ML20072T404
| ML20072T404 | |
| Person / Time | |
|---|---|
| Site: | Seabrook, 05000000 |
| Issue date: | 09/15/1981 |
| From: | PULLMAN POWER PRODUCTS CORP. (FORMERLY PULLMAN, INC.) |
| To: | |
| Shared Package | |
| ML20071K200 | List: |
| References | |
| FOIA-82-524 FI-132, NUDOCS 8304080080 | |
| Download: ML20072T404 (101) | |
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'l REACTOR COOLANT LOOP PIPING INSTALLATION M 3 INSPECTION i FIELD INSTRL'CTION 132 1.0 SCOPE 1.1 This instruction shall provide all pertinent information, and make specific reference to additional documents where
- I necessary, in order to achieve acceptable installation and
'I inspection criteria fer the prir.ary reactor coolant piping.
.I l 2.0 REFERENCE
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.l 2.1 P0f N55-140 a,
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FPf DESCRIPT!0M PH IS0*ETR!C 54060 LP!-HL RC-1-01
- l 54061 LPI-ECI RC-2-01
. 54062 LP!-EC2 RC-2-01 54063 LPI-CL RC-3-01 54064 LP2-HL RC-4-01 3 54065 LP2-ECI RC-5-01
$' 54066 LP2-EC2 RC-5-01 54067. LP2-CL RC-6-01 54068 LP3-HL RC-7-01 54069 LP3.EC! RC-8-01 54070 LP3-EC2 RC-8-01
,' 54071 LP3-CL RC-9-01
- 54072 LP4-HL RC-10-01 7 54073 LP4-EC1 RC-11-01 54074 LP4-EC2 RC-11-01 54075 LP4-CL RC-12-01 f.
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Page 2 FIELD INSTRL'CTION 132 2.1(cont'd)
E DESCRIPTION P-M ISOMETRfC COWENT
$2702 31" 13 40' ELL RC-2-01 Loop 1 52702 a 31" ID 40' ELL RC-5-01 Loop 2 0 Loop 3 52702 31" 10 40 ELL RC-8-01 52702 31" ID 40' ELL RC-11-01 Loop 4
. 50277 WESTINGHOUSE FABRICATION SPECIFICATION 2.2 UE&C GENERAL ARRANGEvENT DRAWING 9763-F-805554 UEAC P & ID 9763-F-805002 UE&C Major NSSS Equipment Setting As-Built 9763-F-815199 l 2.3 P0 #NSS-120 E DESCRIPTION 52618 Steam Generator Outline Model "F" 52619 Details Model "F" 2.4 PO #NSS-125 1
4 FP# DESCRIPTION
! . 50218 RCP Outline ( 7 sheets)
- $0274 RCP Final Casing Machining ( 2 sheets) ,
2.5 PO #N55-105
.: FP #
- , DESCRIPTION 3 50594 General Arrangement of Reactor Vessel
) 53621 General Arrangement of Reactor vessel
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f E Page 3 FIELD INSTRUCTION 132 2.6 PULLMAN PROJECT PROCEDURE IX-39
. P H Instruction Checklist Packages For:
VERTICAL STEAM GENERATORS ( SETTING REQUIREMENTS) 1-RC-EllA 1-RC-E118 4
1-RC-E11C 1-RC-E110
'- REALTOR COOLANT PUMPS ( SET' W,REQUIREwENTS) 1-RC-P-1A 1-RC-P-13
, 1-RC P-1C 1-RC-P-10 1
2.7 ASME SECTION III SUBSECTICN NB 2.8 FI-126 PULLMAN FIELD INSTRUCTION FOR AUTOMATIC WELDING j 3.0 RESPONSIBILITIES 3.1 The implementation of this instruction shall be the responsi-bility of the P-H Construction Superintendent.
3.2 The alignment of the primary loop piping shall be the responsi-bility of the P.H Containment Superintendent.
. 3.3 The alignment and final set of the Steam Generators. Reactor i
Coolant Pumps, and Reactor Pressure vessel shall be the responsi-bility of the P-H Mechanical Superintendent.
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FIELD INSTRUCTION 132 3.4 Implementation of the welding procedures and notification to QA/QC and/or ANI for inspection hold points as well as non-destructiv.e testing shall be the responsibility of the P-H Containment Superintendent and Production Welding Superintendent.
3.5 Implementation of the inspection program is the responsibility of the QA Manager through his assigned inspection personnel.
l
'f 4.0 GENERAL REQUIREMENTS 4.1 The setting of the steam generators 'and subsequent fit-up
- of the primary reactor coolant hot leg piping to the reactor vessel may proceed independently from setting and fit-up operations of the reactor coolant pumps and associated cold leg piping.
4.2 when practical, the actual counter-bore and min well verift.
cation measurements of each component.to be joined shall be
. taken in a minimum of four locations and recorded on a field l weld end preparation instruction sheet (Attachment A) prior I, to fit-up for each weld joint in the primary reactor coolant
- loop piping. This practice may be abandoned if detenfitned unnecessary as t result of no deficiencies being found in the first 6 joints checked.
- 4.3 The loop pipe CD should be protected from fereign debris, and where possible. it should be wrapped with a protective covering such as polyethelyne. The internal surface of the steam generators, reactor coolant pump casings, and primary coolant piping shall be kept clean by rencving all debris and
, dust as necessary, until system is sealed up. Refer to pro-ject Procedure XIII-4
- 4.4 Prior to final alignment of primary reactor coolant piping all welo end preparations on pipe. fittings and nozzles shall
. be liquid penetrant examined. PT preparation shall include grinding and wire brushing of all foreign materials a minimum of one inch back from weld edge preparation on the 00 and j through the counterbore region on the ID.
! 4.5 All weH joint bevels, when not being fitted prior to welding.
shall be covered and protected from dirt, oil, grease, etc. in
~O a manner acceptable to P-H quality control and in compliance with project Procedure XIII-4.
. 4.6 All loop piping shall be adequately supported in a manner which
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will facilitate fit-up and subsequently allow movement to accormnodate weld shrinkage. thus eliminating any possible undue
- stress in the weld joints.
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- Page 5 j FIELD INSTRUCT!0'i 137 j 4.7
- All operations and processes perfomed during the in-
- stallation of the prirrary reactor coolant loop piping which encompasses handling, rigging. fitting, welding inspection.
etc. shall be done Assurance Program.UESC .per Pullman RCE shallPower submitProducts applicableQuality Pullman welding procedures to Westinghouse for review. Westing-house shall have access to all records.
4.8 Each weld shall be preliminar11y fit-up in such a manner i
that will facilitate the establishment of a Base Material Acceptable Discontinuities Profile through Radiographic examination. The intent is to orient end preparation with
! respect to each other as close to final fit-up conditions as practical, preferable without consumeables. The ID and 6J of parts to be joined shall be marked forpanoramict base line R.T. The base line R.T. results shall be used as a comparison to subsequent infomational and final RTs using ID and 00 marks 4
for consistency of source and film placement. This opers+1on will preclude the unnecessary removal of acceptable e ce metal discontinuities which would otherwise be undiscernable is to
. location with respect to the weld deposited.
5.0 TRAM MARK PLACING AND WELD SHRINKAGE HISTORY
, 5.1 Just prior to welding. but after final fit-up shallow tram punch marks shall be applied to the comoonents utilizing a dual low stress center punch tool. Refer to Attachment B for tool sketch. Placement of the marks shall be as follows:
i 5.1.1 Place punch tool parallel to the axis of the pipe
- and perpendicular to the weld joint. Center tram
- 50 that the resultant punch marks will be approx 1
. mately equidistance from the weld edge preps (centered across wald.) The tram tool when centered, should
, result in punch marks approximately (1) one inch
, from the edges of weld preps.
5.1.2 For all SG position welds. (pipe axis horizontal) weld
. shrinkage measurement tram punch' marks shall be placed
. at 12:00 top center. 3:00. 6:00 and 9:00. From 12:00 to 3:00 shall be established by facing toward the nearest
- vessel the pfpe is being connected to and rotating 1 clockwise 90 from 12
- 00 to 3:00.
1 5.1.3 For all other welding positions, weld shrinkage
,, measurementtrampunchmarkssgallbeplaceddue j North. South. East and West 90 apart.
! 5.1.4 Punch marks, once applied, shell be precisely measured 2 from center to center across the weld joint after the i; joint is final fit-up and prior to welding and recorded on " weld shriakage history record" Attachment C.
I Measurements s..all be repeated and recorded as follows:
2
- 5.1.4.1 After reino'al v of blocks (when used per'6.0)-
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FIELD INSTRUCT!0't 132 :
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5.1.4.2 After completion of root pass plus (5) 3 five additionalweld layers or approximate de90 sit of 5/16" to 3/8".
5.1.4.3 After completion of deposit to T/2 level (approximate)
'i 5.1.4.4 After completion of deposit to 3/4 T 1evel
. (approximate) -
- 5.1.4.5 After completion of final deposit, but before
. any grinding for flushing of weld reinforcement.
] 5.1.5 The recorded measurements shall be reviewed by the
- Welding Superintendent to verify that axial shrinkage is being maintained. Ajdustments within the welding program parameters may be made to compensate for lateral movernent and additional measurements for information
. taken to assure adequate compensation methods are being employed.
6.0 FIT-UP AND WELDING
. 6.1 The use of temporary blocks in weld joints is permissible.
! When used, they shall consist of compatable material with 1 the base material (s) and shall be made of small diameter sch.
80 pipe traceable to a certificate of compliance as a
- minimum.Four (4) blocks approximately two (2) inches long .
s%411 be placed fengthwise in the weld joint groove at approximately 90 apart.
i 6.1.1 Preheat shall be established prior to any welding operation being performed including tack welding at fit-up. Preheat shall be a minimum of 60 F and controlled in accordance with
$ the applicable field welo process sheet, field isnmetric and project procedures.
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6.1.2 Blocks shall be tacked in place at the time of fit-up utt-1 lizing a manual GTAW weld process. Tacks shall not exceed t one (1) inch in length with no less than 1/16" b* tween successive tacks.
2
. 6.1.3 Upon completion of root a'nd het past tn the accessible areas b1ocks small be removed by grinding.(The use of hamer blows
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j is strictly orchibited.) Root and hot pass shall be preoerly prepared by grinding at stoos & starts, to facilitate centinuance of welding.
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. e FIELD INSTRUCTION 132
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t 6.1.4 Temocrary block removal areas shall be liquid penetrant examined per applicable process sheets.
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- i. 6.2 When used, backing rings may be of more than one piece to l
facilitate fit-up. Splits need not be welded. Upon completion of weld, backing rings shall be removed, removal area visually inspected. and liquid penetrant tested.
6.3 Sequencing of fitting and welding the primary reactor coolant individual loop piping shall normally be as follows:
6.3.1 Hot leg - steam generator to RPV 6.3.2 Cold leg - reactor coolant pump to the RPV I
i 6.3.3 Steam Generator 40' ELL (must be preceeded by hot leg ref. to para. 6.5.4.1}
6.3.3.1 After completion of hot leg. cold leg, and 40' ELL. measurements for the closure pieces shall be taken. The center of and the outlet of the 40"the RCP ELL shall inlet nozzle be precisely loe 'ed. East West and North-South coordinate an, elevation to within 1/15". Horizontal variance across the weld prep end shalf also be checked to within 1/32" on both the 40 ELL and the RCP suction nozzle.
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FIELD INSTRUCT!CN 132 l
. 6.3.3.2 The Chief Field Engineer, through the Containment Field Engineer, shall be responsible to submit measurements to Westinghouse NCD Site Per::.mel.
No weld shrinkage allowance shall be included in As-Built measurements. Excess material for shrinkage is to be addressed separately by
, contractor, UEAC Welding Department and Westinghouse ,
4 NCD Site Personnel.
T 6.3.4 Cross-over Leg (closure spools)
G.3.5 Paragraphs 6.3.1 and 6.3.2 hot leg and cold leg work may be interchanged. These installations are inde-pendent of one another, however, other work must follow ;
the sequence given above.
6.4 The individual loops (1,2,3, & 4) may be secuenced independent of one another and worked individually or simultaneously at the discretion of the Methanical Superintendent and the Piping 4 Superintendent.
6.5 SEQUENCING OF WELDS 6.5.1 All fit-ups and tacks shall be performed in accordance with appilcable Pullman welding procedures and other instructions as assigned to the field weld process sheet and field drawings (isometrics.) A minimum 1/32" gap shall be maintained prior to weld out on all joints or that spect-
. fied by the assigned welding procedure whichever is greater.
6.5.2 Hot Leg
- 6.5.2.1 The hot leg pipe spool shall be tesorarily fit-up to the RPV in a level plumb condition. The steam generator shall then be drifted into place, under the direction of the Mechanical Superin-tendent, thus enabling SG to hot leg weld fit-up
. to commence. Once fit-up is made, utilizing
- slight elbow roll if necessary, the RR-Hot leg
- fit-up may be finalized maintaining hot leg in a i level condition utilizing shims on the temporary support system if necessary.
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- 6.5.2.2 Tram Soints shall now be applied per section 5.0 and initial measurements takefi and recorded for each weld, as assigned on the applicable iso-l metric.
- 6.5.2.3 Welding may now proceed per applicable weld pro-
- cedure(s) with both welds being welded simul-taneously and weld shrinkage measurements being c taken, observed for possible proolems, and
- , recorded in accordance with Section 5.0. If
- welding for any reason cannot be maintained
- on both joints simultaneously, then welding will
- cease until such time as repairs to equipment
- can be made and both welds can continue.
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FIELD INSTRUCTION 132 i 6.5.2.3 (Cont'd)
Simultaneous welding will continue until both deposit
')
/ levels are out to root plus (5) five weld layers and fshrinkage recorded. Welding may then proceed with little regard in attempting to maintain both joints
- at the same weld pass layer or for that matter steal-
, taneous. The steam generator will be free to move for weld shrinkage comoensation throughout the welding process.
6.5.2.4 Radiographic examinations for information shall be per-formed periodically during the erection cycle. (As a
, minimum at the following stages.)
I
. A. Base-line per paragraph 4.8 above at pre fit-up (approx-imate 'a" root gap and 1/8" hi-1%, or better fit.)
- }*. , B. Root plus (5) five weld layers.(minimu=i). Maximum e dependent upon end of shift. (See note below.)
, /k C.T/2.(Minimum) f .k D. 3/4 T (Minimum)
E. Final for ASME Section !!!. Subsection NS acceptance.
,' This is a Mandatory R.T.
$ k NOTE: Amount of weld deposit is approximate for subparagraphs B.C & D above; therefore, in order to maintain production continuity, welding may
, proceed until such time as R.T. can be performed. but shall net extend beyond the end of the same day night shift.
. F. Base-line radiographs at the RPV and S.G. are required
. at fit-up of the het leg spool piece per paragraph 6.5.2.1 and 6.5.2.2 above. The same R.T action shall take place at Cold leg fit-up and cross-over fit-t'p.
., 6.5.3 COLD LEG ,
. 6.5.3.1 Same as 6.5.2.1 exception substitute reactor coolant pwip
. for steam generator.
6.5.3.2 Same as 6.5.2.2 6.5.3.3 Same as 6.5.2.3 f
6.5.3.4 Same as 6.5.2.4 0
6.5.4 40 ELLS i
a 6.5.4.1 Upon completion of the two (2) hot leg welds (initially j cagped off) within a particular loop. the corresponding
- 40 ELL may be fit-up and tacked independent upon
- corresponding cold leg status. Care must be taken to
- plumb this fitting in such a manner that the outlet side
- 1s as close to perfect horizontal as possible. Horizontal 4 variance....
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6.5.4.1 (cont'd)
- across the outlet weld prep exceeding 1/16" must be reported to the P-H Chief Field Engineer
,; for his concurrence to comence welding.
. 6.5.4.2 Once proper "it-up and tack is completed in accordance with the assigned weld procedure ,
the tram points shall be applied per Section
- 5.0 and initial measurements shall be taken and recorded.
6.5.4.3 Welding may now proceed per applicable weld
- procedure and field weld process sheet with weld shrinkage measurement being taken, observed for possible problems, and recorded per Section 5.0 6.5.4.4 Same as 6.5.2.4 6.5.5 CROSS OVER PIPING (CLOSUREPIECES) 6.5.5.1 The crossover closure egnsists of two pieces. one from the 40 ELL. the other l
to the reactor coolant pump suction nozzle.
- For the purpose of identification. only within ghis instruction, the first piece from the (40. ELL) shall be known as Piece "A" the other as Piece "B".
6.5.5.2 Fit-up and tack Piece "A* to the 40' ELL in
'! a pennanent manner per applicable field weld I a process sheet but do not weld. Fit-up and tack Piece "A" to Piece "B". same as above.
" but do not weld. Align Piece "O" to RCP suction nozzle vertically. The horizontal aliganent will be beyond the RCP the theo.
" " retical shrinkage amount to be incurred at the i weld from Piece "A" to Piece "B". .l-i 6.5.5.3 Temporary supports shall allow for shrinkage t incurred while making weld berween Piece "A" to Piece "8". Apply tram points to the weld between Pieces "A" and "B". Take and record
- measurements per Section 5.0 Comence
- welding Piece "A" to Piece "B". Weld shrinkage measurernents shall be taken, observed for i possible problems and recorded in accordance with Section 5.0 RT as required on field weld ii process sheet.
i; 6.5.5.4 When alignment is reasonable at the weld from Piece "B" to the RCP suction nozzle, cease I welding at weld from Piece "A" to Piece "S".
- Fit-up and tack weld from Piece "B" to the RCP. Check fit-up gnd tack at weld from
- Piece "A" to the 40 ELL. If acceptable, apply tram punch marks at both welds. Piece "A" to j 40 ELL and Piece "B" to RCP. Record measurements in accordance with Section 5.0 i _ __
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- FIELD INSTRUCTION 132 I
i 6.5.5.5 Comence welding on two new welds and resume
- I welding on weld from Piece "A* to Piece "S*.
Take weld shrinkage measuremnets. observe for l'
[*
s possible problems and record in accordance with
' Secticn 5.0 RT as required by applicable field weld process sheets.
)
7.0 INSPECTION *
. 7.1 All operations and inspections shall be controlled through
- utilization of Process Sheets per Project Procedure VI-5.
Weld location and identification shall be depicted on field 8 drawings (isometric) per Project Procedure !!! 5. l 7.2 Those inspections that are deemed mandatory will be e esignated as hold points on the applicable process sheets.
4 7.3 Attachments A and C will accompany the applicable process sheets and utilized as required by this instruction 8.0 RECORDS 8.1 Completed process sheets and attachments thereto shall be e
controlled and maintained in accordance with Pullman Proce-dure XVII-3.
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. QA APPROVED DATE ^
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. ,Rev.l DATE BY E GA . DE$cR Pfl04 7,47,qj jg,.t.sil6Ms ISOMETRIC ORAWING NEW HAMPSHIRE l
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1 lt:L O.Wl:.L O tHO Fr4EPAlWil0N i i ytyt*'entA ,. y .q.y. INSTRUCTION
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..g . . a FW NO.
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. COUNTERBORE AND MINIMUM WALL VERIFICATION
. C-BORE MIN WALL C-B ORE MIN WALL l AE A A AE A A y g BF 3-F B B B B
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- E_ E.
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. SIDE OF WELD S10 E OF W E f.D INSTRUVENT USED: INSTRUMENT USEO 4NS TRUMENT USED INSTRUMENT USF,.C, i e TYP E SER. TYPE SER TYPE SER TYPE SER j OCINSPECT10lN VERFICATIONbirwloart QC.!NSPECTION VERIFK~.ATION twster.TcR o37:
f.Courf T tR E'JRC QlTn41N' TOLERANCC 1(QVNTERGORE WITMtN TCtCAAUCI
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REF. DWGS.W c .1,1,'. 2 OTHERECTS 19/272 A
.03 NO. 7035
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3, REY. DATE SY E DESCRIPfl05 g.j ;.t ISOERIC DR AWING j Gd i z.7,? r z a, NEW HAMPSHIRE
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ATTACHFENT C 4
FIELD INSTRUCTION
?
WELD SHRINKAGE HISTORY RECORD r~
SYSTEM /LINE/ ISO NO. FIELD WELD NO.
~
J After setting, fit.up, and readgF to weld.
initialTemperature Base Metal Tram Mark Location 12:00 3:00 6:00 9:00 Legged by
. N $ E W Cate After melting Base Metal the consumable insert or gepositing root pass over backing ring.
Temperature F
, Tram Mark Location:
12:00 3:00 6:00 9:00 Legged by 3
N 5 E W Cate i
After ccepletion of root portion plus 5 passes. Base Metal Temperature oF
. Tram Mark Location:
I -
12:00_ 3:00 6:00 9:00 Logged by
, j N $ E W cate
~.
i After completion of t/2 deposit (approximate) Base Metal Temperature oF Tram fiark Location:
4 12:00 3:00 6:00 9:00 Logged by N 5 E W Date 5
d
\
"4 After completion of 3/4t deposit (approximate) Base Metal Temperature OF Tram Mark Location:
- 12:00 3:00 6:00 9:00 Logged by
]a N S E W __ Oate i
5" After completion of final weld deposit. Base Metal Temperature CF
- Tram Mark Location
i 12:00 3:00 6:00 9:00 Logged by
.. N 5 E W Cate
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REF. DWGS.'.E f'REETi; 1,'t/ hg,, JOB NO.7035 us a ew O
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P.P.P. "A" SHEET =- Pr V.
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ORAWW l CNK'SAPPir9 SEABROOK STATION 4 Puffman~~Power Products
- a .rf.j., . run .,, ; .r e T r gw j 7, y c, P PUBLIC SERVICE of 3 nEv.. caTE l BY f E,0A OtSCRIPTION i.i.e r t .v .. i , . , Mcw u Aunquenc ISOMETRIC ORAWING ,l
- _ , _ . . . . ... . - . . . .--~ - - - - - - - - - - - - = - - - - - - - - - -
FIELD GENERAL CONSTRUCTION PROCEDURE
- 1. FGCP-1 . Development and Preparation of Field Construction Procedure
- 2. FGCP Drawing, Specification' and Document Control
' FGCP Receiving, Inspection and Storage of Nuclear and Safety-Related Equipment and Ma 4
FCCP General Preventive Maintenance and Minimum St!orage Requirements for In-Place Storage of Permanent Plant Equipment
- 5. FGCP-8 General Housekeeping During Construction of Nuclear Plants i (. FGCP Preventive Maintenance and Protection of Nuclear or Safety-Related Equipment 7.
FGCP Maintenance, Inspection, Testing and Operation of Construction Lif ting Equipment
- 8. FGCP Interface Tagging Procedure
% FGCP The Indoctrination of Construction Supervisory Personnel
- 10. FGCP Concrete Scheduling and Placement Che*cklist Procedure for Tunnel and Marine Contrac
- 11. FGCP Handling of Nuclear and Safety Related Material and Equipment 12.
FGCP Control of Welding and Brazing Filler Materials Nuclear, Safety Related and Non-Safety Related
- 13. FGCP Special Cleaning Processes for Preventive Maintenance 14 FGCP Security System Drawings and Documents
,CP Field Foreign Printing Procedure
- 16. FGCP Transferring of UE&C Equipment Tag Numbers
- 17. FGCP The Construction Report for Concrete Containments per ASME Sect. III, Div. 2 Work 4
- 18. FGCP Installing and Reading Rod Extensometers in Cooling Water Tunnels Seabrook Station
- 19. FGCP Controlled Access to Level "D" Storage Areas for Seabrook Station
- 20. FGCP UE&C/ Contractor Interface on Releasing Equipment and Tanks i 21. FGCP Turnover of Instrumentation From Construction to Start-up i
- l. 22. FGCP Area Interfacing l 23. FGCP Loa'd Testing Kroll K-10000 Crane I
24 FGCP Load Testing Kroll K-10000 Crane (Modified) l l
, 'S i
()
I i
, . . . . . . - . . . . . . - - - m-- - - - - - - - - - -
s*s FIELD ADMINISTRATION CONSTRUCTION PROCEDURE '
- l. FACP Project Instruction for Handling Contractor Nonconformance Reports
- 2. FACP Handling of " Contractor Incident Interface Reports" s
FACP Handling Contractor Engineering Documents on Westinghouse NSSS Material, Equipment and/or Components for Required Interface with Westinghouse Site Representative
- 4. FACP Construction Interface Requirements for Release of Material from UE&C FQA
- 5. FACP Initiating and Handling of Construction Non-Safety Notifications l
- 6. FACP Handling of Contractor Material Deficiency Reports O
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- 1. AP-15 -
- Chansco to Project Docurento, Enginscring Changa Authorizatica (ECA) cnd Rzqunst ,
For Information (RFI)
! 2. AP- 39 -
As-Built Documents
- g {,C I , 3. EQ-1 -
Class IE Equipment Qualification Requirements i
, 4 'WPS-1 -
Material and Processing Requirements for Nuclear Power Plant Components
- 5. MPS-2 -
Material and Processing Requirements for Non-Nuclear Components 4
- 6. MPS-3 -
- Material and Processing Requirements for Bending of Welded Studs, Reinforcing Bars and Anchor Bolts
, ! 7. QAS-1 -
5 Administrative and System Requirements for Nuclear Safety Class Items i 8. QAS-2 -
Quality Assurance Administrative & System Requirements
- 9. QAS-3 -
' Quality Assurance Administrative and System Requirements for Safety-Related Electrical Equipment
- 10. QAS-4 -
Quality Assurance Administrative & System Requirements for Site Contracts
- 11. QAS-5 -
Quality Assurance Administrative and System Requirements for Installation of Non-i 12. RM-1 Safety Related Components in Seismic Category I Buildings Instructions for Site Racords Management System
, 13. WS-1 -
Requirements for Welding and Nondestructive Examination for Nuclear Pressure-Components and Nuclear Power Piping -
' J,4. WS-1-NE
, Requirements for Welding and Ncndestructive Examination for Nuclaar Class MC i 4 Components i 15.
WS-1-NF - Requirements for Welding and Nondestructive Examination for Nuclear Components Supports
- IV' 'S-2 -
Requirements for Welding and Nondestructive Examination for Non-Nuclear Pressure Components and Non-Nuclear Power Piping 1
17(. S-3 -
Requirements for Welding and Nondestructive Examination for Structural Steel
- 18. WS-4A -
Requirements for Welding and Nondestructive Examination for Nuclear Containment Structure Liner i
- 19. WS-4B -
Requirements for Stud Welding and Nondestructive Examination for Nuclear Containmer Structure Liner
- 20. WS-4C -
Requirements for Mechanical Splicing and Nondestructive Examination of the Rein-forcing Bars Spliced by the Cadweld Method
- 21. WS-4D -
Requirements for Mechanical Splicing and Nondestructive Examination of Reinforcing Bars Spliced by Swage Method l
- 22. WS 5 -
Requirements for Brazing and Nondestructive Examination and Test Methods for Nucles Pressure Components *
- 23. WS-6 -
Requirements for Thermit Welding of Rails t
3_24. WS-7 -
l Visual Inspection Guidelines for Nuclear Power Plant Components 1 -
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331.1 WPS 05/27/82 CARBON STEEL
, g' Doc. Desc. Rev. Rev. Date CWS-1 04 07/24/80 1-I-1-KI-12 04 07/21/81 8-I-1-BR-2 03 06/02/81 10-I-1-0B-1 02 06-02-81
'~
11-I-1-0B-2 01 06-02-81 12-I-1-0E-12 02 06-02-81 150-I-1-KI-Al 06 03-Oi'-82 151-I-1-BR-Al 04 03-01-82
. STAINLESS STEEL 24-I-8-KI-12 01 01-19-79 26-I-8-0B-2 01 06-05-19 27-I-8-0B-12 02 02-17-81 f, ,
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29-I-8-08-1 01 . 06-21-79 39-I-8-BR-2 01 04-02-79 l
l 250-I-8-KI-Al 03 12-02-81 251-I-8-BR-Al 03 12-08-81 505-I-45-KI-1 01 04-16-82 510-I-45-OB-1 01 04/28/82 l ,
PQR 505 00 03-04-82 l I PQR 510 00 03/16/82 l CARPENTER t -I-1 i l
i 408-I-CARP-20-0B-1 01 06-25-79
! 409-I-34-0B-1 00 06-18-79 27-A-I-OB-12 00 09-15-80 29A-I-8-0B-1 00 12-19-80 i 412-I-34-BR-1 01 12-19-81 1 -
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. 331.1 05/27/82 CHROME
_RE. REV. DATE 44-I-4-KI-12 01 07-25-79
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01 07-25-79
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50-I-5-BR-2 02 06-02-80 61-I-5-0B-12 02 12-11-80 59-I-4-BR-2 01 06-02-80
PQR 218 01 06-02-80 PQR 217 00 04-06-78 PQR 204.1 00 06-02-80 PQR 206.1 00 06-02-80
/ ' fQR 203 '00 07-07-80
\)DISSIMILARMETALS 71-I-4/1-KI-12 02 06-02-80 -
73-I-4/1-03-1 01 07-25-79 i
74-I-5/1-KI-12 01 07-25-79 336-I-4/GE-0B-12 01 5-11-82 337-I-4/GE-BR-12 01 5-11-82 j PQR 336 01 5-11-82 i . 77-I-8/1-KI-12 01 01-19-79
[ 79-I-8/1-03-1 01 01-19-79 1
80-I-8/1-05-2 01 06-05-79 j 81-I-8/1-05-12 01 01-19-79 i
! 84-I-8/1-K-12-F43 01 07-25-79 i
! 00-I-8/45-0B-1 00 02-18-81 1 ;
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- .. . 331,1 05/27/82 331-I-1/cE-0B-12 02 -
05/11/82 332-I-1/cE-BR-12 01 05-11-82 PQR.302 00 04-06-78 PQR 304 00 04-06-78 PQR 305 00 04-06-78 PQR 331A . _
00 02-10-82 _
PQR 331B 01 05-11-82 PQR 340 - 00 04-16-79
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SECTION III 05/27/82 -
CARBON STEEL
- Doc. Dese. Rev. Date GWS-III 04
. 02-12 ,82
' ~ ~
,- IT1-III-1-KI-12 04 05-28-81 IT8-III-1-BR-2 05 05-28-81 IT10-III-1-0B-1 03 05-28-81 IT11-III-1-0B-2 03
, 05-28-81 .-
IT12-III-1-0B-12 03 05-28-81 150-III-1-KI-Al 06 03-01-82 151-III-1-BR-Al 04 03-01-82 PQR 016A & B 00 04-14-78 I
PQR 017A & B 00 04-14-78
, PQR 019A & B 00 04-14-78 g PQR 020A & B 00 '. 04-14-78
,, ] PQR 021A & B 00 04-14-78 hPQR028A&B . 00 04-28-78 PQR 029A &_B 00 -
09-08-78 PQR 0475 & B 01 04-13-81 STAINLESS STEEL 24-III-8-KI-12 04 05-26-81 t-26-III-8-0B-2 03 06-16-81 f, 27-III-8-0B-12 06 06-16-81 i *:
29-III-8-0B-1 ._03 06-21-79
. l' ,
R 250-III-8-KI-Al 03
- i. 12-02-81 e
251-III-8-BR-Al 04 12-08-81 PQR 126 01 04-13-81 PQR 104A 00 05-21-81 1
m ,PQR.106 -
01 02-08-79 E
PQR 109 00 04-06-78 t-PQR 110 01 02-08-79 l U i i .
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, STAINLESS STEEL CONTINUED Rev. Rw. Date ,
PQR 121 00 06-14-78
\
PQR 120 00 06-19-78
/ \
PQR 114 00 04-02-79 s CARPENTER 408-III-CARP,-20-OB-1 01 06-25-79 409-III-34-CB-1 00 06-18-79 PQR 508 00 02-06-79 PQR 509 00 05-09-79 DISSIMILLAR METAL 77-III-8/1-KI-12 03 06-05-81 79-III-8/1-0B-1 02 06-05-81 81-III-8/1-0B-12 03 ,
06-05-81 84-III-8/1-K-12-F43 02 07-25-79 653-III-3-CL-2 01 04/30/82 PQR 308 02 05-21-81 3
- t-PQR 309 00 04-06-78
%.)
PQR 310 00 04-06-78 l PQR 311 00 s 04-06-78 PQR 313 .
00 04-06-78 PQR 324 00 05-21-81
, PQR 653 ,00 04-30-82
{- CDiENT LINED
. GWS-CS-CL 03 11-07-80 CL1-1-BR-2 02 ~
01-26-82 PQR 13A 00 03-27-78 CL2-1-0B-2 00 08-14-78 i PQR 010 00 03-27-78
. AWS-I-l' 04 10-13-81 AWS-I-2 03
10-13-81 AWS-SW-1 03 12-30-80 l
l BRAZING
! f'S i
B1-P107-P102-n101 B2-P197-F103-H101 00 00 03-17-81 09-20-78 B3-P107-F103-H101 00 03-23-79
+ . . .
~_.._...,-_.... ___ _ _ _ , , . _ , _ . . . _ , , , , _ , , , , _ _ _ . . _ , _.
. . - l DOCUMENT INDEX l 05-28-82 D0C. NO. REV. NO. REV. DATE, TITLE
'N II-2 ,f( 04 10/23/81 NDE Personnel Control and Admin. Examination, Quals, and Certification
'II-3 ,( 02 01/07/80 Control and Admin. of Examination , Qual, and Certification of NDE Level III Personnel
[ II-4 j 05 10/15/81 Inspec. and Testing Personnel Control and Admi
, Training Exam, Qual, and Certification II-5 05 . 07/31/81 QA Engineering Personnel Control and Admin.
of Training Exam. Qual. and Certification II-8 g( 05 06/17/81 Welder Performance Qualification II-8BR 00 11/09/81 Brazing Performance Qualification III-4 4 [' 10 02/24/81 Drawing and Design Control l
. III-5 01 12/01/78 Field Installation ISO, Preparation
?
III-6 00 01/30/79 Field Installation Pipe Support Dwg. Prep.
IV-14 02 01/30/79 Central Purchasing
-s IV-5.18.1MC 01 01/26/82 Purchasing Specification
- t. .
! V-2 01 07/17/80 Safety Tagging of Equipment j VI-l 04 06/26/81 Document Control t
! VI-4 02 07/10/80 Pipe Support Dwg. and Doc. Control i
VI-5 10 02/07/82 control of Process Sheets and Weld Stores Req.
- VI-8 01 04/07/81 Use of DSR t
. VII-l 05 03/05/82 Vendor Qualification VIII-1 1k 06 08/25/81 Identification of Materials, Parts, Components
\.t VIII-2 03 03/13/80 Material and Sub-Assembly Withdrawal Proc.
JS-VIII-3 ( 08 03/10/81 Control of Weld Material
- j VIII-8 01 12/14/81 Hanger Interface Procedure l ) IX-1 09 10/26/81 Installation of Inspection of Concrete
- _) Expansion Anchors and Wedge Anchors I
-. ._ ....m. - . . . - - - - - - . - + ~ -.
-ef-
- . . . -- - -__ .. - - - - .. . . - - - . - - - - . - - - . - . - - - ~ - - . - - - .
DOCUMENT INDEX
.05/28/82 DOC. NO. REV. NO. REV. DATE TITLE IX-3 01 9/22/78 Fabrication and Field Installation Specs, for k' 'N.
Nuclear Power Plant Components, Piping Sys. anG Appurtenances ASME Section III IX-5 08 08/03/81 Installation and Inspection of ASM". III and ANSI Be1.1 Threaded Fasteners for Mech.
Flanged Joints JS-IX-6 05 02/18/82 Instil. & Insp. Sect. III Comp. Sup. (NNS)
JS-IX-14 06 01/30/81 Defect Removal and Repair by Welding IX-16 03 02/02/82 Field Bending of 2" and Smaller Nuclear and B31.1 Pipe IX-27 03 05/21/80 Coal Tar Protective Coating and Lining for Steel Water Pipe Lines Enamel and Tape IX-29 05 04/10/80 Specification for Purge Dams IX-30 07 12/15/81 Cment Lining Repair and Grouting .
IX-31 00 08/03/78 Application of X-Pando to Pipe Joints IX-39 01 04/07/81 Handling, Installation, testing and Inspec. of Safety Related ' Equipment
[- IX-43 05 01/29/82 Preheat, Interpass, and Post Weld Heat Treat-ment IX-46 02 01/08/81 Ultrasonic Thickness Measurement of Material
. IX-47 00 02/28/80 Procedure for Core Drilling II-49 00 06/06/80 Hornflex Sealant of Joints i
i IX-54
?
- l 04 02/04/82 Installation and Insection of Non-Safety Equipment
-i
- IX-55 01 01/27/81 Disassembly / Reassembly of Valves i
II-57 01 08/11/81 Contr. Incident Interface Report t
IX-60 00 07/02/,81 Thermocouple Attach. by Capacitive Discharge
[ .
IX-61 01 09/08/81 Condenser Install. and Erection IX-63 02 02/19/82 3 l 1 IX-67 01 05/05/82 Te$es$adRepairf mper M I B31.1 Noncritical, No r X-4 04 11/18/80 Final Inspection Procedure (Field) 1 I
^
X-5 07 06/26/81 Field Receiving Inspection Procedure j X-9 06 03/24/82 In-Process Field Inspection Procedure L
i.
DOCUMENT INDEX 05/28/82 DOC. NO. REV. NO. REV. DATE TITLE ,
(.. X-10 h 06 08/07/81 Weld Monitoring j X-11 Ol' 02/16/81 Visual Examination (General)
X-21 01 08/11/81 Prep. of Code Data Reports
, XI-1 06 02/04/82 Field Leak Testing, Hydro and Pneumatic XII-2 09 12/03/81 Calibration of Tools, Measurement & Test XIII-4 06 . 04/05/82 Cleaning Procedure (Field) i.
XIII-5 02 01/18/80 Field Storage Procedure XIII-9 06 02/10/82 Field Handling of Materials and Equipment XIII-11 01 01/18/82 Standard Method of Protecting Ends of Fabricated Pipe for Nuclear Service JS-XIII-16 02 02/24/81 Sand Blast Cleaning of Carbon Steel Pipe i
XV-2 12 12/15/81 Handling of Non-Conformances (Field)
XV-3 04 08/11/81 Reporting of Defects and Non-Compliance to 10CFR Part 21 XV-4 05 02/09/82 Hold Tag Usage XVI-2 N 04 10/30/81 Corrective Action XVII-3 08 01/29/82 Records Management
[ XVIII-1 03- 03/26/82 Internal Auditing Proc. of Field QA Program
! . by QEG ,
j I- XVIII-4 00 ol/21/82 Site Internal Audit Program
. IX-RT-1-W77 05 09/01/81 Radiographic Proc. IR-192 Butt Weld Pipe f
IR-192 L
! PQR-RT-1 . 01 07/17/81 NDE Proc. Qual. Record Butt / Weld Pipe IR-192 IX-RT-3-W77 03 06/18/80 Nozzle Welds Winter Addenda 1977 i
( PQR-RT-3 00 08/30/78 Nozzle Welds Winter Addenda 1977, (Proc. Qual.)
{-
l IX-PT-1-W77 03 10/30/80 Liquid Penetrant Exam. to ASME Sect. III j PQR-PT-1 00 09/06/78 Proc. Qual. for Liquid Penetrant Exam. to ASME Sect. III i
q PQR-PT-2 00 10/14/80 Liquid Penetrant PQR
- a. .. . . . _ _ _ _ - - ~ . - - . . - . . -
~ . - - . -
, . . _ . . ~~.~ :* . ~ '.~ ' . . ^ :c.~G ~ . - ~~ ~ -
'~'
_ . _ . . . :. .: '*~""~" Y
' DOCUMENT CONTROL '
05/18/82 DOC. NO. REV. NO. REV. DATE TITLE f
IX-MT-1-W77 06 02/17/82 Mag. Particle Dry Powd. Continuous Prod.
j '
Method PQR-MT-1 00 09/06/78 Proc. Qual. for Mag. Particle Dry Powd.
Continuous Prod. Method IX-MI-3-W77 02 12/09/81 Mag. Particle Dry Powd. Con. Method Yoke Technique IX-UT-1-W77 . 01 10/24/79 Ultrasonic Exam, of Weldment 1
PQR-UT-1 00 ~ 09/07/78 Proc Qual. Ultrasonic Exam. of Weldment
, IX-UT-2-W77 01 10/24/79 Ultrasonic Exam of Weldment of Seamless
& Weld Tubular Material Winter Addenda i
PQR-UT-2 00 09/07/78 Proc. Qual. for Above UT-2 Title II-UT-3-W77 00 07/18/78 Ultra Thickness Measurement Winter Addenda PQR-UT-3 00 09/07/78 Proc. Qual. Ultra Thickness Measurement PQR-MT-2 00 10/28/80 Supporting Proc. Qual. Rec.
IX-UT-1-PCR 00 12/01/80 Ultrasonic Exam, ot Thermite Butt Welds in
~
Rail
\ IX-Rr-6-W77 00 4/13/82 IE Exam. of Class 1 S W i
-) POR-Rr-6 00 4/7/82 PQR NF Supports IR-192 l
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s - y Recommended CAT Inspection Outline
, I. Quality Assurance Program
- \
A. Separate and diverse contractor QA programs
- 1. consistency with UE&C specifications
- 2. application of prerogatives (eg: choiceofHoldPoints)
- 3. adequacy of control B. Adequacy of coverage
- 1. suggestion that optimistic FLD(11/83) is subjugating QA authority to construction expediency
- 2. multishift operation with 6000+ workers
- 3. division of second level surveillance responsibilities between YAEC & UE&C II. Design Controls (Ref: IE Module 37055B)
A. Site Engineering reorganization
- 1. site design authority
- 2. site design verification B. Design change control
- 1. numerous Engineering Change Authorizations (ECA)
- 2. new UE&C Administrative Procedure AP-15
- 3. control of drawing revisions when mods are not ECA based j C. Programmatic Issues
- 1. construction tolerances vs. design bases
- 2. cookbook support options-HVAC, electrical, instrumentation
- 3. ASME Code boundary changes & questions i
III. Project Management A. Control of multi contractors
- 1. Interface Controls - UE&C Procedure FGCP-31
- 2. assignment of responsibility for future work (eg: ECA changes) ,
B. Problem identification and solution
- 1. consideration of interdiscipline generic implications
- 2. relationship with QA/QC IV. Construction Controls Specific Issues $P
particularly electrical contractor
- 2. Trending of pipe weld repairs and piping contractor problems s
- 3. Qualification and training of ASME welders
- 4. UE&C Beam Verification Program - structural adequacy of beams to f ', carry supported loads 1 Y
l V. pr.ocurement Controls l
Scope of Supply r"N' A. '
- 1. test data and purchase requirements scope installed l configurations (eg: cable tray)
- 2. approval and documentation of all material substitutions .
I B. Adequacy of receipt inspection '
- 1. qualification of receipt inspectors to check technically oriented criteria
- 2. availability of current procurement data at time of receipt inspection
- 3. effectiveness of corrective action for identified vendor inspection failures W kl.AML $
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_ _ _ . . _. - - -- - -- ~~ ' ' ' , l 1 I UE&C FIELD QU _ j.tSSURANCECROUP [
~.' -
.' )
i *
- I i
- . Assigned to YAEC'QA. t i
- Field Superintendent'- QA e !
{, , J. O. Azzopar'i d D. C. Lambert (2160) J. Briasco Administrative Assistant * #
- D. Horton !
B. E. O'Connor (2209) H. Lupton I-
+ B. J. Mizzau , ,
Secretary A. Neilson { I f W. T. O'Brien ; i . K. J. Heath (2166) (On site 4/5/82)' R. J..Roellig
- .. I 1 .
i = ! I 1 ) QA Supervisor - R&S t i ! QA. Supervisor-Records & D.S. : QA Supervisor - C/S , { C. D. Hanson (2087) { !
, A. H. Ayers (2163) R. D. Tancibok (2157) i R. S. Lentz (2161) '
OA Engineers j: -QA Engineers QA EnRineers ' '
*C. O. Long (2162)
, *R. H. Beaumont (2164)
J. Bodell (2163/2164) N. A. Chambkrs (2167) W. L. Chapman (2165) ' W. D. St. John (2164), P. E. Couchman (3008) i T. J. DeArmit (2162) C. S. Waitkus (2164) N. C. Hargrave-Thomas (3008)
.J.
i J. C. Cries (2162) - E. Boscoe (2163/2164)
- R. E. Herman .(2169)
H. I. Jones (2165) C. H. Jameson (3008) I C. P. Honette (2165) K. E. Price (Clark-2163) J. P. 'Jensen (2169) ' F. C. Tilson (2166)
- H. E. Shellehamer (2169) '
M. A. Zelepsky (2169) s i
*Rosponnihlo in the absence of the QAS Harch 24, 1982
~ ~
.. - _ __ Za i.T. _ i .
.-~ '._. J Z EXIT INTERVIEW CAT /NDE Van Inspection 32-06 W'N 1 Perk.d: June 21 - July 2, 1982 s
1 Scope and
Purpose:
Determine the effectiveness of the licensees project management i
'through examination of project, design, construction, and procurement control and quality
_,acsuranc,s. -Assess the velding and NDE program by independent nondestructive examinations. Findings: j . P-H audits identified weld monitoring as a deficient area in two successive
) audits. The next audit failed to follow-up in that area due to a lack of
,9.
time.
- 2. (Engineering) (V) The ECA review / approved cycle was not in accordance with
/J-15 in that one individual issued, dispositioned and approved NCR's on more than one occasion. ,
- 3. (III) NCR's containing design change information (accept as is/ repair) are -
7
~3 not reviewed by original design group. (This awaits any mitigation)
- 4. (VI) ECA change log 8, dated June 3, 1982, was in use at'the control drawing j section. The June 23 edition was issued but not in use.
- 5. CIIR's are not tracked to assur's that design /NCR documents are issued as dispositioned.
I
- 6. Engineers responsible for NCR/CDR review are not aware of 10CFR 50.55(e) criteria for reportability (This may be considered violation on .further review).
- 7. (V), The water stop specification is inadequate in that it does not.
- 8. (XVI) NCR 1322 was initiated on 3/3/82 and identified nonconforming conditions with equipment stored in place in the Control Room. The conditions were not
~
corr e ed by 6/29/82. (IX) Welders are not knowledgeable nor are they trained in the welding procedure specification. g94 1.0. (V) QA engineers for surveillance and visual inspection are not certified in accordance with the procedure. VT SNT TC-1A Survei+1ance -45.2.6 not defined. .. m ,en-- - . = w,...._
- 11. Fareman cra par =1ttcd to acsura dution b2fors completing th2 indoctrinstion training.
- 12. YAEC Audits identified management problems in P-H and did not effectively resolve the problem.
. The NRB only reviews NCR's for the preceding month for trends.
- 14. It does not appear that the FSAR com::itments are being implemented for the control of sensitization of stainless steel RG 1.44
- 15. (II) Weld- uns, accepted with code rejectable indications.
15 4r 5 -f i v f A
- 16. Comment: AEC management. audits were focused in only one area per year. This did not provide an adequate over view of the program implementation.
- 17. Comment: - Organization is. personality dependent
- Communications
' Area Spt.
py.' s -
- YAEC QA integrated look
- 18. Comment: Engineering design change control.
' 9. Positive Comment: - Welding Program: Voluntary and paid upgrade Trend analysis (goals, variables)
()
- YAEC
- Audits are well done
" Audit and surveillance personnel well qual.
' Forethought to review 50.55(e)
\.
1
Inhn c sTSC.t iEFF6YT10 f CuDC DW
~
,~g 3.0 APPLICABLE DOCUMENTS i 3.1 CODES AND STANDARDS 3.1.1 American Society of Mechanical Engineers United Engineering Center !
345 East 47th Street New York, New York 10017 ASME B&PV Code: The following sections of the ASME B&PV Code form a part of this Design Specification. For design and analysis of piping systems the applicable issue of the Code is the 1971 issue including all addenda up to and including the Winter, 1972 addenda. v For purchase of components, the applicable issue of the Code is i the issue in effect on the date the purchase order is let. For design of pipe supports, the applicable issue of Subsection i NF is the one included in the Winter, 1973 addenda to Section f III. h
%t For inservice inspection, the applicable issue of Section II is
;_ the 1977 Edition with addenda up to and including Susumer, 1978
_ ,. I for all systems except RHR and ECOS systems. The applicable issue for RHR and ECCS systems is the 1974 edition with addenda up to and including Summaer, 1975. j For erection of piping covered by specification 9763-006-248-51 the applicable issue of the Code is the 1977 issue, including 4 - addenda up to and including Winter, 1977.
$ For erection of piping covered by specification 9763-006-248-3 j the applicable issue of the Code is the 1974 issue with addenda j - up to and including Susaner, 1975.
Section II - Material Specifications { Part A - Perrous Materials {:~ Part B - Nonferrous Materials j Part C - Welding Rods, Electrodes and Filler Metals Section III - Nuclear Power Plant Components Division 1 7.. I V. G /
,r, Spec. No. 9763-005-248-43
? Page No. I-20 m'
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; Subsection NA - General Requirements 3 {., Subsection NB - Class 1 Components
.: 4 Subsection NC - Class 2 Components Y$, Subsection ND - Class 3 Components i :
Subsection NF - Component Supports
. .m
- Division 2 - Concrete Reactor Vessels and Containments
?J Section V - Nondestructive Examination 2' Section II - Welding and Brazing Qualifications 1
1 l-
. ( Section II - Rules for Inservice Inspection of Nuclear Power
[
].' Plant Components t
I Code Cases as approved by Regulatory Guides 1.84 & 1.85 may be
;h used as directed by the Engineer.
s k The following Code Cases have been approved for use on this _ contract: 1644, 1651, 1683, 1724, 1728, 1729, 1734
'-(j?q' N-180, N-192, N-218, N-229, N-128, N-287, N 32.3 (1541-3) o 3 3 3.1.2 American $ct;iety of Mechanical Engineers i 3l - United Engineering Center
, $. 345 East 47th Street
}} New York, New York 10017 t
i ANSI Standards: The following American National Standards with g- the applicability and effective date shown in Table 3.1-1 shall g; form a part of this Design Specifica* on.
's
{-l-- ANSI B31.1 ANSI Ccde for Pressure Piping, Power Piping 7/
- j ANSI N18.2 Nuclear Safety Criteria for the Design of
- j , Stationary Pressurized Water Reactor Plants
- _ ~
d ANSI N176 (Draft) Design basis for protection of nuclear i power plants against effects of postulated pipe rupture
?
- [- ANSI N177 (Draft) Plant Design against missiles M
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Spec. No. 9763-006-248-43
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Page No. 1-21
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Qd f% ' 3,g,3 Manufacturer's Standardization Society of the Valve and Fitting Industry ! 420 Lexington Avenue New York, New York 10017 MSS Standards: The following Manufacturers Standardization rociety a part ofofthis theDesign Valve and Fittings Industry standards shall form Specification. effective data of each standard is listed in Table 3.1.2.The applicabil MSS-SP-58 Pipe hangers and supports - Materials and Design MSS-SP-69 Pipe hangers and supports - Selection and Application
=3.1.4 United Engineers & Construc*ar- Inc.
30 South 17th Street Philadelphza, Pennsylvania 19101 i-UE&C Project Standard Documents date of purchase order form a part of this specificat . 9763-MPS-1 Material and Processing Requirements (Nuclear)
.' 9763-MPS-2 Material and Processing Raquirements (Non-Nuclear) g 9763-WS-1 Welding and Nondestructive Examination for Nuclear Pressure Components and Nuclear Power Piping
' 9763-WS-2 Welding and Nondestructive Examination for l'on-Nuclear Components and Non-Nuclear Power Piping -
9763-WS-5 Requirements for Brazing and Nondestructive
~
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' Examination and Test Methods for Nuclear Pressure Components l
QAS-1 Quality Assurance Administrative and System , i Requirernents (Nuclear) l { MAC/PSNH/001, 002, 003 and 004 Spacing Tables l I
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x - y ( h E 5/, ~ ' 4e g h J3.2 D_RAWINCS 8 3.2.1 UE&C Piping System Drawings 3.2.1.1 Nuclear Piping Drawing 9763-P-805001 P&I Diagrams (See Table 2.2-5A for a list of isometric drawings) 3.2.1.2 Other Piping - (Se4 Table 2.2-3 for a list of P&I Diagrams and Table 2.2-5B _ for a list of isometric drawings.) ' 3.2.1.3 _ Penetrations 9763-F-805574 Containment Structure Piping Penetrations Sections and Details 9763-F-805575 Centainment Structure Piping Penetrations Details 9763-F-805576 Containment Structure Piping Penetrations Plans 9763-F-805577 Containment S.tructure Piping Penetrations Elevations' i 9763-F-805578 Containment Structure Piping Penetrations l Details s 3.2.2 UE&C Standard Drawings i I 9763-F-300219 Service Environment Chart lr h 't y 9763-M-804998 Weld End Joint Design for Butt Welding After { Cement Lining b i i i 9763-M-804999 qt I Weld Surface Preparation for Inservice I Inspection ' ' 9 6 9763-F-805000 Weld End Preparation Details - Interface with i j i W Weld End Preparation Valves, Nozzles and Equipment it g 5000-F-1382 Standard Weld End Preparation Details for Pipe. i l Spec. No. 9763-006-248-43 Page No. I-23 4 t
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Enginnedne OfHess - l M- comportyest New: '-- . e 1671 Worcester Rood Pnuninohem. Mossochusetts 01701 [ (617) - g72 - 8100
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United Engineers and Constructors, Inc. - - 30 South 17th Street _. ._ P. O. Box 8223 Philadelphia, PA 19101 Mr. P. L. Evans Pullman-Higgins - P. 0.-Box 3308
- Williamsport, PA 17701 .
Dear Hessrs. Ebner and Evans:
. s. ,
YAEC SEABROOK AUDIT REPORT NO. SA573CS188
' ~
Attached for your information and use is the subject Audit Report of . Pullman-Higgins (P-H) which was conducted at Seabrook Station by our David A. l Burbine. i In an effort to expedite the resoluti'on of the items identified in the attached Audit Report, you will note that this letter is being forwarded in parallel to the parties addressed above. The audited organization is requested to respond to the YAEC Project Office and the UE&C Project Office by March 10, 1982. The response should indicate the corrective action that has been/will be taken to resolve and to, preclude recurrence of the deficiencies, and the date by which such corrective action will be completed. Prior to the formal response to the. audit, it is strongly suggested that oral communications be held between the auditor an.1 the auditee to resolve any ambiguities apd./.or - .. misunderstandings. , The audit resulted in fourteen (14) deficiencies being identified with particular concern by the auditor that there are numerous (six) deficiencies noted within the Corrective Action Report system, that procedural
. guidelines / requirements / responsibilities within the Nonconformance Report, Corrective Action Report, and trend analysis systems are inadeguate, and that implementation by responsible personnel has not been adequate / effective.
Your attention is directed to the attachment section of the Audit Report. A verification audit will be performed by YAEC in order to verify effective ( implementation of the corrective action.
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, Page 2 If you have"any questions or comments, please contact Mr. D. A. Burbine at (617) 872-8100, Extension 2472.
. iours truly, l.. --
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. Wh G. F. Mcdonald h .,' '~
. Quality Assurance Manager e
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- A. .M. She pard B. B. Beckley R. P. Pizzuti J. W. Singleton J. H. Herrin D. E. McGarrigan D. C. Lamoert .
R. A. Rebel R. G. Davis - P-H F. Cauldwell - P-H J. P. Cady
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YAEC SEABROOK AUDIT REPORT
- NO. SA573C3188 PLACE: PULLMAN-HIGGINS, SEABROOK STATION, SEABROOK, NEW HAMPSHIRE s.
DATES: NOVEMBER 24 & 25. DECEMBER 3, 8, & 30, 1981 AND JANUARY 6, 7, & 19, 1982 PURPOSE: TO VERIPT PERSONNEL COMPLIANCE TO, AND SYSTEM ADEQUAUf 0F, THE QUALITY ASSURANCE PROQRAM AND IMPLEMENTING PROCEDURES, AND T0 . ---
~
, EVALUATE THE EFFECTIVENESS OF IMPLEMENTATION BY RESPONSIBLE. . .
..--:- PERSONNEL. -
SCOPE: AUDIT / EVALUATION OF PULLMAN-HIGGINS' NONCONFORMANCE REPORT, -- fW
~
CORRECTIVE ACTION REPORT, AND TREND ANALYSIS SYSTEMS.
~ ~ '
AUDITOR: DAVID A. BURBINE, QUALITY ASSURANCE ENGINEER THOSE CONTACTED: PULLMAN-HIGGINS _YAEC
- R. G. DAVIS
- P. A. OIKLE
~
- J. E. GODFREY
- J. F. NAY, JR. ..
- E. O. WALKER
- M. W. NEWTON
- ATTENDED EXIT INTERVIEW
+
~ ' ~
I.
SUMMARY
The audit resulted in fourteen (14) deficiencies, none of which are indicative of a breakdown in the Quality Assurance Program. The auditor ~ offers the following conclusions: . A. Nine (9) of the deficiencies were the result of persorinel noncompliance with pertinent requirements of implementing procedures. Six (6) of the nine (9) in this category were related
. to the Corrective Action Report system; therefore, it is rec,ommended .
l that Corporate awareness and involvement be increased to resolve and l , to preclude recurrence of the deficiencies. B. Three (3) of the deficiencies were the result of system inadequacies as defined in the Quality Assurance Program and implementing procedures. It is recommended that an in-depth evaluation and assessment be performed to assure that the QA Program and implementing procedures adequately address project requirements / commitments and provide sufficient definition of responsibilities / requirements / guidelines to assure safety-related activities are satisfactorily accomplished. C. Two (2) of the deficiencies were the result of ineffective implementation by responsible personnel. The auditor feels that the j ineffective implementation is the result of item B above. It is recoimnended that a comprehensive training program be established for. all responsible QA, Construction, and Engineering personnel. * . . . , .
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#5 NO. SA573CS188 PAGE 2 s
Based on the overall results of the audit, the auditor feels that greater Corporate involvement ,in field activities is necessary, especially through audits and review of field-generated documentation (i.e., NCR's, CAR's, trend analysis, etc.) to assure more effective management control of the QA Program.
- The attachments ot this report outline the details of the deficiencies r- '
noted during the audit. -.. .. . - - ._- - -.-....._ - . _ ....
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II. DISCUSSION: *' ~ - - -
~
The Seabrook Station QA Manual Procedure 9.1, and supplemental marked-up procedures were utilized as the guidelines in performing the verification phase of the audit. The objective evidence chosen at random to verify program effectiveness is identified on the marked-up procedures and supplemental sheets. An exit interview was held with the personnel indicated on the first page of this report. The auditor stated the deficiencies and indicated to the attendees that the corrective action should be initiated immediately, and must be completed within thirty (30) days af ter the exit interview.
,. III. OUTSTANDING ITEMS: -
I'
.%. A. Closed out by this report: -
- 1. None
; B. New items requiring QA follow-up:
- l. SSCA No. 0500, NCR's not issued as required.
(15-705-2)
- 2. SSCA No. 0501, "NC Code" not included in the monthly trend analysis summary.
(15-705-2) l 3. SSCA No. 0502, Estimated completion dates are not entered on l CAR's. (16-705-2)
- 4. SSCA No. 0503, verification of corrective action not performed within 10 working days.
(16-705-2)
- 5. SSCA No. 0504, Missing / incorrect entries in CAR Log.
(16-705-2)
- 6. SSCA No. 0~,05, Missing entries on CAR's.
. (16-705-2)
.\_. -
- 7. SSCA No. 0506, CAR signed by Construction personnel.
, (16-705-2) s a . - _
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No. SA573CS188
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- 8. SSCA No. 0507, (1) Nonconformances identified on inprocess documentation not included in the trend analysis program. ,
(2) Data indicates trend which was not reported to Corporate personnel. (16-705-2).- .
. . . . . . . 9. SSCA No. 0508, CAR's completed using other than black ink.
~ ~~ ;. . (16-705-2)
! 10. SSCA No. 0509 Field Procedure XVI-2 does not require - - -- --
distribution of CAR's to Corporate personnel.. . (16-705-1) -
- 11. SSCA No. 0510, (1) Field Procedures XV-2 and XVI-2 are not adequate.
(2) No field procedure defining trend analysis prog ram'. s (15-705-1)
- 12. SSCA No. 0511, Stop Work action by QA personnel not addressed in QA Manua] or implementing procedures.
(01-705-1) .
. 13. SSCA ho. 0512, Inadequate investigation of "cause" on NCR's and CAR's resulting in incomplete corrective action.
(16-705-2) ,
- 14. SSCA No. 0513, only one (1) "cause code" assigned to NCR's *
+
which identify multiple "causes." (16-705-2) Dd I. OmI'_c David A. Burbine 2/9/62 bate Quality Assurance Engineer DAB /fsf - Attachment ec: W. P. Johnson D. C. Lambert
- - - - - - - A. M. She pard -. . . - -.. - . - R. A. Rebel._. . _ - . . . _ . _ _ . , . _ . . . . . . _ . . . . . . . . . . . _ . .
B. B. Beckley R. G. Davis l R. P. Pizzuti - F. Cauldwell J. W. Singleton J. P. Cady l J. H. Herrin W. B. Sturgeon D. E. McGarrigan The contents of this report have been reviewed for items which could require reporting by 10CFR21 and 10CFR50.55(e). The report did /did not .- contain potentially reportable items.
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Quality Assurance Manager / D(te
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..: ATTAC10ENT t 1 of 15 s SSCA No. 0500
.' Report No. SAS73CS188
( Audit Date: 11/24&25, 12/3,
- 8, & 30/81, &
1/6,7, & 19/82 Auditor (s): D. A. Burbine
- - ~
REQUIREMENT: -- - -- - --
~
Field Procedure XVI-2, " Corrective Action," paragraph 3 2 states: "If conditions noted on the CAR warrant, an NCR shall be issued and the CAR closed by referencing the,NCR."_ _ _,, _, 4 DEFICIENCY: - - - There are several CAR's which identify nonconforming conditions for hardware, but no NCR was issued (i.e., CA*. Nos. 44, 40, 38, 33, 12,,and 10). RECOMMENDATION: . j Comply with the procedure. P-H REPLY: ' r- ' pk g c (L sf/ Wf'L _ (w . I l 4 1 l
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2 of 15 SSCA No. 0501 [m
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Report No. SA573CS188 Audit Date: 11/24&25, 12/3, 8, & 30/81, & 1/6,7, & 19/82 Auditor (s): D. A. Burbine REQUIREMENT: , Corporate Procedure I-2, " Monthly Reporting of QA Activities Required by QA Manual / Procedures," paragraph 41 states: "It is the responsibility of the QA Manager to submit a monthly report summarizing . . . nonconformances including trends noted . . . ." ~ ~ - Field Procedure XV-2, "Nonconformances (Field)," Appendix C, Line No. 7, states: " Refer to Appendix A and enter the NC code." , DEFICIENCY: The monthly report submitted by the Field QA Manager summarizes conconformances by "cause code" only, but does not include the "NC Code." RECOMMENDATION: Assure that the "NC Code" is included in the monthly trend analysis summary. P-H REPLY: f ' I' s Ct e
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. SSCA No. 0502 Report No. SA573CS188 i
( Audit Date: 11/24625, 12/3, 8, 6 30/81, & 1/6,7, & 19/82 Auditor (s): D. A. Burbine REQUIREMENT: - Procedure XVI-2, " Corrective Action," paragraph 5 2 states: "Upon receipt of CAR, an estimated completion date will be established and forwarded to
'QA Records for control of CAR until closed." .
DEFICIENCY: _ There is no evidence of any extimated completion dates being established ' and forwarded to QA Records. There are several CAR's which have been open since January and March, 1981 and the corrective action has not been completed to date. . 1 RECOMMENDATION: (1) Comply with the procedure. (2) Review all open CAR's and provide an estimated completion date, as required. (3) Take action to assure that all open CAR's are closed as soon as possible. P-H REPLY: l/ f(fiffVC' f cy cn't a/*J -+ of*' 6 y-_- ,,,-,-,--,--,.-.-_,--,,,,,,-y- - . . --r1-,--,
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Report No. SA573CS188 Audit Date: 11/24&25, 12/3,
- q. 8, & 30/81, &
1/6,7, & 19/82 Auditor (s): D. A. Burbine REQUIREMENT: . . Procedure XVI-2, " Corrective Action," paragraph 6.1, requires that - verification of the corrective action, ". . . be accomplished no later than 10 working days af ter estimated completior' date of corrective action." DEFICIENCY: There are numerous CAR's which indicate that corrective action has been completed, but the verification was not accomplished within 10 working days. (CAR Nos. 48, 45, 44, 43, 42, 33, 27, 21,18,12, an? 10) RECOMMENDATION: . (1) Comply with the procedure. (2) Review all open CAR's and assure that the verification is y accomplished within 10 working days. # l P-H REPLY: (. 1 \ . O k
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.t SSCA No. 0504 Report No. SA573CS188 Audit Date: 11/24&25, 12/3, 8, & 30/81, &
.s
' 1/6,7, & 19/82 Auditor (s): D. A. Burbine
-~ REQUIREMENT:
~
~
Procedure XVI-2, " Corrective Action," paragraph 8.1, requires' that the ~ Corrective Action Report Log " identify the report by number, a brief description, and its current status."
~ '
DEFICIENCY: - - ..? -- -. - A review of the Corrective Action Report Log revealed that numerous entries were missing and that the current status of several CAR's vere in error. (CAR Nos. 45, 40, and 36) RECOMMENDATION: (1) Comply with the procedure. . (2) Review the Correebive Action Report Log and assure that the current status of CAR's is identified. P-H REPLY: L Q ,,,- jer a I
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ATTACHMENT - P 6 of 15
-s SSCA No. 0505 Report No. SA573CS188 Audit Date: 11/24&25, 12/3, 8, & 30/81, &
1/6,7, & 19/82
- - - . Auditor'(s): D. A. Burbine REQUIREMENT: . -
Procedure XVI-2, " Corrective Action," paragraph 4.2.5 states: " Items 7 and 8 will document finding of follow-up actions taken by the internal . auditor." - , - DEFICIENCY: . There are numerous Corrective Action Reports which have no entries for Items 7 and 8. r RECOMMENDATION: Either comply with the procedure, or if entries are not required on'all CAR's, then provide guidelines / requirements within the text of the procedure which will indicate when Items 7 and 8 are to be completed.
- P-H REPLY:'
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~s SSCA No. 0506 1 Report No. SA573CS188 s Audit Date: 11/24&25, 12/3,
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8, & 30/81, & i 1/6,7, & 19/82 Auditor (s): D. A. Burbine REQUIREMENT: - . . - - Procedure XVI-2, " Corrective Action," paragraph 4.2.6 states: " Item 9 will be completed and signed off as designated by the QA Hanager af ter review of documented actions." , .- DEFICIENCY: Corrective Action Report No. 25 was signed in the " corrective Action Verified" by the Construction Superintendent. ,
~
RECOMMENDATION: Assure that CAR's are verified and signed by QA personnel. P-H REPLY: m &L , 4. ( l i
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y- .. , , ATTACHMENT e ~ 7 8 of 15 - - SSCA No. 0507
.s Report No. SA573CS188 Audit Date: 11/24&25, 12/3, ~
- ~
8, & 30/81, & 1/6,7, & 19/82
. _ . ___ . Auditor (s): D. A. Burbine REQUIREMENT: , . . . . _
UE&C's QAS-1, " Quality Assurance Administrative and System Requirenents - for Nuclear Safety Class Items," paragraph 4.14. " Corrective Action," states: "Nonconformances shall be reviewed periodically to identify trending conditions." . DEFICIENCY: > (1) Nonconformances identified on inprocess documentation (i.e., inspection reports, NDE reports, etc.) are not included in the trend
~
analysis program. (2) The auditor reviewed the monthly trend analysis reports for the period from January to December, 1981, and there are several ' instances in which the number of "causes" were indicative of a trend; however, this was not reported on the applicable monthly report to Corporate personne.1 (i.e. , Cauce Code Numbers 01, 03, 04, 05, 26, and 33). RECOMMENDATION: (1) Assure nonconforming conditions identified on inprocess documentation are included in the trending program. (2) Assure that the responsible personnel are comparing c.sch month's - :- * - trend data with previous month's data in order to idsutify adverse trends. P-H REPLY: hc d) a W lh . EM W $ ,
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- ATTACHMENT- -
9 of 15 s SSCA No. 0508 Report No. SA573CS188 Audit Date: 11/24625, 12/3, 8, & 30/81, & 1/6,7, & 19/82 Auditor (s): D. A. Burbine REOUIREMENT: . . In;&C's RM-1, " Site Accords Management System," paragraph 9 states: "It is the responsibility of the contractor to. assure that the records are: (Iten e) Conpleted using black ink pens . ... DEFICIENCY: Two (2) Corrective Action Reports (CAR's) have been completed using othc.r than black ink (No. 24 in red ink and No. 25 in blue ink). RECOMMENDATION: . (1) Assure that the applicable field implementation procedures address the requirement of L%C's RM-1. (2) Currect the discrepant CAR's. (3) Comply with the procedure. Advise Document Control / Records personnel to return discrepant documentation to the originator. P-H REPLY: 4 j' s' e , ,\ r
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ATTACHMENT ~ 10 of 15 i SSCA No. 0509 (~ ( Report No. SA573CS188
\. Audit Date: 11/24&25, 12/3, 8, & 30/81, &
1/6,7, & 19/82 Auditor (s): D. A. Burbine REQUIREMENT: -- . - - . --- . - - . -- l ANSI N45.2, "QA Program Requirements for Nuclear Facilities," Sec' tion 17,
" Corrective Action," states: "The identification of significant
. conditions adverse to quality, the cause of the condition, and the corrective action taken shall be documented and reported to appropriata levels of management." .
9, _~)EFICIENCY:
^
Procedure XVI-2 does not require that CAR's be distributed to Home Office management personnel, or that higher levels of management be notified if corrective action is not effective or implemented in a timely manner.
^
RECOMMENDATION: Revise Field Procedure XVI-2 to require that CAR's be distributed to 7 Corporate personnel and that Corporate persoundl be notified of ineffective or inadequate implementation of corrective action. I.
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ATTACHMENT 11 of 15 _ SSCA No. 0510 Report No. SA573CS188 (, ., Audit Date: 11/24&25, 12/3, 8, & 30/81, & 1/6,7, & 19/82 Auditor (s): D. A. Burbine REQUIREMENT: _ . _ . . . . . . . - ANSI N45.2, "QA Pro 8 ram Requirements for Nuclear Facilities," Section 6,
" Instructions, Procedures, and Drawings," states: " Activities affecting quality shall be prescribed by documented instructions, procedures, . . .
and shall be accomplished in accordance with these instructions,
, procedures, or drawings. Instructions, procedures, or drawings shall include appropriate quantitative or qualitative criteria 'for determining that important activities have been satisfactorily accomplished."
DEFICIENCY:
- 1. Field Procedure XV-2, " Handling of Nonconformances," and Fiel,d Procedure XVI-2, " Corrective Action," do not contain adequate' guidelines / requirements for the initiation, processing, follow-up, and close-out of Nonconformance Reports (NCR's) and Corrective Action Reports (CAR's).
Examples: (a) The CAR must be reviewed for applicability to: i (1) ASME Code. (2) potential significant deficiency, (3) 10CFR21, and (4) 10CFR 50.55(e). (b) Conditions / circumstances which require a CAR.
~"
(c) Nonconformances and/or corrective action which may warrant stop work action. - - - - (d) The steps to be taken by responsible personnel if the identification, implementation, or verification of corrective action is not performed in a timely, effective, or acceptable manner. (e) Identification of "cause" and " corrective action" on the NCR Form.
- 2. Field personnel are utilizing Corporate Procedure I-2, " Monthly Reporting of QA Activities Required by QA Manual / Procedures," for guidance in developing the trend analysis reports. This procedure does not adequately define the responsibilities / requirements / guide-lines for compiling and analyzing data related to trend analysis, for determining and investigating the cause of adverse trends, for reporting and directing the corrective action, and for evaluating the effectiveness of the corrective action.
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- , SSCA No. 0510 (cont.)
Report No. SA573CS188 Audit Date: 11/24&25, 12/3, 8, & 30/81, & 1/6,7, & 19/82
- - - - - Auditor (s): D. A. Burbine 1 1
RECOMMENDATION: - --- - - - . - . . . (1) Review and revise Field Procedures XV-2 and IVI-2 to adequately / accurately define the responsibilities / requirements / guide-lines for the initiation, processing, follow-up, and close-out of NCR's and CAR's. (2) Develop a field proctdure for the trend analysis reporting program. P-H REPLY: y(ff st Y & Y f b ( 61
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.f '.'. ATTACHMENT-13 of 15 SSCA No. 0511 Report No. SA573CS188
., Audit Date: 11/24&25, 12/3, 8, & 30/81, &
1/6,7, & 19/82 Auditor (s): D. A. Burbine REQUIREMENT: ANSI N45.2, "QA Program Requirements for Nuclear Facilities," Section 3,
" Organization," states: " Persons and organizations performing quality assurance functions shall have sufficient authority and organizational freedom to: (Item 4) control further processing, delivery, or .
. installation of a nonconforming item, deficiency, or unsatisfactory
~
condition until proper dispositioning has occurred." DEFICIENCY: , Procedures XV-2 and XVI-2 do not address guidelines / requirements for issuance and processing of a Stop Work Order b'y QA personnel when a specific nonconforming condition is identified or when corrective action is required on a generic basis. RECOMMENDATION: Revise Procedures XV-2 and XVI-2 to address guidelines / requirements for issuance of Stop Work Orders by QA personnel. P-H REPLY: yy y,- /YVIN '
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14 of 15 SSCA No. 0512 fs Report No. SA573CS188 ( Audit Date: 11/24625, 12/3, 8, & 30/81, & 1/6,7, & 19/82
.._ _ _ _ Auditor (s): D. A. Burbine REQUIREMENT:
ANSI N45 2, "QA Program Requirements for Nuclear Facilities," Section 17
" Corrective Action," states: "In the case of significant conditions adverse to quality, the measures shall assure that the cause of the condition is determined and ccerective action taken to preclude re petition . "
Field Procedure XVI-2, " Corrective Action," paragraph 3.2 states: "It shall be the responsibility of the Field QA Manager to evaluate CAR's to specify corrective action required and to verify implementation of corrective. action." s DE?ICIENCY: - A review of Nonconformance Reports (NCR's) and Corrective Action Reports (CAR's) revealed that the investigation of cause and the resulting
-- corrective action indicated by responsible personnel has not been adequate. There are numerous instances in which the investigation did not det. ermine the root causes, or all of the causes, and therefore, the corrective action taken was not adequate to preclude recurrence of the nonconforming condition.
Example: For investigating the cause, responsible personnel must
. investigate the following types of questions: ,
- a. Who or what caused the nonconforming condition?
- b. How or why did it occur?
l I c. Where else may it have occurred? 1
- d. When did it occur?
RECOMMENDATION: (1) Assure that responsible personnel are investigating the cause(s) of nonconforming conditions to the depth necessary to determine the root cause(s), and assure that the corrective action taken will be effective in precluding recurrence. (2) Consider requiring that a limited number (i.e., one to three) of personnel be respensible for concurring /epproving the cause and l corrective action of NCR's and CAR's. P-H REPLY: g [ p Q ' /yng f' gay 1 aNl~.
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' Audit Date: 11/24&25, 12/3, 8, & .50/81, &
1/6,7, & 19/82 Auditor (s): D. A. Burbine REQUIREMENT:. - ANSI N45.2, "QA Program Requirements for Nuclear Facilities," Section 17,
" Corrective Action," states: "The identification of significant conditions adverse to quality, the cause of the condition, and the corrective action taken shall be documented and reported to appropriate levels of management."
V UE&C's QAS-1, " Administrative and System Requirements for Nuclear Safety Class Items," paragraph 4.14 states: "Nonconformances shall be reviewed periodically to identify trending conditions." DEFICIENCY: There are numerous Nonconformances Reports (NCR's) which identify multiple "causes" (i.e., NCR's 1432, 1459, 1471, 1510, 1532, and 1576); however, only one (1) "cause code" number was assigned to the NCR. This practice does not accurately reflect the actual number of "causes" which are reported monthly in the trend analysis. RECOMMENDATION: (1) Instruct the responsible QA personnel to assign a "cause code" number to each identified "cause" on the NCR's, and to accurately account for each "cause" on the monthly trend analysis. (2) Revise Field Procedure XV-2 to reflect this requirement. P-H REPLY: 9
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$b YAEC SEABROOK AUDIT REPORT NO. SA556CS202 Nev . L'fLLT
(~. PLACE: PULLMAN-POWER PRODUCTS, UILLIAMSPORT, PENNSYLVANIA @'t 2f 8 .l- J d DATES. MARrH 8-10, 1582 jfauf 4, y, / ,j j PUFFOSE: QUALITY ASSURANCE AUDIT OF CORPORATE HEADQUARTER ACTIVITIES AUDITORS: PHILIP A. OIKLE, SENIOR QUALITY ASSURANCE ENGINEER (ATL) FREDERICK A. LEAKE, SENIOR QUALITY ASSURANCE ENGINEER (AIT) THOSE CONTACTED. PULIMAN POWER PRODUCTS A. A. ECK, DIRECTOR QUALITY ASSURANCE , D. R. GESKE, TRAINING ENGINEER C. M. NEARY, WELDING ENGINEER L. MCQUILLEN, DOCUMENT CLEPK I. SCt!ARY: The subject audit was performed to evaluate the degree of effectiveness of corporate involvement and support of Pullman's field activities at Seabrook Station and in meeting QA Program requirements. The audit resulted in four areas in which deficiencies were identified. [ II. DISCUSSION: A. Areas covered during the audit included Organization, QA Program, Nonconforming Items, Corrective Action and Audits. The audit was performed with, but not limited to, checklists developed from Pullman QA Manual, Implementing Procedures and Project Er.quirements. Details of the four identified deficiencies may Le found on attachments to this report. B. The results of YAEC Seabrook Site Audit Report No. SA573CS188 vere discussed with Mr. A. Eck, Director of Quality Assurance. The i discussion focused on nonconformance and corrective action; trend I reporting by the field and associated management support. Although the auditors found more management involvement and support than was expected, the deficiencies as reported in Audit Report No. SA573CS188 are valid and remain unchanged. Those items applying to Corporate activities, however, vill not be duplicated in this Report. C. Discussions were held with Mr. Eck and Mr. Geske, Training Engineer, with regard to a longstanding action item on the subject of Pullman developing and Interim Procedure Change policy and implementing procedure. lir. Eck agreed that Pullman would develop such a procedure for use at the Scabrook Station. III. EXIT INTERVIEU. s, An exit interview was held with the parties indicated on page 3 of this report at which time the results of the audit uere discussed and , commitments made for corrective action. l l l __
YAEC SEABROOK AUDIT REPORT . NO. SA598CS203 PLACE: PULDiAN-HIGGINS, SEABROOK STATION, SEABROOK, NEW HAMPSHIRE DATES: APRIL 6-23, 1982 PURPOSE: QUALITY ASSURANCE AUDIT OF PULLMAN-HIGGINS YAEC _ AUDITORS:
.
- PHILIP A. OIKLE, SENIOR QUALITY ASSURANCE ENGINEER (AIM - SUPERVISING)
-
- FREDERICK A. BEAKE, SENIOR QUALITY ASSURANCE ENGINEER (ATL - TRAINING)
*R. E. GUILLETTE, SENIOR QUALITY ASSURANCE ENGINEER
- BRUCE MIZZAU, FIELD QUALITY ASSURANCE ENGINEER (AIM - TRAINING)
PERSONNEL CONTACTED: PULIMAN-HIGGINS RICHARD G. DAVIS, QA MANAGER
*F. M. CALDER, RESIDENT MANAGER C. A. SCANNELL, CHIEF ENGINEER
*R. G. WISE, QC SUPERVISOR ,
R. P. DONALD, QA SUPERVISOR
*H. W. NEWTON, QA TECHNICIAN K. A. SWISHER, QA PROCEDURE ENGINEER DAVID WATERS, QA TECHNICIAN E. BOWES, NDE SUPERVISOR
*M. S. MACCRAE, NDE TECHNICIAN
- PAUL GRASW ICZ, LEAD HANGER ENGINEER
*B. V0GE, TRAINING OFFICER L. LANTRY, TRAINING OFFICER
- ATTENDED EXIT INTERVIN I. SLHMARY:
The subject audit was performed to verify personnel compliance to, and I syctem adequacy of, the Quality Assurance Program and implementing prceedures, and to evaluate the effectiveness of implementaion by responsible personnel. The audit resulted in 20 deficiencies and 2 observations that were identified. II. RESULTS: I A. The audit was performed in accordance with Procedure 9 1 of the Seabrook Station Quality Assurance Program. Checklists generated from Pullman-Higgins' Seabrook QA Manual, Implementing Procedures and Project Standard Documents were used as a guide by the auditors. Areas covered during this audit were Procurement Document Control; Instructions, Procedures and Drawings; Document Control; Identification and Control of Materials, Parts, and Components; and Control of Special Processes. A
YAEC SEABROOK AUDIT REPORT NO. SA598CS203 PLACE: PUL1 MAN-HIGGINS, SEABROOK STATION, SEABROOK, Nm HAMPSHIRE DATES: APRIL 6-23,1982 PURPOSE: QUALITY ASSURANCE AUDIT OF PULLMAN-HIGGINS AUDITORS: YAEC
.
- PHILIP A. OIKLE, SENIOR QUALITY ASSURANCE ENGINEER (AIM - SUPERVISING)
-
- FREDERICK A. BEAKE, SENIOR QUALITY ASSURANCE ENGINEER (ATL - IRA'NING)
*R. E. GUILLETTE, SENIOR QUA'..ITY ASSURANCE ENGINEER
- BRUCE MIZZAU, FIELD QUALITY ASSURANCE ENGINEER (AIM - TRAINING)
PERSONNEL CONTACTED: PULIMAN-HIGGINS
- RICHARD G. DAVIS, QA MANAGER
*F. M. C. 4LDER, RESIDENT MANAGER C. A. SCANNELL, CHIEF ENGINEER
*R. G. WISE, QC SUPERVISOR R. P. DONALD, QA SUPERVISOR
*M. W. NNTON, QA TECHNICIAN K. A. SWISHER, QA PROCEDURE ENGINEER DAVID WATERS, QA TECHNICIAN E. BOWES, NDE SUPERVISOR
*M. S. MACCRAE, NDE TECHNICIAN
- PAUL GRASN ICZ, LEAD HANGER ENGINEER
*B.~VOCE. TRAINING OFFICER L. LANTRY, TRAINING OFFICER
- ATTENDED EXIT INTERVIW I.
SUMMARY
The subject audit was performed to verify personnel compliance to, and system adequacy of, the Quality Assurance Program and implementing procedures, and to evaluate the effectiveness of implementaion by responsible personnel. The audit resulted in 20 deficiencies and 2 observations that were identified. l II. RESULTS: A. The audit was periormed in accordance with Procedure 91 of the Seabrook Station Quality Assurance Program. Checklists generated from Pullman-Higgins' Seabrook QA Manual, Implementing Procedures and Project Standard Documents were used as a guide by the auditors. Areas covered during this audit were Procurement Document Control; Instructions, Procedures and Drawings; Document Control; Identification and Control of Materials, Parts, and Components; and Control of Special Processes.
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ATTACHMENT 19 of 23 SSCA No. 0571 i l Report No. SA599CS204 Audit Date: 4/20/82
' Auditor (s): R. P. Tamm F. J. Driscoll REQUIREMENT:
FECP-403, Paragraph 1.2, requires that the procedure be used in conjunction .with the applicable WPS.
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DEFICIENCY: Contrary to the above, objective evidence was not available to support that the applicable WPS was actually used in conjunction with FECP-403 nor is the specific WPS referenced via drawings and Inspection Reports. A i specific weld application cannot be traced to the WPS used. RECOMMENDATION: Change procedure to direct documentation which will allow traceability of a given veld (s) to the appropriate WPS. FBM REPLY: A N l i e 7 b
{ d3(Imam LOy IT REPORT
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f a lack f d tificaton of 20 deficienc were primarily the result o and W
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audit resulted in the iorenThe impelementing deficiencies proceduresand Drawings; ~ T. Co The
, observations. of the QA Program Special ~,
of implementation of Instructions, Procedures Cceponents; and Control i s and of areas were in theof Materials,of the identified Parts, and deficienc eof this report. The details in the attachment section vident as Processes. observations may be found as repetitive items became d etification
'Two primary areas These of concern areas were 1) material i en nitoring:
C. the audit progressed.and control, and 2) weld mo i identified Material Identificallon, 1 illance activities haveFabrication Previous YAEC audit anddiate surveoblems ini Pullman-Higginscorrect of material identification of this problem is indicat ve nce prAlthough P-H has taken imme QC Shop. ft and QC personnel and inadequate each instance, the recurre quirements regarding mater a il weak training of both cra enforcement of QA Program re control and identificaton. well 2 Weld Monitoring d surveillance activities, as as of l Again, previous YAEC e repeatedly audit an identified areand implem h s' as P-H internal audits, hav noncompliance withIn QA Programeach instance, it was revea ed within theoutsid requirements. were not being monitoretedd weld no evidence - monitoring data qualified welders prescribed frequency;the weld procedure showe i d to repor parameters established weld quality; and no in/ Engineering QC Supervisor andpersonnel as re of evaluation by QA/QC determine impact onweld monitoring records by previous month's shortcomings, little QA Manager. made aware of theseidenced by a review of Although P-H has beenactionhat is apparent as were availableev monitoring weld during the or no corrective h the ing to the weld monitoring of records tall personnel the significance of adher associated wit ry audit. ts and ofproceduraltahing necessaassure t program must be made awareand requiremen program action immediately to corrective action. corrective deficiencies andhe extent of With regard to the attached identified and to auditi s is requested to eva D. observations, Pullman-Higg within their Programn prevent recurrence. the problemaction that will be taken to corrective were made
; auditors' concerns III. EXIT INTERVIEW: hich timeinthethe interest of more timelyediately The exit meeting was held atthat, requested w known.
Mr. Cuillettedeficiencies, Pullman begin imn closeout of audit _ l
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YAEC FQA WEEKLY SURVE.ILLANCE REPORT
- Week Ending February 27, 1982 Page 1. of 1
- 7. .,
Organization Pullman-Higgins , , , , , , Report No.' 163
] _ _ .
DATE AREA CONTACT RESULTS S$TO'AU
- 1. 2/22/82 X-5, R-3 #1647 Receiv. Itrspection R. Wise ' satisfactory
- 2. 2/23/82 N45.2, R-1 #1653 Cont. of Proc. Sheet B. Sautter unsatisf actory (1)
- 3. 2/24/82 IX-6, R-3 #1656 iInstall. Pipe Supp. P-H satisfactory
- 4. 2/25/82 IX-39, R-0 #1664 Hand. Saf. Rel. Equip P-H satisfactory
. 5. 2/24/82 248-51, R-15 #1663 Storage & Housekeep. P-H satisfactory
~
- 6. 2/25/82 IX-6, R-0 #1665 Hangers & Supports P. Grasewicz unsatisfactory (2)
, 7. 2/23/52 IX-14 R-1 #100/ Defect. Rem. & Rep. F-H satisfactory P-H satisfactory
- 8. Z/ Z 1/5Z 248-51, R-15 #1669 Welding Operations
- 9. 2/24/82 IX-6, R-3 01674 Whip Restraint. Inst P-H - satisfactory
- 10. 2/26/82 N45.2, R-1 #1675 Instrue. Proc., Dwg. P. Grasewicz unsatisfactory (3) 1 11. 2/26/52 245-31, R-1) #16/9 Weld Mat. Control P-H satisfactory
- 12. N
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- 34. N -
- 15. N
- 16. N
- 17. N ~
- 18. N
- 19. N m
- 20. N m i i_, 21. N
\s 22. N
- 23. N *
- 24. N
- 25. N REMARKS: NOTE: (1) Process sheet issued to construction with incorrect reference D l
Process sheet reissued with correct references. Item closed. NOTE: (2) Intermittent fillet welds attaching spring can base plate to
.suppor' t are one inch on two inch centers. P-H RFI #3081 to UE&C has been issued and'YAEC QA will follow till deficiency is closed successfully.
NOTE: (3) Unauthorized work in progress, no process sheet and prior to N.CR disposition. YAEC DR #145 issued to track till successful completion.
~
] e e .
O wi, . Form 3.3 Dist.' List 3.1.6 ushr- - Revised: 5/27/81 singi,e QA Manager g
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- ]
YAEC FQA WEEKLY SURVE.ILLANCE REPORT
- Weck Ending March 6, 1982 page 1 of 1 Report No. 164 Organization Pullman-Higgins ._
1 _., 7 AREA CONTACT RESULTS DATE S$Ih1[UCE 1, 3/2/82 248-51 R-15#1681 Welding Operation P-H Satisfactory
- 2. 3/3/82 248-51 R-15#1682 Storage & Housekeen. P-H Rne4=facenrv '
- 3. 3/4/82 KIII-5 R-0 #1683 Storama D. Unearn ifn == *4 =f a c enry (1 )
- 4. 3/5/82 VIII-3 R-2 #1684 Welding Mat. Control P-H sneinfacenev
- 5. 3/5/82 IX-9. R-0 #1686 In Process Tnan. P-n c . ,4 r e,. m ,.
- 6. 3/5/52 KII-2 R-0 #1687 ilandling Nonconf. R. Wise Satisfactorv
- 7. 3/5/82 ANSI N45.2 #1689 Document Review E. Waldman fin em e 4 = f = c eavy / ?)
- 8. 3/3/82 18-17 R-1 #1699 Exp. Anchor Install. P. Gramewicz Uneme4=facenry(1) 9 ._ \
- 10. N
- 31. N '
- 12. N
- 13. N
- 14. N
- 15. N
- 16. A
- 17. A
- 18. A
- 19. N
- 20. N N
(~ 21.
- 22. N
- 23. N
- 24. A
- 23. A_
REMARKS: Note: (1) Reactor coolant looo efoincr in area noe 4daneff4=d == 1=v=1 "n" storage area. P-H QA corrected the deficiency as soon as notified. Note: (2) Nonconformance review board disposition for NCR 1905 referenced NCR 1906 l and vi'ce-versa for NCR 1906. P-H and UE&C Engineering notified and appropriate corrective action has been taken. i Note: (3) ASME safety related hangers were installed over abandoned Hilti holes. YAEC DR #146 issued to follow corrective action till successful completion. J h 1 Form 3.3 Dist. List 3.1 6 MMr Revised: 5/27/81 s'inglet QA Manager j
YAEC FQA WEEKLY SURVE.lLIANCE REPORT - Weck Ending March 13, 1982' Page 1. of 1 Organization Pullman-Higgins _, , Report No. 165
] . . . .
RESULTS AREA CONTACT DATE S$hhI(NCE o 3, 3/8/82 VIII-1 R-1 #1698 Pip. & Erec. Insta. P-H Unsatisfactory (l)
._ __ 2. 3/0/5Z 248-51 R-15#1701 Piping Install. J. Martin Uname4=facenry/9)
I_.__ 3. 3/10/82 XI-1* R-0 #1703 Lenk Teneine T r:na re.y Satisfactorv
. __ 4. 3/9/82 XIII-4 R-0 #1706 Field Cleaning P-H OA Unsatinfactorv(3)
. _ 5. 3/10/82 ANSI N45.2 #1707 Storane Insnection P-H nneme4=facenev/A)
- 6. 3/11/82 IX-1 R-0 #1708 Leak Testing J. Godfrey Satisfactorv '
, 7. 3/11/82 VIII-l R-1 #1709 Ident. of Material P-H Mme4=facenrv
._ 8. 3/11/82 X-9 R-0 #1710 In Process Inspectiol P-H Sneinfacenrv
._. 9. 3/12/82 248-51 R-15#1714 Welding R. Donald - Unearinfactorv(5)
_ . . 10. 3/12/82 248-51 R-15#1715 Comoleted Weld Exam Davi n /Frn1 n tin = *4 -f -enry / A)
- _ _ . _ _ 11. 3/12/82 IX-6 R-3 #1719 Pine Suonort Install P. Cr==avier sm*4=facenev i - _ _ _12 m 3/12/82 VIII-3 R-2#1776 Surv. Weld Rod Cont. P-H QA Satisfactori
_ '_ 13. N _; .34. ^ % - _ 15. N -
.. 16. N
. 17. A
- 18. N
- 19. N W 20. N u N
[ 21.
- 22. N
~_23. N-
- 24. N
- 25. N, REMARKS: Note (1): Code stamping of NPT symbol was stamped numerous times in different positions on the code data plate. P-H NCR 2037 issued for tracking till satisfactory
! corrective action is nehtoved. Note (2): Excessive grinding on 2" pipe'to elbow weld and no welder identification stamp P-H NCR 2042 issued for tracking till satisfactory corrective action is achieved. Note (3): Care was not taken by craft to block contaminants from entering the valve seat area during cutting operations, pipe to valve. Grindings were vacuumed out immediately, item closed. Note (4): Three minor deficiencies noted on storage inspection reports (Ex. SIR #148 naa wrong year list in dateline) and two minor deficiencies noted on walk through inspection reports, All deficiencies have been corrected; item closed, acce tal. Ine portable weld rod oven had been unplugged for a considerable time, consequently the electrodes were cold. P-H QA notified and corrective action has been taken by returning the electrodes to the distribution center. Item closed. Note (6): Surface condition of Field Weld, F0503, not in conformance with code and r-n aur proceaures to perIorm magnetic particle examination. P-H NCR 2008 issued for tracking till satisfactory corrective action is achieved. Form 3.3 Dist. List 3.1 6 Revised: S/27/81
/ r) ,
kinYlet 'QA Manager /
YAEC FQA WEEKLY SURVEILLA!!CE REPORT , Week Ending March 20,1932 - Page l~ of 1 Report No. 166
, ,,_ Organization Pullman-Higgins , _ ,
/ ._ I DATE St I' NCE AREA CONTACT RESULTS
- Installation Pipe
- 1. 3/15/82 FI-156, R-0 #1705 Whip Re straints P. Grasewicz unsatisfactory (1) 3/18/82 FGCP-17. 248-51.1727 Weld Material Cont. D. Johnson unsatisfactory (2)
- 2. .
3/18/82 WS-1,- R-0 #1732 Welding P-H satisfactory
- 3. 1
~
3/16/82 XV-2, R-0 #1733 Nonconformance Rev. P-H satisfactory 4. 3/16/82 248-51, R-15 #1734 Pipe Installation J. Godfrey satisfactory
~T~ 5.
P-H satisfactory l ~ ~ ~ 6. 3/16/82 IX-14, R-1 #1735 Repair Welding l
~
- 7. 3/19/82 248-51, R-15 #1736 Hand. Mech. Equip. P-H satisfactory 8, 3/19/52 245-51, R-15 #1/40 Reccipt Inspection P. Grasewicz unsatisfactory (3) g, J/15/54 N -31, K-13 F1/ 4+J Hadg. & supp. Inst. P. Grasewicz unsatisfactory (4)
; 11. N
- 12. N
~~14 . N
~~~
- 15. N
^
N
- ._ _ _ _ 16.
- 18. N
- 19. N
- 20. N *
~~ i 21. N
- 22. N l 23. N' j 24. N
- 25. N I
REMARKS: NOTE: (1) Intermittent fillet welds do not conform to AWS A2.4-79 in that end welds are not 2" in length per the drawing. P-H NCR 2006 issued to document the deficiency and to f acilitate trackina till successful comnletion. NOTE: (2) Two FBM weld rod requisitions were beyond the maximum 3 day
. reissue ceriod. Weld material had been returned to the distribution center. P-H notified and will monitor more closely.
NOTE: (3) Shop weld J19 is missing. P-H NCR 2083 issued to insure adequate corrective action is accomplished. NOTE: (4) P-H installed pipe support #157-SH-7 and damaged FBM conduit. P-H has issued CIIR # P-H-22 to document the deficiency and f or tracking to insure adequate corrective action. Item closed.
.~ 1 y o wz Form 3.3 Dist. List 3.1 6 ./ M Revised: 5/27/81 . e 'QA Manager [/
' ~~^ - -~
YACC FQA WEEKLY SURVE.ILLAECE REPORT , Week Ending March 27, 1982' Page 1 of 1 Organization Pullman-111ggins ~ . . Report No. 167
..... q 3 AREA CONTACT RESULTS DATE Ih1[NCE ,
~~~~~~
- 1. 3/16/82 248-51, R-15 #1742 Penetrations P-H satisfactorv !
- 2. 3/18/82 248-51, R-15 #1744 Penetrations P-H satisfactory l
' ~ ~
- 3. 3/19/82 18-17, R-1 #1745 Conc. Exp. Anchors P. Grasewicz unsatisfactory (1)
~
- 4. 3/23/82 N45.2, R-1 #1747 Weld Mon. & Pres. MatP-H satisfactory l 5. 3/22/82 VIII-1, R-1 #1748 Ident, of Material P-H satisfactory )
. ~
- 6. 3/23/82 248-51, R-15 #1749 Fit-up & Weld. Root P-H satisfactory
( '- ~ 3/20/52 245-31, R-15 #1750 Weld. Proc. Piping P-H satisfactory l 7.
- 8. J/20/52 245-31, R-15 71/31 Defect' Removal J. Godfrey unsatisfactory (2)
- 9. 3/22/82 248-51, R-15 #1753 Storage J. Godfrey . unsatisfactory (3) 3/26/82 P-H
- 10. VIII-3, R-2 #1755 Weld Rod Mat. & Stor satisfactory
- 11. 3/25/82 FI-132&l36 #1759 Automatic Welding P-H satisfactory
^
- 12. 3/26/52 248-51, R-15 #1760 Receipt Inspection P-H satisfactory
~ 13, 3/26/52 245-31, R-15 #1/61 Exam. (Welding) P-H satisfactory
~ ~ ' - ~
}4. 3/2//52 245-31, R-15.fl/66 Welding F-H satisfactory
~ ~
i 15. 3/27/82 248-51, R-15 #1767 Base Metal Buildup P-H satisfactory
~
- 16. 3/27/82 248-51, R-15 #1768 Welding P-H satisfactory l - .] 7. N
- 18. 'N 1_9 . N
- 20. 'N *
(q.; 21. 22. N
^ w
_2 3. N '
- 24. N
- 25. N, REMARKS: NOTE: (1) Upper and lower left side hilti holes exceed angular deviation specified in UE&C Spec.18-17, Rev.1 and bolts exhibit thread damage. P-H initiated NCR 2081 to document deficiencies and to insure adequate corrective action / tracking till completion. Item closed.
NOTE: (2) Field crew working to outdated revision. to ISO and violated a visual inspection bold point. P-H QA notified and corrective action taken, item closedo l . NOTE: (3) In the storage area, two of three openings on a valve were unprotected and judging by the amount of dirt in the valve; it had been used for a stepstool. P-H notified and adequate corrective action taken. Item closed. l . \
^
1 Form 3.3 Dist. List 3.1 6 g e, f I' Revised: 5/27/81 Singlet QA Manager [
YAEC TQA WEEKLY SURVE.ILLAMCE REPORT
- Week Ending Anril 3_ 1982* Page 1 of 1 Organization Pullman-Higgins Report No. 168
.; - 3 DATE SHIN.ANCE AREA CONTACT RESULTS 1, 3/29/82 VIII-1, R-1 #1770 Material Control P-H satisfactory
] 2.
3. J/4W/04 248-51. R-15 #1776 Welding Examination 3/31/82 Sec. V, R-0 #1777 NDE P-H C. Walkins satisfactory
" ~ ' ~
satisfactory
- 4. 4/01/82 VIII-3, R-2 #1788 Weld Mat. Control P-H unsatisfactory (1
' . ~ ~ ~ 5. 4/02/82 248-51, R-15 #1791 Weld. Proc. Piping P-H satisfactory
- 6. 4/02/82 XIII-4, R-0 #1792 Preventative Maint. J. Hamilton unsatisf actory (2
- 7. 4/02/82 XI-1, R-0 #1793 Hydro Static Test. P-H satisfactory
_8, 3/22-4/2 ASME V, R-0 #1796 Radiography Review P-H- satisfactory
- 9. 4/03/52 n1JZ,126 F1/9/ Automatic Welding F-H sa tist ac tory
- 10. 4/03/82 248-51. R-15 #1798 Welding P-H satisfactory T ~~ 11. 4/02/82 IX-43. R-1 #1799
^ ~~
Post Weld H.T. P-H satisfactory
" ~ ~
- 12. 4/01/82 XIII-5. R-0 #1800 Housekeeping P-H satisfactory
- 13. 4/05/82 X-10, R-0 #1801 Weld Monitoring P-H satisfactory
~~ 16.
N
~' 17.
N
- 18. 'N
- 19. N
- 20. N
, 21. 'N
- x ,,/ 22. N
- 23. % w
- 24. N
- 25. N REMARKS: NOTE: (1) Portable rod oven #1294 was found to be unenergized and the rod cold. The responsible foreman was contacted and he verified that no rod from that oven had been used to weld and instructed the welder to return the cold rod to the rod room. Item closed.
NOTE: (2) Restoration of an end prep in progress without adequate protection for the valve internals. P-H craf t foreman notified, valve cleaned thoroughly and internals sealed. Item closed. d N v -
~ '*
1 Form 3.3 Dist. List 3.1 6 ,,,,,,y y _ , Revised: 5/27/81 31,g y ,g, ,qg g,,,,,,
YAEC FQA WEEKLY SURVE.ILIANCE
- REPORT Week Ending ,
April 10.*1982 Page 1 of 1
.. _ Organization Pullman-fliggins Report No. 169 DATE ShIh1[NCE AREA CONTACT RESULTS
_g , 4/5/82 248051 R-15#1804 In Process. Welding P-H Satisfactory
- 2.- 4/6 /82_- FI-156 R-0 #1806 Welding P-H Satisfactory
.-3.. 4/8/82- - -248-51 R-15#1814 Welding P-H Satisfactory
--4. 4/8/82 248-51 R-15#1815 Welding P-H Satisfactorv
-.7.-- -5 . 4/9/82 248-51 R-15#1819 Welding P-H Satisfactorv
.- -- t - 6. - 4/9/82 IX-6-R-4 #1822 Welding - Pip. Sup. P-H Satisfacterv
- 7. 4/8/82 VIII-3 R-3#1823 Weld Mat. Control P-H Satisfactory
_ 8. 4/8/82 248-51 R-15#1824 Weld Process Piping P-H Satisfactory
- -- 9. 4/9/82
-248-51 R-15#1825 Weld. Process Pipina P-H Satisfactorv
. . _- . - 10. 4/5/82-- 248-51& ANSI #1833 Control of Proc. Sheets D. Johnson Unsatisfactorv(1)
- 11. 4/9/82 248-51 R-15#1834 Control of Proc. Sheets D- .Tnhn a nn Uname4=far.cnrv m
- 12. N -
~
- 13. - N w --
- 14. -
1 N
- 15. N
- 16. -
N.
- 17. -
N i 38. N
- 19. N '
7 20. - A
/
! 21. -
N *
- 22. N '
- 23. N '
- 24. N
- 25. N N
REMARKS: Note (1): Documentation for installation of hanger ASC-2427-SH-1 was mixed up with documentation for another support. Process sheet for 783-RG-03 did not identify the heat code for the welding electrodes. P-H has returned the documentation to the rod room and inserted it in the correct file and the heat code has been recorded on the process sheets for the rod requisitions. Item closed. (2) In process sheet for field weld F0103 did not identify the heat code for the i consumable insett. Heat code has since been added to the process sheet. Item closed. , i b -
/
Form 3.3 Dist. List 3.1.6 Revised: 5/27/81
~ h [$'
gg, 3,g -QA Manager #
- l YAEC FQA WEEKLY SURVE. ILLA?;CE REPORT ,
Week Ending April 17, 1982* Page 1 of 1 Organization Pullman-liiggins Report No. 170 s3 AREA CONTACT RESULTS DATE S$Ih1[NCE
-1.- 4/6&l4/83VIII-1, R-1 #1805 Mat. I.D.-& Control F. Toomey unsatisfactory (1)
-- . . -- 2 . 4/13/82. 248-51, R-15 #1838 Welding Repairs P-H satisfactory
__3. 4/13/82 248-51,.R-15 #1839 Weld. Proc. Piping P-H satisfactory
-__4. 4/13/82 248-51, R-15 #1840 Weld Mat. Control P -H satisfactory
---5. 4/15/82 246-51, R-15 #1546 Weldir g P-H satisfactory o ._..._z 6. N 14613 IX-6,.R-4 #154/ Welding Hangers P-H satisfactory
-- 7. 4/15/82 VIII-1. R-1 #1850 Identif. of Materia 1P,H satisfactory
--__8. 4/16/82 X-9. R-0 #1853 In Process P, H satisfactorv
.-..___.-.9.- 4/15/82- 248-51, R-15 #1855 Pipe Sup. Install. P-H satisfactory
- - - - -10. 4/15/82 N45.2, R-1 #1861 Documentation D.B. Hunt satisfactory
--11. 4/16/82 248-51, R-15 #1862 Weld. Proc. Piping D. Johnson unsatisfactory (2) 2
---- 12 . 4/15/82_ 248-51, R-15 #1866 Weld. Proc. Piping P-H satisfactory
- ._ . . -- - _._13. 4/17/82 248-51, R-15 #187C Weld. Proc. Piping P-H satisfactory
~ .J _ 3 4. . N. _
- 15. Tw --
.=- - 1 6 . --
-- A
~-
- 17. - ---
N "
- 18. d N
- 19. 8 N
^
- 20. -
N ' *
- 21. -
N N
# 22.
- 23. N- "
- 24. N
- 25. N w REMARKS: NOTE: (,1) Plate stock.had been cut and retained without transferring identification information thereon, Corrective action report #66 was approved and signed on April 9, 1982.
NOTE: (21 The heat code for the consumable insert and the piece to
' piece identity were not recorded on the field process sheet. P-H QA notified and adequate corrective actton has been taken.
i m i \ - d - c wl . t. Form 3.3 Dist. List 3.1 6 ~- g -s_-,r r Revised: S/27/81 M
, , . Singleto QA Manager
~ -- .-
YAEC FQA WEEKLY SURVE.ILLANCE REPORT
- Week Ending April 24, 1982 pag. 1 og 1 4
w Organization Pullman-Higgins , , , Report No. 171 _._ 3 _ DATE S I NCE AREA CONTACT RESULTS 4/19/82 IX-43, R-1 #1865 Preheat & -Interpass Temp. Ellis/ Davis Unsatisfactory (l)
. ._1. _ . - -
- - - - 2. 4/20/82 PAXII-5 R-0 #1867 Weld Mont. Housekeep P-H Satisfactory
-3. 4/20/82 X-9?R-0 #1872 Inprocess Field Insp P-H Satisfactory
- -- - 4.- 4/20/82 X-10 R-0 #1873 Weld Monitoring P-H Satisfactory
- - . - 5. 4/22/82 IX-6_R-4 #1877 Inst. of Pipe Supp. P-H Satisfactory
- - . . . 6. 4/22/82 248-51_R-15 #1881 Welding P-H Satisfactory 7.. 4/19/82 VIII-1.R-1 #1882 Ident. of Material R. Donald Satisfactory
- _ - _ . _ 8.. 4/22/82 IX-14,.R-1 #1883 Defect Removal / Repair P-H Satisfactory
- 9. 4/22/82 GT-IT-01 R-0#1886 Master Integrity Tes t J. Fritsen satistactory
- 10. 4/20/82 GT-IT-01 R-0#1887 Master Integrity Iest J. Fritsch satisractory
_-_ _ 11. 4/19/82 248-51 R-15 #1889 Weld. Elec. Penet. P-H Satisfactory _ 12. 4/23/82. 248-51 R-15 #1890 Weld. Elec. Penet. J. Godfrey Unsatisfactory (2)J
- 13. 4/20/82. 248-51 R-15 #1891 Weld. Process Pip. D. Johnson Unsatisfactory (3),.
. 14. 4/23/82 ,248-51 R-15 #1893 Weld Pipe Support P-H hatisfactory
. _. 15. 4/21/82 IX-6 R-4 #1899 Support Welding D. Birch Satistactory
- 16. 4/23/82 II-6. R-4 #1900 Support Welding P-H Satisfactory 17, 4/12-23/ 32 Sec. V #1903 Radiograph Review P-H Satisfactory
- 18. 4/22/82 248-51 R-15 #1904 Loc. & Installation D. Daubert Unsatisfactory (4)
- 19. 4/23/82._ ANSI N45.2 #1905 Document Control L. DeYoung Satisfactory
- 7 20. X
^ *
) 21. %
- 22. N '
- 23. N -
- 24. .
- 25. N -
Note (1): Strip heaters are being used for preheat temperature and QC is REMARKS: not verifying the temperature on the process sheet as required by their procedure TY-A1. VAFP DR #167 fanned to document deficiencies and for trackine till adecuate l action is achieved. Mara (2)! Eremmaive weave beyond requirements of the weld procedure and the heat code for weld rod had not been transferred to the process sheet. P-H QA notified, I work temoorarily suspended pending evaluation and NCR issuance / disposition. Note (3): The heat code from one of the weld requisitions has not been transferred to the process sheet. P-H QA notified and appropriate corrective action has been taken. Item closed. Note (4): Small bore piping being supported' from safety related calbe tray, supports, ! contrary to spec. 48-2. P-H area supervisor notified and immediate corrective action was taken, temporary sdpp5rts removed and craft cautioned about like occurrences in the future. Item closed. l l s a M ~ -- 4 o t ' Form 3.3 Dist. List 3.1 6 - - Revised: 5/27/81 Singlet QA Manager [ i_______ _ , _ . - - - - - -----
YAEC TQA WEEKLY SURVE.ILLANCE REPORT . Week Ending May 1, 1982 - Page 1 of 1 Organization Pullman-Higgins Report No. 172 Sl AREA CONTACT RESULTS DATE hIh1[NCE ,
- 1. 4/27/82 248-51, R-1 #1906 Examination (Weld'.) P-H satisfactory Cont. of Process ShtD. Johnson unsatisfactory (1) ]
(((( 2. 4/27/82 248-51, R-1 #1907 Storage & Housekeep.P-H satisfactory
~~
- 3. 4/27/82 XIII-5, R-0 #1909 4, 4/29/52 245-51 R-1 #1916 Welding Proc. Pip. P-H satisfactory R-15 #1917 Welding Proc. Pip. P-H satisfactory
]_ $,
6. 4/25/62 4/25/52 245-31, 245-31, R-15 #1915 Radiography Review P-H satisfactory R-U F1921 Inst. Pipe Whip Res.fi MiW UfM G i b,c4eparenry
~ ~
- 7. 4/29/52 F1-13b,
- 8. 4/29/82 248-51. R-15 41922 Weldine P-H en ti e#nc torkt
- 9. 4/29/82 248-51. R-15 #1925 Storace P-H tm e n ti ef n e torv (2)
- 10. 4/28/82 IX-6. R-4 #1928 Weldine Suonorts D. Birch tm an tisf ac torv (3)
. 11. 4/27/82 248-51. R-15 #1929 Weld. Elec. Penet. P-H satisfactorv
- 32. 4/28/82 248-51. R-15 #1930 Inst. Pine Suonort C. Lunoli unsatisf ac to'ry (4) 4/29/82 248-51. R-15 #1931 Document Review' S. Ellis unsatisfactory (5)
_, _ __ 13.
- 14. 4/29/82 248-51. R-15 #1933 Weld. Proc. Piping P-H satisfactory unsatisfactorv (1)
' > 15. 4/30/82 248-51, R-15 #1943 Cont. of Proc. Sht. D. Johnson [_ J,6. 4/30/82 248-51, R-15 #1944 Cont. of Proc. Sht. D. Johnson unsatisfactory (1) satisfactory J7. 5/01/82 IX-14, R-1 #1945 Base Metal Repair R. Fultz
- 18. 4/30/82 111-4, R-0 #1947 Dwg. & ECA's Contro3P-H satisfactory
~ ~ 19. N_
m 20. A *
^
I w
.\ j ' ~21. 22. N
- 23. ~N -
- 24. N
- 25. N REMARKS:
NOTE: (1) Failure to record the heat / lot / control numbers of the material issued onto the process sheet, violating P-H Procedure VI-5 para. 3.7.7. Yankee D.R.169 issued to document and track the deficiency till adeauate corrective action is achieved.
NOTE: (2) Storage areas had piping laying on the ground, end caps open.
Contacted P-H OA and corrective action was taken immediately. Item closed.
NOTE: (3) Support angles (3) weld vertical (2 places each) to main horizontal "I" beam, have undercut on bottom welds with attempt to blend (grinding) of welds into base material, depressions adjacent to welds exceed 1/32". P-H has issued support rework order #1394 to document the deficiency and provide a means of tracking till adequate corrective action is achieved.
NOTE: (4) Welder failer' to identify work performed on previous day with his identification symbol. P-H QA notified and adequate corrective action has been taken. Item closed.
Nult. : p) Document : rrocess sneet alo not Analcace welder idenciizcation, r-d ya nocified and immediately corrected the process sheet. ;
Note (5): Unsthorized basemetal bulla up on pipe support. I AtA, UK # 1/ o issuea to document and track deficiencies till adequate corrective action is achieved.
Note (y): wela requisition Iorm v4ovul ala not nave wra revAston numoer. r-n ya notified and J. Scanlain took immediate corrective action.
Note (luj; uniy one welaer i.u. was uoced on""12e process sitee u wiieu ciies e imd ^ueen
.five welders on the joint. P-H QA notified and B. McCann took immediate corrective actie
/ N.
Note (11): Stub bucket containing a quantity of E7018 3 eut by day shif t & found by YAEC QA. Problem discussed w/h2(CC075) h P-H QA 1/8(DD065) was lef t
& was corrected.
Responsible individual retrained on,P-H roc. VIII-3. Form 3.3 Dist. List 3.1.6 ' Revised: 5/27/81 Sin [leto QA Hanager [~ __
~
- YAEC FQA WEErl,Y SURVE.lL1ANCE REPORT , j May 22, 1982. Page 2; of 2 Weck. Ending 175 Organization Pullman-Higgins ,,,
Report No. i_ _ , ,M ._ 8 AREA CONTACT RESULTS DATE Ih.$NCE
~
Welding Process Pip P-H.- Satisfactory
- 26.
- g 5/22/82 248-51 #2094 Disassembly /Assembl r S. Valliere Unsatisfactory (14)f
- 27. E 5/22/82 248-51 #2095 Document Control S. Ellis Unsatisf actory(15) j
- 28. E 5/23/82 ANST N45.2 #2096 Unsatisfactory (16)'
- 29. E 5/23/82 ANSI N45.2 #2097 Document Control S. Ellis Unsatisfactory (17)
- 30. E s/9,/R9 AnqT M45.2 #2098 Dwe. ISO & Doc. Con. J. Kuntz Sat.isfactory
- 31. E s /1 R /R9 - A9MF Sec. V #2106 NDE/RT Weld Hang. Supports R. Davis P-H Satisfactory
- 32. E 5/21/82 24R s1 #2083 E \
N ,
\
~
b s 5 N N N, s\ N (.. ,) s - N N N N Weld rod requisitions #16407 issued for field welds 1 through 8 REMARKS: Note (12):did not have correct original issue date resulting in conflicting records between rod requisition & distribution center log. P-H QA took corrective action. wia (in Nn unidern symbol on field welds. 1. 2 & 3. Final insoection & sign offs had been completed. P-H QA notified & adequate corrective taken. Note (141; Violation of two (2) hold points for operation 1 & 3 respectively for the disassembly of valve CS-V-432. P-H QA notified & proper corrective action taken. Note (15): Field process sheet for field weld F0101 initiated to rework spool in accordance with NCR 2242 did not reflect the repair cycle for the weld. P-H QA noti #ied and proper corrective action taken. Note (16): Field process sheet for field weld F0302 R1, initiated to rework spool in accordance with NCR 2145, did not reflect the radiograph requirements of the NCR's disposition. P-H QA has taken proper corrective action. Note (lE P-H ISO did not have all the dimensions required for fabrication. P-H Engineering has been notilled and proper corrective action nas oeen taxen.
~-
() _
. . . /
Form 3.3 Dist. List 3.1 6 - go M p/C w Revised: 5/27/81 ginglet QA Manager
I__ PURCHASE OCER FCRE'GN 8 8e ** vENOCR ORAWING oR DOCUMENT NO. 5 00
- C'
)
I couu. S t o. PRIN T NO. l0 5
$ REV.
JOB NO.
'a (Svar hoj .
U r k{ y , N O. f Ef $ _. __t_...__.- ,_ 3 is -
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