ML20050C092
| ML20050C092 | |
| Person / Time | |
|---|---|
| Site: | Zimmer |
| Issue date: | 02/18/1982 |
| From: | Felton J NRC OFFICE OF ADMINISTRATION (ADM) |
| To: | Morris B AFFILIATION NOT ASSIGNED |
| References | |
| FOIA-82-98 NUDOCS 8204080126 | |
| Download: ML20050C092 (1) | |
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'a Mr. Brian fiorris e
P.O. Box 323 IN RESPONSE RE fD Portsmouth, OH 45662 TO NRC F01A-82 s 3
Dear Mr. Morris:
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This is-in response to your letter dated August 1,1981 addressed to the Federal Bureau of Investigation (FBI), in which you requested, pursuant to the Freedom of Information Act, copies of documents in the FBI files pertaining to the William H. Zimmer Nuclear Power Station.
On February 12, 1982, the Nuclear Regulatory Commission (NRC) received from the FBI two documents for review and direct response to you.
The NRC has completed its review and has determined that no NRC information should be withheld from public disclosure.
However, the FBI has requested that certain information be withheld pursuant to exemption _ (7)(C) of the Freedom of Information Act (5 U.S.C. 552(b)(7)(C)) because disclosure would constitute an unwarranted invasion of personal privacy.
The person responsible for this denial is Mr. James K. Hall, Chief, Freedom of Information/ Privacy Acts Section, Federal Bureau of Investigation.
This denial may be appealed to the Assistant Attorney General, Office of Legal-Policy, ATTN: Office of Information and Privacy, U.S. Department of Justice, Washington, DC 20530 within 30 days from the receipt of this letter. Any such appeal must be in writing and should clearly-state on the envelope and in the letter that it is an " Freedom of Information Appeal" or "Information Appeal".
Also please cite in your letter the FBI F0I/PA number 2.14,236.
Sincerely, j,,
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7 ' M. Felton, Director 7.
Division of Rules and Records Office of Administration
Enclosures:
As stated cc:
Mr. James K. Hall 8204080126 820218 PDR FOIA MORR I S82-98 PDR
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Docket No. 50-358 5
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.s Cincinnati Cas and Electric 2:
Company ATTN:
Mr. Earl A. Borgmann l
Vice President, Engineering Services and Electric Production 139 East 4th Street Cincinnati, OH 45201 Centlemen:
This refers to the investigation conducted by Messrs. G. A. Phillip, K. D. Ward and T. E. Vandel of this office on April 7-9 and 30, May 1-2 and 20, 1980, of activities at the Wm. H. Zimmer Nuclear Power Station authorized by Construction Permit No. CPPR-88 and to the dis-cussion of our findings with Mr. B. K. Culver and others at the conclu-I sion of the onsite portion of the investigation on May 2,1980.
f This investigation related to allegations concerning installed safety-related piping. The enclosed copy of our investigation report identi-fies areas examined during the investigation. Within these areas, the investigation consisted of an examination of pertinent records and
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procedures, independent evaluations and interviews with personnel.
During this investigation, certain of your activities appeared to be in noncompliance with NRC requirements, as described in the attached Appendix A.
i This notice is sent to you pursuant to the provis'.9ns of Section 2.201 i
i of the NRC's " Rules of Practice," Part 2, Title 10, Code of Federal I
Section 2.'201 requires you to submit to this office within Regulations.
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thirty days of your receipt of this notice a written statement or expla-
.j (1) correc-nation in reply, including for each item of noncompliance:
tive action taken and the results achieved; (2) corrective action to be taken to avoid further noncompliance; and (3) the date when full com-
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pliance will be achieved.
In accordance with Section 2.790 of the NRC's " Rules of Practice," Pat :
opy of this letter, the 2, Title 10, Code of Federal Regulations, a enclosures, and your response to this letter will be placed in the NRC's s
Public Dormment Room, except as follows. If the enclosures contain that you or your contractors believe to be proprietary, you i
inf orma t f ore must apply in writing to this of fice, within five days of yo:ur receipt of this letter, to withhold such information from public disclosure.
include a full statement of the reasons' for which
- lhe application must the information is considered proprietary, and should be prpaso s,-con t ained j
that proprietary information identified in thgmpulCcat'itnit in an enclosure to the application.
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Cincinnati Gas and Electric 2E Company We will gladly discuss any question you have concerning this?*
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Sincerely.
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James C. Keppler Director
Enclosures:
1.
Appendix A, Notice of Violation 2.
IE Inspection Report No. 50-358/80-09 cc w/encis:
Mr. J. R. Schott, Plant Superintendent Central Files Reproduction Unit NRC 20b PDR Local PDR NSIC TIC Harold W. Kohn, Power Siting Commission Citizens Against a Radioactive Environment Helen W. Evans, State of Ohio i
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Appendix A NOTICE OF VIOLATION 7
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E Docket No.e50-358 I
Cincinnati Cas and Electric 4
Company Based on the results of the NRC Investigation conducted on April 7-9 and 30, May 1-2 and 20, 1980, it appears that certain of your activities were not conducted in full compliance with NRC requirements as noted below. This item is an infraction.
10 CFR Part 50, Appendix B Criterion XV, states in part that " Measures shall be established to control materials, parts, or components which do not conform to requirements in order to prevent their inadvertent use or installation."
The Henry J. Kaiser Co. Zimmer Quality Assurance Manual in Quality Assurance Procedure (QAP) No. 16 requires in part that "All non-a.
conforming items will be segregated, where possible, from accept-able items, clearly identified with the applicable Hold or Defi-ciency Tag and documented on the Nonconformance Report."
It additionally requires that "Upon Verification that all work on the item is complete and acceptable, the nonconformance report (NR) is signed off in Section 13 by the Inspector."
Contrary to the above, 5 piping spools identified by NRE-1911 Rev. 2 were released from segregation even though the Inspector had signed off section 13 with a notation of specific exceptions to acceptability of the material by identifying another NR controlling This release was achieved through unauthorized i
the material.
removal of the noted exceptions on the NR.
The Henry J. Kaiser Co. Zimmer Quality Assurance Manual in Quality b.
Assurance Procedure (QAP) No.16 requires in part that ".
material is clearly identified as nonconforming and is segregated, Due to size limitations physical segregation may be when possible.
s of In such instances tagging, marking, or other m.
impractical.
identification is acceptable." Additionally QAP 15 nauires that It is u.e<* *n con-
"A ' Hold' tag is placed on the item...
junction with a 'Nonconformance Report'."
@ ?-20M a Contrary to the above, 3 piping spools identified i
.:s t nonconforming and required to be cleared by additic s
.cion h d 'e w only had been released from the warehouse, but in a installed without any " hold" tag being placed on the mathrial.
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U.S. NUCLEAR RECULATORY CO.SISSION
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License No. CPPR-88 Docket No. 50-358 Cincinnati Gas and Electric Company Licensee:
139 East 4th Street Cincinnati, OH 45201 Wm. H. Zic:mer Nuclear Power Station Facility:
Investigation At: Moscow, OH Chicago, IL Dates of Investigation: April 7-9 and 30, May 1-2 and 20, 1980 M
Investigators:
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. D. Ward (EH il 5~
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tate T. E."Vandel W
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~R. C. Knop, Chief Construction Projects Section 1 ara Investigation on April
'[ Investigation Summary:
, 20, 1980 (Report No. 50-358/80-09)
Because of allegations mat.. primarily relating to Areas Investigated:
the adequacy of piping welds, performed a reviev,of records and procedures, a)M SkJ.f -7 Q
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ande independent evaluations and conducted interviews of personnel.
The investigation involved 94 investigation hours by three investigators.
Of four allegations, one, which related to the installation of Results:
ore-f abricated oicina havina defective welds was cartially substantiated the cines were installed before cuestions regardina dieir accent-in that ability were resolved. Oneitemofnoncompliance.aninfrac$on.was k
identified:
(1) 10 CFR 50. Accendix B. Criterion IV. releas( of material
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REASON FOR INVESTIGATION an individual who contacted the NRC by telephone On Tebruary 28, 1980, 6
One made allegatio.;s regarding the Wm. H. Zimmer Nuclear Power S stion.
y( of these allegations was that piping having defective velds { d bee j,
installed in a safety-related system.
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SUMMARY
OF FACTS 28, 1980, Following the receipt of allegations by telephone on February d
arrangements were made to interview the alleger to obtain m several allegatione, three of which involved matters under the juris-information.
diction of the tiRC. By letter dated March 11, 1980, the alleger was advised that an investigation would be conducted regarding those allega-tions which were as follows:
Defective welds in safety-related systems have been accepted, among 1.
them were welds CY606, HR42 and K811, Five defective welds were identified in pref abriacted piping but the pipes were accepted and installed in a safety-related system 2.
inadequate and a scheduled six-week flush was reduced to two weeks.
3.
Allegation No. 1 was not substantiated.
three of five identi-Allegation No. 2 was partially substantiated in that fled pipes had been installed in the main steam relief system before ques-Two item tions as to their acceptability had been resolved.It was also determined that at the tim were identified in this regard.
i d open the investigation a nonconforming report requiring disposition rema neDuring the inves concerning the acceptability of the three pipes.
i d to additional examinations were made of the pipes and they were determ ne be acceptable.
Regarding A11(gation No. 3, it was determined through contact with the primary source of the informatf o-upon which the allegation was based,
.i r 1978 snd problems in this area e Nom that he had left the site e ~conh whi inspections conducted had been identified and -
- a. legations in March 1980.
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cne between November 1978 an th. Zimmer site, the tt
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Following completion of had evidence of a criminal i
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'f alleger contacted Regior e*.
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_o censpiracy and that the welds on the three above-mentionsd pipI3 h:d b:Gn cut out and repaired during the, course of the investigation and this The basis for these allegations, information was withheld f rom the NRC.
which consisted of recordings of three' telephone conversations, was ob-tained from the alleger during an interview on May 8, 1980. Do in-formation or evidence was obtained to confirm these allegatidns during f
f the interview or during subsequent investigation.
5 One item of noncompliance, an inf raction, was identified during this investigation.
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i cto d:t ctiva The individual stated that he had been employed by a pr vhis employe agency, and the licensee, CC&E, through investigate time card to work under cover at the Zimmer site toHis investigation effort began on Decembe In addition to isformation padding by site personnel, and ended on January 4,1980.
information regarding regarding worker time card padding, he obtainedl allegatfions, some of 10, 1979 other. activities which was the basis for severa of the NIC.
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which related to matters under the juris ict on dk f
ation to the 5
The individual stated he had earlier brought his in orm f any, would 4
FBI.
be taken by that agency.
his allegations The individual stated he had documentation relat f several of his conversations with site personnel.
f the tapes which March 3,1980, the individual played those parts ohe ilable copies of his reports.
3 A11eRations_
with the alleger, i
Based on the information obtained through the interv ewinvestigative i
a review of the taped conversations and h sC j, risdiction were developed.
allegations involving activities under NRBy letter d u
d ised that an investi-d gation of these allegations would be conducte.d is attached to this repo btained with the alleger's identification delete These allegations and information regarding them o as Exhibit A.
forth below.
during the investigation are set Def ective velds in safety-related systems heve been d K811.
_ Allegation l_: accepted, among them were welds CY606, HR42 an llegation was ob-The identification of the specific welds in this alleger had made surrep According to the informa-tained from a review of the tape the aof his conversatio buried in concrete tion obtained by the alleger, weld CY606 was Building. He between the Radwaste Building and the Containmentthey dug it up to it was his understanding that uncertain whether this was done.
said had informed CG6E that h
weld HR42, the alleger said that heHe said he had heard t had confirmed 8
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oeen hired as a consultant, and this firmHe also said was defective.
thfr d was defective.t d to the NRC.
.e this aefect was repor e informed that this weld e
d Regarding veld K811, the alleger said he wasf ault" and that had "an insert
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_. m Th2 011cg2r otetad that P= body Tcsting S2rviccs (Pcbody), c1::o referred to as Magnaflux, personnel had informed him that some J
welds that Peabody, the nondestructive testing contractor, had rejected as f aulty were subsequently accepted by KEI, the site He said that a Peabpdy an-construction management contractor.
ployee had records identifying the welds rejected by Feattody which were subsequently accepted by KEI. He i~licated that by 1Eay of
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explanation, CG&E had informed him that e.te interpretati6n of the 5
film, obtained through radiogrephic e :aminations of welds is a E
The appearance of an item on a radiographic film judgment call.
may be judged to be a defect by one individual and not by another and KEI could overrule Peabody.
Finding:
He On April 7, 1980, the Peabody field supervisor was interviewed.
stated that he had no records showing the welds Peabody had initially He rejected which were subsequently declared acceptable by KEI.
indicated that, although he was aware that this had occurred, he did not know how often and he could not provide any specific instances.
He also stated that the results of radiographic examinations are recorded on reader sheets. The radiographic film and the original reader sheets are turned over to KEI. He said Peabody only had carbon copies of the reader sheets.
As a means of further evaluating whether KEI was accepting welds identified as defective by Peabody, a safety-related system, the High Pressure Core Spray System, was selected and all reader sheets pertaining to it were reviewed. Of 99 velds in the system which were radiographed, two instances were noted in which Peabody had checked the reject column and KEI had lined that check out and column. 'Ihe radiographs of these two velds had checked the accept were reviewed by an NRC inspector who is a certified NDE Level III.
He concurred that the welds were acceptable. Conversely, it was in several instances, between five and ten, the original noted that accept check mark entered by Peabody had been lined through and a reject check had been entered by KEI.
Regarding the subject of welds and radiographs of them, an NRC 12-13, 1978 inspection conducted on November 8-9, and December (Report No. 50-358/78-30) identified several discrepancies in radiographic techniques and reports. During a subsequent inspection on September 18-20, and December 11-12, 1979 (Report No. 50-358/79-17) neveral more discrepancies were identified. CG&E then hired NES to d
- t. review radiographs and reports of all welds which had been accepte for turnover prior to operation. This review began in October 1979 and was completed in early April 1980. The review included 2,390 Of those, 958 had report discrepancies, 543 radiographed welds.
had some technique problems and 14 welds were found to be unaccept-able because of defects.
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V The KE1 Project Superintend:;nt cdvic:d on May 1,1980, tha 14 welds were being re-examined and resolution regarding then had not been He stated that one of the 14 welds found to be unaccept-completed.
able was the subject of a nonconformance report and, therafore, had not been accepted for turnover. His weld, he said, shyld not Another veld had.h.een cut have been included in the NES review.
out of the pipe for examination and it was determined t W t, although
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it appeared to have a def ect on the radiographic film, i't was, in E
f act, an s.:ceptable weld.
Regarding weld No. K811, a review of records showed it was welded on November 9,1977, but because an Authorized Nuclear Inspector hold point was missed at the fitup, the weld was cut out and replaced by weld No. K916. n e missed hold point was documented by Noncon-formance Report (NR) No. E-2138R1. H is NR indicates that the It was determined disposition was to cut out and replace the veld.
that veld No. K916 had not yet received final acceptance.
Regarding veld No. RH42, records indicated this weld was first radiographed on August 9,1976, and found to have unacceptable D e areas were repaired porosity and slag in the areas of 36-48.
and a reradiograph performed on August 10, 1976 found it to be acceptable. A review was made of the radiographs for veld quality, techniques, and report accuracy by an NES Le'rel II radiographer on as part of the above-mention ed re-review initiated January 25, 1980 after the 1978-79 NRC inspections. n e NES 1.svel II radiographer found some discrepancies which have not been :esolved, and the veld has not been given final acceptance.
Regarding veld No. CY606, a review of records showed this veld was first radiographed on July 15, 1976 and found to have incomplete The areas fusion and penetration in the areas of 0-13 and 13-16.
were repaired and the weld re-radiographed on June 8, 1977 and A review was made of the radiographs for found to be acceptable.
weld quality, techniques and report accuracy by an NES Level III 12, 1979 as a renuit of the NRC inspection radiographer on OctoberThe Level III found some discrepancies which conducted in 1978.
have not been reco1ved and the weld has not received final accept-ance.
n e manner in which safety-related installed piping Allegation 2:
was flushed was inadequate and a scheduled six-week flush was reduced to two weeks.
j ne alleger provided information that a site employee informed him l
that another individual who had been employed on December 27, 1979, as a general foreman at the site had objected to the flushing pro-He had also objected when a particular flush that e.
cedures used.
to two weeks. On one occasion should have taken six weeks was cut the individual had demonstrated the flushing was inadequate by pounding on a pipe which released sediment and slag during the ne identity of the former general foremn was provided by flush.
the alleger. _,
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On April 7, 1980, the former general foreman was contacted Finding:
This individual said he had worked at the Zimmer and interviewed.
In 1978 he was the general site from June 1973 until November 1978.
foreman of t5e flush group.
Regarding the six-week versus two-week flush, the indivffual indicated h
it had been anticipated six weeks would be needed to prgare for and He, however, was able to accomplish a y
flusti one of the systema.
He indicated that the shorter satisfactory flush in two weeks.
time did not mean the flush was not done according to the require-Rather, it was a case of he and his men being able to accom-ments.
plish a job in less time than expected.
This individual stated that in his opinion the welding done on the critical systems, such as the main steam lines and in the reactor He said, however, that several problems were building, was good.
encountered in the flushing activities while he was at the site but he was unable to provide information regarding any specific require-ments that were not met.
NRC inspections conducted subsequent to the departure of this indivi-dual from the site included an examination of flushing activities On the basis of one of and some specific problems were identified.
these inspections, conducted January 3-6 and 8,1979 (Report No.
one item of noncotcpliance and one deviation were 50-358/79-01),The noncompliance related to a failure to close a valve identified.
during a flush and an inadequate procedure to assure boundary valves are closed. The deviation was that the procedure did not require A second inspection conducted February tagging of boundary valves.
27-28, March 1-2, 19-23, and April 9-11, 1979 (Report No. 50-358/79-06) resulted in one item of noncompliance regarding flushing activities.
This related to a failure to maintain control of flushing waters re-sulting in the flooding of equipment in a system which had been turned over for preoperational testing.
The individual indicated a' matter of concern to him was that a hydrotest of the reactor containment was successfully performed, l
but af ter the test some instrument lines were cut out which in I
He indicated he was uncertain as to whether CG&E would attempt to use this test as meeting test requirements or whether the the hydrotest.
NRC was aware the test had been invalidated by the subsequent modifi-t l
cations.
On April 8, 1980, the NRC Resident Inspector advised that he as well the initial hydrotest was not valid because as CC6E were aware that He stated that of the subsequent modification of the instrument lines.
another hydrotest was tentatively scheduled to be performed during
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the summer of 1980.
In view of the above, further investigation at the site $1n the area of flushing activities was *.ot pursued.,_
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g Five defcetiva weld 3.wero identificd 10 prcfcbricctcd A: legation 3:
piping, but the pipe was ac,cepted and installed in a safety-related system.
Through a review of reports written by the alleger and Ghe tapes of conversations with si.te personnel as well as informatios. supplied
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through interview on March 3,1980, the following infordh~ tion was obtained regarding this allegation.
gt During the NRC hearings in November 1979, a question was raised concerning an secident which involved the dropping of fuel rods.
A former site employee had provided information to attorneys who were opposed to the licensing of the plant which was the basis for A miscommunication between the former en-raising this question.
The question about ployee and the attorneys occurred, however.should have referred to, piping b an accident tractor trailer rather than fuel being dropped.
'i in about October 1979, a trailer load of The alleger advised that pipes fabricated at the Kellogg Company, located in Pennsylvania, Since personnel arrived at the site in the middle of the night.
and proper equipment were not available to unload it properly a member of CG6E management issued instructions t7 push the pipe from the truck onto the ground.
When the pipes were found on the ground the following day, it was decided that the pipes would have to be inspected by x-ray to Peabody was instructed to determine whether they had been damaged.
x-ray (radiograph) the pipes and 5 to 8 faulty welds were identified.
Since Peabody had been instructed to check the pipes but not the welds, and since the welds had been tested and found to be acceptable bef ore shipment by Kellogg, the pipes were approved by KEI Quality These pipes were installed in the Main Steam Relief Assurance.
System, a safety-related system.
Finding: A bill of lading da:.ed June 29, 1979 showed that Pullman Power Products, a division of Pullman Inc., Williamsport, Pennsylvania, formerly known as M. W. Kellogg Company, released to the Daily Express Company five pieces of pipe assembly I/S, weighing 6,700 pounds, for A packing delivery to the CG&E Zimmer site on Monday, July 2, 1979.
listed the following pieces:
slip accompanying the shipment IMS08BB12-6B IMSO9BA12-1AH IM508BA12-5BH IMS11B12-7BH e
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IMS10BAl2-ICH Copies A KEI receiving stamp shows it was received on July 3,1979.
of the bill of lading and the packing slip were obtaine,d and are attached to the report as Exhibits B and C, reepectively, l
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o Each of these pipes (spool piceco) tnra fer th2 Main Stcan S:fsty Relief Valve discharge and,were carbon steel pipe assemblies ap-proximately 15' 7 5/8" long, 12 3/4" in diameter and having a wall thickness of.687".
T On hand at the Zimmer site were QA documentation packagg for each j
of these 5 spool pieces received from Pullman. A copy op one t
package was obtained and is attached to this report as Exhibit D.
4 On July 5,1979, Nonconformance Report (NR) No. E-1911 was prepared
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indicating " Spools were rolled off of truck onto ground and striking The other spools" and listing the above identification nunbers.
issuance of this NR had the effect of placing these pipe spools in a hold status in the KE1 varehouse. On July 10, 1979, the KEI Construction Engineer entered the following disposition on this NR
" Rework.
(1) Perform liquid penetrant test on all welds; (2) perform visual inspection of weld and preps. Accept on basis of inspection (1) and (2).
Should any pipe spool fail due to inspections (1) and (2) a separate Nonconformance will be issued." A KEI QA engineer concurred in this disposition on the same date. A copy of NR E-1911 is attached to this report as Exhibit E.
1 on the same NR E-1911 was voided and superseded by NR E-1911 Rev.
10, 1979. KEI and CG&E personnel advised that the dis-date, July position shown on NR E-1911 was reconsidered because they wished to avoid removing the paint from the welds which would be necessary NR E-1911 before a liquid penetrant examination could be performed.
" Perform RT Rev. I changed the first item of the disposition to:
examination of all welds." A copy of NR E-1911 Rev. 1 is attached to this report as Exhibit F.
A QA Surve'.11ance Report dated July 23, 1979, addressed to a CG&E QA engineer signed by the KE1 NDE QA engineer, showed that on three spool pieces, weld X4 had rejectable indications, and requested to be advised concerning the dispositioning of these rejections.
The CG&E QA engineer stated that to the best of his recollection, he did nothing in response to this request and could not recall having discussed the matter with anyone. A copy of this Surveillance Report is attached to this report as Exhibit G.
CG&E and KEI personnel stated all five spool pieces were radiographed on an "information only" basis but only the films for those three The X4 weld is Ref erred to in the Surveillance Report were retained.
Radio-a weld which joins a solid cap to one end of the spool piece.
graphy is not the appropriate technique employed to examine a weld of this kind since the gamma rays must pass through the cap (about 12' of metal) as well as the weld. The KEI Construction Engineer
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said the radiographs were done with the thought that they mig't show n
surf ace damage, even though it was recognized the quality of the l
film would not be good and it was recognized that the film would not meet any code standards. 7y-------..,..._,..__.__.
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NR E-1911 R:v. I w:s veid:d cnd cup;rond:d by NR E-1911 Rev. 2 on July 31, 1979. The disposition shown on the latter was to perform kT examinations of all " butt-welds" and to perform visual examinations of all " fillet-welds."
l A QA Surveillance Report dated August 8,1979 showed that$all five j
spoolpieceswerevisuallyexaminedandwerefoundaccephble.
A copy of.this Surveillance Report is attached to this report sa f
Exhibit H.
I Since two spool pieces had shown no indication of damage through radiographic examination and visual examination another NR, No. E-1997, dated August 9, 1979, was prepared as a mechanism to remove those two spool pieces from a hold condition but to retain an open NR on the other three. NR E-1911 Rev. 2 was closed by KEI QA on August 9,1979, with the notation " Exceptions on - :) See NR E-1997." A copy of the NR E-1911 Rev. 2 is attached as Exhibit I.
NR E-1997 showed that the spool pieces IMSO9BA12-1AH and IMS08BA12-$BH were acceptable. On August 13, 1979 the KEI Construction Engineer placed a notation on NR E-1997 "CC&E to disposition." The KEI Construction Engineer stated that this was appropriate since CG&E has responsibility for off-site vendor supplied items. On August 19, 1979 the CC&E Construction Engineer added the disposition " Accept-As-Is" and described the reasons for this disposition. A copy of ER E-1997 is attached to this report as Exhibit J.
Quality Assurance Instruction, QACMI No. C-4, Nonconforming Material Control, requires that NRs dispositioned " Accept-As-Is" be signed I
by the Material Review Board before they are closed out.
NR E-1977 was closed out on October 17, 1979 with a comment added by the Sargent
& Lundy (S&L) board member to the effect that " Welds rejected by radiograph are covered by NCR E-2020."
A copy of the closed NR E-1997 is attached to this report as _ Exhibit K.
NR E-2020 showed the same information as NR E-1997, but at the time of the investigation, E-2020 had not been closed out.
A copy of NR E-2020 is attached to this report as Exhibit L.
A review of records at the varehouse showed that the three spool pieces, whi::h were the subject of the open NR had been released to g-construction for installation as follows:
Issue Date Item IMS11312-7BH 9/18/79 IMS10BA12-ICH 9/24/79 7
IMS08BB12-6B 9/28/79
- t e ;
b I
6, s
[ *# '5 O*O'W1 M 4 M *eh-
_ww H-- - - - - - - - - - - - - _ - - _ _ - _ _ _ _ _ _ _ _ _ _ _ _,.. _
O O
On April 8,1980, it was established that these spool pieces had been installed and no " Hold" tag or " Deficiency" tag had been This is in noncompliance 10 CTR 50 Appendix B, pieced on them.
CriterionXV,andKE1QualityAssuranceProcedureNo.Ig.
thespoolpieceshadbeenreleshdfromthe It was ascertained that f
warehouse on the basis of a later version of NR E-1911 Riv. 2 on which' the above-mentioned notation referencing NR E-1997 had been
/
lined through on September 14, 1979. A copy of this version of NR E-1911 Rev. 2 is attached to this report as Exhibit M.
It was determined that the QA Document Control Supervisor had lined He indicated that he had heard that NR E-1997 out the notation.
I was being voided so he felt there was no pointD e supplier QA man in in it being cross-referenced any longer on NR E-1911 Rev. 2.
the warehouse indicated to him that some pressure was being felt De Document from construction to get the spool pieces released.
Control Supervisor informed the warehouse that NR E-1911 Rev. 2 had been closed out and it was all right to release the spool pieces.
He said this was done on the assumption that what was considered to The Document Control be a paper problem would be cleared up.
Supervisor as well as other site personnel indicated the accept-ability of the spool pieces was regarded as a paper problem rather than a real problem. It was indicated that the probability of actual damage to pipes of that size and wall thickness due to mishandling upon delivery was extremely remote.
The supplier QA man advised that the spool pieces were released from the warehouse on the basis of the version of NR E-1911 Rev. 2 He which had the reference to NR E-1977 lined through (Exhibit M).
indicated that the Document Control Supervisor was instructed to The latter indivi-line through the notation by a CG6E of ficial.
dual, however, denied any recollection of having given that instruc-tion. The improper close out of NR E-1911 Rev. 2, which resulted in the release of spool pieces for installation before their accept-ability had been established is in noncompliance with 10 CFR 50, Appendix B, Criterion XV, and KEI Quality Assurance Procedure No.
16.
Deficiency Tags were placed <m the spool pieces On April 23, 1980
~ >onnel terformed and during the period April 25-28, 1980, Peabes.
V. L. question.
magnetic particle and ultrasonic inspections of reabody in-The reports of these inspections were reviewed a spectors performing these examinations were interv2 ewer' on May 5,
1980. The Peabody personnel stated that t hey h.d centluded en the the aprol pieces were acceptable, basis of these examinations that 1980, Fullmar peisonnel
'f It was also ascertained that on April 28.
visited the Zimmer site and also perforn.J ultrasoric inspections On the basis of these examinations, Pullman provided oi' the welds.
F.eabody a statement to CC&E that these welds were acceptable.
personnel advised that they had observed the examinations performed by Pullman and they agreed with the results..
=e e
f...3
..pg
O U
4.
Additional Allegations During telephone contacts hith the NRC on May 5 and 7,1980, the alleger stated that he had evidence of criminal actions, relating to the spool pieces which were the subject of Allegation No. 3 above.
He stated that he had evidence that between the two vishs to the k
Zimmer site by the NRC investigations team on April 7-9 And April This he 30-May 1-2, the welds had been cut out and/or repaired.
{:
alleged, was the reason that the welds were judged to be acceptable He also stated he had evidence that during the second visit.
pressure was exerted upon Peabody personnel to withhold information from the NRC in connection with the investigation.
On May 8,1980, the alleger was interviewed jointly by NRC and FBI During this interview the alleger provided for review a personnel.
tape recording of three telephone conversations he had had with After listening to the three conversations, the Peabody personnel.
FBI representative indicated that they did not appear to him to be evidence of criminality. he tape was furnished to the NRC for further review and follow up.
The first conversation, according to the alleger, took place on May 5,1980 with a supervisor in the Peabody, Cincinnati of fice. At one "They cut some point during this conversation the supervisor said:
of those welds out."
he alleger responded: "You mean since the NRC had begun their investigation?" De supervisor then said:
"Oh, yes, they did that the next Monday." I.ater in the conversa-tion, the supervisor said:
"I do know they started repairing some welds."
On May 20, 1980, the supervisor Oo had made the above statements, He stated that he had no first-hand was interviewed by telephone.the Zimmer site and that his comments to knowledge of activities at the alleger were based upon his conversations with another Peabody I
This second individual visits the Zimmer site and may employee.
have acquired the informatir.n himself, or through conversations He with another Peabody individual who does work at the site.
stated he did not know whether the information he received con-
[
cerning the repairs of welds related to the three spool pieces or to some other pipes.
The second Peabody employee was, als: finer,ieved '.y telephone on
'le advised that the velde th1t w t. sepaired were May 20, 1980.
He some which had been identified as bad during the NES audit.
12" pipe said to his knowledge no repairs had' been mah on anyef the ultrasonic He added that he had re':eved t,r tewica i
concluded the examinations performed on the 1 7 pipes A hr br1 l
[
welds are acceptable.
ST 7 7-.- m...., -.. -
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The third Peabody individual, who is employed at th3 Zimmer cito, This individual was also interviewed by telephone on May 20.
h 12" stated that the paint had been removed from the welds on t e He said this was pipes so that the tests could be made of them.done with w rinding a.
done on the welds.
Ietweenthe The second taped conversation took place on May 5, 1980 This radiographer h
alleger and a radiographer employed by Peabody.
had been identified by the alleger as being one of the individuals h
pool who had been involved in performing the radiography on t e sDurin The radiographer responded:
pieces in July 1979.
radiographer whether the pipes were bad.The alleger then stated he had been "I can't really say."
The radiographer responded:
the welds were cut out and repaired.The alleger again raised the questio "I didn't "I don't know."
the welds were defective and the radiographer responded:I w The radiographer then identified the Peabody employee who read the film.
The latter individual had been interviewed on film."
May 2,1980. He had stated that all five spool pieces that had been had read the film.
dropped from the truck had been examined and n NR.
The third taped conversation took place on May 6,1980 between the The primary topic of conver-alleger and the president of Peabody.
sation was the action taken by CG&E in early April 1980 in trans-f erring the radiography work f rom Peabody to anoth because it would have a detrimental ef f ect on his firm's position NES.
in the industry, and adversely af f ect their ef forts to obtain future contracts.
the President of Peabody was interviewed con-He stated that the action taken by On May 20, 1980, cerning this conversation.CC&E, and his posture regarding it, had no the Zimmer site. He said that, to his know-ledge, no Peabody employees had been pressured to accept or ap quality of work at He stated that Peabody.'s contract provides for t ce or re-defective velds.
their performing the radiography and that the accep anwith KEI. Peab ibility in e forced or jection of a weld restethis regard and, thet c 3 e, 4A'.1;eg:sien that they pressured to approve Fad work was meaningless.reco'r to KEI according to the terms of the centract.
i ls be was his understarAing the NRC required that these mater a e and aveilable for inspection.
'l retained at the a e
Management Discussion b
5.
d On May 2,1980, the results of the investigation were discusse
(*) in the with CG&E and KEI personnel identified by an asterisk Persons Contacted section of this report. -
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Exhibits A thrtugh M t
Attachments:
] List of Exhibits A - Ltr dtd 3/11/80 NRC to A11eger 3 - Bill of Lading fy" ji C - Pecking List T<: D - QA Documentation Package 94,- E - NR E-1911
. F - NR E-1911 Rev, 1 C - Surveillance Report dtd 7/23/79 H - Surveillance Report dtd 8/8/79 I - NR E-1911 Rev. 2 g
J - NR E-1997 8
K - NR E-1997 (closed)
F L - NR E-2020 M - NR E-1911 Rev. 2 (closed)
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Dear this refers to the meettag between yes Dir. L. Wilitamaan of the NRC Baadquarters Office, and me en Erth 3,1980.
On the basis of the information yee previded we plan to aonduct as savestigation at the Wa. E. Zinner Beclear Fear Flaat regarding the following allagod ametars Defective walds in safety-related systens have been accepted.
1.
asong them were walds CT 606. M1 d2 and K 811.
Five defective welds were identified in pre-fabricated pipiar but the pipe was necepted and insta11aA la a safety-related system.
2.
The amanar la which safety-related insta11taA piping was flashed was finsh was redocad to 2 weehe.
3.
landequate sad a scheduled ? :::S Teu will be taformed of our findiass fellowing angiaties of ear investisaties.
Sincerely.
C. A. Phillip Investigation Specialist k'
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PIPING QA DOCUMENTATIOt! CllECKLIST
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Subcssembly Packages
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Code Data Report 64 N
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Form OAS P1 9-26-74, rev. h-15-75 Exhibit n - tese 1 of 23
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TLX PUL POW WIP CINA 1-01{gglA180002 06/29/79 29 1979 8
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@INCINNATI GAS AND ELECTRIC COMPANYMR W W SC O
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POST Orr!CC SDX 962 45201 CINCINNATI OHIO i
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PACKAGES AND RADIOGRAPH PACKAGES MAVE BEEN I
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DOCUNENTATIONAND ARE COMPLETE FOR PHASE 2 PIPING S CLASS 3 I
JOB NO,7935 F-SHEET REVISION NO MARK NO 1
3874 1MS08BB12-6B 3878 i
1 1MSO9BA12-1AH '
3886 1
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3889 2
f 1MS10BA12-1CH" NES J STATHAM QUAUTY ASSUR ANCE &
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Reference Drawing, Spec. or Stai ~~
[ [ ///[' k.hM-h:
2.,Specifkc'locati$ '
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00FJ.ECTIVE ACTION STATDIENT
~
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Date Corrective Action Verified B :
/
Exhibit B - Page 1 of 1 k
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9 5 SW _ +...,
~
UTfAYNd$in%F w
O NONCONTORMANCE REPORT _ ji%4W4tes DDE '
0F _ '
PAGE_
- s. Ae t h s cr.82EE as.INC.
WO._E-1911 Rev 2 4.5UPPLIE4/ CON 14AC194 BAIRE,;g- ~ g.
L*:.'.E R F OGIR ST ATIDig 3.P0/t0NTRACT NO.
.[
ClU 612 3 DWGlit:5T ALLA1ID's I; APE:
,.Pallass Power D+WJ. M Q Jyu-~
~.
~-...
CC&E 2171 8.$PEC4FICAliOW N(Assagy,34Lrf;,7 '
Pipe Spools
- 7. 0 ATE-
[,,eb21ov M
sEs rtKW No.:
, s. iWSPECTOR; W-221p V
7-5-79, 11. 0tSPOSAT 80N 11tST RIET10NS/JUST 3.iDeerwester r
Qp. 118M -- - n -
- 10. Ol$ POSITION fgsgaarT10$F NONCONf 0RMANCE
%.e r ese.I ' R i M 6 End k k'
m.
brYT VicLds 934ri-F
[
c p-Att 1____
n..w.atsrial to be unloaded with
~ w; w
% R.., mts b u. m mu d
- quipment Eg.pt
~
- msr.v,te.usf M; r-m-w gs d Dot"fJcone d d hE d b firDefri!M
{Spo318wererolledoffoftruck k
C.1 Y 'y,.. _
.m on
.5?W**
d and striking other spool t sn to gros E
Gpqq f Ar M cn 6 na ta_o e t
NAM g.$1Nuiers-1 eJ s r,n-rA >JRtwrs '
W@
b
@ d[2)
=__ -m mw N
w..
A( T"\\
1MS 091.A12-1AH b
4:: u N tI S 2Lw M~
I 2
IMS 0_88tA12-5BH
~'
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1HS 11til2-7BH Nu nele
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tcAiS f G I M.,...A o
a 1MS 10llA12-1CH MT P_ o '
int c -
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ag 3g.g a
J '*W BOARD (REQUIRED ON ALL ACCEPT / REPAIR 0!$ POSITIONS)
/
NGR.DATE
'KEl CONSRUCTIO '
3 f&rAfs
/A
_ ATE KEl SAE DI W,_/L U
OATE fG&E SPdNSOR ENGR DATE Ct AA GQ"
~." J.. '
1 COMPLETE AND ACCEPTABLE
_i_8
[
/
I*
"'t/RE93 R K M
[Mh. *g-6- / f f 7 INSPE6.OR/ ENGINEER 1 f[Wk
- a..(
- 15. CORRECTIVE ACTl0N
% R-V a
~
$Pipe Spools were dropped from No corrective action requiredd '"
'4 carriers truck bed to ground.
.fCQ s
hours and as the result of a mis-
cd This occurred af ter regular working 3:A,/ ~ ~
8
- 16h interpretation of instructions given x p-gq i
to truck drivers
~
Exhibit 1 - Page 1 of.1 m,.
.: *QW
~
g_
9
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NO.E-1997 g
- r. v OWE 5A st3 pg $1tr)W NO.
- 2. DWG/ INST AlLA110N NAI.lE:
3.PG/CouTRACT N0.
4.5UITtIERfC0tif AMTM:
. x n.
a..cu.s.ya &y,v.i.
.- I
?_I P. Spels
._Cp.&E 2UJ Pullsen '~
s p:.( _lb. o #
P 8.$rECif lCA110N b0.
- 3. ft.f
,Y sDATE: _
n255
=
7 E.IN$PECTOR:
,o,gM10N PL AtJ NO.:
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=
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- 10. DISPOSIT10N
- 11. Disrostil0W IwsI R UCit0N5fJUSTffetA110N -*"
g DESCRIPil0N OF NDHCONF ORIAANCE t
.% g-i J:26.,,,,.
..-~.._.n Material unloaded with c 6 A s-wJ t%2,1Edn.M%mzi-stQUIRE S T:
kdOMtigh E; prove [ equipment.
..i:.y.,:Tr??^**gqM;
~
F.: ult:
Spools were rolled off truck Acted-as
- 1 dM v-e Ved b ' hn ItrNan' r-crit h d k 2 on to ground and striking other spools hjece ry;) ion,... d ). b h/a.e Ord.
cs yer E-1911 Rcv.2 E
1007. U Nrt h c *bf
~l Disposition 2 all fillet velds
- ~
vicually inspected accepted as per
,l gy f Ob,,,k h, M (Mke,6
. l'f'ke5*
SR 2251
- /,, g
,y
)
Disposition 1 corpleted all heu d b,5 5 arrib f
e
[
eli Liv au. -
a butt radiographed (IMS 08EB 12-6B had_
rojectabic surface indication-open)
Qjd k,h,wJ d f,2 " ~"
- (, ' 11B12 7BH had rejectabic lack of 1;
f,f NES h,3
. ~.m fusion-open) (IMS 10BA12 ICH had reject
,. -. m M, cbic lack of f usion-open)(IMSO9BA-12 IAH-Acceptable Butt & Filets-Closed)
I
' h, k
!N Og{O f
(IMS08BA-12 5BH-Acceptable Butt & Fille :-
l l
t.,
r/rg C1caed) e>;t1-?L I
n
- 12. REVIEW BOARD (REQUIRE 0 ON ALL ACCEPT / REPAIR OISPOSITIONSI M~""*'"
~ ~
y,[
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.r -
KEl C0dSTRUCTION ENGR! DATE I
S&L DAT E CG&E $PONSOR ENGR DATE CG&E Q.A.&S.
DATE KEl RAE l.
i-
- 11. REPAIR / REWORK COMPLETE AND ACCEPT A*!"
2.Y NtSPE CTOR/ ENGINEER DATE
~
c I'. CORRECTIVE ACTION H. C AUSE
$ &<4.r &
M frare s t#1L /?D/S UM
$'s fogg$
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Exhibit J - Page. 1 of I i rosina g owsra r acto ars enat te$sst tis.n.e.tik on t etrs tosiin-3 g
g 7
W W-
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NO.E-1997
- 4. SUPrtlE n/Cor.1 RAC101:I;Af.1E:
f yg,1f,73.'T If I'0WE n ST All0fl 3.00/r.0:418:ACT f.0.
vMT1'LIA180ril10.
- 2. Dr/C/1tJS1 AL L All0f: f4 AME :
CCI.T 2171
___ Jy11 man..Powcr I
8.SPLCaf IC AllU:J NO.
ASr.* E
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Pipe Spools
- 7. D AT E:
8-9-79 M2255 YES {m00
.SPICil0J PL AfJ fJ0.:
- 6. If45rt CT U H.
g. kl g,
- 11. DISPOSITl0N if4Si nUCT10ftS/JUSTif lCATION
- 10. DISP 0517 0fJ ANCE
'ESURIP110N f)F N0l'C0f1f Onf.:
c s i r. c. 4 c c-A r
-t,.
QUlitR
'T :1 Material unlosded vith D %. Dee r t$_- i% "ItL 3rOvcd equ]pment.
bc(Opf-OS. 5 ll) < -.- f i 6 r.* r rv i. t /
iult:
Spools were rolled off truck r-f /. i-r a
f i r # c. -
n.
i 10 ground and striking other spools
- perf -1911 Rev.2 s,l. m,.. t[.- ).
.f b.:.,-
.r I
IC'C I U l f r.
e $..
Disposition 2 all fillet velds gg.g. $ %f,gg h h,, fl[:
,,,l IW4u 'S-a 9r M lou 311y inspceted accepted as per R 2251 CM C
'($
Q to-1.,I w
l; d b k J) h e, t ' ', w k,is
(
.. r c.,, ff.,
Disposition 1 coc:pleted all
,k t br llw.
..a I
O',
..e
.utt rcdior,raphed (IMS 08BB 12-6B had hjset.cblesurfaceindication-open) y V
h Q.1,.t; k ij,s, ;
,\\- (;_
l
/
t.E'
- h..,,.d MS 11B12 7BH had rejectable lack of b
__ m_ T,, x h, e
m
[m
/j p fg go /gf g / \\
unien-cpen) QMS 10BA32 ICH had reject-j(, ppp[p bla 1:::ck of fusion-open)(IMSO9BA-12 f //re//g fpp.cg g' e
AH-Acceptable Butt & Filets-Closed)
(
sVe[E Edfo.'
/e #spavdeer.e/ p54'#f [
Sd88d- /8 -68k,__
[ // f.50.9d?/J-//-/A// 4ff/
f
/
MS08BA-12 5BH-Acceptable Butt & Fille t-h he. I-. Fli f f ~r-
{ /.S # C Q > ed/8.
- 1wed) w
)
Lt ACCEPT /fi[ PAIR DISPOSIT10NS)g g[
'77 g,,f KEl C0hSTRutil0N ENGR. DATE
.REVIErf BOARD E IRE
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Io-t 2.-n[/.
!"f/bl7L & E ia/p/g.
D1 75&L DATE
&E SDOF% A ENGn DATE CG&E Q.A ES.
DATE KEl DA
[ REPAIR / REY /ORK C0f.1PLE [
D MCf
' ' ' ~
DALE lNSPEC10R/ENGINEE R
- 15. con!1ECTIVE ACTION ~X L-
.CAUSE
[ en,,,,...n i n s m J A <f e.,a.,aats f
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W e tAGE ko. i* 3.P0ft.041RAC1 ko. (suPrt ER&ow1RAc1 ..'. H 2.:".'_?.I I.l ;'t.1.P. i! AT 4 0f.' G. % - C "T.t s;pt.. Y.'. 2.tv.T,ft! 51 AttAttor.LAut: --*~C.c:.1: g~4
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2.or.I,v ;1:1t Alic*.ko. J ./ . u a1 a 8.SPECIFICATioW un.' gge-57 ,, s 7.0 ATE: 6::,k M y _ d 4.siisPEClon: . d, t-:.h s.eus> ECTies. Pt AE NO.: %7 1.C. _;.*3 n2 ll.0:SPDSl180lf itf5T $.CT10.NS/AGT,W*_*Mfm }
- 18. Dr$POSill0N
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- 5 ' *- * * :i
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- },,,, j-
,gQ Ia 12.EEVIEW 80ARD (REQU:RFD ON Att ACCEPT / REPAIR otSPOSI KEl CONSTRUCTION ENCR. D + ~ .. ~.. [ 1 DATl CGM SPONSOR ENGR DATE CG&E ELAAS. DATE KEl SAE %?! A'- r.1 I g - $4L r ,,, c C0urtEtt AND ACCE'" %EE . 9. v,.s. m..... 13.RIFAIR/REWDRK e ~ INSPECT OR/ ENGINEER _. TATE..- e t :%
- 15. CORRECTIVE ACTION b cs.4.Y.*-C.
e wh'Y
:z &
- b.
~~~I. ; F "- 7 6 ~ y l l l-W.. W 4 .c ~ /.*Nb' :. J% e /* 2.' &.* r - s * :p h ,C & * *.; < < < *.* -s"- s' ' Srs s. e / f.:.. ~ e /*.w.d s G J k 1%. [
- 1 1 :. s.'
- .:.e a t. e o.
v.; -. f
- i*
Exhibit L - Page 1 of 1 '+***b .%.A sits a ones e
- - ~.
I - ~. -
g~ g QV 'ef y w
- . ' rrSE P. EN0ir;E E RS, lN C.
l NONCONFOP.fAANCE REPORT 'y;r.f. H Z;*.".'! R PD/.E R ST ATION I NO._E-1911 Rev 2 PAGE OF
- 1. 0t'. Gilt.ST A L L All0!. N O.
- 2. 0WG/ INST AL L ATi0r: NA?.1E:
3.PD/CONTR ACT NO.
- 4. 5UPPLIE RICGt.T RACT OR nAL:E.
S:a below Pipe Spools CC&E 2171 Pullman Power
- 5. shSPE C flor. PLAr. N O.:
- 5. INSPE CT O R;
- 7. D AT E:
- 8. 5PE CIFICAllDf; N O-AS!.:E QAk' 118 J. Deervester V
7-5-79 M-M 55 YESO flC *
- g. DESCRIPil0N OF N0hCONFORr.tANCE
- 10. DISPOSITION
- 11. DISPOSITION I RUCTIONS /JUSTIFICATI0ta e
REQUIP.EM5ST: D p,woea RT m d, e Matarial to be unloaded with OF ALL Eu-r-r -Vlelds " cyproved equipcent h S. o coitu Ys u M. ="AfA rm t k FAU1.T: or Au T~ t mT. NA f t:rt td Spools were rolled off of truck d D o c o cy n c d M d d i d e i,. I 3 l cn to ground and striking other spools on A s. ft. f2. c. o crt-r. I f? c w o e t( Spool Numbers-A r, -.ek o n E ar t.s o e IMS OSB312-6B l 1 r4 s t -r-dn 4 CtL:9.fc75 de <m IMS 09EA12-1AH N 1 r_% l lC N1 \\ IMS 083A12-5BH I 1MS 11B12-75H bb !<::i4 o u LD h u,ei _cc./, ~1MS 10SA12-1CH l h o- /r o, -70 Due TuC I _o p.1 " r '. ' '--- l I n5 to g f 4.60S @}dh. Oh _i , s 1 J ac : e.c,, A. m !=a %.e..d u n u l Iassued. l l n REVIEW BOARD (REQUIRED ON ALL ACCEPT / REPAIR DISPOSITIONS) ,/gg w,[ _ yy 9g EEi CONstRylw.- ncR M' A /r ~ f. 4/Sy s &E SPdNSOR ENGR DATE CG&E/ Q.A.& S. DATE KEl QAE A R, i a ' t. .. A.CCEPTABLE N e (? hf7/ .. +.A' e I ~ y,, gh I!.SPE CT O R/EN GIN EE R, [A% lo. CAUSE
- 15. CORRECTIVE ACT10N Pipe Spools were dropped from carriers truck bed to ground.
No corrective action required. This occurred af ter regular working hours and as the result of a mis-interpretation of instructions given to truck drivers Exhibit M - Page 1 of 1 p } lc -..----.,.m._'..m. "''*'" ~*'~~~ ~ ~ ~~ ~ ~ - - 2}}