IR 05000289/1979175
| ML19312D930 | |
| Person / Time | |
|---|---|
| Site: | Beaver Valley, Limerick, Crane  |
| Issue date: | 04/08/1980 |
| From: | Gallina C, Lester Tripp, Walton G NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | |
| Shared Package | |
| ML19312D929 | List: |
| References | |
| 50-289-79-175, 50-320-79-175, 50-334-79-175, 50-352-79-175, 50-353-79-175, 50-412-79-175, NUDOCS 8005220643 | |
| Download: ML19312D930 (11) | |
Text
y, U. S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT
REGION I
Report No.79-175 Docket No.
50-289, 50-320, 50-334, 50-412, 50-352, 50-353 CPPR-105, DPR-73, CPPR-106, DPR-107, License No. DPR-66,DPR-50 Priority Category A-C
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Licensee:, Philadelphia Electric Company Duquesne Light Company Metropolitan Edison Company Facility Name:
Beaver Valley 1, 2, Three Mile Island 1, 2, Limerick 1, 2 Investigation At:
Shippingport, Pa., Middletown, Pa., Limerick, Pa.
Investigation Conducted:
Dec. 10-13, 1979, Jan. 8-9, 1980, Jan.' 14-16, 1980 h 70 Investigators:
A/, 9t[22[m
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dat'e G. Walton, Rea or Inspector
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AA h/fff0 C. Gallina,/ Investigation Specialist 7 /date
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date
Approved by:
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C. Tripp, 6dction Chief, Engineering Support 7 date Section #1, RC&ES Branch Investigation Summary:
Investigation on Dec. 10-13, 1979 and Jan. 8-9 and Jan. 14-16, 1980 (Report 79-175)
Area Investigated:
Unannounced investigation st six nuclear facilities of four allegations concerning welder qualifications.
The investigation involved 60 investigative hours onsite by one NRC regional based inspector.
An inspector and an investigator also interviewed the allegers in their home.
Results:
None of the allegations investigated were found to be substantiated and no apparent items of noncompliance with regulatory requirements were identified.
t Region I Form 167 (August 1979)
8 0052 2Of 4]
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i SUMMARY OF FINDINjS A.
Allegations and Investigation Findings The NRC representative investigated four allegations at six nuclear facili-ties.
The allegations and NRC findings on each are as follows:
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1.
Allegation No. 1 It was alleged that crafts bought union " books" and were sent to Three Mile Island Unit 2 with instructions to state they were certified welders.
During the actual welding test given at TMI, if welders could not pass the test given in the vertical and overhead positions they would take the test in a flat position.
Gary Boring stated that several of the individuals who bought " books" were never qualified welders and could not pass a valid welding test.
Gary Boring could not name any specific individuals who were not qualified.
The NRC investigation found no evidence that welders were not properly qualified at Three Mile Island.
2.
Allegation No. 2 Gary Boring stated that he was a, signed during the construction at TMI Unit 2, to weld on the inside, southwest end of the condenser.
Someone had already welded from the outside and before Gary Boring commenced welding he wanted to remove some obvious slag already present in the weld. When he brought this to the attention of the foreman, he was told to go ahead and weld, regardless of the slag present, which he did.
The NRC investigation found the condenser is a non-safety system and not included in the quality scope of work at Three Mile Island.
3.
Allegation No. 3 Gary Boring stated that while he was working at a fossil-fueled plant for Schneider Inc., he took welding tests for eight other welders.
As a result, they were qualified by Schneider Inc. without ever taking a test.
Further, that Schneider Inc. is currently working on nuclear facilities at Beaver Valley, Units 1 and 2, and some of these indi-viduals might be working there for Schneider Inc.
It was also alleged that welders at Beaver Valley are being supplied from Union Local 636, Titusville, Pennsylvania, which sells union " books" and as a result may be supplying unqualified welders.
The names of the eight individuals that Gary Boring took the test for were not provided nor the names of any individual who bought a union
" book".
The NRC investigation found no evidence that welders were not properly qualified at Beaver Valley Units 1 and 2.
4.
Allegation No. 4 The Borings believe union " books" are being sold out of Local 329, and as a result, unqualified welders and fitters may be working at nuclear facilities such as Limerick and Hope Creek.
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The NRC investigation was conducted at the Limerick Generating Sta-tion and found no evidence that welders or fitters were not properly qualified.
B.
Conclusions The determination of whether " book buying" and other allegations of fraud described in Gary Boring's letter had occurred was not investigated by this office.
The NRC understands from discussions with Gary Boring that he is pursuing these matters with the Department of Justice.
By request the NRC has forwarded to the Justice Department a copy of Gary Boring's letters.
The NRC does not rely on the unions to provide crafts who are qualified.
We require the owner and contractor to assure through training and testing that crafts are qualified to perform these assigned tasks.
The allegations that unqualified crafts are working at nuclear facilities were not substantiated by the investigation.
III.
DETAILS A.
Introduction This investigation was initiated as a result of a telephone conversation between NRC Commissioner Victor Gilinsky's office and Mr. Gary Boring.
Allegations were made that craft personnel were working at nuclear facili-ties who were not qualified.
The NRC Region I contacted the individual by telephone on November 15, 1979, and scheduled an interview to obtain additional information regarding the allegations.
Gary and Wayne Boring were interviewed at Gary Boring:s residence on November 20, 1979 by Dr. C. Gallina and G. Walton.
After the interview, a letter, dated December 12, 1979 was sent to Gary Boring that described the concerns as the NRC investigators understood them.
(Letter attached)
A response dated December 29, 1979 was received stating our information was correct.
Additional information was also provided that stated several local unions and individuals were selling " union books" and allowing unqua-lified crafts to work at nuclear facilities.
(Letter attached)
B.
Scope of Investigation This investigation was limited to allegations made against nuclear facili-ties except for conditions where welders qualified at fossil-fucled facili-ties might transfer these qualifications to a nuclear facility.
In all cases the investigations were conducted on-site at nuclear facilitie ",
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The onsite investigation commenced at Beaver Valley (BV) on December 10, 1979 followed by onsite investigations at Three Mile Island (TMI) on January 8, 1979 and at Limerick on January 14, 1980.
The investigation consisted of:
Discussions and interviews with Quality Assurance personnel, welding
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inspectori, welding supervisors, and welding foreman Review of documentation applicable to welder qualifications
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Review of examination records of completed welds, including radiography
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Visual examinations of completed welds.
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The investigator evaluated the findings against the following documents.
ASME Boiler and Pressure Vessel Code Section IX, Welder Qualification
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American National Standards Committee ANSI N45.2.6, Qualification of
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Nuclear Power Plant Inspection, Examination, and Testing Personnel 10 CFR Part 50, Appendix B, Criterion II, IX
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U.S. Nuclear Regulatory Commission, Regulatory Guide 1.58.
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C.
Persons Contacted 1.
Duquesne Light Company - Beaver Valley R. Coupland, Director of Quality Control R. Washabaugh, Manager, Quality Assurance Department F. Green, Quality Control Engineer R. Ricard, Welding Supervisor P. Dickson, Welding Foreman j
R. Raymond, Welding Supervisor 2.
Metropolitan Edison Company - Three Mile Island J. Wright, Quality Control Manager T. Corry, Quality Control Engineer 3.
Philadelphia Electric Company - Limerick J. Corcoran, Field Quality Assurance D. DiPaolo, Quality Assurance Engineer
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The inspector also interviewed other licensee and contractor personnel during the investigation.
D.
Specific Allegations 1.
Allegation No. 1 a.
Allegation It was alleged that crafts bought union " books" and were sent to Three Mile Island with instructions to state they were cer-tified welders.
During the actual welding test given at TMI, if wolders could not pass the test given in the vertical and overhead positions they would take the test in a flat position.
Gary Boring stated that several of the individuals who bought
" books" were never qualified welders and could not pass a valid welding test.
He could not name any specific individuals who were not qualified, b.
NRC Investigation The ASME, B&PV, Code,Section IX recognizes different positions for qualifying welders.
A welder who fails an overhead qualifi-cation test may be tested in other positions, such as flat.
His qualification test certification must describe the position or positions he is qualified in and he must be limited to that while welding.
It was. requested, from the allegers, but not provided, the names of these welders who changed the welding positions during these tests.
The investigator audited the welder certifications for all boiler-maker welders who took the welding test in the same time frame that the alleger took the test on-site at TMI.
The investigator determined that Gary Boring qualified on-site on September 13, 1972 and June 28-29, and July 5, 1973.
During the periods from August 30, 1972 until September 27, 1972 and June 11, 1973 until August 30, 1973, 59 welding tests were taken and acceptable.
Of these 59, 22 of them were taken in the overhead position, two of the tests being taken by the alleger.
One welder qualified in the flat position, and the balance of the tests were taken in other positions.
Fifty additional welder test certifications made during the con-struction phase of TMI 1, 2 were audited by the investigator and no discrepancies were found.
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This allegation could not be substantiated.
2.
Allegation No. 2 a.
Allegation During the construction at TMI, Gary Boring stated that he was assigned to weld on the inside, southwest end of the condenser.
Someone had already welded from the outside and before he com-menced welding, he wanted to remove some obvious slag already present in the weld.
When he brought this to the attention of the foreman, he was told to go ahead and weld, regardless of the slag present, which he did.
b.
NRC Investigation The NRC investigator found that the condenser is not a safety related system.
It was not required to be included in the qua-lity scope of work at IMI.
No records on these type systems were required and no nondestructive examinations, such as radio-graphy, were required.
Since this is not a safety related system, the investigator did not pursue this allegation.
This allegation could not be substantiated.
3.
Allegation No. 3 a.
Allegation While Gary Boring was working at a fossil-ft21ed plant for Schneider Inc., he stated that he took welding test for eight other welders.
As a result, they were qualified by Schneider Inc. without ever taking a test.
Further, that Schneider Inc.
is currently working on nuclear facilities at Beaver Valley, Units 1 and 2, and some of these individuals might be working there for Schneider Inc.
Also at Beaver Valley he stated that welders are being supplied from Union Local 636, Titusvilla, Pennsylvania, which sells union " books" and as a result r.ay be
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supplying unquclified welders.
b.
NRC Investigation Although the allegation that one person took a test for eight others occurred at a fossil-fueled facility which is outside the jurisdictional authority of the NRC it was investigated because welder certifications within a comp,any can be transferred from a fossil-fueled facility to a nuclear facility.
In this case Schneider Inc., the contractor involved in the allegation, is the piping contractor at Beaver Valley, Unit 2.
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The names of the individuals that the test were taken for could not be supplied, nor could any individual be named who had bought a " book".
The allegers furnished the investigators with the name of a welder who works on site at Beaver Valley 2 as a source of information to support the allegers' statements.
The investiga-tors attempted to contact this individual by telephone on numer-ous occasions without success.
The NRC office also sent the individual a certified letter requesting him to contact the investigator.
No contacts were made until March 19, 1980.
This individual was interviewed in Region I offices on March 31, 1980.
No new information to support this allegation was provided at that time.
Other allegations not related to matters of this investigation were made durin of separate investigation (s).g that interview and will be the subject Having no specific information regarding individual welder quali-fications, the investigator conducted extensive reviews of all welders activities at Beaver Valley Units 1 and 2.
The following concerns were investigated.
1.
Can welder certifications be transferred?
The governing code, ASME, B&PV Code,Section IX does allow welder qualifications to be transferred if the individual conti-nues to weld for the same organization.
For example, Schneider Inc. could transfer welder qualifications from the fossil-fueled plant to a nuciaar facility.
The practice at Beaver Valley is to administer a welding test to all welders who report on site as welcers.
If the individual fails he may be given reinstructions and retested immediately.
If he fails the retest, he must wait 30 days before he can retest again.
The investigator found that no welder qualifica-tions were transferred by Schneider from another location to BV.
All were required to retest.
2.
p * weld test stringent enough?
The investigator reviewed the test results of 604 welders who had taken welding tests on site.
The 604 welders had taken a total of 1428 weld tests, 399 of the tests were failed for a failure rate of approximately 28 percent.
This included crafts in the ironworkers, pipefitters, carpenters, sheetmetal, elec-tricians and boilermakers unions.
This failure rate could be attributed to unqualified welders attempting to pass the test.
Regardless of cause of test fail-ure, it indicated to the NRC that stringent tests are being given and welders who cannot satisfactorily weld are disoualified.
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Are the people who give the test controlled by the unicns or
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The investigator interviewed the people who administer the weld test.
This included 2 welding supervisors, a welding foreman, and a Duquesne Light Quality Control Engineer.
The welding foreman is a union employee with job responsibilities for welder orientation, providing test booth and weld samples, welding machine assignment, weld rod issue, and instruction to welder on type of test he is to take.
He does not control the decision of whether a welder passes or fails a test.
This is controlled by the welding supervisor who is not a union member.
In addition, the Duquesne Light Q.C. engineer audits 100 percent of the examinations.
He is not a union member.
Gased on the above the investigator is satisfied that the weld tests are not controlled by the union.
This allegation was rot substantiated.
4.
Allegation No. 4 a.
Allegation The Borings believe union " books" are being sold out of Local 329, and as a result unqualified welders and fitters may be working at nuclear facilities such as Limerick and Hope Creek.
b.
NRC Investigation The investigator was not supplied with any names of individuals who are not qualified and working at either of the sites men-tioned above.
Therefore, the investigator performed a detailed audit of welding activities at the Limerick Generating Station.
The following areas were audited; Interviews with the welding supervisors who conduct the
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weld tests.
Evaluation of the welders' reject rate.
The reject rate of
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welders is a higher percentage than BV although comparable to each other.
Audit of welder qualification.
This was accomplished by
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reviewing weld history records and tracing the welders to assure initial and continuing welder qualification.
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Audit of numerous weld history records to ascertain weld
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quality
Visual examinations of numerous welds to ascertain weld
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quality
Review of radiographic film to ascertain weld quality
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Review of production weld failure rates based on radio-
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graphy.
The reject rate of welds deposited is less than 1 percent.
The NRC investigation found no information or evidence that unqualified welders are working on site.
This allegation was not substantiated.
E.
Management Meetings Management meetings were conducted at the Beaver Valley site on December 13, 1979, Three Mile Island site on January 9,1980 and at Limerick Generating Station on January 16, 1900.
The investigator discussed the reason and scope of the investigation.
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