ML20199A517
| ML20199A517 | |
| Person / Time | |
|---|---|
| Site: | Comanche Peak, 05000000 |
| Issue date: | 11/27/1984 |
| From: | NRC |
| To: | |
| Shared Package | |
| ML17192A346 | List:
|
| References | |
| FOIA-85-313, FOIA-85-59, FOIA-86-A-20 NUDOCS 8606120436 | |
| Download: ML20199A517 (63) | |
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i' QW l. WW . - ALLEGATION INTERVIEW -4 . _,,./ 3 i 5 i i l . l LOCATION: BETHESDA, MARYLAND , PAGES: 1 - 138 c DATE: TUESDAY, NOVEMB'ER 27, 1984 , 3 l t
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p 06 02 . 70 . ; DAVpP 1 Y* ** . 2 MR. CHEN: Did you.jtave an allegation regarding 3' hold points? .if
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4 : MR. HOU: Yes. AQW.30. This relates to the QC 5 hold points. ,,
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6 Arose'. talking about-the weld tech' *
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7 hold points in the - lfEc'ident? ". l i 1 8 MR. CHEN: The what incident? I . 9 MR. WESSMAN It wa.s known as the - 10 incident, Paul. j . [ 11 MR. CHEN No, I'ar"hpo,t,' aware of that. : .
- 12 Are we talking about weld tech 8 13 hold points on RPS7 '
i ; . - 14- MR. CHEN: Right. 15 "What I was talking about there was f , 16 that this had already been brought off by quality control 8 17 inspectors on the original weld data card. .The final NDE l L 18 and the final visual. It busted on an RT. 1; 19 MR. CHEN: .I'm sorry, I lost you there a minute. h. j 20 Repeat that last sentence, please? l 21 When they did an RT it was -
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. 22 rejected. Instead of writing up a repair process sheet ,
t . , , 23 assigning quality control hold points to it, they gave it ! ' \ , I '
; 24 weld tech hold points. [
; 25 MR. CHEN: ,
Okay. When we investigated this, . i c - 1 . 1: [ ' t, . I
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f" y - 2 mentioncd, wo lookcd at
- specific welds We didn't see any
;-thece were no assigned.
were assigned, and we , way which hold pointsway in which they were to be . y las in the k y? g led a bunch of samples, o a rong with the samples i We couldn't find anything w cordance :.
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Aj We found everything was in ac pecific I' ( that we looked at. Do you happen to know what s a t I could take ?
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[ weld was being repaired at the time, that w t look at it? Mr. Chen, this is l ,' .,: MS. GARDRs ecific weld in laet Are you not aware that the spt of litigation f j question haa been the sub ec with g - 13 three and a half months? I'm actually sitting in here * ' No. . ; MR. CHENs 14 . someone else, okay? l l 15 Paul, where's Richard? MR. HOUs I
; 16 He's out sick today.
'.[ MR. CHENs So another guy did this?
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18 l in? This is What did you say, Paul, aga a 19 t ij MR. WESSMANs ! r. 20 MR. CHENs I asked which weld it was. did l / t
- 21 Who was the guy that actually
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MR. WESSMANs 22 on this? Was' this Chuck Richards? 23 the review Right. has MR. CHnts 24 Do you know if Mr. Richards 25 . . G I ,
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1y* * ' i* . 72 p M 04 reviewed the transcripts of the ASLB proceeding in which + mypp 1 this has been litigated to ' death? ' 2 ,
. I think he has reviewed ASLB hearings 3
MR. CHEN: i , 4 but I.'s not sure whether he- has done so for this particular
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5 item or not. Everything about, this particular 6 ISBOO7, 7 weld, whioh.,is field weld 40C, which 'is on drawing AF 3 8 rev 16. * ( And the issue that's left for you to look at ,is f
. 9 i ts [ *;
10 that because of the assignment of weld tech hold po n : C f after it had failed NRT and a major repair was done on a 11 ' I 12 weld instead of it being cut out and done over, which was f the r 1 13 what was required by procedure and by the assignment o i h t 14 weld tech hold points, and the work done by weld tec s, i 15 there was no QC involvement. l There fbre, the weld was acceptable even though 16 That technical 17 there was a major repair done on a C weld. i 18 issue has not yet been resolved by the Staff. is And everybody, including the Board Chairman, 19 j 20 expecting the Staff to resolve that question. l - Do you understand? . 21 MR. CHEN: When was this litigated? 22 ( _ It's been litigated in the 23 f 2. h.rra. _ nt m m i..tio. he. m g. .s th. w incide.t 2, .t.rmg .ie w ee . .ition .nd going t,ro.gh 4 e S . e
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- DAVpp 1 all of the individuals involved with this particular weld.
2 All the doctamentation is available. Preliminary findinge l '
,. 3 have been written. The B'oard' a inquiry has been conducted.
4 All of the people have been deposed or have testified. The : 5 only question left is the one that we thought you were s, . I '. 6 working on.' 7 .MR..WESSMAU: I guess we've 'got sogne confusion on ** 8 that. We have to go back and be .sure that we have looked at p
. 9 it. It doesn't sound like we have fully looked at all those -
10 ASLB doctaments and I'm' not sure we do have a staff position {<
"I 11 on it yet. I think that's what we're saying. ,
t I MR. HOU: For the issue of the QC hold point - 12 13 our review'--- we feel that this is a violation. 14 MR. CHEN: It was a violation. MR. HOU: It is an item of violation. We're 15 16 going to pursue on that. You mean that weld tech hold points j 17 18 were assigned. 19 MR. HOU Unfortunately the reviewer today is -
'4 20 sick and will not be able to provide the detail but we find l'-- .
21 this is a violation. This is' an item which we have to 22 pursue further. , That's only half the story. Was 23 MR. WESSMAN:
' ~ 24 there a violation on the handling of ;the weld tech hold 25 points. The other part of the story 'is what's the sa fety aC- ..
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y'l DAVPp 1 acceptability on acceptability of the weld? How can you say that when you don't
, 2' 3 ,know what the weld is?
MR. WESSMAN: We've got to pin down what it is.. 4 MR. CHEN:
-let me point out what I'm -
5 reading from here was some stuff which was done about a 6 7 month ago, okay? Subsequently Mr. Richards has been back at c ,
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the site and back in Betherda doing some other things, okay? 8 I
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. 9 It would appear from what shou was telling me that indeed it . :
was picked up as a violation. What I'm reading here is from O alll 10 .', some preliminary stuff, okay? 11 I see. Well, if he is not looking at , i 12 , 13 the ASLB materials I'm not so concerned about the lawyers 14 arguments as much as the documentation and the facts i 15 developed by the testimony of the people involved in this 16 incident. And then you're not looking at the full story. 17 MR. CHEN: I understand. MR. BOU: I can tell you we have not finished our 18 l 19 review of this item. We feel this is a violation and we l j 20 actually say that TUEC should make a complete tabulation of . 21 all well documentation that was not revealed by the ANI for 22 BNR procedures. ! 23 So until that point we will know. 24 Your resolution? f Reviewed by ANI, let me see. 25 MR. BOU: e e t
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p 06 07 MR. WESSMAN: We won't go for just accepting what , i gypp 1 I 2 the ANI people say. (
, 3 MR. HOU: I know we'll hatte to make an ,
[ ! 4 independent. decision on it. i \ 5 Anyway, this is an open item., We're going to do h 6 more work on,it.- !, '7 What you're suggesting is in your ! 8 request for information you're going to have them look at ?
.' 9 amount of weld tech hold points that were assigned have the -
J 3 10 ANI look at the number of weld tech points that were .. i
- 11 assigned?
MR. CHEN: Who is that, This is Paul 12 , 13 Chen, again. ! 14 Apparently some other. things have developed since i 15 I last spoke to Charlie Richards on this. From what Shou is I ' 16 saying it would appear that subsequent to the preparation of 17 the report that 'I have here, it has been identified as being 18 an open issue or as being a violation, rather, of our 19 procedures. I think at this point we're going to have to do 20 some kind of safety assesmaent of that. 21 I hope you go out and look at that 22 particular weld. MR. CHEN: I'm sure we'll have to do it as part
'23 24 of our assessment.
MR. WESSMAN: The transcript identifies the 25 i e
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p 06 08 - 76 _ gypp 1 particular weldr doean't it? 2 In the hearing, it's been litigated 3" to death. 4 MR. WESSMAN: We know where we can find it in the 1 5 documentation. Let us go back and look at 'it. I don't 6 think we can do anything more while we're talking, about it 7 now. Okay. , 8 MR. HOU: So wie'll be able to identify the weld 9 location. h 10 You haven't seen it yet? ,[ 11 I MR. WESSMAN: We can't say for certain whether we , 12 have or not. We don't have the reviewer with us because 13 he's the guy who's sick. 14 He'didn't write it down anywhere?
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15 MR. WESSMAN: He didn't. write it down in the
- 16 document that Chen has so we don't have it.
17 MR. CHEN: It's about a month old. 18 MR. WESSMAN: Let's go on. We don't have all the 19 in formation. What else do we have for Paul. 20 I think Paul has finished his items. 21 MR. CHEN: I have.nothing else at this point. l 22 MR..WESSMAN: Do .we have any other questiona for 23 Paul before we lint him off the phone, then? 24 I do. 25 In your searching through the reco'rds in whatever O e e Y'$
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,$h0609 it is you' re doing out there, are you in contact with the 1 DAVpp 1-l 2 quality engineers. and the engineers -- the site engineers --
l #f . 3 for both TUGCo and Brown & Root, talking to them about l 4 this7 . - 5 MR. CHEN: About what7 About the problems that you've G
- 7 just talked to.ine about, the three problems that you have . ,
L-e 8 pursued with me because of my allegations. l . For the buttering-up, okay. And . MR. CHEN: No. 9 the out-of-round, I think there's enough documentation . 10 I talked 11' available for me to be able to make an assessment. 12 to them 'to get procedures and that kind of stuff, to 13 identify procedures. I think that's about the extent of my f 14 conversation with them about these items. Okay. Let me caution you this,
- 15 16 that if you should have the occasion arise where you thought l
17 you needed to consult with them, before you put a heavy 18 amount of. weight to 'what they have to say, you might check 19 their credentials, because you'will find that what they're l 20 calling engineers out there and quality engineers have
- 21 generally come straight from craft or are sleeping with
' 22 somebody's daughter or somebody's son, and are not really 23 pes or QEs.
Oh, 24 That's off the record I hope. 25 cod.
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!i 70 That's the truth. . pp 1 g Let's go on. Do you have anything .* 2 MR. WESSMAN: ( , ., ! 3 else? . No, I think I've got both feet in 4 - my mouth now satisfactorily. i
' .5 tbt. WESSMAN:
Shou we'll chat with you
' G tomorrow.
We're going _to let you off and pick up another 7 : f - ' l guy. 8 l ' Before we pick up the next guy - . . . . l 9 . MR. WESSMAN: We're off the record. ~ 10 11' (Discussion off the record.) I'd just as soon this be on the g 12 - ( record. Can you identify the rest of the problems and tell 13 k P
- 14 us what the disposition is before we go any further?
l MR. HOU The other one is the loss of CNC. 15 What's the disposition?
'16 MR. WESSMAN:
Milanson's got it. You don't know 17 1 18 what he's going to say. l 19 HR.'HOU That's the last item. Let me go to OA. , 20 MR. WESSMAU: If this is the way it's going to go, 21
' 22 Mr. Wessman - I. appreciate where you're coming from, but 23 it's a waste of my time. '
i . MR. WESSMAN: I understand that wei have
- 24 On the other hand, the only way incomplete' stuff here..
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.we' re going to find out' whether it's incomplete sometimes. i l3 DAvpp
^ 2 What difference does it make? We've 3
showed you violation after violation of procedure, violation f 4 of documentation, violation of filing falsification of l f 5 documentation, and you say you're right. That's right, l 6 but I.t's okay, it's as built. What the hell , Aren't we spinning our wheels? , i 7 difference does it make? .
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8 It's okay. You've identified the problems, they are
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j 9 problems. 'But it's okay. .. 10 The pipe's out of round, we know it's out of
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11 round, but it's okay. It's been jacked together but that's l :
*. 12 okay,. Nobody's even gone and looked at it, they haven' t f done a stress analysis on it, they haven't done anything to 13 14 see if the metal's imbrittled or any. other thing.
15 You're taking the documentation of Brown & Root. [ You remember. That's why I asked Paul i l 16 ' MR. HOU: If, according to whether he checked the welding procedures. 17 18 the welding procedures, they would not have a high stress 19 concentration. [ I 20 Also, there's another effect. The area reduction 21 has' caused a flow reduction. Go we look at it from two f 22 poist of views. One is the stress,, one is the flow l 23 reduction. We know'the flow reduction which they're having ' i ' 2,4 will not cause the problem. ! ho that's why I keep asking Paul ,on the phone ! 25 That's why he says 2G we' re going to work on the procedure. l i 0-
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i;' C $ t 1 80 ( ; 4 l he's going to look again. That item is not finished.
;8E 06 12 DAVpp 1.- .
1 When it is finished, in lieu of what 2 d 4 3 you have said of the other things that have.been identifie , 4 won't it be just to leave it alone? ' We didn't finish our review, you see. i 5 MR. HOUs ' 6 No, like the violations, the violations that we identify been 7 that there is a violation, that there is a group that s the QA, oc. You're going to hear , f handling the violations, B ** 9 their story.
Let's hear their story.
10 Then MR. ROU Then we'll just give them a copy. 11' 12 when we are finished we'll have a copy. . It's tedious, I know it, but I 13 HR. WESSMAN: QC part as 14 think I've got to ask you to try to listen to QA, well. We haven't had very ' good conclusions on some of those 15 16 mechanical things. I understand what you' re saying. , , What I'm saying to you is why do we 17 l have procedures. Why don't you just throw them out the 18 d l window and let's all go out there 'and do what we want to an ' 19 h k it i 20 then you come out .there when we all get through, c ec We f that one's good, that one's good. 21 out and say, uh-huh, f Violate the procedures. 22 don't have to go by procedures. We had a team with MR. WESSMAN: Wait a minute. 23 24 :the OA, QC fellows. We called them our as-build , 25 verificatiori guys. They went'out and, looked at a lot of They're going to be able to tell you'that 26 stuff out there.
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1060 OG 13 DAvpp 1 some of the stuff they looked at is, in fact, not okay. 2 Some of the welds that these guys looked at they feel are . /* 3 within the bounds of acceptability. 4 !!R. WESSMAN: I'm not going to judge a weld, 5 Dobie, I~ don't know. MR. HOU: All the safety implications are 6 7 underway. We look at it as under procedural violations.
!!R. WESSMAN: Let's try and keep going.
Lot's - ,5 , B i 9 pick up Milan' son. Let's try and finish him up and let's get . l 10 onto the QA, QC picture, okay? 11 Let's go off the record. . 12 (Discussion off the record.) . i 13 3 14 e f 15 ? ? 16 17 18 19 20 21 i I 22 23 . l' 24 l'
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'I 84 1 really upset them'.because they had done the work and they
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4 2 'didn't have an ANI; and I went and got an ANI. And he came 3 up and I showed it to the ANI man, . And he came i 4 up th'ere and we did verbal battle with them over it. 5 And the guy didn't want to give me the NCR number i 6 but, like I said, I went down the hill and got me one anyway. 7 Q Okay. f -- [ M8 You indicate here another NCR that you wrote in 9 n which a weld tech was called in and 10 performed inspections on QC hold points incorrectly? b n
/( A Yes, sir.
cpfL i{h f 12 - According to procedure, if a final NDE on the weld 13 data card has been bought off, then if there is an RCS to be 14 issued, if for some reason the weld failed, an RT, then, 15 you are to -- the RPS is ' assigned QC-hold point. 1 16 The final NhE had been bought off on the 14th;
~17 on the 15th they did an RT on it.
, It busted. It was not good 18 So they issued a repair process sheet on the 16th.
b 18 I have that.here somewhere. f 20
;. They issued the RCS on.the 16th and they issued .
I 21 it with weld tech hold point. ., 22 So in order to cover -- to me, in order to cover
- 23 wh'at they had done, where it should have been QC instead of 24 weld tech, they went to
,, and they told that they 25 wanted him to line through date of the 14th, .and put down the i
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1 17th.
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2 And(hlllsaidthathedidn'twanttodo.that.
- 3 He didn't think he was supposed to do that. .I t
i 4 Q And h 5 A Quality control inspector.
- I 4
They' wanted to change his' inspection date to the 7 17th, which would make what they did okay for procedure. - '- . s So, now -- I'm jumping around here -- I'went to
. 9 nd I showed it to and I said, o something's wrong here. .
U I said, if(llllfforgot to put " late entry" on the. 12 bottom of this, then I've got no problem with it. 2 But the way it looks now, I've a bad problem. i l 14 And I said -- he said, "Oh, don't worry about that. 1 - That 2 RT was an information RT and it dide't count." -
- la I said, "That doesn't makaesense."
i 17 Well, come to find out, on that AF* system, -- j 2 Q What is "AF"? 2 A- Alternate feedwater. l
'A We have a directive, I understand, from the NRC 21 that we are to RT the AF and CT systems, I believe.
22 Anyway, it was a legitimate RT and included in the i 23 package. ~ 24 I said, that just doe'sn't make sense to me, that, .
- 25 you know, if it was just an-information RT and it still called b
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l l 1 for repair work that we did it out of procedure. 2 So I talked to First I went to the super- - 3 visor. .I went to everybody first. Before I wrote the thing ' 4 up. 5 And I told I got and I told
- 8 I said, if you forgot to put ' late entry' on here, a
j 7 then that's all I need to make it fly with ANI. But otherwise ,..', 8 I've got a problem here." " 3 - 1 e i 9 And he said, "No, no, that's not what happened at 10 all." He said, "The craft people brought that package to 11 me and wanted me to change the date from the 14th to the 17th. l l 12' And I said, I don't think I can do that." , c ) . 13 And they said, "Yuh, you can; and it's okay; we've s 14 already talked to your supervisor and you can do it." 1 ] 15 - So M said, "I contacted He 18 contacted him twice, called.him twice, and went up the hill { j 17 once to see him about it. 18 And told him, "Oh, it's just an information l 18 RT, it doesn't count; go ahead and change the'date." )
) 20 So did change the date.
21 So with that I went , ahead and wrote the thing up. 22 Q An NCR? <
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23 A Um~-huh, an NCR. -
^24 And then - ~that was-actually the 24th; I put the r
25 27th; but it.was the,24th -- on.the 2 th, there was l .i
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I a meeting. And I was called into the meeting with
~ l 2 Seavers, Ted Blixt, Dwight Woodard, Terry Methjeni and .,
3 : 1 \ 4 And before I went into the meeting I went down to - l-5 office to meet with everybody so I could go up th're e 6 with them. l 7 And tiurned t and he says, "Oh, by ,,, 8 the way, we fixed that problem up. just forgot !. ( 9 to put ' entered in error on there'". , j 10 And so, when I got into the masting and they asked ( l 11 why I had written the NCR, then I started to explain. 12 And ust jumped up and started yelling l 13 at me. "How come you to, write this NCR and not even talk l 14 to the inspector? You'didn't have to write this NCR. It 15 wasn't even necessary." i 18 And I said, "You just wait -- you just give me 17 30 seconds, sir, I'll explain to you why I wrote the NCR." 18 I said, "I did go to the inspector and I did talk 18 tc the inspector." 20 And then I told them jast what I just told you. 21 And t.he inspecter was sitting right' there , ,, 22 So, they came back with, "Well, we're just going l 23 to annul the NCR, because it.'s all been took care of now."
- 24 And, "Do you concur with this?"
i 25 And I said, " Gentlemen, it's up to you", you know.
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<E 1 Q Did the NCR.have a number? *
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2 A Yes, sir. .i j 3 Q And it was put into the system; right? 4 A I have a copy of it; yes. ~.
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5 Q, bkay, will you provide that to us? 6 A Yes,' sir. 7 Q Now, if we go back and talk to is he going to .. 8 say that it was an error, a typographical error? Is that O 8 going to be his story to us? j 10 A Yes, sir, because he's been-told to say that.
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11 'Q Are you convinced that he knew that by changing 12 that number that he was. making a false entry? l 13 A I think g was afraid he was; but when you meet 14 you'll know that fraid of everybody. 15 And he came to me and he said, he wanted "I just is want to know one thing, S why did you write me up?" 17 I said, i I didn't write you up. In fact, 2 I tried to cover up for you." 18 Because they came in the next day, the Level-3 20 waJ running around hollering " falsification of documentation." 21 And said, " Wait a minute: you and I both know M did what 22 he was told to do." I;said, "where the mistake.was made 23 was with weld engineering.. They knew, they had the paper right 24 in front of them, telling them that that final NDE -- thev 25 . knew it had a QC hold point." 9
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. 1 So I tried to cover for I said, _.
. 2 there's going to be a meeting, a meeting its going to be !
s- 3 . 3 called." see, I didn't know 'that he had already done this
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4 1 5 other stuff -- signed " late entry" on it. 6
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[there's going to,be a meeting. called. I said, "
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. 7 I said, "when it's calle ,,., when you go in there, please,
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- 8 tell them the truth. Tell them exactly what happened.
8 Use the names -- everything; but tell the truth!" You know, W because I was still trying to protec+ - 11 And I didn't know that I was the one in trouble. 12 (Laughter) l i / 13 And so, about that tima came up behind me 14 and he's patting me on the shoulder and saying, g there' s 15 going to be a meeting at two o' clock this afternoon, and 18 we want you there. And, we want you there." 17 And I said, "Oh, boy." - 18 So turns around to me again, he says, "Why 18 did yota write me up?" 20 I s. aid, I didn't write you up." 21
.Everybody says you did." , .
22 He's just that way. 23 Q okay. , N 24 Next your affid'avit says, a Level-3,
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25 approached me about my NCR; was' at the time convinced it f I - l
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i l I was a typographical error, or do you think he knew at that ,
. 2 point? l i
3 A ew; he knows. Oh, yuh, he knew. . 4 Q He knew it was changed? ' 5 A Yuh, he knew. 6 Q To make it right? 7
. A Yuh, he knew it; sure. --
a Q Why was he trying to get you to sign it? 8 A He'd been told to. ,
" Q By who? -
11 A By ' 12 And he came up to me and says, "You got'to sign ! 13 this concurrence slip." I' And I said, "Got to?" 15 He said, "Well, no, you don't have to." 16 And I said, "Well, I'm not." 17 And he said, "I didn't thin.k you would." 18 And I said, "I don't want my name on there." M
.And then he.took off and went straight into-8 '
office with it. So that was, at that point -- the 1 21 next day or two, then I was. notified that I,was on the layoff 22 list ; then I was notified when I objected to that, becaus'e
.23 1 .
of my experience and my-level and my certification, then,
, they came back, then came back'and told me that.they were going to put in weld engineering and cut my pay in half.
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I, f' C 1 1 And I just said,"Okay."
'}.
J? 2 And I knew then that if I didn't leave that they 3 l were going to discredit me in some way.
/
4
- , They had done it -- I had three other people, .'
5 (' friends of mine, that they'did that to. l j 6 One, they came up and said that they wanted to , 7 get rid of hiin. And wouldn't leave. So, suddenly ?
- 8 they went out into the parking lot out there, and out of all - .;
8 i i s the cars out that that I know had' marijuana in,them, they " I 8 l found a stub of marijuana in his car.
, )!
11 { That's just strange to me out of all the parking 12 let, and I know the guys that go out there and light-up as 18 soon as they get there -- and the one they got. 14 They did the same thing with They got j u him, too.
- s f' 18 He.was writing an NCR and I told him, I said, 17 don't write that N!Ut; I wrote it and as a result of 18 f writing it I ended up with -- I lost my lead position because i
3 f .of it. And in order to protect myself, I had to go nights,
" ' to get away."
21 And he said, "Oh,,I'll be careful. about my l = .or m g.. . 4 23 I said, ,I was very careful." 24
.. Well, in a few days they came and got on 8
4 falsification of documentation. And there it is'. 1 I 9
8
- ,- p l
- 1. ,
g 12 4
.t i
1 working on a chicken farm. Two weeks ago he cut his finger . ! 2 off. -An A-inspector, with about eight years experience, ! . 8 and he's working on a chicken farmt
- It's the only joli he .
4 can get. l 5 And you believe this was because he was doing his f -Q l . 8 job? ! 7 A Yuh. Becaus,e he wrote NCRs on stuff -- it's -. j 8 all right to write NCRs on minimum weld and it's okay to l 8 write NCRs on arc strikes. 3 + 18 But don't write them on'anything important. ' 11 Anything that's really important, anything that's going to i 12 hold them up. 18 Arld then, of course, - we all know 14 the story of 15 Anyway, after that, various events occurred in Q i 16 which they complained about you being out of your work ares, i t 17 and you'aventually gave tweiweeks notice? 18
- A That was after I gave two weeks notice, they came 18 in and said I had been -- it had been reported that I was l
- \
? l 8 out of my work area, and that I'didn't feel like I could 1 21 stay in my area, that I could just go. . l 22 Q Okay.
'8 The events you've identified that we've just_been )
t 24 talking about, is this what you have filed as'your basis for 25 - your e k'
" ___L_______________._.-m__;____._.__
------w
)
.; q
+ *
. 's i
=. *y ;
l 93 :, 1 0 l 1 A Yes. .
'2 Q Okay. 4
/
3 MR. CARPENTER: Partially, not all of those. 4 THE WITNESS: Well, yes, not all of it. 5 BY MR. GRIFFIN: 8 Q Well, I'm talking about this last incident?
' 7 Did that lead up to your leaving? - ;
*O i
J8 A Yes. #
, % 9 Q You make a general observation in here that you 10
- believe QA lacks independence, and that there is pressure 11 from the craft side on QC inspectors?
12 A Yes. - l' 13 Q You said that last year you were called to inspect 14 a pipe hanger and that you saw another hanger? 15 A Yes. ' i . 18 Q And they told you not to look at that hanger? 17 A Yes., 18 Who was the goldhat, do you remember? Q 18 A No. I want to say it was but- I knew it 20 wasn't I've always thought of him as_ but that's 21 not his name. He's a tall, skinny, old, fsllow. 22 It's just a thing. I'm not the oniy one that it's 23 happened to. I think it's happened to just about every 24 inspector out there, that if you call in and'you see something j, 20 else, you're told -- I know it's happened to because N
\
a T *- - w -y 9 , - - , -
s en o,mw-
, ._ ^
-;w '*' '
+r c% %
l C - 51'- i i L 111.J. J. _NCR with Inaccurate Dates _ testified about a Honconfonnance Report III.Jgl. E From .
-wrote, and the actions taken regarding that NCR. ..
(NCR) whic 33/ 3 ' The witnesses and their testimony which deal in whole or in p , with the alleged incid nt are as follows: Au ust 1, 1984 Tr. 59.500-683) Deposition.of
.and August 2,1984 (Tr. 59,694-825 ;
July 28, 1984.(Tr. 59,000-246);
)
o July 24, 1984 (Tr. 56,500-605); July 25, 1984 (Tr. 57,500-587); f uly 25, 1984 (Tr. 57,000-076); ) , n of_
~
July 25, 1984 (Tr. 58,000-139); July 10,1984 (Tr. 41,000-i fp*p 1 7 j August 15, 1984
'Prefiled Tes mo of I (pp. 1-38);
August 15, 1984 (pp. 1-9); P estimony o August 16, 1984 (pp. 1-24); P Testimony o August 16, 1984 (pp. 1-20); P timony of l 3 : 2 Q 2 : n , M g h .) August 15, 1984 (pp. 1-21); Testimony of
~
lh FolA-85-5%
~^ . - . ~ . -
~.
- o. .
i i* ftheincidenth approximately November, 1983 and through theDocumenta- time o was working as a QC document reviewer in the Inprocess
~
at 59,540 Exhibit 1). tion group, a Brown & Root ASME supervisor
- at that time was '
at 56,505-506; Exhibit 1). QC/QA supervisor at CPSES. the supervises twenty-two QC ASME mechanical inspectors on responsibilities as a at 56,508). f day shift. had been document reviewer were essentially to ensure that everything [. ,, ,
- had been covered, that ANI had signed Y
. signed off, that all hold points listed.' ..,
off their hold points, and that proper heat, numbers were . t59.541). shared an office 111.J.2. At the time of the incident in, , who was training' with, inter alia. training at 59,541; Barnes at 59,149). l job. might have if function was to respond to questions' at59,149). ncountered a problem. work _ 24, 1984,'during the course of On or about January III.J.3. encountered a Weld Data Card (WDC) for reviewing dccuments, Exhibit 1, _ l Field Weld 40.C from Drawing No. AF-1-SB-007There are at59,545). Exhibit 3). WT (weld for this weld, with " hold points" assigned to oneExhi- ' or more of
)
technician) QC and ANI (authorized nuclear inspector . . bit 3). Operation number 5, " Final VT" (h. visual test) and ' o be'en signed off as tion number 6. " Final PT" (i.e., penetrant test) had at59.564). Both
" sat" (for satisfactory) by e,
e i
~ ~~ - - - - - _ _ . . ,
s C, " f j operations had been originally dated 1/14/84,-and both dates had been - *" ! t lined through with the 17th put in over the 14th. (M.). Beneath.each
' line-through is the date 1/17/84 and the initials Exhibit 3)'. ,
! III.J.4. testifiedthathbecameconcernedaboutthe . line-through on the WDC because %had nothing to tellhwhat the at 59,564). k then looked through line-through was for. [' $ the package accompanying the WDC to find the visual and penetrant at 59.564-565). Mwastryingto.. find inspection sheets. l out why there had been a change in dates. (M.). The inspection sheets were not in the package. (M; at59',754). ]d f did, however, locate a Repair Process Sheet (RPS)'for Field Weld 40C Exhibit 42-3 (p. 3 of 9), e_t t al,.). noted that the hold points which were l MExhibit9 at59.564). marked with an "X" on the RPS were WT or weld tech, and not QC, hold points. t59,565). III.J.S. The RPS Exhibit 9) is similar to the WDC in that hold points may be assigned for each operation to WT,QC and/or ANI. ' j testified that since the WT hold points on III.J.6. f the RPS had been signed off on 1/16/84, this would be after the original l I dates of 1/14/84 (before the change to 1/17/84) for the final NDE (non-
~, at destructive examination; in this case the PT and the VT).
l: 1 59.565-566). L d k* ll
- k
, O
* . . * - l
~ t
. 54 - k
( III.J.7. It should be noted that the RPS in question - -
~
Exhibit 9) represents a ' repair to Field Weld 40C with work performed on - l This RPS < e 1/16/84 and a final VT with & WT hold point signed on 1/17/84. t is discussed in more detail infra. if a repair is made to a. weld 111.J.8. According t
. /
after QC has made its " final"'NDE inspections, new QC hold points need be at59.565-566). established for another final QC inspection. and
'showed the WDC package to f Ill.J.9..
at 59.567.;; at 59,006). k :. expressed neerns. -( . 5, M also showedMkas part of the package, a radiographic " Exhibit 8,MExhibit 42-3 (P. 5 of 9)), marked
~
report (RT) (
" rejected," which was the basis for issuing the RPS to repair Field Weld 40C. at 59,567-568).
l .te!,tified that there were two things that III.J.10. f first, in regard to the changed dates, bothered %abcuttheWDCpackage: f the words " signed in error" did not appear; second, there were no QC hold at 59,112-117). However, does not points on the RPS. personally know if the lack of QC hold points is indeed a problem. /* I j at59.117). old to talk to III.J.11. According to f at 59.006). recalls upervisor, ' tellingMto talk to j lead man for l ~ at59,568-569). In the QC inspector who signed off cn the WDC. l f L 4 4 i -
'ee .ee ao e **
Mm e e. m
- _ gg _ 'l t
and showed him the WDC 9 any event, went to see (_Id,.).E
.]
package. III.J.12. According t
~
came intoNoffice
^
at59,580). (showed him the toseewha'tkneeded. 3 . WDC package and asked him about the line-throughs on the dates of 1/14/84, ' which changed them to 1/17/84. ( H.). M asked him, "Did you forget to then replied, "No,'no, , put ' signed.in error' on t'his?" (M.). testimony is that that's not what happened at all." (Id.). j.- told %some craftsman had come to him with the card on 5'the f ' ~ 17th for an inspection that he MAad done on the 14th, and the . craf tsman told him to line through the 14th and change it to the 17th. 2 old he was concerned about doing it, (1d.) . ' . so he called his lead man twice; each time he was told to go ahead and sign the card, that it was okay because the RT did not count,- (Id.). At told .he put the lines through the that point, _ dates and changed them to the 17th, at59.580-581).
' testified that the conversation ~~with l
III.J.13. ' auseMgreater concern about the line'd-through dates and i
~
d s been as to what i 34] Testimony from plicant's counsel as earsay. at objected to by t or state-59.570-571). Staff coun 1 joined the o ect acted. , b and upon whic acted the nts ma l at , 5 e apparently state:nent, , l QC Inspec or, as a result a asked 11owing: the Board sho d only a f he org n to "sig d ' if he would as 9,578- d > i n erro " on the WDC. which did. at l' to "get wit . 59,579). : l 1 i
- - - - .- - - -- - _ _ - _ _ ~ ~ - - - - _ _ _ , _ _ _
i
$C. ,
5 at 59,792). Based on that conversa-the weld tech hold points. - then believed that weld engineering had issued the wrong tion, e. hold points, that they realized what they had done, and that they "had to line through it and change the date so that dotten et 59,792-793). According what .they did would be all right." ~ b didn't always understand things, and he just did to what he was, told to do." _at 59,793). , III.J.14. [who testified M was in the office with I Mat the time of this conversation, provides some corroboration to testified that 7 testimony about the conversation. "
.ask Mif he signed the WDC in error. M .
M heard said_no, he did not; at59,007). According to ,
- his lead, told him
,' he completed ~all the inspections and , asked the "to do it that way" (quotingM. (M.).- same question "several times" and received the same answer. (Id ). , The entire conversation lasted "three or four minutes, five minutes." at 59,054. tipon cross-examination by Applicant's. counsel,$' ' meant by the phrase "do stated k does not know what ' f also testified that if l it that way". M at 59,129-138). ' had put the words " signed in error" on WDC, referring to the f changed dates, tnose dates woeld not have raised.any concern in % mind [ M at 59,138). l 11f.a.15. After the conversation with at, either took the WDC package to%upervisor;. f! ffice_ M at 59,'008), 55,58J),or came to . at56,569.56,584). In any event k or both, in that order s } 4 4 . . , . . _ . . 4 -
~
7c. l I j _w hat M had, and told testified that' M howed ' him "what M had said". M at 59,581). M M _ recalls j was concerned about the cross out and change of dates, that and the fact that there was an NDE report missing fram the package. ' at 56.569). M, testified they discussed the "inconsis-states tencies on the Weld Data Card." % at 59.008). . that, after discussing the discrepancies and the , documents, and he agreed that the best way to get the documents corrected was for at56,570). This is. consistent ]j to write an NCR. ( 59,008). , with the testimony of. (59.582-582)and ! ? was offered III.J.16. The NCR as originally . written by f into evidence as Exhibit 11-(also identified as M l There are two subsequent. versions of the NCP, in the record, , ' Exhibit 4). Exhibit 12 M. Exhibit 3); and Exhibit 13 Exhibit 42-3, p.1..of 9). , III.J.17. The narrative section of the NCR, as written by t states: WDC #40851 for FW40C shows a final PT & VT signed originally 1/14/84. Because of an information RT reject. dated 1/15/35 S/N RT 30964, an "In Process Weld Repair" was issued by Weld Engineering with Weld I Tech hold points. PT and VT hold points on WDC 5a0351 were signed by Q.C. Entrys [ sic] on VT & PT ere lined through, initialed and dated 1/17/84. Because it appears final NCE was signed at time of issuance of RPS 1/16/84 QC hold points needed to be established and reviewed by ANI. I had with is of I!1.J.18. The conversation had has' testified that if ' I particular importance. not signed off on the final QC NDE (h, the final visual. and final pene- l
. 1 I
* ~ - - -.- . - - - , __ _
~
. . . ~
-3,
. 1e
' d Weld ]
trant tests) on the WDC, and a repair to Field Weld 40C was require , '
- Engineering could issue the RPS as an "in-process".atrepair with weld '
f ,
# not QC, hold points, since the weld still belongs to craft. _ ,
had signed off on the final QC .s 59.736,59',740). However,if. ' NDE before the repair was made, the RPS should have been assigned has agreed that the RPS at 59,737). points. .
~
Exhibit 9) represents an in-process' repair sheet, which is a
,at 59,743). Therefore it can have
- repair sheet for craft, j
~
weld tech hold points.E (Id.). The issuance of an in-process repair . sheet means that there are QC steps left undone and it would revert back ;f to the WDC by referencing going back to the WDC at the bottom of the at 59,744). The RPS in' question purports to do this. page. t (Jd,.) .; ~ III.J.19. Nevertheless, has testified that k believes t toldM that "he had signed it off on the 14th." estified . 59,738). Given this statement by
% felt constrained to write the NCR; in fact, ifN"had not had t would not have written the NCR."
i conversation with i at59,796).- III.J.20. However, testified that_%did not write the ' p t 59,786). Nwrote it against NCR against fj Weld Engineering and stated so in the NCR. (Id.). The NCR reflects f .The latter 3y The transcript has the word "cannot" instead , of "can". I is correct. t t! j . 1 L - - - - . -_ - _--__ __________._---.:--;---. 3 --- ,
~ ;o .
C f i j to do Y concern that' Weld Engineering had told ' *' . has testi-at59,793). In fact, " something wrong. concerning the NCR, "You know I was just fled that h old a alsoexpressedM at59.590). trying to? cover for a victim." at 59.749)'. belief that has also testified concerning this inci-III.J.21. office l ' recalls that called him down to J dent. lat 57,518). h "just kind of asked and showed him the WDC. *.j < several questions about it."- (H.).- He could.not, at .the time, : l remember any of the particulars about the WDC. ( H.). k asked him . if he had perfomed a PT and a VTi he to1 M hat he had. _ _w 'as having with the at57,519). He did not know what problem f did not testify to any statements made~by him WDC. (,Ij. ) . I l concerning the change in dates.b(M.). to first f _ testified that M ,saw.the WDC for the III.J.22. t 59,739). M did not witness ' time whengwas reviewing it. _ l perfom any of the inspections listed by his signature on sign any at 59,740. %did not witness ! the WDC. . of the hold points on the WDC. (M.). , deposition was taken on 36/ ItJuly should be noted was taken on August I and 2, l 25, 1984, whilehere that eposition it was not at all 1984. At the time of the l arent fr t e record th t the alleged statements which purportedly led to
' to c
writing the NCR, were of significance. i., L i
) .
N
. ~ .,
* 't l
C, j has testified to his version of the chronology ' III .'J .23. He had volunteered for a'special job on Saturday, ; represented on the WDC. January 14, 1984. M at 57,514). QC inspectors were.not working J l , The WDC had an unsatisfactory listed for weekends at the time. (M.). iihd (H.). [ operation 2. " cleanliness" and craft wanted to get thed item f n s e . ' reverified the cleanliness, found it satisfactory, and signe . at 57,514-515). He then remained with it off as operation 2A, d no other work that particular crew of welders and fitters because he-ha !} t 57,515). A _few hours later, the crew was ready . assigned. had (M. )'. for the hold points en operation 3. "fitup." ' day, and , previously notified ANI that there was a _ fitup in progress that and the ANI inspector he got an ANI inspector. (M.). Both ' ctive verified that the fitup was good, and both signed off on their respe At the same time he' signed the (M. ;_ Exhibit 1). hold points. fitup, he went ahead and did the next hold point, which was " prehe Atthispoint,itwas3:30p.m.,andh (M.; Exhibit 1). ' asked the welding crew how long it would be before they were was at 57,516). ready for a final VT and PT. informed that it would take them twelve hours to complete the weld, i. at 57,516).. After discussion with until early Sunday morning. . the welding crew, it was decided that there was no reason for M)
. went home on the afternoon of to stay. (J.d,.)
d . Thereupon, (Ijf..). without having done any more QC inspections. January.14, 1983, further testified that the next time he,saw 111.J.24. 17, 1984. (M. ) .- He did not know why no the WDC was 'on Tuesday, January 16, 1984'. (M.)- work had been done on Monday, January
. .. a _
--=. - _
1c t ' ,- 5 i III.J.25. On Tuesday, January 17, 1964, according to " the welding. crew signed up .on his ca11 board for the final' VT and PT inspec-and another QC i.nspector,
^ at 57,517).
tions. whb was then in training, pe'rformed these inspections.' (Jd.). perform the PT. d .). (I_d , erformed the VT ar.d observed reviewed the WDC and ! After climbing down from the scaffold, . He then inadvertently wrote the same proceeding to sign it off.' (Id.). (Id.). 1 dates for the VT and the PT as the dates above, i.e._,1/14/84. ' l - As soon as he' had signed the WDC, he looked at it again and noticed that > (Jdl,. ) .
'he had signed off on the same dates as'the preceding inspections.
[ words, I cussed myself. out real good verbally." (Id.). In why,and told him he had written a,ske , down the wrong date. '(Jd,1,.), i then crossed out the wrong date,'initia11ed j III.J.26. ' at . it, dated his initials "per procedure," and forgot about it. turned in his 57,517-518). Having finished the inspection, at ' paper work and the WDC to the craft working on the weld. did not see the WDC again until he was called into 57,518). l; at 57,566). office a few days later. (Id,. i , f III.J.27. After writing up the NCR, had another I at59.592). Accordingtok_ F conversation with~ why%had came.into%officeand. asked I written'him up. (Jd). This testimony is in conflict wit , testimony tha had called him down toMarea and showed at 57,520). Both witnesses agree him an NCR g was writing. ' that Said%was ' writing the NCR 'against Weld Engineering.
. . . _ ? "~ '
,l . _ _ _ - . _ _
) 1 t and j at 59,592; _at.57,520). - .! was upset at the time of this second meeting. testified that i _and M also
#' M at 59.592; M at 59.009)., h initial testified thatMdenied what he had said during t e at 59.009).
)at59,794; conversation.
recoll'ection of that meeting was thatM III.J.28. told him Weld Engin'eering had not added additional hold points. does not remember saying anything to at 57,520). \, . , ,
; he was still confused about the WDC because he could notl-
~
l
~
l h ld .. see anything wrong with it and did not understand why additiona ~ o l points were needed. (M.), l The next event in the. progress of this incident was a meeting t III.J.29. QE (Quality E'ngineering) NCR. concerning l M at 57,048). Group' Supervisor has the NCR _0ffice under his direction.in_ l
- He receives a printout on currently open NCR's, and if he notices one
" he attempts to expedite closing it. (Id.). l the " quality house or arena, M' Accordingly, upon noticing the NCR in question he discussed it wf f the QC Group Supervisor.
(M.). Together they decided to at 58,068-069). (Id.; have a meeting with the parties involved. ! l - Those present at the' meeting were l l all those present at the at56,571). With the exception of With some exceptions, all the meeting have ' testified as to'.what occurred. and 1 Mte ' witnesses agree essentially on the events which took place. Mexplained the purpose of the meeting, had which written was to re
~
f NCR was initiated (Blixt at 57,050),
' explained why l
~
{
. j
__ - - - - - - - - - ~ - - - '
4 1c b
( u _at 57,051; M ,at 59,595-596)'. After discussion, the NCR. J
)apparentlydecidedtovoidthe'NCR.
M t 57,051; - and
^ at 58,070; at 59,596). M _ testified that at the time I' he first s'aw the NCR and the WDC package before the meeting, the actual 'I t 58,067).
VT and F1 inspection reports werk not in the. package. , At the meeting, asked M if he had performed the ' tests. at 57,069; ,at 58,070). ,M replied with words , to the effect that he had signed the WDC, or he thought so. (M.).
$ gi Accordi'ng to he could not at the time connect the WDC with the -
~
at'57,552). actual inspection events. _ recall that at the end of ; 111.J.30. . All the witnesses except
'was ordered to retrieve the actual VT and PT reports the meeting. ;
at 57,052; 58,071; % M at he had done on January 17, 1984. ~ at 56, 572). admits to being'" confused" at the 59,598-time _at 57,575)', an'd went out and checked with the piping in order to jeg has memory concerning the department forema the t 57,553; 57,580). .According to inspections. ered the WDC well because the welding crew had been working foreman re all night Saturday to weld it up. (M.). 111.J.31. The main Liceptions to the consensus recollection of the meetirg involve the date of the. meeting and precisely when the NCR was voided by ystifiedthatthemeetingwasheld at59,593). testimony is that it or. Jamary 27, 1984, t 56,571; Exhibit 5). occurred on January 25, 1984. The only significance to these dates appears to be whethe%actually voided the NCR before he had the missing VT'and PT reports in hand, since 9 e t
= - - -
- L:--__; - - --
IC ~l. voided the NCR at the meeting, and then testified that - . at 59,598). , to produce the PT and VT. asked e. on the other hand, while he agrees that at the meeting a decision was did not have the PT and VT reports made to vo4d the NCR, and that , j remen.bers that he did not actually void the ' at 58,070, 58,075), HCR at the first meeting. M at 58,075-076). l According tom _ there was a second meeting that day 111.J.32. 157,554'). At that time,M told Mto get with .; l Qd,.). % confirms that he i M and send.him to that meeting. talked with Mabout to corroborate thatMwas with W- 7 when the examinations were performed. M at 58,078). M testi- , fied that after the first neeting~he did receive copies of the VT and PT j a) 58,077; 17, 1984. _ reports, which were dated January wridedown f Exhibits 2 and 3). % also testified that he had nd had I the sequence of events as related by later signit.E at 58,076-077). In addition, and
" asked around" to see if %andMwere buddies in order to preclude in his own mind the possibility of a cover-up.
% at 58,078-58,079).
! After reviewing the PT and VT reports and the signed state-111.J.33. ment of old M to asterisk the two lined-through dates on the K0C and add the words " dated in error," whic ? r This particular document was not made an exhibit during the 3_7/ evidentiary depositions. P ~
/ -3 - . _ .
y ..
1 v q 7; t 58,078). The date following the words " dated in ' was done. error" on the.WDC is "1/26/84 " preceded' by the initials f voided the NCR and dated Exhibit 42-3 (p.9 of 9). Subsequently, -
' Exhibit 3). 'While '
it "1/27/84." _ % t 58,080, 58,082; , recalls.Myoiding the NCR in the first meeting, which $also recalls being held on January 27, the discrepancies in - l dates are not signif.i cant. It is evident that a decision to void the l NCR was made at'the first meeting, albeit the action of voiding would '-j
. await substantiating documentation.
Q:! l ' in , , . , i 111.0.34. Ther,e are two other points raised by ; ssembled. , After the NRC was voided ' I relation to this incident t the complete package associated with the WDC, added the WDC with ;
" dated in error" words, and renumbered the package from pages at 59,604-605; 1 of 8 through 8 of 8 to 1 of 9 through 9 of 9.
Exl.ibit3). On the voided NCR (p. I of 9), Exhibit 42-3; f f dded the words " copy voided NCR, corrected WDC added"., then crossed l out " voided NCR", installed and dated it "1/27/84", to show%was"n at 59,605). However, according happy" with the KCR being voided. j at the end of the meeting when it had been decided to f . indicated % was satisfied with the direc-to void the NCR, t f 3 I tion they were going in, with the outcome of the meeting. i 56,548; at58,074). f testified 111.J.35. Subsequent to the voiding of the NCR, l l' that told M had to " sign concurrence" on the NCR, which k I' r ;
' ~
7c i l' 66 - I I ;l at59,606;59,781). Upon cross-examination. j I
~ M would not do. . '
by Staff counsel, could not show wherekwould " concur" e- on the NCR.
'at59,781). In fact,$does not know of any l,
place on the NCR wheregcould concur. _ at 59,763). M
- testified that'when an NCR is voided, the individual who initiated ,
\ ~
' the NCR is presented a copy of the NCR with an explanation as to the reasoning behind the voidirig of it. _ at 57,054). If the indi- . i vidual did.not concur with the voiding, the individual could revise the ICR. (M.). 'This involves rewriting the NCR, putting "rev 1" in the des-4 cription block with a reason. -~ _ at 57,055). If it then.could not the' .j be' resolved, it could go as high as _ at 57,056). There is nothing in the- record to indicate did anything further with this 'NC.R. III.J.36. The second point raised b[Mwas elicited during cross-examination at the end of the second deposition session, was asked whyMwould doubt the authenticity of the VT and PT reports dated January 17, 1984, which fomed the basis for voiding the NCR. at59,807). According to three times to go to at the meeting asked j i his desk and find the documents, even though does not actually i ~ Qd,.). Thereupon, because " understood the have a desk. game"Maiso told to "look for" the documentation. I at59,808). also testified that the forms for the PT.and VT reports are not controlled, that inspections can be post-dated, and that , l ghasdoneso (H.).
~
I _ _ .
~
C t Shortly after the events comprising the incident with the ' ~ III.J.37. submittedhresignation. . NCR, on Febnsary 8,1984 if. at59,607).E , an ASME QC Inspector employed by Brown 111.J138. [
& Root at CPSES, recalled performing an inspection of Field Weld 40C on January 17. 1984. ' at.8). At that time he was in training to .
(J_d d ) . On the date mentioned, become a certified Level 11 QC. Inspector. i ct, aft signed up on the QC call board for a final visual and _PT
') inspec eeded more PT time" under a certified inspector, 4 (Id.at9). Siric .
.. .i
_ ted w h
-evidence three documents conn 38/ Intervenors have o handwritten resi tion dated Exhibit "Que on that resi hibit 14 tten connent b to CPSES
' effective Q QC , w th a han f r Pers ns Leavi Exhibit ;"An en let Exhibit 16, Exhibit 15 na t and Brown & Root", signed by ntervenors stated during bit 3). However, Counsel for ,
t deposition: Let me just state one more time: MR. ROISMAN: here as part of its direct case CASE is not a11egin resignation was that the reason for has related to'any of the events about which testified. That is not part of the case; harassment, intimidation, the position we are stating here l -- e we are stating that on the record as clear y as w
' can -- that is not in any way related to the. question ose events may or may not have been the of wheth ~ resignation; but it is not part of the cause of is being presented by the Intervenor here.
case tha . An examination of the doc ments reveals no specific references toThe S - the incidents alleged by to admission of these three docun,ents. e 1. 9
- _ i
~
?
9 j C. 4-
^l I erformed 1 5
(,Id . ) . ' he went on the inspection with , had climbed
- the PT himself on a ten-foot high scaffold, while 1 eported to i down off the scaffold to fill out reports. (M.),
tated that he had rio indications from the test, an [ then (M.). (from below) that that was good enough for him. [' was cleaning told to " clean it up." (M.at10). While f tter'a curse and ask, "today's not the fourteenth, up, he heard f replied that it was'the seventeenth. (M.). is it?" (H.). had put the. wrong dates down remark that heard 4 and had to change them. (M.). Then the:two of them "made out the
- f. '
has authenti- 7 paperwork, signed everything'off arid left." (M.). l ' c. cated a document entitled "Kon-Destructive Test Inspection Request" Exhibit 5) for Field Weld 40C, which requests a final visual and f
"L.P." (liquid penetrant) test, and which he had ' signed on 1/-17/S4.
S (,Id.). M testified that his signature next to the data indicates (M.at beyond a doubt that he performed the inspection on the 17th. l 10-11). f also identified his initials on a document entitled III.J.39. Exhibit .6. Stanford Exhibit 3), which relates to "MT/P1 Report", , initials appear just above Field Weld 40C. (Id at 11). f (M.). signature and were placed there on 1/17/84. _ was. approached by Ill.J.40. After the inspection on the 17th, ~ j who wanted help to " jog his memory." (M.at12). According to was being questioned about conflicting dates on a weld f did not, at that time., recall the inspection, l data card. (M.). 1 i 1 . f l . 1 [ .
.~ .
~
[i q talked to the crafts people who did the work, so - remembered , (M. at 12-13).- After speaking to also recalled the the inspection : and after he talked to , then asked to speak to inspectiont .(Ld. at 13). l and appeared spoke to about the inspection. (Ld.). ~ testified that the proper satisfied. (Ld. d at 13;14). Finally,
- procedure for correcting an. error on a QC reporting document is to cross cut the error, enter the correct infctmation, initial and date.
(M.at ! 14). ' Q, _a pipe fitter employed by Brown & Root at III.J.41. _ "
-I at 5).
CPSES, recalls working on Field Weld 40C in January,1984. _ ~ l duties entail prepping and cleaning pipe to make it ready
' (_I_d . ) . In January, 1984, for his welder and for QC inspection.
(Ld. s crew was replacing a valve in the Unit 1 auxiliary feedwater system. + There were three welds associated with valve IAF 067, among them
- at6).
i Field Weld 40C. (Ld,.at6-7). l testified that on January 2, 1984 the old valve III.J.42. (id,.at8). was cut out and he prepared the area for a QC inspection. i The QC inspection for cleanliness was performed on January 3,1984 by f and the result was unsatisfactory due to a minimum wall violation. (Id.; Exhibit 5). No further work was done on Field f - Weld 40C until January 14,1984,i(id,.at12-13). At that time the STE - (Startup Test Engineering) was pushing for the job to be' finished and (M.). On Saturday, crew had to stay until they were.through with the job. eaned.up the pipe and valve, since they needed January 14, 1984 (Id at j to have QC sign off on cleanliness for Field Wel'ds 39C and 40C. t
===.. .
* * * *m======..
~ ~ * ' - -_ . . _ _ _ _ _ _ _- - , i 7e ;
i called for cleanliness QC inspections for both valves, which (i 14). " were performed by (M.). (Midentified the WDC's for Field Welds 39C Exhibit 14)'and 40C % Exhibit 5) and 40C ] hibit 5) which show satisfactory cleanliness inspections signed off by M on 1/14/84. (M.at15). and his weloer, ' proceeded with the III.'J.43. fitup of both welds and called for a QC inspection. (M.a't16). . performed the fitup and also the preheat inspection,s on both welds, then ' (Id ; ,See, hibits 4 .;. signed off on both WDC's as satisfactory. and 5).
.Ill.J.44. After ' approved the fitup and preheat ( k started .
welding "spuetime around lunch." (M. at 17)'.'Mtestified- that it
.I
' with help from welder . approximately thirteen i took hours to complete the welds, and that did not leave until 2:30 a.m.
the following morriing. (M.at17-18). identified the weld
~
~
filler material log (WFML) for Field Weld 40C hibit 7) and on 40C on explained how the WFML showed welding by January 14, 1984. (Id.at19,21). left work at 1:30 a.m. Sunday morning; and 111.J.45. general foreman, were still there, prepping for left, there were no QC inspections. (Id. at 22). At the time ' QC inspectors standing by, and had le~ft s'ametime on the afternoon of the 14th. (M.). ' III.J.46. Referring to the WFML for Field Weld 40C Exhibit 7), had identified a repair done on that weld. (M.at21). He testi-fied that on Monday morning, January 16, 1984, he:recetW u RT (radio-e
(
. .. 4 i
3 j graphic test) report which rejected 40C. ( M. at 24). g _ ( - ' began the repair on Field Weld 40C that afternoon using the' RPS Exhibit 9 Exhibit 5; Exhibit 9). Qd,.at24,28). . According.to there are no QC hold points'on the RPS because it I estified that a final VT is an in-process repa'ir. (Id at 28). had not been performed on Field Weld 40C at the time his group repaired , the weld on the 16th nor. had a final PT been performed prior to the , repair. Qd.at28-29). d Repair work on Field Weld 40C was completed at learned
.approximately 7:30 p.m.. on Monday, the 16th. (M.at29).'- '
-4 on Tuesday morning that there' had been a subsequent. RT on 40C which was ..
an " accept." (M.). Since the weld was now ready for a final VT and PT, requested the inspections by putting'his request on the 'QC call hibit : board. ~( M. at 29-30). M identified the document _
- 10) dated 1/17/84 as the sheet he used to request a QC inspection. (M.
at 30). The final VT and PT were performed by M_ accompanied by also identified as Exhibit 13 a "Non-(M.). Destructive Test Inspection Request" which he had filled out and dated 1/17/84, and which had b'een previously identified by Exhibit 5. Qd at 33).'Mtestified that it would not have been i possible to perform a final VT and PT on Field Weld 40C on January 14, 1984. (H.at34). 111.J.47. employed as a piping foreman by Brown & Root I at CPSES, testified he recalled working on January 14, 1984. at 4-5). He was supervising the installation of six-inch auxiliary feed valves. as a (H.at5). He originally ha%as a pipe fitter and welder, but later brought' over another welder, M.at5-6). f. t I: _ __ _ 7-
~.
3 He made a special request for a QC inspector that' day to _ I (Id,. at 6),. That morning his crew prepared the pipe for QC inspection of cleanliness, fitup and preheat on Field Welds 39C and 40C. (M.at7). (M.). crew p'erforned the QC inspections on those welds. comenced welding after lunch on Saturday the 14th, and completed welding $ after midnight. (Id_.at'8). f
~
III.J.48. piping. general foreman employed by Brown & l koot at CPSES, had assigned the valve replacement work to ! a I
'at6). Shortly before 3:30 p.m. on January 14th, it became apparent to M that M erew would not finish the job on the 14th. (Id.at
[ , ot a conference together with where it 6-9). was decide'd that the QC inspections could not be done that day and at 9; home at 3:30 p.m., the normal shift change. _ III.J.49. Around 1:30 a.m., s,ent
~
home, remaining wit . to prep the pipe for QC inspections, particulary RT and Pl. % at 10-12; McBee at 8-9). M had previously prepared ll e hibit3), a "Pequest for RT" for Field Weld 40C dated 1/14/84 a before leaving Sunday morning. at 11-12). which he gave to ] Oleft the form at the RT traile'r before he left at.2:30 a.m. t 13). III.J.50. received Exhibit 3 back with the word j " Rejected" stamped:en it shortly after 6:30 a.m. on Monday, January 16th, 1 for an RPS on Field l % at 12). At 7:00 a.m. he went to 4
-Weld 40C, which he received mid-morning from Welding Engineering. (Id.
i 1 i at 13). b Q l _ l_ - - - = - _ _ _ _
b o;
- 1 Weld Technician V, employed by Brown & Root at III.J.51.. ?
CPSES in the Welding Engir.eering department, testified that he prepared Exhibit 9, I the RPS for Field Weld 40C , Exhibit 1 Exhibit 5)*on January 16, 1984. _at 7). testified that to ' (Id,. at 9). In prepare the RPS, he used the WDC for Field Weld 40C. response to a questio'n on how he knew he had the proper WDC in front of him, testified that the hDC and RPS.are printed forms, preprinted
.on opposite sides of the'same sheet of paper (Emphasis by Board). (M.at l .
L g i . 9-10). 111.J.52. ) testified that he specified in the R'PS an "in-process repair cycle one," a repair that;is do.ne before'the final NDE's have been signed off. (M.at10). He could see that on the WDC Exhibit 3) steps 5 and 6., the final NDE hold points for VT and PT, were blank and not signed off by QC. (M.). The final stepM put on the RPS was " return to step #5 on the WDC." which is placed directly above his ( M. at 11; M Exhibit 1). testified that signature on the RPS. there is no way he would have written the RPS as he did if step #5 on the WDC had been signed off. (M.). If steps 5 and 6 on the WDC had been signed off by QC, the RPS would have been specified as a " major weld would have repair, repair cycle one." (M.at12). In that cas'e, included QC hold points on the RPS. (,I_d . ) . Exhibit 4 as Brown & Root's con-III.J.53. %identifie struction procedure CP-CPM 6.9D, section 3.19.1,'which defines 'in-process repairs. (M.). He also identifie Exhibit 5 as section.3.3 of 1 CP-CPM 6.9G which provides the procedure for preparing an RPS. (Ld. at [ t l 4
d
,}
1C. prepared the RPS for Field ,f 13). Both procedures were in effect whe '
~
i, We1d 40C. (Id.).
~
Weld Technician IV, employed by Brown & .,
,. III.J.54. '
Root at CPSES in the Welding Engineering department, testified that he reviewed the RPS prepared by t 8).. One of the items (Id.). he reviewed was to make sure the final NDE had not been signed off. e the final VT and PT had not been signed. He specifically checked to ensur.
, testified that they (M.at14). Finally,both ?j nor have they ever discussed the.RPS or the 4 neither know ~
4 - WDC with any QC inspector. (M.at14-15). " f III.J.55. AfterMreceived the RPS from Welding Engineering, his . crew worked on repairing Field Weld 40C, completing the job the same day. ht13)., thereuponprepared,and(JusticUubmitted,anotherRT (Id.at14; at 15;- Exhibit 4). request on Janaury 16, 1984. ' learned the second RT was accepted on Tuesday at 17-18; at16). then morning, January 17, 1984. f instructed his crew to request final PT and VT QC inspections on Field at 18). As noted supra., . weld 40C as soon as possible. testified'that he requested the inspections, which were performed by accompanied by at30). . played by Brown & P. cot at CPSES III.J.56. Finally, I as Chief Timekeeper and Payroll Supervisor, testified as to the check-in and Based check-out times of various individuals involved in this incident. on business records of which he is the custodian,Mtestified that on ^ g.hecked in at 7:00 a.m. and left at Saturday, January 14, 1984:
~
3:30 p.ra.;% checked in at 7:00' a.m. and left at 1:30 a.m. Sunday e L-
.- 75 --
10 9,
'J checked in at 7:00 a.m. and -
morning, as did at 11-15). These 1 eft at 2:30.a.m. Sunday morning, as did ; times reflect the times testified to by the individuals. Traveler Incidentz claims was improperly ordered to III.J.57. h t sign off on " travelers," documents relatedAccording to linertoplates in t e spen fuel pool, which was not in accordance with procedures. . the incident occurred sometime in 1983, when 5[ (QC Group Supervisor) an (QE Group Supervisor), at ) (QC/QA Supervisor) were all on the night shift. told they had a "special. 59,516). According to project" fo hhatnight-approximately142travelersinthemi11 and wright (M.at59,516-517).- _ shcp which they needed%to sign off. accompaniedMtothemi11wrightshopandshcwed dthetravelers to be signed. (M.at59,618). The travelers related -to the stainless l (M. at steel liner plates for the spent fuel pool and the transfer cana . (M.). With 59.526)., estimated there were about 112 travelers. toldMthat the signatures on each traveler was a " chit," and tors the chits coveredksigning off on 'the travelers, t' hat the inspec (M.at59.518, who had signed the chits had not signed the travelers. 59.524-525). could not understand whyMwas signing off III.J.58. (I_d,. d at 59.524). It' hold points for something another inspector had done. belief that if an inspector signed an inspection report. d is -(M.at59,640). cannot sign a missing hold point for the inspector. e
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. ,. c.aJee- m % N a w ssa w g ARMS G.5m@ " Brownf5RootJnciNDEXED' QUAUTY ASSURANCE DEPARTMENT "' MR No. M-1931 R1
~1A RECORD NONCONFORMANCE R*.T"' Ze DATE:
PROJECT CPSES JOS NO. 351195 PAGE OP (21 UNIT STRUCTURE / SYSTEM COMPONENT TAG /lo NUMBER LOCATION oR ELEVATION RIR NO. 1&2 Spent Fuel Pool Piping See Below Fuel Buildina N/A (3) NONCONFORMING CONDITION $r"Eo"oRy ist ooCUMENT VIOLA'TED: 2323-MS-100 REv 5 ,,,4 a.7.4 M-4 Dwg. #BRP-SF-X-FB-027, spools SF-X-FB-30-2 and SF-X-FB-30-3 were installed in pl, ace of ~ spools SF-X-FB-27-1 and SF-X-FB-27-2. Du. #BRP-SF-X-FB-030, spools SF-X-FB-27-1 and SF-X-FB-27-2 were installed in place of Sb X-FB-30-2 and SF-X-FB-30-3.- Dwg. #BRP-SF-X-FB-41, spools SF-X-FB-44-3 and SF-X-FB-44-4 were installed in place of spools SF-X-FB-41-4 and SF-X-FB-41-5. , Hold Tag Applied to Spool SF-X-FB-44-4. Other spools are inaccessible.
~
F0R lEDRWIDH OD ~ i Revised t2 chance disposition.
, e Hasten 10 / 80 M' / Md in PREPARED SY: e (8) DATE: till I (121 DATE:
Fred Burnett ! 1 / 10 / 80 D f:f.NI]ct.(( sod
/
L3 //// Id l J l (13) DISPOSITION ASSIGNED TO: 114) CUE DATE: 115) CORRECTIVE ACTION REQUEST: CAR NO.'(161 ASME COCE CLASS l 0. C. Frankum 1 / 24 / 80 C Required E Not Required l9(Y'8 No 117) DISPOSITION: REWORK X REPAlm USE AS IS SCRAP - The following spools will remain as now installed: SF-X-FB-27-1, SF-X-FB-30-2, . S F- X-FB-44-3. Spool SF-X-FB-041-4, SF-X-FB-27-2, and SF-X-FB-30-3 shall be installed , in place of spool SF-X-FB-044-3, SF-X-FB-030-3, and SF-X-FB-027-2 respectively. The ! other spools will be switched to their correct location. See CMC's 12218, Rev. -t, / ep j 12219 Rev.l-4,12220,12221Rl,The spools to I,e left "as-is" are identical to each M l l other. e,% -rd 6"$-n u I
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[ A 38191 OATE: 12 01 OVAL 8 (211 DATE: 11b81NSTRUCTION
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WI/flo 126) VERIFI TION: 133) REMARKS; l __ Satisfactory CUnsatisfactory O Not Reg'd QA RECORD l s2n (p)QC ENGRilNSPR. VER CATION- 1281 DATE: RTN. QA REVIEW W i291A GD 9M 2 URRE3SE y/ 9 /go L cn/p FILE NO.
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- 3) Denote Satisfactorv inscection bv an "S"; Unsatisfact::r i instsetions bv a "U". -
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.l'A RCOT INC. WDC Serial No._/f3 g 3 dO l FT5,403__d35-1195 ;
DA A A0 OraW ng No. m n w o -I _ 1 tm A:.t.ATION TO BE IN
- c. :.>A:c:5 v.iTH FROCEDURES Weld No. #4/ - /c, /
;;,; cr.e.' ! O IN CFM G.11
.I!!E f WPS i REVf/ICN# FABRICATION C0bE -&
ffo#5's e'
/ .2- i " 4 W CLASS /ACC. STO.
1 A -dS l. s'd&-6 M S 2 / ASME III
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7,SF.MAiut1AL , POSTWELO HEAT TREXIEhf , :T & /)> to HTi #4 TIME NA Hrs., TEMP. NA ' 'F '
- 'C 0 .S o .2 to PC# 6 o '1 i 'd r to P # 8 HEATING RATE NA , */Hr. NA f.
! :0EP/REV NO PT/ O&/$l lA A*l MT/400-lA 2 ~=*L RT/101' NA 12 ~ 3 UT l A T' O .w , -b (S)
7 M.&T.E.- CALIB. QC WELD FILLER MATERIAL REQUIRED '4' 00E DATE
*C VERif. IR00T CLASSt,c. sot i :~AT : l IFILL CLASS u-So# .-
^ -
CLASS I CLASS 1 3fES: (1) Applicable QC/ANI hold points.shall ca. Indicatec by cneck:narx /. ..t,
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(2) ANI inspection points iridicated b (X). - (3) Denote Satisfactory inscection by an "S"; Unsatisfactory inscection's by a "U". - PRODUCTION RELEASE i r L
.'i EA . OPERATION HOLD POINTS CON SAT. INSPECTION RESULTS (SIGN AND OATE) .s~
~~
- ;0. Wi .QC 'ANI or QC or WI NDE CERT. ANI -; ' i UNSAT. LEVEL - ' **. t 6 .
1 Verifv Cut X NA Mc. _<* N <-2.4-cr - 1 i 2 Cleanliness NA / Nc. Se M1o[ME . 2I ~ l'i l JJb 3 Fitup KA / Nc. hf @ _fjpf gjff[ 4 Preheat NA / Alc. . g *
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E 5 Final VT NA / Acl $~/M"' .fjdhMI. . .It- J.' ~! w ;a-rr 6 f$JL )0 7~ $A V hY bW >8 W~$ ~'.*.'- kd.a. h 2 b"l1/ /101 AM hMlf/1bf/ . Final Accept 30C2 l I I R. ill.4.-85-59 -
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.'It0'dN 1 ?.C':T, INC. WDC Serial No, d'.3 -/ 74 //
? ?SES JCB d 35-1195 WELD DATA CARD Orawing No. d.s-/.//d-c Co - /
WSTALLATiON TO BE in
^MDA \':E WITH PRCCEDURES N*1d NO S'0*lEYI i I'CIERENCED ist rou_ e , ,
i . UNE f WPS f REVf/ICN# FABRICATION CODE & f
, 220<!S~~ Sakl a i "'f-!2-nCLASS/ACC. STO.
- .? ' e'.5 -/- fe/G- (, O/ 4- 2 ASME III '
y iASE MAiiRIAL . POSTWELD HEAT TREATM 1 T .a A14 ,to HTJ n4 TIME NA Hrs,, TEMP. NA F nC i l. c a to PCf n2 ( 4
# 3 _ to P f, B HEATING RATE NA /Hr. NA <
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.,0EP/REV VT/200- PT/200 MT/400- RT/101- UT
- l'? 7 -n ,4p 4 -i /A .7-J 18. 2 .2 NJ, 2- 3'
[5F(5)__ M.&T.f.. CALIB. QC WELD FILLER MATERIAL REQUIRED OUE DATE l.'iC VERIF. al f , ROOT CLASS ft. sop
; OATE: I I I FILL CLASScg. Sop
. CLAS5 -
CLASS n0TES: Applicacle QC/ANI holc points.shall be incicatec by checx: nark /. - ANI inspection points indicated b (X). , l 3) Denote Satisfactory inscection by an "S"; Unsatisfactory inscections by a "U". PRODUCTION RELEASE YPEA. OPERATION HOLO POINTS CON SAT. INSPECTION RESULTS (SIGN AND 0 ATE) i RO. WT QC ANI or QC or WT NDE CERT. ANI e. . i UNSAT. 1.EV El. '** I Veriev Cut X NA NG- .S XJ / ,- l :2 Cleanliness NA / MC $8[4/ y M
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WC; Sarial fio. 43953 /2. <- .FSE5 ,:03 1 35-1195 . , FN- WELD DATA CARD Drawing No d5-/./4-451-2 i l'CCGi! , . r. 5 00 TO BE'In Weld No. AJ./2A R"rf t- . . . -- ITH pgocyn,,,,,,,, [~-~ CFM 6.13 ' ~] WPS i
'J!!E i N ,] REVf/ICN! FABRICATIONC05E&
8102.s*5 =L / d % y"'% %1'kLA55/ACC. STD. i.
.? d 5-/ 48-/fM '2 / ~M ASME III 1 / A .
fASE MATERIAL , POSTWELD HEAT TREA
;tt # N4 to HTJ AM TIME NA Hrs., TEMP. NA ~ 'F '
- C. i n2 to PCI so1 }
>p / to P # # HEATING RATE NA '/Hr. NA ,
I h .\ "W R-l .
;:057/ REY VT/2005.4 PT/960- MT/400- RT/tet- UT . I n r-n,s ? ? '- /s.2-/ /s. 2-2. /s. 2-3
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/,Rr(s) M.&T.E. CALIB. QC WELD FILLER MAIr. RIAL REQUIRED
'I 00E DATE l JC VERIF. ROOT CLA55 rs.Jos a
.) ATE: FILL C1.A55 u.ses s C;.A55 ,i l ,'" C:.A55 ..;
4 ':0TES: (1 Applicacle QC/ANI hold points.shall be indicated by cneckmark /. . (2 ANI inspection points indicated by (X). . i (3 Denote Satisfactory insoection by an "S": Unsatisfactory inscections by a "U". f 'I PRODUCTION RELEASE
,ii J I
& ER. OPERATION HOLD POINTS CON SAT. INSPECTION RESULT 5 (SLGN AND DATE) i to. WT .QC ANI or QC or WT NDE CER". ANI UNSAT. - LEVEL ,
L1 Verify Cut X NA NC.- $ $JNf/ V . i 2 Cleanliness NA / #c. .g.7- g"D L,f g ' l 3 Fitup NA / gc, 97 hThggg , l 4 Preheat NA / pc ,g,y Yg gjg '
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\ 5 Finst VT PT' NA / #c gj;f' khfk s Sc-9a M l (. f/Ahl AT$o N) V NC $NI~ M $ - LUJ- lYSA) - Wr Ni
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ARMS Brownf5' Root,Inc!,NDEXED' , f4t$]p QUAlfrY ASSURANCE i nvitm 56 Ncn s M-1192-R3' j*
@C QA REC" ORD (NCR)
NONCONFORMANCE R ne' i oP M Joe no. as.s iss nin no. _ acr cesss TAano suusan i.ocAvion en stsvATion
<21 un T sTnuct,RaisysTag : h en LCo m e d Fuel Building i Elev. 856'6" N/A 4701 Str.nt Fuel Pipe X Pool Cooling , lSeeBelow 8 j y 4.U.2 _ L M-10 d)yONCONTORMIEQ..CONDITJ,QN nsv 3 cAnA MS-100
.occuussT viouTro:_
The interpass temperatum was.not recorded on the Weld Data Cards for the fol welds: Spool Field Weld Number ~ DWG_ 2Q3 QA RECORD TI-3 '- 2&3 SF-X-FB-044 T1-1 and T-2 SF-X-FB-041 --nru. oA navicw T-1 2 SF-X-FB-015 4, dA// Af-#_ 2 T-2 2 SF-X-FB-032 T-2 SF-X-FB-033 ,,ge no, / f /'
- SF-X-FB-034 sueFil E NO. T-2 1
! S F-X-FB-30 'gjgy3- T1-3 1.
' M-1192-9 .
SF-X-FB-27 ' NOTE: These welds are stainless steel. Hold Tag Number M-1192-1 ' Rev. 2 issued to add spool f. Rev. 3 to change disposition. VAL i l DATE: ai REPORTED SY: I461OATE ISulfvtsW Ap*
,T / > l! to/ /V/JF .
Rich Scallan ! 10/ 4 / 78 , IH21pATE: f g/t PRipaREO 3Y: e 181 DATE: 44fl 5 EO SY: ygM ~! g /apypf 10 / 4 /78 i George Willis ~ f 1I41 Out D ATE: 1151 CORRECTIVE ACTION RiovisT: CAR No NO.'Itse A , nsi cisposmoN Assiasto ro: % Recuired ~~ Not Required S-28 l 1Y'8 U. D. Douglas 9 / 13 / 79 *
^ - -
11 D OlsPCstTION: REWOnX NI^^HKEW81DNUN.IP-i - I ' a !O VN & ROOT, 1- ! Accept as is. ! 1. Referenced welds ars tcmporary for hydro tes*ing and will bl renpve6Q
- 2. p
! weld prep refinished before continuing the i .o) . g f
- 3. Perform PT on affected end preps after re-prepping. - FEB 4 19@
l 4. See attachment -
,. a ..NoTao See GHF-3251 attached n.,,,-....~
Sis DH - M.sv OHMJrd ' " ' ' ' ' ' ' If il DITI:" i H S) DATC: (2 WIAPPROVAL
'9/y/n 501WntVIEW Z. APPnNOV L:AL"3 !
iist CONSTRUCT 60NbREVfs/r / .dW ' 124FT APenOVAL: , ikl siDATE 1223 ENo. REVIEW 4 APPROV AL
>i238 OATE:/v/n M WNIREvie
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, l1261 V E Satisfactory CUnsatisfactory G Not Reg'd g gj g fg (281 oATE:
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Brown &RootJnd,NDEXED Q~ C O QUAUTY ASSURANCE 968 ART. MENT Ii, NCR No-M-1860 QA RECORD NONCONFORMANCE REPORT (NCR) JOS NO. 351195 PAGE ! 05 i CJECT CPSES COMPONENT TAG /10 NUMSER LOCATION OR ELEVATION RtR NO. (21 UNIT STRUCTUREISYSTEM Spent Fuel Pool BRP-SF-X-FB-41 X yooling& Cleanup Piping FW-3 South Fuel Pool N/A (3)HONCONFORMINGC0gT[.Y 0 3.9.6 A EGORY g. y 131 DOCUMENT VIOLATEO:_ REV PARA , ,y Item #1 On. drawing BRP-SF-X-FB-41. FW-3 was repaired using RPS. R-1 for Weld Data Card #4319. Repair was completed as required by operational steps on RPS without ANI Review. Item #2 - The Weld Filler fiaterial Log attached to this same field weld (3) (for entries #3 and #4) has been lined through without being initialed and dated. F0'R lIF0HE0N ONLY Hold Tag Applied i(8)DATE I EV1 VAL i (10) O ATE:' 156 REPORTED SY: Greg Fannino ! 12 / 10/ 79 e tal CATE: f,,t,V6 i U Q 8Y: _ M f . /2.47//8 1 (121 DATE:
'r fl PREPARED SY: ' ' Greg Fanning 12 / 19'79 s # //A '/c2 /p/ 9f r
(13) CISPOSITION ASSIGNED TO: 1Idi DUE DATE: IISI CORRECTIVE ACTION RECUEST: CAR NO.'ilei~AsME C00e cf. Ass D. C. Frankum 12 / 31 / 79 C Reauired & Not Required { t Yes _No i171 DISPOSITION: ' REWORK REPAlm USE AS is Y SCRAP - Item #1 Give ANI's the opportunity to select hold points on subject operational steps. I Item #2 Have applicable craftsmen initial and date the WFML log and accept as is. NNM M YN QEst He.A a- /),rj eg;;f x .if.gr l
$ 65 C/>"/
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VAL 6 191 O ATE: ' #201 QA/ W APPROVA ' 1218 OATE: Iulxin W (18) CONSTRUCTION REVI IA M/ Av ~ Y-)EIN
'l231 O ATE: 12 4) 11251 OATE:'
1221 ENG. REVIEWIAPPRgVAL 1 Rt ."EW AP*Rg
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l JLCkleb ^ M7+ < _ mP */? - TION: 126) VEdRirisfactory : Unsatisfactory C Not Reg'd (33) REMARK : jp,vr '^#[ h d l l QdR[ CORD
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Minutes of ANI/QA Meeting of 1/9/80 Distribution: J. Westmoreland D.C. Frankum J. Hawkins S. Timko J.P. Clarke J. Ainsworth l G. Bennetzen P.F. Foscolo R. Klimist J. Benjamin , L.E. Whitson 8. Baker t
- 1. A general discussion was. held concerning the review of MTF packages and the need .
f for increased ANI support. The ANI's were requested to work as necessary on Fridays and Saturdays until the subject backlog was eliminated. Jim Westmoreland comitted the ANI's for such overt;ime when possible, and also placed a temporary ANI on site to assist in eliminating the backlog. } It is anticipated that the ANI's will be able to " keep up" with subassembly pro-duction after the Inspection Plan is fully implenanted, relieving them of the massive process sheet reviews now required.
- 2. . Although discussed in last month's meeting, the elimination of QC hold' points for preheat, cleanliness, and fitup was briefly discussed. It was agreed that as long as these inspections are perfonned by qualified personnel, whose training
- . and qualifications are documented, and the inspections appropriately documented j j on the process sheets '}that QC is not required to perform them. t l Welding Engineering must revise its training program for the new personnel being-i trained to address these items. Those individuals already trdined must be 5 given additional training before conducting such inspections. After this has l been completed, QC will phase out of the activity. /
- 3. A QA Manual change deleting the requirement for Weld Data Cardsiir"clAssIM
- 3 hanger welds- was briefly discussed. Although Hartford personnel could see no
" obvious" problem with such an approach, formal coment was reserved until such j time as the Code could be researched and the proposed QA Manual revisions evaluated.
! 4. Westmoreland expressed two concerns over the subcontracts of Jim Ainsworth and Jim Hawkins: ! 1.)effectivedate c 2.) dismissal clause . Greg Bennetzen was to prepare a memo to the Subcontracts Group requesting the i effectivity date be stated in the subcontracts, and identify to the ANI's the effectivity dates. Additionally, Jim Benjamin was to meet with Houston Subcontracts . to have the dismissal clause wording changed from "may request removal" to "may have removed", thereby demonstrating control over the subcontractors, r
~
! F01A-85-59 1 e --
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, .- ( Mpeg 1 i OW-%) \b N g THE H ARTFORD STEAM BOILER yggb INS PECTIO N an ct INSURANCE COh1PANY mon HARTFORD . CO N N E CTIC UT 0 8102 HOUSTON OFFICE - SUITE 2u0. 4151 KOUTitWEST 1;REEWAY. HOUSTON. TEXAS 77027 - (713) 623 2220 January 22, 1980 Brown & Root, Inc. r py TO P. O. Box 1001
- Glen Rose, Texas 76043 Attn: Mr. Pat Clark, Quality Assurance Dept.
MINUTES OF AN!/QA MEETING 1/09/80 In Item 2 of subject minutes you state " Quality Control will phase out of the activity". This should be corrected to indicate Quality Control is still responsible for monitoring these inspections, in-
,cluding personnel records and inspection documentation.
Your attention to this matter is appreciated.
// / =
J. N. Westmoreland, As istant Regional Manager Special Inspection Service Division e i JNW:aj , F01A-85-59 . 3126 7.) REY. 7178 M /$. -
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. .. r g THE HARTFORD STE AM BOILER h
Smoo ' INSPECTION and INSURANCE CO MPANY HARTFORD - CO N N E CTICUT 06102 HOUSTON OFFICE - SUITE 200. 415I SOUTHWEST FAEEWAY. HOUSTON. TEXA5 77027 - (713) 623 2229 "- January 24, 1980 - Brown & Root, Inc. . * P.O. Box 1001 '* Glen Rcse. Texas 76043 's.. A 4,30
-- -- - Attn:--Mr.-Pat Clarle-- -
t Quality Assurance Dept. ## . Re: llinutes'of ANI/QA Meeting 1/9/80 .
~'
ily Letter 1/22/80
Dear Mr. Clark:
In addition to cocments of subject letter, please artvise how your proposed weld examination program will coirply withd9I451,L7 A copy of your procedure describing this activity would be appra lated.
. Best regards, g/gd '7Y J. it. Westnerelana Asst. Reg. 'fgr.
J"'.1/sp/73 . . 1cc: Jim Benjamin ; Icc: Steve Tirko g y . F0lA 85-59 3,23.,,i. n. ,,,,
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The Hartford Steam Boiler Inspection & Insurance Co. i / - k J D , Suite 200, 4151 Southwest Freewa Houston, Texas 77027. 5 j y g) J.N. Westmoreland ' ATTN:
. .,,,, , , ,, ,,,g , p .g Comanche Peak Steam Ele.tric Stat on -
f 1981-83 2300 MW Installation Compliance of Weld Examination Program h *
Dear Mr. Westmoreland:
~hV fy Thfs letter is written in response to your memo of 1/24/80 conc i th!t welding inspection , program and compliance with MA-4511. ,
As discussed in our previous meetings, certain " inspection" operation ill
- be performed by craft personnel responsible for the work. At this time these opera-tions will include cleanliness, preheat, and fitup of component supports. Quality -
V: control personnel will monitor these activities and ensure the craft personnel are properly performing them. { , ,
- While we recognize that these activities must conform to certain Code criteria,\D Y ~
i there is no need for them to be inspected 100% by QC and the monitoring activity t is adequate. These activities may be compared to maintaining interpass temperature , protecting against filler material contamination / environment exposure, welding within j the parameters of the WPS, etc. The aforementioned items.are the responsibility of the individual performing the work, are not documented, and are monitored by QC. l . Besides the monitoring activities, final inspections will be performed by QC ! who will verify the following items, and only QC inspections will be documented:
- 1) support and material identification; -
- 2) location, elevation, configuration, and fasteners;
- 3) proper WPS, filler material, and base material combination used; l 4) final visual inspection and NOE.
s The craft personnel performing these activities will be trained specifically in This training is to be performed by l the requirements an'd the training documented. ' { the !!elding Engineering Department. The trainint program is currently being deve-loped and you will be sent a copy for your information when it is ccmpleted. ' L t F0lA-85-59 -
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. hann7 Root.inc. --
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"Page 2 Th'e reference to NA-451'1 is from the Summer '75. addenda to.wh - -
committed. In any case, we have complied with NA-4511 by establi- . _ n _..
. examinations to verify.the _. ._ _ __
above and are performedquality by' quality control of personnel.- the work, and these examina. __. Picase contact me if any additional information is' required. Very truly yours, .
. BROWN & ROOT, INC -
f/ , * - Senior Staff Engiw A JPC/cin _ cc: D.C. Frankum m2. P.F. Foscolo __._ R.M. Klimist
- T.H. Gamon -
i G.R. Purdy , W.E. Baker _ S. Timko
. R.G..Webb.
i S t + t i l l I O S
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C w%svg "A. 3 A Qu 30, 't b U. S. NUCLEAR REGULATORY COMMISSION AQ.u-TD OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report: 5's-445/81-07; 50-446/8'l-07 Docket: 50-445; 50-446 Category A2 Licensee: Texas Utilities Generating Company 2001 Bryan Tower Dallas, Texas 75201 Facilii.y Name: Comanche Peak, Units 1 and 2 Inspection at: Comanche Peak Steam Electric Station Inspection conducted: April 6-10, 1981 Inspectors: 4 f/5/8/ L. D. Gilbert, Reactor Inspector, Engineering and 'Date Materials Section, (Paragraphs 1, 2, 3, 4 and 6)
- c. 3,p & w f, gh-frj L. E. Martin, Reactor Inspector, Reactor Projects Date Section No. 3 (Paragraphs 2 and 5)
Other Accompanying Personnel: K. A. Whittlesey, Reactor Inspector Trainee, Engineering and Materials Section Approved: M MMI.'ab S/MS'/ Date g W. A. Crossman, Chief, Reactor Projects Section No. 3 fR. E. Hall, Acting Chief, Engineering and Materials 8 Saye 4 Section hj i \ h c '
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DETAILS ,
- 1. Persons Conta'cted Principal Licensee Personnel
*R. G. Tolson, Site QA Supervisor, TUGC0
*J. T. Merritt, Manager, Engineering and Construction, TUSI J. Lowry, Quality Engineer, TUGC0 Other Personnel i
J. V. Hawkins, Project QA Manager, Brown & Root (B&R) W. E. Baker, Senior Project Welding Engineer, B&R F. Nichols, Supervisor Welder Qualification Test Center, B&R - T. B. Maxwell, Site NDE Level III The NRC inspectors also interviewed other licensee and contractor employees during the course of the inspection. .
- Denotes those attending the exit interview.
- 2. . Follow Up of Previously Reported Unresolved Items (Closed) Unresolved Item (50-445/80-28; 50-446/80-28): Incorrect Designa-Y v. tion of QC Hold Points on Weld Data Card. The licensee performed a review u'\ .f M of 600 Weld Data Cards which represented approximately 20 percent of the dd outstanding Weld Data Cards and found no QC hold point errors. The NRC y D f no inspector reviewed an additional 25 completed Weld Data Cards and found QC hold point errors. The Weld Data Card with the QC hold points V S,,..-) erroneously marked is therefore considered an isolated case.
The NRC inspector had no further questions on this matter. (Closed) Unresolved Item (50-445/79-06; 50-446/79-06): Non-Class IE Cable Tray in Seismic Category I Structures. The NRC inspector reviewed the following procedures: CP-QP-11.10, Revision 0, " Inspection of Electrical Raceway Support Systems" QI-QP-11.10-2, Revision 2, " Cable Tray Hanger Inspection" i QI-QP-11.10-4, Revision 4, " Inspection of Seismically Mounted Conduit Supports" I i . e
CoJte.$wg '13 W '50 $ 3 hcw, /f c' '
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IV Ffgure 16.1-1 i . SRQdN & ROOT, INC. l QA RECORD Quality Assurance Department NCR NO. M-3120 Nonconformance Report (NCR) j t. '
- CFSES-35-1195 PAGE OF 1
j DRAldING/ IDENTIFICATION TAG /ID NUPEER LOCATION OR ELEVATION RIR N0. N/A N/A N/A N/A l 1 MONCONFORMING CONDITION
; . TREND
/ DOCLMENT V10t.ATED: B&R QA Manus 1 REY.12-28-81 PARA. 10.5 CATEGORY G-3 A s j Construction Operational Travelers MP-79-374 A, B, C, ... .-XXXX thru MP-79-945 A, B, C,....XXXX and HP-79-948-XXXX*thru MP-81-3432-XXXX were - not submitted to the Authorized'!iuclear Inspectors, prior to issuance, for review and establishment of hold points. a\
- O REFORTED BY: DATE: RE' /APF VA DA TIME:
Ron Faulkner 1/7/82 Y b~- d ( 'E }-') &2.1pti DL5PQ5LT10M AESPON51BILITY: 015PQ51flon AssiraNED TO: CAR NO : A5ME CODE ITEM:
~
XX Yes No
~' D. C. Frankum G. R. Purdy - ! %,, . 3ISP05ITION: .
4 REWORK REPAIR USE AS IS XX SCRAP kETURN TO VENDOR " s > Travelers completed and submitted to the Permanent Plant , Records
'A i1 Vault shall be noted with this NCR number on'the traveler'by the .
V
~
Systems Release Turnover Group (QA). -
<2. Travelers issued but incomplete shall be submitted to the ANI for review and establishment of hold points and/or signature.
j 3. AllnewOperatiynalTravelersshallcontinuetobesubmittedtothe i ANI prior to istuance for construction activities. i 1 4 / O _ /If - 1 2._ A m/ L A) . l- - 1 5 QC ENii/ . ON: TE: Ntl CONC E: QATE: k - 1P-2 -P7 - cF 8 ! i % T. j'
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Welding Engineering gdtion OnD REQUEST FOR RT RF.OtJESTED 1::Y tkh DATE._ h_!.L' O - FLAGGED BY 8/4< - DATE Ib 7 -# 2
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No. 4160 \ . . l 9.h TO: costity Anurana Final
, Date loint Welded _ - T N 3C Weiding Engineedng nformitionh- N k 6 eO fA Lu()
REQUEST FOR RT - REQUESTED GY NMd//kT DATE !#** Y- L FLAGGED BY_ Ad DATE 9^k2
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- P.9EVICUS RT LOG NUMBER IF A REPAIR
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reu ca.ce :d tem, c'c w. r. a .m3 CU ALITY ASSURANCE DE?ARTt.1ENT VISUAL EXAMINATION CF.ECXLIST PROJECT: CO.'.1ANCHE PEAK JOB NO. 35-1155 UNIT PAG 6 oi-GM AwlMb af57EM GLA&& w g LG!a T g s4 n u am a t ft s LO CA TIO .e iO O. N ovi
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' QUALITY ASSURANCE DEPARTMENT
. r40 JECT: COMANCHE PEAK JOB NO. 35-1195 MT/PT REPORT UNIT f PAGE OF MT O P raveler # $3 Y298 Drewing
[ M@] System (( Class 3 , Weld:litem # (Yh h Location $ [ h9(O.LlRev. [ Mig Stagt NDE Procedure No Equip / Mat'is Mfg ff/[ h Acceptance Std. [ s f Penetrant Batch # [3 Cleaner Satch #[ h/)(([ Developer Batch # [/ h j 2 7 AC Ycke O DC Prods O gj Modei a M M&TEIRC # ' Mat'l Type h .- [ Mat'I Thickness O *10 O n th [ Sketch & Commerts 10 0 OD I l . t PTp W6e 6395298 _ ( . YA0 W . S l P, ' 2C % 7490 gg
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'y INSPECTION REPORT PAGE OF
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- nosmo no e,cos auf seuweER NuugWt NEATAoT/BATCN No. oWANTITY OR No. STATUS oAft re re aMe EMS 90 108 toe sts 112-121 133-13F PURPOSE / AND TYPE 2I@ON/ %.J SURVEILLANCE:c h ( NcR l
, RESULTS OP INSPECTION / SURVElLLANCE:
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* <J5IS. RECORD FOR MONITORING Q.AdQice PROGRAMS t *Se GM 3')
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- THE HARTFORD STEAM BOILER INSPECTION and INSURANCE COMPANY C .o.:l v5h gy g H ARTFORD. CONNECTICL"T ost02
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- Q.A srW1a.<or us5P. GRANDL if.27-72 msP. REGION OR F0 Ate COUNTrf (#fo#0ssAL 4/88 Omtr) l lor l
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6 M 6. AI C Y 4 ffnU Shenn.nt Ele tYtte. ,$ h'b'JO A I'* l the undersigned, have monitored your QA/QC manual on: 8-27-El ,o. , and find the following sections: t - . e r e, Es="=c'*m. _S e c+1oa ._10 .1. Av+b orsz eL. Awete+< ._INsf ecet. .- l 1 1 _ .---:_ : en especeenet N""""*'*****gneentdr CAICC onenuar eeeren (No. and reen) QM Jeontory one neees l% a . ll. 3 . S a y s .W+ ia sp e c+na s cve_-lo 4<.. . ins /< _hy..p usus . l g o+ke r . % # e 08e s A. o sas #* w ort e....dr .a AL.)l, I .26' ssy.s 3% .*t. lG c\eaiae s s .o1 f&f.4 ,o ar <. /-o.h e. _ven Goed by A.c. i8.s,*e.chv: .
%s is not.beim _Aosa. .au _zoaposeat. s .ypods ._ The. a.A . inmusL orfaceebre. do es, s.*+. Ai s /Myrsl.._ .h e hat e d._ fife e.a.l s.ypr /s. .
fe.k, keforY $ .25Y C.0/ Y 8 f$s.c$tk. , UCVEP -l ', CUSTOMER: Please describe the resolution of these items in the " CUSTOMER'S RESOLUTION" section below, and give
-' date for completion cf corrective action, so that items may be remonitored by: 9 IA J coeno Please keep the Original of this form for your records and return a copy to inspector named below.
oisteiscrion ses
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' BisAufl0N of THQst ITDes otscasED a40vt As atWuG UNsATisFAcr0rf (Contenue on A. verse S oe d J
.. . . _ . . . _ _ _ . . _ . . _ . . . _ _ . . . _ . . . _ _ _ _ . . . _ . . _ ~ . _ _ _ .
See Attac!nent _ _ . . _ _ _ . . . _... . _ _ . . . _ . . . . . . . . . . . . _ . . _ . . . . _ . . . . . . . _ _ Eil as - ga . . . . . u-r p m'OVER I onra coastcfrvt action mu si cownTr3 cart seco setore men,e .,e,.e, k i None 99-%1 > > M-kl I, the undersigned, have remonitor?d the above unsatisfactory conditions on: C[- Q-((7 ,, and found them: hatisfactery CUnsatisfactory (Explam below) E i
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r 5 RESPONSE TO SIS # 308 , 1 N.l ; l Neither the Code nor the B&R QA Manual require ficup inspection of each joint. ' I The ficup inspection includes the verification for cleanliness and joint dimensions. l l QI-QAP-11.1-28, Rev.11, Para. 4.3 states that the fitup inspection, when required, shall be indicated on the process sheets as QC hold points. B&R QA Manual, Section 10, Para.10.5.2.1 requires the Project Welding Engineer i to enter QC inspection hold points on the process sheets in accordance with an inspection matrix provided by the Site QA Hanager. As stated in Para. 11.3 of the QA Manual, these inspection activities to verify the quality of the work are being performed by persons other than those who performed the work. ( Also, the construction and the craf t are required to assure that fitup and cleanliness raquirements are met as they are responsible for the quality of the work they perform. 9-Prem Lahoti l l ~ i
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h Aktu$ 1 J MW 3 0) IM L3 BROWN & ROOT. INC. Quality Assurance Depart:nent NCR ?IO. M-2690 R.6 CA '4EC:co Nonconfonnanca Report (NCR) CPSES-35-1195 PAGE OF TAG /ID NUMSER LOCATION OR ELEVATICN RIR NO.- CP. AWING / IDENTIFICATION N/A N/A N/A N/A NONCONFORMING CCHOITION 10.4.2 CPSES TREND - _ CATEGORY G-3 OCCU4ENT VIOLATED: B&R @ Manual REY.Trans.#28 PARA.10.6 See Attached. Pavision 6: 'Ib add to and clarify dispsition. . N Revision 6: By R.E.Penzoni CATE: REVIEW / APP CATE: REPCaiiD Sy: g/fg/yg J. P.awkins 3-5-81 p g ,~ ,,, _ _ f ACT;CN A00RE55EE *N' 5 TAMPED CCMPONENT CAR it0.: A5ME CODE ' ITEM: Y"I O ^ b I'8 NO B. Baker i-OT.C..:05iiION: A-AEaGRK S-REPAIR C-USE AS IS xx 0-SCRAP E-RETURN TO VENOCR See Attached. i l 1 f
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- Attachment to >
- k. ' , NCR H-2690 R./d> [f[*#5 NO" CONFORMING CONDITION:
(#. . .g~. , On February 15, 1980 a memo (copy attached) was issued by the Hartford Steam Boiler Inspection- and Insurance Company (ANI - Steve Timko) with instructions that effective February 25, 1980 preliminary review by the ANI of CSTP's, MRS's, WDC's, etc. was no longer required prior to issue. Therefore, all welding documentation packages with the exception of new spool fabrication and Repair Process Sheets were issued and worked without preliminary review by the ANI as of February 25, 1980. On February 25, 1981 B &.R was advised by HSB Region Supervisor (J.Westmoreland) and HSB home' office represencative (B.Higginbo. tham) that the Timko instruction was void as the ANI's did not have the authority to waive preliminary documentation review. Hence, as of March 2, 1981, welding documentation packages were onca again j routinely routed through the ANI's with the following exceptions: ! a. Ranger packages for hangers CH-1-235-005-S43R, SI-1-002-006-542R, H-GH-X-AB-t ~~ 025A-0240-3 and SI-1-031-035-Y32K were inadvertently issued to the craft j without ANI review after March' 2, ~1981.
- b. Sway strut modification packages were not routed through the ANI till March 12, 1981.
p QU DISPOSITION - l1 } Construction Procedure CP-CPM-6.9 has been revised to outline requirements for j ANI preliminary review to preclude issuance without such review. f All weld documentation packages are being routed through t'he ANI for preliminary review. { . ANI to review all welding documentation packages that were issued between h February 24, 1980 and March 12, 1981 without their prelimMry review. s ) The only exceptions would be the work completed packages that were issued during l this period, whose weld documentation will reference this NCR number and be ) reviewed by the ANI during final review. This includes that work which was j performed between 3-12-81 and 10-23-81. Z/P 9 i 4/M/83 i i . l . o L
i Figure 16.1-1 j , BROWN & ROOT, INC. -- .. f M E'# OA R MORD Quality Assurance Department NCR NO. M-2690 R.5 i , Nonconfomance Report (NCR) CPSES-35-1195 t, PAGE OF l DRAL'ING/ IDENTIFICATION TAG /ID NUMBER LOCATION OR ELEVATION RIR NO. 1;/A . N/A N/A N/A i
\
l 40'C0iG0RMING CONDITION
-~- CPSES 10.4.2 TREND t DfjCittENT VIOLATED: B&R QA Manual REV. Trans. #28 PARA.10.6 CATEGORY G-3 I -
l s ? l ' See attached. $ Revision 5: Rewrite of the nonconforming condition and the disposition. 1 4 V'L
- REPORTED BY:
J. Hawkins DATE: 3/5/81
\ REVIEW /""
Qg a fp/ d:,,- T IM5: DAT& gg% DISPOSITION RESPONSIBILITY: DISPOSI f ASSIGNED TO: R 60.( MME ' CODE ITE4: D.C. Frankum J. Haw ins A XX Yes No
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DISPOSITION: . REWORK REPAIR USE AS IS XX SCRAP RETURN TO VENDOR-l *: j See attached. .. l .. .. s
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Attachmsnt to NCR M-2690 R.5 NONCONFORMING CONDITION: On February 15, 1980 a memo (copy attached) was issued by the Hartford Steam Boiler Inspection and Insurance Company (ANI - Steve Timko) with instructions that effective February 25, 1980 preliminary review by the ANI of CSTP's, MRS's, WDC's, etc. was no longer required prior to issue. Therefore, all welding documentation packages with the exception of new spool fabrication and Repair Process Sheets were issued and worked without preliminary review by the ANI as of February 25, 1980. On February 25, 1981 B & R was advised by HSB Region Supervisor (J.Westmoreland) and HSB home offica representative (B.Higginbotham) that the Timko instruction was void as the ANI's di.d not have the authority to waive preliminary documentation review. Hence, as of March 2,1981, welding documentation packages were once again routinely routed through the ANI's with the following exceptions:
- a. Hanger packages fpr hangers CH-1-235-005-S43R, SI-1-002-006-S42R, H-CH-X-AB-025A-0240-3 and SI-1-031-035-Y32K were inadvertently issued to the craf t without ANI review after March 2,~1981.
- b. Sway strut modification packages were not routed through the ANI.till March 12, 1981.
. )
DISPOSITION , Construction Procedure CP-CPM-6.9 has been revised to outline requirements for ANI preliminary review to preclude issuance without such review. , All weld documentation packages are being routed through the ANI for preliminary review. , ANI to review all welding documentation packages that were issued between February 24, 1980 and March 12, 1981 without their preliminary review. The only exceptions would be the work completed packages that were issued during this period, whose weld documentation will reference this NCR number and be reviewed by the ANI during final review.
+ _ _ _ _ _ _ . - _ _ _ _ _ _ _ . _ ___ .__.__ __.___.____.____.
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. DA P.ECORD 8ROUN & RGGT I .' C .
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'~k:N'yj?$:$$$U-Ii Quality Assurance, Department
' ' ). . .
Nonconfomance Report (NCR) CR N0is$dE90$hi5fh
^
CPSES-35-1195 efsf. g 5 <M PAGE
% .n & .,.ch..
M OF . - ORAWING/ IDENTIFICATION N/A TAG /ID NUMBER s.. N/A LOCATION N/A OR ELEVATIONf sMRIRtNO. .-
- j:5}. ,
{,,. Ugggf.'," i 30NCONFORMING CONDITION _ 1 00CLMENT VIOLATED: CPSES B&R QA Manual 10.4.2 TREND . REY. Trans. #28 PARA.10.6
~
CATEGORY #3 # I* .~
,. G,:,% % .:. ..g See attached.
- 5.k '-
g . Rewrite of the nonconforming condition and .lMi.' . s.:hI. Revisi'on 5: i . .; 1 the on.
- dispositi
**e..'*
~
e . I s
.: i
** REPORTED BY: n J. llawkins DATE:
3/5/81 REVIEll/A"lGV 'l DATE mg e DISPOSITION RESPONSIBILITY:015P0517 y y _ , f gf,:g , TIM gg 5:
.)s . D C. Frankum l ASSIGNED TO: CAR. NO. f
'. J. Haw ins A MTc 'C00E LIEM:
JISPOSIT10n:. ~ ~ XX Yes No + REWCRK - REPAIR USE AS IS XX SCRAP
., . RETURN TO VENDOR See attached.
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/ ' /Ok-3,/,,,,, N ENG. REVIEW /A R0 L:
DATE: A EV :
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QA/QC EtiG/INSPR. VERIFICATION:Q4TE:
- i * ~
1 ANI CONCURRENCE: e DATE: ~ !@d
?
QA REVIEW /C1.0SURE: Q
'-- DATE: ?? li r:p$
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' ' .t, FO::CONFnRMINC CONDITION: *, ;',->i:qf,, ,,j,. tyg'.j,,, $1.
.? , i A:is&%'s.4?g "
F On February 15, 1980 a memo (copy attached) was' ' issued'by l ' the Hartfo[fd Steam ,,.
- Boiler Inspecti'on and Insurance Company (ANI - Steve Timks) with instructions *'
that effective February 25, 1980 preliminary review by the ANI of CSTP!s.. MitS!5h-WDC's, etc. was no longer required prior to issue. j i k,jhg 9,i. 3p s C,~.'; <.}g$$k{~ T $' i Therefore, all welding documentation packages with the exception of.~new spool' - f[ fabrication and Repair Proce'ss Sheets were issued and worked wit.hout:; preliminary ^ i - review by the ANI as of February 25, 1980. # .i ,',,,,c,<.*,. !
. . A ;.<; ; - : ;; .
. . .x ,,.,.. :u..
On February 25, 1981 B & R was advised by HSB Region Supervisor (J.Westmore
* )- l and NSB home. office representative,(B.Higginbotham) that the Timko instruction .. I was void as the ANI's did not have the authority to waive preliminary documentation '
review. .
; _ r, -
Hence, as of March 2,1981, welding documentation cei againpackage i . . ( , routinely routed through the ANI's with the following exceptions:
- a. Hanger. packages for, hangers CH-1-235-005-S43R, SI-1-002-006-S42R, E-CH-X-AB 025A-0240-3and SI-lg031-035-Y32K were inadvertently issued ,to the craft
, dichout ANI rev6ew af ter March 2,1981.
,,,,, . b. Sway strut modification packages were not routed through the ANI till March 12, 1981.
~
..}
.'.. . .) .
. DISPOSITION .
. Construction Procedure CP-CPM-6.9 has been revised to outline requirements for
, , ANI preliminary review to preclude issuance without such review. .
e s . , '.
', ,- All weld documentation packages are being routed through the ANI 'for prel'iminary
~
review . : ANI to review all welding documentation packages 'that were issued between February 24, 1980 and March'12, 1981 without their preliminary review. The only exceptions would be the work completed packages that were ' issued during this period, whose weld documentation will reference this NCR number and be reviewed by the ANI during final review. @ f,y j g t.u.N. r 7ja.f gg og g p,fg,cu Am CD EM J/n/h A*O /6/*Jlff.
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4
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. . - . . . ~ . . . - . . .. . . . . . .- .
, 5 9ure 16.1-1 .
BROWN & ROOT, INC. CA RECORD Quality Assurance Department M-2690 a.X f NCR NO.
. Nonconfomance Report (NCR)
CPSES-35-1195 PAGE OF DRAWING /IDEffrIFICATION TAG /ID NUMBER LOCATION OR ELEiATION RIR NO. N/A N/A N/A N/A NONCONFORMING CONDITION CPSES 10.4.2 TREND 00ClNENT VIOLATED: B&R QA Manual REY. Trans. #28 PARA.10.6 CATEGORY G-3 See attached. Revi-sion 24 To-edd-hangee-number-CS-1=iS5415-S4tR to-ii. um 1,e.- 2 ci the
.unnennFaming ennMrion on Rev4 =4 na 1_ 'h; dispegiti;a ;ill ; iu l.. .se. -
Revisivu . ' , . '^ -dd hea.= uum^u a. ii-5'n"-1-A ;-01^ ^23-0 ;e it m uomoer Z or une aoaraa Faming a-Miti;; ou 2.11.1va 1. m A4 pa-4*ia- "*1' ---in - t; :: _ mg v. .v - ... - - >
%$@ (*i %E.L.0DInf OF *TYtf 33; MM NMW4 DMDN ht3D M QAf f02VTM O.
>- -. / O .-sA A l REPORTED BY: DATE: REVIEX/'"?R VAL . O TE: TIME:
J. Hawkins 10/21/81 A u ,. , X i_ %Yoh DISPOSITION RESPONSIBILITY: DISP 05 FI N ASSIGNED I CAR NO.: ASME CODE ITDi: D. C. Frankum J. Haw ns N/A
~
DISPOSITION: - REWORK REPAIR USE AS IS n SCRAP RETURN TO VENDOR 1 l l See attached. l l .
~
A / .L LY /t i / e ,, /O ~2 > EttG. REVIEW /A R VAL: / / DATE: ANI REVIEW:/y QA/QC ENG/INSPR. VERIFICATION: DATE: MI CONCURRENCE: . DATE: aA REVIEW / CLOSURE: DATE: 9
.. . . . _ . . ...=1 .- :. = - -
. . . = . . -
Figure 16.1-1 4 BROWN & ROOT, INC.
, . QA' :ECORD Quality Assurance Department NCR NO. M-2690 R.4
. Nonconfomance Report (NCR)
CPSES-35-1195 PAGE OF DRAWING / IDENTIFICATION TAG /ID NUMBER LOCATION OR ELEVATION RIR NO. N/A N/A N/A N/A N0!! CONFORMING CONDITION CPSES 10.4.2 TREND DOClNENT VIOLATED: B&R QA Manual REY. Trans. #28 PARA. 10.6 _ CATEGORY G-3 l See attached. I Revision 2: To add hanger number CS-1-155-015-S42R to item number 2 of the i nonconforming condition on Revision 1. The disposition will remain the same. Revision 3: To add hanger number H-SW-1-AB-019-023-3 to item number 2 of the , nonconforming condition on Revision 1. The disposition will remain the same.
- Revision 4
- To add to item 1 of the disposition.
I i
'~
. /O sA-El
/'"^^'
~
i REPORTED BY: DATE: TE: TIME: l J. Hawkins 10/21/81 REVIE s h b'w,_ VAL X (_ Wroh i DISPOSITION RESPONSIBILITY: DISP 05 FI ASSIGNE) T CAR N0.: ASME CODE ITBi: l D. C. Frankum J. Haw ns) N/A
~
JISPOSITION:
- REWORK REPAIR USE AS IS n SCRAP RETURN TO VENDOR l
- see attached. -
i i C l t
\ ^ $s A* s 9/ a .. ID 1, r>
fj ha^"t aemwo ' o^*: l waamweg^% " aA/QC ENG/INSPR. VERIFICATION: DATE: l ANI CONCURRENCE: DATE: I j aA REVIEW / CLOS'J RE: DATE: i i e
.. = :- . = -. -..-.a -
.' Attachment to
. NCR M-2690 R.4 Nonconforming con'dition:
) 1. On February 15, 1980 a memo was issued by the Hartford Steam Boiler Inspection and Insurance Company (ANI - Stese Timko) with instructions that effective February 25, 1980 preliminary review by tie ANI of CSTP's, MRS's, WDC's and etc. was no longer required' prior to issue.
On February 25, 1981 B & R was advised by HSB Region Supervisor (J. Westmorland) and HSB home office representative (B. Higginbotham) that the Timko instruction was void as the ANI's did not have the authority to waive preliminary documentation review. l Therefore, all welding documentation packages with the exception of new spool
; fabrication and Repair Process Sheets were issued and worked without preliminary l review by the ANI between Februarf 25, 1980 and March 2, 1981.
$ Revised to add:
- 2. CH-1-235-005-S43R, SI-1-002-006-S42R, H-CH-X-AB-025A-024-3 and liiI-1-031-035-Y32K. .
Hanger packages for the above hangers were issued to craft without pre-review by ANI.
~
i 3. Sway strut modicication packages were not routed thru ANI'for establishment of any required hold points at a time frame above in_ item 1 thru March 11, 1981. Disposition:
. 1. During the February 25, 1980 to March 2,1981 tim.e frame the on-site ANI's monitored the construction activities and all required inspections were performed and documented by B & R QC.
Effective March 2,1981 all welding documentation will be routed thru the ANI's
+
for preliminary review and establishment of any hold points deemed necessary. , 'ANI'to review all welding documentation packages with the exception 'of new spool I fabrication and repair process sheets'that were issued and worked, without pre-
; liminary review by the ANI, between February 25, 1980 and March 2, 1981.
- 2. As this was the first week for the ANI pre-review of hanger packages a break p down in communications between Welding Engineering and QA developed and these four packages were issued to craft.
1. li Construction Procedure CP-CPM-6.9 is in revision to outline requirements for ANI pre-review and will preclude repetetion of this problem.
- 3. Construction Procedure CP-CPM-9.13 outlines program for stamping back of WDC's with QC hold points for sway strut modifications. All sway sturt modifications packages will be routed by Welding Engineering thru the ANI for i pre-review and establishment of any required hold points effective March 12, 1981.
In addition any sway strut modification ree,uired on hanger's which had packages issued during time frame noted in item 1 will be routed routenly thru the ANI for pre-review of sway strut modificatic . t ec,uirements. h a 4 g _
Figure 16.1-1
. . BROWN & ROOT, INC. c'e O' RECOR3 Quality Assurance Department UCR NO. M-2690 n. .X Nonconfomance Report (NCR)
. CPSES-35-1195 PAGE
./ OF b
DP. AWING /IDEllTIFICATION TAG /ID NUMBER LOCATION OR ELEVATION RIR N0. N/A N/A N/A N/A NONCONFORMING CONDITION CPSES 10.4.2 TREND 30CtNENT VIOLATED: R&R QA Manual REY. Trans. #28 PARA. 10.6 CATEGORY c-3 See attached. Revision 2: To add hanger number CS-1-155-015-S42R to item number 2 of the nonconforming condition on Revision 1. The disposition will remain the same. Revision 3: To add hanger number H-SW-1-AB-019-023-3 to item number 2 of the nonconforming condition on Retision 1. The disposition will remain f'@"&q.:o nooto(Tmi'e m NN /'n N. 3EPORTED BY: DATE: EVIEW/,3RPR VA ATjj: TIME: J. nwm, 1/s/si *# 6 . ~ < M 777BM/ 9,'444. DISPOSITION RESPONSIBILITY: DISP 05IpN ASSIGNED TO: CAR N0.:' ASME CODE ITEM:
- f XX Yes No
,( D. C. Frankum J. Hawkins
~
)lSPOSITION:
REWORK . REPAIR USE AS IS XX SCRAP RETURN TO VENDOR See attached. - QA RECORD HTN. oA REVIEW
- h. ( $$l F IL E .N O. , , , ,
J.. SUBFILE NO. a A. .s l's.s. ?
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Attachment'to '
,.,w-NCR M-2690 R.4 *
,:di '? 0 'o' l'onconforming condition: , 3ctRo.ej.ud.]
C. On February. 15, 1980 a memo,was issued by the Hartford Staam Boiler Inspection
. and Insurance Company (ANI - Steve Timko) with instructions that effective February
! 25, 1980 preliminary review by the ANI of CSTP's, MRS's, WDC's,and etc. was no "' , longer required prior to issue. , Therefore, all welding documentat, ion, packages with the exception of new spool
- fabrication and Repair -Process Sheets were issued and worked without preliminary review by the ANI between February 25, 1980,2 d "
- c.h 2, 1981. , ,
{ 23 00- _,
. .. ..-..a.._,
b .. . . . .- . ! On February 25, 1981 B & R was advised by HSB Region Supervisor (J. Westmo and) , ! and HSB home office representative (B. Higginbotham) that the Timko instruction was void as the ANI's did not'have the authority to waive preliminary documentation ~
- ' * " ~~
review. .. ,
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Figure 16.1-1 9 . . . BROWN & ROOT, INC. _ . , I,, D
. / } }'{ - Q Q f , (/ () ,
-NCR NO. M-2690 R.2
'0A RECORD _ Qua ity Assurance Departraent
No.;confomance Report (NCR)
'l CPSES-35-1195' ' PAGE / OF e2 LOCATION OR ELEVATION RIR NO.
DRAWING / IDENTIFICATION TAG /ID NUMBER N/A N/A N/A N/A iONCONFORNING CONDITION CPSES 10.4.2 TREND REY.Trans. #28 PARA. 10.6 CATEGORY c-3 DOCLNENT VIOLATED: B & R QA Manual See attached. Revision 2: To add hanger number CS-1-155-015-S42R to item number 2 of the nonconforming condition on Revision 1. The disposition will remain the same. e l
~ ~ '
[0 AL DAT,E T IME: DATE: REFORTED BY: ((REVIEWAP <w V D I M: r I 8/M M e J. Hawkins 3/5/81 w'"1 - A5ME CODE ITEM: l 015P051 TION RESPON5IBILITY: DISP 05y0It A55IGhED TO: CAR fiO' : No Yes ~ D. C. Frankum J. Hawkins
' ') JISPOSITION:
. REPAIR USE AS 15 n SCRAP RETURN-T0 YENDOR
? REWORK See attached. QA RECORD 2 RTN. CA REVIEW , A- J u .L:.'j i FILE NO. .
/[ [ ,
SULFILE NO. h1 ~ .2 f ' . ' r' 2 o E: f : j REVIOd,8 QVAL* , ( QC 4 ATE: CATE4 E{G\ REVIEW / APPROVAh: O,i// N 3 .n' .r/ j/gnl RJVIEW: o '/. , .u .s o
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' Figure 16.1-1 B?.CWN & ROOT, INC.
QA RECORD _ Quality Assurance Department ' CR NO. M-2690 R.1 Nonconformance Report (NCR) CPSES-35-1195 PAGE / OF 2* DRAWING / IDENTIFICATION TAG /ID NUMBER LOCATI0tl OR ELEVATION RIR NO. N/A N/A N/A N/A . NONCONFORMING CONDITION CPSES 10.4.2 TREND 00Ct!'.ENT VIOLATED: B & R QA Manual REY. Trans.#28 PARA.10.6 CATEGORY G-3 See attached. . . a DATE: ( REPORTED BY: ,
' REVIEWKPRj0 t AL 04TJ: r. TIME: / oA1
.pf,Jt/p J. Hauktns 3/5181 %'A Gw , 4 8.*N)
JISPOSITION RESPONSIBILITY: DISP 051(LON A551GhED TO: CAR h0/: ' AS4E CODE ITEM: xx Yes ~ No
- ) D. C. Frankum J. Hawkins
)lSPOSITION:
REWORK . REPAIR USE AS IS xx' SCRAP RETURN TO VENDOR See attached. QA RECORD l irm.' cA nevicW j_ (.g z -16.% FILE NO. ~
/S / .
SucFtLE tio. i ri.f i ?.'4'o
. ht.'Itt) -, 9 3 / \/ n i. a % l< _ P1 ERG. REVIEW / APPROVAL: ' ,DATE:
- ) A///1 rJ/ a -/.2 .V/ [\ ANI \ u- Rf, VIEW-i.% h '/., , . :/'. / CATE:h/
sl yi C HON: DATE: s ./ QA/QCiENG/INSPJ
'1,6We/ G O i C5c VE,RIFijL ..e X -/ Z-81 OATE:
til CONCf8RENCE-V/7lc lLtbef?(0 2/>> Yl
,1 ,1
Y $ Y^
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- _ ~ ' . ._ _ _ _:' L __ __ _.
- ~~ _ - .
.! j\l .' /.' r - - : ' d. .,
** Attachmen; :o .
NCR M-269L R.1 [j, : .e1-b - .7
/, ce, Nonconforming condition: j, ,
- 1. On Februray 15, 1980 a memo was issued by the Hartford Steam Boiler Inspection and Insurance Company (ANI - Steve Timko) with instructions that effective February 25, 1980 preliminary review by the ANI of CSTP's, MRS's, WDC's and etc. was no longer required prior to issue.
On February 25, 1981 B & R was advised by HSB Region Supervisor (J. Westmorland)" and HSB home office representative (B. Higginbotham) that the Timko instruction i was void as the ANI's did not have the authority to waive preliminary documentation review. . j Therefore, all welding documentation packages with the exception of new spool fabrication and Repair Pr' ocess Sheets were issued and worked without preliminary review by the ANI between February 25, 1980 and March 2, 1981. Revised to add:
- 2. CN-1-235-005-S43R, SI-1-002-006-S42R, H-GH-X-AB-025A-024-3 and SI-1-031-035-Y32K.
Hanger packages for the above hangers were issued to craft without pre-review
. .by ANI.
- 3. Sway strut modification packages were n'ot routed thru ANI for establishment of any required hold points at a time frame above in item 1 thru March 11, 1981.
. . Disposition:
1 '
- 1. _During the February 25, 1980 to March 2,1981 time frame the on-site ANI's monitored the construction activities and all required inspections were performed and documented by B & R QC.
Effective March 2, 1981 all velding documentation will be routed thru the ANI's L for preliminary review and establishment of any hold points deemed necessary. Peo tnSest A-As this was the first week for the ANI pre-review of hanger packages a break L 2. down in communications between Welding Engineering and QA developed and these 0 four packages were issued to craf t. . Construction Procedure CP-CPM-6.9 is in revision to outline requirements for ANI L pre-review and will preclude repetetion of this problem. 1
- 3. Construction Procedure CP-CPM-9.13 outlines program for stamping back of l
MWDC's with QC hold points for sway strut modifications. All sway sturt l codification packages will be routed by Welding Engineering thru the ANI for pre-review and establishment of any required hold points effective March 12, 1981. l In addition any sway strut modification required on hanger's which had packages l issued during time frame noted in item I will be routed routenly thru the ANI for pre-review of sway strut modifica: ion requirements. I
, . .;; sy l=. .
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' Allegation No. 21 It has been alleged that safety related welds were repaired with weld tech'(W.T.) holdpoints, instead of QC hold points in violation of -
procedures. What are the effects of this? Evaluation of Validity g 2 j,. The facts in this allegation are correct; however, this practice is not l . prohibited by procedure. In fact, procedures endorse this practice.
?" Prior to initiating a weld repair, Welding Engineering prepares a
' )s Repair Process Sheet (RPS) describing the method of repair, including 4
(.8
!J the weld procedure to be used and required welding technician and s .
! 3 quality control hold points for inspection. QC hold points are listed c
- c. on the RPS from an inspection matrix providid in a procedure approved
'l$ by the Brown & Root QA Manager. Once the QC and Weld Tech hold points f"
are specified, the RPS is sent to Engineering where required, to - E7 Westinghouse for review (for Westinghouse components only), and to the
~ '
ANI for review and assignment of ANI hold points, all of which occur , prior to issuance to the craft. Weld Tech hold points are those added at the discretion of the Welding Engineering departme'nt, but are not in lieu of QC required hold points. Consequently, no procedure . I violation exists. i . Both Brown & Root and TUGC0 NCR logs were s'earched for this type of violation. The only related instance (although not substantiating the' allegation) was detected by QC, documented on an NCR, and corrective
. action taken. In this. case, a welding technician signed what was- -
indicated to be a QC hold point. In fact it had been incorrectly W designated. It should have been a weld tech hold point. ,. g 4 l Safety Significance None Gene c n Other Systems or Contractors - N
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TXX-4187 6/1/84 " T-$ U N Allegation No. 19 cL/ f It has been alleged that craft personnel would satisfy a CMC on an inadequate weld by welding over it instead of following the procedure of cutting it out and then welding. Evaluation of Validity The term " inadequate weld" used in this allegation is vague. For example, a weld which was undersize and therefore " inadequate" would g require no weld metal removal prior to performance of additional welding. On the other hand, welds may be termed " inadequate" due to y 4 relevant indications and rejectable by applicable codes or standards. In these cases, procedures require removal of the def.ect, verification ; of defect removal by the same nondestruct.fve examination method which detected the defect, rewelding, and repetition of required NDE. In
~
neither case would " inadequate welds" be welded over in violation of procedure.
- Without any specific information to aid in the evaluation, we are
~
unable to address this allegation more specifically.. Safety Significance None Impact on Other Systems or Contractors . Not applicable O
~
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74 . 1- "Well, I don't have any problem here, no problem 2 That's what they would say. here." 3 Q It sounds like, without ide stifying your friend, 4 that your friend, is it safe to say, had information but he 5 refused to give it? 6 or did he indicate that he thought they had f,5,1 freedom to inspect? . . , I-
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8 A They indicated they had not given any information
, 'f " no matter what. Because they were afraid.
Q Okay.
~ 11 Let's move on to the next one here, it says, about p 12 CMCs, commodity modification cards on welds. Tell me about 18 that?
I' A Okay, what I was talking about is they would want, is like, you had a 3/16 weld, fillet weld -- 16 Okay. Q II A -- okay, and they decided through stress analysis la or something that it should be a k inch.. 18 Well, all they'd do is they'd just go up there and
" they'd just put -- tch-tch-tch -- a quarter inch of weld 21 on there, you know? And that's all they did.
22 And unless I misunderstood what was supposed to happen, what's supposed to happen is they're suonosed to out 24 You can't just go up there a minimum amount of weld on there. 25 and put a quarter-inch weld on that thing. - F0lA-85-59 oua
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75 ,, 1 You've got to Put more than that. You've got to 2 - l put -- 3 Q Did you ever witness anything like this? - 4 A _Oh, yuh, all the time; because that's what we did 5 all the time.
- e on those walkdowns and those backfits, that's 7 what we were doing, is adding weld like that; the whole time. ],
8 And it's your understanding it's a violation 7 Q 8 A The VCD walkdowns, that's what we did. / 10 Q What is a VCD walkdown? U A Vender Certified Drawing, we'd make walkdowns on 8 the vender certified drawings; we would measure the weld that 08 was on there and the weld that the engineers said they j ' 14 wanted on there; and if it wasn't right, then we'd write it 2 up. - 18 And they'd issue an RPS to go out there and put IT a quarter-inch weld on it. , 8 The addition of the weld material was done with Q 8 engineering approval? E A Yes. 21 Q Don't the engineers have.the authority to request 22 and_have this happen within procedure? 8 A Well, the engineers have the authority. I just 24 don't think it was right. 25 Q Well, we'll have to evaluate that'.
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i 1 A That's a concern of mine, I didn't think it was ' 2 right.
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3 Q I see your concern. 4 It would help -- could you identify the area or 5 the pipe where they have done this with the CMCs? 8 A Yes, sir. 7 If you go to the stuff that was in the VCD walkdowns,[
,e a if you will go there and pull the documentation on that, 8 you'll see where what we did, we went in and measured how i i 10 much weld was there. And we would write it in there, how 11 much weld was there.
12 And then we would go back and they would repair 18 the weldt they'd have an RCS, a repair card to add that 14 quarter-inch weld on there, or whatever, put a half-inch 18 weld on there or 1/16: we would measure it again; and we is would write it down. 17 And the CMCs were prepared by the engineers Q 18 specifying this was what was to be done? -- that there was 18 to be additional weld material added? 30 A Yes. 81 There are many of these, and if we looked at Q , 22 the -- if we pulled these records, we'd have no trouble findin z 23 an example? 24
. A Right.
26 g gem asking now, are there numerous examples?
~ , _
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j 1 - A There are numerous examples -- I'm trying to think
. 2 on the CMCs -- I wouldn't worry about the CMCar I'd get the i 3 VCD walkdowns and look at thoser beciuse those tell the whole -
l 4 story. _ 8 When we started out, they called them " red 6 packages". And we started out doing.the program that way. 7 And then they said, well, that didn't work out i
}!
l 8 so they called us back in and they set up another program I I 9 that they called VCD walkdowns. 10 And that one didn't quite go', so they set up i 11 another one; and we did it again. i So we" started the program over three times. -
./ - ,
, #8 okay. i .V 18 Q ( o l % 14 Another issue you raise in here is undocumented 18 weld gepairs; would you tell me about that? 18 A well, I wish I could give you an example, I could h 17 , give you a number or something.
~
18 Q Un-huh. 18 Anyway, these repairs were done without QC 38 inspection; craft would just go out and -- E A Yuh. . M Q -- dig them out, repair them? 23 A okay -- it's several times I've been over this 24 today, so I forget where I've been.
".i l
- 28 okay.
Q I l l _______ . _ . . _ _ _ _ . . _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ . _ . _ _ _ , _ _ _ _ _ . _ _ , _ . _ _ _ _ _ _ _ _ _ _ .
~. A 4) ~2; Cc_begeg 2,3 A h *3 03
- . , a yn j Mt.O. 4 of,y I saw that QC UQL j
.]
- I wrote one of my last NCR's on January 27, 1 984.
had signed off on weld numbe.r 40-C- AF1.on January ' Inspector, ~ 14, 1984 A Radiograph Test (RT) was performed on the weld in question on ' The The weld failed the RT. January 15, 1984 as part of a routine program. -l- ' weld then received a repair process sheet with weld tech (W.T.) holdpoints, - instead of OC hold points. This. distinction is important since W.T. hold The points a,re not for safety-related work, and this weld was safety-related.
.,?
RPS should have QC hold points. Ci 0 . ' 9 - S The old weld was then " dug out". and a new w id was put in, without On January 17, a craft person, receiving QC inspection on January 16. unkwnon), approached S and told him to cross out his (identity original date of January 14 and put.in January 17, to make it appear a L l L ! PolA-85-59 4
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g d y had simply made a mistake in the date; that he had actually inspected and signed i off the weld on January 17.6 did this. This was the paperwork solution to the problem of using W.'T. hold points instead of QC hold points.
, my immediate supervisor, and told At that point, I went to -
He told me "to write .it up." The next morning., I heard a him oflmy concerns.
^
l level 'III inspector, known to me only as 6 yelling about " pencil-whipping" hold Some time on January points. He was referring to what I wrote up it' my NCR. f 1984, a 2r00 p.m. meeting was called which included: 27, h , and me. M
) .
I star,tet yelling at me for writing the NCR, and said that $ad just signed [.1 the report in error. I told them exactly what happened as I knew it to be. '
- y .They decided to void my NCR, and they asked me if that was all right with me.
l l I said, " Gentlemen, that is up to you," which they took as agreement, t M
- L, The next day. O a Level III QC M, approached me with my NCR and .
I I asked him, "You mean j told me,I had to sign the concurrence to the voiding. So I refused to sign it. I 1 have t'o ?" Wsaid, "No, you do not have_ to." knew it was wrong, and I refused to go along with it. t l f f I .
CAN*3 1 AQW 30 'sNye 3 3 C M *1 e i Another problem I found at Comanche Peak was that craf t would get a Control Mod,ification Card (CMC) on a wel.d that called for a stronger weld. Instead of cutting o'ut the weld like they should, I have seen, on occasion,
* ~ -. - The technique they workers simply add weld metal on top of the old weld metal. ~
A9tatfl . used would be to weld and re-weld the same piece of steel over and over again. I believe . This causes brittleness and, of course, violates weld procedures. . this is a comon. practice at Comanche Peak. . 6 6 9 4 e e 9 6
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UNIT FAGE / , JOB NO. 35 1195 cuss P OJECT: COMANCilE PEAK s eersw sD sE sO 0:nCn OR wiMs 4T03 - _ AU-C T-/-f8-/7 war /lTEpe MUMBER LOCATIOeg
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' 02 Analyzer SN N/ E 3r"309
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- 1. FITUP (Prior and During) l U4/' /2 fg g S
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- 2. AFTER WELDING OF ROOT
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- 3. COMPLETION OF WELD (10) i INFORMATON '
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- 4. COMPLETION OF WELD (OD) sus-. V, ' s Reinfortement $f e W Undercut W e l
F6ttet Site ./ 7, siendice of survec. Joent/ Welder indent. V ,e # Suitet>6titT of Surface for NOT . # ,
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Surtees free from Arc Strikes tC .s r Wald $pletter, etc. / / Purse Oem Removed l - : DATE [ ,,umE,gr a g , g ym f gg yt:f ACCEPT ANCE sTO. AeCEr7 ASME SECTION lil M, .iU4. NN-DM BMSPECT ~ ~ ~ CERT lPIC ATggM LEvg 6
# MOEP DURE 1 08/39/78 O A 904*2
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0 4 3c l'.nt. Imormation Onw Weldeg Eng.ncering I REQUEST FOR RT I / Q.9/1 DATE 8/ A9[ N _F LAGGED BY hfaU N ... DATE i r EN_516N
- I REQUESTED BY -:l PRIORITY N
LINE _fchTI A 2_ WELD [W- l
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ORAWING_8RPzfT-J:5.8 iso)?-O [N ' PREVIOUS RT LOG NUM8ER IF A REPAIR _ JOINT DESIGN: 80** -(IN.I ' PlPE Dt AMETER ,; OPEN BUTT h ~ . ebbb IIN.)
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Specification 2323-MS-100 Revision 5 ' February 26, 1979 1 Page 4-38 t
- 4. 27.7 (Q)
ASME Class 1 and 2 welds which are subject to in-service inspection shall have their surfaces prepared as required by - ASME Section XI. and shall meet the following additional requirements:
- a. "The weld crown shall be approximately flush with the base raterial or, for reinforced welds, the weld crown shall be flat-topped. The transition between the flat top and the 4 d base material shall be tapered at a slope not exceeding 4: 1.
blend A junction radius of not less than 0.5 inch shall exist at the between the weld and base raterial."
- b. "The weld crown shall be ground smooth, eliminating all depressions and grooves from between weld. beads. The adjacent case material shall be left in it's "as ranufactured" condition, unless nicks, gouges, etc. exist.
These discontinuties must be blended into the base raterials with a taper no greater than 4:1 and a blend radius of not less than 0.5 inch at the surface of the base material."
- c. These welds shall be marked as described in paragraph 2.18.9.
4.27.8 e
- lielding parameters shall te controlled to avoid excessive heat input resulting in excessive necking down of Butt welds on thin j wall piping.
j ____ 4.27.9 . l (Deleted) ' 4.27.10 The craters of each head deposited in the root pass and on groove faces shall be removed by grinding to sound metal before depositing the next successive pass of metal. All craters in subsequent passes shall be visually examined by the welder for soundne ss and all questiocable craters shall be renoved by grinding prior to resuming welding. F0lA-85-59 m-.-- -s-
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M*g,~s* NDE RADIOGRAPHIC REPORT RT N9 25416 -- pnoJact"cosiAA PEAx JOB NO 35 1195 UNIT 2 PAGE f op / 5 IDMAwlMG 3 *.* ST EM cLA SS / s I nop.M-2-AA- Otr f3 498f) :a a RC SO orHan
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ATTENTION: .v.R. J.C.AERRITT/J. EELLER/J.R. JOHNSON JOS MO;. 2323 I - 30EJEC'): RADIAL WELD SH"JMKAGE.
, IN REGARD TO THE RADIAL WELD SHRINKAGE SITUATION ON T4 TIM WA%
'ST1INLESS STEEL PIPES, HE PROPOSE TO CLARIPY GER SPECIFICATION i
[ 2323-MS-100/REVISICM 6 " PIPING ERECTION SPECIFICATION" .WITE A
*DECD, AS FOLLCWS 9
PARACRAPR J 27 a CP SPzCIFICATION 2323-MS-100/REV. 6, "PIPIMG ERECTION 69ECl?ICATIGN" STATES: tj 3
" WELDING fiRAM3TERS SHM.L BE CONTROLLF.'.", TO AVOID EXCESSIVE HEAT i -
- tINPUT RESULTING .IN EXCESSIVE NECKING DOWN Of SUTT WFAS ON THIN.
, - 1 WALL PI9E". - I
- A CLARC'1CATICn 0? THE TERM " EXCESSIVE NECKING DOWN
- IS AS FOLLOWS: -
"A. TES irdLD 'CONTCUR SECULD SE CAPABLE SP SEING TitTID BY l
CLTRASONIC t:2TEODS AS REQUIEE5 BY 1D(2 OCDE ..C2'. TION XI, 1 8 INSERVICE INSPECTION, A:iD
~~
E. TEE "NSCKING Oct!N (CR SACIAL .38.HIEIAGE) , S"2 E , ~?OR
' PISE WALL THIC?dESS OF 09 TC 3/E", ilCT EXCEED ONE ~ FAT ?
THE WALL THICK::ESS. POR PIPE WALL TEICENESS OF 3/8" AND GREATSR,. i'SE RADIAL iiiELD SHRINEAGE SHALL NOT EXCESD 3/16". F01A-85-59 \ - - m/8 0
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- THE~ ABOViL CRITERIA APl%T55 TO NON-CLPSS 1 FIPINGr 0.T1TERIA TOR, CM 1 PIPING IS TU BE CETTEMINED BY 4557INGnOU53.
hie WOULD APPRSCIATS TOUP COiiDiENTS ON TE5 ABOV3 PRCPOSED DECD. i a i l' 2
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$ FIGURE l'. Page 1 of 1 COliANCHE PEAK STEAM ELECTRIC STATION DESIGN CHANGE AUTHORIZATION .
(WILL) (WtW3@DJ BE INCORPORATED IN DESIGN DOCUMENTS DCA NO. 13,335
- 1. SAFETY RELATED DOCUMENT: XX YES NO
- 2. ORIGINATOR: CPPE ORIGINAL DESIGNER XX
- 3. DESCRIPTION:
A. APPLICABLE SPEC /ME/ HEgMENT 2323-MS-100 REY. 6
- 8. OETAILS _ Problem: The referenced specification has no measurable criteria for rad'ial weld shrinkage..
Solution: Add the following to paragraph 4.27.8: - Excel'sive neckino down shall be defirred as follows: _.
. a. ASME' Class I welds "-
- 1. For of oe wall thicknesses of .75 inches and creater the radial weld shrinkage shall not exceed .1875 inches.
- 2. For ofoe wall thicknesses below .75 inches. the radial weld shrinkage shall not exceed one-quarter of the wall thicP. ness.
h- ASMF ('Intt ? A 3. clatt 5. aml NNG weldt ? l 1. For pipe wall thicknesses'of .375 inches and greater, the l wndial weld thrinkage chall nnt arceed .1A75 inches. -
- 2. For pipe wall thickresses below .375 inches, the radial weld -
l , ehrinan. ehall nne n ..d nn.. half nf th. wall thickn.<t . NOTE: The amount of shrinkage shall be measured by the distance front the lowest point of shrinkage (at the toe of the weld) and tne i 4. SUPPORTING 00CUMENTAT N I CPPA-19384 I"AfOlhj(( M MO l b ' L WH%L. AllVtA U V h= w""
# ~
- 5. APoROVAL S' IGNATURES: J -
5-18-82 A. ORIGINATOR: 4 DATE T-/8-8 7
- 8. DESIGN REPRESENTATIVE:-
4M OATE- f/b/32.
- i t
- 6. VENDOR TRANSMITTAL REQUIRED: YES NO XX
- 7. STANDARD DISTRIBUTION: i DCA FORM 11-30 ARMS (Original) -
(1) ! Quality Engineering (1) JOB NO. 35-2195 i TS fer Orig. Design. E C ElV g Westinghour*-Site n u 1982 6
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- CPPA #19,384 ( :XAS UTILITIES SERVICES I&: ARMS ST-CPSS-1078 OFFICE MEMOR ANDUM INDE%n ~
T. J. C. Keller cien d ,^ M i May 21.1982 Subject COMANCHE PEAK STEAM ELECTRIC STATION CLASS I PIPE STRESS ANALYSIS JOB NO. 35-1195 ! WELD SHRINKAGE REF: (1) DCA #13,335. ECFIvF= ~ REF: (2) Specification 2323-MS-100 Rev. 6. REF: (3) NUREG/CR-0371 September 1978 f.i/iY 271982 ECEIVE With regard to the definition and criteria on weld shrinkage (Reference 1 and 2) on Class I piping, we feel that the proposed allowable of the lesser of one quarter of the wall thickness or a maximum of 0.1875" is acceptable for CPSES. These values are consistent with the reocmendations of reference 3. I C. W. Gay d Westinghouse a CWG:ery cc: ARMS H. R. Deem D. M. Headrick J. R. Johnson D. H. White (2L) C. W. Gay (2L) B & R DCC DIST* A. T. Parker -
.l _I PROJECT ICR. I
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.} OA RECORDa BROWN & ROOT, INC.
Quality Assurance Department MCR NO.M-3220 Monconformance Report (NCR) CPSES-35-1195 PAGE OF DRAWING / IDENTIFICATION ]G{IDNUMgR LOCATION OR ELEVATION RIR NO.
~
RC-1-RB-016 spool 5 R3. #1 901' N/A MONCONFORMING CONDITION' M O. 04 t- b T/0 5501 I TREND DOCUMENT VIOLATED: QI-QAP-10.2-7 REY. 6 PARAAttach.21 CATEGORY M-5 Wald 3-5 and W-3-4A have excessive concavity due to weld shrinkage and/or U grinding. This condition precludes blending of weld into base material. This is a PSI weld. Spool 5 is a 4" schedule 160 pipe. t l (. Hold tag applied n REPORTED SY: DATE: REMEW AP ROV L 0 iE- TIME: Phillip R. Hilton 2/16/82 Y 2. , ~1(fr'l 4'.30 ACTION ADDRESSEE CAR N0'.- ASME CODE ITEM:
- ,2gg, Yes _ No i B. Baker
! OISPOSITION: ! REWORK REPAIR USE AS IS re SCRAP RETURN TO VENDOR The amount of weld shrinkage is .0625". This is acceptable per 'DCA 13.335(copy attached). , f l r
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1 f' H j! O - - l h (WILL) .(lJttXMBC) BE IllCORPORATED Ill OESIGil 00CUrtEliTS DCA fl0.
~ .
13,335 1
- 1. SAFETY RELATED 00CtNENT: XX YES NO
- 2. ORIGINATOR: CPPE ORIGIfML DESIGNER XX
- 3. OESCRIPTION:
~
j A. APPLICA8LE SPEC /EH/E8E8MEXX 2323-MS-100 REY. 6
- 8. OETAILS Problem: The referenced specification has no measurable criteria for i radial weld shrinkage.
! Solution: Add the following to paracraph 4.27.8: - 3 . * ! Excelsive neckino down shall be defined as follows:
- a. ASME Class I welds i 1. For oice wall thicknesses of .75 inches and creater, the radial weld shrinkage shall not exceed .1875 inches.
. 2. For oion wall thicknesses be. low .75 inches , the radial weld
- shrinkage shall not exceed one-quarter of the wall thickness.
., b. ASMF flate 2 A 3. class 5. and NNS welds -
- 1. For pipe wall thicknesses of .375 inches and greater, the rarHal weld thrinkaos shall nnt avcond .1975 inches'.
- 2. - For pipe wall thicknesses below .375 inches, the radial weld ehrf nlenna chall nnt ovepari nna half nf the w-all thicknatt.
NOTE:' The amount of shrinkage shall be measured by the distance fr"om i the lowest point of shrinkage (at the toe of the weld) and tne ' too of the b'ase metal. L 4. SUPPORTING DOCUMENTATION: l [ CPPA-19384 ) F GTT-8679
- 5. APPROV)L SIGNATURES: J S. .
5-18-82 A. ORIGIIIATOR:- /~ *OATE F/8-8 2 B. DESIGN REPRESENTATIVE: ed DATE f o/[2. *
- , i t
$ 6. VENDOR TRANSItITTAL REQUIRED: YES NO XX
- 7. STANDARD DISTRIBtJTION: . OCA FORM 11-80 ARMS (Original) (1)
;9 Quality Engineering TS for Orig. Design.
(1) ' 5,lf S I I r Westinghouse-Site jg g THIS DocyMDIT I ~- } ONTACT DOCUME!T CONT 0LNf0RMAT10N on , ON
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; BROWN & ROOT, INC.
OA RECORD.,' Quality Assurance Depart::ent NCR NO. M-3177 R-1 Nonconformance Report (NCR) i .l . , '.
- l ;;f CPSES-35-1195 PAGE / OF 4 ORAWING/ IDENTIFICATION TAG /ID NUMBER LOCATION OR ELEVATION RIR NO.
VA-1-RB-02 W-4-5 R.B.#1 885' N/A NONCONFORMING CONDITION T/0 4601 TREND DOCUMENT VIOLATED: CP-CPM-6.9D REV. 4 PARA. 116. 2 CATEGORY y_s Weld 4-5 have radial. shrinkage and their acceptance for inservice inspection is indeterminate. The area of shrinkage is 3600 around the pipe and at the lowest point is 3/16" shrinkage. ,
-re.pov b -<
Revision 1: To cesseet non-conforming condition.Cevne.cjk , Hold tag applied. R REPORTED.8Y: DATE: .REKIJW/AP ROV L 4, DATE: TIME: Donny.Doyle 5-28-82 \voti.~ n d ulrj@l, t So 9t"f CAR N0.: ASMECODEITE53 i9 ACTION ADDRESSEE
- XX Yes No C. Moehlman DISPOSITION:
REWORK REPAIR USE AS IS XX SCRAP RETURN TO VENDOR Upon field verification it was found that both velds 4-4 & 4-5 have max. of 3/16" shrinkage at their lowest point. This condition is g found to be acceptable per DCA 13,335. See attached sheet. mm 9 2 2 coa g_aep A E a^%am m g wa_
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' PROJECT: COMANCHE PEAX JOB NO. 35 1195 UNIT PAGE I OF [
DR AWING SYSTEM C L ASS - ,
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- 8. 7 VB4 Arn h1 11 sv Aos or Mrs.
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(WILL)(NLNNm)BEIflCORPORATEDIllDESIGNCOCUMENTS DCA fl0. 13,335
/-
- 1. SAFETY RELATED DOCUMENT: XX YES NO
- 2. ORIGIf!ATOR: CPPE ORIGINAL DESIGNER XX N
- 3. OESCRIPTION: . af A. APPLICA8LE SPEC /5MB/58EllMEXX 2323-MS-100 R 6 m
B. DETAILS Problem: The referenced specification has no measurable criteria for radial weld shrinkage. Solution: Add the following to paragraph 4.27.8: Excelsivene~kinodownshallbedefinedasfollows: c -
- a. ASME Class I welds
- 1. For oice wall thicknesses of .75 inches and creater the radial weld shrinkage shall not exceed .1875 inches.
- 2. For oice wall thicknesses below .75 inches . the radial weld shrinkage shall not exceed one-quarter of the wall thickness.
- h. ASMF Clast ? A 1. clast S. and NNS welds-
- 1. For pipe wall thicknesses of .375 inches and greater, the N. radial wp1d thrinkaan shall not excpad .1879 inches.
) 2. For pipe wall thicknesses below .375 inches, the radial weld chrinleano chall nne orr pod nno. half nf the wall thickness.
NOTE: The amount of shrinkage shall be measured by the distance f[om the lowest point of shrinkage (at the toe of the weld) and the top of the base metal . - 4. SUPPORTING 00CUMENTATION: CPPA-19384 GTT-8679
- 5. AFPROVAL SIGNATURES: J -
'5-18-82 A. ORIGINATOR: C 6 OATE F/8-S z B. DESIGN REPRESENTATIVE: twed DATE _ f/I M 2.
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- 6. VENDOR TRANSi4ITTAL REQUIRED: YES NO XX
- 7. STANDARD DISTRIBUTION: uqA FORf1 11-80 ARMS (Original)
Quality Engineering (1) (1) .: f5 e . . O"I 13 " j e TS for Orig. Design. Westinghouse-Site (1) (1) THIS DOCUMENT IS FOR lilFORMATION ONLY. CONTACT DOCUMENT CONTROL FOR CURRENT STATUS AND REVIS10N.
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Wg , yp APPENDIX B 1 U. S. NUCLEAR REGULATORY COMMISSION REGION IV Reports: 50-445/83-07 50-446/83-04 Dockets: 50-445 Category A2 l 50-446 Licensee: Texas Utilities Generating Company 2001 Bryan Tower Dallas, Texas 75201 , Facility Name: Comanche Peak, Unit 2
. Inspection At: Comanche Peak Steam Electric Station Inspectica Conducted: January 27-28 and February 1-2, 1983 Inspectors: .f w aN 3 //.k3
' L. D. Gilbert, Reactor Inspector, Engineering Date/
- Section (paragraphs 1, 2, 3, 4, and 7)
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-[ 1 C. E. Johnson, Reactor Inspector, Engineering 3 ^/M Y ussn1.se 8 Da'te /
Section (paragraphs 1, 5, 6, and 7) V
- Reviewed: 2- -
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T. F. Westerman, Chief, Reactor Project Section A Date j 1 Approved: k/ 44MEM D. M. Hunnicutt, Chief, Engineering Section _y9 Ddte /
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! Insoection Summary ! Inspection Conducted January 27-28 and February 1-2, 1983 (Recort 50-445/83-07)
- Areas Insoected: Special, announced inspection to follow up on allegations on I pipe and pipe support welds and protective coatings. The inspection involveo l 48 inspector-hours by two NRC inspectors.
I [ Results: Within the three areas inspected, one violation was identified F (failure to follow procedure, paragraph 2.a). L lyumn FCA-85-59 mm
t t o.- l Inspection Conducted January 27-28 and February 1-2, 1983 (Report 50-446/83-04) . Areas Inspected: Special, unannounced inspection to follow up on allegations - I on pipe welding records. The inspection involved 12 inspector-hours onsite by one NRC inspector. . Results: In the area inspected, no violations or deviations were identified. l l 9 O
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li ' DETAILS
- 1. Persons Contacted Principal Licensee Personnel
*R. G. Tolson, Site Quality Assurance (QA) Supervisor, TUGC0
*C. T. Brandt, Quality Assurance / Quality Control (-QA/QC) Supervisor, TUGC0
*0. N. Chapman, QA Manager, TUGC0 .
Other Personnel
*G. R. Purdy, Site QA Manager, Brown & Root (B&R) J W. E. Baker, Senior Project Welding Engineer, B&R
- E. Op21 ski, Site NDE Level III, B&R J. Patton, QC Mechanical Superintendent, B&R H. Williams QC Superintendent, Non-ASME, B&R
- 8. Wallace, Lead QC, Protective Coatings, B&R B. Dunham, Lead QC, Backfit Program, B&R
- The NRC inspectors also interviewed other licensee and contractor employees during the course of the inspection.
- Denotes those attending the exit interview.
- 2. Followupito A11ecations on Pipe Support Welds in Unit 1.
A special inspection was performed to follow up on an allegation that three pipe support fillet welds were fit-up and welded with excessive gap. The three pipe supports were identified as: SW-1-012-010-A33R, SW-1-102-106-Y33K, and CC-1-087-004-A33A. r-
- a. A documentation review of Pipe Support Mark No. SW-1-102-106-Y33K provided the following.information. The support is a safety-related ASME Code Class 3 NF support for the service water piping system.
The weld attaching piece 7 to piece 4 is classified as a "T" fillet joint that was welded by welder BLU in August 1981 using Welding Procedure WPS 11032 and Construction Procedure CP-CPM 9.10. 5 To permit inspection of the fit-up gap, a portion of the weld was removed from the fillet weld designated on Pipe Support SW-1-102-106-Y33K alleged to have an excessive gap. The NRC inspector measured the gap as being 1/4". The 1/4" gap exceeds the 5/32" maximum allowable fit-up gap requirement of Procedure CP-CPM 9.10 for "T" fillet joints. This is an apparent violation of 10 CFR 50, Appendix B, Criterion V, for failure to follow procedure. The allegation, as it relates to Pipe Support SW-1-102-106-Y33K, was substantiated.
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- b. A documentation review of Pipe Support Mark No. SW-1-012-010-A33R provided the following information. The support is a safety-related ASME Code Class 3 NF support for the service water piping system.
The weld attaching piece 18 to piece 19 is classified as a "T" fillet joint. The support was welded by welder BLU in November 1980 usir.g Welding Procedure WPS 11032 and Construction Procedure CI-CPM 9.10. To permit inspection of the fit-up gap, a portion of the weld was removed from the fillet weld designated on Pipe Support SW-1-012-010-A33R as having excessive gap. The NRC inspector measured the gap as being'1/16". The 1/16" gap meets the fit-up gap requirements of Procedure CP-CPM 9.10 for "T" fillet joints. No violations or deviations were identified. The allegation as it relates to Pipe Support SW-1-012-010-A33R was not substantiated.
- c. A documentation review of Pipe Support Mark No. CC-1-087-004-A33A provided the following information. The support is a safety-related ASME Code Class 3 NF support for the component cooling water piping system. The weld attaching piece 45 to piece 55 is classified as a partial penetration "T" joint. The support was welded by welder BMG in February 1981 using Welding Procedure WPS 11032 and Construction Procedure CP-CPM 9.10.
In reviewing the joint design and fit-up requirements for the partial penetration "T" joint, the NRC inspector determined that the joint design requires a 3/8" bevel on the 1/2" thick material and a 0-3/16" fit-up gap which would give the appearance of having an excessive fit-up gap for a "T" fillet joint. Also, it should be noted that the strength of the partial penetration "T" joint would not be affected by increasing the fit-up gap, where as, the strength of the "T" fillet joint could be affected by increasing the fit-up gap. No violations or deviations war.e identified. The allegation, as it relates to Pipe Support CC-1-087-004-A33A, was deemed to be without technical merit.
- 3. Followup to A11ecations on Pipe Weldino in Unit 1 A special inspection was made to follow up on an allegation that a weld, identified as FW 1-B on Drawing CT-1-SB-017, contained unconsumed con-
-[b sumable insert material hanging down on the interior of the pipe and yV ' excessive radial shrinkage which could cause flow problems. ,
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l After performing an inspection of the weld and reviewing the radiographs ) l of the weld, the NRC inspector determined that the material hanging down ! l 7 approximately 1/16" was caused by melting through the weld root for an l g g area 3/32" irt diameter. The melt-thru condition meets the ASME Code requirements for weld reinforcement and radiographic quality. Radial shrinkage occurs in all pipe weldments, but its effects areWeld FW 1-B } - predominate in large bore, thin wall stainless steel piping.does I
' inspection and adequate. flow within the pipe will be demonstrated during
' the preoperational test of the containment spray system (Preoperational j Test 1-CT-PT-48-01). No violations or deviations were identified. l' j-i
'The allegation, although partially substantiated, is without technical >
I merit. . ,i t
- 4. Followup to Allegations on Pipe Welding in Unit 2 l
i l A special inspection was made to follow up on an allegation that the weld documentation for Wald FW 1 on Drawing MS-2-RB-19 for the main steam l l system has been lost and reconstructed, but does not include the two ! repairs and, therefore, the weld may be defective. The NRC inspector reviewed Nonconformance Report NCR M-3425, Revision 1 a: which stated that the weld data card package had been lost and disposi-j tioned the weld to "USE AS IS" based on other information being available j ' to reconstruct the weld data card sufficiently to satisfy the ASME Code requirements for weld documentation. l I I After reviewing the nonconformance report, reconstructed weld data card, and other available documentation which included weld rod issue records, weld material certification records, drawing requirements, piping material certif'ication records, welder qualification records, procedure qualifica- ) tion reports, and radiographs and radiographic inspection reports for the weld; the NRC inspector determined that sufficient information was avail-able on the weld and two repairs to provid2 adequate assurance that the c weld, as repaired, is of good quality and meets the ASME Code requirements l r for Class 2 welds. i No violations or deviations were ident fied. The allegation that the weld data card was lost was substantiated, but is without technical merit.
- 5. Protective Coatings The purpose of this inspection was to substantiate allegations concerning unsatisfactory coatings application in the Skimmer Pump Room and the Drain Tank Heat Exchanger in Reactor Building (R8) Unit 1 being accepted by QC I
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i l - I 3 l as satisfactory. There was riso some concern of the use of manufacturer's - recommendations when performing patch tests when using the E1cometer 106 , Adhesion Tester. The NRC inspector also reviewed the overall coatings program to determine if there were any other QA problems. The inspection covered a review of procedures, records, observation of the areas in question; a review of the backfit, and ongoing in process program,
- a. Review of Coating Procedures ,
1 The NRC inspector reviewed protective coatings procedures and
- specifications for the application and inspection of work in process and for the backfit program established. ~
The purpose of this review was to determine if the licensee had incorporated all necessary standards, codes, and manufacturer's recommendations into the QC procedures used in the field by QC i inspectors. i l During this review of procedures, the NRC inspector observed that Gibbs & hill Specification 2323-AS-31, " Protective Coatings," stated in paragraph.9.2.2.e, in part, "An E1cometer 106 Adhesion Tester or equal shall be used for patch testing in accordance with the recom-The NRC inspector mendations of the manufacturer of the instrument." The NRC inspector then reviewed the manufacturer's recommendations. observed an instruction of the manuf acturer's operating instruction that was not referenced in any of the QC procedures. This instruction l states, "When the adhesive curing time has elapsed, a cut is made around the dolly through the coating to the substrate (this is especially critical for electro plated coatings) with a sharp knife or special cutter obtainable from E1cometer Instruments Limited." After a brief investigation and interviews with QC personnel by the l NRC inspector of this matter, it was found that no QC procedure l i referenced this instruction, nor were QC inspectors performing this i function. There was some doubt by the NRC inspector whether.this procedure was necessary. The NRC inspector informed the licensee of this finding. The licensee immediately contacted the manufacturer to determine if this procedure was necessary. Through a telephone coa-versation, the manufacturer of this instrument stated that the procedure in question was not necessary, except for electro plated coatings, which is not the case at this site. The NRC inspector has determined that this is an unresolved item until a letter from the manufacturer confirms this. (445/8307-02) The NRC inspector observed in Civil Construction Procedure (CCP)-30, paragraph 4.4.1.1, item 6, that cure time before topcoat shall be in accordance with Attachment 3, which contains graphs that specify hours of cure time with respect to temperature of Carbo Zine II primer after application. During a discussion with QC personnel, it N 4a.m=v 4m em
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. 7 was found that QC inspectors check for ambient conditions before primer is applied and record time. However, after primer is applied, the start of curing is not recorded on any inspection report (IR).
The NRC inspector has determined that if QC is to perform an accurate l curing time in accordance with the graphs, they must record a starting I time after application and an ending time for curing on the IR. - This will be considered an unresolved item. (445/8307-03) Procedures reviewed are listed below.
. CP-CPM-13.1, " General Calibration Procedure"
. CP-QP-18.0, " Inspection Reports" .
. CP-QP-2.1, " Training and Certification of Inspection Personnel" !,
. CCP-30, " Coating Steel Substrates Inside Reactor Buildings and Radiation Areas"
. QI-QP-2.1-4, " Qualification of Protective Coating Inspection Personnel"
. 2323-AS-31, " Protective Coatings" 35-1195-IEI-15, Revision 5, " Calibration of Mechanical Dr'y Film
- Thickness Gages" .
35-1195-IEI-36, Revision 2, " Calibration of Coating Adhesion Tester" CCP-30A, " Coating Steel Substrates Inside Reactor Buildings and Radiation Areas" ~
. QI-QP-11.4-1, " Inspection of Steel Substrate Surface Prep ration and Primer Application"
. QI-QP-11.4-5, " Inspection of Steel Substrate Primer Repair and Seal and Finish Coat Application and Repair" -
. QI-QP-11.4-23, " Reinspection of Seal Coated and Finish Coated Steel Substrates For Which Documentation Is Missing or Discrepant"
. QI-QP-11.4-24, " Reinspection of Protective Coatings on Concrete Substrates for which Documentation is Missing or Discrepant"
- b. Observations M&TE Calibration Shop The NRC inspector reviewed calibration procedures for the Mechanical Dry Film Thickness Gage (DFT) and the E1cometer 106 Adhesion Tester, as indicated in paragraph 5.a. The inspector also observed the calibration of the Adhesion Tester by a technician. The test was .
performed by the weight method, which is an acceptable test. Calibra-tion records were up to date and the equipment was calibrated during the required intervals. No discrepancies were noted.
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8-i Skimmer Pump Room i ! The NRC inspector and several QC inspectors visually inspected the Skimmer Pump Room and the R. C. Drain Tank Heat Exchanger Room in the reactor building at E1.808'-00". This inspection was performed j because of allegations concerned over unsatisfactory protective j coatings being accepted as satisfactory. The main concern was the
- floor in the heat exchanger room. The NRC inspector and QC inspectors noticed some unsatisfactory areas on the floor, however, some unsatis-j factory spots had already been prepared for repair and the remainder
! had not becauseo'f the temporary stop work order. During the course
- of the inspection, the NRC inspector located all irs related to coatings application in these areas. It was found that proper
- documentation of unsatisfactory conditions were reported for these areas in question and work was being performed as corrective action. ;
l i l There is no substantial evidence to this allegation in the areas of .' concern. ! c. Review of Records . The NRC inspector reviewed many records of steel and concrete coatings } applications and inspections. Documentation was readily retrievable
- and legible. There were no discrepancies observed. irs reviewed are
- listed below.
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IR# NCR# . PCR 00879 C-82-0030 PCR 00874 PCR 00899 i PCR 02274 i PCR 00872 ! PCR 02246 i *PCR 01652 l PCR 01233 i PCR 01071 ( PCR 01419 l PCR 00721 PCR 01045 . PCR 01046 ! PCR 01846
*PC 48805 l
*PC 48760
- *PC 48693 "PC 48721
*PC 48302
*PC 48670
*PC 48750 "PC 48190 1J._ - -. 's. .aY NT D= yzevM g w y g gj[_'t-' ___ r ,.q_
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*PC 48747
*PC 48633
- Skimmer Pump Room /P., C. Heat Exchanger Room l
- d. Review of QC Personnel Qualifications The NRC inspector reviewed approximately 18 qualification records to determine that inspection personnel were qualified to inspect activ-ities in the ares of protective coatings. The inspectors were qualified in accordance with site procedures.
- e. Protective Coatinos Program The overall coatings program consisting of the backfit program and ongoing in process program since report 81-15 shows substantial improvement in areas such as retrievable documentation and more specific inspection criteria for QC.
No violations or deviations were identified.
- 6. Unreso'1ved Items -
Unresolved items are matters about which more information is required in order to ascertain whether they are acceptable items, violations, or deviations. An unresolved item related to testing of protective coatings is discussed in paragraph 5.a. A second unresolved item, related to curing time for protective coatings, is discussed in paragraph 5.a.
- 7. Exit Interview The NRC inspectors met with licensee representatives (denoted in paragraph 1) and R. G. Taylor (NRC resident reactor inspector) on January 27-28 and February 1-2, 1983, and summarized the scope and findings of the inspection.
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+ ,w Telephonic Interview of M On September 19,1983,Mi fomer Brown & Root Inc., welder at CPSES, was telephonically interviewed by NRC Investigator H. Brooks GRIFFIN. @ ted he was employed at CPSES from December 1979 until he was terminated during a reduction af force (T,0F) in April ISE3. Mstated thatM w&s his forerr.an ar.c 6 was his superintendent.
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When asked whether he had ever been intimidated into perfoming improper work, , M stated that on one occasion he had worked on a stainless steel pipe that had a insert which he believed created slag in the nine_and could interrupt h b the flow or break offind clog the system. Monfinned that this information hao already been reported to B&R, CASE and the NRC. Ocalled that a
' upervisor named M had told him not to be concerned by the concave weld.
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'. .' e CM3 h 43 Comanche Peak Open Issue Action Plan Task: Improper or Defective Pipe Welds Ref. Nos.: AW-52, AW-59, AW-62 Characterization: AW-52 alleged that field weld 1-B of spool ITT5 of line CT-1-SB-017: , (a) had consumable inserts which had not been consurred and were hanging down in the interior of the pipe. (b) had been made with too much heat and the weld had become convex on the inside, creating a flow problem. AW-59 was the same allegation. AW-62 alleged that a stainless steel pipe had a concave insert which created slag in the pipe and could interrupt flow or break off and clog the system. Initial Assessment of Significance,: There appears to be sufficient specificity to warrant followup of these allegations. The safety significance is difficult to evaluate with the available information. Source: Mechanical and Piping Allegations (Category 3) F01A-85-59 o -
. />y 9f _
2 Approach to Resolution:
- 1. Review B&R drawing CT-1-SB-017 for requirements.
- 2. Identify and revies pertinent GAH specifications and B&R procedures, ,
for applicable codes, materials, welding requirements, etc.
- 3. Identify and review applicable codes for requirements.
- 4. Identify and review pertinent NRC Region .IV OI and IR reports,
- 5. Identify and reviev weld documentation packages for field welds installing line CT-1-SB-17-5.
i
- 6. Identify and review weld procedure specifications used for field welds.
- 7. Determine if weld radial shrinkage requirements were imposed and, if so, what and when.
l
- 8. Evaluate allegations for safety significance and generic implications.
i
- 9. Report on results of review / evaluation of allegations.
, e
I 3 Related Open Issues:
- 1. Using system code from the tracking system open itens, list and
, identify any open items.
- 2. Review activities necessary to close or partially close related items
based on evaluations conducted above.
- 3. While performing physical inspections, examine surrounding system, components, and structures for any apparent defect or indicator of faulty workmanship.
i
- 4. Complete portion of IE module on welding if it relates to effort made on allegation.
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.s.c assss, April 27, 1984 i Peter B. Bloch, Esquire Dr. Walter H. Jordan ,
Atomic Safety and 881 West Guter Drive Licensing Board Oak Ridge Tennessea U.S. Nuclear Regulatory Conssission Washington, D.C. 20555 Dr. Kenneth A. McCollom Dean Division of Engineering. Architecture & Technology / on b d e. Ma^ Oklahoma State University Stillwater, Oklahoma 74078 [d(Men ICIM # 7~'* % Subj Texas Utilities Electric Company, et,al. t (Comanche Peak Steam Electric Station, Units 1 and 2), Docket Nos. 50-445 and 50-446 Centlemen: In accordance with the Licensing Board Chairman's request (Tr. I 11784-7), the attached affidavit of W.E. Baker and C.T. Brandt provides a
> report on the required documentation regarding F.E. Coleman's welding of misdrilled holes in the Unit I cable spreading room. As indicated in the affidavit, Applicants determined that (1) the welding of misdrilled holes by Mr. Coleman in the Unit I cable spreading room was not in conflict with l applicable procedures, the pertinent welding code (AWS D1.1), or engineering instructions and (2) documentation reflects that QC inspections of such welds were being performed.
Sincerely, i N Malcolm H. Phil ps, Jr. i
- Counsel for Applicants l,
cc: Service List ,,, l , l l i 's
- moso-, F0lA-85-59 fy ,
t
1 y l UNITED STATES OF AMERICA i NUCLEAR REGULATORT COMMISSION !
; BEFORE THE ATOMIC SAFETY AND LICENSING BOARD i I
In the Matter of )
)
I TEXAS UTILITIES GENERATING ) Docket Nos. 50-445 and I COMPANY, et al. ) 50-446
)
) (Application for I (Comanche Peak Steam Electric Operating License)
Station, Units 1 and 2) ) AFFIDAVIT OF W.E. FAEFB AND C.T. BRANDT I i RZCARDING BOARD QUESTION CONCERNING F.E. COLEMAN We, U.E. Baker and C. T. Brandt, being first duly sworn do depose and state as follows:* (Baker) My'name is William E. Baker. I reside in Cranbury. Texas. I am the Senior Prpject Welding Engineer employed by Brown & Root. Inc. at Comanche j Peak.
- My educational and professional qualifications are attached to ,
Applicants' Rebuttal Testimony Regarding Allegations o I Concerning Weave Welding, Welding of Misdrilled Holes, Downhill I l Welding, and Weld Rod Control, previcusly filed in this proceeding. (Brandt) My name is C. Thomas Brandt. I reside in Fort Worth. Texas. I an employed by EBASCO Services at Comanche' Peak. My educational and , professional qualifications are attached to Applicants' Exhibit 141 which was previously received into evidence. f
*Except as otherwise indicated, each affiant attests to all parts of this I .
.ffIdayit. <
Page 1 gy Er /LVDW L/f -
. _ _ , -- - - , _ . _ _ _ _ , . )
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. . l This affidavit will address the Licensing Board's request for information regarding documentation of misdrilled holes velded by F.E. Coleman in the Unit I cable spheading room. (Tr_. 11784-11787). In researching this issue, we interviewed numerous welders, foremen, and QC Inspectors who worked in the Unit 1 cable spreading room with Mr. Coleman, and engineering personnel who generically eva_luated welding of misdrilled holes. In addition, we have reviewed the appropriate documents associated with this issue, including construction and QC procedures, engineering documentation, veld filler material requisitions and QC inspection documents. ,
Mr. Coleman worked in the Unit 1 cable screadl== room during the period of November,1978 to January,1979. During this time period, welding of cable tray supperts in this area was the responsibility of the pipe hanger department. In January, 1979, this responsibility was transferred to the electrical cab 13 tray hanger group, and Mr. Coleman was transferred to the Unit 1 turbine deck. While Mr. Coleman was working in the Unit 1 cable spreading room, the erection drawings for the structural steel in this area were modified due to, among other things, changes in the elevation of the cable trays. Because of the changes, some holes which had already been drilled in the flanges and/or webs of columns used to support the cable trays were in the wrong location. It was determined that these holes would have to be welded or the columns scrapped. (Initially several columns were scrapped). On October 25, 1978, craf t requested instructions from the. Civil
.ngineering Department regarding this issue. In response, the Civil agineering Department instructed the craft to weld the misdrilled holes
$ther than to scrap entire columns. Civil Engineering determined that Page 2
_-c-e----,.,---,-.-- - - - - , - - - - - - . - . . . . - - - - - - - - - - - * - - -
the welding of misdrilled holes was to be treated as a correction of a fabrication error, as opposed to a base metal repair. Accordingly, welding of misdrilled holes at this time did not require issuance of repair process
. ; I documentation, as would have been the case if the welding was treated as a base metal repair. However, as with a base metal repair, a final visual ,/
inspection of the weld by QC was required. Thus, the documentation necessary to complete welding of misdrilled holes in the Unit 1 cable sprea' ding room during this period was the welding filler material requisition form which lists, among other things, the support on
/'
which the w.11 ding would occur and the procedure to be used. Mr. Colenan ; stated that he had this documentation. Tr. 11545. We have determined that documentation signed by QC Inspectors exists to confirm that misdrilled holes welded by Mr. Coleman and other welders in this yr area were inspected by Q.C. h Fase 3 I e t
. . . .. . . . , . - . - _ . . ~ . .- - - . . , ,. ~
- o . .
i 1 f/$/ A * ? l// William E. Baker i
. i-l Sworn to me this 27th day of April, 1984.
4 Li \ Notary Public A-4 i It , l% N
'C. Thoaad-4fandt I
~
' Sworn to me this 27th day of April, 1984.
4
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