ML16341C106

IE Insp Repts 50-275/83-37 & 50-323/83-25 on 831114-18 & 1128-1209.Noncompliance Noted:Failure to Assure That Welding Inspectors Qualified & Certified Per Procedural Requirements

ML16341C106
Person / Time
Site:	Diablo Canyon
Issue date:	02/29/1984
From:	Canter H, Hernandez G, Kirsch D, Ross T NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V)
To:
Shared Package
ML16341C107	List: ML16341C106
References
50-275-83-37, 50-323-83-25, NUDOCS 8403060149
Download: ML16341C106 (8)

See also: IR 05000275/1983037

Text

U. S.

NUCLEAR REGULATORY COMMISSION

REGION V

Report Nos. 50-275/83-37

and 50-323/83-25

Docket Nos.

50-275

and 50-323

License

No,. DPR-76 and Construction Permit No.

CPPR-69

Licensee:

Pacific

Gas

and Electric Company

77 Beale Street,

Room 1435

San Francisco,

California

94106

Facility Name:

Diablo Canyon Units

1 and

2

Inspection at:

Diablo Canyon Site,

San Luis Obispo County, California

Inspectors:

.d

G

.

ernandez,

act

nspector

Inspection

conducted:

November

14-18 and November

28 - December

M

R ss,

Reactor Inspector

I

91

1983

Date Signed

D

e

igned

Approved by:

D.

. Ki

ch, Chief, Reactor Safety Branch

H. L. Canter,

Chief

Reactor Projects

Section

No.

3

D te Signed

>Q.

8

Date Signed

Ins ection Durin

the Period of November

14-18

and November

28 - December

9

1983

(NRC Ins ection

Re ort Nos. 50-275/83-37

and 50-323/83-25).

Areas Ins ected:

A special,

unannounced

inspection by regional-based

inspectors

to perform an in-depth review of selected

findings contained in an

audit of the Pullman Power Products Quality Assurance

Program

conducted

by

Nuclear Services

Corporation

(NSC), during August - September

1977.

Concurrently,

the licensee

and contractor

responses

were evaluated

to

establish

whether the outstanding

issues identified by NSC were resolved or

corrected.

The inspection involved 402 inspection-hours

by three

NRC inspectors.

Results:

Of the areas

examined

one item of noncompliance

was identified

(failure to assure

that welding inspectors

are qualified and certified in

accordance

with procedu'ral

requirements,

paragraph

No. 17).

Kirsch Exhibit 1

41

program.

(The Pullman internal audit program is further discussed

in

paragraph

no.

9 of this report).

No items of noncompliance

or deviations

were identified.

44.

Conclusion

The

HSC audit contains

a total of 175 documented

findings, of which 110

were findings of apparent

discrepancies

or program weakness

by NSC.

has

completed

an examination of 50 of the

NSC findings identified

apparent

weaknesses

or discrepancies.

The criteria used to select

those findings for NRC examination are provided in paragraph

4 of this

report.

Of the 50 findings examined

by the

NRC; three of these

were

examined prior to this inspection

and are

documented

in NRC Inspection

Report No. 50-275/83-34.

Although, the

NRC has identified

a potential violation (paragraph

17)

during this inspection,

regarding

the qualification of Pullman visual

welding inspectors,

this item is of reduced significance since all but

two of the inspectors

had adequate

backgrounds

and experience

in the

areas

of welding or quality control inspection.

It does not appear that

this problem was chronic or widespread.

~

a

l

Furthermore,

based

on this significant sample'of

the most important

findings it is concluded that examination of the remaining items is not

warranted.

45.

Mana ement Meetin

On November

18,

1983,

the inspectors

met with licensee

representatives

denoted in paragraph

1.

The inspection

scope,

observations,

and findings

were discussed.

The licensee

acknowledged

the potential item of

noncompliance identified in paragraph

17.

LEGEND

22 ~ S$ 'R 22

21

~ SSIR

21

IR

Irspection Report

Ic

A

~ Tl'e staff has previously addressed

the issue

ALLEGAT 0)l SWRCE

DOCUHEHT

ALLEGER

2/2/B412/22/'i3/I/B413/2/b4I3/23

4

JI

GAP

CIUUlACTER IZATION

OLD

UP

CLOSED

t

>ts Criteria

l 1 22/p E-6,7

.. ~

IHKLE

1

1

2

2

!

3

3

1

4

1

5

5

I

ILOCKERT I PULLNAH MELDERS HAVE BEEN QUALIFIED MITHOUT ANY gh COVERAGE.

I

ILOCKERT I HANAGEHEHT DID HOT DEHONSTRATE ANY COHHITHEHT TO MELDER qUALIFICATIOHB

MllEH NOTIFIED OF THE VIOLATION

I

I

ILOCKERT I PULLMAN REFUSED TO PROCESS h FORMAL AC REPORT

OH THE UHCOHTROLLED

MELDING

UALIFICATION TESTS

I

ILOCKERT I A PRODUCTION OFFICIAL REFUSED THE QC INSPECTOR ACCESS

TO IHSPECTION

RECORDS

I

I

22

ILOCKERT I QC IHSPECTOR TERMINATED IH RETALIATIOH POR PURSING MELDER QUALIFICATIONI120 ~

TEST VIOLATIOHS

130 OI

I

I 1ZS

I 123

129

12b

129

129

I

I

I (22)

I

ILOCKERTI PULLNAH Qh NANAGER TOLD HRC THAT THE QC INSPECTOR QUIT, MHEH HE MAS

1120~

ACTUALLY FIRED

130 OI

I

9

9

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I

10.

I

10

7

7

II

i

b

I

I

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IRUDMH

I FRO?l 1974-1979,

MELDER qUALIFICATIONS ARE INDETERHIHATE

I

I

IHUDSON

I PGbE

CllANGED CONTRACT SPECIFICATIONS THROUCll NOTES MITHOUT CONTROLLED

REVIEM AND APPROVAL (A'MAITIHG SPECIFICS

FROH PGAE SEE t215

I

I

IHUDSOH

I MELDER QUALIFICATIONS CONNOT BE VERIFIED BY RECONSTRUCTING llELD ROD

I

I

ilmDSON

I IMPROPER MELD PROCEDURE MAS USED TO MELD TUBE STEEL TO PIPE

SUPPORTS

I

IHUDSON

I ASNE-BASED MELD PROCEDURE

CODE 7/B MAS IHPROPERIY USED TO MELD THREADED I

MELD STUDS

ON CLASS I PIPE

SUPPORTS

I (22)

I 103-119

I

22)

I 103-119

2

i 103-119

6

bE IR83-37

I (22)

I 103-105

I (22)-

I 103

105

LEGEND

22 << SUER 22

21

~ SSER

21

IR

I ~spection Report

I'

Ti e staff has previously addressed

the issue

~ ~

ALLEGAT'OH FSlQCE DOCLNENT

ALLEGER

.'2/2/84l2/22/ '4l3) 2/84l3/2 84l3/23/84l

CHARACTER1 ZATION

PG&E

lER 22/p E-

PGE

HRC

13

)

a

14

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15

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l i7

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18

l

I

19

20

12

l

14

15

16

17

18

19

20

IHUDBOH ICODE 7/8 MAS USED TO MELD THREADED STIJDS TO COHTAINMEHT LIHER - gh

I

l

IHUDSOH IWELDIHG OF TIIEADED STUDS VIOLATED COI'E 7/8, MHI~I CALLS FOR THE USE OF

h BACKING BAR

I

I plJLLMAH OVEREXTENDED CODE 7/8 BY MELDING COMMOH HARDWARE BOLTS,

INSTEAD

~

~

IHUDSOH lOF THREADED STUDS ~

CONSTRUCTION CREWS TURNED THE BOLTS INTO STUDS

BY

HG

E HEADS OFF AND CHISELING TO h POINT

I

I

IHUDSOH ITHE "liOMEMADE" STUDS NEITHER HAVE CONTROLLED CHEMICAL CONTENTS HOR

CRABILITY

I

I

IHUDSON

I CODE 7/8 MAS USED TO WELD AT LEAST EIGHT PIPE

SUPPORT JOINT COHFIGURA~

R

B

CODE

I

I

IHUDSON ICODE 7/8

MAS USED ON MELDING PIPE

RUPTURE RESTRAINTS TO FIVE METALS

PPROVED P-

MATERIAL

I

I

IHUDSOH ICODE 7/8 MAS IMPROPERLY USED TO MELD "W" SJ{APES AND TUBE STEEL TO PIPE

I

I

IHUDSON ICODE 7/8 MAS IMPROPERLY USED

FOR

11 PIPE

RUPTURE RESTRAINT JOINT

I

I

IHUDSON

I PIPE

RUPTURE RESTRAINT MELDING MAS CONDUCTED WITHOUT AHY ESTABLISHED

E

ROCEDURE

I (22)

I 103-10>

I

22)

I 109-110

(2

I 103-10$

a

13l

I (22)

I 131

l

22)

I 103-.105

l

22)

I 105,

110

l (22)

I 103-105

I (22)

l 104

I

22)

126

22

22

21

.

21

I

I

lLOCKERTIPULLMAH SUBSTITUTED A WELD TECHNIQUE SPECIFICATIOH

{AWS Dl. 1) AS

10N

FOR USE OF ASME PROCEDURES

I (22)

f ios

I

I

l(22)

l

I LOCKERTIQA MANAGEMENT DIRECTED INSPECTORS

TO

WINK

AT VIOLATIONS ON GROUNDS

I 120 o

l

THAT DEFECTS

WOULD BE CAUGHT BY OTHER DEPARTMENTS

130 OI