Text

Submits Interim Rept of Natl Board Notification ASME Code Related Const at Facility,Per State of Oh,Div of Boiler Insp
	ML20023C049
Person / Time
Site:	Zimmer
Issue date:	05/12/1982
From:	Mcdonald D; OHIO, STATE OF
To:	Milan D; OHIO, STATE OF
Shared Package
ML20023C048	List: ML20023C047; ML20023C049; ML20023C050; ML20023C053; ML20023C055;
References
	FOIA-83-74 NUDOCS 8305090545
	Download: ML20023C049 (76)
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SUBJECT:

National Board Audit' as Requested by the State of Ohio,. Division of Boiler Inspection,Cof the ASME Code Related Construction of the Will.iam H. Zimmer Nuclear Power Plant, Moscow, Ohio INTERIM REPORT

Dear Mr. Milan:

The State of Ohio, Division of Boiler inspection, in a letter dated December 9, 1981 frc= ik. Donald M. Milan, Divis' cn Chief, to Mr. Earl A. Borg= ann, Senior i Vice President, Cincinnati Cas and Electric Company, requested the audit be initiated and to continue in effect as required (by the State of Ohio) until said plant became operational or commercial. As a result of this request, a meeting was held in the National Board of Boiler and Pressure Vessel Inspectors' offices in Columbus, Ohio, on January 6, 1982. ~ vith representatives of the_ State of Ohio's Division of Boiler Inspection, Cincinnati Cas and Electric Company, Inc., The Natienal Board of Boiler and Pressu're Vessel Inspectors, and Henry J. Kaiser Company (Cincinnati Cas and Electric Company's contractor), where arrangements were made to begin the audit March 1, 1982. On March 1, 1982, the initial National Board / State of Ohio Au~dit Team made up of Donald J. Mcdonald, Richard Jagger, Charles W. Allisen, Michael Sullivan and Donald M. Milan met with the following personnel at the William H. Zimmer l Nuclear Power Plant site: B. R. Sylvia Vice President Nuclear Operations Cincinnati Cas and Electric Company, Inc. H. R. Sager Manager Quality Assurance Cincinnati Cas and Electric Company, Int D. J.>Schulte Director Q.A. Engineering Cincinnati Cas and Electric Company, Inc. Bob Arthurs Coordinator of 0.C.P. Cincinnati Cas and Electric Company. Inc. B305090545 830317 PDR FOIA SAPF83-74 PDR 6 I y..h 3

4: May 12, 1982 Mr. Donald M. >ylan Page 2 of 13 C. H. Stanfield Construction Manager Henry J. Kaiser Company W. A. Hedzik Site Q.A. Manager Henry J. Kaiser Company J. W. Watkins Staff Consultant Henry J. Kaiser Company G. L. Fones Q.A. Records Manager Henry J. Kaiser Company M. L. Goedecke ' Project Welding Manager Henry J. Kaiser Company N. R. Vitale Q.E. Manager Henry J. Kaiser Company D. L. Heward Director Q.A. Programs Henry J. Kaiser Ccmpany P. K. Botts Q.A. Manager Catalytic, Inc. R. J. Fisher Resident Project Manager Catalytic, Inc. F. Christianson Resident Inspector United States Nuclear Regulatory Commission D. R. Hunter Chief of Reactor Projects, Regien III United States Nucicar Regulatory Comnission Lowell R. Burton A.N.I. Hartford Steam Boiler Inspection and Insurance Co. Mr. Mcdonald stated that the National Board Team Audit was at the request of the State of Ohio, Division of Boiler Inspection, with the concurrence of the Cincinnati Cas and Electric Company. He charged the. National Board Team with conducting a comprehensive and complete independent audit into the ASME Code related construction and the Authorized Nuclear Inspector and Authorized In-spection Agency activities that are subject to the requirements of the State of Ohio (Ohio Revised Code Chapter 4104 Paragraph 4100.01). He also recognized the verification and confirmation programs that are in effect due to reports by others, and said that the National Board's activities would be independent of these; however, there probably would be some overlap. negardless, the National Board Team is to report all " findings" assure corrective action relative to their findings, and to assure confirmation of verification and corrective action in all Code related activity for compliance with the ASME Code and State of Ohio requirements.

..~ a' May 12, 1982 Mr. Donald M. Milan Page 3 of 13 4 e i The State of Ohio Division of Boiler Inspection Chief, Cincinnati Cas and Electric Company, and U.S. Nuclear Regulatory Commission representatives are to be advised of the National Board Team's activities, and are to be assisted in every possible way to achieve total compliance with the Juris-I dictional enforcement and Regulatory requirements. 1.0 Introduction. The results of the audit to date are as fo11cus. a 1.1 Cincinnati Cas and Electric Company, Inc. (CGSE), Dayton Pcwer and Light, and Columbus and Southern Ohio Electric Company are the owners of the William H. Zimmer Nuclear Power Plant. It is located in Moscow, Ohio. t Cincinnati Gas and Electric Company is in possession of ASME Owner's Certificate of Authorization N-610, issued September 2, 1981 and expiring September 30, 1984 for the William H. Zimmer-Nuclear Power Plant, Moscow, Ohio, Unit #1. The origir.a1 issue date was March 6, 1973. The docket date number is 50-358 (April 1970) for this 810 MWE unit. The construction permit number CPPR-88 was israed in October of J972. 1.2 The Architect / Engineering Contractor (AI) and Subcontractors at this site are: ~ 1.2.1) AI - Sargent & Lundy Engineers, Chicago, Illinois. 1.2.2) Henry J. Kaiser Company (formerly Kaiser Engineers, Inc.), Oakland, California, is the Prime Contractor. Hen.y J. Kaiser Company is the holder of NA Certifi-l cate of Authorization N-1436 and NPT Certificate of Authorization N-1437, both due to expire June 25, 1982. (Henry J. Kaiser Company has recently had a g-renewal survey (March 22-24, 1982)fnr the above Certificates). These Certificates are issued for the William H. Zimmer Nuclear Power Station, Unit #1, Moscow, Ohio only. The A.I.A. is Hartford Steam Butler Inspection and Insurance Company. 1.2.3) General Electric Company (G.E.), San Jose, California, is the designer of the NSSS systers. The reactor vessel is a G.E. boiling water reactor (BWR) fabricated by Chicago Bridge and Iren Nuclear. Memphis, Tennessee. ATTACHMENT A 1.2.4) Reactor Controls Incorporated. San Jose. Califctnia -- NPT #1299-2 and NA a1300-2 fie]d fabrication and installation of Class 1. 2, 5 3 appurtenances and piping l l

j i = May 12, 1982 Mr. Donald M. Milan Page 4 of 13 9 subastemblies component supports and installation of Class 1 central rod drive housings and Class CS core support structures at the William H. Zimmer Nuclear Power Station, Moscow, Ohio only. (Certificates expired June 7, 1979). Reactor Controls left the site 1979. The A.I. A. was Hartford Steam Boiler Inspection and In-l surance Company. 1.2.5) Chicago Bridge and Iron Company, Oak Brook, Illinois, fabricated and erected the containment vessel. The con-tainment is a General Electric Mark II design which was j not, inspected and stae. ped in accordance with ASME Code . requirements nor accepted as a state special. i 1 e. l.2.6) Catalytic, Inc., Philadelphia, Pennsylvania -- N-1301 (NPT) ,g est and N-1302 (NA), expiration date, February, 1985 -- installa- ['l tion of Class 1, 2, & 3 components, parts, appurtenances, j piping subassemblies and component supports and CS core t-support structures at various field sites (subject to, site I j f audits). Catalytic, Inc., to the Team's knowledge, has J performed no Code work and to date, has not been surveyed by ASME at the site. The A.I.A. is Hartford Steam Boiler Inspection and Insurance l Coepany. 1.3 Based on CC6E's letter dated February 22, 1?78 (KEQ195), the follow-i ing ASME Code editions and addenda were used as a basis for the team audit, i l ATTACHMENT B j 1.3.1) Reactor Pressure Vessel Desien and Construction Section III, 1968 Edition, with Addenda through Su=mer 1970 (except Paragraph N-355). 1.3.2) Phase I Pipine Fabrication Section III, 1971 Editiun, with Addenda through Winter 1971. l 1.3.3) Phase II Piping Fabrication ) Sectior. III, 1971 Editiun, with Addenda through Winter 1972. i 1.3.4) Phase II Fipine and Eouipment Erectio_n Section III, 1971 Edition, with Addenda through Summer 1973. i 1 .m---.-e---. --- ,-._-__y_mm---.-.- v--r_,__m-,--v--_~_-,,--.-r --w_,,,,.,. -,w v. -ry.- --.,,r ry-

e-s' May 12, 1982 Mr. Donald M. Milan Page 5 of 13 e 1.3.5) Weldine Procedure & Welder Performance Oualification Sections III and IX, 1971 Edition, with Addenda through Winter 1973. 1.3.6) Nondestructive Examination Section III, Appendix IX, 1971 Edition, with t Addenda through Summer 1973. 1.3.7) Instrument Penetration Fabrication Section III, 1971 Edition, with Addenda through Winter 1972. 1.4 Charles W. Allison and Michael Sullivan, National Board repre-sentatives, and Donald M. Milan, State of Ohio, were the National Board Team Members the dates March J through March 5, 1982, with Michael Sullivan present throughout the audit to date. Other National Board Team Members present on various days.throughout the audit were: Robert Holt, Michael Houle Richard Jagger and John McLoughlin. 2.0 CINCINNATI GAS AND ELECTRIC COMPANY NA 3220 2.1 The National Board Audit Team questioned the adequancy of a Generic NA 3250 Design Specification which fulfills the requirements for all piping l NA 1210 systems. The CCSE, Sargent & Lundy, has submitted a certified Design Specification listed as Appendix A of Specification H-2255. Appendix A is dated November 11, 1976, Revision O. The date of Specification H-2255 is August 23, 1973. Appendix A of Specification H-2255 lists several other documents which must be used in conjunction with, and form a part of, the Design Specification. The Registered Professional Engineer (RPE) who is certifying the Design Specification does not in all instances certify the other documents which are considered part of the Design Specifications. Nor does he certify revisions to said documents. Further, it is difficult to determine whether or not the certifying RPE recertifies the Design Specification after a revision to the other documents which forn part of the Design Specifications. 2.1.1 The National Board Audit Team is of the opinion that any + revisions to the Base Desicn SpecificationTor to any docu-ments which are listed as a part of the Desien Specifica-tion must be reviewed and certified by the RPE of record on the Desien Specification. Further, all documents which are to be used as part of the Design Specification must be listed by revision in the Desicn Specification. l l l J, ---e ,,__t-m., r .-..__-- _~,., ---.

.s e g May 12, 1982 Mr. Donald H. Milan Page 6 of 13 \\ r 2.1.2 -CG6E has received an interpretation from their AE. The interpretation however does not address the control of revisions to the Design Specification. Furthermore, the interpretation regarding this Code requirement did not come from ASME as required. ATTACHMINT C 2.2 Cincinnati Cas and Electric Company procured piping subassemblies from M. W. Kellog Company, ASMI N-1251 NPT Certificate of Authori-zation number (now Pullman Power Products, Williamsport, Pennsylvania). As part of these purchase orders, M. W. Kellog Company supplied loose material such as pipe, fittings, flanges, etc. The material was received by Kaiser and was accepted for release to construction based on a notification of release from CONAM, CG6E's source Inspection Agency. ATTACHMENT D t NA 4441 / 2.2.1 National Board considers this procedure for the release of NA 4442 material by Kaiser through CG&E and/or CONAM, who do net hold N Certificates of Authorization to be in apparent non-l conformance to Paragraph NA 4441, NA 4442. 2.3 CG&E, in'some cases, refused to allow Henry J. Kaiser Company to perform qualification surveys of material manufacturers. CG&E insisted that only they (CG5E) could approve whom Kaiser was to qualify. In some instances Kaiser was required to place material manufacturers on the Approved Vendors List based on CG&E's " personal experience" or by virtue of appearing on the Case Register, i ATTACHMENT E 2.3.1 The National Board Audit Team considers this procedure to be an apparent non-conformance to ASME Code requirements. Paragraph NA 3451. Sub-article NA-3110 specifically states that responsibilities set forth in Section III relate only to Code compliance and not to contractual relations or legal liabilities. Cincinnati Gas and Electric Company must cease preventing Kaiser from the performance of those Code activi-i ties which are required to be performed by i*siser's Certifi-cate of Authorization. ATTACHMINT F NA 3440 2.4 CG&E has a procedure, ADMIN 3, Rev. O, 2/21/80, " Performing Con-NA 3451 struction on Systems / Areas under EPD Control." (Electrical Produc-NA 3460 tion Department). This procedure has been implemented to allow CG&E to take over piping systems which are still within the juris-diction of Kaiser and are not completed or covered on an N-5 data report from. NA 5241 CG&E then directs the performance work on these systems or portions of systems, which in some instances may include the removal of or l

5 May 12, 1982 Mr. Donald M. Milan Page 7 of 13 r addition of welds. In so'me cases this work has been done with the use of Kaiser craft, but neither Kaiser Q.A. or the A.N.I. has been involved in the activities or review of proposed activities. Further, there is the possibility that there have been no records kept of weld material or piping material which may have been used to make these system modifications. ATTACHMENT C 2.4.1 It is the opinion of the National Board Audit Team that this is an unacceptable practice. This also is in conflict with NA 3440, NA 3451, NA 3460, and the specific requirements of Interpretation III-1-77-159, dated June 30, 1979. The National Board Audit Team is of the opinion that until such time that an N-5 has been completed, piping systems that are to be Code symbol stamped must remain in the custody of the NA Certificate holder. Further, any modifications or changes to these systems shall be made under the requirements of the Q.A. program of the NA Certificate holder who is responsible for executing the N-5 data report. All turnover packages and associated documents involving modified Code piping systems shall be reviewed to assure that no Code work has been performed by other than the holder of an appropriate Certificate of Authorization and that this modification was properly reconciled with the design specification and documented final record package. Table 2.5 Cincinnati Cas and Electric Company at present does not have an NA 3120-1 inspection contract with an Authorized Inspection Agency to providei, NA 8124 inspection services for the Owner's activities. As of this date NA 8430 there has been no Authorized Nuclear Inspector auditing or monitor-ing the CG&E activities in the compilation of Code required documents for completion and certification of the N-3 data report form (s). 2.5.1 It is the opinion of the National Board Audit Team that by the rules of the 1971 ASMI Section III, Summer 1973 Addenda of the Code, CC&E or their agent is required to have a valid inspection contract. The National Board Audit Team suggests that CGLE immediately contract with an Authorized Inspection Agency for inspection services. l 2.6 The National Board Audit Team has been advised by CC&E supervisory personnel that there is a possibility that modification or repair by Catalytic, Inc. may be performed un piping systems for which Henry J. Kaiser Company has not completed the N-5 dica report and stamped the system. KC-16365-Q, dated March 15, 1982, is a pro-posed Code Data Report Code stampinc acreenent between Henry J. Kaiser Company and Catalytic. Inc. ATTACEMENT H e-

i May 12, 1982 Mr. Donald M. Milan Page 8 of 13 e ~ 2.6.1 It is the opinion of the National Board Audit Team that such construction shall be in accordance with Code require-ments and be acceptable to CG6E, the A.I.A., and the State of Ohio, prior to beginning construction. 2.7 The containment vessel apparently is within the scope of the State of Ohio Boiler and Pressure Vessel law regarding construction, in-spection, and stamping, and there is no evidence of compliance with these requirements. 2.7.1 It is the opinion of the National Board Audit Team that CG6E contact the Boiler Pressure Vessel Division of the State of Ohio for possible resolution. 2.8 A pressure vessel Manufacturers Serial No. 276 manufactured by Lamco Industries, El Cajon, California, and installed in a " Standby Liquid Control System" Tank No. ICAIA001, Line No. ISCOIA4, ISO, Dwg. No. PSK SC-1 Project Specification H-2256 was modified by re-placing a 3 inch nozzle with a 4 inch nozzle. KC-15604-Q, dated July 1, 1981. This letter was written to Mr. Donald M. Milan, Chief, Division of Boiler Inspection, State of Ohio, requesting permission for the Henry J. Kaiser Ccepany, ASMI Certifi-cate Holder N-1437 and N-1436 to make the above modification as out-lined in FDDR KN-1-1012. Permission was granted by the State of Ohio (August 13, 1981) for this modification. However, the National Board Audit Team noted the modification was made October 6-12, 1981 in accordance with FDDR KN-1-1012 Revision 3 that did not include the reinforcement pad as proposed in the original FDDR submitted to Mr. Donald M. Milan, Chief Inspector, State of Ohio. Furthermore, there is no evidence to date that the Authorized Nuclear Inspector participated in the inspection of this modification, witnessing the final hydrostatic test and signing the Data Report accepting the modification as complying with Code requirements. ATTACRMINT I 2.8.1 The National Board Audit Team recommends that CG5E and Henry J. Kaiser Company obtain acceptance from Mr. Donald M. Milan, State of Ohio, for this modification as in the last revision. FDDR No. KN-1-1012, Revision 3 require the certificate holder's (H.J.K.) Authorized Nuclear In-spector to inspect the modification, witness the final hydrostatic test and, if acceptable, certify the Data Re-port. e 3.0 HENRY J. KAISER COPA1Y NB 4622 3.1 A Main Steam Feedwater system PSK FW1 Line No. 1, F'OZEA18 MK43-37A Table NB to MK1B21F032A Field Weld No. K-50. WPS 3.1.47 18" Nominal 1.351" 4622.1-1 Wall, Weld Data Sheet was reviewed. The WPS specified 600F minimum

a May 12, 1982 Mr. Donald M. Milan Page 9 of 13 r preheat and was qualified without PWHT. The Weld Data Sheet veri-fled these conditions.. NB-4622.1-1 requires a PWHT or a minimum preheat of 200 F for 0 materia; over 3/4" up to 1 " thick. Neither Code requirement was met (2000F minimum preheat or PWHT). The problem is generic throughout the Feedwater system and may exist in the following systems: Residual Heat, HP Core Spray, Mainsteam and Reactor Feedwater. ATTACHMENT J 3.1.1 It is the opinion of the National Board Audit Team that the only acceptable resolution shall be to identify all velds documented in the H. J. Kaiser Company KE-1 form (Welding Data Records) as having been velded with i= proper minimum preheat or using one of the improperly qualified WPS's, and to undertake actions to have them post-veld heat treated in accordance with the Code. This action of course is to be in conjunction with the required requali-fications of those WPS's. 3.2 Purchase Order 7070 22506 (and further documented on non-conformance report no. E3633 R1) was released to: LaBarge, Inc. Tubular Division 20 South Fourth Street St. Louis, Missouri 63102 to supply 20' 2 " Sch. 40 SA 106 Cr B ASMI Section III C1 1 pipe and 220' 4" Sch. 40 SA 106 Cr B ASMI Section III Cl 1 pipe. Kaiser' required: "All material contained in this order shall be manufactur-ed by J6L Steel. Corporation, Aliquippa and Pittsburgh, Pennsylvania, a purchaser-approved suppliet." NA 3451 3.2.1 There is no record of a J&L Steel Corporation, Pittsburgh, Pennsylvania, Vendor Survey, nor does J6L Steel Corporation, Pittsburgh, appear on any Kaiser AVL. NB 2610 3.2.2 The J6L Steel Corporation C:!TR for Mill Order d263 556674 does not identify which plant, Aliquippa or Pittsburgh, manufactured this material. 3.2.3 20' of 2h" SA 106 Cr B pipe was manufactured by Youngstown Sheet & Tube Company and not J6L Steel as required by this purchase order. NA 3451 3.2.4 Material uas manufactured prior to anv Kaiser vendor surveys of either Youngstown Sheet & Tube Company or J&L Steel Corporation. NB 2130 3.2.5 CMTR's are not certified as meetine the special recuirements of NB 2000.

a ( May 12, 1982 Mr. Donald M. Milan Page 10 of 13 o a NA 3451 3.2.6 Ultrasonic examination required by NB2550 was performed by i Industrial Testing Laboratories. Inc. for LaBarge, Inc. and would appear to be invalid in that this NDE company does not appear on any Kaiser AVL as a supplier of Non-destructive Examination. 1 3.2.7 The material reported on the CMTR for Heat #31582 appears to have been shipped from Youngstown to LaBarge on or i i about February. 27, 1976 on Truck PPIE 28114 Approxi-mately fifteen (15) months prior to the release of this Kaiser purchase order, this material does not carry any type of certification to Section III requirements, and the pipe was manufactured about three (3) months prior to-Youngstown's being placed on Kaiser's AVL. In addition, i ve do not have copies of LaBarge purchase documents used to acquire this pipe. ATTACILENT K r 3.3 It is the opinion of the National Board Audit Team that disposition } " Accept As Is" documented NR No. E3633 R1 appears invalid based on l the above-listed apparent non-conformance with Section III require-ments. The National Board Audit Team shall be provided with docu-mentation to assure this material was manufactured and purchased in accordance with Code Quality Assurance requirements, alternative-1 ly or removed. Acceptable documentation shall be in the form of the following: 3.3.1 LaBarge purchase and receiving documents for material provided on this P.O. 3.3.2 Certification provided by Youngstown Sheet & Tube and J6L Steel that Section III requirements, except UT were j met. n 3.3.3 The National Board Audit Team further believes that a thorough evaluation of all Kaiser P.O.'s to LaBarge (as a supplier of Nuclear Quality MateriaD shall be made, i 3.4 Kaiser P.O. 7070-17688 dated June 22, 1976 for Carbon Steel SA106 Gr B ASME Section III-CL2 was purchased thrnuch LaEarge Tubular j Division, St. Louis, Missouri. This material was manufactured by l Gulf States Tube Corporation, Rosenberg, Texas, sometime prior to November 25, 1974 and February, 1975. Gulf States Tube Corp. is f. listed on Kaiser's AVL, approved date September 28, 1976. The National Board Audit Team noted the followinF: a 5 NA 3451 3.4.1 The material reported on the CMTR for Heat KA-2097 sppears to have been shipped from Gulf States Tube Coro. On or about November 25, 1974, approximately one year and seven l months prior to the release of this Kaiser P.O. and one { year and ten months prior to this orcanization's being i placed on the Kaiser AVL.

May 12, 1982 Mr. Donald M. Milan Page 11 of 13 NA 3451 3.4.2 ThematerialrehortedontheCMTRforHeat#RA-0001and

RA-0005 appears to have been shipped from Culf States Tube Corp. on or about February, 1975, approximately one year and foursmonths prior to the release of this Kaiser P.O. and one year and seven months prior to this organiza-tion's being placed on the Kaiser AVL.

NB 2130 3.4.3 This material does not carry any type of certification to Section III requirements. 3.5 The National Board Audit Team shall be provided with documentation to assure that this material was manufactured and purchased in accordance with Code Quality Assurance requirements. Acceptable documentation shall be in the form of the following: 3.5.1 LaBarge purchase and receiving documents for the material provided on this P.O. 3.5.2 Certification provided by Culf States Tube Corp. that Section III requirements were met. 3.6 One additional problem noted during this review was: Material identified by Heat #KA2097 was shipped to LaBarge Tubular Division, 121 East Koeln, St. Louis, Missouri. This supplier /varehouse facility does not appear on Kaiser's AVL. ATTACHMINT L 3.7 The National Board Audit Team believes that similar problems exist in all Section III materials provided by LaBarge and possibly other suppliers. This shall be resolved by Kaiser. c 4.0 GENERAL ELECTRIC COMPANY (NSSS) NA 1140 4.1 The National Board Audit Team noted that the pumps and valves in (d)(e) the reactor water clean-up/demineralizer system were not "N" Symbol Table 3120-1 stamped and the connecting piping subassemblies were "NPT" Symbol stamped. 4.2 Ceneral Electric Company stated that they prepared.the Design Specifications for the system. The fabrication and design of the system was subcontracted to Ecodyne. Ecodyne subcontracted the fabrication for the pumps and valves in the system. General Electric stated that the purchase order to Ecodyne (P.O. #205AA169) (dated June 25, 1971) established the Code effective date for the system and specified the 1968 Pump and valve Code. s NA 8412 4.3 In addition to the above, there appears to be no evidence on site that the valves in question comply with any edition of Section III. NPV 1 Data Reports are not available for review by the Audit Team.

~ = May 12, 1982 Mr. Donald M. Milan Page 12 of 13 4.3.1 The National Board Audit Team is of the opinion that Ecodyne apparently purchased pumps and valves from other manufacturers after July 1, 1971. These pumps and valves should have been stamped with the "N" Symbol and built to the Code in effect on the contract date for the co=ponent. Unless documentation is made available that these compo-nents were purchased by Ecodyne before July 1, 1971, all valves and pumps not documented on NPV 1 Forms should be removed from the systems. ~ 5.0 (M. W. KELLOG) PULLMAN POWER PRODUCTS App. IX 5.1 The National Board Audit Team reviewed the conformation program Para. 3334.3 19-QA-01, Revision 2, now in process of being implemented by CG6E Para. 3334.4 as a possible resolution to the problem of radiographs that were improperly shimmed by Pullman Power Products. App. IX, Para. 3334.4 specifically requires that the penetrameters used be shimmed so that the total thickness being radiographed under the penetrameter is the same as the total veld thickness and backing strip is used and not removed., 5.2 The National Board Audit Team is of the opinion that this program 19-QA-01, Revision 2 will not satisfy the requirements of the Code, Appendix IX, Paragraphs IX-3334.3 and IX-3334.4. Further, all radiographs not meeting Code requirements are considered unacceptable.

SUMMARY

6.0 This interim report is being submitted as a progress report of the National Board Audit Team activities to date. The National Board Audit Team recognizes the Verification and Confirmation Programs initiated in an attempt to correct deficiencies encountered to date. However, the audit team is continuing,its audit efforts in other areas of concern. This includes, but is not limited to the entire Welding program, apparent inadequacies of the non-conformance activities, loss of material traceability, design and configuration control, and Authorized Inspection Agency involvement in Code construction. The results of these efforts will be describ-ed in future reports as agreed to at our initial meeting. The National Board Audit Team is of the opinion that should CG&E wish to continue activities which require an N-type Certificate of Authorization, they shall obtain an "N" Certificate of Authorization, which would allow CG5E to assume overall responsibility for piping systems. In compliance with the State of Ohio's request, in addition to the i current audit activities at the Zimmer Nuclear Site, the National Board Audit Team will continue to provide surveillence of the various i e

May 12, 1982 Mr. Donald M. Milan Page 13 of 13 o Verification and Confir=ation Programs to assure that proper corrective action is completed in accordance with the require-ments of the State of Ohio. Respectfully submitted, Donald J. Mcdonald y g m Director of Inspections / National Board Audit Team Charles W. Allison kt h_ Team Leader John D. McLoughlin 4, d Team Member !/ i - Robert P. Holt e Team Member / ~ ). [ Michael Sullivan Team Member j(4 /< Michael J. Houle A' */'/v DJM/C'a'A/JDM/RPH/MS /."JH : ca1 Attachments (12) cc: E. A. Borgmann, Senior Vice President Columbia Gas and Electric Company ,[J.M. Taylor,DeputyDirector V U.S. Nuclear Regulatory Commission m S

s INDEX OF ATTACH >ENTS r ATTACHMENT "A" Nuclear Reactor Stamp Page 3 of 13 ATTACH)ENT "B" KE Q195 Page 4 of 13 ATTACHMENT "C" SLC-21737 Page 6 of 13 ATTACHMENT "D" Unit #1 Phase II Piping WO 57300 Job E-5590 File 2400-11 Page 6 of 13 ATTACH)ENT "E" KC-1760-Q Page 6 of 13 ATTAC M T "F" Admin. 3 Rev. O Page 6 of 13 ATTACHMENT "G" Turnback 96 Page 7 of 13 ATTAC N T "H" KC-16365-Q (H.J.K./ Catalytic Agreement) Page 7 of 13 ATTACHMENT "I" KC-15604-Q Page 8 of 13 ATTACBENT "J" PWHT (CAR No. 089) Page 9 of 13 ATTACHMENT "K" PO (Contract No. 7070-22506). Page 10 of 13 ATTACDENT "L" PO 7070-17688 Page 11 of 13 W em ,.n.,-- - - -,-, .-r.-- =

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== p)']nstrur.cnt Pen,etration Tcisrication i Section III,1971 Edition, with Iddenda thrcuch !! inter,1972. ~ If you h ve any questions, please let us know. Very truly yours, Tile Cli:CI :::ATI Gl.S & ELECTrilC CD:4 pal!Y By (/y.*.sfr-% O ~.,=r i n, -=" G L ~.h- -O" r H. H. SCH'.!!ERS PRli!CIPt.t C:'JALITY ASSUP10!CE hl:D STh::DARDS El:Gl:! eel P.LM:p-y cc: R. D. Sahlbergs B. K. Culver R. L. Dirr QALS File t I, I ? it om: I *W;~ i s -a. o. s.:se..., J... ON - dn.. o- .-l 3-h.'..I-I. "..Q 4 -D v l [y (z;......~...,Qs ~ AC-.r: : g l l ~ ', ' ~ -r T: - n :....s n t O (,' %..'~ 5: *' r.a. c..,:., nJ ':. y. o r 4 L.scf .9 9.'a (c.' S' c'.i e rtc -f-' 4 q- .s / l'..s's ci Cerf ro! ; 4s c CO 'l.- ' 4# l c a,,- 'l ', 's7** 's 7 [ l.',%.* l Th-5' ~ A L3

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7) TT~k'lTI'y)L*E Dce=her 10g.1974 r

xnM-ej a Kaicer Engineers, Inc. P,0. Box 201 Hoscow, Ohio 45153 Attentient Mr. D. R. McSparrin E31 UM. H. ZIMMER HUCLEAR poi 1ER STATION - UNIT #1, pnAsn II pypyng l W.O. 57300, Jo2 E-5590, FILE 2400-11 Gent.1

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3g4.y$ ), i ---..i..ejn and inspection requirementa of the r spcer g by the M. W. Ecllogc Coconnv unde-cat *on H-2255 have boca raviotted by various~= embers ~ of my staf-and yours. We would like rocced as followcr r A. c': Vill inspect doc =catation of a Class A,B, Kellogg shop.and C piping at the M. U. Cona. will send a telex to Mr. W. J. priedrich confir=ing that all documentation is accentchic for all Clacs A,3, and C pipiiif"TTis telex ) will serve as Kaiser Engineers, Inc.'s // -authori:ation to accept the pipin.g.__for/ . aryction. / w J -D. Kaiser's rocciving inspection of D and b DOC piping should be limited to physical damage and: con.pletencan only. incpection of D or DOC piping is not toRccciving - be concerned with any docu=cntation ':ht tc cever. which 0111 clirainate the renoiremont to ship oneWe are p 1 docuh.cntation to the site t:{th piping sh'pnents (1) copy of tion will than be shipped to Mr. E. All documenta-it to the sito for stc.e72. C. Pandorf, who will forward m /93 _m

i ?) y g. Decbmber 20, 1974 To: Kaiser $ngi.eers, Inc. Pago 2 Re Um, H. 7.' ear Nuclear Po.ter Station - Unit $1, Phase II Piping. W.O. 57300, J03 E-5590,. PILE 2400-11 o Picane td.e this letter as your instruction to .3 set up your receiri-.g plans according to the above criteria, very truly yours, THE CIliCIliNATI GAS & E12CTRIC CO:GAh"? l /. Mana/ n p m ., s By E. A. BORG'17dal, ger General Engineering Department 6 BC3: rat ec: W. J. Fried-ich/ E. O. Christerren M. E. Schustar, Jr. M. G. Hagerer ' R. J. Pruski R. L. Dirr E. C. Panrorf W. B. Murray W. W. Schwiers T. T. Fox

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l fo e f.' )f & %vc5Khisdr jyp;cHMenT ff et A e tl se E N G s N E E ft S. t N C. P O Som 208 M o Scow. O M oo e st S 3 f February 20, 1974 KC-1760-Q Mr. A. E. Rothenberg, Manager Gencr:1 Engineering Oepartment ' The hacinnati Gas & Electric Co. 139 ast Fourth Street Cincinnati, Chio 45202 Attention: E. C. Pandorf, Principal Engineer

Subject:

Vendor Surveys for ASME Code Materials Centlemen: As a =anufacturer and holder of an "N" stamp, we are obligated under Systen Progrc s-of-suppliers.section NA 3361 of the code for surveying and 'Our Quality Assurance Manual QAP 05, Procure = ant Docu=ent Control a paragraph 6 was rewritten to sctisfy the Code Committee (Mr. Fritts).fi Ee was very emphatic at that ti=e that cc= plied with. this par: graph be included and the Code Inspector assigned to the project.He stated that this is one iten j At the present tice KEI is purchasing code =aterials such as weld red pipe, and pipe fittings. It has been our practice to perfor=t at the suppliers plant, and we wish to continue and not put surveys status in jeopardy. our ASME Recently you have disapproved requests for such surveys. At the time of your deci= ion it was discussed with ra and I did agree. However, since that time I have had an opportunity to review the code and discuss the details with the KEI personnel involved. and I erred, and I would like you to reconsider.I am convinced now that you 'and it would behoove you to review your proc dThis sa=e requir hardware and act accordinCly. e ures relative to essential Very truly yours, e RAISER Ei'GINTERS, INC. f. /.k:$h.$./ U. J. Trie d ri ch k'.J r :sb c Site Quality.bstrance Mana;er

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D. R. McSparrin D. II. !!illiams M: , % T. A. Ecc' ford V. P. Mc;;ahon

r V l I t" Y Q o a=we THE CINCINNATI G AS & ELECTRIC COMPANY = ',= ,s'a '7 .~ 3 f .t, March 4, 1974 -. gr-377 ,.,:....+..... c.,..... n ~ a ~- ?,,.;. ; 1,,.,{.". ~. ' ' ' ' s. . Si ?. 5 Kaiser Engineers, Inc. ~ , v. P.O. Box 201 . Moscow, Ohio 45153 u_ : Attention: Mr. D. R. McSparrin R".: UM. H. ZIMMER NOCLEAR POWER STATION s VENDOR SURVEYS, W.O. 57300-957 ...u ] JOD E-5590 Gentlemen: } We have Mr. Friedrich's letter EC-17GO-O regarding c plant quality system surveys of vendors of ASFE Code caterials. ' The Cincinnati Gas & Electric Company's policy, which should also guide Kaiser Engineers policy on the ::ir. :cr project, with regard to vendor quality syste:a surveys, is as follows: r A survey at the vandor's plant is not required for inclusion on a list of bidders. Vendors are selected for tho biddars list on the basis of ono or more of the following qualifications. 1. Acceptable quality assurance manual ~ 2.' Holder of a current AS.T. Cortificate of. Authori::ation 3. Acceptance of the vendor by the Architect-Engincor or Owner 4. Tho vendor has been approved under an. industry spcasorod evaluation program 5. Prior satisfactory performance The need for a pre-award quality system evaluation is datormined on an individual basis. Circunstances which i.- 8.. ~ - ~. ~ 4 /

y y I, e e g, { To: Kaiser Engineers, Inc. Page 2 9 RE: Um. H. Zi =ner Nuclear Power Station Vendor Surveys, W.O. 57300-957 ) ~ Job E-5 590 cay preclude the necessity for a plant quality systen survey are as follows: l.- The vendor has been previcusly surveyed by'

1 the Architect-Engineer or 0.mer 2.

The vendor has been aporoved under an - 7 industry-sponsored evaluation program . C A S L. 8 We shall expect Kaiser Engineers cooperation by observing this policy on the Zi:.ner project. 3 If you have any questions, please lht us know. i., J Very truly yours, r ' THE CINCIN'.iATI GAS & ET"CTRIC COMPANY

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// A Wd& .=. By A. E. ROTHENBERG, CHIEF ENGINE" [ I 3 & Manager, General Engineerinpbepartment .s. AER rt 'r O cc: W. J. Friedrich 4 ~ f J. D. Flynn /.',..- E. A. Borgannn ~' E. C. Pandorf .? W. W. Schulers e. c.- e m if>J g/ '. '. ; ~ t , cy, ~. a [/.,~,.h p'\\*\\ \\ r- + ~. a I 'U \\

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p. o s o m 3 oi W O s C O w. O w a O 4 313 3 Date:
I.-19-74 KEI No.: OA-286 Mr. A. E. T.othenberg, }:anager General Engineering Depart:ent The Cincinnati Gas & Electric Ccrpany 139 East Fourth Street Cincinnati, Ohio 45202 Attention: Mr. E. C. Pandorf, Copies: (_ ) Principal Engineer ( )
Subject:
Quality Assurance Sur/ey Ge= tlemen : Purchasing has requested Quality Assurance te perform a Quality Survey on I.adish Comane Co. located in Cudahv. *a'is censin This cc pany is a supplier of Class 1. 2. & 3 fit tines The survey is scheduled for Ae sy Please indicate your approval or disapproval by checking the appropriate block and return. Approval Disapproval h4 AM6,1)LN/LO' / PM A h# 3 vAhwLu). aaj f69.(hbeg. (/ Signa:u e Ve n truly yours, l KAISER ENGINEERS, INC. W. J. Friedrich Site Quality Assurance Managey WJF:sbc .c
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e. o n c. n s u o s i., o... o.i n s Date:_ __10-3-75 KEI No.:
OA-561 !!r. l.. A. L:r;,r. ann, iicnager Cer.cral Eng..ecring D.partment The Cincinnati Cas & Elcetric Ccepony l 139 E..sr Feurth Street C.aciana.ti,. Ohio 43.7.02 Attection: ):. C. C. Pcadorf, Ccpics: ( ,_) Principal Enginner ( ) S.b.. L'..slity Assurance t rvey Cc nriciten : Purel:csing c requn<:: cd Qua:Ity Assurance to perform a Qu.12ity Su.vey ci. I'l ' u.rper Co..incated in ?:orton Crove, Ill. "~h...i.apci; is n.sut. plier or 1.'hiu.:es traint Boltine, ifate rial The s.urvey Ja. scheduled for ASAP Picase, indicate your approv:. or d..appr..;l by che king the appropriate blocic and return. Approval Disapproval , [ ..vi.. Sipiaturg, (, -'n 2 c,,[., s . ::6.;:,, :., a ! 7.,..., ;:-..- ...r..,- 3:n t_ _. a.. ~. 1., Very truly yours, ~ .= KA1.T... ENGINEERS, INC. 1 g bd II. J. Friedrict!. Site qualit'y Assurance %nage=r DCT17 5975 l*.!F: sb c Mg (Id.g g p q.[. 3 fg gg / s. Wr1;.tu-j'r 6wLQopV ObS0 f". G '~ e .a ~ a y
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r-Cn.e...w..C....... ._:.n.,. r.n.. x .I 9 a_~ RIVISION ND3ER: 0 = PROCEDU.E TIII.E: PERFORMING CO':STRUCTIO:: ON ?AGR 1 c7 S v. S.-. S.r. : = S ,.-.'3. =,.. :-: C r..~,....L e.. -. a.. 1.0 SCOPE
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.c estar....sn :ne =e:..oc :c: p:ccessing c:. the "Re:u = cf Sys te=/Subsys:e= :o Cens:=ction" Fe= ??2-01.-2 (:u=back), " Construe:icn Work Authorization" Fo= ??J-04-1, and the " Work Rec,uest" Fe= between CG~I Genera:ica Const=c:icn Depart =ent (GCD). H. J. Kaiser Cc=:a-.y and o:her subcon-tractors, and CG&E Electric rrocuc cn Depar =en (EPD). 2.0 PROCEDURI 2.1 _ General Censtruction activities cence=ing syste=s or areas which t.=.ed over to che Electric Freducricn Derar=ent are i=ple=ented in accordance wi:h W. H. Zi=er Startup Prcj ec: are af SU-??J-OL, "?unchlis: I:e= Cc cle:icn and Mair.:enance In Tu ned Over and Ncn-tu=ed Over Areas". 2.1.1 E?D '".Jork 2.eeues:s" (Sz:ple 1, attached) shall be / used to ce ol.e:e work en s.vs:ers whien have been turned over :cr preeperar:. tem is in an area tuned over to E?D..cna_ :es:= g unen :ne sys-
= _
2.1.2 " Return of Sys:e=/Subsyste= to Cens:=crien" Fo= ??2-04-2 (Sa:ple 2, attached) shall be used to ecm-plete work on syste=s which have been tu=ed ever for preoperational :esting bu: is in areas not turned over to EFD. 2.1.3 "Const uction E rk Authorica:icn" For:: P?2-04-1 shall be used to gain access to an area turned over to E?D to perro = work en L over.,or preopera::. systems vn.cn.. ave net.onal tes t:.ng; er to u. seen u=ec punchlist work ite=s on syste=s tu=ed over for preop-erational tes ting where the syste= is in an area cu=ed over to EPD. 2.1.4 A syste=/ area ra:ri.v. to assist in dete =ining rec,uired fo= s are a:: ached 'A::ach=en: 1). 2.1.5 A flew char: depic:ing he routing of ru= backs and &.q, verk rec.uests is she n in A::ach=en: 2. o g.[{g(hM2M .e. a .v c .. 4 (~.' '. ..~ l l O s o ,m
o 40CeDi t. o. r. w-.v: R AD.v..rN 3 (, . ICE.CICA* CONS-"RUC-IC;; IST FRocz3;y,; f.'.E.. R.EVISION NCGER: 0 2D --OC7DE r m 7. PERFORy.ING CONSTRUCTIC:: ON PAGE 2 OF - 5 y .c.. S _s :.yS o, a. ~ _.....: .,a_.1 :.n c m._, g,u u.. a..... -cu. C.- d M 2.0 PROCEDURI - continued 2.2 Processing of "Retu= of Syste=/Subsys:e= to Constr.:c:icn" Tc= PRF-04-2, (Sa=ple Fo= 2) 2.2.1 Section 1 of the fo= shall no= ally be co=ple:ed by GCD or a Superintenden:. The originater shall state :he reason for the tu=back, (i.e., punchlist ite=, NR, DDC, ECR, e tc. ), and shall dete=ine the cons =ction testing required upon co=olecion of the work. Additionally, any special recuirenen:s such as housekeeping, clea=liness, hold points shculd be so annotated. 2.2.2 The ru:nback fc= shall then be given to the GCD Preco-erational Tu=cver Group who assigns a nu=ber to the ' Q turnback and records :he ":u=back" in a "tu--.b ack" lo g. 7. The necessary au:horica:icn signatu es are eb:ained by ( the GOD Preopera:icnal Tu=crer Group frc= E?D in See-tion 2. The GC? Frecteraticnal Tune ter Grrur shall dir:ribu:~c -he f:= :s indi::.:ed a: :he h::::s of :he ,forn with an addi:ional copy :o HJK C:A, and re:n= wo ropies of the fo= to the appropriata GCD Cens:=c: ion -Engineer. The original is re:ained by the GCD Freep- -erational Tu=over Group. '2.2.3 The GCD Construction Engineer shall then tag out the syste= per approvec. _,D procec,ures to :ne extent neces-sary to,perfo=. t.he wo syste= _s drainec or c.rk and if necessary, verify the e-energized. 2.2.4 ' A copy of th'e tumback fo= shall then be sent tc the . HJK/FIC punchlist group or :o the appropriate sub- $ contractor. The RJK/?EC punchlist ticket shall be ' issued in accordance vi:h established cons =ccion procedures. ( 2.2.5 Upon co=pletion of the work, the EJK/T C punchlist group shall return a copy of the tu=back :c the GGD Construc-tion Engineer who vill ensure tha: const=crien is ce=- ple:ed and tha: any recuired cens:=::ica testing is ce=cleted and si=ed eff in Se :i n 3 of :he original fors. The tumback fc= shall be re:urned :c :he GCD O Preo.cerational Tum over Grous. who vill verifv. tha: the L e:ed nec es sary cens.. _.. s es t:.ng docu=en ts are c ong. and obtain the EJK QA/QC verifica: ion. F p / ~... _ O .ii
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( .:.so C.:.u-u ::.w.v r.e. m..yN 3 r n.. s .yCHA';ICA'. CONS.CCT:C:: TEST FRCCEDURE .s.V,..C,. ,e R: n. .c. r. 0 ?ROCEDi'RE !!L E: ?E?.70??.I::G 'CD::STRUCT:C:: 0:: ?AC'E. 3 07 - 5 S Y S : ':.'..c /.*. '....s' _e ".'.'..:.. .D D F.. ".. ~. ~.). "., ~_ ~ 2.0 ?ROCEDURE - continued 2.2 Processing of " Return of Syste:/Subsyste= to Const=c:~ ion" Fe= PRF-Ot.-2, (Sa:ple Fe= 2) 2.2.6 The tuinback for= shall then be ret :=ed to EPD for appropriate re:um si na:ures. 5 ?$ocessingE?D"i?crkRequest" 2.3 Fo = 2.3.1 The "origina:cr" section of the I?D '"Jork Recues t" Fe= is nor: ally inizia:ed by the ec5nizan: CG&I GCD Cens:==- tion ens neer. E?D Syste: Engineer, or ;ne .:s f.aintenance i Engineer. The origina c: shall indica:e recuired cens:= cc A-tien tests, s ecial requirenen:s. NR n -k e r, ECR nu.ber, punchlis: i:e= n=her, e:c., and s'eff the fc= :o the Shift Supercisor. 2.3.2 EPD shall conplete the fo= in Ecccrda.ce ei:h other E7D approved procedures and return the fe= to :he GCD Precp-erational Tu=over Group. The GCD Preoperational Turnover Group log in the 'vierk. 2.3.3 Request and route it through E.IK QA/QC for QA/QC require-The GCD Preeperarienal Tu=cver Greup shall then cents. return the for= to the respcnsible GC0 Const=ction Engineer who shall tag ou: the sys te= per ap and obtain any required pe= quired to perfo=preved E procedures to the exten: re the work its, and if neressary, veri-fy that the syste= is drained or de-energined. 2.3.4 The ~?ork Request. Fo= shall be sent to the H.~~/?IC pu.ch-1:..se group who will :. .n tu= issue an c..T l :.C punchlist o e ticket in accordance with established procedures. The GCD Construction Engineer or Const=ction Superintendent I shall then obtain ce =ission to star: work fre= the Shif t e Supervisor who sha'll re=ove the yellew co5y cf the "! ork Re c.u e s t". 2.3.5 The '". crk Reques:" reutinc shall be handled in :he = sane (.... =anner as the tu=back in Section 2.2.1 above. A descrip-tien of :he verk peric=ed shall be filled cu: by the re-so.casible Cens- --d-- Sto Engineer en the reverse s. erint.er. den:.. or GC : Cens: =c:ica ..ce or tne -ork .s e qu e s :. F . -.,,...... ~. - -. ....] l$
.~PROCEDURI lC SIR: Any23 3 MICu.A.NICA*. CONSTRUC-'ON TIST PROCIOURI .:: z.... 3. C"s.iD.:.:.R: 0 {~ .u.
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~ .RCCrD.. . _4.. :. : FIRFORMING CONSTRUCTION C" ,. r. ., g ...ac. _L O F c C. V. ~. ~.". '..s..c / n e ; q e t.=.. = ; w. v..s ;. ;. 5_ C n... S.m w.. +.. 2.0 PROCIDUF2 - continued 2.4 Processing "C ns:=c:ie: Work Au:h: riza: ion" To = PR?-C4-1 2.4.5 Vnen the work is co=cleted, the cogni=an: GCD Construe:icn Engineer or Superin:enden: shall sign and date the original copy of the fo= and shall be =aintai=ed by the Shif: Supervisor. The copy posted at the access poin: shall be re=oved and discesed of. If the work cannot be acco=clish-ed before the a' cess for= expires, a =cw for= shall be ob-e tained, following the above described procedure. 2.4.6 In the even a securi:y guard is posted at the access point, an access fo= shall not be receired and access constrol shall be =ain:ained by :he guard. .-r= 7"4 2.4.7 Work authori:a:icn fe=s shall not be =ecessary :o gain access for nen-work rela:ed fune: ions 'such as inspectors, da:a taking, e:c.,; hewever, access to the area shall be controlled by I?D. 3.0 AT*AC"9ENTS 3.1 Construction Work Authorization Form PRF-04-1 (Sa=ple 3) 3.2 Return of Sys:c=/Subsyste= to Construction Fcrm PRF-04-2 (Sa=ple 2) 3.3 Work Reques: Fo= (Sa=ple 4) 3.4' Welding and Bu=ing Fe=i: (A::ach=ent 1) 3.5 Processing For= Flow Chart. (A::ach=en: 2) g me 4.EED
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.i a..O:.. .s (* THE CINCI:C:ATf GAS & EIECTRIC COMPANY WM. H. 21:0S?. ::l CLEAR ?O'..IR STATION MECHANICAL CONSTRUCTIC;; TIST PRCCILU?2 PROCIDURI NDSER: ADMIN 3 F2V: 0 DATI: Febrcary 21 1980 PROCrDUp:.r..r. PEFSOF_"ING CONSTRUCTION ON SYSTD'5/A?2AS UNDER EPD CONTROL APPROVAL RICORD APPRCVID BY. (R ( 2-7., s t. f a MANAGER - GT.NIRATICS CONSTRUCTION DATE ~ M---a 2 h MANAGER - QUA*.ITY ASSURANCE D ^* "^ ~ ( F - f f / 4
g so ri.s u / r_ _.C i, Originates :u-. backs e C. Adds ..=:bers, le s .nunen34st
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w Authoricatien signa:ures Grcu: 6 Distribu: cc ies "== \\- 8
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u s
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ters c c..
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10. Rev:.as oriE nal co=v Enrineer i
4i Grou: 1 21 2 ..t. o i .e.s construe:.-..cn test docu=en:s, interrace with
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12. File criginal s
Originater 9P E?D (Shift S uc e-.-i s er) s t a r t w e rk r e -.i_s _s i en Field re:ains.vellow l* 6 Yl bl *M GCD ( Tu-nover 'a GCD L F.u..JK/FE D m Cens::ucrien ' Punchlis: (. Grou: n Enrineer 't Grouc k-- U ! 'l 5-Ob: sins QA/QC ree.uirenents .._/Qa. Issue pune.,is: r. exe: nau n_
3. Signs criginal work ce=plete, fills in back cf she

4. For.:ards

5. Obtains QA certifica: ion

6. Forwards to EPD for cicsu: c signatu: e

7. EPD retains original in Docu:sen: Center r, on v-.2_u. -.

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S M r. 2. R.EniR.N CF SYSTDt/5U35YSTDI T CO.' STRUCT:C.N - FC?.'d P/.P - 0 * - 2 g Date: Release Ne: Turnback Ve: ..he i should be retu ned to GCD for: e .o .e u l u m g Prepared 3y: Date: Required cons: uction retes: (Refer c syste= index es: =atri.: as applice eo Test M.=be-Descrictica and Reeui: e-.en s c5.o cou C ~- ~ s... - '.. 4. s. s D ".. .. a..- d. v.. B. 5 V-P. e. . e.. s. '..,-... " '.. d..-.Nc (v. - s . - s..Nc, = r. ec .e.4... ) c-a ~= Svs..' _=.~..'-...- D a...- 1N o e' Reviewed Ev: Date: >g Opera :cns superv:.scr o c:.z. u.. - _ : e.: Sv n g .e. hat =:::ance Supe:7 scr N .-_c..., .o.e...__ yw y p,. u.. : s a .g 5 : g ed 3y' Da.e n n.. ..... s s .e E The werk requested abcve has been c =ple:ed and necessary const.:ction e,,.es.4..3-e.......- d v i..k..-. o. -. 4. 2. e. e s c' c c _.. e.. a..i. n -. s 2 ;.- e. c.., u-y preeperational turncver g cup with work peric =ed by -u s* o ei LC.3a.-'._.-..c-.) s. 6.y e.:... 1 s b e g...... e d o _= '.' D j' u. ' 5 '. c ~ ' e n. cc oo e t,,; C-{..:....... Co.s.. -.:.C... 1 e.. Da.c w 3 Gw-r e.e i"..... -. u.-. ",.... 3 -.. e.. Da..- QA/QC recu=en:2:ica C:=ple:e 02::: m .c =. ..u.e s..... 1s c.s _:.e.: .. c.r e. s.. -,.. v.a:...... c c......:sw. . u e...-........>.._.... n. .e o:
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e. s.. 3 .. L.-.,., e.. s... .s ~ 5ys. -.. > -.... -..... _.. -. z. s..-. .c. ...ec.......c... .es: cocrdin :or . 9.:.,s.e ._...e. .syste=.-ng s.. e e - .c. y 3.. _. e s. s'..-...'......-. .V.. 3......-.. e ....-4.2.-. Cpera:icts Superviser.;....... a.- 5 : : :n qu.1. - E. >., e e :. / 5"W..
.3 w
e Sp.m et e Adthe i:2:1on,:u=ber .s e g.. U.,4 g.. g, e... v a.s ,.d>......... m.., cory i in 7m?-0. 4 vru _m.. ,Q _ .n s Area to Which Access is R:cuir-d:_ Area Release Number: S ys t e= : Da *...c n ~..~ ~ s s =..*...'.'. '. - =.- ~. Descriptics of Werk To Se Peric =ed: eo M u_ w W mco U g , Does Werk Invclve Welding c Su ning? Yes Ne Nu=ber cf Craft Required: Pipefitters uo .l e c :::.c:ans Mil., wr. gn s e coe Boil er:ak ers Insula:crs Painters Other (Specify) Requested By: Date g, g.... u.,..... _. ...m I. ; : _,. -.: s..:.. .....:...._._.;. A-e v.., .t.. e:- g
y.. _.
C '.e. C-. a _'_ _-.. '. -..s.- uc. a. =_2.,, w o a c u = o . o.= me u u = g< Reviewed Ey: Date s = services superviscr su: cing o c h o c-3 Syste= Engineer Appre,*al Date u o "u I Dates Access Authori:ed: From To ., o u c: Access Authori ed By: o Date s r.... u. _ e _.... s. o. ~ -_o We. k C~- ~~r '. *. *. > - D 1..- 2 L., gn_. _. _,. u - >. _...,.. .._.e.. e m ,.su,. ,,e,...._:. Ds.. .,a. F'" 44 .e.. :. .e. u _.. 3 3 c: .e. .e.., ; 3ey e ...be. 3, z .s...c .e.. Sa -.... a. c. u..a .0 .. ~ ....~.. 7dy,03 S,, Q ,;3 f { j.. e...s. ~ ~ _......... g
m q(\\niptE 4 A::ach en. } Page 1 of 1 >M. 4. = R..\\ t.=..?..Ler.=p* = ' ?ts=* T.=lp.. .C, e.=.. CN s s... s WELDING AND SURNING 75?.'.::7 WCP.K REgl.~37 NC.: ISSUED TO: CAT:: .e o..... :.., Activity
Description:
M f, Esti:::ed Dura:icn: Tc u .ue... .../. e ..e,.i e Fireestches. Nu=ber (mini =: of one): na:et,s) oi perscns ass:.;-.e: - Loca:icn(s) Posted: TO REPORT A FIRI DIAL (later) Neares: PA/Telephene Locati:n: Neares: Installed Fire Fer:ecti:n I:uip ent: Fire P-::.cti:n Checks 1. Is additi:nal p ::ecti:n recuired f: ec,uip:ent withi: 33 feet? Yes No (If yes, spe:ify u.de "resarks"). 2. ne loc :icn of the main:enan:e a::ivity has been persen211y inspected and: a. H e area within 33 fee: Of the jeb is free of c:=h.: stable =2:e-i:.1 ..u. e.....a 1.; s.. e.. a.. u. y a : -..... e... _... _ c: b. ne are2 within 33 feet cf the jeb is free cf i'.z :ahle lin:, dust, .u. .,..,..s, z
s..i.a._ 4.:s....... s..
..,.s ....a.1 g.... __.c.:.., . /. t c. A=ple pert:ble extinguishing ec,uip=en: has been p : vide:1. O ~~~ b d. Wall cpe.ings and deers to adjacent enclosed ::e=s or c=hicles are p cperly sealed or closed. 3. De sai=:e.ance a :ivity and its loca:icn have been survey-d fer pess. ible spark potential and a=y necessa: r prec:::i:ns have been :21.-n. TGLGKS: .s G icre=an Late u t i. Aut::ati: Fire P ::ection Syste=s Disa:=ed o. Oate/ Time C'T Rear =ed - u .= 2 Da:e/ Time
~-
.1 sn
a.......s

feliing'3urning as ;isted abeve is

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c ,g p y I 1 u a Ng oi N T LI R H E. D ' T q R t.*.= C O V C i>. O */ c,". Ecr -recpera::.c.a. C e g,;g 3 p For Preoperational Testing hg7;f?// TO e hot C o ri s 7. ?R o c 2D u.7.= 5 Fo R m .r.J.,..! :. ' (Turnback) . o 'I =. -.N C c ris T. C o a -in L 5 C o a.s T, ,~a = c 5: u?3.s n .I C o n s 7. Con R Ls t l S. k ( c N S* I~. 'NO.T *5
l. ' Th.
Ee D ' S C sT,T :D).! ;.~I A J_' Q,yED -r-O.- M }-ic u s 3.c ;; .7. W *,. is O V C, C.L.2 A rJ:. H 1..$ C c)J 5 ~~. ?.iD C E hl.T E.S W G Q J M *.r V.3.d.? N :M.'e \\ .D - 2 p.. ;~ Coasr. CoarnaLs EPb Coarno:S; Ho u Z EKS E s3)M C-g 1 W 5t. b l H c. i-3 H 2 8,J '. =I m : k,' Syste:/ Area /Fer:.v.a t riz. r.t . Attach =en: 1 _mg.%=....,... e w ~p~..,. ..y ,se yu ~. v. m...n. p y w =-. .,. 3.. %. g - .M.....aK*-~Y %.')Qq.W? e x. r
7.,%
y u / i- - ( f S' es FE N RY J. K AISE R. CO. NONCONFOR*/.ANCE REPORT vi!.L N. Ziti.!!E A POViE R STAT 30'ti N O. Pl. G E OF
1. 0'.'tG 'IfiST A L L ATIO N N O.

2. Or/CliNST AL' AT10N N AME:

3. P0/;0NT R ACT :40.

4. SUPPLIER /CCNTF ACTOR NAME; P&ID M-SS-1 Prinar
Centain ner.t Valve IV?OC63 Ventil>a tien Chill ed k'a t er 7070
'm /An: hor Darline
$JJR: -
5. INSPECT 10N PLAN NO.:
? E
7. D AT E:
.' E EPj,C,l Ff C A TIO N N O,' ASME m v,/
0A?., Re.0 r.
v.. c-N/A i. R. Stro ler v.v 3'/'/82 / v.
AE?'I III 1971 YESy-NO O S. DESCRIFTION OF NONCONFORMANCE

10. O!SPOSITIO N

11. O!SPOSITION It:STRUCTIONS/ JUSTIFICATION Syster:
VP Ileva:ien: 570 :G Suilding: Reacter l I Recuire:en:: i i ASME III 1971 Para. NA-8114.1 states: l l "The certificate of authorizatien shall! identifv the facilirv covered and I l t i state the linits of activities which autherizatien is tranted". I i i v
r. v. e...v.. e.v..
i 1) The disasserM v ef velve TV 004: i i ter CG5I Tur.back M01 tal. *T-n oc0L l 1 is not vit'.in the stere of_acvv i i certificates of autherizarien N-1636 er N-1437. I 2) 0 ner 2:rreved OA/ OC pre g r---s l and crocedures fer this work secpe
12. REVIEV/ EC ARD (REQUIRED ON ALL ACCEFT/ REPAIR OISPOSITIONS)
A NI DJ.TE NPD DATE HJK CCNSTRUCTiCN ENGR. DATE S&L DATE CG&E NED ENGR DATE CGLE O E. DATE FJK 0.E.
12. R EP AI RiR E7.C R K CC:/?LETE AND ACCEPTABLE ort 3:NATOR DATE

14. C AUSE

15. CO RRECTivE ACTION 6
w ip 9 M s iT-
E
.a s .i e....
..,.s....
n...._...s
,.,g.... ........... _ -,s..
,:- t,..c.::- f, ts: t e.
C.h t o s ; t ; ;

-
2.3::s':i:n 155;;J:- L - s;..... vere not in place at the time of i this activity. l ~
3) There are no OA/OC/. records verifying that this valve was reasse= bled'to the manufacturer's specifications.
RIQUIREMINT:
1) ASMI III 1971 Para. NA-4451 '
states;."The manufacturer or . installed shall operate under a controlled syste= such as process s sheets, shop procedures, check lists, travelers, er equivalent procedures. Measures shall be established to assure that processes including velding & , heat-treating are contFolled in accordance with the rules of this section of the code and are acec:plishedbyqualifiedpersonnell i using qualified procedures." l,
2) ASMI III 1971 Para. NA-4510 states;"Inprocessandfinalexa=id na:i:ns and test.shall be establishdd I
e assure cenfor=ance with docu=entdd lilh l l V i
. :. : 7.
.-.. ::-i:r : ::
.: 7 3:rst:::. 5.*. / : ?': :- - - :::.... l. instructiens, procedures and drava 1 ings. l r w I
3) ?E QA?-7 Rev. 6 Para. 3.3.1.2:
} ~ " Welding and non-des:ructive exaninations vill be perforced in accordance with the recuirements I of the ASMI Code Section III I .Div..I and identified on the KI-l for= and reviewed bv the authorizeb s nuclear inspector to establish held points." I
4) S??M S.0 Rev. 5 ? ara. 3.1.1 e
states; "The documentation of piping systers is achieved through the use of the folleving documents : A. Construction Inspection ?lan B. KI-Weld 1 For= C. 5=all Ecre ?ipe Data Shee: D. KE-Weld 2 For= E. KI-Weld IA For= I t DEFICIENCY: I i
1) Valve ~VP0063 dis guide ex:en -
i. I siens* vere velded to the valve ~ i body without,decurented evidence (; 4 1= c. / y #7 / ) - ' o
-..s.-:
. a.
... ~
v..s
.v... -.s .. C.3 ' s : e 8 ;
I '.
h:::s:*. :' '. ? ' M : - -~=t A. Instructions, procedures and/, or drawings. / B. An approved construction inspection. plan. C. Approved or specified veldinc I procecure. 1 D. Specified NDE. E., ANI concurrence and hold peints. F. Filler raterial traceability. G. Proper filler =aterial. H. HJK QA/QC concurrence or hold points. s e .g 1 I I. I 8 I F I 'l11 9
[ t. I: 51: H Er; RY J. K AISE R. CD. NONCONFORt.ANCE REPORT WM. H. Zlt.tr.tE R POWE R ST ATION N O. PAGE _ 0F _
1. CV.G!lNST AL L ATIOri N O.
2. OWGliNST AL LATION NAME:
l, 3. P0/CONTR ACT NO.
4. 5UPPLIE RIC0r.T R ACT G R ri Att.E;
?. !. ID.vs a:ve inru;;d M ReagingWatertor Building Closed H.J.K./Ancher Darling Coo - i 7070 c 6.g AS?/E Class C
5. INSFE CTION PLAN NO.:

7. 0 AT E:
2 SP C Fi AT ON rd0. N/A Strozier
t. - 2 5-8 2

9[7dev, c h yECG re 0 0 5.0ESCRIPTl0N OF NONCONFORMANCE
'I
10. Ol5P051Tl0N l 11. 015P051T10N INSTRUCTiar.'5/JUsi I
cve nj. gg l l ELEVATION: 370 N.W. l l 37:LDING: Reat:or i* l REOUIR.EMENT: ASMI III 1971 para. l l N!.-8114.1 states; "The certificate l cf authorizatien shall identifv the l facility covered & state the limits l _ cf activities which authorization is ! granted." l l DITICIENCY: l
1) ane casasse :1y of valve 1WR1333 I per C.G.6E. turnback #01 Rel. FT-VP I I
FC04 is no vi:hin the scene of ASMI l l cer:ificatesofauthorizationN-1436l c N-1437. l l l l
2) Owner approved OA/QC progra=s &
l l
12. REVIEW BOAho (REQUIRED ON ALL ACCEPT / REPAIR DISPOSITIONS)
ANI DATE NPD D A_,TJ, H,;K CONSTRUCTICN Er.GR. DATE S&L DATE CG&E NED ENGR DATE CG&E 0E. DATE HJK O E.
3. ?.EP AI R.'R EWO R K CO?.tPLETE AND ACCEPTA3tE ORIGINATOR DATE 1 *. C AUSE I 15. CORRECTIVE ACTION F

R r.0
.M.!:,E ' E. tt g li .' 1E : ' E : - ::.t.o t e. ::1. i., 4: 3. c z,.t ts, a.c. _.c e, c... e s.
....._e-..s.-....-. w .w. ..,..r...~......-__. .; ::rf::: ..n..g...-. 3...>.. I procedures for this work scope were; not in p' lace at the time cf this j 6 activity. I
3) There are no QA/QC records verifying that this valve was reasse: bled to the manuf acture's l
specifications. RIQUIF,I.G T:
1) ASMI III 1971 para. NA 4451 states, "The ranufacturer or installer shall cperate.2nder a centrolled syste such as process I
sheets, shop precedures, check lists,, travelers, or equivalent procedures. Measures shall be established to . assure that processes including velding and heat, treating are controlled in accordance with the l rules of this see:icn of the code l and are accomplished by qualified personnel using qualified proce-i. i du r e s... ~ t
2) ASPI 19 71 para. NA 4 510 s ta t e s ;
"In prc:ess and f.inal extrinaticas and tes: shall be established to / 7 47 / 7 i 0 assure conformance v.1:h decu ente
-. s... ;... -....;... ':.:. :(....::-f:: :-:: s .e......... I instructiens, procedures and draw-: t i l .ngs. i i i 1
3) Per QAP-7 Rev. 6 Para. 3.3.1.2,
...., ding and nondestructive exani- -e-i nation vill be perferned in accer- ! i dance vi.h the require ents of the ! 1 I .W 2 Code Se::icn III Div. I and identified on the KI-1 for: and reviewcd.by the authorized nuclear I inspecter to establish held points." i l a) S??M S.O Rev. 5 Para 3.1.1 states; "The docurentatien of ri:- t ing systers is achieved threugh the use of the fellering documents: A. Censtruction inspectien rian .3. KI-Weld 1 Tcr= C. S=all Scre Pipe Data Shee: D. KI-Weld 2 Fer: I. KI-Weld 1A Perm I. I* DEFICIENCY: i Valve LWR 1335 disc guide extensiens i were velded :e the valve body with-i rut documen:ed evidence of: ..sn app::ved cens t ruc tien insee:- 189 1 1 tien pAan.
-:r ; ;.:::n c i ';en::r f e r=:.:n e c c0.tstesi:::n ill Di s c e s : : d e:- :ni 7 0:. L. i: 3 ;;,, ;,
2. ' Approved or specified welding procedure.
~ } 3. Specified XDE. ~ 4. ANI concurrence or hold peints. 5. Filler =aterial traceabilitv. 6. Preper filler caterial. 7. HJK QA/QC concurrence er hold p ints. I i = F e W ~ k e m Y l o m / 9, -
l 2-8 l
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.h HENR Y J. KAISER COMPA N Y Qf . o oox,,, RECEIVED 5 MOSCOW. oMio 45tb3 77.*3$i,uy. n. .' L.\\,. ' -' f PM 16 '82 .dr ~ ' G' March 15,1982 p KC-16365-Q ' y"5 ------.
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J Mr. B. Culver Cincinnati Cas & Electric Co. 139 East 4th Street Cincinnati, Ohio 45202 I l
Subject:
Code Data Reports and Star. ping Agreement RE7uktgtg jf.LQ rio. [ 1 ~ Centiccen: Attached is your copy of the Zi=:er Nuclear Pouer Station Code Data Reports and Stamping Agreement betueen the Henry J. Kaiser Cc=pany and Catalytic Inc. The original will be retained in Henry J. Kaiser Company caster files. Sincerely, HENRY J. KAISIF. CD::PANY h gY M. Albertin Proje t **anarerY k i y7 W D. 1.. Ha ard Directer, Quality Assurance Programs - KEI DLH/MA/j g* Attachment ec: H. Sager - CCSE D. Fit: patrick R. Fisher - Catalytic H. Hunsaker R. Bryson - Catalytic 'V. Hed:ik P. Botts - Catalytic J. Watkins V. Dent - Catalytic N. Vitale J. Coyle L. Dykstra - Harti:rd Stes: 3 iler D. Sahlberg L. Burton - Hartford Steam 3 oiler D. Iselin File to. 7 e \\ *6 . - o.c,~, r,m..o ~., u e... ~, 6--,
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'For ASMC cede work at the Zimmer Nuclear Project, it is agreed by the parties that modification or repair by Catalytic Inc. of any AS:!E code system for which fleury J. Kaiser Company has not completed the N-5 Date Report and stamped the system, shall
,[ be performed under the following controls. r 1. H.J.K. Co. will not be required to submit an N-5 Data Report prior to Catalytic Inc. beginning system codification or repair work. 2. Catalytic Inc. shall initiate a request for release of a system / component to the Project Manager in accordance with jointly approved procedures prior to performing work on code syste=, with boundaries identified on drawings as written record of cede responsibilities. H.J.K. Co. shall naintain config-uration control cf code systems indicating on drawings work perferned by H.J.K. Co. and Catalytic Inc. (F.eference ZAPO 6) 3.. Catalytic Inc. vill generate field drawings when needed to perform the work they are assigned. (The dravings will be generated according to SEL/Kalscr standards). At the canpletion of the assigned work, Catalytic Inc. will issue a copy of these drawings to the Kaiser CCC so that the caster drawings may be corrected to as-built conditions. 4. H.J.K. Co. vill pressure test all piping systens cc=pleted and installed by H.J.K. Co. as defined in :he design specifications. Ca:alytic Inc. vill be responsible for pressure testing all verk cceple:ed by Catalytic Inc. Pressure tasting may be perforced jointly by H.J.K. Co./Cataly tic Inc. 5. H.J.K. Co. vill prepare an N-5 Da:a 7.eper_(s) fer each piping sys:e that is completed by H.J.K. Co. The N-5 Repert shall exclude all rodifications or repair work by C :alytic Inc. Signed N-5 Code Oa:a'Repor:s will be forwarded to the CCSE Records Center. 6. Signed N-5 Code Data Reports will be forwarded to the CCEE Records Cen:er by Catalytic Inc. for portiens of the sys e: ce:pleted by Cataly:ic Inc. 7. H.J.K. Co. vill apply the appropriate cede s:ang (indicating resp:nsibili:y and cede ec=pliance; for installatien of only that portien of the sys:en installed by H.J.K. Co. 8. Catalytic Inc. will apply the appropriate cede sta:p (indicating responsibility and code co=pliance ic: installation cf only ths: pertion Of :he systen installed by Cataly:ic Inc. 2 I. kr d ,[ fj/./ l[f Q D. L. Howarf j 3'.M' fisher /$/* Director, Quald f Assurance Progra=s-KEI dsident Project Manager / D Catalytic, Inc. M. Y $ d<~. M. Albertin Project Manager - HJK Co. f + 1 og 2_
e w O p. e e. 4-C-M%Qh [ ~ ? H E N R Y t]. K A /EE.= C OMPA N Y Pcipe i e.g (fc, = c ees:m \\ a: sten e~.o m53 N - July 1, 1981 1:C-15604-Q i i )C C]\\/ C 3 Donald M..htiian, 01ief \\L
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Division or oller Inspec:lon c Decartrent of Industrial Relaticas .ll11 29ISbl S:a;e of Ohio l THE nATrorant coARo op 2a22 - h,. rl :h As'e. P.O. 8.a DOILER & PRESSURE VESSEL Coltnbus, Ohio -o 216 INSPECTOR 7,
Dear M. Milan:
Tne hk.. H. Zimer Project has on hand an ASE 35PV Sec. III "N".,2ca-stamped pressure vesse, on w.. h 1: is necessary to nase a modi.. nic. Tne moc....i:1ca:1cn. is to remove tion, cue to a later engineer ng cnange.. our ( T incn no::le a three (a.) inc., no::,e anc replace it with a :. y o:- :ne same length. Chio State 12w now recuires modifica:icn cf ASNE 35.r' sta=c. ed cc - i ponea.:s to.De repairec or moci:lec by tne holc.ers c: an appropr ate "R" stanp. It is ' understood, that exceptions to this requiremen: can be made bv the State Insoec:cr. He:n J. liiser Compa:.y is the holder of Nuclear Certificates of ,ctnor::ation.\\-1,,0... an; 1,,a..o issuec e,cgus:..,.e.-. r an,s exp r ng 7une s-25,19S2, covering Class 1,2 5 3 componen:, parts and appurtenances, pipin; subassemblies, componen: supports and tubular products welded with filler metal and for the instalistion of such items. h's are en:losi-.; copies of the approved engineering change recues:: and associated documents including FDDR 15-1-1012 which includes a sketch cf the poposed change. Fernission is requested to -erfo:. the necessag ::.odifications withi.t r the sccpe of the existing Quality Assurance Program for Section III of the ASNE E5.7.' code. Enry J. Kaiser Company is pursuing both the "P" stamp and the "'G" stamp, but has been infomed that schedulin; of a survey for a. "'a stamp is a: leas two mon hs awr.v. m_ C.C bsi b +l d I ?1oe \\ \\b s =: v.: =.
) f o'r your censideration. If there are any questions, Thank you please do not hesitate to contact me. r - Very truly yours, THE HINRY J. KA I SIR COMPANY ,p 'l,b.E. N Aj-Paul Kyner HJK Site Quality Assurance Manager JN/bw Inclosures cc: R.A. Jagger Ass't Lirector ef Inspection National Board of Eciler & Pressure Vessel Inspectors 1055 Crupper Avenue C olun.b u s, Ohio 43I29 1 L. Burton (ANI) S. Swain (CG&I) 1 t i a 8 b i l 2 4 I i e 4 ]F d 4 2 5 /L I i .i
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No Keviewed by _ A;WA3)b'h%M Sa t e M s 5. Struc tural iets;f a:s iteview Required Tes No Systcr_s Affected Do:Wnt Changes Aequired _ Yes No L!st of NcWats to be C.Sanged A r t s:..Sen t for Additions! Oestription Tel Ne leviewed by h te Y C. Electrical Interface Review Accuired Tes No Systews Affected Drawing Changes Required Yes flo List of Drawings to be Changed Ettac.'s.ent f or Addi t ional Oe se r t;t t on Ye: No Keviewed by tatt n. Additional Discip!!r.e Review Re:uteed as fallevst Ins t rudes ta t ica Tes Ne Aeviewed by Date Weat 6 Ventilate Tes _ Y No Keviewed by Date QA/QC Yes N No Maylewed by Os t e _ _ Misc ellanecus Ot se f,:lir.e s t 1 Tes No _ Reviewed by N te , 2. _ Tes _ No _ Acvieweg n y ___ C4 t e S e e a t t a c.'c e r. t a f : r d e s c r i p t i e n o f a f f e c t e. sis:ces a:: erawings. rinal teview ty Froject b eater
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+ r-j D^ rC OF 8L UC r ygrg so, n..-I-lOI. 9 ~ ~ ~ ' ~ R(Vi$ TON I IE '.D T4.*.*/I,. I If.,;J Di-DOSITION REQUEST tstET ca I 2 emo;Ec7 _';g-.V. unit I 8 :[c-*:. ii.,hA m cart touwvt.sT rue. ca :Esr.aie ica ca e:rg D I-l'J01 g C.C mir.a : an-n,.a : u r
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g sm 80.l nEv. l TITLE 762 969?003
1 5
Pur:hase Par: D:: vin: 5:c :Te Tank ctviAticN CEs:aieTicN Thi.s revisi:n is to replsee shee: 2 of Revision 0, ske::h sheving :he Sargen: & I. undy design fer enlargin; the 53*.C pump sue:ica ne::le. The previous ske:ch ciid r. : take ac:cun: ef :he :ank physical layout. SITI IS'? AC~: Ne-d ed crier io tre-on test. /o O /I, ' (A 'N d'/(-El I. T. E. Bloc: /
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.,e tw s o. =a JUSTIFICATION Ot Oi57C5tTION 010:510*# tSAF Err, A E LI ABILITYl CISIGN V E AIF SCAT &ON STATEMENT te.e t s e
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W DYDR $ il} e ( G. E. WORK-RELEASE FORM A /FDDR NUM3ER: fAl-l- Iol?_. cev. 3 DATE RECEIVED: 4 f ~11?I MPL NUMBER: C.4 l -AooI FDI/FDDR DESCRIPTION: kevec.eJ n e rz le. ci-]S / WORK TO 3E COMcLETED 3Y: CG&E PRODUCTION DEPARTMENT: b ,CG&E TESTING DE? ART.-IENT: H. J. KAISER CO.: kck L.3 e. ...C.: ra r OTHER: ,.g g 7 y i 7 .k..s/ 9 1 i TESTING CC'IPLETED: YES NO: NOT REQUIRED: , g-S/ DATE: THE A30VE FDI/FDDR HAS 3EEN COMPLETED: S/ DATE:- FDI/?DDR CLOSED OUT 37 G.E.: DATE: T s (ATTAC:-TENT I. ) /g
~ h s DISTRISUTION: CG&E SITE CONSTRUCTION MANAGER (d CG&E QA&S (f CG&E PRODUCTION DEPARTMENT (g H. J. KAISER CO. CONSTRUCTION ENGINEER ( /) INSTRUMENTATION ( ) E. J. KAISER CO. PIPING ENGINEER ( ) H. J. KAISER CO.. INSTRUMENT ENGIEER- (FIELD) ( ) F.E.C. CONSTRUCTION ENGINEIR { ( ) CG&E TEST DEPARTMENT ( ) G.E. STARTUP .]. ( /)' f PREOFERATIONAL TURNOVER GROUh ([ s ~ .P hhDA.f g. ky.. .i 3 s i s .s-4/K ~ ' IS RESPONSISLI FOR PERFORMING THE WOR'< s a OA _[ o[a/[F / CG6E Ri?./DATr., / i l [ ./. 1 (ATTAC:OENT 2) //nA b e. r g-
' cme'i trs-to isstn't t m.orgArtes er (mdB em c.itt 1.sT xrActs Fel ctsics CHA.scts Id:stif testies of oenign c: s=:;. FeDp_Ex>-;-!ols n.g3 cat. xce.tvee 9-lf 4j N _ Artasta Casta,n Istarface _ k Yes p;epsed by __ 1 _ __ ta t e 7_21'/) tsvirved by hojest Kansgst _ A. N chacical Interfaes Review Required Y Yes No Systems Affected h '( M d l3 M M.rt d _ L(. [ W.u r f.//- N W N* Seswment Chan;ss Required Yes No h List of Ox o.mts te be Changed T A 9/ ^ < M__ At t.a cMas t f or Addi t ica 04 cription Yes No Rayfeved by / ta't s M / w N 8. Strvetural Interfa:s deviev 1: quire'd Yes Ma fysteas Affsetti Cesagist Char.ges Required Yss Na List of os.eu ents to be Changed _' Att : bent for MditIcnst casertptien Yas No Esviewed by tate Y C. Ilutrical Intorface Eeview Acquired Yes Wa Systt1s Affactsd ...s ...m.,,.. Drawing Changes Required Yes No
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g. List el Oravings te be Chak;;er! N' Atta chan t for M dittcas! 04scriptlen fas _ Fe Rey!cved by Date 0 Additicftal Ofselplina Revley Required as follows: lus tru:-da ta t t en Yes No isvieved by __ __ tate Ntat & Y4St!!4tt Yet ' No. A4vleved by _ Oate CA/QC Yes 1 No 2* viewed my tat Miscell:secus 01::tplines: I._ _ _ _ Yes _ No livf(Vid by _ tats __
2. _
Ye, _ v. Reviewed by _ _ ca s e See artsch ents ter description of af fected systen and gravings. 1 vin.i x,vi.y sy n.., sn..., u, .g Frier.to isne / _ h. /*M _w* gag 3__,. 3/, . ~. -.
DATE OF stSUE h,,**, '. "..~.T. FDDRNO. K'!-I 1012 3 f.:i e '. e .* ' s ** REVI5 ION 3 .F FIELD DEVI ATION I 'V DISPOSITION REQUEST SHEET OF 2 ( ECulPMENT IMPL OR DESCRIPTION OR BOTH) PAOJECT ZI:ser 1 Site UNIT I FDDR A *IPfATOR DATE ././e d C'1-A00t SBLc Storece Tank V-4_ u.2.--
oficio, DOCUMENT NO.
l SH NO.l REV. j TITLE KEl 762E969P003 t I t 5 1 Purchase Part Drav%d e*ar?" 7,.,9 DEVIATION DESCRIPTION RE% @.C"' i'#1 Revision 2 to the FDDR would have required boring the I.D. of the pipe. This is difficult to perfor= per the constructor. Therefore, the revised design proposed'is per this FDDR Ci-1-1012 Rev. 3 Sheet 2. SITE IM?ACT: Needed prior to pre-op testing. / c' /. d*, 9 W { ~/)&
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=.~er T. E. sloem sm c:::=:.= = =ct u v. my =r O SUGGESTED DISPOSITION @, EXPEDITED DIS. ')SITION Engineering is to advise acceptability of the revised no::le detail per sheet 2. COST ACCOUNTING: All costs CG&E Per telecon: T. E. 31ce=, H. T. I. arkin, J. V. eis esire= =ri::are W E143
,ecitro ce esirio~...asvat svresta. J. C. k*alker o/17 A*?61 INAL DISPOS & TION Note that this is an ASMI II repair, and must be in accordance with that code.
,.*O ,E 1 ,s' J. W' --J f CA/ r Cru 8088.o. JUSTIFICATICN CF OtSPCSITION DECISION ISAF ETY, REL! ABILITY) DESIGN VERIFICATION STATEMENT venirito ev carr r s TMs tcuir-E Nr es sas try art.Arto (syts APPROVALS DATE CRF NO. lF APPLICABLE s.A7 TTY FUPeCTICN is AF F E CTro vt3 p. C3uPLaTICN a t CCHo 5;.;"tlE R ACTat.A* -~ AFPROVALS ,OATE. atovisto sy n. s. a t ovia t o o w n s.a r y O vis Oo O '55 O :o ,4"L***" FIELD WORK ORDER No. 4.- ~ DISTRIBUTION CODE DISPCSIT!CN COMPLETE C AT F. INTERNAL EXTERNAt. [ taca ma ac.sg ... ~...,... ~....... a.-..... ~....,... n.s ar.1 ti, o e u. -..,..
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. n]:ltY J. *>AISElt CO. y/ {
occew, Ohio 45153 COnit);CTIVC !sCTIO:1 KtPORT d-d ~Ib C.A.R. No.
O la r.c I _of I 'I.ocgic.,: { 11 fo: M. Albertin Organization: 5 !?.I'. C o r e M. Coedecke !!JK liaincteam & Teedwatcr vt-t-- Icquirenents: ASME Section III Tabic ;;B-4622.1.1 requires postweld heat treatment for oipe wall thickness over 3/4 inch thickness, execpt when such material is preheated to a ninf r:um of 200*F. (Provided carben content is not more than 0.30': and tensile strength not execeding 70,000 PSI and material thickness is less than 112 inch). It en No. Description of Adverse Condition 1 Welds were preheated to 150*F for first 3/16" of uciding and 300*F for balance of thickness. L h i tated By: Titic: Date: ( m r.6ve.4 h/l/,,
Title:
D '. c e ;. ') V.W.\\ C V M. $$bII-f $E W1U Db'O' ?' I __ - s mW. s- . wE..ce. s.s s,e. a s v. vx....v..c goc-.. 0.v.W - mF _d n . x.s :- e-Co:Cie C 1C:: (tem No. - Corrective Action Statctent bate \\ l Co,rrective.*.etion Scutement - Prepared Sy: Tit 3 c._ Date: fu.x,._ - v. v._.p. ~* l .;c rrective Action Follow-up and Verificatzun: f I kWQ.C. N Y1C N ' ; m'y /.ccept eu t>y urir.inatue: lu te : Accept ed by tM !!anager 'D'a t c : l l 70!'J1 No. TF216/2-r,2/:tev.1 l
.:.V .N.. g' y.1 i. (3 g %..o ' ENRY J. KA!SER, CO. f.G H 3'NONCONFORMANCE REPORT h wu, H. ZiMME R POWER STATION N O. E 0 RI PACE - / OF E$
1. 0wG/ NSTALLATION N0.

2. 0WG/INSTALLATl0N NAME:

3. P0/C ONT R ACT N O.

4. SUPPLIER / CONT R ACTOR NAME:
r Q See Belbj PIPE 7070-22506 1.a b a r g e, Inc. 5.INSPECTl0N' PLAN NO.:
6. CRIGINATOR:

7. D AT E:

8. SPECIFICATION N0*
ASME ".1 QAtt 114 J. Deerwester 9-23-81/2-4-8 J SA-106 YES QU NS 1.$ 3.0ESCR'IFT10N OF NONCONFORM ANCE
10. 0ISPCSITIO N

11. 0ISP051Tl0N INST R UCT10NS/ JUSTIFICATION
'9 (? f ff *(./ I REQUIREMENTS: Essential /ASME y @ p (g,g g j( 3 code Section III & XI must be pO/:/t pfd g/, n-y, 7 pg,h ip usha s e_f_r o n l h L d % 1 6 r e M n g M fi % < g an acoroved su>olier, b l O(~ N N_$ N @nM No,P?i.nC1 (dfb jfC OA -tM( _ g FAULT! Material on this Durchas e order was supplied by Labagre, nc. f_ g p g,.g. 7 g 3 Tubular Division 20 South F o u r t '.) Street ft;p myg[4 ..t 7 St. Louis'. Missourj. Not an J,$ _ approved uJK Vendor for supplicid of ((Iq"e.MfA T~ pM(- T4 R ..e i g ASME code material. On date the e g r, m g n y } d. above ourchase order uns ziven g the,. v3v ree2tyc4*the follouint 0/ l_ } \\f.f/, y f pine en Material received Reperd ( _,y, 1 =y 7 .,.1.4pf -h q 39739. // / 4 V r J 20.42'-2 1/2" sch. 40 SMLS SA 106 M.: Gr. B Pine Code el.1 Yj 230.67'-4" seh. 40 SMLS SA 106 ,]
12. REVIEW BOARD (REQUIRE 0 DN ALL ACCEPT / REPAIR DISPOSITIONS)
[f g-,k 2// f ANI DATE _NPD DATE J8[CCNSTRUCTION ENGR. All m $' 2-17-l'2 hV IJf DAA0& '3f2,lh f8 ) Sit DATE CG&E7 NED ENGR DATE CGsf 0.E. DATE M HJK C E. ]
13. REPAIR /R EWO R K COMPLETE AND ACCEPTABLE s
,a' CRIGINATOR DATE 9h
14. CAUSE

15. CORRECTIVE ACTION

l.
1 M C' n
fQ C $0 h CAR NO OF APPL! CABLE) j il unst a retto in. ccat tes. sat inn. A.s. tis. ca retts ionec. /1
> " C C F C '"d ",0,
diZ:.~$ERNUCLEAir70WEdSTATION NO.F ~3(pM @ / PACE 2 0F t. . pes?riptioh_of Nonconformance 10 Disposition
11. Disposition Instrue. & Justitics Cr. B Pipe code cl.1 h6 Mdf6R$ Abk D G4(As M9 OM
~ NR-G -% 93 WGtG fuPaMAtp B (AME@ %d. 6/j 7 7 [ [,39 HJK varehouse has following amoun t in stock. oFJ MP>ROVGP VG/J POR kl67 49 bl2P! ? 10R CA&nTrAL b!!N-Cop 7 M4 L Algf-1l!), MnAG "ThE; MS 17'-2 1/2" sch. 40 SMLS S'A 106 7 Crib Pipe code CL.1 tyTfh AC%tAbb\\' !<$1d7ACfdfGP A 4umli&9 BV M. u#dGrnis) 4hr4T--- n 190'-4" sch. 40 SMLS SA-106~Gr.B ji4BG Cp, (l24fpp N f y[ 4SCg C 'fCR M754h 4F4Nad I [14//_ 4Ller Pipe Code CL.1 Au9 'GN 4$ IMHlM Co. (Lib The vanufacturer of 2 1/2" otpe IAI hUl $ 11)CG ?b PA N 7 vas Y o u n e s t o te n Sheet and Tube 'C o. 4f400/JT F]AM L 2,3, M/r//.- hMP,0blN - Carrbell Works and the'4" pipe was en.nfmerured by Jone= & Lauchlin-M /PPIft04 'd6 6{W4f Ml-414 n u s n.3 2. pr. Offdl 90cmM6hTGP 61r#l C24 TIFF n n e s m s n.. - 2.,u r a r r u r e = ver, on Of-Tf/hM/fGRl/rbt IG6T, I HJK's approved vendor's list at 7 time of purchase. IM MCroRDdMCE WITN [4 nib' manufaeturers certifications on f ile _b - / 0 ((, h [,jMd d $:2C. f in site document center. 'dGEf1MO 1tG Cdfscfr v6 kr. GF Wr' - G 'ab M REV. l l6 e Ac/A,ttr Ars T4. n V 1) i ( J /,r f a 17,/s 9(- y 1 f K e C/ub9y
acottss ELL Co.2tskoNotNCE 13 A /SER ENG/NEERS. /NC". PURCHASE g D4*th t*MNEEH1. INC. ORDER NO. ,M-506 r .PROCu%Et4ENT DEPARTMENT D"' The C.ac.nnges Gas (* Etsctric Company
o. abu 201 Columbus 8. Southera Ohio Electric Company 5"El' 1
0' 7 s =0 and The Dayton Power and Lig.st Commny
05 COW. OH10 45153 Yms cagge Nus sie u st appgan 0 s
att iNvoiCat. *acnact s, raC aic o...: 7_19_77 sties. sitts oe taciNo. etc. SELLER f sh.o To 1.a3arge, Inc. Kaiser Fngineers, Inc. Tubular Division Kaiser Receivin;; k'arehouse 20 South Fourth Street U. S. Route 52 St. Louis, Missouri 63102 Moscow, Ohio 45153 an.. 314) 231-340b es si~. v..: tMis PueCMass oaogn is issuto to stLLEa sus >tCT to att CONost 0Ns aNo sNstat.CtioNs sit FCatM mgetiN ANo to TMt CoNitNis os tat Sottowe(b IIMassis ATTA CMEo M(R(to aNo 87 ' Mis af fl At NCE haap( A Pa At M{agop; gawisit **A" s*tCipicatioN No. WORK ORDER NO. 57300 gzeessit "s" - tiet.s aNo CONO;ttoNs tamisit "C" - smeemo iNstavCrioNs tilM NO. SHIP DATE: 8-2-77 POINT OF ORIGIN: J & L Mill TER*.'S OF PAYMENT: 2~ 10, Net 30 F.O.B. PO!NT: Jobsite, Moscow, Chio " RICE POLICY: Firr. WE! Grit: CUBE: '.y l ouaNiit t vNit l os sCain tion lvwiteniCal total . J account No. Stock Material For Various Piping -) ' S Syste=s Per S&L Seet E-2256 .o* Seller shall furnish and deliver c.s. 6911.9610.31 pipe in the quantities shown and in accordance with specifications on the attached Procurenent Specification Sheet nu=ber 7023 which is by this reference 'C0g @ g cade a part hereof. T '; ' i All r.aterial contained in this order INSPECT TO INSTRUCTION shall be manufactured by J & L Steel KEl-MMY 5b ~ ~ Corporation, Aliquippa & Pittsburgh, .,2., Pennsylvania, a Purchaser approved I Q*
5'""' 'N.
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SALES OR USE tax EXE*.1PTION .v i ..e... e t.s..e. c...t.?... *. r s. a... c.. . s a . ~ * *e: .........,.,. e ..e.. e. s...... s.s s.. t. n. '. e e r.r a.... t i... E
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..:t...e...,. $ 160.O.00 .. e e.,. s....a., a : .c 4. 9:. ag,y s.a.. : ..a INVCICE PURCHASER E .0h 24t.76 fo,C. H-2256 l evaCw a st e AsisER ENGINEERS. INC. l .gg gy AND.saat
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./Go f_gg p PROCUREMEtii Jo23 1 zwame cus SPECIFICATIONS war ,.3, . FOREIGii.FATERI ALS PURCHASE FROM "Q" 'o"M 's NDT ACCFpTARfe Appenvrn yrnnnp UC. a. 7070,w?6 7.c.c. 7c7c ^ ~ Pipe, seamless, blac carbon steel, per ASME SA106, Gr. B with plain ends k protected with taped on plastic end cap seals. Materials and certification must comply with all requirements of Section III of the ASME Code, Article NB2000 (Code Class I) in its entirety including any references therein as applicable and with all requirements of Sargent and Lundy Standard Specification Forms 274-C and 405-C. Complete Mill test certificates per the specifications, including but not limited to chemical analysis, mechanical properties, bending properties, heat treat, ultrasonic tests and hydro test (referencing Kaiser P.O. and item no.) shall be furnished in accordance with ASME Section III, Paragraph NA3756.4 with shipment of material. Marking shall include the manufacturer's - name or brand, heat number, spec and grade, hrydro test pressure, pipe schedule and any other marking called for in the ASME Code & S&L specs. Marking shall run continuous along length of pipe. Color Code marking shall consist cf two continuous longitudinal 1/8" wide orange stripes. The color code marking shall be on the opposite side to the manufacturer's marking. Pipe shall be unpainted on the interior surfaces. No foreign materials acceptable. 4E-v NUCLEAR OR ASME CODE CLASS 1 l CHEMICAL & PHYSICAL i ULTRASONIC HYDRO TEST ANSI CLASS A AEC CLASS Essential i CERTIFIED TEST REPORT TEST REPORT REPORT i CERTIFICATION BY CERTS IDEliTIFIED CONTINUOUS MARKit'G ! COLOR CODE MATERIALS PANUFACTURER TO P.O. BY ITEM NO. SPECS-HEAT NO.-ETC. i MARKING e.y IT s -i,I s ,c,- i ... _..l.... ...I ILF 11/8 h 40 I .068 Wall Pice-ASME 2-Orance I-7n?1 120i i I ILF I]/4140 i .028 (SA 106. Gr. B) ~ i- - 140 I i l lLF 83/8la0 I .091 (ASME Sec III) _l- -160 I i l 11F M/? san i .100 (Class I) -170 I I il 4 l ILF 13/4140 I .113 - L -190 i i i l hF11" an i .133 l- - ?in i l I i - 220 l i (L F lit-40 I .1a0 l It F h h 140 i .14s I -230i lLF 12' 140 l .164 I - 255 I ~ i 12OILF '28 ia0 i .?n1 I-I -?70I I ILF G !a0 1 21A l-I - 200 I (LF G55 140 I ??6 lI - 310 I ?. 220'L F 4 lan i 917 l- - 375 I_ IL F 5 140 1 740 l- - 350 1 IL F 6 j40 i ?on l' - 375 l 1 i LF B ta0 i 199 i i-1 40D i I LF 20.an ' .365 a l-I - *5S I i LF 12 ion i i '- 2 550 406 (J_14 i4n 433 1 i-1 - 600 I I l 'LF 96 I40 .500 l.I - 625 I i 1 l
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litQ, JO8, CONI A ACI NO. Purcle.Ordar t4o. yf,, h,,,,1,y,,,,;; f ih g gh g,,, p,,,,,,,,,,,,gg,, [i,,,,.gg .' J } 7C'"I soeulti of leats peelormeel,,ille es.p.cl to ilisi mule.~ein! ' , invoi,e n D<ila Shipp.*'s ido-desceibyf h e.on .s shown Ier Ccenseuny encoede. YOUNG 5fOWN SilCET AND TUDE COMPANY (b .) OU 4Gs y 4 :'tif. At4D Illtf CO. d '3 I Ytl400ft WOitKS dM-'Ur 1 D Y ___ fe ' - 7
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t / ^'""08'"D 5'GH" D a R i n <t ~~ n$TAir: ~ ~ ~ - ~ ~ ~ ''" ~ OF COUl41Y OF
3 3'P28 " Ii I l#
I"* S d~'" 0 SHIP > 5',1,sceibed anil sween te.iceo m. ee ::. len St.. i.'6 flountain Jirl!.i. J 1.r.. Iestil r.,..). 63102 10 , Ilu.s day of A.D. I? 4,6. 148:1 h. .9. e 3 f.r t C. ' MY COMMIS$1014 EY.PIRES: '.II ', r. gr7.-4 @ ~~U - I Y M ^f.'.* ...--L-- N'" Iw.........i......-,........ NO. M:lt OP.'Ifl NO. MATERIAL DESCRIPTION QUANiliY IiL AI/ Lol st5T 03 YittD .Illi5IL L
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'lV Du o..gg.'I t.tl ' Ut. Is AI:t NO.
>a cE ID F51 P5I 7"
l 0" PR. PSI iflG !.si t 181.5 t%il5'rt e..) 'toir:p t'ot.u A.r.iloca.181 f.ine l'Ir,e 'i'l-Dr. Gra lo is i:ll: ISII 11:13 naterial also conforic to .;mc A :( '.bl'.YJ ii.kt-53 Gra lo l' 24666 53220 02340 37 2500 OR .>.0f* !.:n 1 ) ' *l/i'..) ) S. "It.: 117 P4559 ,;;t940 7004() 37 u,t. a f . I- 'a'ips sci.n.:1.:e cir:nn Plpe ,i.;i
it-1C6-74 Ja i e il ':ll: I'E l
Yhlo n.itstrial also confortas to ep..c. eu I-m-106-Gra 10 0 24666 53220 07340 37 2000 0i; l' '..>'.Kr' .'al O t-7/u"01 S.7!'ll 122 ';1 6 '11 56420,, 'TIJ40, 35,, 25 t'O.. ' r 2 f.50?
53 !?, 3.T'4'.'l US
5tTI C
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?-7/""O3 10.0111 b? 'il583 5"'60 G')720 ~!6
!':00
E 24(,(>6 4/i140,
74740 36 .?S00. s.1L.. .)* liC AT tiO. SNetELCN. C Mn P 5 Si J 1,,,.h,t j s I;l Ilis'@ ,,y F.1 -- M a.. m,- ) u_,
' w;
. 2.s .93 .007 .0?4 m.
a. -..
s air.3: ..!.1 J.o) .u.ri ..c?c . 2.1 ar5 r .a1'.u? -.0 nf.0M.17' 'gs y,f - // ind,n) il. i 11 '[r* U1:' '/% *17 ') '.'20.us '.00i '.024.io ao filESE Mll.L TEST REPORlS APPLY 10: 6 e n YOUR P. O. # ' o nti. : n.m. f. L v I B fiGE INVOICE #_t1..m n_ 5 5 %s oi o m
. fT"* .L 1 N.1,/ t/QL .L'"L.1../"'1 L .' l
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Ch e mists ,; A.~ - ' A..... TE S TI N G Engin e e rs LABORATORIES e M e t allu r gis t s 1nC. ' St. l.ouis, Missouri 63104 3!4/ Prospect 171!1 2350 Sevent' Elvd. n g_. @, -j[,'j 3 Report No. 7-8-221 p> h ] 67-lo p August 16, 1977 Ultrasonic examination of seamless bla&Ae.1, pipe ASMS SA-106 Crade B. N \\. b r-r,. :. 5, ? ? O LaBarge Inc.
).,
Tubular Division g -. 20 South Fourth Street AUG 2 *o 1977 '" F 9 ' P. O. 3966 IMP ',. i,',, St. Louis, Missouri 63102, ""3E. I" UIN_'_'_"3- ] Attn: ILr. Doyle Ferry c,J
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- -".i,- The following lengths of ASMS SA-106 Crade B pipe vere exa=ined by shear - vave ultrasonic techniques in accordance with the recuire=ents of ASME Boiler $[.' .'end Pressure Vessel Code, Section III, paragraph N3-2550. ~The results obtained .. '. ' ~...,,.. during i:he exzminations of July 29 - August 4,1977 vere as follows: A. '.. -,.} f& y,,t gu=y,, -,' Size Number of Pieces Total Lenrth Results jE....- ....ih..,- I/2" Sch. 160 _ . JE9922 4'.. 76'0" Satisfactory I'sf. 7 1" Sch'. '80 JC 1646 1 24'0" .,~ Satisfactory '..y..............._h o../8 ".; x. 203 "..., .31582 ~. ( ;,', i.. ~. 1, . ~. ~
7
^
..%. L.. *.. r.*-'. '
20'5" ea
. Satisfactory r .-~?'...,..- -e.,,,.,_ ? T 3-1/2" x.216", - 21'1" Satisfactory 32138 1 . h... " - 3-1/2" x.303" 25468 1 19'8" Satisfactory 4" x.226" L40851 1 20'1" Satisfactory 4" x.318" 238095 1 20'4" Satisfactory ,'4.1/2". x. 23 7."... 33 85 81.... n.13.. - 242'0" .,_. Satisfactory,' 4-1/2" x.337" N13728 1 ,,b 'I '.7,-... -- 2 ' 8 " - Satisfactory
g v.::
-7 7 g THESE MILL TEST REPORTS APPLY TO: 2 wot yoi.i .p = ~~.,.m LA Bs.RGE INVO!CE # A% 'Jg8 [ --__...L",., h. -rqs t 3 O O
.. ~... ,1.. f'ulg.P" .L n.LJ U b T.M.l -\\. L e.o miau . /. 3 : TE STIN G -#l ~ ,. LA B O R AT O RIE S M e t allu r gis t s 1 Il C. .~ ,,.e 2350 Seventh Blvd. St. Louis, Missouri 63104 314/ Prospect I.7111 Report No. 77-8-221 g.$ h3 Page 2 t ..,.;s --s .' r. Heat Nu=ber Size Eu=ber -of Pieces Total Len::th Results . 5-9/16" x.258" 334663 1 20'0" Satisfacto g ., ~. .N33067 1 21'4" Satisfactory - 9/16"..x.375" ~- /.'.. ' 6-5 /8 " x. 28 0 ". N54126 -l- "1 -- 2 2 ' 2 " Satisfactory ~ .a.. ?. ~ 5/8" x.432" 425636 1 22'0" Satisfactory =
.e..
. '.n . e. ;.....:; m.- - .~ ~' ,8-5/8" x.322" 25379 1 24'2" ,,Ja tis f a c to ry *" ~ ~ ~ " ' - - ~ - - =. .e . - a. ; :.- 1... ., ~ p. , 7-i' h.. 4U .};.. 5 /8 " x.5 0 0 " 25987 -1 20'4" p *. Sa tis fa,cto ry__, /k y.G. 3 .3 .:"~~'*'---- 4..I-[* ' 10-3/4" x'.365" ". '137806 . 1 ~ [.' 'i4 " y Satis f aetory
.=. < > v...
10-3/4" x.594" 337083 1 ~ '0" Satisfactory 12-3/4" x.406" L22928 2-19"2 '" _, _.--
Uns atis fa,c tory
. ',~.' ~ .. '...... 12-3 /4" x. 6 8 8. LO5055 ^'.....,1 2114.".--_ tatisfactory 4~... The items noted as satisfactory revealed no defect indications-in excess of' .the 57. vall thickness calibration standard notch indications. ..f.,. ,'
Unsatisfactory item possessed surface la=inations along entire length.
- ~~. ;._ Respectfully submitted, t k l 1 INDUS lRIAL TESTING IABORATORIES, INC. / [ ..W.- /""
c. <..
i :. e : 0. Allan H. Siegel...P.E. e- ...- Dir;ector - - =.. ~_ l ,7;S /ps ~ ~ Rs D,Z ',. a g =- gg r ;. ~.~...-e. = ,w. ,.~-r.,.,----wg,-
a' ';on;ss lts os:v$o%otuct to gA/SER ENG/NEERS, /NC PURCHASE a y -.'?;; P r$ IER3. INC. RO CU4Y,ENT.D EP A RTMENT ORDER NO. - 7070-17638 r The Cincinnati ca t. r ctric Company 1 3 e Columbus 2. Southe'n Ohio Electric Company 8"'ET O' sH' .C.Eox 201
05COi.'.ONIC45153 and Tb, Dayton Power and Leg *tt Comr.any TMis o.ota Nuweta uust apetas (
A t t *Nvoic t s. P A c.s ct s..a cw o...: 6/22/76 st s.. tts or ta oi%c tre. SEttEn Ship To. LaEarge, Inc. Kaiser Engineers, Inc. Tubular Division raiser Receiving k'arehouse 20 South Fourth Street U.S. Route 52 St. Louis, }iissouri 63102 Moscow, Ohio 45153 Doyle Perry 4 i....n: (800) 325-3363 se.. v..: <ts peacmast osota es issuto to SELLER sUkJECT To att coNostioNs ANo i%stacCtioNs sti Fontw mantlN ANo lo THE CoNit A13 of f at sottC rK s.sesits ATTAcato *stano ANo 87 TMis Rif tetNCE uaot A P ART MtateF: noi.it a - s tciric Aviou ~o. MM wong agoga yo, u.usit s~ - traus ano cosoiTious puisit ~c" - swieriNo i% st ouctiows ITEY No. -ilP DATE: L'/O 7/5/76 POINT OF ORIGIN: St. Louis, }iissouri IR'.*S OF PAYMENT: 2:: 10, Net 30 days F.O.B. POINT: Jobsite ilCE POLICY: Firm WElGHT: CUSE: '21 l ova = tit, j l accou%t ~o. uuiT H otsenietioN u~iteniet Totat Carbon Steel Pipe - Spec. E-2256 (ASME C1. 2/AEC Cl. Essential) Furnish and deliver carbon steel pipe 6911.9610.31 in accordance with the attached pro-cure =ent specification sheets 7010 and 7020. ESSENTIAL INShECT TO INdTRUCTION All material on this order cust be furnished and certified by Gulf States KEl-G n' Ng-. Tube Corp., an approved Kaiser Engi- /y g 7.,y, rjf neers supplier. A ---]----------- CCNHMNG-CD NOT DUPUCATE l rocu:,2 u,, muri r Intrud.d QA AP$' ROVED wa roch sw.e."' OS RECEIVING INSPECTION s REQUIR REQUIRE 0 N7&jD G) NOT_g 7 p y a s.,., r. s.a., re, m.m vir % ,g y f , -s.e...n .:. t i w~..* g g y,q,yg,,t, .i.:, -, :.s..... w.. ~ o - e- -.i s,..........i. a,,, i,ro ..,4 e6..w..... m <..~,,s SALES OR USE T AX EXEMPTION I 3,':":.:::W..'::7:.::': ;:'.*::::.'n ::'.=::.'.::~'..~.M'::.'? ::e n :u ':: ~ l = -. w :: =... m..... 8 u. :.=.... n. n..v. e..:.::. '.:_.=.::.. a..w. v =..m...i.n..=.-..n...;.=...:;Jo; L,s.,i 00 INVOICE PURCHASER ,vac-a st a a 70 to-lo c;p gg NO. K AtSE R ENctNrrPs ta:C. a ...-,.M:'/72 M F.we (5) 3,1 cv ,~o wait =..I s n, t. C.*.._C g g en 5 c.-c.--.i. c.. a ti.e...e c m., cm t E n _......-....m.,-,'2~^******"* RAD:jv 6/.29/76 .. oasc:Nat a:LL cr LAcisc T0. l ~~ c _.... '5 '""'I I"C-w ic . _.Cs.o,ss,, m t-.
... { '?.... ' ' .Q O PROCUREMENT 7010 lh.,5'E<"? sucuccas SPECIFICATI0'iS s tte e:o. : TOREIGN mTERIALS ?URCF.ASE FEO)! atr o tatt l p.o.tAtt 6/22/76 NOT ACCEPTASLE APPROVED VENDOR ht2. :.o. 7C7:r-1856 3 l r.o.ho. 7070 -17658 Pipe, seaniess, black carbon steel per ASME SA106, Cr. B vith plain ends pro-tected with taped on plastic end cap seals. !bterials and certification must comply with all requirer.ents of Section III of the ASME Code, Article NC 2000 (Code Class 2) in its entirety including any references therein as applicable and with all. requirements of Sargent & Lundy Standard Specification For=s 274-C and 405-B. Co=plete mill test certificates (referencing Y.aiser P.O. and Ites No.) per specifications including but not 11=ited to chemical analysis, mechanical properties, bending properties and hydrotest shall be furnished in accordance with ASME Section III, Paragraph NA 3766.4 with ship =ent of caterial. Marking /shall include the manufacturer's na=e or brand, heat nu=ber, spec. and grade, hydrostatic test pressure, pipe schedule and any other =arking called for in the AS.W Code and S&L Specifications. Marking shall run continuous along length cf pipe. Color code markling shall consist cf one continuous longitudinal 1/8" vide orange stripe with one 1" long x 1/S" vide perpendicular cross stripe. ~ spaced at l'-0" intervals for designating pipe schedule. The color code carking shall be on the opposite side of the pipe to the =anufacturer's marking. No foreign =aterials acceptable. Pipe shall be unpainted on the interior surfaces. ' ]/ .r HUCL-EAR OR ASME CODE CLASS 2 EdEMICAL & ?HYSICAL-CERTIFICATION BY ANSI CLASS B AEC CLASS ESSENTIAL CERTIFIED TEST. REPORT M TERIALS MANUFACTURER CERIS IDENTIFIED HYDRO CONTINUOUS MARREIG 'COI.OR CODE TO P.O. EY ITE! NO. TEST SPECS - HEAT NO. - ETC. M.WGNG .ve !., sf,. i. ' ' o c = * *. $ umt S vom v... ., s..... c......... e e. %*,'f." 1 Orante11 I7010-120 I i Y t-1/8" 80 .09s" (Pine ASE SA106) I1l -140 l 1/4" 80 .119" (Gr. E AS W ) i1I " -160 I 3/8" 80 .126" (Sect. TIT cl. 2) 1/?" Rn 16 7" U211 11 1 " -170 l1 l " -1gn 1/4" Rn 1 c;4" un11 l l1 I 1" pn _170" U311 " -910 1. 200 1L" H Rn 101" tv,11 N 1 ! " ??n $1.73l S 346. liyu 19n ?nn" tv,11 2. 800 9mn l 2.063 1.648. il lan 919" u,11 1 'is I I ii I An I 97A" 1921 1 l t1 I " -27n 1 I (" pn i 3nn" it,11 a a -?on I i1 1 ~- l1 i Tin i Rn min" t'211 [" I l en .m" t ' $ 1 ii l a _3,c _1sn l l li1 c" en ,,c t" A" ten i b,",.. 3, a i i " _yc i i a i I ai in Ion e ena"...,, l _.no i i I i"l in" lAn [An1" t*,11' l i 1I -450 I I l l"l 19" lon I AR7" 15,11 ssn l l a i I1 ! 1 I"I i t," 1."n ! 7 sq" 't311 l Ano I I !ii .-) L 1 I" .c" lon / . q,..... i 3 i ,3 .. _c3g. G.s i o.,,...., 3 i i " i 2.. ~ i .. _no, l i i " l,.. t..n is., 3, ".. 5 3 i ...cn ; . A f' I ea! .i..,,.,i J'
g:
I !"i (_ ~ ien :1,213" nail a ! 1: -725 i e," isv .: m 't<!! :.. M
'a .a _.c...- 9 9 f@f;,g f;;r PROCUREMENT e 7020 sucmeras SPECIFICATIONS mtr i.e. 3 FOREIGil MATERIALS PURCHASE FROl W 3 c'"
.oatt 6/22/76 fiOT ACCEPTABLE APPROVED vet:00R -
no. so. mo -18563 r.o.ho. 70.'o -17688 Pipe, seamless, black carbon steel per ASME SA105, Gr. B with plain ends protected with taped on plastic end cap seals, l'aterials and certification must comply with all requirements of Section III of the ASME Code, Article ilC 2000 (Code Class 2) in its entirety including any references therein as applicable and with all requirements of Sargent & Lundy Standard Specification Forms 274-C and 405-B. Complete mill test certificates (referencing Kaiser P.O. and Item flo.) per specifications including but not limited to chemical analysis, mechanical properties, bending properties and hydrotest shall be furnished in accordance with ASME Section III, Paragraph liA 3766.4 with ship. ment of material. Marking shall include the ranufacturer's name or brand, heat number, spec, and grade, hydrostatic test pressure, pipe schedule and any other marking called for in the ASME Code and S&L specifications. Marking shall run continuous along length of pipe.-. Color code marking shall consist of one continuous longtudinal 1/8" wide orange stripe with four 1" long x 1/8" wide perpendicular .. cross stripes spaced at l'-0" intervals for designating pipe schedule. The color code marking shall be on the opposite side of the pipe to the manufacturer's marking. Pipe shall be unpainted on the interior surfaces. No foreign materials acceptable. fiUCLEAR OR ASME CODE CLASS 2 CHEMICAL & PHYSICAL CERTIFICAT10tl BY AflSI CLASS B AEC CLASS Essential CERTIFIED TEST REPORT MATERI ALS IGliUFACTURER CERTS IDENTIFIED HYDR 0 CONTIliUOUS l%RKIllG COLOP, CODE TO P.O. BY ITEM f;0. TEST SPECS-HEAT t:0.-ETC. f'ARXING o -., .........,c...........e. city,- $
===c--. S um S iom lLF'1/81 Pipe ASME SA106 1-Crance i 4 17020-120 I LF-1/47 Gr. B A5 tie l 41 -1a0 l l LFI3/87 a Sect. 111 Cl. 2 14 -160 i LFn1/27160 .187" Wall 8 4 170 1 LF 3/4tl60 .218" l 41 100 1 LF 1" 160 .250" 14l ?10 1 __3 100LLF Ik" 160 .250" I a1 ?pn s2.20 1 5220.00 2 l LF11h",160 ,281" l i eI ?in I I LF-2" 1160 .343" ! 4i ?c:: I LF 21s"i l60 .375" l 41 -770 i LF 3" 160 .43R" I a1 ?cn i I LF! 3k" 160 l l F! 4" 160 _s31a i eI _un i a i I al me 1 I l LFI S" 11601 r3?c" l I al .nn I I ILFl6" 1601 _7 m" i a .G: i i l ILFIS" 1160I cn:;" a i e 2nn i i I .ILF110"I]60I !.175" I aI .c:n i I i ILFil2"i1601 1 ?iy" .c! _::n I I a _l i LFl 14"I l601 1.t.nc" i al . nn l 8 f 8 ! LFt 16"s ica i 1 cc3" .t -i 4 i_ ILFils"i,601 1 p 1 ai - 53 i ' > n.( l. 8 iL:420";1501 1 ccea 'J c -f;5 4 l i !_i_ Fi 22"i l s.7 9 n c.. a a
nc i 1
'LF 2?"i s en ; .3 3.. a m.
. m' N* ~ * " "* '" " ? ) DC v O CECf "
S'"?
~ i ' Q, ** Ack to E3 W5 .. STATES TUBE CORPO. ' ' ION ' e# fW33 'm ' "',,ycnoff G ( b t. ..s a3. 222 CH;' - L lic,....* ' : g, Tea s 1021 N . ~ 16 -...~...v.r.. e -l4-1-74 7 p y.... .; d6_2i5-66276 ..,6589 w.. 59,i 01 i 20 - 01 00352005LES l E 5 _j g r LaBarge Tubular Div. [H LaBarge T'ubul'a'r ~DiV.~' s acow.rs.- 7501 South Broaduay 121 East KOeln [" o St. Louis, Missouri 63111 I e e k[ o r e '~
e S t. Loui s,Mi s sc,uri I
11-25-74 j i 3""/f lj fis. '..MO i. "**""' Ppd. - b est way - T135k To tt om o f loa d with '4" Y 4s-64696-96 and strio out the balance with at least 2 x 4's. '" '~ Car,* .25 Max Carbon - Seamless - per ASTM /r M';-J ~,' ' -~ ,w...o l'06-A r*.,... p'o' A = a = c- --wn q[ Grade B 'plai6 ends - laccuer coa test re r t's. 4 x.. Q Q. THESE Mll.L TEST REPORTS APPLY TO:i r44 ' ^ j "F 3 g)ds(b.h@ YOUR P. O. # 70fd -#4r/ II) # . I.ll, S "M
13. BARGE D 0lC p.... E m
" *d._t.;cg, ? z_.' ~ I~ M .v. ..v. 4 3,, 13 4805' 1.660"- .250' Rdm. 17' - 2 4' 3.765 18,090 Co 1-4/4"-Sch '160 l 14 3723' 1.900" l.281" Rdm. 17' - 24' 4.859 18,090 cc 1-1/2'.' Sch. 160 j ,j .1 o j. I .'..l. l uj : CHDIICAL ANALYs!S (Average Ladle Analysis) e r Ar eso. l c. un i e. s i si se ca i .io v cu JA-0954 .20 /O neuaus KA-2097 . 2 0 <.76.013,fd19 k17/ Item 13 mh _d .17 J -9314 .20 78 .011 .012 18 Item 13__ .L t e m 1 t+ c. PI!YSICAL TEST ST=
se
_ virto e s e r t e s c.a r io n rta~cc w.e.o rest noc=wrtt o_ .t,u, 74600 47100 55.0 Item 13 2500 psi OK Bend oK 67000 437oo #,go,o% tem 13 2500 psi ox / Bend OK ~ - 77400 48900 47.0 Item 14 9 2500 psi or i gene og u i w l-/b~ 1'.'. J3/ I. g I' j .~ i, . '. t ). '> t s v c t v y7 -af a t 's:rs st; re grw n e e r;u a n g s.,. t . A o : :" Gr;.2 7-N : sr e r *** < >.o w or o: c 4 >.o in r u c r. . f.2
p s g s '.v e. T

4 o s.as scais to a(P C m! u t Wid-'
f p./ \\ sil.h, n i / ~~ag: p _ h % ---~A ' 'A *. 2 i _,, 2, s ,, n...o-v~, -s. a ..e
m i .jy.e of McK to Bill Wyckort .p.C C6; -(7,' G,UQ STATES TUBE CORPORGION Q [$f'] ((N fy Uj Rosenbers. Texas 102t P, S u, .A. ._..m. c.. :. .'966539-66541 7231 10-23 _i4 59 01. 20 - 01 00352005LES 4 5:. 5 LaBarge Tubular Div.
s Lallarge Tubular Div.
"t=
f7501SouthBroaduay 7 7501 South I: roadway Feb,1975' o St. Louis, Missouri 63111 IP St. L0di s,i-Iis s ouri Allocatio h, .;~ u S.. _..
==en-*. _ __ lock bottom of load with 4 x 4's and strip out- 's., ppd. - best way /- -. --.- -. th e ba l. wi th a t least 2 x 4's. ,,,,,,7,.- gg .i ':A. 25 Max carbon - Senmicas pressure pipe p A f' f( " ~ ' "
SA-106 - Crade li - plain c.1i.s - S c.; u,..-
T eT., 5. pg/ J." 4 /n :(,a M./. reports. 0. e;.n ; n o-THESE MILL TEST REPORTS APP T i~e.n
z

4
'% }# ""JUL1 - C-1 . - M* s (M LA BARGE INVOICE # 934 3Ak'$..v h I. .X= '- YOUR P. D. # 7 o *? ' [ l ' I. ' "'" ~S .g,.. i,, ;.._,,,,,, 5 11,910', 1.315"p 1.. .. u. ,_3 r., l .133" Rdm. 17' - 24' .1.679 l19,997 T Coc 1" Sch. 40 i i 49y l t
119c 6
10,00C' 1.660" .191" Rdm. 17' - 24' k.997.29,970 co$ j
1-1/4".,Sch. 30
444
.. :.r a 113,775' 1.900". .200" Rdm. 17' - 24' 3.5311 50,017! Co: i 11004 7 1-1/2" Sch. 80 7 i ! 687 i
1438 s
.h ' CORRECTED DOPY _i-CHDIICAL ANALYSIS kAverage Ladle Analysis) 6-30,7n HraT No t_ c ww p s t .si .we l* cm uo v. t cu neuamms HA-0001 ,. 20,.7 3
011 019 419 HA-OdO5/
.2T .80.010I 017. 1 9,. Ite=s 5 & 6 &7 Item 7 j PHYSICAL TEST
i. c y virus, s t ctouc
,,oy v. i st4~ct a avo=o rest soc wett~oi u ty. sr= 79100 56700 45.0 Item y 2500 psi OK Bend.0,K ar-a. s ,75600 58600 47.0 74800 50000 47.0' Item 6 2500 psi OK Bend OK ~ 73600 51400 49.0 70700 #
48200,
. 42.0 Item 7 2500 ps/OK < d: '. ' 72200 ' 48600 i 3end CKi;S,,,L', 44.O ' '"n W k -/6-7 6 q,.. ? $.(.A-?h...'. b m f ..~<.. p T-r-;. - c,.cr. c,.= w, e.,,,... c... : u. wf
~o c:.
] ?lb'd. ,n.=,- l gy,-c,~ ro.~o su nc j.y== e c -c ~'=: 7 .sr or.<, - l. u s= c -o. Licr. ,,,,,,.g W 49-A T' Ov-da L -}}

ML20023C049

Contents

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Dear Mr. Milan:

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ML20023C049

Text

SUBJECT:

Dear Mr. Milan:

SUMMARY

Dear Mr. S"lvia:

Subject:

Subject:

Description:

Subject:

Dear M. Milan:

Title:

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