall be made and kept for all tests governed by this procedure. The record must indicate the following:
(Use Form #21, Attached). 3.1.9.1 Identification and location of the unit of cable under test. 6 3.1.9.2 Identification of persons performing the test, q .. and date test was performed.
- s 3.1,9.3 Test Equipment used, by serial number or ,iden-tification number, and associated calibration due date(s).
3.1.9.4 Test conditions and/or procedure used. (i.e. megger voltage, etc.). . 3.1.9.5 Te=perature and relative humidity (ambient), thermometer used and calibration due date.
, 3.1.9.6 Test measurements obtained, with units identified (i.e. ohms, megohms, etc.).
~
3.1.9.7 Acceptability of tests, either by conformance to. specified requirements, or within acceptance limits ** of this procedure. (QC Inspector).
,3.1.9.8 Identification of inspector witnessing or verifying the test. (If applicable).
~-
3.1.9.9 Reference to corrective action documents, if applicable. 3.1.9.10 Remarks, as necessary to explain methods, identify retesti, or note peculiar conditions or circumstances g j related to the test. t PREPARED APPROVED R EvaSED T4TLE . o RIG. o ATE REV.oATE PAGE ROM RPR TWP PROCEDURE 3/13/79 5/6/80 3
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1 K.COMSTOCK & COMPANY,INC. PERRY NUCII.AR P0kTR PLANT 4.I1.1 i; Sh QA/OC SECT (l s ll INSPECTION REPORT NO. $ Y O 7 LOCATION DA[E /6/F3
#a"/f- oc aa INSnCTOR h 1 j REQUIREMENT AND
REFERENCES:
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i RESi'ONSE DATE AUTHOR ATTACHMENT e'
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DISPOSITION: ACCEPTABLE UNACCEPTABLE Signature Date COMMENTS: s I 1 PREPA RED APPROVED REVI M TITLE O R t G. D ATE REV.DATE PAGE i - RSL PRM TWP PROCEDURE
-7/14/80 4/28/82 FORM #118 c .
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1.[ . ij 6 ci i t. A8 k cousTocx Perry Nuclear Power Plant
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LK. Comstoc ( Engineering Company, Inc.
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s A COMStoCK group COMPANY
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August 12, 1982 L. K. Comstock Co. - P. O. Box 97 -~
- Perry, Ohio 440o1 - 1 _
J . . '- - 1 s __ T. J. Woodman Attention: -' Project Manager .- a
;..q . ;
Control Nor i
Dear Tom:
' 5
Craft has been using the infinity symbol ( C>C) extensively. The 3 Procedure states that the reading should be in ohms, megohns, etc. ~ 3.1 , Procedurc 4.3.18, Meggering and Cont'inuity Testing, paragraph 3.1.9 d ( statesi "A record shall be made and kept for all tests governed by I this procedure.. The record must indicate the following: (Use Form #21, Attached)". .
. m ['
" Test measurements obtained, with units identified (i.e. ohms, meghoma, etc.)." .
Please have the Craft record the last full scale nu=erical reading and ,,',- if the needle goes beyond this point record a plus (+) sign for example " - ' - ' 200+. megohms.
. ~. , . . . . g Sincerelyg '. , ,
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( 3 . W. i-Farry G. Seese LGS:ect -
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(TITLE) (DATE) ,(TIME) 1 i TOPICS COVERED INCLUDEr (INSTRUCTOR MAY ATTACH OUTLINE OR. COURSE MATERIALS l
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QA/QC SECQ INSULATION RESISTANCE /C0hu:<ulu TEST REPORT / c .r/ c 2 12.8 8 l TEST rnoCEacRE aEF: K 3. / 8 SYSTEM A/A @fE #
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EQUIPENT BEING TESTU) TEST INSTRUMENT TEST PE2 FORMED BT: Nan E TB -19 NAE AR *YJlo MoDEL/CI. ASS NM SERIAL # LKC G - 2 2/ f 2. 2. 6 VOLTAGE 600 RANGE USED ['f f1_ A[A SIRIAL i A//) VOTEA & APPLIED ,fo O DATZ: ) 2, Zo 82. LOCATION * # f2Bg39 CAL. Duz nATE 2. 2.3 83 INSTarxENT # Lfc 6-No Cit DET suLa 4v.- F; WET suLa f7 F; REL. HUMIDnT 9'7 DUE DA~E b S 83 CABLE f/CIIC 2228 cusrauAu gg , E ccEE TEST CCND. l I NO. COLOR PASS FAIL [d-CR EED-CE WHT-GR HLI-CR EED-WH"*i.~d!-3IISLE-RED Loor 1 BK / nx 2 2.o o t-ggj - f gjg, t - 2,a o e B 3 R . / H Jt. 4 loor , c C, / nit ( 5 k - 6 rn - r. _,,_, ._ -
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ILLUMINATl.lG COPSAW ~ g v. o. No. P - 1600 'Z FERiW Nf tm = n o r:~ ~*~m . 9 o PLANT . UNIT l 10 . Cuata uATION SHEET _ CCNTINUITT ME30D. P6e, Co%m iCucN, a ITMAYES: k 6 W O R N k 2. 6 O 2.7 LKc. '/</6 8 4/M p)P # /Dit . ACCEPTANCE STATDfENT: ABOVE-LISTED VALUES FALL WI3IN ACCEPTANCE LIETS. Q _ . . _ oC plSFECToa pm E'A m ED APPmOV ED mEVI / bW TITLE Omlu.DATE DATE [ Z Z- h4-' REV.DATE PAGE ~ ECM 'IFE I-F PROCEDURE 8/16/79 5/6/80 TOEM #21 , 6
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[ TEST PROCEDURE REF: Y
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EED l l Perry Nucl ear Power Pl ant - Uni t 1 and 2 Construction Duality Section ' Surveill ance/ Inspection Report (SIR) SHEET,1 OF 3
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L. K. COMSTOCK 33/ IV SE - /3M Contractor Spec. No. SIR Number
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LKC TASK FORCE # TF - 29 (Item #4) - Equipment TF 4 System / Component Name MPL Number N/A 2/21/83 Location Date "C" 5:08.1,2,3,5,6,7, & 28 33/Rev2 Inspec. Type Area of coverage SIP Number-Rev. (A. B. C.) (Code No.) s DESCRIPTION of SURVEILLANCE / INSPECTION: LKC TASK FORCE ITEM: 4 It appears that a large number of Material Receiving Reports have been lost. It also appears that .an attempt has been made to redocument the Receipt Inspection without any back-up information. N/A ' Corrective action documentation - (NRs - ARs - CARS) Measuring / Inspection Tools I .D. : N/A
- . .. Remarks: '
Ins'pector W p f %KCnY t} J BfMl65 RYvi ewed - Redd. DE Date Approved - Lead DE Date f }'
- Perry Nuclear Pocr Plant - Uni t 1 and 2 .
Construction Quality Section Surveillance / Inspection Report (SIR) Continuation SHEET 2: OF 3
.. - g L. K. Comstock SP- 33/ IV Contractor SE -- /M 3
- Spec. No. SIR Number IMPACT ON CURRENT WORK: None "
ACTIONS TAKEN/ PLANNED: Missing Material Receiving Reports (form # 39A's) do not impact current field activities. The initial receipt inspection of equipment is performed by the Site warehouse receipt inspectors when the equipment is phycically placed at the Perry Plant from the Vendor Supplier. All necessary receipt inspections are performed and documented by the Site Warehouse Personnel such as: shipping and handling damage, quantity, description of equipment, identification, applicable maintenance requirements, etc. At the time of equipment jurisdictional transfer to the respective contractors, a Site Organization warehouse issue ticket (form
# 62) is completed and signed by CQS receipt inspection. When L. K. Comstock receives safety-related equipment from Site warehouse another receipt inspection is performed (by LKC QC) and documented on a form 39A.
LKC has transferred the filing of Material Receiving Reports to the QC Records trailer. This provides for file maintenance and restricted access to the records. This will ensure that these forms are controlled and not misplaced. This Task Force Concern is specifically regarding the equipment received from the Owner - form 39A. LKC has reviewed and evaluated this Task Force Concern and has issued IR # 5410 (attached) to address the problem. This SIR'will remain open until IR # 5410 is closed. After CQS acceptance of IR # 5410 this SIR will be closed. m I ATT CHMENTS:
# 1 - LKC IR # 5410 issued to track TF-29, item # 4 .
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, Perry Nuclear Power' Plant - Unit 1 and 2 Construction Quality Section Surveillance / Inspection Report (SIR) SHEET 1 OF Al' L. K. Comstock Sp 33 Rev IV 5C / 3 iP3 Contractor Spec. No. SIR Number LKC Task Force # 26 - Penetration 3 TF 26-1 System / Component Name MPL Number N/A 2-24-83 1
Location Date C 5:08.1 33 Rev II Inspec. Type Area of coverage SIP Number-Rev. (A. B. C.) (Code No.) DESCRIPTION of SURV5ILLANCE/ INSPECTION: LKC Task Force Item: Al See Attachment 2 Paces urv Tyr Tu mios i I l i e I .' i-N/A t; Corrective action documentation - (NRs - ARs - CARS) l , Measuring / Inspection Tools I.D.: N/A 6 Remarks: See Attached [ i 6 Q{_ f1/ p .17-F3 f Y 4 jgv[; ZfS1f6b InspeMor Rd' viewed - Res# QE Date Approved - Lead QE Date 59
Parry Nuclear Power Flent - Unit 1 and 2 Construction Quality Section l Surveillance / Inspection Report (SIR) Continuation . , SHEET 4 - OF 4 I LK COMSTOCK 33 ' g p_. 5 E -13 &3 Contractor Spec. No. SIR Number-IMPACTONCURRENTWORK-N/A ACTIONS TAKEN/PIANNED A. This concern was a misinterpretation by the Task Force of the Pullman Power Products Program. Attached is the Pullman letter dated July 19, 1982, address-ing this concern. The letter states that the date by the QA approval on form 7026-102 is for the date the rod is returned. This date should be regarded as being part of the " return" column and not the row showing QA approval. B. The Pullman letter also addresses this concern. At the time of the Task Force Review the field weld process sheets were for "information only". The information is filled in during final QA Review. ATTACHMEFIS
#1 LKC IR 5195 1 page
#2 Pullman letter dated July 19, 1982 2 pages
#3 7 pages weld rod storage requisition forms
#4 7 pages PF. field weld process sheets -
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Perry Nuclear Power Plant - Unit 1 and 2 .b Construction Duality Section Surveillance / Inspection Report (SIR) SHEET,1 OF i L..K. COMSTOCK -SP-33, Rev. IV
' st; n2r Contractor . Spec. No. SIR Number 3 mgG LKC TASK FORCE #26 - Penetrations TF-26-f a. 26-0 System / Component Name MPL Number N/A 2/24/83 Location Date C 5:08.1 33 Rev. 2 Inspec. Type Area of coverage SIP Number-Rev.
(A. B. C.-) (Code No.) DESCRIPTION of ..SURVkILLANCE/ INSPECTION: LKC Task Force. Item #3 - SPEC 33-4549-00, Page V23, Section 5:08.1, Paragragh 4C states: 4.0 "Before welding, the contractor shall': 4C Attach backing ring to nozzle for attachment." There is no evidence that a backing ring was installed or that the step was deleted. Pullman Power does not indicate a backing ring was installed. Westinghouse Specification Drawing E-40048 indicates a backing ring to be installed on the two 18" penetrations. (See Attachment C) I-i l Corrective action documentation - (NRs - ARs - CARS) N/A Measuring / Inspection Tools I.D'.: N/A j - Remarks: - ir , See Attached WL A &h ' 2-n-n 7 d.dtisk- 2/nlas
- Inspect M hevi ewed - Redp. OE ' Da t'e r .
SO [ . , , , Spproved - AmM QE Date
Perry Nuclear Powcr Plant - Uni t 1 and 2 Construction Quality Section Surveillance / Inspection Report (SIR) Continuation SHEET 2. OF 7
. . . . .i L. K. COMSTOCK SP- 33 - SE 1385 .
. Contractor Spec. No. SIR Number IMPACT ON CURRENT WORK: ..
Yes, see stop work - LKC SWN-ll dated 2/17/83 attached that addressed Unit 2 medium voltage penetrations. ACTION TAKEN/PLAITHED: NR# LKC 1769 was generated to document this nonconformance for Unit 1 penetration already installed. A stop work was issued until acceptable resolution of NR LKC 1769 ATTACHIEN'IS
#1 LKC IR 5198, 1 page
#2 NR # LKC 1769 , 2 pages
#3 LKC Stop Work Notice # 11 dated 2/17/83,1 page
#14 Westinghouse drawing for the penetration,1 page en a
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r-Perry Nucl ear Power Pl ant - Unit 1 and 2 5 Construction Quality Section Surveillance / Inspection Report (SIR) SHEET,1 OF (o L.'K. COMSTOCK s P- 3 3 //2 rv. I V 6 - 13 PQ Contractor . Spec. No. SIR Number L. K. COMSTOCK TASK FORCE #26 - Penetrations TF 26-4 System / Component Name MPL Number N/A 2/24/83 Location Date C 5:08.1 3 3 erv. TI Inspec. Type Area of coverage SIP Number-Rev. (A. B. C.) (Code No.) DESCRIPTION of.SURVNILLANCE/ INSPECTION: LKC TASK FORCE ITEM #4 - There is no documentation to add Penetration 1R72-S029. SP-33-4549-00, Section 5:08.1, specifies the installation of two (2) 18-inch penetrations and t'wenty-six (26) 12-inch penetrations, per unit. The Equipment and Material F.B.O. list specifies a total of 28 penetrations. Additionally, GAI Drawing D-215-443, Rev. J, addresses 35 Penetrations. Again, the proper documentation does not exist to add these additional penetrations. i L I Corrective action documentation - (NRs - ARs - CARS) N/A Measuring / Inspection Tools I.D-s N/A
- Remarks: -
See attached ( [ f .2 .27-9.3 761m Me k27/6S Inspecie(r '#' Reviewed - Respf DE 'Date Approved - Lead OE Date 4/
Perry Nuclear Power Plant - Unit 1 and 2 Construction Quality Section ' Survei ll anc e/ Inspec t i on Report (SIR) Continuation SHEET 1 0F i
. L. K. COMSTOCK SP-33 _ ( (_ -- / 3 PG
_ Contractor Spec. No. SIR Number W R*., .g3 tse REF: . lek IR 5200 TF-26 CONCERN 84 IMPACT ON CURBENT WORK: N/A ACTION TAKEN/ PLANNED: ECN 9252-33-2035 dated 8/11/82 was issued adding equipment to the material section 5:05 os SP-33. IR 72S029 was added to SP-33 on the above-mentioned ECN. AYTACHMENTS: Excerpt from: II) LKC IR 5200
#2) ECN 9252-33-2035, 2 pages O
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' i' i i P.O. box 97 m P ERRY oHlo 44081 5 TEL EPHoN E (216) 259 3737 s ADDRESS-10 CENTER Ro AD Serving The Best Location in the Nat ion PERRY NUCLEAR POWER PLANT March 3, 1983 PY-S/ CON 5820QA L. K. Comstock 10 Center Road Perry, Ohio 44081 Attention: Mr. R. Bower RE: Installation of Electrical Penetrations Dear Dick; CQS is instituting a mandatory hold point on the welding of Unit 2 electrical penetrations per LKC procedure 4.3.10, " Installation of Electrical Penetrations". CQS shall be notified 24 hours prior to the start of this activity.
Your attention to this matter is appreciated. Sincerely,
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. 4/04/83 ACTION REQUESTS (PROGRAM E7887558) PAGE 113 CONSTRUCTION AUDIT AR'S - ALL AAR'S BY RESPONSIBLE ORG.
FILE RESP AUDIT AR APPEND 8 CAUSE LEAD ISSUE RESPONSE DUE RESPONSE COMPLETION ACC/REJ VERIFY ITEM NUM8ER ORG. NUMBER NUMBER CRITERIA CODE AUDITOR DATE DATE DATE DUE DATE DATE DATE COUNT 3017031 PPP 044 0505 0001 17 000 MAB 3/24/81 3/24/81 3/24/81 3017031 PPP 044 0506 0001 08 000 GFP 3/13/81 3/27/81 3/25/81 4/02/81 4/02/81 I 3017031 PPP 044 0513 0001 08 000 EFP 3/23/81 4/07/81 4/04/81 1/13/82 t/13/82 i METHOD OF IDENT. ROD LENGHTS NO IDENT. IN PROCEDURE ' g 4017031 PPP 044 0513 0002 05 000 EFP 3/23/81 4/07/81 4/04/81 t/13/82 t/13/82 PROC. DOES NOT ADDRESS THAT CONCRETE UNDER PIPE SUPPORT BASE BE CLIPPED g[4et1707tNPPP 044 0513 0003 05 000 EFP 3/23/89 4/07/81 4/04/81 t/13/82 t/13/82 I PROCEDURE DOES NOT ADDRESS FORMING OF VASE PLATES FOR GROUTING i 3017031 PPP 044 0518 0001 09 000 MAS 4/17/88 5/06/81 4/29/81 10/06/82 10/06/82
- WELD MONITORING REPORT RECORDED OUTSIDE PARAMETER BY 35 AMPS l '
3017031 PPP 044 0518 0002 09 000 MAB 4/17/81 5/06/81 4/29/81 5/04/81 5/04/81 l , 3017031 PPP 044 0518 0003 12 000 MAB 4/17/81 5/06/81 4/29/81 5/04/81 5/04/81 i I l 3017031 PPP 044 0518 0004 09 000 MAB 4/17/81 4/17/81 4/17/81 g ED5ZETE3h PPP 044 0518 0005 09 000 MAB 4/17/81 5/06/81 4/29/81 1/27/82 4/05/82 PROCEDURE DOES NOT ADDRESS IN-PROCESS REPAIRS Q GCSEED7Kk PPP 044 0518 0006 10 000 MAB 4/17/81 5/06/81 4/29/81 10/06/82 10/06/82
. PROCEDURE Vt-5 DOES NOT REFERANCE PROCEDURE x-st g gdMtdD57t-ARP 044 0518 0007 10 000 MAB 4/17/81 5/06/88 4/29/81 10/06/82 10/06/82 s PROCEDURE DOES NOT ADDRESS WHAT CONSTITUTES AND NR WHEN HOLD-POINTS ARE VIOLATED l
3017031 PPP 044 0518 0008 13 000 MAB 4/17/81 4/17/81 4/17/81 3017031 PPP 044' 0518 0009 08 000 MAB 4/17/88 4/17/81 4/17/8 t" 3017031 PPP 044 0528 0001 15 000 MAB 5/22/81 6/22/81 6/29/81 3/04/82 3/04sJ2 PULLMAN'S HOLD TAG LOG NOT BEING PROPERLY MAINTAINED 3017031 PPP 044 0542 0001 09 000 GEG 6/22/81 6/22/81 6/22/81 3017031 PPP 044 0543 0001 16 000 RH G/19/81 7/03/81 6/23/8t 6/23/81 2/0G/82 COULD NOT PROVIDE DOCUMENTATION FOR VERIFING NR PPP 4G3 AND 468 I i
1 . 4/04/83 ACTION REOUESTS (PROGRAM E7887558) PAGE 114 CONSTRUCTION AUDIT AR'S - ALL AAR'S BY RESPONSIllLE ORG.
- FILE RESP AUDIT AR APPEND 8 CAUSE LEAD ISSUE NUMBER ORG. RESPONSE OUE RESPONSE COMPLETION ACC/REJ VERIFY ITEM HUMBER NUMBER CRITERIA CODE AUDITOR DATE DATE DATE DUE DATE DATE DATE COUNT 301703t PPP 044 0543 0002 17 000 RH G/19/81 7/03/81 6/23/81 6/23/89 6/23/89 apesFUTIEPPP 044 055G Ooot 04 000 s
RH 8/t4/81 9/01/81 8/31/81 10/19/81 10/19/88 P.O.7690-531 DID NOT REFERENCE 10CFR21 AS REQUIRED. 3017031 PPP 044 0556 0002 10 000 RH 8/14/81 9/01/81 8/31/91 10/t9/81 10/19/81 NO SIGNATURE ON EVE EXAM FORM DATED 5-29-81. NAME PEELER !$ PRINTED. 3017031 PPP 044 0556 0003 09 000 RH 8/14/81 9/01/81 12/10/81 s A 11/t5/82 11/15/82 ! INCORRECT AMPERAGE DURING WELOING OPERA-TION BY WELDER DU. 4 g agWuzuJi=PPP 044 0556 0004 09 000 RH 8/14/81 9/01/81 12/10/89 A 11/t5/82 11/15/82 WELDERS NOT FAMILIAR WITH PROCEDURE REOUIREMENTS FOR AMP SETTINGS. i j 3017031 PPP 044 0556 0005 18 000 RH 8/14/81 9/01/81 8/31/81 10/19/81 10/19/81 NO BACK UP DOCU. TO SHOW HOW VERIFI.0F COR. ACT. WAS DONE TO CLOSE OUT AR'S l 3017031 PPP 044 0556 0006 13 000 RH 8/14/81 1/04/82 NO OBJECTIVE EVIDENCE OF OUALIFICATION FOR OPERATORS OF CRANES. j 3017031 PPP 044 0556 0007 06 000 RH 8/94/81 9/01/81 8/31/81 12/10/81 12/10/81 ] INITIALS IN LIEU OF SIGNATURE USED ON SEVERAL DOCUMENTS. t
- 3017031 PPP 044 0556 0008 17 000 RH 8/14/81 8/31/81
! 9/11/84 9/11/81 1
NOTED SEVERAL CASES WHERE WHITE OUT WAS USED TO CHANGE DCCUMENTS. 3017031 PPP 044 0589 0001 09 000 TLC 9/23/88 10/01/81 10/05/81 10/09/81 10/09/84 NO WELDERS SYMBOLS OR FW e5 ON FOLL. HNGRS. 1G4tH310 & H363 & 1E12H244 301703t PPP 044 0589 0002 02 000 LFV 9/23/81 10/01/89 10/05/88 10/t2/81 10/14/81 NO INDOCTRINATION & TRAINING FOR CRAFT PERSONNEL FOR USE OF GROUT 3017031 PPP 044 0589 0003 05 000 TLC 9/23/81 10/01/81 10/05/81 10/09/81 10/09/81 ECN 307 REFERENCED TO WRONG HANGER i h 8QR037DCQ PPP 044 0589 0004 05 000 TLC 9/23/81 10/01/81 10/05/81
- t/05/82 t/05/82 PPP DOESN'T ADDRESS IN THEIR PROCEDURE METHOD OF GROUTING HOLES 3017031 PPP 044 'O589 0005 09 000 LFY 9/23/81 10/01/86 10/05/81 10/12/81 10/20 81 PROCESS SHEET ,WELO pt ,HANGR. DRW.1G41H310 CALL FOR IT-11. ROD ISSUED FOR IT-8A 3017031 PPP 044 0589 0006 05 000 LFY 9/23/81 10/09/81 10/05/89 t/14/82 t/14/82 GAP BETWEEN LUGS & SMALL BORE LINE IS TOO LARGE ---HANGER DRAWING IP47HtO35 f 3017031 PPP 044 0589 0007 08 000 TLC 9/23/81 10/01/81 10/05/81 10/09/81 10/09/81 1P47H1035--PIPE ATTACH. LUGS HAVE MARKINGS WHICH DON'T COMPLY WITH PROCEDURE 3017031 PPP 0'44 0589 0008 07 000 LFY 9/23/81 10/01/81 10/05/81 1/14/82 t/t4/82 GENERIC PROBLEM OF LISTING " ITEM" NUMBER. NOT "PC. MARK 04 HEAT NUMBER"
.~. __. .-. _ _ . . _ _ _ _ .. . _ . . . . _ . . f- . . . 4/04/83 ACTION REOUESTS (PROGRAM E7887558) PAGE tt5
( CONSTRUCTION AUDIT AR'S - ALL AAR'S 8V RESPONSIBLE ORG. FILE RESP AUDIT AR APPEND 8 CAUSE LEAD ISSUE RESPONSE DUE RESPONSE COMPLET!ON ACC/ red VERIFY NUMBER ORG. ITEM . NUMBER NUMBER CRITERIA CODE AUDITOR DATE DATE DATE DUE DATE DATE DATE COUNT gggggg231LPPP 044 0589 0009 05 000 TLC 9/23/81 10/01/81 10/05/81 10/09/81 10/09/81 F DIREC. FOR DRILL. 12 HOLE
S. PROCEDURE
GIVES PERMISSION FOR 2 HOLES , 3017031 PPP 044 0589 0010 05 000 LFY 9/23/81 10/01/81 10/65/81 10/13/81 10/13/81 ! + PPP INSP. GAVE TOLERANCE OF 1/16 OR t/320N ORILLING OF HOLES--INSTALL. OF H/8LT + 3017031 PPP 044 0589 0011 09 000 TLC 9/23/81 9/24/81 FW a5 1.2,3,6 ON HNGR. DETAIL 1G41N192 2 WELDED W/0UT WELD SYMBOLS ON DETAIL , i 3017031 PPP 044 0590 COO 2 08 000 CdF 10/02/81 10/05/81 ! CONCERNS ON IDENTIFICATION & CONTROL OF MATERIALS, PARTS & COMPONENTS *j 3017031 PPP 044 0590 0001 08 000 CdF 10/02/81 10/16/81 10/19/81 1/06/82 t/OG/82 SEVERAL VIOLATIONS IDENTIFIED DURING AUDIT a590 3017031 PPP 044 0602 COO 2 09 000 CdF 10/28/81 10/28/81 10/28/81 FIVE VOILATIONS WERE NOTED DURING AUO!T ALL RELATED TO ROOS IN SOME WAY ' i 3017031 PPP 044 0602 0001 09 000 CdF 10/28/81 11/13/81 11/30/81 12/04/81 12/04/81 TOUR VOILATIONS WERE NOTED DURING AUDIT ALL FOUR WERE RELATED WITH ROD CANS 3017031 PPP 044 0630 0001 05 000 MA8 12/04/81 t/18/82 12/28/81 2/08/82 2/08/82 ' NR #360 WAS WRITTEN BECAUSE OF A MISSED HOLD POINT ! 3017031 PPP 044 0630 0002 15 000 MAB 12/04/81 12/19/81 12/28/81 1/06/82 t/06/82 NR #718 WAS WRITTEN TO DOCUMENT A SPOOL LOST DURING STORAGE 3017031 PPP 044 0630 0003 15 000 MA8 .12/04/81 1/18/82 12/28/81 2/08/82 2/OS/82 NR #391 WAS WRITTEN TO 00CUMENT THAT TWOVALVES WERE INSTALLED IN WRONG LOCATION 3017031 PPP 044 0630 0004 10 000 MAB 12/04/81 t/18/82 12/28/81 2/08/82 2/08/82 NR a619 WAS WRITTEN TO DOCUMENT A MISSEDHOLD P0lNT FOR FITUP AND TACK 3017031 PPP 044 0630 0005 15 000 MA8 12/04/81 12/19/81 12/28/89 1/06/82 t/OG/82 VARIOUS DEFICIENCIES ON SAND 8LAST OPERATION ON THE R45 YARD SYSTEM PIPING t 3017031 PPP 044 0630 0006 15 000 MAS 12/04/81 1/18/82 12/28/81 2/08/82 2/03/82 PPP'S SYSTEM FOR NR CLOSE-0UT ODES MOT PROVIDE FOR POSITIVE VERIFICA TION j , v sz517071bPPP 044 0655 0001 02 000 PGD 7/09/82 8/09/82 7/12/82 8/09/82 9/30/82 PPP'S OA PROGRAM FAILS TO IDENTIFY PERSONNEL QUALIF.TO PERFORM INSPEC. & TESTS 6 3017031 PPP 044 0655 0002 10 000 PGD 7/09/82 8/09/82 8/04/82 9/07/82 9/07/82 HANGER FIELD _ WELD-1 TO EXISTING STEEL NOT FIT-UP INSPECTED 3017031 PPP 044 0655 0003 14 000 PGD 7/09/82 8/09/82 8/04/82 A 8/06/82 10/21/82 H4NGERS NOT BEEN HYDRO / PNEUMATIC TESTED 3017031 PPP 044 0666 0001 05 000 RWM 3/15/82 4/16/82 6/23/82 9/14/82 9/15/82 CONTRACTORS FIELD PROCESS SHEETS DID NOTCONTAIN APPLICABLE OC SIGNATURES
. l 4/04/83 ACTION REQUESTS IPROGRAM E7887558) PAGE 116 i CONSTRUCTION AUDIT AR'S - ALL AAR'S BY RESPONSI3LE ORG.
FILE RESP AUDIT AR APPEND B CAUSE LEAD ISSUE RESPONSE DUE RESPONSE COMPLIETION ACC/REJ VERIFY NUMBER ORG. ITEM NUMBER NUMBER CRITERIA CODE AUDITOR DATE DATE DATE DUE DATE DATE DATE COUNT 3017031 PPP 044 0666 0002 07 000 BET 3/15/82 4/16/82 6/23/82 6/28/82 6/28/82 NO EVIDENCE OF OWNER APPROVAL OF HE TYPEOF CURING COMPOUND BEING USED 3017031 PPP 044 0666 0003 05 000 BET 3/15/8; 4/*16/82 6/23/82 6/28/82 6/28/82 CONTRACTOR IS NOT INCREASING OR DECREA3;i43 THE AMOUNT C7 WATER IN GROUT 4 3017031 PPP 044 0666 0004 07 000 BET 3/15/82 4/16/82 6/23/82 6/28/82 9/28/82 VARIOUS PROBLEMS OF HE CURING COMPOUND IN THE FIELD TO THE QUALITY RECORDS , N IE3E503Dg PPP 044 0660 0001 10 000 PGD 3/26/82 4/23/82 4/22/82 4/22/82 10/08/82 PROCEDURE IX-6 DOES NOT ADDRESS VARIOUS PROBLEMS 3017031 PPP 044 0682 0001 05 000 TLC 4/14/82 5/14/82 4/23/82 4/30/82 6/02/82 PPP HAS BEEN USING RED VERIFIC4 TION STICKER TO SHOW WELD MACHINE AMPS. d Ct5EZEEZI3kPPP 044 0682 0002 05 000 TLC 4/14/82 5/14/82 4/23/82 4/30/82 6/02/82 b PROCEDURE DOES NOT ADDRESS WHERE AMP ANOVOLT OUTPUT WILL BE TAKEN !
\ g35Q335g3 PPP 044 0682 0003 03 000 TLC 4/14/82 5/14/82 4/23/82 4/30/82 6/02/82 OA MANAGER IS REVIEWING WELD MONITORING REPORTS PROCEDURE STATES OA SUPER. DOES 4
3017031 PPP 044 0682 0004 05 000 TLC 4/14/82 5/14/82 4/23/82 4/30/82 6/02/82
- NO EVIDENCE THAT OA MAN. REVIEWS WELD MONITORING REPORT WITH OA SUPERVISOR l 3017031 PPP 044 0682 0005 05 000 TLC 4/14/82 5/14/82 4/23/82 4/30/82 6/02/82 4
WELD MONITORING REPORTS FOUND TO BE INCOMPLETE = 3017031 PPP 044 0686 COO 2 12 000 CEE 5/13/82 5/20/82 TOROUE WRENCHES & PRESSURE GAUGES REMOVED FROM SERVICE WITHOUT DISPOSITION l 3017031 PPP 044 0686 COOS 12 000 CEE 5/20/82 5/20/82 CALIBRATION OF TOROUE WRENCHES & PRESSURE RELIEF VALVES. ETC. 3017031 PPP 044 0686 0003 12 000 CEE 5,13/82 5/27/82 6/03/82 6/07/82 6/07/82 CALIBRATION RECORDS FOR PRESSURE GAUGES SHOW MORE THAN ONE MANUFACTURER amm2r0371kPPP 044 0686 0004 12 000 CEE 5/13/02 5/27/82 6/03/82 6/07/82 6/07/82 NO PROGRAM FOR
- LIMITED USE EOUIPMENT*
j 3017031 PPP 044' 0694 COO 1 06 000 PGD 5/05/82 5/05/8'd' i PPP'S DOC. CONTROL SV5. CONTAINED VENDOR DRAWINGS OF LATER REV. THAN SITE ORGANIZ.
) ECHTPE6IlEDPP 044 0694 COO 2 06 000 PGD 5/05/82 5/05/82 ; DRAWINGS STAMPED " UNCONTROLLED "WHICH ARE NOT ADDRESSED IN CONTR.OA PROGRAM 3017031 PPP 044 0695 COOL 13 000 PGD 5/25/82 G/02/82 MAINT. FOR OWNER SUPPLIED ITEtiS PERFORMED BY OWNER WHILE ITEMS WITH CONTRACTOR 3017031 PPP 044 0695 COO 4 10 000 PGD 5/25/82 6/02/82 NO EVIDENCE PROVIDED FOR OC MONITORING OF TRANSFER OF TRACEABILITY MARKINGS
. s
, e .
- O/04/83 ACTION REOUESTS (PROGRAM E7887558)
PAGE 147 CONSTRUCTION AUDIT AR*S - ALL AAR*S BY RESPONSIBLE ORG. FILE RESP AUDIT AR APPEND 8 CAUSE LEAD ISSUE
, NUMBER ORG. RESPONSE OUE RESPONSE COMPLETION ACC/ red vtRIFY ITEM NUMBER NUM8ER CRITERIA CODE AUDITOR DATE DATE DATE DUE DATE DATE DATE COUNT y E2EQ2DQD&PPP 044 OG95 0002 to 000 PGD 5/25/82 7/28/82 9/01/82 9/07/82 9/07/82
-CONTRACTOR'S AO PROCEDURE (E.G.,XII-5 AND XIII-9) INCOMPLETE 3017031 PPP 044 0695 0003 05 000 PCO 5/25/82 G/08/82 6/09/82 G/tt/82 9/08/82 VALVES REQUISITIONED 11/13/80 USING THE " MATERIAL / COMPONENT REQUISITION
- V E2q2fg6jgPPP 044 0695 0005 05 000 PGD 5/25/82 G/08/82 6/09/82 G/11/82 sPPP PROCEDURE XIII-4, PARAGRAPH G.1.2, 15 UNCLEAR G/11/82 4
3017031 PPP 044 0701 0001 08 000 LdE 5/12/82 5/27/82 5/24/82 G/04/82 7/21/82 DEFICIENCIES ON TRACEABILITY OF HEAT NUMBERS ECEEED77I"$PP 044 0703 CO25 OG 000 JMP 7/08/82 7/08/82 PROCEDURE VI-4 IS IMCOMPLETE IN REGARDS TO RETENTION & STAMPING OF ORAWINGS 3017031 PPP 044 0703 CO26 03 000 dMP 7/08/82 7/08/82 SEVEN TRANSMITTALS TOOK LONGER THAN THREE WORKING DAYS 9 g/ ma r1 2 yrakPP 044 0703 0001 Of 000 MAB 7/08/82 8/24/82 8/13/82 10/08/82 3/07/83
-PROC. XII-1, CONTROL OF MEAS. & TEST EQUIP. PROC.XV-2 HANDLING NONCONFORMANCES
%) ep5NEDW3hPPP 044 0703 0002 Of 000 7/08/82 MA8 7/23/82 8/13/82 8/31/82 8/31/82
- PARA.t.3.15 0F PPP OA MANUAL IMPOSES ON SITE OA RESP. FOR IMPLE. OA PROGRAM
] glGWZDTWhPPP 044 0703 0003 02 000 MAB 7/08/82 7/23/82 8/13/82 10/08/82 FAILURE OF PPP PERSONNEL TO UNDERSTAND PROCEDURES & CODES THEY WORK WITH
- ggUI7551h PPP 044 0703 0004 08 000 MAB - 7/08/82 7/23/82 8/13/82 8/31/82 8/31/82 l AVIOLATION OF PROCEDURE X-G, PARAGRAPH 4.2.2A ----INSPECTION REPORT w
CNET7523hPPP 044 0703 0005 09 000 MA8 7/08/82 7/23/82 8/13/82 A 10/08/82 11/03/82
-FROCEDURE VI-5 FAILS TO PROVIDE ADEOUATEDIRECTION & DETAIL TO FIELD WELD DOCUMT M E3QI7D71RPPP 044 0703 0006 09 000 MAB 7/08/82 7/23/82 8/13/82 A 10/08/82 a
11/03/82
- PPP PROC.2-8 DOES NOT PROVIDE ADEOUATE DIRECTION FOR CUALIFICATION OF WELDERS sf43DIIU31DPPP 044 0703' 0007 09 000 MAB 7/08/82 10/22/82 10/28/82 10/28/82 A 11/03/82 11/03/82
- PPP VI!!-3; STORAGE OF MATERIAL TO PREVENT MIXING DIFF. CLASS. SIZES & HEAT / LOT 3017031 PPP C44' 0703 0008 09 000 MAB 7/08/82 7/23/82 8/13/82 **
l A 10/06/82 11/0378'2 FAILURE TO CONTROL FILLER MATERIAL STUBS Y ELwLigyvJ3PPP 044 0703 0009 09 000 MAB 7/08/82 7/23/82 8/13/82 A 10/12/82 11/03/82
PPP FAILED TO DEVELOP & USE ADEO. PROC. FOR C0f4 TROL WELDING FILLER MATERI ALS V 4LG017dTOPPP 044 0703 0010 ,09 000 MaB 7/08/82 7/23/82 8/18/82 A 10/08/82 11/03/82 PROC.GWS-III.iX-3 AND IX-14 ---CONTROL OF FIELD WELDING ACTIVITIES 3017031 PPP 044 0703 0011 09 000 MAB 7/08/82 7/23/82 8/13/82 A 10/12/82 1t/03/82 INFORMATION RECORDED ON FIELD MONITORINGRECORDS CONTAINS MANY ER(ORS
6/04/83 ACTION REQUESTS (PROGRAM E78875581 PAGE 118 CONSTRUCTION AUDIT AR'S - ALL AAR'S BY RESPONSIBLE ORG. FILE RESP AUDIT AR APPENO B CAUSE LEAD ISSUE RESPONSE DUE RESPONSE COMPLETION ACC/ red VERIFY ITEM NUMBER ORG. NUMBER NUMBER CRITERIA CODE AUDITOR DATE DATE DATE DUE DATE DATE DATE COUNT CSRf0Id$ PPP 044 0703 0012 09 000 MA8 7/08/82 10/22/82 12/13/92 12/13/82 A t/11/83 1/11/83
'PPP DOES NOT HAVE A SITE PROCEDURE TO COVER CUALIF. OF WELDING POR'S gg22971 PPP 044 0703 0013 09 000 MAB 7/08/82 7/23/82 8/13/82 A 10/06/82 11/03/82
' VIOLATION OF PROC. IX-46, PARA. 2.4 -- CERTIFICATION OF COUPLANT MATERIAL
- 3017031 PPP 044 0703 0014 09 000 MAB 7/08/82 7/23/82 8/t3/82 A 10/06/82 11/04/82
- PPP USING "JO BLOCKS" TO CALIBRATE DIGITAL THICKNESS GAGE I
gggggggg,PPP 044 0703 0015 09 000 MAB 7/08/82 7/23/82 8/13/82 A 10/06/82 12/23/82 PROC. IX-46 DOES NOT REQUIRE PERSONNEL TO BE CERTIF. IN ACCORD. W/ SNT-TC-1A qgggy3017031 PPP 044 0703 0016 09 000 MAB 7/08/82 7/23/82 8/13/82 8/31/82 8/31/82 ANNUAL REVIEW OF MANUALS AND PROCEDURES NOT BEING DONE 3017031 PPP 044 0703 0017 06 000 MAB 7/08/82 7/23/82 B/13/82 A 8/31/82 12/23/82 PIPE HANGER TRANSMITTAL FOR FIELD ENG. NOT BEING RETURNED IN THREE DAYS -f 3017031 PPP 044 0703 0018 12 000 MAB 7/08/82 7/23/82 8/13/82 A 8/31/82 1t/03/82 POTENTIOMETER OUT OF CALIBRATION --PPP FAILED TO FOLLOW THRU ON WORK PERF. BV IT 3017031 PPP 044 0703 0019 12 000 MAB 7/08/82 7/23/82 8/13/82 8/31/82 11/03/82 ! TICKIER FILE USED TO ASSURE TIMELY CALIB. OF M&TE NOT KEPT UP-TO-DATE ifjjifjjbpPP 044 0703 0020 12 000 MAB 7/08/82 7/23/82 8/13/82 A 10/06/82 11/03/82
'I.D. NICROMETER NOT IDENTIFIED AS REQUIRED BY PPP PROC. XII-1 E55T7Dgg PPP 044 0703 0021 000 MAB 7/08/82 7/23/82 8/13/82 A 8/31/82 11/03/82
- s )12 ROC.XII-t FAILS TO PROVIDE CORRECT DIRECTION & DETAIL FOR CONT. MEAS. & TEST EQUIP _
SEN2032gPPP 044 0703
- 0022 13 000 MAS 7/08/82 7/23/82 8/13/82 A 9/01/62 11/03/82
' VIOLATION OF PROC.XIII-5 --STORAGE AREASNOT ACCESS CONTROLLED r@R120takPPP 044 0703 0023 15 000 MAB 7/08/82 7/23/82 8/18/82 A 10/08/82 t/05/83 PROC.XV-2 FAILS TO PROVIDE DIREC.&DETAILFOR PPP CONTROLLING NONCONFORMANCES ggp,Q129971EPP 044 0703 0024 s 18 000 MAB 7/08/82 8/24/82 9/08/82 9/03/82 A 9/13/82 11/09/82 PPP PROCEDURE XVIII-4 PARA.S.4.1C. 5.4.10, 5.5.1 AND 6.2
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g33%ZDG37)PP 044 0708 0001 13 000 WJC . 6/01/82 9/09/82 8/30/82 9/03/82 3/C2/83 N FPP'S OA PROGRAM. E .'G . PROCEDURE XIII-5. AREAS NOT DESIGNATED FOR MATERIAL STORAG I 3017031 PPP 044 0708 0002 08 000 WJC 6/01/82 6/04/82 6/09/82 A 6/18/82 1/21/83 BURLAP BAGS USED TO CONTAIN ITEMS ASSOC.W/ SAFETY RELATED HANGERS OR PIPE COMPON. 3017031 PPP 044 0708 0003 13 000 WJC 6/01/82 6/30/82 7/12/82 7/15/82 7/15/82 CODE PIPE FOUND IN OPEN BUILDING STORAGEAREA EXPOSED TO ENVIRONMENT s 3017031 PPP 044 0708 0004 13 000 WJC 6/01/82 7/tG/84 7/23/82 8/30/82 3/02/83 CODE PIPE SUPPORTS IN OPEN STORAGE AREA ---BALL BEARING SWIVEL ENDS RUSTED 1
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. =
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- Cr w e .2 J l w G > 4 CL 4 W 4 to 1 2 4 3 G W **
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a ~ u O J m O CD == 2 4 O> w2 0 =C Oe Q 4 *= wN O .J O=
== > wa ye CL == a*
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4 3 o as Cr 4 W 2 3 l ew w >> 0 2 30 Q OO w
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*= UU O
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- 2W NO ME e CL e w> *> Ov
- CL 2 CL ==
0 CL & U MU k l w N ,s a cD 43 a v >w e tp tp
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_ _ _ _ _ _ . __ ._. - ~ - - - - -- f 4/04/83 ACTION REOUESTS (PROGRAM E788755BI PAGE 121 CONSTRUCTION AUDIT AR'S - ALL AAR'S BY RESPONSIBLE ORG. FILE RESP AUDIT AR APPEND B CAUSE LEAD ISSUE NUMBER ORG. RESPONSE 00E RESPONSE COMPLETION ACC/REJ VERIFY ITEM NUMBER NUMBER CRITERIA CODE AUDITOR CATE DATE DATE DUE DATE DATE DATE COUNT 3017031 PPP 044 0588 0001 15 000 CJF 9/22/81 9/29/81 10/05/81 . 10/12/81 10/12/81 AFTER REPAIR ON HANGER HAD BEEN COMPLET-ED. HOLO TAG WIS NOT REMOVED. ' 3017031 PPP 044 0588 0002 15 000 CJF 9/22/81 9/29/81 10/05/81 10/t3/81 10/13/81 HOLD TAGS WERE LISTED IN LOG AS BEING REMOVED BUT TAGS WERE STILL ON MATERIAL 3017031 PPP 044 0753 0001 09 PGD 10/22/82 12/21/82 THE REPAIR ORDER MAPS THE DEFECT AND MUST BE INITIATED PRIOR TO GRINDOUT 3017031 PPP 044 0753 0002 09 .08 PGD 10/22/82 11/04/82 11/09/82 11/09/82 & 11/11/82 11/11/82 BASE METAL REPAIR WAS COMPLETED & NO MT OR PT WAS PERFORMED 3017031 PPP 04 0759 0001 06 .08 WJC 10/27/82 11/10/82 11/10/82 11/10/82 A 11/16/82 11/16/82 PPP DID NOT DOCUMENT THE MOST PECENT THREE MONTH TEMP.VERIF.0F PORTABLE ROO CANS ; 3017031 PPP 044 0759 0002 08 .08 WJC 10/27/82 11/10/82 11/10/82 11/10/82 A 11/23/82 11/23/82 COATED ELECTP>DE DETERMINED TO BE UNKNOWN OUALITV DUE TO LOSS OF ELECTRICTY 301703% PPP 044 0762 0001 14 .09 TES 11/09/82 11/16/82 11/17/82 12/03/82 A 12/13/82 3/18/83 PRE-AUDIT AND POST-AUDIT CONFERENCES ARENOT BEING CONDUCTED AS REUUIRED EEEEMEQMbPPP 044 0770 0001 13 .15 CdF 12/21/82 1/11/83 t/18/83 1/18/83 A t/18/83 2/02/83 A PROCESS AUDIT WAS PERFORMED BY CQS TO EVALUATE COMPLIANCE To REFE
R. PROCEDURE
S 3017031 PPP 044 0771 000% 09 .08 GG 12/13/82 12/30/82 12/22/82 12/09/82 A f/06/83 3/16/83 B. URBANY. EVE EXAMINATION PERIOD HAD EXPIRED. 3017031 PPP 044 0771 0002 09 .08 GG 12/13/82 12/30/82 ' 12/22/82 12/22/82 A 1/04/83 3/16/83 "HIGH RADIATION AREA" WAS NOT POSTED DURING A RT EXPOSURE AT R82 NO OF ITEMS 10 l e . . . . e
e [ N T Ik w2 w >3 0 ~O 4 U a e e e e e e e e e e e e m 5m
> > & & > 6 m o o o b o e o >
uw N N N N N N N N N N N N N .N mn N e e n e m e e M m m e M .M a4 - O O O O - O O - 0 N O N O wO N s N N N N N N N N N N N N
> v O O
N O e T O O 4 m e - m - e e e e e e e e e e e m e m 7 h M M W M N M M M M & F W W ww N N N N N N N N N N N N N N GH N O W 5 O m O O M @ m e M M N4 - 0 0 0 0 - O O - O N O N O UO N N N N N N N N N N N N N N
' " 9 ' ' * *
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M O 2 Ow w ~H J M4 m WO w a e aw 2 23 O 00 a U W a w w e e e e e e e e e e e e e e e G W b b b & M N N N b b 6 & N 6 m Zw N N N N N N N N N N N N N N m > O> - - - - - O - - - - e - - N o e a4 O M M M M - M M M O O O O - e e W mo w N N N N N N N N N N N N N N M M M M M 4 M M M p e o e o b
- Q w e 4 w ~
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& J W W 5 W W 6 N 5 M N N & N N c a ww N N N N N N N N N N N N N N O 4 er e > 0 m W W 6 6 6 M M M M 4 m 24 N - N N N N N N N O O O O O a . 00 N N N N N N N N N N N N N N w a N M M M M M M M M m o e o O W
w 2 e e e e e e e e e e e e e e M N W 5 & 6 6 N N 6 6 W 5 6 m WW N N N N N N N N N N N N N N
- m De O 9 e O O O O O O e e e e 6 e - e4 N O O N N N N N N N N N N N w a MO N N N N N N N N N N N N N N 3 4 m N M M M M M M n M 4 4 T T 4 O
w 2 Q O O
= 0 2 > OH 4 U O U U U U U U U U U U U O U 4= 7 w w w w w w w w w w w w J
~ w WO > a a a a a a a u a E a a a
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= w
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O O - - 0 0 - - - , 2 a-O am l U WU l a _ e T . M , . e - e e - e m - Om M M M T T T 4 9 T m O O O e
- *) 8 8 8 8 8 8 8 8 8 8 8 8 8 8 U -
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6 5 6 5 5 5 6 5 6 > > ~> T T T
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_O T T T T T T T ,. ,. ,. T T 4 WM V 4 9 T T T T 4 1 T T T T 4 20 a a a a a a a a a a a a a a M a a a a a a a a a a a a a a E w N N N N N N N N N N N N N N H
, M M M M M M M M M M M M M M M M -1 m ww O O O O O O O O O O O O O O
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a W W e e E M M
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W G CL 4 N e en O N e m W e M
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W .J 5 O .J WW N i O 4 e> * , i G 24 M L 4 s OO N
= CL e i W i 2 4
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i __- ._. - Of ni Ik b w2 w .>3
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- O O O - N - ~ ' ? N N - N
> e e e P- P- e e ao e e e e e {e ao e in bW N N N N N N N N N N N N N N N N N
=> Ow e e N e o e N e > *r = > -m N m n G4 - ke *- C
- N N
- N N N O O n O *O - N ->
wO Nw N@ N N N N N N N N N N N N N N .NW
> fe 2 nI e e
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-ow 3 .- - - * -O -
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- 2 > -x U
@ O O U U O i O' > 1 O == w Q cr
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*=>
to >- e.* w w
> 2 w w w == 0 >
J k4 cr 3 2 cr 4 co wQ O e *= 0 - I
= d I C w 0 cL e CL w U J 2 e I e b-
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> co CL 4 w w 4 n 0 - - N O O e- N N Nw Ow NO
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- cr - - == *= 2
- o. -- co cr 0
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- Nw N .Q O 4 m e- 3 - q.D r= 5
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m
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.. O .J 4 - - - O e6 -O -e i w 2 4 w > > 2 2 Q Q M > cr w ct 4 w *E
.I- - O 4 w w a > Q t 2 > 0> >w O UX U U O I 3 CL co co U co CL > 24 = CL O O U 4= wO w2 7 w w w to u w d *E 4 6 ww 3 .J 4O hw
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>= c6 .J 3 . O .O. *
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> c I ct 2 = 4 U co 4 2
.o O > -
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- O e - CL o O O= ** - CL Oa 2 G ee j O CL cr i U *E U ct w e t- e m N N r- e t- 9 m m N O n to O e o e r= cn v e r= P= m en c) O - - N n 4
crl 8 3 3 5 8 8 8 8 8 8 8 8 8 8 8 8 il l i i i i i i i i i l i i i i i i 42 w or =r gr w r r ar w gr =r r w -v v <r v T gr 9 *r 9 w 4 9 *t 4 4 *r 9 T 4 4 4 IL O O O O O O O O O O O O O O O O O ed-WG tr O CL cL cL 0, cL cL CL CL ct (L CL cL cL c6 CL CL CL cL CL CL cL cL cL CL CL cL cL CL CL CL CL a CL cL CL cL EL CL CL CL CL CL CL ch CL CL CL CL CL sk CL / N N N N N N N N N N N N N N N N N to er n n n n n n n n n n n n n n n n n ( ao ww O O O O O.- O. O O O O O O O O O O
- - - - O.- . . - - - . - - - .- -
N., J. 2co *- - - * * -- - *- - *- - - - *- - - *- O w3 O O O O O O O O O O O O O O O O O N 2 n n n n n n n n n n n n n n n en n N
e n e 2> w2 w m3 0 =O 4 0 4 e e e N e N e N e N e N e N e N e N e N e N e }N
.e N
e N e N e kw N N N N N N N N N N N N N .N N N N
=> - N m 4 e N N o e e m - nJ .m n 90 n 24 *
- O * *
- N
- N
- N N NN N N O2 N WO N N N2 N N N N N N N N N NO N N NJ N
> - - N= - N - *
- N - n - W m2 N N et N
- = = 0 J e e O 3 w 2 2 O O w O w O O O 2 O k' a > 2 a =
*J *O N N= NC N N N NO N N= Ne N= N N> N 7 eO e4 93 e e4 em e e e WI ed e .2 mo eO WJ e ww Nw N> NJ N NO Na N N NO No N2 NO NC NJ Nw NO N ap -3 NO ma 4 W Nw g N m2 m m= *2 W= N= 42 em n N4 *O -m O * -w *a *a
- N3 -m N> N= Ne ~3 N= -2 N 00 Na Na NH N N> N NO N NO N4 Ne Ne NO Nm N4 N3 %
U -O *a NO
- N= * * -O * -m nu -w @@ Nw N N> n N 4 *> *4 e 2 e e J O > = 2 > 2 m O O e 6 2 2 2 m O w 0* 0 > w w A 4 2 = a O 4 U >
a 2 U a 3 a w O O u U = 6 0 2 4 w w e O > > > a C J I 4 a Ow 7 3 m > w Q 3 0 = 0 g w => > 0 = m = a . U w & 2 3 = w . J >< w a e w J V 3 J e = 4 I e e m WO e a 2 e > 4 2 O O m O Y 3 w
= J w 4 J 3 O a 2 = J 4 w I 1 e aw 0 > > 3 4 O U 4 = m X X > > 4 2 23 2 3 0 > w = 2 * *
- O 00 = 0 2 a 2
- O m > = 0 t O a U w I C U n a o e 2 > 2 w w e m > 0 w a N = J > > = 2 > a a w w - *= =a N N - N NO Nn N> N4 NO Ne Na N Nw NO N=
m a e me e3 C 20 WJ 20 ez mN eJ W= mz em .m O We => m2 Ca e 2W N> N Nw N2 N4 N> Na NN N NR N NM N= NI No Nw N c > CW ma N2 ma ne ->
- g> -N eY Ow mw Ow Na NO m na ne o e a4 00 -O Om * -e *O -J -- *2 N> Na
- Na -O -O - N-e WO NW N= N4 Nw N2 Nw N N N3 N4 Nw Ne N Na NO Nw Na W e w * *> N> *a *= *= ww *2 *C *2 *3 02 NO N Na MO Na o
- a ** == *a O w a O w w 2 O U E.
w a > e O w O = = O e J = 0 2 4 w J O a w > > a O w > O m a m - e M I 4 'O = a m 2 w a a J O - I J = 4 0 -1 -e -> N Na Nw N N> Nw NO Nw Na Na Na NU NO N a O a ww e e= e4 m2 mo mo e mO m3 m= m3 ma e sw mz eO mJ J NO NO NI NO N= N= Nw N2 N Na N N N2 NI N3 Na N2 0 4 em -> N Nw *= wm e *a e me *a mJ NO 00 N> cJ oe n= a a 24
- Na
-m o Ok on Ow -= Ow Om n 04 Ow N *= N N NO e 00 NO NO Ne N Na Na Na N3 NO Na N3 NJ Nw %e NW Ns w a "O *w NZ -w *O *w * -w ** -w Nw TO NJ N N= NO Nw e == * -3 3 k 3 e 3 e a > I 3 2 I = 3 w a O O O N u w e a = m a a w w I w e w w w e O 2 0
> 0 . a O O O m e O e Z = *
=a -O *e as -O ~2 -I ~2 NO Ne NI N- NJ NO N= N N ma ma W4 WW ek e4 CW e4 ea m2 ew em WO me er ek ed e ww Na N> N3 Na N %= Nw N= N> N4 NH N2 NU Nw N4 Nb N2 e
> e 3> n Ow W P6 * - MJ e3 mJ OU *a Ne e O m> ow ww e=
- ed Ok 00 *> 0 Na Na N Na Ow N> N> Nu *O On -I ,J -2 w m eO Nm N %= N4 NO NX NC N2 NJ N Ne NO Na Nw N % %=
*e w
3 O 4 2 wh h
-O "0a3 N
*C NI 3
No
-O 2
Nw ex
=
NO
*U 2
-w O
"ww 2 -
w e
=
Nw N Na 3 e Ne e 3 Nw a w N4 a
- 2 O a O U 4 0 2 O w e a e 2 3 w
= 0 4 O 2 2 > -
> 0 m > a 2 > O> >O we 4 Ew >> > Ow > 64 we Ow EJ w 00 w2 we w Q U 4= Ew 72 4 h2 ww hk Ja 6E 70 WO JI uw w2 J we WJ we
= w WO JZ UO 42 wm JO JO >= JC UU UZ >> O2 UO WM UD V4 U2
> a JD 0 0 = 0 4 4 = 0 2 = w U e 4 = w C e e w 0 > > w a -
4 2
= w e ,
e a w
> 2 w
J w 2 w E 4 4 2
=
g 6 4 O w w m 0 mw > 9 4 a O > w > I k w 2 a 4 4 a 2 30 2 4 O w = > = w e a w e 2 a O 40 = m J e a e w > 2 2 2
= UU C a O 4 = e J = 0 e 3 = 0 e e
> a a 3 3 4 3 2 4 3 2 O U O 3 3 U m4 a > h O O 2 = w 2 O U Q O 3 3 = 0 Y = m w w Y J = 0 0 = =
a O2 J & 2 a a a a > a a = a O 2 2 e Zw OO cu mO no @a 04 nn Ow 04 e4 -I m3 ,0 oO no 04 me wp -I -2 Ou 03 -a -> *U -e -m O2 -3 OO ~2 O2 -m *> O> 2 a= 0 am U MU a w O n > c w e > e m w e m n o e
- v mm w w , e > > > > > e e e m m m O O 42 m n n n n n n n n n n n n n o v w g O O O O O O O O O O O O O O O O O a
is 42 i i i i i i i i i i i i i i i i i w n , w n , n n n n n n n , w n n a - O O O O O O O O O O O O O O O O O' ed Wu ao a a a a a a a a a a a p. a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a- a a a a N N N N N N N N N N N N N N N N N n a n n n n n n n n n n n n n n n n n s-e ww O O O O O O O O O O O O O O O O O N Jm - - - - - - - - - - - - - - g =X * - - - - . - * - . . . .- - - - - O 63 O O O O O O O O O O O O O O O O O N 2 m n n n n n n n n n n n n n n n n M G
N M I
. 2>
w2 w >3 0 =O 4 U a N N N N N N N N N
> m e e e N N N N .N N N
e e o e e e e e e e N N kw N N N N N N N N N N e e m
=> 0 m n N m N N M e N N *N N N a4
- O N
- O NO Om * - M
- n o e .M O N, e WO N N N N N Nw Na N N N
- - O
- N N *
> M M @ M M Mk ww M M M N
p N N N N N N w 4 w e w > c h 0 0 2 a 2 w U C O 4 U
= =
I 2 N N> N Nm N n> 2 O 7 m2 mm W W= N N nm N M4 N= N N N N N ww NO N N N> mU e NH em e sw M m2 mk e e e e m a> N - No N - N= N= Na O= 20 -m Nw mw 0C Os Me ok N4 % N N N N N4 -> O as Ow -a 0 -w - -w
-2 o0 ou e N w m o UO N= N= Mg -u -= N - N Nk NC N NM NO Nw N> N> N NZ U ny NE N N N 4 MQ 90 w 3 MO 2
Mu w M Mw MO M= MO 90 w=> w w em N p N 4 7 O w O > 2 U
- w O+ 2 = m O I a u 4 2 0
U w 3 2 m C 4
> w U 2 2 J 4 3 -N h w U 2 4 0 2 O a a 2 m w 2 O O w 6 ow 2 m w 0 2 a w => = 4 X o a e I I > = m w
m w J kW X 2 3 w > > U k m 3 > O O U w = & 2 O WO a m w > c = 0 2
= J O J >
=
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= M4 -O NJ NC N= N N4 NC N6
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4/04/83 ACTION REQUESTS (PROGRAM E7887558) PAGE 133 CONSTRUCTION INSPECTION AR'S - ALL AAR'S BY RESPONSIBLE ORG. FILE RESP AUDIT AR APPEND B CAUSE LEAD ISSUE NUMBER ORG. RESPONSE OUE RESPONSE COMPLETION ACC/REJ VERIFY ITEM NUMBER NUMBER CRITERIA CODE AUDITOR DATE DATE DATE OUE DATE DATE DATE COUNT 3011032 PPP 044 0000 0479 16 000 PC 5/18/82 7/23/82 7/27/82 8/02/82 8/02/82 REJECT RATE OF 43% DISCREPANCIES INVOLVING VISUAL HANGER INSPECTION 3011032 PPP 044 0000 0482 09 000 CEE 6/03/82 6/17/82 6/21/82 7/01/82 7/01/82 WELD RECOROS INDICATE WELDER CONSUMING MATERIAL HE NEVER WORKED ON 301.1032 PPP 044 0000 0484 06 000 WJC G/09/82 6/23/82 6/30/82 7/09/82 7/09/82 WELD ROD REO. FORMS INDICATE MATERIAL NOT RET'O TO DIST. CENTER FOR 17 MONTHS m 2CUQGssfPP 044 0000 0490 10 000 PC 6/22/82 6/29/82 6/29/82 7/02/82 7/02/82 INSPECTION PROCEDURES NOT BEING FOLLOWED 3011032 PPP 044 0000 0491 05 000 TLC 6/25/82 6/25/82 6/25/82 6/25/82 ' 9/23/82 NEGATIVE TREND DEVELOPING IN AREA 0F PULLMAN POWER PRODUCTS ROD CONTROL 3011032 PPP 044 0000 0493 05 000 WJC 7/08/82 8/13/?2 9/02/82 9/30/82 j 9/30/82 150 DOESN'T CONTAIN FIT-UP CRITERIA FOR FIELD WELD g3Gjfee21PPP 044 0000 0496 '05 000 RAS 7/19/82 7/23/82 7/28/82 7/30/82 9/23/82 PPP IS STORING THEIR BARE WIRE IN LEATHER POUCHES: VIOLATION PROC.PPP VIII-3 3011032 PPP 044 0000 0499 08 000 RAF 7/23/82 8/27/82 8/26/82 9/09/82 9/09/82 MATERIALS ARE NOT ACCOUNTED FOR PROPERLY 3011032 PPP 044 0000 0500 05 000 JBH 7/27/82 8/10/82 8/19/82 9/01/82 9/07/82 DELETED SHOP WELD COEF & SPOOL PCS.( 13039-5) NOT DELETED ON F-SHEET LOG Egggfg32bPPP 044 0000 0503 OG 000 WJC 8/02/82 8/09/82 8/06/82 8/09/82 8/09/82 NOT COMPLYING WITH PPP PROCEDURE IV-5, PARA. 6.3
\ l 3011032 PPP 044 0000 0505 09 000 WJC 8/09/82 8/16/82 8/16/82 8/16/82 9/23/82 PPP OC INSPECTORS NOT RECORDING PROPER WELDING INFO. ON PORCESS SHEETS 3011032 PPP 044 0000 0506 05 .02 TLC 8/11/82 8/31/82 8/23/82 8/23/82 A 10/26/82 10/26/82 HANGER 1C11H397, ACCEPTED BY PPP !NSPECTOR WITH GAP BETWN P!PE AND PIPE STRAP C703TD33 PPP 044 0000 0507 09 .08 WJC 8/12/82 8/20/82 8/20/82 8/20/82 A 11/09/82 11/09/82 Pf? '.LE PERSONNEL NOT COMPLYING WITH PPPPROCEDURE IX-PT-1-W75, PARAGRAPH 13.1 E3CIIQQpgCPP 044' 0000 0510 06 .08 CEE 8/16/82 9/24/82 3/07/83 3/07/83 A 3/16/83 3/16/83 MEMO USED TO DIRECT WORK--INSTRUCTIONS CONFLICT WITH PROCEDURE IX-5 SECT.4.2 P 1 3011032 PPP 044 0000 0520 09 000 WJC 9/15/82 9/27/82 9/20/82 10/t5/82 10/15/82 DEMINERALI2ED WATER CONTAINS ORGANIC MATTER AND METAL PARTICLES 3011032 PPP 044 0000 0527 09 .15 DES 1070G/82 11/05/82 11/11/82 11/11/82 A 11/19/82 TEMP. COLD PULLING OPERATION HAS BEEN PERFORMED wtTHOUT UTILIZING PROCESS SHEETS EUTMITMT3DDPP 044 0000 0529 09 .09 RBM 10/13/82 11/12/02 12/02/82 A 12/09/82 12/09/82 PRO.1X-PT-t-W75 DOES NOT ADEQUATELY ADO.A MAX.DRvlNG TIME AFTER PENET. REMOVAL
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4/04/83 ACTION REOUESTS (PROGRAM E788755BI PAGE 142 ' CONSTRUCTION INSPECTION AR'S
- ALL AAR*S BY RESPCNSIBLE ORG, '
FILE RESP AUDIT AR NUMBER ORG. APPENO B CAUS'E LEAD ISSUE NUMBER NUMBER CRITERIA CODE AUDITOR DATE RESPONSE DUE RESPONSE COMPLETION ACC/REJ VERIFY DATE DATE DUE DATE ITEM 3011032 PPF'D*1 ^^^^ DATE DATE COUNT
^"?? 19 TLC 10/21/82 11/03/82 THIS AR 13 c...u - o m :; . -,,c- 6 v,
. .. 2 : ;,,vst - IO/2G/82 3011032 PPP 044 0000 7333 13 .l5 CJF 10/21/82 11/04/82 INSP.ON HOUSEKEEPING AND STORAGE OF 11/04/82 11/04/82 A 11/15/82 tt/15/82 3011032 PPP 044 0000 0538 THE CONTRACTOR NOTED NUMEROUS DEFICIENCIES 15 GMD 10/29/82 3/22/83 3/18/83 3/18/83 3011051 PPP 044 0000 DURING DRILLING OPERATIONS THE CORE BIT CONTACTED AND CUT RE8AR.
0438 05 000 TLC 9/08/89 9/18/81 9/21/81 LINES HAVE OPEN ENDS AFTER CRAFT DONE 9/22/81 9/23/89 WORKING FOR THE SHIFT 3011051 PPP 044 0000 0440 09 000 EFP 9/10/81 . 9/15/81 9/15/81 3011051 PPP 044 0000 0441 WHEN000IS A FINAL ACCEPTANCE OF A PIPE SUPPORT: AT WHAT STAGE OF THE CONS 06 EFP 9/10/81 9/25/81 9/24/81 NOTED WHILE CHECKING DRAW. AT S&D WORK 10/12/81 10/12/89 I 3011051 PPP 044 0000 STAT.THAT ECN HAD NCT BEEN POST. TO DRAW 1 0442 OG 000 EFP 9/10/81 9/25/81 9/24/81 WHAT PROVISIONS ARE THERE TO CONTROL 10/12/81 10/12/81 3011051 PPP 044 0000 0443 IN-SPECTION OF UPGRADED N-S RELATED SYSTEMS 09 000 EFP 9/10/81 9/25/81 9/24/81 APPARENT LACK OF DETAIL IN REQUIRE. 10/12/81 10/12/81 ! 3011051 PPP 044 0000 0444 FOR OC CHECKLIST ON FIELO PROCESS SHEETS 02- 000 EFP 9/10/81 9/25/81 9/24/81 10/12/81 DURING NRC REVIEW. 10/12/81 ( 3011051 PPP 044 0000 NOTED EXCESSIVE TIME LAPSE BETWEEN HIRE DATE &TRAIN ADMIN.0F 0449 13 000 TLC 9/14/81 9/28/81 9/21/81 SPOOL PC. 9/22/81 9/23/81 NO OF ITEMS HAS NOT YET BEEN REMOVED FROM RIGGING AFTER REPEATED NOTICE I 10
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- Notify the NRC vithin 48 hours af ter receipt of information. If notification l; by means af ter other than information written report, a written report is required within 5 days is received.
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a . , DEVIATION ANALYSIS REPORT LOC Re g.,f m'y=,sn W.J.U.AqE r"" CD or Report pursuant to 10CFR50.55(e) - Notify the NRC withln 24 hours af ter identification of deficiency. Issue written report within 30 days, 'or Report pursuant to 10CFR21 - Notify the NkC within 48 hours af ter receipt of Information. If notification by means other than written report, a written report is required within 5 days after information is received. ENC. A REPORTABLE WRITTEN 10CFR50.55(e) 10CFR21 REPORT 1AR 1RIGINATED DESCRIPTION SYST/ EVAL. l () E VAL NO YES(DATE REPORTED) REPORT WITilDRAW REPORT NO. NO. (DEFECT / RESP. ORGAN 17.ATION SPEC BY/DATE BY /DATI- 10. 55 (e) 10CFR21 DUE DATE BY/DATE (DEFICIENCY) NONCOMPLIANCE) 40 BY/DATE GTes Hn sch Crigion Ihiloro 6 60 Kthh forf&lI \/ lJQ yhp 66vffa sj,ojg, e l2h & f A,)p N,p 4//p
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DEVIATION ANALYSIS REPORT LOG y g .t - Issue written report ar Report pursuant to 10CFR50.55(e) - Not Lfy the NRC within 24 hours af ter identification of deficiency. within 30 days. or Report pursuant to 10CFR21 - Notify the NRC within 48 hours af ter receipt of information. If notification by means other than written report, a written report is required within 5 days af ter information is received. ENG. REPORTABLE WRITTEN 10CFR50.55 (e) 10CFR21 REPORT QA EVAL NO YES(DATE REPORTED) REPORT WITHDRAW REPORT NO. NO. (DEFECT / AR 3RIGINATED DESCRIPTION SYST/ EVAL SPEC BY /DATE BY/DATI- 10. 55 (e) 10CFR21 DUE DATE BY/DATE (DEFICIENCY) NONCOMPLIANCE) BY/DATE- RESP. ORGANIZATION 'O . 3Evere t1 Ce & n mer* 5 p f V.phy 5f4i B PFNNL pp Pder>hd s+e W/R MQ WQ D/A Qg/ c-, m in unn w g.g g'ddW sieete, 4 gay, [f$% '56Bl WTS/P!! Sitc/dI 0/ 1% "ijk% J D/^ M/A DIA U/A N/A N/A ll?P ECa?'a'IML Assembtds w/o orfavd 56 4 "t h $riss
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4 ".sm f Y mmn"4E03 npt VM AM. A DNUf DEVIATION ANALYSIS REPORT LOG Issue written report to 10CFR50.55(c) - Notify the NRC within 24 hours af ter identification of deficiency. gr Rcport pursuant within 30 days. or Report pursuant to 10CFR21 - Notify the NRC within 48 hours af ter receipt of information. If notification by means other than written report, a written report is required within 5 days af ter information , is received. REPORTAllLE WRITTEN 10CFR50.55(e) 10CFR21 REPORT ENG. QA EVAL NO YES(DATE REPORTED) REPORT WITilDRAW REPORT NO. NO. -(DEFECT / lAR BRICINATED DESCRIPTION SYST/ EVAL NONCOMPLIANCE) BY /DATI- 10. 55 (e) 10CFR21 DUE DATE 15Y/DATE (DEFICIENCY) RESP. ORCANIZATION SPEC llY /DATE 11Y/DATE-10 . [Y, Z'22-81 // 2f[8J) N/A 6 Ludich 3 cogdown in 62ur.d.h/ YM Solk'Eu84 TA Polenhal I'13'O# A//A of ProtecEve, ,, z-2.f,-81 7.Tg r/f Hogs Con + cache . H,4nto,1cl N/n W/n nqn N/R A//A g/r?
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- 10. 55 (c) 10CFR21 DUE DATE BY/DATE (DEFICIENCY) NONCOMPI.IANCE) 0 BY/DATE RESP. ORGAN 17.ATION SPEC BY/DATE BY/DATI:
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DEVIATION ANALYSIS REPORT LOG Issue written report r R port pursuant to 10CFR50.55(c) - Notify the NRC within 24 hours af ter Identification of deficiency. withl'n 30 days. of Information. If notification by means r Repart pursuant to 10CFR21 - Notify other thanthe NRC writtenwithin 48 hours report, af ter a written recalptis required within 5 days af ter Information report is received. REPORTABLE WRITTEN 10CFR50.55(e) 10CFR21 REPORT ENG. QA NO. (DEFECT / REPORT WITIIDRAW REPORT NO. l SYST/ EVAI. EVAL NO YES(DATE REPORTED) NR ;)RIGINATED DESCRIPTION DUE DATE BY/DATE (DEFICIENCY) NONCOMPLIANCE) SPEC BY/DATE BY/DATI 10. 55 (e) 10CFR21
- b. BY/DATE RESP. ORCANIZATION gjg gjf) N/A Nh9 f4.6rown Ruskin Fic,*Darnpers >P 41/ Dkeema Eddman N/A Polenlied 8-'3-80 10}&tl60 groar 9/ B-i4-so 30-20-8o 8
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o u. DEVIATION ANAL.YSIS REPORT LOG Issue written report ir Riport pu rsuan t to 10CFR50.55(e) - Notify the NRC within 24 hours af ter identification of def t::lency. within 30 days. Notify the NRC within 48 hours af ter receipt of information. If notification by means or R: port pursuant to 10CFR21 - other than written report, a written report is required within 5 days after information is received. ENG. s QA REPORTABLE WRITTEN 10CFR50.55(e) 10CFR21 REPORT EVAL EVAL NO YES(DATE REPORTED) REPORT WITilDRAW REPORT NO. NO. (DEFECT / AR 2IGINATED DESCRIPTION SYST/ DUC DATE BY/DA.TE (DEFICIENCY) NONCOMPLIANCE) RESP, ORGANIZATION SPEC BY/DATE BY/DATI- 10. 55 (e) 10CFR21
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within 30 days. Ir R2 port pursuant to 10CFR21 - Notify the NRC within 48 hours af ter receipt of Information. If notification by means other than written report, a written report is required within 5 days af ter Information is received. ENG. REPORTABLE WRITTEN [ 10CFR50.55(e) 10CFR21 REPORT QA EVAL NO YES(DATE REPORTED) REPORT ' UITHDRAW REPORT NO. NO. (DEFECT / iAR :1RIGINATED DESCRIPTION SYST/ EVAL NONCOMPLIANCE) BY/DATI 10.55(e) 10CFR21 DUE DATE BY/DATE (DEFICIENCY) SPEC BY/DATE 10 . BY/DATE-R Gibson RESP. ORGANIZATION sampbg of Clas3 $" SP.1/ R.Pech Eddman V g[g A/[4 gp jfp g gp pil
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G. ulha ke- D&un 4-28-80 c aUbro. hon un;4-3/ E1340 (,. 3.go IL51 Pressure Trensm+ . 27 IIhC, (CE) W' c,. a .i-<. Seo<no roc o;vr r3 se aoi 4' O Safel e. lief thlve.s UltMLhl1H'thE.?]A kj 'l'l0h O'06*0$ vj-0 l g thpott .6 >-+1olez-om c o- ;kllf@lO.
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ftP'O YI10.[5 pjj DEVIATION ANALYSIS REPORT LOG b # W *" " Issue written report ir R: port pursuant to 10CFR50.55(c) - Notify the NRC within 24 hours af ter identification of deficiency. within 30 days. pr Ripsrt pursuant to ^0CFR21 - Notify the NRC within 48 hours af ter receipt of information. If notification by means other than written report, a written report is required within 5 days af ter information is received. ENG, REPORTABLE WRITTEN 10CFR50.55(e) 10CFR21 REPORT QA EVAL NO YES(DATE REPORTED) REPORT WITilDRAW REPORT NO. NO. (DEFECT / LR :lRICINATED DESCRIPTION SYST/ EVAL BY/DATI- 10. 55 (e) 10CFR21 DUE DATE BY/DATE (DEFICIENCY)- NONCOMFLIANCE'n ). BY/DATE RESP. ORGAN 17.ATION SPEC BY/DATE Thpson Class IE 980V. sP653 Grcen FJd % n y g/n M/4 /i//4 g/g /t//4 N/& -l it-21,-, 9 Load Cen w g.g3 d% '** s-n-to syse. i (ITE Gau.td) ! so ,210', H< sana ~s se M 9 m ,1edelme , glA glA N/n- WlR Wpi pp) tsanuaec p;pe (Jh.p Restraints 3-27-9o l r 70 2 7 0 UnJ 1 bWo/ ~ 72 ~ 5{ - 5'-2-10 A incluch pccim. (%p Motor- SP %9 (fygIc>j E'de!"un y MlA rJ/A W/R MlA h//A N/A - T L ass 9er Support s RHR Sct " 5-'40 2 11-90 4 Bo LpWre(testen;nts + y 73 31* ,323' s ws L. Qipe g ,, te) hit.wr4 RmraintrOMZ)
- c. ) Y Larmnochon Tclenfi6ed $P 33 Shonen47Edelman g/4 %M QA p i g.q, . N/A gq(,go) gg/A
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1- Q hF i: I!illi DE"IATION ANALYSIS REPORT IJ)G Issue written report or R2 pert pursuant to 10CFR50.55(e) - Notify the NRC within 24 hours af ter identification of deficiency. within 30 days. or Report pursuant to 10CFR21 - Notify the NRC within 48 hours af ter receipt of information. If notification by means other than written report, a written report is required within 5 days after information is received. ENG. REPORTABLE WRITTEN 10CFR50.55(e) 10CFR21 REPORT QA EVAL NO YES(DATE REPORTED) REPORT WITHDRAW REPORT NO. NO. (DEFECT / AR llRICINATED DESCRIPTION SYST/ EVAI. NONCOMPLIANCE) BY/DATF 10.55(e) 10CFR21 DUE DATE BY/DATE (DEFICIENCY) 10 . BY/DATE RESP. ORGANI7.ATION SPEC BY/DATE spe of 12xw- sose wee # irdeiman v/a hl g/n in- 19 g/n tic,3) v/a - T Goss 5 89 80-3-'9 10-3-79 10-3-79 bestos ble Jacket Y K $2 sys. l - Anchorbol+5 ford 4,sd SF 567. @ MM #/4 F/A N/# N/R T 13oss Bariele_Y 11-1-7 9lEctc),mnM 79 Gene e @ V 14 age 10-9 ~19 % ^*b r) ( g.,/y C De.laveJ) 9 45 Gamej Edciman V gg pjg M/O M/S M/// IStans.ger Procurement 4rnsfal- SF 35D 11-29 ? 11-30 19 10- 4 19 !a.fion of +he. A/6 4
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J$i a Ik.i in-DhvIATION ANALYSIS REPORT LOG Issue written report for Report pursuant to 10CFR50.55(e) - Notify the NRC within 24 hours af ter identification of deficiency. within 30 days. Por Report pursuant to 10CFR21 - Notify the NRC within 48 hours af ter receipt of information. If notification by means other than written report, a written report is required within 5 days af ter Information , is received. ENG. REPORTABLE WRITTEN 10CFR50. 55 (e) 10CFR21 REPORT lQA REPORT WITHDRAW REPORT NO. NO. (DEFECT / SAR ;)RIGINATED DESCRIPTION SYST/ EVAL EVAL NO YES(DATE REPORTED) ' DUE DATE BY/DATE (DEFICIENCY) NONCOMPLIANCE) NO. BY/DATE- RESP. ORGANIZATION SPEC BY/DATE BY/DATF 10.55(e) 10CFR21 G; alit Aeommce., 50 19 v/4 EdeJman PolenhJ glg 2. 7 9 ^//4 07(79 M/M Tarn i -i s-'S i. n.-13 I _ g~7 '8reaMoron ( wi d b-M Cont.nIcte/ t4alVorseA ll (S4h T Goss Rocebes+os cosie. SP N q7/lg @," 8//4 Fbtenwal g/g zv-7f N/n OB (79) y/g
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DEVIATION ANALYSIS REPORT LOG 10CFR50. 55(c) - Notify the NRC within 24 hours af ter identification of deficiency. Issue written report Report pursuant to within 30 days. Report pursuant to 10CFR21 - Notify the NRC within 48 hours af ter receipt of information. If notification by means other than written report, a written report is required within 5 days af ter information is received. ENG. QA REPORTABLE WRITTEN 10CFR50.55(e) 10CFR21 REPORT SYST/ EVA1. EVAL NO YES(DATE REPORTED) REPORT WITHDRAW REPORT NO. NO. (DEFECT / ORIUINATED DESCRIPTION _ BY/DATF 10.55(e) 10CFR21 DUE DATE BY/DATE (DEFICIENCY) NONCOMPLIANCE) BY/DATE RESP. ORGANIZ ATION SPEC BY/DATE 5* 7 I 6'77 /A Il-6-77 U/A 04 (77) O[A
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- TELEPHONE (216) 627 9800 ILLUMINATING BLDG - 55 PUBLICSQUARE Semng The Best location on the Nation MURRAY R. EDELMAN April 15, 1983 VICE PRt31otNT NUCLE A R Mr. R. L. Spessard, Director Division of Engineering U.S. Nuclear Regulatory Commission, Region III 799 Roosevelt Road Glen Ellyn, Illinois 60137 RE: Perry Nuclear Power Plant Docket Nos. 50-440; 50-441 Response to I.E. Report
Dear Mr. Spessard:
This letter is to acknowledge receipt of Inspection Report Number 50-440/ 83-06; 50-441/83-06, attached to your letter dated March 16, 1983. This report identifies areas examined by Messrs. P. A. Barrett, K. R. Naidu and P. R. Pelke during their inspection conducted February 6-11, 1983. Attached to this letter is our response to the three Violations described in the referenced Notice of Violation, dated March 16, 1983. This response is in accordance with the provisions of Section 2.201 of the NRC's " Rules of Practice", Part 2, Title 10, Code of Federal Regulations. Our response has been submitted to you within thirty days of the date of the Notice of Violation as you required. If there are additional questions. I please do not hesitate to call. Very truly yours,, u .84L ,' s M. R. Edelman Vice President Nuclear Group MRE:pab Attachment cc: Mr. M. L. Gildner USNRC, Site Mr. C. E. Norelius, Director Division of Projects and Resident Programs
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.S. Nuclear Regulatory Commission, Region III 799 Roosevelt Road Glen Ellyn, Illinois 60137 0 U.S. Nuclear Regulatory Commission c/o Document Management Branch Washington, D.C. 20555 bf
- APR 181983
4 i RESPONSE _TO ENFORCEMENT ITEMS Below is our response to Appendix A Notice sf Violation, of United States Nuclear Regulatory Commission I.E. Report 50-440/83-06; 50-441/83-06. Noncompliance I. (440/83-06-01; 441/83-06-01) , A. Severity Level IV Violation 10CF350, Appendix B. Criterion II states, in part, "The quality assurance progsam shall provide control over activities affecting the quality of the identified structures, systems, and components, to an extent consistent with their importance to safety." CEI Corporate Nuclear Quality Assurance Program, Section 0200, Revision 4, paragraph 1.1 states in part, "The program grovides for accomplishing activities t.ffecting safety under suitably controlled conditions and in accordance with the program elements of procedures, instructions, speci-fications, and drawings." Contrary to the above, the L. K. Comstock QA Program failed to provide control over deficiencies identified by an internal LKC documentation task force, in that these deficiencies were addressed in uncontrolled review checklists and internal LKC letters. B. Response
- 1. Corrective Actions Taken and Results Achieved L. K. Comstock has written a QC Inspection Report for each of the concerns identified during the LKC Task Force document review. This will provide for status tracking of each concern until it is fully addressed and closed out.
e As identified above, the LKC Task Force generated checklists for each document package as they performed their review to detail their comments. Thcse checklists have been procedurally addressed within the LKC QA program to ensure that each specific item is tracked and resolved prior to turnover. Along with the contractor's actions, the Cleveland Electric Illuminsting Co. (CEI) has developed a Special Project Plan in accordance with the requirements of our " Project Administration Procedures," that defines the actions necessary to resolve the task force issue. As a part of this program, all of the " task force" concerns have been addressed on Project Organization Surveillance Inspection Reports (SIR's). This duplicates the LKC tracking of these items. The SIR's are assigned to individuals within the Construction Quality Section. This enables CEI to monitor, provide follow-up, and ensure resolution of each item.
L j . s i RESPONSE TO ERFORCEMENT ITEMS i PAGE 2
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- 2. Corrective Action Taken to Avoid Further Noncompliance In light of this NRC concern, the PNPP Nuclear Quality Assurance Department Manager re-emphasized to L. K. Comstock by written memo-randum that all quality issues shall be processed in strict accordance j with the Project approved LKC QA program. On a Project level, this .
j message was additionally directed to all site contractors performing , safety-related activities at Perry. In addition, the NQAD Construction l Quality Section performed a review of all safety-related contractor's internal correspondence files to insure that quality issues were being I processed in strict accordance with their QA programs. This review j netted positive results. In order to provide continuous monitoring of L. K. Comstock, a Project I { Organization QA representative has been assigned to L. K. Comstock on a full time basis. This individual will monitor all LKC inspection i reports and provide a continuing review of documentation packages that 1 are in process to ensure that the Task Force items are being properly , addressed. !
- 3. Date When Full Compliance Will Be Achieved l
The concerns and individual checklist items noted by the LKC task : force have been addressed on QA program documents. Therefore, full compliance has been achieved. Noncompliance II. (440/83-06-06; 441/83-06-06) A. Severity Level V Violation i 10CFR50, Appendix B, Criterion III, states in part, "The design control measures shall provide for verifying or checking the adequacy of design, such as by the performance of design reviews... performed by individuals or > groups other than those who performed the original design. ..." CEI Corporate Quality Assurance Program Section 0300 states in part, "CEI performs a design coordination function consisting of selected reviews and design control monitoring program.... These procedures shall assure...
" Design activities are conducted in a planned and systematic manner... ,
Perry Safety Analysis Report requirements have been appropriately addressed in design documents... Design requirements can be controlled and inspected and/or tested to specified acceptance criteria." Contrary to the above, CEI failed to assure that Gilbert Associates Inc. (CAI) adequately reviewed and verified that the requirements of Westinghouse Electric Corporation drawing E-40048 for medium voltage penetrations and electrical specification SP-33 were adequately translated into the isometric drawings 1R-72-3 and 1R-72-4 prepared by Pullman Power Products. Specifically, drawings IR-72-3 and IR-72-4 were approved by GAI, without the consumable insert specified on drawing E-40048 and the backing ring specified in l paragraph 5:08.1.4C of specification SP-33. Consequently, the medium l voltage penetrations were welded in Unit I without the benefit of either a consumable insert or a backing ring. Furthe rmore, there was no assurance that this discrepancy would have been corrected during the installation of medium voltage penetrations in Unit 2.
- RESPONSE TO ENFORCEMENT ITEMS PAGE 3 J
4 B. Response
- 1. Corrective' Action Taken and Results Achieved L. K. Comstock issued Stop Work Notice ill on the installation of the medium voltage penetrations. The discrepant welding conditions that ,
exist on the Unit 1 medium voltage penetrations have been documented on Nonconformance Report LKC 1769. The nonconformance report has since been dispositioned, accepted, and verified.
- 2. Corrective Action Taken To Avoid Further Noncompliance
, The Construction Quality Section issued Observation Action Request
#605 to Gilbert Associates for inadequately reviewing the Pullman Power Products isometric drawings for the medium voltage penetrations.
As a result, the Unit 2 penetration drawings will be revised to reflect the specification requirements and GAI personnel have been alerted to assure that drawings are reviewed to the specification governing the work. To ensure compliance, an owner hold point has been established on the welding of the Unit 2 medium voltage penetrations.
- 3. Date When Full Compliance Will Be Achieved t Drawing revisions will be completed by May 20, 1983, and full compliance will then be achieved.
Noncompliance III. (440/83-06-03; 441/83-06-03) l A. Severity Level IV Violation 10CFR50, Appendix B, Criterion X states in part, "A program for inspection of activities af fecting quality shall be established and executed by or for the organization performing the activity to verify conformance with the documented instructions, procedures, and drawings for accomplishing the activity." CEI Corporate Nuclear Quality Assurance Program, Section 1000, Revision 3, paragraph 1.1 states in part, "A program for irspection shall be established by CEI to ensure that all safety-related components, systems, structures, and activities affecting those items meet the required quality standards." Contrary to the above, a program for the inspection of in-process fillet veld activities performed by L. K. Comstock Company had not been established or executed to verify conformance with standard AWS-DI.1 1975, Section 6. B. Response
- 1. Corrective Action Taken and Results Achieved 1
The immediate corrective action taken by L. K. Comstock was to issue Stop Work Notice #10 on all welding performed by LKC.
. ' RESPONSE TO ENFORCEMENT ITEMS PAGE 4 As a result, a program for the in-process fillet weld activities has now been established by the contractor. This was accomplished through a revision to their veld inspection procedure 4.8.18, paragraph 3.7. To address the procedure deficiency concerning previous in-process inspections, the contractor initiated Nonconformance Report LKC 1788. .
- 2. Corrective Action Taken to Avoid Further Noncompliance To prevent recurrence, training was conducted to the revised LKC Weld Inspection Procedure. The procedure currently reflects the in-process veld inspection as required by AWS D1.1-1975.
- 3. Date When Full Compliance Will Be Achieved Full compliance has been achieved.
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