Text

Forwards Info Providing Detailed Accounting of Times for Each Welder During Completion of Special Welder Qualification Program & Special Training During 820720-1101, Per NRC 830517 Request.No Welders Received Special Training
	ML20076J475
Person / Time
Site:	Zimmer
Issue date:	08/15/1983
From:	Williams J; CINCINNATI GAS & ELECTRIC CO.
To:	James Keppler; NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
References
	LOZ-83-0111, LOZ-83-111, NUDOCS 8309070202
	Download: ML20076J475 (62)
	v • d • e

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E i?E =m THE CINCINNATI GAS & ELECTRIC COMPANY d

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CINCINNATI. OHIO 452ol August 15, 1983 LOZ-83-0111 J. WILLI AM S, J R stNfCR VtCE PRESIDENT NuCLEA R OPERATIONS

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U.S. Nuclear Regulatory Commission

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Attention:

Mr. J. G. Keppler h

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7 Regional Administrator Gentlemen:

RE:

WM. H. ZIM'fER NUCLEAR POWER STATION - UNIT 1 NRC LCTTER, DATED MAY 17, 1983, REQUEST FOR INFORMATION CONCERNING WELDER QUALIFICATIONS W.O. #57300, JOB E-5590, FILE NO. 956C By letter dated May 17, 1983, the NRC requested that CG&E provide a detailed accounting of the times for each individual welder, listed by ' stamp' in the enclosure, during the completion of the special welder's qualification program for the periods specified noting any special training, either casite or offsite, provided the individual during implementation of the requalification program between July 20, and November 1, 1982.

If no special training was provided for the listed individuals, your submittal should state that fact."

Our previous response, LOZ-83-0082, dated July 15, 1983, stated that CG&E was taking steps to confirm the accuracy and adequacy of the requested information prior to its cubmittal. CG&E has completed its review of the information contained in the attached report and believes the information accurately reflects the activities for each of the listed welders during the specified periods. The review also found that no special training, either onsite or offsite, was provided to the listed individuals. All documents used in the preparation of the report are available for NRC review at the site.

3 8309070202 830815 PDR ADOCK.05000358 A

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Mr. J. G. Keppler Regional Administrator August 15, 1983 LOZ-83-0111 Page 2.

If you have any questions or require additional information, please contact me at your convenience.

Very truly yours, THE CINCINNATI GAS & ELECTRIC COMPANY By R.

SENIOR VICE PRESIDENT

,r RNT/sfr ATTACID1ENT cc: NRC Office of Special Cases, Region III ATTN:

R. F. Warnick NRC Senior Resident Inspector ATTN:

W. F. Christianson NRC Zimmer Project Inspector, Region III ATTN:

E. R. Schweibinz State of Ohio

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SS County of Clermont)

I have read the foregoing and it is true and correct to the best of my knowledge, information and belief.

&)A L ~

jfJ. WILLIAMS, JR//

r SENIOR VICE PRESIDENT Sworn to and subscribed before me this /h th day of August, 1983.

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' NOTARY PUBLI'C PATP.! CIA LOUISE BROWN Notary Public. State of Ohio My CCiTJJ551;G Ltpires May 1,1986

Attachment'

.Mr. J. G.- Kepplir-Regional Administrator-August _ 15, 1983-LOZ-83-0111

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r NRC REQUEST FOR INFORMATION (NRC LETTER, DATED MAY 17, 1983)

SPECIAL WELDER'S QUALIFICATION PROGRAM

o HENRYJ. KA/SER COMPANY P.O. BOX 201 MOSCOW, OHIO 45153 August 15, 1983 I, Manfred L. Goedecke, do hereby affirm that the documents submitted herewith (Special Welder Qualification Program) were prepared under my direction and have been revised to accommodate comments from the Cincinnati Gas and Electric Company to further clarify sequents of events and are true and correct to best of my knowledge and belief.

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/Manfred L. Goedecke Project Welding Manager 7%d dMl-NW

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$4ML PATRICIA LOUISE BROWN NetE y 'ub ic. $ tate of ohfo My Comm.bsbn Erlies my 1,194 l

A FIAYMOND INTEHNATION.\\L COMPANY i

TABLE OF CCNIINTS 1.

09-0210, KDY 2.

09-2125, NFL 3.

09-1683, LIX 4.

53-0162, NDY 5.

09-2022, LSA 6.

50-0079, QBB 7.

53-0641/59-061,IQr 8.

53-0144, NDO 9.

09-0279, LUJ 10.

09-1169, 10 %

11.

09-2543, FEB 12.

09-3152, PEG 13.

09-3153, PEH 14.

09-2157, LTY 15.

50-0030, MAM 16.

53-0348, RBG p).

17.

09-1538, I K 18.

09-2851, NFS 19.

95-0692, IJS 20.

09-1911, Im 21.

09-0217, KDA

TRAINING All training that was pedonre:d during the special welder performance qualification program was conducted on site at the Mn. H. Zinmer Nuclear Power Station, by H. J. Kaiser Caupany, in accordance with NCP-2, Appendix B.

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9-?l0 KDY 7-20 Setting Up (.28) h 7-21 25% welded (.28) 7-22 90% welded (.28) 7-23 Ready to cap 7-24 Grinding ring out, inspection completed, coupon sent to NES 7-25 Fitting Up (.7) 7-26 60% welded (.7) 7-27 90% welded (.7) 7-28 Completed (.7) Inspection completed (.7), RT Accept (.28) 7-29 Fit-up (.19) 40% welded (.19), RT Accept (.7) 7-30 80% welded (.19) 7-31 Inspection completed, coupon sent to NES (.19), assigned booth (.1) 8-01 85% welded (.1) 8-02 Inspection completed, coupon sent to NES (.1), Assigned booth (.62H).

8-03 Setting Up (.62H), RT Accept (.19), RT Accept (.1) 8-04 Absent 8-05 10% welded (.62H) 8-06 90% welded (.62H) 8-07 Inspection completed, coupon sent to NES (.62H), welder waiting in test shop.

8-08 Sunday - did not work 8-09 RT pending ( 62H) - in field 4 hours4.62963e-5 days 0.00111 hours 6.613757e-6 weeks 1.522e-6 months MSRB, NR-2-282, ETRA-6012,

- in field 4 hours4.62963e-5 days 0.00111 hours 6.613757e-6 weeks 1.522e-6 months RT-1-300 cut and end prep.

8-10 RT pending (.62H) - in field 8 hours9.259259e-5 days 0.00222 hours 1.322751e-5 weeks 3.044e-6 months MSRB, N8-2-282 8-11 RT pending (.62H) - in field 8 hours9.259259e-5 days 0.00222 hours 1.322751e-5 weeks 3.044e-6 months SRB test blocks, A-6102 8-12 RT Reject (.62H) - in field 8 hours9.259259e-5 days 0.00222 hours 1.322751e-5 weeks 3.044e-6 months PSK-RT-35A-(9968-9106) 8-13 In field 5.8 hours9.259259e-5 days 0.00222 hours 1.322751e-5 weeks 3.044e-6 months PSX-RT-35A-(9968-9106), Assigned booth (.62H) 8-14 Two (2) hours training, Fit-up (.62H) Retest 30% welded retest O-8-15 Awaiting visual inspection (.62H)

9-210 KDY 8-16 Coupon sent to NES (.62H), welder remained in test shop for the day 8-17 RT pending (.62H) - in field 8 hours9.259259e-5 days 0.00222 hours 1.322751e-5 weeks 3.044e-6 months grinding J-bevel, PSK-RT-34 8-18 RT Accept (.62H) - in field 8 hours9.259259e-5 days 0.00222 hours 1.322751e-5 weeks 3.044e-6 months grinding J-bevel, PSK-RT-34

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7-21 Fit-up (.28) 7-22 40% welded (.28) 7-23 50% welded (started vacation) 7-24 Vacation 7-25 Vacation 7-26 Vacation 7-27 Vacation 7-28 Vacation 7-29 Vacation 7-30 Vacation 7-31 Vacation 8-01 Vacation 8-02 90% welded (.28)

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8-03-82 -;(.28) weld complete, visual inspection complete 8-04 Grinding (.28) 8-05 (.28) coupon sent to NES/ Fit-up (.7) 8-06 50% welded (.7), RT accept (.28) 8-07 Absent 8-08 Absent j

8-09 (.7) weld complete, visual inspection completg coupon sent to NES, fit-up (.1) 8-10 (.1) weld complete, visual inspection complete coupon sent to NES, RT accept (.7) 8-11 RT pending (.1) in field 8 hrs. clean up 8-12 RT pending (.1) in field 8 hrs. system RR 8-13 Welder remained in field, RT accept (.1) i O'

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j WELDERS NfNE BADGE NO.

9-1633 STENCIL 1.1x DATE INPROCES$

TiNAL VISUAL FINAL VISimE riNAL VISUAE HJK CG8E TEST PROCEDURE (S)

POSITION (S) TEST NO. TEST BEGAN VISUAt WELD ENGINEER HJK-QA CG4E-QA TEST TEST TRAINING SHOP SHIFT REMARKS ACC/REJ ACC/REJ ACC/REJ ACC/REJ RESULTS RESULTS d

3.1.23 6C 7105 7-20-02 ACC/ 8-2 ACC/ 8-3 ACC/ 8-3

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7-22 Absent 7-23 75% welded - 3G (.51) -

7-24 Completed 3G, Final Visual 3G(.51) accept, fit-up 4G (.51) 7-25 Welder in test shop 4.5 hrs.

7-26 Bend tests 3G accepted, fit-up 4G (.51) 7-27 Absent 7-28 Completed 4G, inprocess inspection (.51) 7-29 Visual inspection complete, cut bend & prep specimens Bend test accepted - 4G (.51) l I

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53-641 LQT 59-061 8-06 Fit-up, (.28) 8-07 Eng. rej. due to no root insp. performed (.28) 2 hrs. training Fit, tack (.28) Retest 8-08 40% welded (.28) Retest 8-09 80% welded (.28) Retest 8-10 Test weld complete, awaiting inspection (.28) 8-11 Inspection Complete, grinding for RT (.28) 8-12 Test Coupon sent to NES, welder waiting in test shop 8-13 RT reject (.28) - in field 4.5 hours5.787037e-5 days 0.00139 hours 8.267196e-6 weeks 1.9025e-6 months ECR 312, 9106, in field 3.5 hours5.787037e-5 days 0.00139 hours 8.267196e-6 weeks 1.9025e-6 months RR Snubbers A3, B5 8-14 Weekend, did not work 8-15 Weekend, did not work 8-16 4 hours4.62963e-5 days 0.00111 hours 6.613757e-6 weeks 1.522e-6 months training

Fit-up (.28) Retest 8-17 20% welded retest (.28) gg 8-18 40% welded (.28) in 7.-

8-19 75% welded (.28) 8-20 90% welded (.28) 8-21 Saturday, did not work 8-22 Sunday, did not work 8-23 Absent 8-24 Absent 8-25 Absent 8-26 Test completed, awaiting inspection l

8-27 Inspection Complete, grinding for RT (.28) l 8-28 Saturday, did not work 8-29 Sunday, did not work 8-30 Test coupon sent to NES, welder waiting in test shop 8-31 RT Accept (.28), welder reassigned to the field

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1 7-19 Assigned booth (.51) 4 h

7-20 65% welded, 3G, hurt hand at 3:30 PM (.51) 7-21-82 to 8-12 Out of work on Workman's Compensation 8-13 Assigned booth (.51) 8-14 Fit-up, 4G 8-15 Completed 4G, completed 3G, 4G bend test accept 8-16 3G bend test accept, welder assigned to field 9

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7-20 Setting up On L

7-21 50% welded (.28) 7-22 Completed test (capped out) (.28) 7-23 Inspection complete, grinding for RT, coupon sent to NES (.28) 7-24 RT pending (.28), set-up new test (.7) 7-25 20% welded (.7) 7-26 Completed (.7) 7-27 Fit-up (.19) 10% welded (.19) final visual inspection HJK (.7) 7-28 Inprocess visual reject (.1h) 3 hrs. training, Fit-up (.19) Retest, inspection pending CG&E (.7) RT reject (.28) 7-29-82 Absent, coupon sent to NES 7-30 30% welded (.19), RT accept (.7) 7-31 90% welded (.19) 8-01 Completed (.19) coupon sent to NES, Fit-up (.34),15% welded (.34) 8-02 60% welded (.34) 8-03 RT. accept (.19), visual reject (.34)

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09-1169 EMA During the time period between 10-5-82 and 10-17-82, velder was returned to the field and assigned work in accordance with his qualifications.

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09-1169 KMA 8-07 Fit up complete (.28) h.

8-08 50% welded (.28) 8-09 80% welded-(.28) 8-10 95% welded (.28)

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8-11 Capped out, waiting inspection (.28) 8-12 Inspection complete, grinding for RT (.28) 8-13 Assigned booth (.56), test (.28) sent to NES 8-14 Tack up (.56) 8-15 30% welded (.56) 8-16 95% welded (.56) RT Rej. (.28) 8-17 Completed (.56), coupon sent to NES 8-18 2 hrs. training, Fitting up (.28), reject RT (.56) 8-19 25% welded (.28) 8-20 40% welded (.28)

Q) 8-21 Saturday, did not work 8-22 Sunday, did not work 8-23 75% welded (.28) 8-24 85% welded (.28) 8-25 Weld complete, waiting inspection 8-26 Inspection completed, grinding for RT (.28) 8-27 Fitting up (.7), sent to NES (.28) 8-28 Saturday, did not work 8-29 Sunday, did not work 8-30 Tacked up (.7), RT Accept (.28) 8-31 In process visual reject (.7), fitting up retest (.7) 9-01 10% welded (.7), visual rej. (.7) 9-02 Fit-up on (.56), 20% welded on (.56)

O' 9-03 Completed (.56), visual inspection complete, coupon sent to NES 9-04 Saturday, did not work

w 09-1169 KMA 9-05 Sunday, did not work 9-06 Holiday, did not work 9-07 RT pending (.56) - in field 2 hrs. start up 7851-8810

- in field 6 hrs. IWRC-02-HR 2679-6951 9-08 RT Reject (.56) - in field 6 hrs. IWRC-36-HR 2679-6951

- in field 2 hrs. start-up 7851-8810 9-09 Fitting up (.7) 9-10 50% welded (.7) 9-11 Completed (.7), visual inspection complete, coupon sent to NES Fit-up (.56) Retest, Completed (.56) Retest, coupon sent to NES 9-12 Sunday, did not work 9-13 RT Reject (.7) - in field 6 hrs. INX-094-HG 2679-6954 RT Reject (.56) in field 2 hrs. start up 7851-8810 9-14 Welder in field 8 hrs.

9-15 Welder in field 6 hrs., 3 hrs. craf t training 9-16 Absent 9-17 Absent A..

9-18 Saturday, did not work 9-19 Sunday, did not work 9-20 Fit-up (.7) Retest 10% welded (.7) 9-21 25% weldad (.7) 9-22 75% welded (.7) 9-23 Completed (.7), visual inspection complete, coupon sent to NES 9-24 Welder in field 8 hrs., RT accept (.7) 9-25 Saturday, did not work 9-26 Sunday, did not work 9-27 In field 8 hrs.

9-28 4.5 hrs. in field, assigned to Test Shop, Fitting up (.6) n.

9-29 Visual reject (.6), 2 hrs. training, fit-up retest (.6) 9-30 20% welded (.6) Retest

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09-1169 KMA 10-01 Complete (.6), visual inspection complete. coupon sent to NES 9.6) 10-02 Saturday, did not work 10-03 Sunday, did not work 10-04 Welder in field 8 hrs. RT reject (.6) 10-05-82 thru 10-15 Reference attached cover letter 10-16 Saturday, did not work 10-17 Sunday, did not work 10-18 3 hrs. training, Tacked up (.6) 10-19 25% welded (.6) worked 6.4 hrs.

10-20 Completed (.6), visual inspection complete, test coupon sent to NES 10-21 Welder assigned to the field, RT accept (.6)

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9-2543 MCB

~ b 7-20 Set-up (.28) 7-21 35% welded (.28) 7-22 90% welded (.28) 7-23 Capped out (.28) 7-24 Inspection complete, grinding for RT (.28) 7-25 Seut to NES (.28), Set-up (.7) 7-26 60% welded (.7) 7-27 80% welded (.7) 7-28 Completed and sent to NES (.7), set-up (.56), RT accept (.28) 7-29 Fit-up (.56) Completed (.56), RT pending (.7) 7-30 Final visual (.56) coupon sent to NES (.56) Set-up (.19) 7-31 Fit-up insp. (.19) 60% welded (.19) 8-01 90% welded (.19) 8-02 Completed and sent to NES (.19), set-up (.56) 8-03 RT Reject and set-up retest (.56), RT accept (.7) RT accept (.19) 8-04 Absent j

8-05 Fit-up insp. (.56) 25% welded (.56) l 8-06 Welding completed, final visual (.56), coupon sent to NES (.56),

welder waiting in shop

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8-07 Saturday - Did not work l

8-08 Sunday - Did not work 8-09 RT accept (.56) retest 8-10 Vacation 8-11 Vacation 8-12 Vacation 8-13 Vacation 8-14 Saturday - Did not work 8-15 Sunday - Did not work 8-16 Fit-up (.5t,

l 9-2543 MCB 8-17 30% welded (.59) 8-18 75% welded (.59) s 8-19 85% welded (.59) i 8-20 95% welded (.59) 8-21 Saturday'- Did not work 8-22 Sunday - Did not work l

8-23 Completed and sent to NES (.59) 8-24 RT pending (.59), welder in field for 8 hours9.259259e-5 days 0.00222 hours 1.322751e-5 weeks 3.044e-6 months (INBB2BA 3/4")

8-25 Welder in field, RT Accept (.59) l 1

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9-3152 PBG 7-20 Assigned booth 7-21 Fit & Tack (.28) 7-22 Inprocess visual reject, 3 hrs. training, fit-up retest ( 28) 7-23 Fit-up inspection rej. (.28) Training Fit-up.28 Retest, Inprocess rej. root (.28) retest 7-24 Absent 7-25-82 -_ Training

7-26 Fit-up insp. acc. (.28) 25% welded (.28) 7-27 80% welded (.28) 7-28 Completed test, waiting inspection (.28) 7-29 Final Visual- (.28) Grinding (.28) 7-30 Coupon sent to,NES (.28), welder waiting in test shop-7-31 Saturday - Did not work, RT pending (.28) 8-01 Sunday - Did not work, RT pending (.28)

O; 8-02 Welder waiting in Test shop, RT pending (.28) 8-03 Walder in field 8 hrs.'1WR-561-HG RT Reject (.28) 8-04 Fit-up (.28) retest 8-05 50% welded (.28) Retest 8-06 90% welded (.28), Retest 8-07 Completed test, waiting inspection 8-08 Final visual as welded (.28), Grinding 8-09 Coupon sent to NES (.28), welder waiting in test shop 8-10 Welder in field, RT accept (.28)

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INTER OFFICE MEMORANDUM b

to : John Flaherty oate : Janurary 14. 1983 at : Weld Engineering

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Senior Welding Engineer comes to p

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Jos me.: 7070

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9-3152

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QC personnel entered booth MO for surveillance purposes on 7-25-82.

Welder # 9-3152 was working on the root layee of a 3.1.28 teit coupon.

Upon surveillance. QC immediately rejected the coupon.

3 P'

Wald Engineering had not been notified by welder # 9-3152 that coupon was ready for visual of root layer. Weld Engineering had not perfomed l

a visual inspection of root layer. prior to QC rejecting coupon. or notified QC that coupon was ready for a root inspection. At this point of testing the root layer had not been completely cleaned up f

for inspection. Verbal reason for reject by QC was excessive grind-ing and slag traps.

Respectfully Submitted.

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1 Chuck McCormick i

I Senior Welding Engineer

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7-31 Fit-up and tack. (.28) 8-01 35% welded (.28) 8-02 75% welded (.28) 8-03 90% welded (.28) 8-04 Visual reject (.28), 4 hours4.62963e-5 days 0.00111 hours 6.613757e-6 weeks 1.522e-6 months training

8-05 Evaluation prior to testing (training *) Training form dated 8-06-82 8-06 Absent 8-07 15% welded (.28) 8-08 80% welded (.28) 8-09 95% welded (.28) 8-10 Welding completed, visual inspection complete, grinding for RT (.28) 8-11 Coupon sent to NES (.28), welder waiting in test shop 8-12 RT reject (.28), 4 hours4.62963e-5 days 0.00111 hours 6.613757e-6 weeks 1.522e-6 months training

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8-13 Fit & tacked (.28) 8-14 Absent i

8-15 60% welded (.28) 8-16 80% welded (.28) 8-17 90% welded (.28) 8-18 Completed test, waiting inspection 8-19 Inspection complete, grinding for RT (.28) 8-20 Coupon sent to NES (.28), welder waiting in test shop l

8-21 Saturday - Did not work l

l 8-22 Sunday - Did not work 8-23 RT pending (.28) - in field for 8 hours9.259259e-5 days 0.00222 hours 1.322751e-5 weeks 3.044e-6 months (LDV 016 HR 2679-6950) 8-24 Welder in field, RT accept (.28) e-

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7-20 Assigned booth

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7-21 Tacked up (.28) 7-22 75% welded (.28) 7-23 Visual reject (.28), fit-up retest (.28) 7-24 Absent 7-25 Absent 7-26 20% welded (.28) retest 7-27 65% welded (.28) retest 7-28 Absent 7-29 Visual reject (.28), 6 hours6.944444e-5 days 0.00167 hours 9.920635e-6 weeks 2.283e-6 months training

7-30 Setting-up (.28) retest 7-31 Fit-up insp., comp. 50% welded (.28) retest 8-01 90% welded (.28) retest 8-02 Capped out, waiting on QC 8-03 Inspection complete, grinding for RT, coupon sent to NES (.28) l l

8-04-82 -- Fitting up (.7), RT accept (.28) l 8-05 Fit-up insp. comp., 40% welded (.7) 8-06 75% welded (.7) 8-07 Completed (.7), visual inspection complete, coupon sent to NES (.7) 8-08 RT pending (.7), Sunday - Did not work 8-09 RT pending (.7) - in field 8 hours9.259259e-5 days 0.00222 hours 1.322751e-5 weeks 3.044e-6 months , remove defects PSK HP 7, end prep spool #190 8-10 RT accept (.7) - welder in field

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was returned to the field and assigned work in accordance with the qual-ifications to SPPM 3.1.28.

On 10-11-82, due to a QA directive,.

was reassigned to the HJK Test Shop.

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=

8-06 Fit-up (.28) 8-07 50% welded (.28) 8-08 Completed, waiting inspection 8-09 Coupon sent to NES, welder waiting in test shop 8-10 RT accept (.28) (absent) 8-11 Set-up new test - 3G (.80) Inprocess visual reject - 3G (.80),

noted amperage problem - 2 houts training

8-12 TAN #1 approved for (.80) to increase amp range 8-13 Fit-up 3G, (.80), Completed 3G (.80) 8-14 Final visual insp. comp. 3G, Fit-up 4G, 40% welded (.80) 8-15 Completed 4G, cooling for inspection 8-16 Fit-up insp. 2G (.80) 2G 90% welded (.80), VT reject, 3G, after backing removed.

8-17 Fit-up 3G (.80) Retest O

8-18 ^6 e c 8-19 Grinding 2G & 4G for RT, fitting up 3G (.80)

8-20 2 hours2.314815e-5 days 5.555556e-4 hours 3.306878e-6 weeks 7.61e-7 months training *, 3G Fit-up insp. comp. 3G 50% welded (retest)

,'8-21 Saturday - Did not work 8-22 Sunday - Did not work 8-23 Complete 3G, inspect & grind; 2G, 3G, 4G test plates sent to NES 8-24 RT pending (.80) - in field 10 hours1.157407e-4 days 0.00278 hours 1.653439e-5 weeks 3.805e-6 months , repair leak chase wall liner 9965, 9674 8-25 RT reject 3G & 4G (.80) RT accept 2G (.80), welder in field 10 hour1.157407e-4 days 0.00278 hours 1.653439e-5 weeks 3.805e-6 months s-repair leak chase wall liner 8-26 2 hrs. training Fit-up (.80), fit-up 3G (.80) retest 8-27 Welder in field 10 hours1.157407e-4 days 0.00278 hours 1.653439e-5 weeks 3.805e-6 months - repair leak chase wall liner 8-28 Saturday - Did not work g

8-29 Sunday - Did not work

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fit-up 3G retest, (.80) inprocess visual rej. 3G retest (.80) completed 4G (.80) 4G bend test accept (.80)

50-30 M.A.M.

'(Cont.)

9-01 Absent 9-02 3 hrs. Training Fit-up 25% welded 3G (.80) Retest 9-03 Complete 3C, visual inspection complete Bend test accept 3G (.80) 9-04-82 thru 10-10 Reference cover letter 10-11 Evaluation prior to testing (.41), set-up (.41) 10-12 Coupon completed and sent to NES'(.41), welder sent to field 10-13 Walder assigned to. test shop, fit-up and 20% welded - 3G retest (.80)

RT accept ( 41) see note #1 10-14 90% welded 3G (.80) 10-15 Completed 3G, inspection & grinding, 3G bend test pending 10-16-782 - Saturday - Did not work 10-17 Sunday - Did not work 10-18 Walder in field, 3G bend test accept (.80)

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FINAL VIStlAL FINAL VISUAL ENALVISUAL luK CG4E TEsi PROCEDURE (S)

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TEST NO.

TEST BEGAN VISUAL WELD ENGINEER HJK-QA CG4E-QA TEST TEST TRAINING SHOP SHIFT REMARKS ACC/REJ ACC/REJ ACC/REJ ACC/REJ REStLTS REstLTS 3.1.28 6C 7133 8-6-82 ACC/8-7 ACC/8-9 ACC/8-9 ACC/8-9 ACC/8-10 SCC /8-10 N/A 2

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1 ACC WELD. TEST FUR 3.1.80 3c 6853 10-13-82 ACC/lo-15 ACC/lo-15 ACC/40-15 ACC/10-15 ACC/10-18 ACC/10-18 N/A 2

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7-20 Booth Assigned 7-21 Fitting up (.28) 7-22 Tacked up (.28) 7-23 107, welded (.28) 7-24 40% welded (.28) 7-25 80% welded (.28) 7-26 90% welded (.28) 7-27 Absent 7-28 Welding complete, waiting inspection (.28) 7-29 Inspection complete, grinding for RT (.28) 7-30 Coupon sent to NES (.28), welder waiting in test shop 7-31 RT pending (.28) Saturday - Did not work 8-01 RT pending (.28) Sunday - Did not work 8-02 RT pending (.28) - in fiald 4 hours4.62963e-5 days 0.00111 hours 6.613757e-6 weeks 1.522e-6 months Drywell Steel El.561 #6107 extra work

- in field 4 hours4.62963e-5 days 0.00111 hours 6.613757e-6 weeks 1.522e-6 months Drywell Steel El.561 #6257 extra work 8-03 RT accept (.28) - in field 8 hours9.259259e-5 days 0.00222 hours 1.322751e-5 weeks 3.044e-6 months Drywell Steel El.561 #6250 l

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8-10 Fit-up (.28), inprocess visual reject (.28), 8 hours9.259259e-5 days 0.00222 hours 1.322751e-5 weeks 3.044e-6 months training

N 8-11 Fitting up retest (.28) 8-12 30% welded (.28) 8-13 80% welded ( 28) 8-14 Absent 8-15 Absent 8-16 90% welded (.28) 8-17 Visual inspection completed, grinding for RT (.28) 8-18 Grinding (.28) 8-19 Coupon sent to NES (.28), Tacked up (.7) 8-20 50% welded (.7), RT accept (.28) 8-21 Saturday - Did not work 8-22 Sunday - Did not work l

8-23 Coupon sent to NES (.7), tacked up (.1) l 8-24 80% welded (.1), RT pending (.7) 8-25 Welding complete, visual inspection complete, coupon sent to NES (.1) 8-26 RT accept (.7), RT reject (.1), welder in field 8 hrs.

8-27 Fitting (.1) retest 8-28 Saturday - Did not work 8-29 Sunday - Did not work l

8-30 Fit-up inspection complete (.1) 50% welded (.1) 8-31 Welding complete (.1), visual Inspection complete and coupon sent to NES l

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9-01 RT accept (.1) - in field 8 hours9.259259e-5 days 0.00222 hours 1.322751e-5 weeks 3.044e-6 months (lRH-820-RR) i 1

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a 7-20 Fit-up (.28) per daily log 7-21 8% welded (.28) per daily log 7-22 Test stopped, filler material problem per daily log 7-23 40% welded (.28) new test per daily log 7-24-82 -- Saturday - Did not work 7-25 Sunday - Did not work 7-26 No welding performed, pipefitters left site 7-27 Tuesday - Did not work 7-28 Wednesday - Did not work 7-29 Absent, personnel records indicate welder R. Skaggs terminated due to absenteeism.

9-01 Personnel records show welder R. Skaggs rehired on this date Tacked up (.28) 9-02 50% welded (.28) 9-03 85% welded (.28) 9-04 Saturday - Did not work 9-05 Sunday - Did not work 9-06 Holiday - Did not work 9-07 Final visual reject (.28), (evaluation prior to retest) per daily log 9-08 40% welded (.28) retest 9-09 Welding complete, awaiting inspection 9-10 Inspection complete, grinding for RT (.28); fitting-up (.7) 9-11 Saturday - Did not work 9-12 Sunday - Did not work 9-13 RT accept (.28), final visual reject (.7), welder returned to field r0 v

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8-07 Fit-up and tacked - 3G (.51)

(ll,y 8-08 Inprocess visual reject, 4 hours4.62963e-5 days 0.00111 hours 6.613757e-6 weeks 1.522e-6 months training *, 10% welded - 3G retest (.51) 8-09 90% welded - 3G (.51) 8-10 Welding complete - 3G (.51), tacked up - 4G (.51), bend test 3G pending 8-11 10% welded - 4G (.51), welder lef t early, bend test accept - 3G (.51) 8-12 40% welded - 4G (.51) 8-13 Welding 4G (.51) 8-14 Saturday - Did not work 8-15 Sunday - Did not work 8-16 Final visual ace (.51), bend test accept - 4G (.51), welder reassigned to field Y'

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9-1911 L.O.W.

(.

Welder L.O.W., was terminated on 6-24-82, prior to the start of the Special Qualification program. On 8-2-82, he was rehired and at that time his original qualification for SPPM 3.1.18 was still in effect. At the time of rehire, he was assigned to the HJK Test Facility and was given the opportunity to add to his present qualification by testing on SPPM 3.1.28 and SPPM 3.1.56, the results were unsatisfactory. On 8-23-82, was returned to the field and assigned work in accordance with his original qualification of SPPM 3.1.18.

On 9-15-82, he was reassigned to the HJK Test Facility.

(Reference Attachments) On 10-14-82, was returned to the field and assigned work in accordance with his qualification 3.1.18.

On 10-28-82, the welder was assigned to the BJK Weld Test Facility.

(Reference Attachments) wu I

9-1911 L.O.W.

=

8-02 Req. for Welder Qual.

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8-04 Assigned booth (.56) 8-05 Fitting up (.56) 8-06 Fit up complete (.56) 8-07 Saturday - Did not work 8-08 Sunday - Did not work 8-09 Inprocess visual reject (.56), 6 hours6.944444e-5 days 0.00167 hours 9.920635e-6 weeks 2.283e-6 months training

form dated 8-8-82 8-10 80% welded (.56) retest 8-11 Final visual reject (.56), fitting up (.28) 8-12 25% welded (.28) 8-13 70% welded (.28) 8-14 Saturday - Did not work 8-15 Sunday - Did not work (3

8-16 Welding completed (.28)

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8-17 Visual reject (.28), 30% welded (.28) retest 8-18 80% pelded (.28) retest 8-19 Weldirig complete (.28) retest 8-20 Final visual reject (.28), 3 hours3.472222e-5 days 8.333333e-4 hours 4.960317e-6 weeks 1.1415e-6 months training

8-21 Saturday - Did not work 8-22 Sunday - Did not work 8-23-82 thru 9-14 Reference attached cover letter 9-15 Fitting up (.1) 9-16 Absent 9-17 Absent 9-18 Saturday - Did not work 9-19 Sunday - Did not work ll /

9-20 Inprocess visual reject (.1), 3 hours3.472222e-5 days 8.333333e-4 hours 4.960317e-6 weeks 1.1415e-6 months training

9-1911 L.O.W.

(Cont'd.)

=

9-21 10% welded (.1) retest 9-22 75% welded (.1) retest 9-23 Welding complete, visual inspection completed, coupon sent to NES (.1) 9-24 RT reject (.1) 9-25 Saturday - Did not work 9-26 Sunday - Did not work 9-27 Evaluation prior to retest (.1) welder in field 8 hrs.

9-28 cleaning coupons, retest (.1) 9-29 Visual reject by Weld Engineer (.1) retest, additional training

l 2 hrs., retest (.1) 9-30 Tacked up (.1), 15% welded i

10-01 Visual reject by Weld Engineer (.1), fit-up (.56) 10-02 Saturday - Did not work 10-03 Sunday - Did not work 10-04 90% welded (.56) 10-05 Welding complete and coupon sent to NES (.56), welder in field 3.5 hours5.787037e-5 days 0.00139 hours 8.267196e-6 weeks 1.9025e-6 months (1RI-19-SR) 10-06 RT pending (.56), in field 8 hours9.259259e-5 days 0.00222 hours 1.322751e-5 weeks 3.044e-6 months (INX-3376-HG) 10-07 RT reject (.56), welder on vacation 10-08 Absent' 10-09 Saturday - Did not work 10-10 Sunday - Did not work 10-11-82

, Tack up (.6) 10-12 Final visual reject (.6) 10-13 1" socket weld, visual accept 3.1.1 10-14-82 thru 10-27 Reference attached cove.r letter 10-27 Setting up retest (.56) 10-28 Tacked up (.56) 10-29 90% welded (.56) a

9-1911 L.O.W.

(Cont'd.)

10-30 Saturday - Did not work 10-31 Sunday - Did not work 11-01 RT pending (.56), welder waiting in test shop 11-02 RT accept (.56), welder assigned to field l

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I WELDERS NAME BADGE NO. 9-1911

_ STENCIL 1 0.w.

g P ngs. I oF g.

j DATE INPROCESS FINAL VISUAL FINAL VISUAL FINAL VISUAL NK CG8E TESI i

PROCEDURE (S)

POSITION (5)

TEST NO.

TEST BEGAN VISIML WELD ENGINEER NK-QA CG8E-QA TEST TEST TRAINING SHOP SHIFT P.EMARKS j

ACC/REJ ACC/REJ ACC/REJ ACC/REJ RESULTS RESIA.TS yf[,[7,g 3.1.56 6C N/A 8-5 lld 8-9 N/A N/A N/A N/A N/A 6, hrs y

g E

N/A N/A N/A N/A N/A I

1 V.T. Rej 3.'t. 56 6c N/A 8-10

\\CC/ 8-10 RU / 8-11 i

3.1.1 6C N/A 9-15 RU/9-20 N/A N/A N/A N/A N/A J hrs.

2 I

tv.T. Fej L 't. I 60 6774 9-21 ACC/9-22 ACC/9-23 ACC/9-23 valved RU/9-24 N/A N/A 2

1

$,T.Pej L t.1 60 N/A 9-28 RU/9-29 N/A N/A N/A N/A N/A 2 hrs.

2 2

V.T. Rej

11.1 60 n/A 9-29h ACC/ 10-1 RU/10-1 N/A, N/A N/A N/A N/A 2

2 V.T. Pel 10-lh ACC/10-4 ACC/10-5 ACC/10-5 ACC/10-5 RU/10-7 N/A N/A 2

2 v.T. Rej Lt.56 6C 6821 3.1.6 6c N/A 10-11 ACC/10-12 R U/10-12 N/A N/A N/A N/A N/A 2

2 V.T. Rej Socket

t 3.t.1 6c 6848 10-13 ACC/lo-13 ACC/

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2 Weld 3.1.56 6c 6890 10-27

.:C/ 10-2 ACC/ll-1 ACC/Il-1

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j-ATTAC *ENT 1 TO

%1 ding Engineering should not have allowed fourth weld test to SPfw 3.1.1

" Performed socket weld test Welding Engineering unable to use because ASME Section II,1971 Edition does not show a graphic for a socket weld test assently. (Socket weld graphic not included in ASME Section II until the 1974 Edition. Sweer Addenda).

IMEDIATE CORRECTIVE ACTION Welding Engineering shall remove all current qualifications from subject welder sr.d require complete requalification if welder returns to the b1 employ of the Henry J. Kaiser Co.

NOTE: Welder laid-off on or about Novem6er 15,1982 due to " Construction Slow down".

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9-217 K.D.A.

o 7-19 Fitting-up (.28)

~ '

7-20 Fit-up inspection (.28) 30% welded (.28) 7-21 80% welded (.28) 7-22 90% welded (.28) 7-23 Waiting inspection (.28), welder remained in test facility 7-24 Saturday - Did not work 7-25 Sunday - Did not work 7-26 Absent 7-27 Waiting inspection (.28), welder remained in test facility 7-28 Grinding (.28), final visual (.28) 7-29 Test coupon sent to NES (.28), fitting-up (.56) 7-30 RT accept (.28), Fitting up (.7), inprocess visual (.56) 7-31 Fit-up inspection (.7) 75% welded (.7), final visual accept (.56) ll )

8-01 Welding complete, visual inspection complete, coupon sent to NES (.7) 8-02 RT pending (.7), welder in field 8 hours9.259259e-5 days 0.00222 hours 1.322751e-5 weeks 3.044e-6 months (WR-484SR installation) 8-03 Welder in field, RT accept (.7) 9 kj v[

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