ML20080K342
| ML20080K342 | |
| Person / Time | |
|---|---|
| Site: | Perry  |
| Issue date: | 03/19/1982 |
| From: | Furness J CLEVELAND ELECTRIC ILLUMINATING CO. |
| To: | Tulk S CLEVELAND ELECTRIC ILLUMINATING CO. |
| Shared Package | |
| ML20079G896 | List: |
| References | |
| FOIA-83-199 830319, PNPP-SP-557, NUDOCS 8309290118 | |
| Download: ML20080K342 (112) | |
Text
- . ______ ___ ____ _________ _ ___.
. .. THE C ELAND ELECTRIC ILLUMIN ATI.' CO M PANY E L. . .. . MEMORANDUM
- XF~ *: arch 19, 1982 TO S. P. Tulk noon rnow J. Furness oArc .
PHoNC Room susaccT PNPP-SP-557 Class lE Motor Control Centers Construction Quality Engineering has researched the applicable Codes and Standards Section of SP-557-4549-00, Rev. VI for which all the materials used in the fabrication of the Motor Concrol Centers were manufactured (Reference paragraph 2:05) by Cutler-Hammer in Itasca, Illinois. As a result of this research, IEEE h20-1973 is not applicable for the dzsign, manufacture or inctallation of Class lE Motor Control Centers.
IEEE 420-1973, pdagraph4.31usesthework"should"describingthe
" Recommended" J)e' sign Criteria for fleur.e retardance of nonmetallic com-ponents and devicer. (See attached page 9 of IEEE-420). This pc.ragraph does not specifically state that you "shall" meet these design considera-tions for the nonmetallic components.
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8309290110 830622 PDR FOIA HIATT83-199 PDR
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Rf:FE RE!!CE: 5'ritt !'o. ._ 2 k CA R.'t4R b'o.: 02 4 O Full Refe::se Ui] Partici Rc! case The ncncenfermir.g conditions for which the refercnced STCP WCRK t40TIFICATIOt1 have udeq,ctely oddressed /ccarected. You cre hereby cuthorized to resume the offected work sebject to the fc!!vwing limitations (for partial release only):
7cif'.cra ' f'::Tifi1C PARTICLE I::SFECTIOh'S in accorca:re with L. K. Ccatock trece6re-h.7.8. - - ------------------------------
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CORRECTIVE ACTION REQ [$EST c .sion REVliED RESPONSE SHEET C EV.'9 41 ?
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- Project Organization 82-09, Rev. 1 3/30/82 ^ c *" ce t o* T s' 4/2/82 RESPONSE - Ennineering has reviewed the _ quality requirernents relative to identification, control and traceability of rnaterials for the major installation specifications (SP-44,
- 47. 90. 49. 85. 17, 53, 96) and find the practices now being used meet the requirements of 10CFR50. Appendix B, Criteria VIII.
Tha traceability requirements for each specification are surumarized on the attached position l peper. The positions are offered as clarification and are not intended to change the practices currently in use.~
This, along with the partial response on electrical (SP-33) traceability submitted earlier, constitutes the total response to this CAR.,
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, Y Z 82 CLOSE OUT: " "'
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The Cleveland Electric illuminating Company
. CORRECTIVE ACTION REQUEST NO. 310s REVISED RESPONSE SHEET i
ctvis.st S An Nuugg n ngge. ngy. DAff ISSUED TO S . Pro _icct Organization
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82-09, Rev. 1 3/30/82 4/2/82 1 RESPONSE Ennincerinn has reviewed the cuality requirements relative to identirication, control, and traceability of insterials for the major installation specifications (SP-44,
- 47. 90. 49. 85. 17._53. 96) and find the practices now being used u.ect the recuirements of 10CFR50. Appendix b, Criteria VIII.
The traceability requirements for each specification are sunearized on the attached position paper. The positions are offered as clarification and are not intended to change the prectices currently in use. This, along with the partial response on electrical (SP-33) traceability submitted earlier, constitutes the total response to this CAR. DATE gy, h =2 f? oATE CLOSE 0UT: Accept Reject COMMENTS: e
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- ENCINEERING POSITION ON TRACEABILITY RECriveo
. REQUIREMENTS FOR MATERIALS USED IN APR 141982 SAFETY-RELATED SYSTEMS AND STRUCTURES [
oopr't'..- t l The following is a summary of the requirements for identification, control and trace-ability of materials used in safety-related systems and structures. It covers the , major installation contracts. Piping and I and C (SP-44, 47, 90) All materials used in pressure vessel systems follow the traceability requirements L defined in the ASME Boiler and Pressure Vessel Code, Section III. This essentially is unique traceability to the final location. Materials not covered by ASME, Code III are traceable, as a minimum, to their receipt on Site. Their use is then controlled by procedures. Structural (85, 17, 53, 96) Materials used in these structures are uniquely traceable to their final location with the exception of Rebar and embedments. Rebar and embedments are traceable to their receipt on Site. Their use is then controlled by procedures. J' HVAC (SP '- 49/91) Material traceability is required, es a minimum, to its receipt on Site. It's use is then procedurally controlled. The contractor has chosen to impose more rigid requirements for some materials, such as duct sheet metal and hanger steel. These materials are uniquely traceable to
! their final location. There is no intent here to relax these requirements.
Coatings (SP-64) Material traceability is required, as a minimum, to its receipt on site. For Class 1 materials (used in containment) they are traceable to their final location. Mechanical Equipment (SP-38/39) Haterials in general in these centracts follow the traceability requirements defined in the ASME Boiler and Pressure Vessel Code, Section III. This is essentially unique traceability to the finsi location. Materials not covered by ASME, Code II are tra:: cable, as a minimum, ti> their receipt on Site. Their use is then controlled by procedures. iw
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Revised 4/14/82 CAR-82-09 d f WI. '_ l 3 h.h Y~?S$b
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,o . CORRECTIVE ACTION REQUEST
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' March 4, 1982 Project Organization REQUIREMENT: Title 10, Code of Federal Regulations, Part 50, Appendix B, Criteria VIII, Identification and Control of Materials. Parts and Components. Perry Mucicar Power Plants, Preliminary Safety Analysis Report, Chapter 3 - Design of Structures, Components, Equipment and Systems; C!iapter 17 - Quality Assurance. IEEE Standards 279, 306.
CONDITION: vn-inun anfory-roinrod apec% ationn do rtot_ adequately _ define _ quality requirements relative to identification, control and traceability of materials: 1.e.. SP-33. __ s
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NQAD March PESPONSE The following is a partial response to this CAR for electrical materials only. t ,
'. ion remainder of the disciplines will be addressed by 3/31/82. Engineering has researched 10CFR50, Appendix B, Criteria VIII, the Perry FSAR, Chapters 3 and 17 and IEEE Standards 279 and 308 with respect to the identification, control and traceability of materials. 10CFR50 continued end the FSAR set forth general requirements for this topic but are not specific (see attachment)
BYs DATE CLOSE OUT: BRJ9u- ~' uneas
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- s 30 82-Accept Reject O COMMENTS: 1) We find the attached <sponse from Electrical Engineering (SP-33) acceptable.
3/30/82 - 11. Wall 80 DISTRIBUTION: Y romu co4p era 1rMte - Original Canary . Organization Pink ^ - File Goldenrod - Follou -up . s s-' Con Distribution:
CAR No. 82-0 dtd 3/4/83 1 Attachment i with respect to electrical materials. 'Ihe IEEE documents referenced do not address traceability. SP-33 was also reviewed and invokes similar requirements to 10CFR50 and the FSAR. Because the documents are not specific on this subject, engineering has defined the attached
" Engineering Position on the Identification, Control und Traceability of Materials Used in Electrical Safety Related Systems". This statement is intended only to clarify and reinforce the practices currently in ef fect on traceability and does not add to or change them. (The weld-rod traceability requirements were changed in accordance with the second sentence of the position.)
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ENGINEERING POSITION ON THE IDENTIFICATION CONTROL AND TRACEABILITY OF MATr. RIALS USED IN ELECTRICAL SAFETY-RELATED SYSTFMS Position: Materials and equipment used in electrical safety-related systems shall be identifiabic and traceable to their receipt on the Site, as a minimum. Some materials may be traceable to their installed location (unique traceability) in some specific instances when specifically required by codes or for convenience or future economic reasons. All materials shall be controlled in safety-celated system use. Justification:
- 1. 'Ihis position meets the intent of the law 10CFR 50, Appendix B, Criteria VIII, Identification and Control of Materials, Parts and Components.. The final sentence of this section states "These identifications and control measures shall be designed to prevent the use of incorrect or defective material, parts and components" which our program as outlined here does.
- 2. Neither the FSAR, Specifications or Procedures require unique traceability specific to electrical equipment and materials.
- 3. Traceability beyond this point becomes a matter of economic justification rather than safety. If a batch of material or type of equipment is identified as defective, unique traceability could reduce the cost of finding and correcting the potential defects, however, not having traceability would not preclude the ability to find the questionable material.
- 4. All material used in safety-related systems or non-safety seismic systems is purchased as safety-related material and is accompanied by Certificates of Compliance.
- 5. There are Site Organization and Contractors procedures in place designed to prevent the use of non-safety materisis in safety applications.
- 6. It is not practical or possible in some cases to provide many materials with unique traceability. Cable tray, conduit, conduit support hardware, etc. is not available with such information as heat numbers, etc. It would therefore be inconsistent to require some but not all material to have unique traceability.
Equipe nt does not have material traceability for the most part.
- 7. Materials used in (, S r disciplines are not always uniquely traceable including such items as embedments. Electrical equipment such as trays and conduits are supported off these embedments. Again it would be inconsistent to require unique traceability of the electrical components.
- 8. Electrical Equipment and System Standards such as IEEE467 (Section 8) have not required unique traceability except where required by specific codes, standards or specific safety justification.
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Engineering Position en the Identification Control and Traceability o,f Flaterials Used in Electrical Safety-Related Systems Page 2 l l 9. Industrypracticeissuchthatuniquetraceabilityonelectricklmaterials is not used. A typical example is the use of Unistrut for tray supports
- on other nuclear plant sites. Unistrut is not traceable in the sense used j l here.
I ' l 10. At this stage in our project it would be impractical to require unique l traceability for materials not yet installed, even if this were desirable and possible. Tray and conduit installations are nearing completion with the exception of inside containment, and there is little naterial left to install. The advantages would be minimal. i i I l DRG/iw 3/29/82 O
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l THE CLEVELAND ELECTRIC ILLUMINATING COMPANY l I no longer wish to l MEMORANDUM '"*3 'h ' ' = ' ri 'l-a;*
, , , , , , , j qv vs E. Riley acow W115 raoM T. B. Stear DATE 1/11/83 ;
E. Walls W175 PHONE 5346 accM TW 2 < ; susaccT Revised Position for Engine'ering Disposition CAR 82-09 Rev. 1 In view of the Engineering disposition and position statement regarding the Identification Control and Traceability of Material Used in Electrical Safety-Related Systems, it has been identified that the justification listed per line number four (4) is not clear. The item in question indicates that all ; material used for safety and non-safety seismic systems are procured with a Certificate of Compliance. To clarify this subject please revise item number four (4) to read as follows: 4 .. - All materials used in safety-related systems or non-safety seismic systems are purchased as safety-related material and are accompanied by a Certificate of Conformance as a minimum. Approved by: ,4/ [c g. J n Shins;1er AI Lead Elect. ngineer Approved by: k
, G. R. Leidich Senior Electrical Engineer TBS /JS/GRL:dm cc CAR distribution K. Pech W260 M. Lastovka W220 J. Kerr TO 6 J. Furness TO 5
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THE CLEVELAND ELECTRIC ILLUMINATIND COMPANY I no longer wish to
"3 " 'h l = 'a'"' *1-g;*,, , , ,, MEMORANDUM To T. B. Stear. nooM W2 rnow 11. Walls, Dr oAva January 18, 1983 PHoNr 5140 m ou W175 suGJECT Revised Position for CAR 822-09 Rev.1 As per your memo dated January 11, 1983, I concur that the correct statement is " Certificate of Conformance", and the CAR should be changed to reflect the correction.
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PIRRY NUCLEAR PO4LS PLANT PROJECT ORGANIZATION I no longer wish 13 tcccive thin rnatcritl. THE CLEVEL.AND ELECTRIC ILLUMINATING COMPANY AND KAISER INGINE ERS. INC. Pu4 acv.s'.so MEMORANDUMn Proc no.
.D H. Walls, Jr. Room W175 raoM J. R $uar/J/ HaycSDATc May 20, 1982 PHoNc 257 Room W160 s u eJ ccT . CAR # 82-09 ' REY.~~ 1\ .
s...___.- - ._ , . Attached please find a copy of the addendum to the response to CAR #82-09. This revised response was submitted by Engineering on April 2, 1982. As of this date, there is no record of an evaluation of this response. Please investigate and provide an evaluation by June 4, 1982. JRD/JRH:pab Attachcient cc: CAA File 401.JED en G S
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REFERENCE:
SWN No. .._' 2_Th_BdI_ CAR / NR No..
<?2-06 ad 82-07 f,3 Full Rc!cose [~] Pertici Rc!cese The ner.cenferm.ing conditions for which the icierented $1CP YlCRK NOTIFICATION heve cdcc.uctcly oddressed/ccrrected. You are hereby authorized to resurne the offected work schlect to the following limitctions (for portial release only):
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1 The Cleveland Electric illuminating Company CORRECTIVE ACTION REQUEST
- e. nos REVISED RESPONSE SHEET
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^cti " u s o^ T E' 82-07 rev. 1 April 15, 1982 April 15, 1982 RESPONSE Je m MA JMix,, Ao-82-4-,71 la. L l A & onrw -+xi u. PR-1A Ad
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cousiocx Perry Nuclear Power Plant l l Pc - A i N :f y e senc e 1904 L.K. Comstoc < Engineering Conpany,Inc. ~ A CCuSTOCK GROUP COMPANY April 14, 1982 Cleveland Electric Illumintaing Company Perry Nuclear Power Plant Perry, Ohio 44081 Attention: Mr. Hudson Walls Subj ect: CAR 82-07 Dated 2/25/82 PY-S/ CON 4219 QA Dated 3/8/82 CONTROL NUMBER:Q-82-4-771
Dear Mr. Walls:
The following actions have been taken to correct the deficiencies stated in CAR 82-07.
- 1. The below listed procedures were revised to provide weld material traceability for weldments on supports or equip-ment. LKC Procedures 4.3.11; 4.7.6; 4.8.18.
- 2. Weld material purchase orders and receipt inspection records were reviewed to assure all required documentation and certifications were received and attached to the applicable record file.
- 3. LKC receipt inspectors have been retrained to assure all purchase order requirements are met and certifications are attached prior to acceptance of weld materials.
Yours truly,
- d.~./
Clarence W. Hart Asst. QC Manager - CWil: eea cc: R. Marino T. Woodman S. Tulk QC File P.O. BOX 324, PERRY, OH 44081 l (216) 259 3755
Th2 CI;vstsnd Elsctric illuminxting Csmpany
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n ev. 5-oo CORRECTIVE ACTION REQUEST wNuumEn DATE 8 5M D T o 82-07 February 25, 1982 L. K. COMSTOCK, SP-33 l j REQUIREMENT: Title 10, Code of Federal Regulations, Part 50, Appendix B,' Criteria VIII, SP-709, Rev. IV, Section 1:03.8.1. L. K. Comstock & Company Procedure 4.76 " Storage. Issue & Control of _ Weldine Materials". Rev. 1/16/81 CONDITION: Contrary to the above. welds cannot be traced back to detailed records certifyine the characteristics of the weldin_g material used. Traceability of welding material t hall be extended to items _(such as indixidual uniauelv desianed_gunnprts. conduit runs, equipment cubicles, etc.). s
- 1. Waj a/ ChG ANIZ A T ION: RESPONSE DU E
((h_1s/G.R.LeidichJN,_fghMNh Nuclear Quality Assurance Dept: ? larch 12, 1982 ar.SPONSE See Enclo e #1 Attached. Way Ct.0Sf OUT:
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l- .. . , ENCLOSURE #1 CORRECTIVE ACTION REQUEST 82-07 2/25/82
' RESPONSE: All weld rod, safety or non-safety related, is issued id, accordance with L. K. Comstock procedure 4.7.6 on form #67.
This form provides traceability to the relevant drawing. The form itself provides the option of providing the drawing number or the detail number, a search of LKC documents (Form 67) indicates that the use of drawings is and has been, consisti ,t throughout our program. Neither reference provided specifies a more stringent traceability requirement, even though actual work, documentation and traceability is in accordance with our approved procedures. 5 s 1
r.%] TH E C L EV E L Al{ D E L E CT!;lC I L L U f611< ATlii G C O I6 P A R Y j"L
. P.O. BOX 97 e P ER RY. CHIO 4t.081 a T EL EPHONE (216) 259 37 37 m ADDRESS- to CcNTER RO AD Serving The Best Location in the Nation March 16,1982 t PY-SO/033 11,001 ,
L. K. Comstock P. O. Box 761 Painesville, Ohio 44077 Attention: Mr. T. Woodman Re: Corrective Action Request No. 82-06 and 82-07.
Dear Tom:
- Attached for your information and review are the action items outlined per our meeting of Friday, March 12th in regards to the CAR's written against L. K. Comstock which address Weld Rod material traceability and magnetic particle inspection. Those in attendance included: I T. Woodman - LKC H. Walls - NQAD R. Troff - LKC S. Tulk - CQS P. Merlin - LKC C. Wright - NED , J. Marginen - CQS T. Stear - NED G. Sterle - CA The purpose of this meeting was to outline Site Organization concerns and . delineate the corrective steps necessary to implement and respond to the two (2) CAR's written.
- 1. CAR No. 82 identifies omission of the acceptance standards required by AWS D1.1 (1975) per L. K. Comstock work procedure 4.7.8 " Magnetic Particle Inspection".
LKC responce to CAR has been received with an addedum written to include acceptance standards per AWS. No formal response has been issued by Mr. Hudson Walls, although the procedure addedum has been approved by Quality Engineering and C6nstruction Engineering elements.
- 2. CAR No. 82 identifies program deficiencies in the storage, issue and traceability of welding material per L. K. Comstock pro'cedure'4.76 virsus the requirements per the specifications and the Federal Code of Regulations, Part 50, Appendix B, criteria.
. L. K. Comstock PY-SO/033-11,001 - March 16, 1982 Page 2 LKC response to CAR has been received and found unacceptableg The formal rejection letter was issued with a copy transmitted to Mr. T. Woodman (at this time).
- 3. Site engineering outlined the requirements needed to be addressed and implemented by LKC to satisfy traceability of weld material from receipt inspection to final insta11at. ion by the contractor. Major action items include:
- a. Recertification and inspection records for welder No. 56.
- b. Re-inspection of past Certificants of Conformance for weld rod received from Airco Company to insure adequate documentation. This requires identification of lot nunber, MIL spec numbers and chemical properties for each. All material receipts without complete documentation to be scrapped, (discussion indicated only one (1) specific case wherein no l information was available.)
- c. Weld material traceability to be expanded to cicarly identify and trace installation to field and accurately identified on weld filler metal withdrawal tab (form 66) and associated inspection forms. Implementation by LKC to include:
- 1. Identification of weld materials to each unique cable tray and conduit support (series SS drawings).
- 2. Identification of weld material to each direct attachment conduit support. Traceability to be identified via the unique , conduit race-way number or numbers associated with the support.
- 3. Identification of weld materials to each uniquely numbered cable tray.
- 4. Identification of weld noterials to equipment MPL numbers. For MCC's switchgear and unit subs, the addition of cubicle or section number is required.
- 5. Identification of weld materials for pre-fabricated generic conduit direct attachment supports which are not assigned unique numbers per SS series drawings. The contractor shall establish a unique numbering system for traceability of said hangers.
- 4. To implement the program requirements associated with item 3 above, a 4
preliminary listing of Work Procedure changes were submitted to LKC. - This included:
.- _ - . _ . . _ _ _ , _ . _ , . , _ _ , , _ , . _ _ . . _ . , , _ . . , - - . _ _ _ _ . _ _ _ ~ _
L. K. Comstock PY-SO/033-11,001 , March 16, 1982 Page 3 Procedure 4.8.18 Under section 5.9 for Records, add statement which directs inspector to identify the unique SS series conduit or tray hanger support; Equipment MPL numbers (for MCC's switchgear and unit subs the addition of cubicle or section number is re-quired); or unique conduit raceway number (for direct attachment supports). This information shall be included on Form 94 and/or 107. Procedure 4.7.8 Include on Magnetic Particle E). amination Report (Form #70), the unique hanger number or equipment MPL number (and compartment designee if applicable) or unique conduit Raceway nurber associated with direct attachment support, and location and drawing references. Procedure 4.7.5 Include on Liquid Penetrant Examination Report (Form #69) the same unique identification as listed for Form #70 per procedure 4.7.8. Incorporate Form #70 as part of procedure. Procedure 4.7.6 Under Attachment #1 Form 66 " Weld Filler Metal with-f drawal tab" Incorporate block and field for other types of Filler Metal. Under Section 3.6.1.2 the foreman and/or welder shall properly identify the unique hanger number via SS drawing, or MPL number of equipment (in the case of switchgear, MCC's and Unit Substations the compartment number or section number are applicable), or unique conduit raceway numoer for direct attachment
- or unique tray raceway number.
Procedure 4.3.11 Add new item under 3:3 Raceway Hange'r inspection, to ' address inspection and weld documentation verification as a prerequisite for sign-off per check list form 17 and 82. Add new item under 3.1 Receipt, Fabrication and In-sta11ation, to address fabrication of direct attach-ments (non-unique conduit suppor.t numbers) which are assembled in the Contractor's fab shop for traceabilit; of vold naterials. This will require a date stamp, month and year and the welders number being permanenti: indented on the unique hanger assembly, or other means for traceability. In developnent of these changes and/or others as required, Site Quality and Engineering elements will assist LKC ef forts as required.
4 L. K. Comstock
- l. PY-SO/033-11,001 March 16, 1982 1
Page 4 i 5. Upon Acceptance of these procedural changes, the contrac; tor will have ! to conduct a traini6g session for both the construction and quality sections. j 6. The question related to overall material traceability for Class 1E 4 materials as perchased per SP-33 was submitted by LKC. Engineering's response, indicated that a total review of these requirements were in process (in respo'nse to c CAR written against the Site). Pending re-solution of this Correction Action request, Engineering would follow-up j with the contractor for definition and implementation of additional re-quirements. 1 Very truly yours, T. B. Stear Engineer i . i I 1 D. R. Green Senior Project Engineer TBS /jg . l cc: R.P. Jadgchew - W140 E. Riley - W120 B. L. Barkley - W220 EDS File P0/DC - R290 4 I 1 d i g a D l i 1
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l . _ . . . INFORMAT102t. g- ,_ - i The Cleve.larul E2ectric Illsaminating Company Nuc] car Engineering Departaent
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97 . Pe.rry, Claio 44081
. Attentiour Mr.. I. M. T astavr.m $ Rc: Perry Nuc1 car Power plant, Unitse.1 6 2 Tiannable Materials in Electrical Switchncar & MCC's Gentlemen:
Questions were raised by the NRC inspector at the plant concerning the use. of flanamb3e materials in r.afety-related.4KV, -480 volt and 125 volt DC switchgear 'and rootor control centers. He cited such iteses as p3astic - h protectors in openings for enhle entry, cover on terminal blocks, spiral p3=stic natMn3 to hold wiring packs in shape and sof t rubber tape natcrial used over" sharp objects to protect wiring as iterns of concern. Irfc have contacted Cutler Manaer, the supplier of the motor control centers, and TTT.-Gould, the supplier of our switchgear, to discuss this prob 3en. with then and obtain information. Cutler Hamraer is currently in the procem
- of como111ng a dera12cd 31 sting of every item on cach starter size down -
i to nutz and bolts for purposes of the environmental qn-m fication report. i Every itew. including such things as small nylon or rubber bushingn with
! the type of materda3 wi13 he listed. Prna this, we expect to know the i narcrial for any non-metallic material and evaluate the amount of -
i et=n:=etibic veterial. and the potential hazard involved; ITE-Gould .! respcoded that they would furnish no information that vc vanted unless we
!_ paid _for -it.- -
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.he Fire P.valuardon Report in written, recognizing that elisminatdoo af
,[ a13 f]arsa.ahle matednja in desirabic, but not completely achievable, j , Cricerian h page 16DE, of 10CFK-50 recognizes this in the stat-t ,i "Eoncordevstible exI heat resist =nt materials shall be used wherever practical thoughout the unit , particularly in 3ocations such as the - l? crmtrinsent and erme-rol roo:a." S a i s* >-I 5 i i
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.---4 "In' order.to compensate for, flatwaabic materials, estimates were made .of the amount 'of non-metallic material in mediure voltage switchgcar, low voltage 2
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Hh' 7Thelestimated hights used -in the evaluation were 403bs. per 201nch width , of .MCC's, 80lbs.. per 20 inch vidth of . low: voltage .switchgear and .70lbs. per 20 inch wJdth of medium voltage switchgear. - The 803bs.. per 20 inch vidth- - 1 1
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transformer in'480 volt load centera prcrated over- the sections of. switchgcar. These estimated weights of materials were made on the basis of taking-our . the-scight of steel and copper from the total weight and considering.every-thing e3nc organic materials that. were flaasnabic'. This in itself was_a conservative approach. TheJ10,000 ETU per pound is.also considered i conservative number for. the burning of the material considered. - We fec1 that in our conservat1ve approach to addressing the fire eMumtsosi criteria, we have compensated for the small amounts of flaner.ab3c materials that -were addressed as matters of concern. Such items as covers on terwinal blocks and spiral wirc wraps, can readily be replaced; a3though it would he cirme consussing and expensive. The replacemment. material would stillnern to somme degree. The rubber bushinbu would be more difficult to replace., but not dispossible. Here also thy replacement material-would burn,.'.
- although to a lesser or slower rate.
i. It -la our intent to pursue .this further by analyzing the inforsmetion :we-receive frcus Cutler Haaseer to correlate- it against -our Fire.Evn3natioss-Report. " If you concur with our approach, we also intend to write to ITT.-GouiC to ' request the material type and supplier for items in the meditna voir:ab . and Icw voltage switchgear, including DC switchgear, which we feel should he
, considered. . The result.c of this, if we can obtain them without a prohibitive '
,- poy.m.i. to IIE, will also be evnluated against our Fire Evaluation Report
.-. est-2==rns.
,_. ' Ple-mine give us your cocuments or concurrence on our approach.
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Jg T. A. Schlegel Project Electrical T.ngineer P. B. Gudikunst i Project Manager j in'M:TAS tPBG arap 4
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P. B. Gud1kunst (2L) D. R. Green . J.'D. Crier
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S ER RY. CHlo 44c81 m TEL EPHoNE (216) 259 3737 m ADDRESS.to CENTER Ro AD f u ' erving S The Best Lc: :.x - s !.' ::cn May 24, 1982 h.p ,. fj.g.1..
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L PY/S0-33-12076
Response
n @ i (k'.K.Comstock L , P. O. Box 76 Painesville, Chic 24077 Attentien M: . C. EP.rt RE: Electrical Penetration e Weld Documentation Ref: LKC Letter date'd 5/12/82
Dear Clarence:
Engineering has made a cursory review of the weld documentation submitted per your letter transmittal dated May 12, 1982. Based en our review it is determined that numerous packages are incomplete due to missing documentation er inconsistent and inaccurate inspection sign-offs. Refer to the fellowing examples:
- 1. Electrical penetration No.'s 1R72-7 and 1R72-14, no Ultrasonic Flaw Detection Record.
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- 2. Electrical Penetration No. 1R72-26 keld rod stores requisition indicates issue date of May 8, 1981, for welder No. 01, with a Q/A approval date of April 8, 1981.
. Please clarify and correct.
3., Electrical penetration No.'s 1R72-5_and 1R72-14 weld rod withdrawal slip; have ~QA acer ovals on later datan versus wiIEY the actual weld was fit-up and tacked. Note that the
, fore =an dated the withdrawal in the appropriate time frame, but QA sign-off was ,afterwards. It is a requirement'that QA sign-off and verification be done prior to issuance of materials and performance of the specifiec task.
These items a e representative of the inconsistancies found wnich will be required to be corrected before completion of.the quality Joc. Package.. Respectfully, ,
/
T. B. Stear
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Lead Electrical Engineer T33/ cab Oc: J. Margenin S210 S. Hawe W210 NDS 3 1 ~
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,h S. Tulk TC4 T. Wood =an LKC SO/DC G. Sterie W150 P. Merlin LKC C. Wrish: 3AI E S File df
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ENGINEERING CHANGE NOTICLn PERRY NUCLEAR POWER PLANT 3 SP ECN O DWG. ECH h SUBJECT Cable Tray Till
, h ECN huMPER b 7C/- M- /9/2 EV. -
, ORIGINATOR N .' C- if' 8 2 -
DEPA RTMENT E E r. ineTr?g'-Electri'cT1' . AFFECTS Sr. E-l M -00 l
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hDETAILSANDBACKGROUNDOFREQ'D.DESIGNCHANGE: DOCUMENTS TO BE REv! SED
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The purpose of this ECN is to clarify SP-33 BY THIS ECN requirements when cable fill reaches the top of the side. SP-3 3-4549 - Co R2v. TT s . _ s.m .m, . - . .n op E '# FDI?h'df.Viuv2h,b'. d
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/ i SAR CHANGE REQ'D? G NO O YES '
h SYSTEM AFFECTED N/A REASON FOR CHANGE: g MATERI AL TO BE PURCHASED O UNSATISFACTORY TEST RESULTS O NO O YES
' O INTERFACE PROBLEMS DURING CONSTRUCTION g DESIGN REVIEWER APPROVAL O FAILURE TO MEET FUNCTIONAL REQUIREMENTS O DISPOSITION OF NON-CONFORMING ITEM O CHANGES IN REGULATORY OR OTHER REQUIREMENTS g g, , , , , , ,g ,, ,
O OPERATIONAL EXPERIENCE @ Q A APPROVAL (if REQ'D) E DESIGN IMPROVEMENTS BY: CO w *e DATE: fo -t2-6 2 O OTHER g na manasustat g PROJECT MANAGEMENT APPROVAL ATTACHMENTS # 1 BY: DATE: __ p gg _ , , , Revise SP-33 Item 5:08.13 sub-item 6. *
@ CEI ACCEPTANCE BY:
DATE: RESPoN$lStt 3rNInt IntinttR INTERFACING DEPARTHENTS Q/A REVIEW REQUIRED NOT h REQUIRED O
@ ORGANIZAfl0NS OR GROUPS /- ,
1 0 civil O STRUCTURAL REVIEWED sY: h ~// ^ DATE: l 0 ELECTRICAL D c.i. arrststarailut
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O BLDG. SERVICE QUALITY ASSURANCE (SEE @ ) D MSSS Ol&C D OTHER sitt or mattniat nuvarats: assuto O HECH. / NUCLEAR SPEC.NO. AND CONT. /PO NO. P-
@ PROJECT ENGINEER APPROVAL
@ DESIGN CHANGE INCOR'PORATED BY- N ,[f4L66FL. DATE: Je/O 62, BY:
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l Paestet ensingte DATE: NOTE:
- MOT REQJIRED IF FOR DI(AWING CHANGES ONLY.
-SILDERT ASSOCIAlt1, INC.
UTILITIES DIVISION
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ll EC'N # $701-3 3 IO 3 b IJ Atta,-hment #1 Spec. No. SP-33-4549-00
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5:06.13 Subitem 6. - Lov voltage power, control and instrument cables shall be
,. installed in tray without maintained spacing. The cables
; shall be placed in the trays so that they are straight and lie flat with a minimum of crossovers, except as specified .
in Item 5.:08.17.1_ subitems h through k. The cable fill I may exceed the top of the tray side rail due to field installation conditions. k' hen the cable fill reaches within
... . 1/2" below the top of the side rail, the contractor shall inform the PROJECT ORGANIZATION of locations where cable fill will exceed and/or is within the prescribed 1/2" criteria via the Q/C inspection report or comparable document.
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- THE CLEVELAND ELECTRIC ILLUMINATIND COMPANY s fr, ..,,
MEMORANDUM 73 R. L. Farrell Room S260 rROM c - r :gr- = DATc June 17, 1982 E. Riley W115 PHONE RDOM TQ6 - suestcT L. K. Comstock Status . l ! 2 l Attached is an overview report on the status of our actions taken with the L. K. Comstock QA program. I Additional emphasis is currently being placed on the following priorities: l
- 1) Complete closure of all 37 NRC concerns
- 2) Continued pressure on LKC to meet hiring commitments
- 3) Resolution of audit findings (with the Audit Group) l 4) Closeout of open NR's In addition, we are carefully monitoring and documenting field activities to ensure that the recent resignations of LKC personnal do not adversely affect the installation.
If you have any questions or need more detail, please let me know. l l l Attachments . CRL:lle cc: M. R. Edelman J. A. Kline D. R. Green - E. G. Sterle J. M. Lastovka
- 302.CRL 3G
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OVERALL RESPONSE TO ELECTRICAL INSTALLATION CONCERNS 2 As a result of concerns expressed by the NRC during the investigation / inspections, several major tasks were undertaken. 'Ihese tasks , while geared toward the electrical installation, are a part of the overall Project Organization Action Plans developed by NQAD and reviewed by the QA Advisory Committee. The tasks include: l
+ Identification and tracking of specific NRC concerns. These concerns were treated (in-house) as if they were infractions.
I Development of actions taken by the Cantractor, the focus of which was an in-depth corporate cudit and subsequent action plans.
- Development of actions taken by the Project Organization, the focus ,
t of which was the development of several action plans and a complete
, audit of the Contractor.
- A complete evaluation of the organizational adequacy of the Contractor (QA/QC) and the responsible Site Organization (CQE). -
The attachments detail each of these areas.
IDENTIFICATION AND TRACKING OF SPECIFIC NRC CONCERNS Utilizing notes from previous discussions, a list was compiled of all known NRC concerns from the November - March visitn. 4 37 concerns were identified
- 18 dealing with the contractors' QA program
- 19 dealing with ve.rious portions of the P/O program involving CAI, NDS, CQS, NTS All of the concerns were treated as if they were infractions for tracking purposes. All were assigned an applicable criteria as if they were infractions ,
pending receipt of a report from the NRC. The identified concerns ranged in severity from a question on tray supports to overall unsatisfactory corrective action on the contractor's program.
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Of the 37 concerns, 27 are satisfactorily answered and collection of the supporting documentation is progressing well. The remaining 10 are being reso1'ved on a priority basis. e
%6 h e***
ELECTRICAL INSTALLATION
SUMMARY
OF ALL KNOWN NRC CONCERNS APPLICABLE QA NO. CRITERIA PROGRAM ITEM
- 1. QA Program (P/0) Overall Unsatisfactory Corrective Action on I.KC
- 2. QA Program (P/0) Timely Close-Out of AR's (P/0) and AFR's (LKC)
- 3. Design Control (P/0) Weld Symbol on Battery Charger Vendor Drawing
- 4. Design Control (P/0) ,
Swgr. Plug Welds Improperly Specified
- 5. Design Control (P/0) Hangers: Multiple divisions on common support
- 6. Design Control (P/0) Use of flammable materials in electrical equipment
- 7. Design Control (P/0) Adequacy of separation fire walls - CC-620'
- 8. Design Control (P/0) Capping of conduit in manholes
- 9. Design Control (P/0) Overfill of cables in tray
- 10. Inst / Proc /Dwgs (LKC) Use of all pull points not in procedure
- 11. Inst / Proc /Dwgs (LKC) Procedure improperly specifies bend radius for coiling
- 12. Inst /P. roc /Dwgs (LKC) NR's improperly voided by LKC personnel
- 13. Inst / Proc /Dwgs (LKC) QA Organization Chart incorrect
- 14. Inst. Proc /Dwgs (LKC) Cable tray splice bolts torque req. not in procedure
- 15. Inst / Proc /Dwgs (P/0) Establish penetration acceptance criteria
- 16. Inst / Proc /Dwgs (P/0) g.._ Turnover proc.edures do not compliment each other
- 17. Inst / Proc /Dwgs (LKC) - Coiled cables violated. training radius
- 18. Doc, Control (LKC) Switchgear dre. wings - wrong rev, and workplace
- 19. ID of Materials (LKC) Inadequate control pf purchased materigt
- 20. ID of Materials (P/0) Traceability of gusset plates -
- 21. Inspection (LKC) Inspection of penetrations not performed as required
- 22. Inspection (LKC) Cable tray splice plate bolts not seated
- 23. Inspection (LKC) Sharp edges and burrs on trays
_ .= - APPLICABLE QA NO. CRITERIA PROGRAM ITEM
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3 -
- 24. Inspection (LKC) No in process inspection of switchgear
- 25. Inspection (LKC) No in process inspection of Unit Substations
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Inspection
- 26. (LKC) No in process inspection of Motor Control Centers
- 27. Inspection (P/0) Hold tag not on switchgear
- 28. Inspection (LKC) Reinspection of holes in four penetrations
- 29. Inspection (P/0) , Separation of cable tray ( < 14")
- 30. Inspection (P/0) Identification of switches on DC panels
- 31. Inspection (P/O-JCI) Johnson Controls - Hangar problem AR #417
- 32. Handling / Storage (P/0) Housekeeping: Local panels and annulus area
- 33. Handling / Storage (P/0) Storage of MCC's (NR CQC 2290)
- 34. Nonconformances (LKC) NR's not being trended to prevent re' petition
- 35. Nonconformances (LKC) Separation violations not identified
- 36. Nonconformances (P/0) Supporting documentation for penetration FQ's ,
- 37. Audits .
(LKC) Internal auditing program not adequate
SUMMARY
QA Program -2 Design Control -7 Inst / Proc /Dwgs -8 , ., . Doc Control -1 -
/
ID of Materials -2 Inspection - 11 Handling / Storage - 2 _ Nonconformances -3 Audits ,.
-1
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ACTIONS TAKEN BY THE CONTRACTOR The focal point of the actions taken by the contractor was the internal corporate audit performed March 10-18, 1982. While the audit generated many (64) findings, the contractor responded, at the corporate level, with actions geared toward
" root causes" rather than specific symptoms. The significant root causes and actions taken (and planned) are:
Craft Training and QC Training LKC hired a full time site LKC training director in February. Extensive craft and QC training related primarily to work procedures has been performed. To date, 15,229 manhours have been expended in training. In the period November - April, meetings were held with NECA and IBEW key personnel to discuss craft training at Perry. The effort was -
, finalized by the , development of a two-day workshop, held on June 15-16, for craft supervision. .The workshop emphasized the QA/QC
. documentation and inspection. Union support has been excellent.
Records - The audit revealed the quality records were not adequately completed, collected, or stored.
A Records Review Task Force was assigned in Marr.h by LKC to review all safety related documentation. Eight personnel are invol ed in this on a full time basis. This group has completed the review of 1
; all ductbank records and is progressing en hanger records, targeted for completion August 1,1982. '
A controlled access facility for quality records was established March 5, 1982. p il L A 100% Document Control Field Audit was completed May 1. This included verification of correct revision of procedures and drawings in the field. ! A computer system has been developed to track nonconformance reports, audit finding reports, action reports, field variance authorizations, and engineering change notices through QC close-out. This will be used for configuration control and trending. Procedures All LKC procedures are being re-reviewed for adequate incorporation
-of requirements and clarity. Since November, 41 procedure revisions have been processed. -
m _._________..___m--__
t y . Inspection
+
As a result of increased staff (from 25 to 33) and improved emphasis, a the inspection backlog in the field has been reduced. For example, in November 411 conduits were awaiting inspection. The current conduit inspection backlog is 61. The number of inspection records on file increased from 1278 to 1702 since November. Closecut LKC hired a full time coordinator to track and expedite closeout of AFR's and NR's. Since March, open AFR's have been reduced from 172 to 69. The number of open NR's has increased as a result of increased inspection. Corporate Emph' asis At the corporate level, major organizational changes were made in February.
,A corporate level position for Manager QA/QC Services was established and filled. - -
Regional staff. positions were created and the Eastern Region Manager position filled.
Organizational responsibilities were clarified and emphasized by LKC i executive management. *
; The QA/QC staff at Perry has increased from 25 to 33.
- Efforts are being finali2ed for additional staff:
2 - Quality Assurance Engineers 1 - Welding Engineer 4 - Inspectors Replacement for QC Manager and QC Supervisor 4 s
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ACTIONS TAKEN BY THE PROJECT ORGANIZATION In addition to several broader action plans dealing with the adequacy of the Project Organization QA program, specific actions were initiated by NQAD for L. K. Comstock. The action plans were reviewed by the QA Advisory Committee. The first action taken was to provide separate supervision, on an interin basis, to the Electrical /I6C discipline within the Construction Quality Section of NQAD. This was done to increase emphasis and develop action j plans to resolve concerns. Having completed the action plans, the organization was returned to its original configuration. l l The first task in the action plans was to perform a complete audit of the contractor. 'Ihe audit was performed in May. The contractor's responses are being evaluated. The audit revealed problems in welding) procurement and overall QA coverage that require resolution. NQAD determined that these problems did not indicate a significant program breakdewn. Special project plans were developed and implemented for: switchgear, unit subitations, motor control centers, penetrations, flammable materials, and turnover (these are part of the 37 NRC concerns). This effort is approximately 75% complete. -_. . The internal audit of the site conduit design team was completed. One finding was written.
s .
'r A series of in-depth process audits have been echeduled and are being performed to verify implementation of procedures in field, e.g., cable pulling, terminations, separation criteria, and hangers.
7_- In-house questions on traceability requirements for electrical items were formally resolved by Engineering. Engineering has been assigned the responsibility of reviewing all LKC procedures for inclusion of proper criteria (by September 1). 41 LKC procedure revisions have been processed to date, indicating good progress on this item. Open nonconformances, SIR's and AR's within CQE are being resolved with additional staff and clarified responsibilities. For example, since June 1, the backlog of NR's in CQE for review has been reduced from 128 to 14. Weekly coordination meetings are continuing between the Contract Team and LKC. Meetings (in-house) are continuing at least twice weekly to resolve the 37 NRC concerns. Field surveillance by CQE of the installation has increased, particularly in light of the resignation of the QC Supervisor. Within the -past week, we have observed that the resignation has not adversely affecfed the quality of the installation. Our monitoring and close involvement will continue I until LKC is adequately staffed.
I f EVALUATION OF ORGANIZATIONAL ADEQUACY (LKC QA/QC and CQS) ,
+
Id developing steps to preclude recurrence of the implementation difficulties of the LKC program and adequate monitoring by CQE, an evaluation of organizational strengths and weaknesses was performed. The organizational structure of LKC was modified at both the corporate and site levels. The organizational structure of CQE was determined to be adequate. Individual personnel changes (both LKC and CQE) have occurred, and improvements have been noted. The contractor and site personnel interfaces have improved. Staffing has increased for both LKC and, on a temporary basis, for CQE. To increase emphasis, the LKC Corporate QA/QC Hanager and the CQE Supervisor are jointly coordinating all activities. This is a level higher in each organization than routin'ely utilized. m e e y- ,ow w-'we- 7 w- T -yw w- '*-v vrw w '-*r = w- --w-
AUDITS, AR'S, NR'S, CAR'S, STOP WORKS, SIR'S, AND QA/QC MANNING . . 7/1/60 tn 6/30/02 1980 1980 1981 1981 190t 1981 19'J2 1902 3rd Qtr. lith Qtr. 1st Ot.r . 2nd otr. 3rd' Qtr. lith Qtr. 1st Qtr. 2nd.Qtr Audits 0 1 5 1 2 1 3 2 d 0 0 19 it 16 lli 3 tAudit AR's. 3 Inspection and Observation AR's 0 0 6 2 8 11 6 3 Metalweld Sill's . 16 11 9 59 '43 66 14 1 30 20 Tiffs 6 14 8 1 11 11: U lia CAR's 0 0 1 0 0 0 0 0 Stop Work's 0 0 1 0 0 0 0 0 QA/QC bbnning 3 5 7 9 1 11 17- 16 19 Audits 3 3 1 3 6 2 3 1 Audit AR's 2 2 1 6 9 1 9 2 Inspection and Observation AR's 2 0 0 0 0 14 li 1 PBI 37,g, s 30 30 36 29 2 14 15 32 lib NH's 25 2 14 14 3 28 26 30 21 lis CAR's 1 0 0 0 1 0 0 2 0 0 0 0 0 0 0 0 Stop Work's QA/QC Manning 12 11 8 8 9 9 9 10 Audits 2 6 1 ef- <f. U 2 9 Audit AR's 1 7 ill 13 2 22 5 26 Inspection and Observation AR's 11 6 21 15 lill / 0 2 11 5 I*"" 69 136 ;L*. 2011 239 581 S1H's 99 lill _100 6li 18iU 165 / 1 511 23fi 3 911 NR's 53 1 114 CAR's 2 0 2 2 1 0 1 1 Stop Work's 0 0 0 0 0 0 0 0 QA/QC tbnning 14 0 39 11 6 53 61 68 87 01: Audits 0 1 3 1 2 3 3 3 Audit AR's 0 10 0 0 6 9 11 1 14 __ Inspection and Observation AR's 6 1 7 8 0 28 5 21 L. K. Comstock S1H's 63 79 22 73 111 150 61 11 5 NR's 91$ 91 65 93 70 129 130 100 CAR's O G 0 0 0 3 3 1 Stop Work's 0 0 , 0 0 0 1 _2 0 QA/QC tbnning 35 15 ' 17 19 26 27 31 l lil tshl ' k%Q\ Yh t (*Er oJS uSN#i?~ 4.1'h pm."hp lid /
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- 1960 1960 1961 1961 1961 198$' 1982 1982 .
3rti Qtr . 4th Qtr. 1st Qtr. 2nd Qtr. 3rd Qtr. 4th Qtr. lot Qtr. 2nd Qtr.
' ~
Totals PO QA/QC ~
- &nning 129 128 139 i60 162 167 167 189 s Contractor - 4 QA/QC mnriing 70 70 78 89 110 121 146 164 4 Audits 5 11 19 10 13 14 11 15 g Audit AR's 3 22 15 38 21 48 39 45 Inspection and M Observation AR's 19 7 34 25 52 36 39 30 y SIR's 230 255 253 266 -301 410 362 692 !
NR's 175 183 264 236 272 327 393 522 4
% CAR's 3 0 '3 2 2 3 4 4
~
Stop Work's O' 0 0 0 1 2 0 g l 1
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4 CAR NO. DATE CONTRACTOR DEFICIENCY ' CORRECTIONS , RI'SPONDED DATE CLOSED l 0501 7/30/80 PBI PBI authorized a weld PBI generated an NR 8/28/80 9/4/80 - CQC wrote repair w/o' proper NR 8/28/80 procedure-reviewed t l , i i 0502 9/10/80 PPP SP-45 Trend analysis indicated PPP responded on 9/25/80 11/3/80 - Accepted i . negative trend in drawing 9/25/80 via letter of 9/27/80 PPP letter i interpretation and viola- Action Plan and answers i tion of PPP procedure to P.O. questions i i 503 11/24/80 PPP SP-45 P-54 w/o an approved aug- PPP blamed P/0 for not 12/4/80 12/23/80 - accepted mented QA program PPP response w/ including it in their , contract comment 4 i j' 504 1/23/81 MW 10 items covering QC MW submitted Action Plan 1/26/81 4 /29/81 - after a i quals, calibration, QA which included revising / series of partial Sv i Records, Inspections, and creating procedures, re- Releases i Internal Audits, SW No. trainin6, etc. ! 81-01 4 ! 505 2/2/81 PPP Trend of pipe contamina- 4 pmcedures were revised 2/24/81 6/12/81 - after proc
! tion supported by NR's, Rev. 1 & I & T sessions' j AR's, and Inspection Reats .
1 i 507 2/17/81 PPP Weld rod control Changed QA personnel in 2/25/81 3/6/81 - No comment weld rod shack. Reminded on CAR form ,
, applicable individuals
] of proc. requirements i { 509 4/20/81 PPP Inadequate storage of PPP held training classes, 7/14/81 7/20/81 j pipe spools increase surveillance, No comment j and documented the above
- Established increased
} ! 510 5/29/81 PPP Deficiencies in training, training activity, a Lead 6/12/81 4/6/82 ; supervision, perfonnance , QC Inspector. Hiring addi- PYiS/ CON 4085-QA i e tional inspectors initia- Verification j '
ted independent surveill- { ance pro 6 cams, etc. i
"~
,' , 2 of 2 CAP'9 DATE CAR NO. DATE CONTRACTOR DEFICIENCY CORREdrIONS RESPONDED DATE CLOSED -
81-02 7/8/81, PBI[ Working w/o approved PBI revised QAM to clarify 12/3/81 12/4/81 - Issued drawings (2 beams) OBS AR 356 to track 81-08 11/16/81 LKC Cable pulling Procedure revised-NRC 11/20/81 1/20/82
- concurred 81-09 11/23/81 LKC No continuity or megger Will. conduct required test 12/1/81 1/12/82 - No ccament test on 1500 terminations in penetrations 81-10 12/18/81 LKC Security Document Control Revised procedure 3/18/82 8/19/82 Procedure violation 82-04 2/19/82 PPP Weld' rod control AR-404 Training session 2/23/82 2/25/82 - No comment 82-06 2/25/82 LKC Mr Procedure does not in- Added addendum to pro- 3/2/82 3/24/82 clude all acceptance stds. cedure 82-07 2/25/82 LKC Control of welding mat'l. Revised procedures; re- 4/15/82 4/15/82 .
viewed certifications, Rev. 1 training 82-08 3/2/82 LKC No pmcedures for panel Wrote procedures 3/17/82 9/3/82 - Audit steel mod and meter & Report 741 device installation 82-13 4/12/82 PBI Failure to reply to AR 419 submitted response dated 4/21/82 4/22/82 - No commen 4 4/21/82 82-111 4/19/82 PBI Repair performed w/o pro-i Training 4/21/82 4/22/82 - No 'commen per authorization inspeci Issued NR tion and documentation similar to CAR 501 82-15 5/20/82 LKC Failure to perform internal Revis6d program - Ilired 6/7/82 8/26/82 audits Lead Auditors; Training HP- l '/ b /16/U2 PPP Purge dam mat'l. not re- Mat'l. removed from site b/22/62 9/29/U2
STOP WORKS -
' ~- ~
~
DATE CONTRACTOR CAUSE RELEASE DATE , COMMENTS 1/23/81 MW ' CAR-0504 Partials 2-12-81, 2-16 81, 2-26-81 Conducted I & T ' SW 81-01 Full'4-29 81 . Procedure revisions Performed Internal audits Requalified ins'pector. Developed procedures CAR 05011 closed 11/29/i' 11/16/81 LKC CAR 81-08 1-6-82 CAR 81-08 closed SW 81-02 _ 1/20/82 8201 LKC LKC Procedure 3/24/82- Proccoure addendum
" sutaitted and approve ;
2/26/82 CAR 82-06 4.7.8 Mr insufficient 3/30/82 CAR 82-06 closed 3/4/) CAR 82-07 - Partial _ CAR 82-07 closed 4/15 Control of welding mat'Is. 4/15/82 - Fbil 82-03 LKC Plastic protective edge 3/10/83 Use-as-is disposition 3/19/82 stripping in MCC flammable has been accepted by ' NR CQC-2'131 s 1 e e
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G3.BERT ASSCCIATES, Vic. P O Bu $458, Seasog PA tMIO.'Tel 215-775-EECO. CaMe Gasoc, Te!n 83643J
~
June 22, 1982 2 PY-CAI/CEI-12669 INFORMATION Cleveland Electric Illu:ninatias Co. Nuclear Engineering Department P.O. Bo.x 97 Perry, CH 44081 Attention: Mr. J. Bellack Re: Perry Nuclear Pcver Plant, Units 16 2 Flamnable Materials in Electrical Equiptz:ent Centlement Per Mr. D. R. Green's request, attached is a comprehensive electrical equipment 1 flammability report incorporating all the information contained in previous l CAI/CEI correspondence. Very trul ours, 1 Q. J. Ioannidi Electrical Engineer T. A. Schlegel z Project Electrical Engineer N /* . P. B. Gudikunst Project Manager JI:TAS:PBG: rap Attachment CEI/NED (2L, v/ 2att.) y P. B. Cudikunst D. R. Green (2L, (IL, w/ latt.) w/att.) Nw J . D. Grier (lL, w/att.) - J. F. Hilbish (1L, w/att.) R. F. Mayhev (IL, w/att.) J. Shinglar (1L, w/att.)
.. : . . . .s.
..s. . $$
. -s -
0 p ,) 7 Fe.rry Nuclear Power Plants, Unit I and 2 f,' Timble Material in. Electrica. l Equipment
/-
The " Perry Fire Protectii_ Evaluation Report" (PPER) is written recognizing that elimination of all flamunable materials is desirable, butiot completely achievable. Criterian 3, page 1608, of 10CFR-50 recognizes this in the - statement' " Noncombustible and heat resistant materials shall be used uherever practica1 throughout the unit, particularly in locations such as the contain-ment and control room. "In order to compensate for flamable materials, estimates were made of the amount.of non-metallic material in medium and
- low voltage switchgear, Motor Control Centeis (MCC), and Instrument and. Control--
(I6C) panels and racks. For the sake of conservatism, this was all considered flannable with a heat rating of 10,000 STU per pound. The estimated weights used in the TPER were 40lbs.per 20 inch w$dth of MCC's, 80lbs. per 20 inch vidth of low voltage switchgear, 701bs..per 20 inch ~ width of medium voltage switchgear, and 40lbs. per 12. inch width of I&C panels and racks. The 80lbs. per 20 inch width cf low voltage switchgear includes the insulating materials of the power transformer in 480 Volt load centers prorated over the sections of switchgear. The esticated weights of material in switchgear and MCC's were made on the basis of taking out the weight of steel and copper from the total
- weight and considering everything else organic materials that were flamable.
Tor I6C panels and racks, the estimated weights of flanraable materials vete based upon a detailed investigation of conbustibles within representative cabinets. The preceding approaches in themself were conservative, with additional conservatism applied by utilizing the 10,000 BTU's/3b.value for all organic materials. For comparison to and verification of the above values assumed in the s~ 7PER, a study was performed to determine the heat content (BTU /lbs.)
- of organic material in safety related.4KV and 480 switchgear.and MCC'a. .
The study was based on the organic material information contained in references 1 and 2. Attachment 1 is a compiled listing of the predominsut organic meterini in the svitchgear and Motor Control Centers. In the st.udy of switchgear, for each organic material, the heat content and the percent of the total organic content each represented was determined. For Motor Control Centera.. percentages were not determined, however, the review of reference 2 established the predominant materials by frequency of use and function. For I&C panels and racks, no additional studies were performed since the values in the TPER were originally based on a detailed investigation of combustibles. . Cor.penents internal to the switchgear and MCC's were also reviewed for combustibles to determine an estimated weight of combustibles per twenty (20) inches of equipment width. The components reviewed included itens such as protective, metering and auxiliary relays, wiring, switches.. fuse and ter-minal blocks, and other items transformers, contactors, containing organic meters, indicators, circuit brea'.<ers, material. The switchgear and MCC units selected were those with heavy concentration of equipment / components and approxir. ate worst case conditions. , I Fens.wsms:stestaseasawamewaseer awgeWgsstag -
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,Q' Page 2 i'
The results of the study indicate that the heat content of the majority (i.e., majority by number and weight) of the organic mate *:ial 1s less than the 10,000 BTU's/lb. assumed in the FPER varying from appfoximately 9,000 BTU's/lb. for the unfilled phenolics and polypulfones to negligible for the ceramic, gypsum and asbestos materials. Materials exceeding the 10,000 ETU's/lb. either are not used extensively, do not significantly exceed this value, or have been tested for flame retardance (e.g., polypro-pyline, un-reinforced nylon, and epoxy copolymer, respectively). In addition.
' items in switchgear such as bus insulating and support components comprised of glass-reinforccd polyester, molded . vinyl, and epoxy copolymers, and control wire were tested and set the flame retardance requirements of applicabic ANSI, AS7N or IEEE standards. I&C pancis and racks are required by specification to have materials that are used for wire troughs, conduit, wire or cable ties, and terminal boards which are non-burning, as defined by ASIN E84 and D635, and flame rctardant wiring.
The estimated weights of flamable material p.er 20 inches of equipment width dercrnined by our study confirmed the conservative approach taken in the FFER. The results indicate that the FPER values are conservative in this area by approximately 171bs. per 20 inch vidth for 4KV switchgear, 201bs, per 20 inch width for 480V switchgear, and 16 to 20lbs. per 20 inch vidth for MCC's depend-ing on the combination of starters in a section. Fence, as can be seen from the above, both the BTU's/lb. and estimated weights per width of equipment values used in the TPER include allowances for miscel-laneous flamable, material. We also believe that the results of this analysis i are at minimum represcutative and most likely worst case conditions for similar i electrical equipment . including ac and de dictribution panels,. auxiliary relay cabinets and control panels, J. Ioannidi 6/18/82 l
References:
- 1. Gould-Broveri Suratary Reports #33-51958-08 and 633-51817-08
- 2. Eaton (Cutler-Hanener) Environmental Qualification Plan A-SO-10250, 4/16/82 o
D aus e 6
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'. ATTACP.ML'NT 1 i'
, 4kV and 48GY $witchgest and MCC's ' '
i . Predominant Organic Material . .i
- , A. 4kV end 480V Switchgear
~
.' Class Re-inforced Polyester ". 31sphenol Epoxy Glass Re-inforced Epoxy
- Enamel / Varnish
; Tilled Phenolics Broninated and . Tilled Cross-J, inked Polyolcfin
. Glass-Reinforced Ny3on Epo.7 Copolymer Holded Vinyl Cordier$te Ceramie Polysulfone Bakelite ',,
Molded Asbestos . .. Silicone Fluid Neoprene B. 480V Cut 1cr-Maremer MCC's ,, .. Pilled Phenolics Polyesters {i Haneral filled Epoxy - i
%1vsulfones (Filled and unfilled)
Bakelite I Neoprene
- I
'Helamine
$ Polyester-Polyinide-Imide '- Persecel Tape P248 Glass cloth Tape Vulcanized Fibre .- .
' Thermoplastic Polycarbonate Glass Fortified Nylon ,
Asbestos Polyester Tilm , Polynide . Paper
- Glass. Polyester Fiberganss .-
Asbestos Paper Teflon Si Rubber Tilled and Unfilled Nylon Rostone Rosite (calcium aluminum - silicate nixed widh asbestos) Bias Cambric
~ Tiberglass Re-inforced Alkyd. ~
Polytcrcphtholate I I tzr c c . , r s . _- -- _ v. . c.2 - m g s vrrg. A r a p e r, &v.qz- Y -5 -r-
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,t ,.p L. K. Comstock & Company, Inc. ELECTRICAL CONSTRUCTION h ~ ~ ~
Perry Nuclear Power Plant P. O. Box 324 Perry, Ohio 44081
~ Phone: (216) 259 - 3755 July 7, 1982 3 /
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/g To: Larry Seese ,'l i, From: Arthur Frew Ref: May 24, 1982 letter from T. B. Stear PY/SO-33-12076 Concern #3.
Review of Unit 1 Electrical Penetrations indicate that the ficup and Tack operations for Penetrations number 1R72-S004, 1R72-S014, 1R72-S019, 1R72-S021, 1R72-S023, and 1R72-S026 have been signed off before the issuance of weld rod by the Quality Assurance Specialist-Process. j)gZ: [dO M60 /47c7-Sc705%. ,, n According to Pullman Power Products, Project Procedure Man-ual, Document Number VI Control of Process Sheots and Weld Rod Stores Requisitions - Sections; 6,1 The Weld Rod Stores Requisition is submitted by the Welder / Fitter to the Process Sheet / Weld Material Dis-tribution Center where it is reviewed by the Quality
'~h Assurance Specialist-Process for accuracy and that 'l the designated welder is qualified for the work to be performed.
6.2 He shall then sign and attach the requisition to the applicable Field Weld Process Sheet. 6.5 The Quality Assurance Specialist shall record the following information on the requisition. 6.5.1 Heat / lot or Manufacturers Control Number for each type and size of material. 6.5.2 Amount of material issued. 6.6 Prior to issuing welding material, the' Quality Assur-ance Specialist-Process Sr 11 remove the yellow copy and retain until the original and the attached white copy is returned. 6.7 The procedure in paragraphs 6.1 through 6.6 shall be followed for additional welding material as required
't o complete a weld.
Per Pullman Power Products, Document VIII Control of Weld-ing Materials (field) - Sections: 6.2 Each Distribution Cehter shall be staffed by a' Quality Assurance Specialist-Process who shall have total con-trol over all activities involving the distribution 39 _- - _ . .: -- .. TDm'o 'na'
TF-24 I 4:lh6
. i!Iii O -
6.2 Continued and return of welding materials. 6.2.3 When the Quality Assurance Specialist-Process is not in attendance at the Rod Distribution Centers, no rod'shall be issued. This inconsistancy concerning Pullman Power Products' Weld Documentation must be addressed as a definate concern prior to turnover of penetration documentation. Respectfully,
- I Arthur C. Frew cc: M D. Friend W. Ladochy J. Zilka File 0 -
Page 2 of 2 .
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Attachment to NR 0QC-0151 Line 9 Proposed Disposition 1 Per GE's panel specification 22A3888, sheet 7 of that specification is attached, fire retardant materials shall be used throughout, insofar as practical. In other words, the use of combustibles may be used, but shall be limited. A check of the Product Quality Certifications (PQC's) for the panels listed in this NR indicates that these panels did not have any NR's concerning combustible materials. Thus, the amount of combustible material used in these pancis is within the panel manufacturer's l imi t s .' All but three of the panels listed in this NR (P601, F680,.P821) are termination cabinets. As noted in NR OQC-069, the installing contractor (L. K. Constock) did install unapproved tie wrap mounting devices in termination cabinets. The disposition of the closed-out 0QC-069 indicates that these devices have been replaced by project approved devices. In keeping with GE's position on limiting combustibles, the acceptable tie wraps have been kept to a minimum and contain no PVC.
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i ECC/iw i 7/8/82 IM0mmT103 OM JJf
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' ' (o;gi, RECEIVED RECEIVED REV.9-81 Tb CI:v211nd Elsetric liismin ting Campray
.' OCT 1 1982 Hl; CLEAR QUALITY ASSURANCE DEPT. sEp2 91982 AR 18 d i>2 ACTION REQUEST REVISION SHEET
'"^?!^f4'a-T a .^'." .??J'"- REV Id'I I File No, lE o,/, ,0,3,M OBS Number l 404 l . I 7 l B Criteria No. l/.71 Responsible Organizatio5 IS$lk l43.31
~
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Action Due By Date lO,7,0,9i 8,2l j Corrutive Action Reply Revision Txc oc Tc: cunnENTr.v TNvnT.VFD TN TMPT MfFET ATTnM OF A NEW FILING SYSTEM. MARKED IMPROVEMENTS HAVE BEEN MADE IN THE RECORDS THEMSELVES AND IN THE RETRIEVAL OF PACKAGES. THIS AR (397) SHOULD BE CLOSED BASED ON THE RESULTS OF RE-AUDIT OF #684. l l p1CEd g 5 $37-Response By C E Response Date l 4 92f,f,2 l Response Evaluation: bl42A'M, f., Ab thtOL CF A W /Y AYO '? O'O
/ 46 M N 7xCs M w (P A nczw($o mb , w : ?Y 'Ol#
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Nbs .rtQ/Ed < << I _ '7 .b S & . s n,La A J J L J Evalcation: , Accept Reject Evaluation By: /// - ($-607% Etatuation Date: l/.01O./ l N Verified By: < i 6ddA Verification Date: l/idd 2l
"/
N o.tsas. A arv.s.e' Ib Ci;V3IInd Elsctde ill::miniting Cstnpiny AR 009 O, HUCLEAR QUALITY ASSURANCE DEPT. File No. 3 .0 .1 il 0 .3 2, 1 ACTION REQUESgm
*g.f-1.7 k'J OBS Number . O. O. O. 8 Criteria No. if . E, C , ,0,3,3, k.eipons[
/ %
e Oija$1zations Prepared By: M. A. Brown /A. Bradshaw Initials I. A' .B D IssueIDate .0.3 0 .5 E 2 ,
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Appendix B Criteria QA Records [h 2'i iS
.m Observation: _.Reenrds nortnining en the receipt: issuance: 'itista11ation . and insocction of fremn are not. in some cases. easily r etri evabl e. . Records such as Receipt Inspection with the associated C of C's could not be produced to the auditors in a timely manner.
All Conditional Releases for items were not filed with the items. The Weld Inspection loas were not filed with the associated inspection r_eports. e Review for Significance: C Justification: Appendix B, Criteria XVII Recommendation: TEC tn revi ne their nrenent filine system to nrovide for essv
~
retrievability for all records associated with a given item'. All iteme should be fil ed no that supporting documentation from the receipt of the item through the final _atteptance of the item is identifiable and retrievable. Acknowledged By: i Action Due By Date . O. 312.218.2. l Corrective Action Reply: ALL OC DOCUMENTATION IS CURRENTLY BEING REVIEWED, SCREENED AND ( FILED IN A LOGICAL MANNER. ACCESS HAS BEEN RESTRICTED AND ALL DOCUMENTATION IS UNDER TATAL CONTROL BY THE OC MANACER OR HIS REPRESENTATIVE. Response By: Respdnse Date .N.M h D Response Evaluation: _idE_ ArrAc//GA Evaluation: Accept Reject Evaluation By: 4 _inE Evaluation Date: id hi2 MIE 24 Verlfled By: Verification Date . . I .l
. * ~ . .,
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?
Response Evsluation of AR 397 6-24-82. }- l l A check of equipment documentation packages revealed tiat a total review of QC files has not been completed and is not in the process. Missing documentation needs to be addressed. Making a list of missing documen-tation is not an acceptable solutiott for inadequate packages. Retriev-ability appears to depend on the completeness of the files. I l 1 M M
w o. is as - a The Clavaland Eleestic illuminating Cornpsny y l,0 AR . . O, 2,3. Y v.s.st HUCLEAR QUALITY ASSURANCE DEPT. ACTION REQUEST i File No. . 9. O.117. O.1 1, bdit Number . 7. O 3. B Criteria No, , 1, 5 Responsible Organization . P. P, P, , 0, 4 , 4 , Prepared By: J. A. Nicholas Initiats J. M. P - !ssue Date . O,7,0,8 i8 .2 , Append!x B Criteria XV - Nonconforming Materials, Parts. or Components Observation: _ Procedure XV-2 fails to provide adequate direction and detail as to how PPP is actually controlling nonconfor nances. Ine following observations were no, tea:
- 1. PPP is usins an informal system um int creation sneet) to process reportea m n conditions through QA and Engineering prior to making a Iormal report un.rt J .
The NRIS is an uncontrolled document which is being usea to evaluate ano control the quality of safety-related materials ano systems. (continued on attached) Review for Significance: Justification: Failure to meet the requirements of Spec. 709-4549-00. 1:05.5 which states all activities performed by the CONTnTTOR or his SUSCONIRACIORS which alTect the' quality of the items shall be pres .ribed by and performed to clear ano complete documented instructions, procedures, or drawings. Inese documents shall cescribe the necessary actions and acceptan;e criteria to effect the control oI cuality. jAlso, failure to meet PPP QA-Manual, Sect. V. Recommendation:
- 1) Modify procedure to provide basic cont.rol of nonconforming material and eliminate
. " informal" controls.
-2) Instruct personnel in revised procedure.
- 3) Review NCR relating to suppliers and obtain corrective action as required. ..
/J ,
Acknowledged By M x >
/ f Action Due By Date . O,7l2 3182 Corrective Action Reply:
Response By: Response Date . . I I - Response Evaluation:
- s. . ./
Evaluation: Accept Reject
, Evaluation By: Evaluation Date: . . I I - 1 Verified By: _ Verification Date . . I .
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- _ _ . . .-~- _ . .
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- 2. Para. 5.2.2 requires the QC inspector to place a Hold Tag on the item when an NCR Condition is discovered. However. PPP is only placing an " informational type" Hold Tag on items until QA and Engineering deicide if it is an NCR condition based upon the NRIS above. No Hold Tag number or reference to the NRIS is applied to the Tag. This item re=ains uncontrolled. <
3 Per the informal system. PPP removes the Hold Tag and replaces it with a Controlled Hold Tag only after an NCR is typed. The inspector never knows what the state of his reported NCR conditions is and it can be voided without any traceability. ,
- 4. A review of closed NCR's revealed that for the NCR's examined. PPP has not provided documentation to substantiate training that they said had been complete. Also, in several NCR's. PPP stated they would contact the supplier for corrective action. but there was no docu=ented evidence that this was done.
e . . W **e 6 l I
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[, jf. 'f R E C EW T.D e (3,s. 4 The CI:v:Inci El:etric litrmir. tire C mpa y AR i .0 0 1
.HEv.8-01 HUCLEAR QUALITY ASSURANCE DEPT. gn~ (. pg ACTION REQUEST File No. .3,0.1 i 7,0.3il-ng,:4. -
.udit - 01 O44 Number - 7. O. 3. B Criteria No. Responsible Organization . . . ..,, ,
A. L. Bradshaw Prepared ey: Initials Issue Date . P 1 i Appendix B Criteria I - Organization Observation: It was observed by the audit team that in some procedures, although cngineering and construction personnel have respons10111Lles which aIIect qua11Ly, thsse respcosibilities'iEve not been adequately delinea ana Lne personnel nave not been f or tally trained in the implementation of the procedures li.e., Proc. A11-1, Contrcl of Measuring and Test Equipment, anZ Proc. XV-2, Procedure for handling - Nonecmformances (Field )). r-Review for Significance: - Justification: SP-709. cara. 1:05.2 states in part "The lines of authority, organizational _ structure. functional responsibilities, and duties shall be clearly established and delineated in writing. Recommendation: 1) Review all procedures'to assure that engineering and construction responsibilities have been adequately celinea.
- 2) Assure that all personnel are trained to procedures for which they have responsibility.
RECEIVED MAR Z 51983
/) s s i, Acknowledged By: ~~
Mf l V Action Due By Date . 0,7 l2 .3 @ 2 Corrective Action Reply: (See attached sheet) Response By: IP e a- - - sponse Date 0 81 3 18.2, N/z fitp Resp se Evayatton: l M 8mw- ~hbl rza [8f/ I ' fRJr Mhg 4u bfr-- '
/' ** % 0 b Evaluation: Accept ca* t Evaluation By: .-
f , / Evaluation Date: >/./>ld 818.Af . Verified By: N , Aerification Date 83M7$31
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1 CORRECTIVE ACTION REPLY:
- 1) Pullman QA and CQS have reviewed all applicable procedures and are in joint agreement that responsibilities are adequately addressed either in the text of the specific procedure or in the QA Manual.
- 2) Documented formal training is on file for Engineering and Construction personnel.
/ ,
JOHN E. MILLER , {-
- i. s 13FORMAfl0DON
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r- ' 1 s** f .. ( . 4 *. g&9 (g - O C ,- L. K. Comstock & Company, InC. Perry Nuclear Power Plant TF-26 P. O. Box 324 ELECTRICAL CONSTRUCT Perry, Ohio 44081 ebone: <22e3 2se . 37ss July 13,1982
Subject:
Identification of Concerns as a Result of Unit #1 Electrical by the LKCE Task ForcePenetration Documentation Review j
\
s c+ The following is a identified as a summary of the Document result of the Unit ten (10) areas 1 Electrical of concern sponse to Review the conducted by the Penetration the importance following concerns Task Force. is requested. A written re-of these Because of be greatly appreciated. concerns, your timely response will Also attached during is a list said review. concerning these subjects,If of generic open items identified me at there are please anyl iuestions or com contact your convenience. V. A. Eichlerments or Cordially, N W ACF/bb A. C. Frew As/d<tY"w b* cc: W. G. Ladochy 7 ' R. E. Marino b^ "^ E. C. Yockey T. J. Woodman L. G. Seese D. G. Friend V. A. Eir.hler J. R. Zilka File
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<s ;n TF-26
'e A LIST OF MAJOR CONCERNS / PENETRATIONS Concern #1 - Review of Pullman Power's welding documentation has indi- l cated two areas of Major Concern.
'/ A. On Electrical Penetrations 4-5-14-19-21-23 and 26, I
the Fitup and Tack was signed off by the Quality
*F
/ Control Inspector before the rod was issued by the ceg,if,/ 'l ,A Quality Assurance Process-Specialist from the Process Sheet / Weld Material Distribution Center.
f e (See Attachment A) fi g e'gy*. f,;F./ / Pullman Power's Documet.: VIII-3, " Control of Weld-y , ing Materials (field)", Para.6.2 states:
$ e
# "Each Distribution Center shall be staffed by a Quality Control Specialist-Process who shall have total control over all activities involv-ing the distribution and return of welding materials."
Also, Para.6.2.3 states:
"When the Quality Assurance Specialist-Procesc is not in attendance at the Rod Distribution 1
O Centers, no rod shall be issued." Pullman Power's Document VI-5, " Control of Process
- Sheets and Weld Rod Stores Requisitions", states in the following paras.6.1:
"The Weld Rod Store Requisition is submitted by the Welder / Fitter to the Process Sheet /
Weld Material Distribution Center where it is reviewed by the Qualtiy Assurance Specialist-Process for accuracy and that the designated welder le qualified for the work to be per-formed." 6.2 "He shall then sign and attach the requisi-tion to the applicable Field Weld Process Sheet." 6.5 "Th'e' Quality Assurance Specialist shall re-cord the following information on the requi-sition." , 6.5.1 " Heat / Lot or Manufacturer's Control Number for each type and size of Mat-erial." 6.5.2 " Amount of Material issued." l Page 1 i
I f g I'e TF-26 ll '
'mak I, % IIP 'Ik Concern #1 - Continued 6.6 " prior to issuing welding materi51, the ;jl Quality Assurance Specialist-Process shall
- t remove the yellow copy and retain, until
! the original and'the attached white copy ,, is returned."
6.7 "The Procedure in paragraphs 6.1 through 6.6 shall be followed for additional weld-ing material as required to complete a weld."
.B. On Pullman Power's Field Weld Process Sheet, the weld record has not been totally completed. Such information as welders symbol, wire heat number, electrode heat number, and final check by ANI and Quality Assurance have been left blank. (See At-tachment A - Field Weld Process Sheet, for example.)
Concern #2 - It should be noted that the original documentation, pertaining to Unit #1 Penetrations, is on file in the a Quality Assurance Records. Trailer. All original docu-5j mentation should have been transmitted to the OWNER per letter PY-S/ CON 4016 QA from Mr. G. R. Leidich - h []. C.Q.E., dated December 3,1981. (See Attachment B) Concern #3 - SPEC.-33-4549-00, Page V23, Section 5:08.1, Paragraph 4C states: _: 4.0 "Before welding, the contractor shall:
/ 4C Attach backing ring to nozzle for attachmeat." . tl ' , *gh There is no evidence that a backing ring was installed or I that the step was deleted. Pullman Power does not indi-cate a backing ring was installed. Westinghouse Speci-j' fication Drawing E-40048 indicates a backing ring to be l installed on the two 18" penetrations. (See Attachment C) l Concern #4 - There is no documentation to add Penetration 1R72-S029.
! S0-33-4549-00, Section 5:08.1, specifies the installation of two (2) 18 inch penetrations and twenty-six (26) 12 r inch penetrations, per unit. The Equipment and Mater- {i(/,l ial'F.B.O. list specifies a total of 28 penetrations. Additionally, GAI Drawing D-215-443, Rev. J, addresses 35 Penetrations. Again, the proper documentation does
. not exist to add these additional penetrations.
Concern #5 - Review of 1R72-S001 and 1R72-S002 indicate a discrepency on the sequence of events and the date that the Quality
.[
Control Inspectors made their verifications. (See Attach-
,/ ment D) i
. , L. K. Comstock Inspection Report 339, states: 1R72-S001 was uncrated on 2/3/81 and the inspector signed off item Y{} 4.3 and 4.5 on 2/2/81.
I Page 2 _ _ _ _ _ m - ___ - ,. _.. . . _ . _ _
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t' TF-26
'. N h Concern #5 - Continued .
The Receiving Report for 1R72-S002, states.that the per-manent ID tag was verified on 2/1/81 and tMat it was un-crated on 2/2/81. For these Receiving Repo'rts, the sequence of events and inspector verification sign-offs are inconsistent. Concern #6 - L. K. Comstock's Nonconformance Reports have been re-issued by L. K. Comstock under a new revision after a i ./ time period of up to 16 months after the original has [ been originally written. There is no new wording to y warrant a new revision. A period of up to 17 months
\ has lapsed without the original disposition being ver-ified. (See Attachment E)
Concern #7 - On 6/10/82, a Rework Report #10339, was used to perform rework on Penetration 1R72-S002. The Rework Report ref-hg,v
,/ { 9 erc.nces L. K. Comstock Nonconformance Report 881 rev. 1, which is presently open. If this work was accomplished
,v,h(# to the Rework Report, this is in violation of the L. K.
( Comstock Quality Assurance / Quality Control Manual, which g does not address the Rework Form as a sanctioned docu-ment. (See Attachment F) , l .d p,\' Concern #8 - There was a large amount of weld rod consumed to weld Electrical Penetrations 1R72-S003, 1R72-S004, 1R72-S007, I j* 1 -
/g .N . and 1R72-S019. (See Attachment G)
)k
/ 3 This appears to indicate that repair work was done with-f'y '
y ( $ out any documentation of the repair. Pullman Tower's g* .i Document IX-14, " Defect Removal and Repair by Welding", c' y p , k~ Para.8.1 states: fv ; 6 " Repairs shall be controlled by use of a k p [\ f Repair Process Sheet." y/ 8.3 "For major repair, a weld map shall be pre-
)# < pared showing the location and size of the g?p yp cavity as it was prepared for welding. This
? map shall form part o f the final documenta-
\ tion package."
8.4 "The first repair to a weld, or part, shall be designated R-1, the second R-2, etc." No Repair Process Sheets have been used to indicate the repair of any weld, on any Electrical Penetration.
'. Concern #9 - Review of Penetration IR72-S003, indicates -a base metal buildup performed on 3/30/81. Pullman Power's Document f g 6 ,[ IX-14, Section 3.3, states:
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O Concern #5 - Continued
. " Base Metal - Repairs which exce;yd the lesser of 3/8" or 10% of the section thickness and cracks shall be documented as a nonconformance.
Welder Repair (i.e. Weld Metal buildup) of weld edge preparation, which is necessary prior to the issuance of Installation Pro-cess Sheets shall be addressed as noncon-formances." Pullman Power has not included a nonconformance in their weld documentation. Concern #10 - Review of the Penetration Equipment Maintenance Records hy furnished by L. K. Comstock Engineering has indicated a p '
) number of required inspections that were not performed
,/ 6 in accordance with the applicable Field Storage Mainten-t
^ 3 ance Requirements, Electrical Penetrations (1&2R72), -
t' J c'* Generic Rev. II. l \ '[p A list of the problem areas are as.f'ol-lows:
$ ,/ f Item #18A: requires that the Purge Gas Pressure e
i f N h* j be recorded every three months. This ((- (f s/ j i y p'fy item was not checked per requirement on the following dates:
/
/ ,Y L Penetration # Date pd , 9 fj j 1R72-S001 9/30/81 i4 [d 1R72-S002 9/30/81
,\/ l 12/4/80 (e / 1R72-S003 1/27/82 E,/P'f .
8/20/81 1R72-S005 2/18/81 W{/ Item #19: requires that the temperature inside the protective housing be recorded every month. This item was not check-ed per requirement on the following dates: Penetration # Date
~
1R72-S001 10/16/81 2/23/82 O t2/8o 1/8/81 p **
. Q
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j %, TF-26 a 1: Concern #10 - Item #19 Continued .- Penetraion i Date IR72-S002- 10/16/81' 2/23/82 12/4/80 1/8/81 3/3/81 1R72-S003 2/23/82 1R72-S004 2/10/82 1R72-S005 2/23/82 1R72-S006 2/23/82 1R72-S007 2/23/82 4/6/81 1R72-S008 2/23/82 4/6/81 1R72-S009 2/23/82 O 1R72-S010 2/25/82 4 4/21/81 1R72-S011 2/23/82 1R72-S012 2/23/82 l 4/6/81 1R72-S013 2/10/82 4/6/81 1R72-S014 2/23/82 3/26/81 l 1R72-S015 2/25/82 4/21/81
- 8/25/81 1R72-S016 2/23/82 1R72-S017 2/23/82 ~.
j 4/6/81 1R72-S018 2/23/82 Q 1R72-S019 2/23/82 4/6/81 l , IR72-S020 2/25/82 ('{ Page 5
- h. TF-26
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, 4h f
(F . Concern #10 - Item fl9 Continued ~[
. Penetration i Date
. 1R72-S021 2/25/82 4/21/81 1R72-S022 2/25/82 1R72-S023 2/25/82 4/21/81 1R72-S024 2/25/82 3/31/81 1R72-SO25 2/23/82 1R72-S026 2/23/82 1R72-S027 2/23/82 1R72-S028 2/23/82 4/6/81 1R72-S029 2/23/82 Item #22: requires electrical doors, covers,
() ,k and lids are in place and should be checked every three months. This 8 item was not checked per the require-(, \t'f ment on the following dates: Penetration # Date IR72-S003 11/17/81 1R72-S004 2/29/81 1 R7 'z -S 0 05 11/17/81 - 1R72-S006 12/1/81 l' 1R72-S007 6/2/81 i 11/17/81 1R72-S008 /81 11/171. 1R72-S009 6/30/81 11/12/81 , 1R72-S010 11/17/81 1R72-S011 11/17/81 1P.72-S012 6/2/81 11/17/81
. IR72-S013 6/2/81 l 11/17/81 I
Page 6 _
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T7-26
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' Concern #10 - Item #22 Continued .{
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Penetration # Date 1R72-S014 6/30/81 l 11/17/81 1R72-S015 9/30/81 12/29/81 1R72-S016 11/17/81 1R72-S017 6/30/81 11/17/81 1R72-S018 11/17/81 1R72-S019 6/30/81 11/17/81 1R72-S020 12/15/81 1R72-S021 6/30/81 11/17/81 1R72-S022 12/15/81 1R72-S023 6/30/81 i ()' 11/17/81
- 1R72-S024 12/15/81 1R72-S025 12/15/81 1R72-S026 11/17/81 l
1R72-S027 11/17/81 1R72-So28 11/17/81 i t o l Page 7
- . ~ _ . .
d TF-26 Asik khhk (:V 4 LTST OF GENERIC PROBLEMS / PENETRATIONS
- 1. No Perry Site Warehouse Equipment Pull Sheet - Form #96.
- 2. No Insulation Resistance / Continuity Test Report - Foro #21.
- 3. No Field Storage Maintenance Requirements - Form #5034. -
- 4. No Equipment Maintenance Record.
- 5. No approval from Project Organization to begin welding on penetrations,
- 6. No NR.CQC 1226, in Penetration package IR72-S003 through 1R72-S029, which documents conditional releases for lack of IEEE Certifica-tion. Conditional Release numbers effected are: 338, 368, 403, 372, 548, 393, 407, 405, 404, 392, 394, 417, 410, 419, 396, 399, and 463.
- 7. Per.etration Installation Checklists are incomplete - Form 116A, 116B.
A) File number is blank.
~
B) Item 11 pertains to torquing of outboard boxes. The boxes were torqued out of sequence on Penetration numbers 4, 14, 20, 22, 24, 25, 26, 27, and 28. [ The remaining boxes have to have torque verified upon o completion of previous requirements. I l C) Item 8, Welding of Penetration by Pullman Power is not verified. I D) Item 9, No Insulataion and Continuity Checks have been performed. E) Item 10, No leak rate checks have been performed.
- 8. Pullacn Power's Weld Documentation is not in the Electrical Pene-L tration packages. (Note: Pullman Power's Weld Documentation was added by the LKCE Task Force to aid in the review.)
O i l l
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. .: s. .'.... l P.O. BOX 97 E P ERRY CHIC 44o81 5 TECEPHON E (216) 259.r737 5 AObRESS.to CENTER RO AD Serwng The Best Location in the Nation ATTACHMENT B .;_'
December 3, 1981 _ PY-S/ CON 4016 QA L. K. Comstock - . P. O. Box 324 Perry, OH 44081 Attention: Mr. R. Marino Corporate QA Manager RE: Electrical Penetration Installation Records 1 l
Dear Mr. Marino:
As a result of the current investigation by the. Nuclear Regulatory Commission, 4 pd we are requesting that you transmit to the OWNER the originals of all Unit 1 i electrical penetration installation records. It is understood that the records
, will remain under the control of the OWNER's Quality Record File and any supplemental records should be transmitted directly to the Quality Record File when available. Thia request will not apply to Unic 2 documentation as is becomes available.
We appreciate your cooperation. Very truly yours, G. R. Leidich Supervisor Construction Quality Engineering cc: R. L. Farrell - 5260 urogs.AT10R Q 40 1 E. Rile; - Wil5 g A i T. J. Woodman - LKC -
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- 4. ,2 Correct Quantity------- - - - - - - - - - X g4.3 Shipping or Handling Damage------- - - - - - - - - - - X 4.4 Items Correct Description--- ---- - - - - - - - - X g 4.5 Plant Identification System Number Supplied------------ X 4.6 SMR Removed from equipment------ - - - -
LOCATION ffA crof Aint: dtT9'flgu Colu L7 t , mym 8 a-a-e u - Date N-J'/- 70 b bs Q. C. Signature kw r e m - - 5.0 ITEM WAS TRANSPORTED AND PLACED WITHOUT DELETERIOUS INCICENT Q. C. Signature w_ W~ Date // .?y 20 6.0 COMMENTS Y. 3 F r%,%rar e r epar r rgie rsur m c wiu forprer-f.O J/fr/ UM O/A7th .,, (o AlOi1"lA AlAl_ fil-A x f T.T9 YA s N Che f 22d Y Cec
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TAG NO. / 8 #7B f de S/N fo n // '/ I DESCRIPTIONr1f cr4 *r_ M DrsfrffA1 i?ns/ 'fs/stBioxx voly Ai: F 1 3.0 DATE OF L.K. COMSTOCK RECEIPT //-44/-70 4.0 ADDITIONAL INFORMATION: YES NO N/A 4.1 Field Storage Maintenance Requirements Received-- - - - - - - - - - - - - - - - - - - 8 4.2 Correct Quantity-- - - - - - - - - - - - - - - - - - - - X M4.3 Shipping or Handling Damage-- -- --- - - - - X 4.4 Items Correct Description------ - - - - - - - - - - - - - - - Y _
#4.5 Plant Identification System Number Supplied- -------- X 4.6 SMR Removed from equipment------------- - - - - - - - - U LOCATION AFALC of ALDC dA* 9 'ffrunTIou Colau /R
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PERRY NUCLEAR POWER PLANT
*[*
NONCOy'ORMANCE REPORT ATTACHMENT E
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'ND.1523 R EV. 4 7s 1R72-5003 PENETRATION
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IRELA7ETC LiNE NO. 61 THE OUTBOARD SIDE TEREIAL BOX FOR oNCoHroRMANCe s .. ifl075 PENETRATION 1R725003 HAD THE PAINT SCRATCHED ON ONE SIDE WEILE IN ROUTE FROM COMSTOCK AREA TO STORAGE LOCATION IN I.B. 657'. i, l l-. yu _E j . s ayoggFoR NCE Coo l$[2[7 MISHANDLING L <b n . u
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IFU pmOPOSED 015PO51 TION WAS REJECTED THE RESPONSIBLE ORGANIZATION $H ALL COMPLETE THE SECTION BELOW
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- [h 2 5'19 0 h PERRY NUCLEAR POWER PLANT ATTACHMENT E p' HONCONFORMANCE REPORT g 7/ , j Page 6 Of 12
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# ? (INCLUCE ACCEPTANCE oOVEANING / l mEOuimEMEN 1 ..'.. CmiTEm A AND COC'MT. N05.3 LKC PROCEDURE 4.10.1 _
dESCR d O'F NC . . . . . . . IRELATE TO
- NONCONFORMANCEg . 4 CODE 1[Qjj$ LIN E NO. 6) ,
THE OUTBOARD SIDE TERMINAL BOX FOR PENETRATION 1R725003 HAD THE PAINT SCRATCHED ON ONE SI, WHILE IN ROUTE FROM CCMSTOCK STORAGE AREA TO STORAGE LOCATION IN IB 657'. , d 1 V VV 'v ' CAUSE OF CAUSE I--.- CNCONFORMANCE CODE ~2.J M i S MA M O L1 u 6 1 FOR '***
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ATTACHMENT G Amount of E7018 Rod Consumed Per Electrical Penetration Weight of Rod Penetration # In PounMs 1R72-S001 5 3/A 1R72-S002 5k 1R72-S003 15 3/4 1R72-S004 18 1R72-S005 6 1R72-S006 6k 1R72-S007 13 1R72-S008 No Documentation IR72-S009 5 1R72-S010 6k 1R72-S011 3 3/4 1R72-S012 4 % to 6 k (poor copy) 1R72-S013 8 j 1R72-S014 6 3/4 1R72-S015 7 3/4 (' v 1R72-S016 4 1R72-S017 6 1R72-S018 5 1R72-S019 12 3/4 1R72-S020 7 1R72-S021 6 3/4 1R72-S022 6k 1R72-S023 7 1R72-S024 3 3/4 1R72-S025 5 4 1R72-S026 1R72-S027 6k 1R72-S028 9k 1R72-S029 5h O i Page 40 7,
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C K. Comstock & Company, Inc. Perry Nuclear Power Plant P. O. Box 324 ELECTRICAL CONSTRUCTION Perry, Ohio 44081 0 -- ,enoae: <2ie> 2se . 37ss July 17, 1982 ) t xy To: From: V. A. Eichler N. Kilgore, A. C. Frew p:$ i, EJ
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Subject:
Review of Equipment Installation Packages Af ter the review of seventy-two Equipment Installation Packages, several areas of concern have arisen that we feel must be brought to your immediate attention. The concerns are as follcws:
- 1. There appears to be no standardized method to filling out Form #21, Insulation Resistance / Continuity Test Report. The forms have been altered by the craft to suit their own interpretation. Often, the results are indecipherable.
- 2. We have found documentation on panels that are not listed in the Spec 33, Equipment Jurnished by Owner. These are panel numbers 1H13-P74, P607, P619, P621, r630, P632, P634, and P680.
- 3. There is a lack of IEEE Certifications or NR# CQC 1226, to document the lack of the same. There is also a problem with tracing the Conditional Releases to the panels since most C.R.'s are also miss-ing.
- 4. It appears that a large number of Material Receiving Reports have been lost. It also appears that an attempt has been made to re-document the Receipt Inspection without any back-up information.
- 5. Prior to the approval of the Meggering and Continuity Test Proce-dure, the craft still used Form #21 to document their tests. The Quality Control Inspector has put a qualifying statement by his signature indicating that the Procedure for Meggering had not been approved. Of what value was this work being done, to an unapproved procedure?
- 6. Craft has been using the infinity symbol (00) extensively. The Procedure states that the reading should be in ohms, megohms, etc.
Procedure 4.3.18, Meggering and Continuity Testing, paragraph 3.1.9 states: "A Record shall be made and kept for all tests, governed by this procedure. The record must indicate the following: (Use Form #21, Attached)"
3.1.9 states
" Test Measurements obtained, with units identified (i.e. ohms, megohms, etc.)."
O 3.2.1, under acceptance criteria states:
"Unless otherwise specified by the Project Organiza-tion Engineer, values in Figure 15 (Page 12) shall be used."
\ .
,a TF-29
~ Mb t!F 0 6. Continued Figure 15 lists the: e
" Minimum Acceptance Criteria for Field Meggering" and lists the "Megger Readings (in Megohms)."
- 7. Six (6) L. K. Comstock Inspectors have been performing and signing, for inspections outside of their Certification areas. These signa-tures appear on Form #32, " Class 1E Switchgear and Termination Cab-inet Installation Checklist", and on Form #100,." Stud Weld Inspection Checklist". This problem is common to Panel Numbers 1H13-P706, P707, P710, P711, P712, P713, P714, and P715.
The list is as follows:
- 1. Brian Palmer has made inspections on the Class 1E Switchgear and Termination Cabinet Installation Checklist (Form #32). He ita5 never certified to perform Equipment Installation Inspections.
Example: 1H13-P706, P710, P711, P712, P713, P714, and P715.
- 2. G. Young has verified inspections on the Class 1E Switchgear and Termination Cabinet Installation Checklist (Form #32) before his certification date of 4-7-81.
Example: 1H13-P706, P707, P710, P711, P712, P713, P714, and P715.
- 3. G. Hagler has not been certified to perform Equipment Installation but has performed inspectfons and documented such on Form #32.
( ) Example: 1H13-P710, P711, P712, P713, and P714.
- 4. L. Samosky has documented stud welding on Form #100 but has never been certified to Stud Welding.
Example: 1H13-P706, P710, P711, P712, and P713.
- 5. M. Bires was not certified to Level II Stud Welding on 2-14-80.
There is no co-signature by a Level II. Example: 1H13-P707, and P715.
- 6. H. Hanson was only a Level I and has signed Inspection Reports (Form #118) withou. a Level II co-signature.
Example: 1H13-P711, P712, P713, P714, and P715. We wish to bring these seven (7) items to your immediate attention. If you have any questions or comments, please contact us. Respectfully, 2 N. Kilgore W$ A. C. Frew 0 Hx/iCF/bb cc: R. E. Marino W. G. Ladochy L. G. Seese D. G. Friend J. R. Zilka, ECI orvnJLaa_5)
.; - "P"" TF-32 cousrocx Perry Nuclear Power Plant k) o , _ . . .
L.K. Comstoc ( Engineering Company, lnc. - A COMSTOCK GROUP COMPANY u.
,a r August 6, 1982 William G. Ladochy Eastern Regional Manager, QA/QC Services L. K. Comstock Engineering Co., Inc. '
920 Fort Duquesne Blvd. Pittsburgh, PA 15222 Subj ect: Concerns an a Result of the Review of the Equipment Installation Packages Bill, The following are major concerns as a result of a partial review of Equipment Installation Packages performed by the Task Force. Concern IA. L. K. Comstock Inspectors have been performing and signing g for acceptance of inspections outside of their areas of cert-U ification. As a result of these findings all personnel and inspections performed prior to January 1, 1982, must be held in suspect. This is to include Switchgear, Termination Cabinets, Rotating Equipment and Penetrations #1R72-S001 thru 1R72-5029. A par-tial list of examples is as follows:
- a. Brian Palmer has made inspections on the Class IE Switch-gear and Termination Cabinet Installation Checklist (Form
#32). He was never certified to perform Equipment Instal-l lation Inspections. Example: 1H13-P706, P710, P711, P712, l P713, P714, and P715.
- b. G. Young has verified inspections on the Class 1E Switch-gear and Termination Cabinet Installation Checklist (Form
#32) before his certification date of 4-7-81. Material Receiving Report indicate verification of Material Received before he w:s employed. Example: 1H13-P706, P707, P710, P711, P712, P713, P714, and P715. _
- c. G. Hagler has not been certified to perform Equipment Insal-lation but has performed inspections and documented such on Form #32. Example: 1H13-P710, P711, P712, P713, and P714.
- d. L. Samcsky has documented stud welding on Form #100 but has h never been certified to Stud Welding.
P710, P711, P712, and P713. Example: 1H13-P706,
- e. M. Bires was not certified to Level II Stud Welding on AA (,
kh W !O Concern 1A. e Continued , _m 2/14/80. There is no co-signature. Example: lH13-P707, and P715.
- f. H. Hanson was only a Level I and has signed Inspection' Reports (Form #118) without a Level II co-signature.
Example: 1H13-P711, P712, P713, and P715.
- g. Phil Romano inspected Class IE Switchgear on 2/11/81 (Form #32).
He was not certified until 4/13/81 and only as a Level I. Example: Package OR24-S023.
- h. Lucille Cleary received material since 8/13/80 (Form #39A).
She was not certified until 2/23/81 and then as a Level I. Example: Package IH22-P030.
- 1. Brian Palmer signed off Form #32 Class 1E Switchgear and Terminatic Cabinet Installation Checklist on 1/8/80. He was not certified foi Equipment Installation. Clarence Hart co-signed this form.
Additional examples available,
- j. R. L. Coffman co-signed Inspection Report #356 for Phil Romano who was not certified on 2/11/81. He was not certified himself O until 4/7/81.
Approximately six (6) people were certified out of 22 people who were signing off various Inspection functions and were not certified to do so at that particular time. This partial list of uncertified individuals was taken from the personne files and based on the information available. The necessary Site approval letter for certification was not noted in most individual personnel files at the time of review for specific activity certificatic i 13. The IR24 packages are inithe process of being turned over to Site and I were reviewed for Validity of Inspections prior to transmittal from ! the Task Force. The results of this review also indicated inspections performed by individuals not certified to specific activities. The documentation in question consists of Nonconformance Reports, Inspectiot Reports, Material Receiving Reports and Checklists for documenting electrical equipment installation. , IC. In reference to electrical penetrations, 1R72-S001 - S029, all inspections performed and documented on form #39A, Material Receiving Reports, and Form 41166A:& B, Installation Checklists have been generated by inspectors who were not certified on the date the inspections were performed. l O l Page 2 of 4
I!E . O Concern 2A. There appears to be no standardized method to fil-ling out Form #21, Insulation Resistance / Continuity Test Report. The foms have been altered by the craft to suit their own interpretation. Often, the results are indecipherable. SP 709-4549-00 Section 1:05.10 Control of Inspections and Tests Paragraph 1 states: -
- 1. A program of inspections and tests shall be prepared for all activities affecting quality, and shall identify those inspection and tests points to be verified for conformance to documents such as instructions, procedures, drawings, specifications, etc., that are used to perform the activity.
The inspection and tests shall be performed by individuals other than those who performed the activity being inspected or tested and who do not report to the supervisor who directed the original WORK. There shall be an adequate number of incpections and tests performed to assure that all operations of the activity fulfill the predetermined quality requirements. The CONTRACTOR shall describe the system which he will utilize to identify, implement and verify HOLD POINTS, or WITNESS POINTS which will assure that inspections and tests are performed as required. Paragraph 1:05.10 3.C states: O" 3. c. What written instruction the person performing the inspections and tests will be working to, including the specific acceptance criteria, tolerances, etc., which must be verified. 2B. Craf t has been using the infinity symbol (ep) extensively. The Procedure states that the reading should be in ohms, megohms, etc. Procedure 4.3.18, Meggering and continuity Testing, paragraph 3.1.9 states: "A record shall be made and kept for all tests governed by this procedure. The record must indicate the following: (Use Form #21, Attached)"
3.1.9 states
" Test Measurements obtained, with units identified (i.e. ohms, megohms, etc.)." 3.2.1, under acceptance criteria states:
"Unless otherwise specified by the- Project Organiza-tion Engineer, values in Figure 15 (Page 12) shall be ased."
It is a requirement of Spec 33-4549-00 that 100% of all Class 1E and Non Class 1E cables have a Megger/ Continuity Test and the results be documented. This activity is performed solely by the construction O d 9 re at- (re tias aa ooc ==eati=s)- the o= 11tv Coatret o et-has accepted these test results in accordance with procedure 4.3.18 prior to this procedure being approved. At this time, per the Task Force Document Review of Electrical Equipment
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(-) Installations and as a result of these findings, all inspections performed prior to 1/1/82 should be considered invalid and the lack of certifi' cation of the individuals performing these inspections should be addressed immedi.ately. Additionally, all Megger/ Continuity Tests should also be considered invalid, as a result of the acceptance of test results without an approved procedure. Also, all inspections presently being performed and all personnel certifications should be reviewed at this time because of the fact that some of the inspectors identifie< as being not certified in specific activities are currectly employed by L. K. Comstock l at the Perry Site. 1 Cordia y, V. A. Eichler Leader, Task Force ces R. E. Marino L. G. Seese D. Friend R. L. Bower J. Zilka, ECI I l i l
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J TF-34 cousTocx Perry Nuclear Power Plant o liFsonce 1904 L.K. Comstoc( Engineering Company, Inc. A COMSTOCK GROUP COMPANY August 13, 1982 -
Subject:
Identificati'on of Concerns as a Result of the Electrical Equip-ment Documentation Review performed by the LKCE Task Force The following is a summary of the five (5) major areas of concern identified as a result of the Equipment Package Review conducted by the Task Force. Also, a list of Generic Items is also attached. A written response to the following concerns is requested. Co dially J V. A. Eichler Leader, Task Force VAE/bb l I cc: R. E. Marino { W. G. La.tochy R. L. Bower L. G. Seese D. G. Friend J. R. Zilka, ECI File i !O i YY l P O. BOX 326, FK@27, @H M81 l (816) 259 3755 _
=
Ah CONCERNS AS A RESULT OF ELECTRICAL EQUIPMENT INSTALLATION REVIEW Concern #1 L. K. Comstock Inspectors have been performing and signing for acceptance of inspections outside of their areas of certification. This is to include Switchgear, Termination Cabinets, Rotating Equipment and Penetrations #1R72-S001 thru 1R72-S029. A list of examples is as follows: . A. Brian Palmer has made inspections on the Class 1E Switchgear and Termination Cabinet Installation Checklist (Form #32) . He was never certified to perform Equipment Installation Inspections. Example: 1H13-P706, P710, P711, P712, P713, P714, and P715. B. G. Young has verified inspections on the Class IE Switchgear and Termination Cabinet Installation Checklist (Form #32) before his certification date of 4-7-81. Material Receiving Reports indicate verification of material received before he was employed. Example: 1H13-P706, P707, P710, P711, P712, P713, P714, and P715. C. G. Hagler has not been certified to perform Equipment Installation but has performed inspections and documented such on Form #32. Example: 1H13-P710, P711, P712, P713, and P714. D. L. Samosky has documented Stud Welding on Form #100 but has never been certified to Stud Welding. Example: 1H13-P706, P710, P711, P712, and P713. O E. M. Bires was not certified to Level II Stud Welding on 2/14/80. There was no co-signature. Example: 1H13-P707, and P715. F. H. Hanson was only a Level I and has signed Inspection Reports (Form l #118) without a Level II co-signature. Example: 1H13-P711, P712, P713, and P715. l G. Phil Romano inspected Class 1E Switchgear on 2/11/81 (Form #32). He l was not certified until 4/13/81 and only as a Level I. Example: Package OR24-S023. H. Lucille Cleary received material since 8/13/80 (Form #39A). She was l not certified until 2/23/81 and then as a Level I. Example: Package i 1H22-P030. I. Brian Palmer signed off Form #32 Class IE Switchgear and Termination Cabinet Installation Checklist on 1/8/80. He was not certified for Equipment Installation. Clarence Hart co-signed this form. Addition-al examples available. ! J. R. L. Coffman co-signed Inspection Report #356 for Phil Romano who was not certified on 2/11/81. He was not certified himself until 4/7/81. K. R. L. Coffman co-signed Insulation Resistance / Continuity Test Report (Form #21) with Zack Space on 4/30/81. Mr. Space was not certified in any activity until 3/26/82. L. Fon Gillette signed Form 39A - Material Receiving Report - on 6/19/81. 1 At this time he was certified as a Level I and the report was initialed only, not co-signed and dated. Page 1 of 5
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OConcern #1 Continued M. M. Imhoff verified Item #1 on Form #32 for Installation of Equipment on 8/8/80. He has never been certified in Equipment Installation. N. J. Ruff t signed for acceptance of welds on Form #107 on 8/11/80. He was certified in Visual Inspection as a Level II on 8/26/80. O. T. Ross and C. Skarupa co-signed verification of Item #2 of Form #32 on 2/28/80. Neither one was certified for Equipment Installation. - P. P. Romano and B. Erwin co-signed an Insulation Resistance / Continuity , Test Report for verification of FSMR Requirements date 3/24/82. Mr. l Erwin was certified Level II on 3/26/82 and Mr. Romano was certitied i Level II on 5/4/82. This partial list of uncertified individuals was taken from the personnel files l and based on the information available. The necessary Site approval letter for certification was not noted in most individual personnel files at the time of review for specific activity certification. The certification dates referenced are L. K. Comstock only. Spec-709-4549-00, Dated 5/24/79, Paragraph 1:03.2-2, page 7, states in part
" Notification of all new or upgraded qualifications / certifications of Con-tractor QA/QC and NDE personnel assigned to the Site shall be submitted to the Owner's QA Element for review and concurrence prior to assignment of the individual to Safety-related work. The Owner's QA Element Review shall be comleted within two working days after receipt of Contractork notifica-('JN
\- tion."
The documentation in question consists of Noncenformance Reports, Inspection Reports (Form #118), Material Receiving Reports (Form #39A), Weld Documen-Lation Records (Form #107), and Checklists for documenting electriedi equip-ment installation, Form #21, 27, 32, and 128. I In reference to electrical penetrations, 1R72-S001 - S029, all inspections oerformed and documented on Form #39A, Material Receiving Reports, and Form
#116 A&B, Installation Checklists have been generated by inspectors who were not certified on the date the inspections were performed.
i
- Concern #2 There appears to be no standardized method to filling out Form #21, Insula-l tion Resistance / Continuity Test Report. The forms have been altered by the
! craft to suit their own interpretation. Often, the results are indecipher-able. l SP 709-4549-00 Section 1:05.10 Control of Inspections and Tests,, Paragraph 1 states: I
- 1. A program of inspections and tests shall be prepared for all activities affecting quality, and shall identify those inspection and test points to be verified for conformance to documents such as instructions, pro-cedures, drawings, specifications, etc., that are used to perform the activity. The inspection and tests shall be performed by individuals other than those who performed the activity being inspected or tested O. and who do not report to the supervisor who directed the original WORK.
There shall be an adequate number of inspections and tests performed to assure that all operations of the activity fulfill the predetermined quality requirements. The CONTRACTOR shall describe the system which he will utilize to identify, implement and verify HOLD POINTS, or WIT-1
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- 1. .
Cancern #2 Continued
- NESS POINTS which will assure that inspections and tests are performed I as requir.ed.
. Craft has been using the infinity symbol extensively. The Procedure states that the reading should be in Ohms, Megohms, etc. Procedure 4.3.18, Megger-ing and Continuity Testing, paragraph 3.1.9 states: "A record shall be,made and kept for all tests governed by this procedure. The record must indicate the following: (Use Form #21, Attached)."
3.1.9 states
" Test Measurements obtained with units identified (i.e. Ohms , Megohns, etc.) ."
3.2.1, under acceptance criteria states:
"Unless otherwise specified by the Project Organiza-tion Engineer, values in Figure 15 (Page 12) shall be used."
Paragraph Spec-709-4549-00, 1:05.10 3C states: l i C. What written instruction the person performing the insp1ctions i and tetts will be working to, including the specific acceptance ! criteria, tolerance, etc., which must be verified. It is a requirement of. Spec 33-4549-00 that 100% of all Class 1E and Non Class 'O IE cables have a Megger/ Continuity Test and the results be documented. This activity is performed solely by the construction department. (Testing and Documenting). The Quality Control Department has accepted these test results in accordance with Procedure 4.3.18 prior to this procedure being approved. Concern #3 The following pieces of Electrical Equipment were not listed in Spec-33-4549-00 Equipment Furnished by owner (FBO) List. The concern is what documents address installation of this equipment by L. K. Comstock, if any. The list is as follows: 0251-P094, 2H13-P624A, OH51-P095, 2H13-P731, 1H13-P74, 2H13-P732, 1H13-P619, 2H13-P736, 1H13-P621, 2H13-P822, 1H13-P630, 2H51-P056, 1H13-P632, l 2H51-P846A, 1H13-P634, 2H51-P864B, 1H13-P680, 2H51-P847, 1H13-P731, 2H51-P848, 1H13-P732, 2H51-P849, 1H13-P864, M40-C001B, 1H13-P865, 2P42-R22, 1H13-G 66, OR24-S012, 1H13-P867, OR24-S013, 1H13-P870, OR24-S032, 1H13-P872, OR42-S006, 1H13-P902, 1R24-S026, 1H13-P904, 1R24-S036, 1H22-P022, 2R24-S012, 1H51-P056, 2R24-S015, 1H51-P846A, 2R24-S028, 1H51-P846B, 2R24-S037, 1H51-P847, 1R24-S033, 1H51-P849, and 2R42-S007. Concern #4 All Equipment Packages reviewed by the Task Force had numerous inspections that had not been performed. Concern #5 It appears that a large number of original Material Receiving Reports have been lost. It also appears that an attempt has been made to re-document the Receipt Inspection without any back-up information. At this time, per the Task Force Review of Electrical Equipment Installations and Os a resuit of Concern <1. a11 inspections Performed Prior to 1/1/b2 should be consid-crsd invalid and the lack of certification of the individuals performing these inspec-tions should be addressed immediately. Additionally, all Megger/ Continuity Tests should cico be considered invalid, as a result of the acceptance of test results without an cpproved procedure.
' <$bh fl9 Also, all inspections presently being performed and all personnel certifications should be reviewed at this time because of the fact that some of the inspectors iden-tified as being not certified in specific activities are currently employed by L K.
Comstock at the Perry Site, as previously identified in part on 8/6/82. O O
4% (OM%HME
% ATTACHMENT 1 LIST OF CENERIC ITEMS
- 1. There is a lack of IEEE Certifications or NR# CQC 1226, to document the lack of the smae. There is also a problem with tracing the Con-ditional Releases to the panels since most C.R.'s are also missing.
- 2. Forms were not properly filled out (i.e. all blanks not filled in).
- 3. All Form #62 - Warehouse Issue Tickets were poor Quality Reproductions.
- 4. Many' forms were missing from each equipment package.
- 5. Field Storage Maintenance Require.ments were not performed properly and all temperatures and pressure readings recorded shawed no evi-dence that calibrated equipment was used.
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