ML20092G778

Affidavit of Rd Parks Re Concerns Over QC Problems.Related Documentation Encl

ML20092G778
Person / Time
Site:	Diablo Canyon
Issue date:	05/22/1984
From:	Parks R GOVERNMENT ACCOUNTABILITY PROJECT
To:
Shared Package
ML20092G713	List: ML20092G712 ML20092G728 ML20092G743 ML20092G761 ML20092G777 ML20092G778 ML20092G787 ML20092G791 ML20092G798
References
NUDOCS 8406250231
Download: ML20092G778 (48)

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AFFIDAVIT My name is Richard D. Parks.

I work as an investigator for the Government Accountability Project (GAP) in the Diablo Canyon Powe.r Plant (DCPP) Investigation.

I am providing this sworn state-ment to evidence concerns over a problem at DCPP.

Recently a packet of documents came into my possession from a series of anomyous sources.

These documents included Design Change

1. DC-2-E-P-10544, Deficient Condition Notice (DCN) #1350-011, PSA Snubber Checklist, Field Support Process Sheets, Pipe Support Design 1

Tolerance Clarification Forms (Quick Fixes) #QF-2-6916, QF-2-5168, QF-2-5156, OF-2-20ll], Minor Variation Report #M-4490, PG&E DCPP-Environmental Qualification (EQ) Maintenance Training Course #MA050, and HP Foley Valve Maintenance Report #1845.

They are enclosed in a packet identified as Attachment 1.

These documents relate to Residual Heat Removal (RHR) Pump

1. 1 Recirculation Valve (FCV-641A-Unit 2), and its associated hanger b.

4 413-143 SL.

On page 40 of Attachment 1, this valve is iis'ted as being Environmentally Qualified., pages 37-41 explain the l

significance of this qualification.

Af ter receiving and reviewing this packet of cocuments, I reviewed the documents with'several past/present Quality Control (QC) inspectors from DCPP.

Each of these individuals are aware of the problem contained in the DCN and confirmed that the problem still exists in the plant.

I also reviewed NUREG-0588 to complete my familiarization with the Qualification requirements.

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Page of Four Pages N

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i A review of the attached documents reveals the following problems with the Environmental Qualification Program practices at DCPP:

Problem fl:

.During the "As-built Inspection", the responsible QC Inspector Identified that the'5/8" studs holding th'e valve motor to

~

the seismic valve support plate (piece i 1, Attachment 1 page 9) had never been replaced.

These stuos were required to be changed by the original Design Change f DC-2-E-P-10544, (ref er to Note 12 Attachment i1, page 7). ~ This ' 'deficie'n t condition ~ was ' documented on a DCN (Attachment 1 page 16) and identified that a Deviation Report should be submitted to PG&E.

This should have resolved the problem; however, the original inspector was over ridden and his DCN changed by A. Weinstein on 2/27/84.

A. Weinstein's justification for his action is described on page 17 of Attachment 1.

The individuals that I reviewed this problem with informed me that the teason the studs had to be replaced was 1) due to the addition of a 1/2" support plate being bolted to the motor housing, it was necessary to ensure suf ficient projection of threads, and 2) the existing old stuos had visible indication of damaged threads.

Apparently the craft, when disassembling the valve to make the modification, had usec vise-grips to back the studs out of the motor.

Thus to ensure adequate strength with respect to f astening/ torque requirements the stuos should have been replaced.

They were not.

==

Conclusion:==

If the threads on the studs in question were in fact camaged, they should have been replaced.

Paragraph 3 on page 36, identifies that if any doubt existed on the studs, "gooc maintenance practice" would have been to replace them.

Unfortu-nately, they were not.

Problem J2:

The uncontrolled disassembly of an EQ Nuclear Safety Related Valve without use of a controlled procedure resulted in damage to the valve and discharge of personnel involved.

This is documented on pages 35 and 36 of Attachment 1.

This incident resulted in the generation of an MVR; that was deemed to be only a violation of Pro]ect Instruction 18 (Tagout Procedure) and a "PPP in-house Non-Compliance Report".

However, the MVR was marked as "not reportable" and "not a Non-Conformance", despite its relevance for NUREG-0588 compliance.

==

Conclusion:==

Due to the significance of the valve and the conflicting statements on reportability, it should have been oeemed " reportable" and repor ted to the NRC.

Problem 13 : pase 36, "EQ Ef fects On Maintenance" states in part "... provide detailed descriptions of maintenance work per-formed as input for failure analysis (trend) stucy."

Page of Four Pages

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However, a review of Valve Maintenance Report (#MVR-1845), Attachment

~l page 41, does not in'clude a listing of "what damaged parts were repaired or how they were repairea."

Problem 54 :

A letter f rom D'. A. Rockwell to P. Stieger (Attachment 1 page 34) identifies that the practice of installing seismic valve supports to EQ valves could be violating EQ requirements.

The letter requires ~ Pullman Power Products (PPP) to r'espond and provice "a list of all seismic valve supports completed or presently being workec" by March 5, 1984.

This is a problem because valves that have alreacy been disassembleci to install the seismic supports may have already violated EQ Nuclear Safety Relatec Requirements and have gone unre-ported.

In the instance of~FCV-641A, the ' violation occurred 10 months before the problem was officially " flag 9ed" to PPP for EQ compliance.

==

Conclusion:==

There is an apparent deficiency in PG&E 's training program to acquaint personnel with the requirements of EQ and Nuclear Safety Related Equipment.

The problems identified in the _ review of the attached documents reveal significant deficiencies in the QA/QC and EQ com-pliance requirement practices of the Nuclear Safety Related Equipment at Diablo Canyon Unit 2.

Even though the documents are restricted to Unit 2, the witnesses informed me that the problems they address are generic to both Units with respect to training anc familiarity with specialized requirements.

The same people perform the same type of work in both units.

If the practices discusseo in this statement exist in Unit 1 or Unit 2, the reliability of any EQ valve similarly disassembled is indeterminate.

Unfortunately, the reliability of these valves is taken for grantea by both the NRC and the operators of the plant.

I will further discuss tr.ese issues with NRC good faith efforts to address these issues.

I have read

_he above page statement and attached documents, and swear under penalty of perjury, this. statement is true Page of Four Pages O

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t and accurate to the best of my belief.

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Richarc.D. Parkt Subscribec. and sworn to before me this '2.1 th day of May, 1984.

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A-/ 3 z.. INGiHEERING Q{g SF C.:!C.AT!CN 3p gc,,yo, Nw, g 8711 '. s. ENGINEERING CESARTMENT E5 "~'- C .. ~........ .---~~.,,. -. e - a.. .u-o.a ':his pr:ctdure is 1 sfers : guid a f: agpr:ved velding ;;:: dares. Altheu'gh :he velding pr:caders =ay he cualifted !=r =cre :ha: :his ::eesdure ree:=ar.ds tha ::::=endatt:cs of this pr:ctdura shall a;21v unless :he

• Jetti:3 I..ite.ner st res pe=lasi=r.== davta:s f;= :his ;r:ceburn. ;t: devt.

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• / c "/u"o -c 55 m ccTxt_ s ue.,c.u G

l 6 l */g " c x. G' LG W t t :: t W.vt v S:t 5, Ms.J E.v e c : = z_:/.t ' 7 I l EiTzu siew Pips i.c 5 c.cs 113 r,. t..,. T,,4:: (urt.,s-3 y =, s - 5; O l 1 l R'E AT:. B R A:: V T = c t: 1:'S A t/ I.. l l I n n T r' T A T A T l l g w u v.u_. _ _ _ g 4-..- s I d i(./A_VV 11N D I ,.n m 4 C. S 3. H.'I V.-l i D i d @ Y l l l "* 7 9 $. IM '4' E J, is tidli'J. - u 'a' * ~ ~ l " APP.90VED WITH l 's.) - 3 4f LUNUlliUN InAf l l l ,~ c.==nn =a vu l l 1. I I I FOR m-mi;NG t I l l s I i l l l o c 2 E = t c s u n.< c l l sn. 4su.a.= Ev. _ a \\ I:50* '-3 ! c a wisc.w l } t& _n .:_wi - N-5. ~. I. l i c.n:- .t% mg^. a CC mg ' zev r ~ FRC.JEC : UNIT: F-- fM~ CF m3 PGa: C.Auv0M es '7 i i

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, SHEETc.or 7; 7 .A. 1-N LINE - E-S I-536 *3 E E l HANGER SYMBOL AMEA gl3\\ D p 2,,2g R -- m.W, t - EL e,o _c" ,ye sysrey LCC CN DWG COOT 22 8d S5' b $ 5 .0 $ 5 "' DE d I'-1 J U., b'.; c 5 l~9 t,y Th a$ Uj'... k h. Ql - ~ 4'

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s. su.

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DC 2 = P Icc.u. Cgjo c,o t-c' o SK. # M 3-R.R EV.1_ d e s ci. u>

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O W S M ?!?C / -Q-h O N K 3 'J t % i =9cesc : 1GO UNIT: e swis .: GaECO I s H 7, c / 1. ""t

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• A

.ANEA DN UNE A - D T30~ E I Op gg .I N~M - 6d-EE.W MU %. G O '-O,f 2 'm,*K SYS T.E AA gg s.6 t.C C ON DWG Ow.. 1 e .,O f SEE %C'TE. ( ) Id *.. d T E @n@ HCLES TD MATCH '%, $40 5 I +4 W47W VALVE. M n;GEG A ET N EV E 0/

• t, i

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"AFFROVED WITH e CONOLTION THAT NO RESAR EE CUT" L t FOR REFERE_1NLc! DC 2 E.P tc54 Cejc] SK. #/=_m:EV.O i DOON Neb 3 A A FflNL NO 0 " % N ".' * :.:.-- I C.= c i. s m p s.. s r 1 l 2 q 0,* g ; 7 \\A3 ,qg., 7 3,7 ,,,,.f 3, g pG Cg I"j % ~,.. s = r:.5-I : arv i j [ bs t 02 0 F !L W 3

,,,,_,,_ } ,,, 4 ,(, Q 33 ~ SHEET 40F7 z-- u~, 2-s i-m-s 2 = "^d;ifirec' A3x ,y, k M-4Y-6W eA--3. ~.~ 0 0,- 0,, R W E. SYST M e ....- E L X L C C O N D W G '_TO 0 9 ".S - - .i "a 5==" l "- = v u-gg oescai,riouc,cHisca3 aav l esan om csxcl aus snaa(lsuev ~ ENGR SLIPPORT ADDE ') Pgg s7 Egg g E FROS. C-Cc3-C4, Ev GPO ou 3-23-g3 NM h ~ lM i, s p:nr O w a-E 10 E IGE d l s ' FOR REFERENCE i I. e. o i ORIGINAL M DRAWING C u'I 9 1 l "AFFROVED WITH ' M p CONDITION THAT

.=

l NO RESAR SE CUT" l &=H I. _'j g i g t t NOTES: W

1.,,,,W E %ik.G 16 IM 7'do b' A wV ES ALO is Tc BE. W E: =E CA-U A. C E F S ' O r 1.,7: i E R: Sc. 7:NG To Tyc yA. vg ptA ggg f..."te'-.O s R E.F' A r_ T ExisTwo, */g* e w= $

gw y%g W 06 o= 6A u e. 7_c Fie:.Am oQ. Mrs te3 s c. 3 7 DC-2 E P Ic5m e_,= tc SHEETS AS3:GNE: TO THis MANG3a syymCL (70TAL I SHEET 3) ' Iai* M/43.R.;C.EV.- C N !I9!,'4% '472l l l l l l l l l l l l l l l i: ( i:*3N U.S ! :n n:NO mo i l l o w. > v .. :_::., I

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PG&ECO I~ l --~~ - - ,s s.; g l au 1

~ g -/ ?- DY ~ pac t r r o a-As Awr s Lz e r arc c o u rAwr ~OGsG OIABLO CANYON PROJECT

• GENERAL CONSTAUCTION

~ ~ _ " 7 0. BCX 117 e AvlL.A eEAcH. CAUFC8NIA 3424 + t.805: $9_5 2224 - :..:...:... =. ::.. . a. ~ . 7. ;; ; February 29, 1984 .f *. N ~ P. Stieger ~ Pullman Power Products P.O. Box 257 Avila Beach, California 93424

Dear Mr. Stieger:

Pullman Power Products is presently installing seismic valve supports per various CCN's. However, no notification is being given to J. Arnold, Mechanical Department - Attention: Valve Maintenance, price to installa-icn of the supports. This could cause violation of valve Environmental Qualification Procedures. Written notification for each seismic valve support shall be given to Miscellaneous Mechanical prior to start of work. Yalve Maintenance will issue a Yalve Maintenance Report and order parts as required, to allow installation of the support. In this manner all valve QA/QC and Environmental Qualification Procedures can be complied witn. Please supply a list of all Unit 2 seismic valve s"mrts coe.cleted or presently being worked. CRIGINAL slGNgo gy D.A. RCCK,vELL 1.. O. A. Rockwell Project Field Engineer Reply Requested: Yes [ Due Date: March 5, 1984 t JArnold/RT:cb !!!!!s?" FON INFORMr:0g ONLy. i J. B. Hoch J. R. Manning 1 l G. H. Moore .. E. R334tta R. Lieber l J. Hacias l

3.. Icemire l

DCC 2 ~.:.3 U, ~c

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• h'.I:s
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:a. : na _ em, O v.

C se l "*'-e rui aman ec. 2r erecuct2 essentsv: c= orscarsaucy

• mIic!stica sf ?rc'ect Instructf:n # 3

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• 2 7C.s

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c. fi.,ig,eer:

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,

,5f 1 ;j33

.w .3 , e i u.a., < u.....,, a.s.,, ,o m i. nota s m 4 i2l Q lt *tst a.Ne*ts*tter nets .,,,......,,,,,. r.:.,

pa s..: : :

c.a vs :i*:. s. r,-- [* "H..d* =,=w'./$, I s'.' . c,., 7 _TJ ,* s*

• 89,.gstes *. sin 4

,q/_ p g !i 2 3:,,/1',,/.g. e. DIIP%:*:c'd A "c:..'.t.Suth t 3 S e t?ss t .u.m m es W I@ . am nr **#.D D I4 k el E, fM i Nd'2'U DIN 'd I I M * * ~ ~ ~ ~ v.. .b 04 ee e.e.mo e e. .s. _e 4 . Su. em. .**.ege,, 3.- . :ste .e %.e.

g A ~-) 6 t.....,..a..... k....e. ~.... .o .u :. n , w.. us... Q e. I;-4470 Fr.g3 2 of 2 e........,.... ... u..w. u... Curing c:ns:ructica of pipe tu port 412.L4.3SL, 4. bolts tiare rechv.!d fr:m the .:.:c : rive" sey;ert, FCY-641-A, by Pullman.craf t. The preceis T9est in the ...i....... $;3eial ?.3 marks secti n stated before instal. ling ! tem 1, contact engineering Pullman P uer f ailed to do this. .:.:.i*;l ::.nact !1.P,0. for clearance. 12:10 P.M., ii.P.O. activated the mot:c def ve' fr:= the C:nr. col Ca i/10/33, 4: 2 ; and va va s:e t driv 7.:c.- causi..; it n unscra, itself, e.cm:ging the valve s: 4 Craf t did have the. :or. dri,te sus;:end2e with s!!ngs a.d a chain g: tar. fall, pravanting cetor drive frei.. f:11ing to tha f t'cor and :a; sing m:re can.t;2. O!';?OSITIO(: inSsc har.;ers -hit will require cieeran:es will te highlighted in rad, cn '. ) 3 seek sc".adu'.e. "012 aran:c P.ezutred" uilt be sta ;2c in red en :: var and :rc:ess snes. 2?

3) 'A cene to ali project team nenber: sad contracter pers nnel will te gene-

1. d.ers cle rences rated noting that Unit 2 ylli te treated si;nitar to 'Jni:

2ra required. C. T.zining sessi:ns will be hald to reinf:r:e the ne ssity Of clearance: On c:2 rating systa.is. Tha 3essions will :e ;fven by :9e F.esi:ents a.d C ntra::cr su ervisten. Fers:nnel c:vera.;e v.111 te increased in the field by P.T.G.C. and C:ntra:: r su;cevision. The : Prat individuals involvad in the disassembly have taan terminated. ~)

• )

isles :: be re:aira: a:e:rding :: 2:pr:ved ?rc::e.iur':', :ar H.P. F ley :. O. A '!:he !!str.:cr:2nce Repor: # 1845. this on in-htusa i;;n-CO.pitance Re: Ort af.d :r'/.'! fe 5:e;5 f 3) t ?.P.P. :s :::urte: i

1. 1: ? i\\ l'.t '.*: urrence.

( y a. A i! .,e M . :'..F t ,et ,.. i n. ,......n Da m. 't i v. 5 p" s e e. r '. ',1.,

fp

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i g7 k ... ~. D 37 ~ PACIFIC GAS & ELECTRIC COMPANY DEPARTMENT OF NUCLEAR PLANT OPERATIONS OIABLO (ANYOM PO*4ER PLANT DCPP MAINTENANCE TRAINING MANUAL COURSE NO. 5A0E0 ENVIRONMENTAL QUALIFICATION MAINTENANCE TRAINING REVISION O JUNE 16, 1?E2 m e APPROVED BY _/ 8_- M e o' N' - q'I A h*'

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P* ,o AL-/ ~0 # Invircnmen:al ;ualifica:fon raintn; Outline FOR INFORMATION ONI SC0pE The purpose of this training outline is to familiarize Maintenance Decar: men: personnel with requirements and responsibilities of the Envir:nmental Qualifi-ca:icn Program. INTRODUCTION A major ca agory addressed in assuring safe operation of nuclear cower olan:s deals with equipment operation under vartcus environmental concitions. stated, if the equipment is required to operate during and after a worst caseSi= ply accident, we ne Srove that the ecuicment can ocerate in an environment similar to the one caused bv such an accicent. To verify coerabi t ity, equipment pualified thrcunh laboratory'fied as being potentially exposed to accident icen:1-tests and/or encineering analysis. DE.:iNITION OF ENVIRONMENTAL QUALIFICATION Environmental'ly Qualified (E.Q.) eqt'ipment is a scecial catacerv of Safe Jittl_t ui: ment _. This equipment is not only requirec for safe con:rol of tne plant but may also be required to operate in extreme environments or adverse temperature, pressure, humidity, chemistry and radiation that could occur dur .and following a Less of. Cooladt Accident (LOCA) or a -Main Steam c ndi:fons resulting fr:m a major piant ac:fdent. Basically, this mea 1:entifies equi: ment which mus: Ancther E.Q. ::nsiceration must survive for only a short :eriod after an accident. fail in a safe mece :uring a tne first re uirement since 1 is most cemandin We wili generally adcress direc:ed toward electrical equipmen ; however, g. Currently, E.O. has been ex:and to most other ecutement includina seismic consicera ions.in -h tive Procedure 0-7E5 s:ates that,tien of E.Q.. 'taxen fr:m NRC requireme A formal cas:ris- ...elec rical equipment shall have :'een environmen: ally :ualifie: would :: era:e during or "following an accident."the envircnment in whic for of this equipment be maintained as it ages and after re: air or 3:ia W... sesat 2nd understand the tscend statamst

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-'u. E.O. AF:ECTS ON MA!'iTENANCE 'n tiettien :o ne maintenance de:umentation re:arec f:r st e. s! :s: wa ust, :n E.O. e:utpment, provide cetatiod descri :i:ns :f mai :enan:e e. r<e:ui: men:,

er':rms: as in:u-for failure analysis (:rtn:f r.g,'

stu:y. ti; s :f 1;

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.:, a. 0, always be cer:ain that the parts look alike.

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..::ars an: nat a manufacturers suggested "ecual replacement" is,10T acceo:acie in :his application unless E.Q. is'specifically addressed. 1RC rec u i re e n t s s cesi y_.- ha. '._..any...

material chance m * % % accordance with the criginal oesi:n recuire.en s and its environ-ental cualif4-=-dan-- Materials censidered susceotible to postulated wors caseenvir:nmenkareall" fr:m non-metallic groups. Examoles which we will er.ccun er are: cc::r and cable insulations, lubricants, seals, molded switch materials, gasket materials and special conductor terminations. Bevond the additicra' aintenance 'cccumentation neecs arc - + =cra c!a= aecessa*v in car:s icentifica:icn and reolacemenc. aa-al "coce ata enance crac: ices" _shoula ensure acera:le ecui: ment under all envircnmental concitions. Attention to suociter assemolv instructions (wnen orovidedl. -arefui caste: creaaration 2nc ciacement, crocer connec cr torcuinc and strict acherence to tne a: licacie. _ maintenance or:cecure siii guaran:ee a successful orocram. .o..rn n r e....v..iy 6 3 h.J p. :.. n.. -a ws. Guidelines for establishmen: Of an E.Q. program are containec in the N'C de ureat.- M:C.-0 8L PG1E managemen: directive to OCPP req iring icolementation of an E.Q. ;rrogram was issued as Administrative Procedure JP33 c 21 and the detailed methods and instructions by which we actually acc:molish E.Q. are shewn in Lo-0 7M m Ques-ions not answered in this E.Q. training outline should be covered in the latter procedure..

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A-/ ,J.t a ' I..l'. '. .N .u. ,,.e. ..S u.... u.. 1. Environmentally Qualified equipment helps us maintain plant safety curing normal opera-icns and in accident conditions..

2. ;The Environmental-Qual.ification Program provides the orcanization and 3uidance

-- - necessar:y to'=aintain qualified ~5d;uipmbnt }n' design condi-ion fcr the life ~ cf the plant. 3 ~. adherence tc the E.Q. Program assures ecmoliance with 'GC cuicellnes and {regulaticns. ~~~ 9 e N* ..m. '3, ?p '( h':(2 Ij'-[s,'.h. ,{.;,,)*,-*, 1 e r .., we #71 * .e. - [ re:.m. y

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FOR INF0PJMT10fi QR ~ a " 01AELO CanYO:t.3C'.iER ?LA?;T y pf0 ENVIRC?; MENTALLY OUALIFIED EOUIPME"T List includes'enly those currently designated E.Q. devices assigned as Electrical / Mechanical Maintenance responsibility. I1C associated devices.arente ifsted separately. Refer to " controlled listing" of E.Q. devices if us-to-date ac:uracy is required. .... "IH" ' ~ ' '" ~~~ '~" m " ITEM FILE NO. ITEM FILE NO. EHRS-1 @H: Rec:mbiner ------ 20 8501A Limitor;ue 70V ------ 15 EHRS-2

---

20 88015

---

15 FCV-355 Ro: rk MOV ------------ 28 8802A

---

16 FCV-363 23 88023

---

16

~ FCV-357 Limitorque MOV -------- 15 3803A

---

16 FCV-440

---

16 88035

---

15 FCV-441

---

16 8804A

---

15 FCV-641A

---

16 88048

---

15 FCV-6413

---

16 8805A

---

15 FCV-749 7a 88055

---

16 FCV-750 7a 8807A

---

15 LCV-106

---

12 8807B

---

16 LC7-167

---

12 8809A

---

16 LCV-108

---

12 88098

---

15 LCV-109

---

12 8821A

---

15 LCV-110 ITT Gen. Cntis. EHOV -- 14

'83213

---

15 LCV-111 LCV-113

-- 14 8S35

---

15 a

a -- 14 8976

---

15 LCV-1.1.s

-- 14 8950

---

15 8COCA Limi torcue MOV --------

7b 9003A

---

15 20003 7b 90033

---

15 3000C 7b 2072A Ta/get Rcck 50V ------- 15 oe

• -. ;go 33753

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15

d. O '

207&C

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15 511-515 ;CFC Met:rs ---------

5 3073D

---

15 SI Puto 1-1 & 1-2 ----------- 15 8105 Limitorque MOV -------- 16 RHR Pumo 1-1 & 1-2 ---------- 11 1 8105

---

15 CC Pume 1-1 5 1-1 ----------- 11 8107

---

15 Con t. El ect. Pen. -----------

1 8112 7b Soecial. Cables-Inside Cent. 10,16 3701 7a LOCA Seals - OZ Gedney ------ 13 8702 7a LOCA Solices - Raychem -'---- 11 8716A

---

16 8716B

---

15 FM Pr::ecures, NP.:R's, Shee $rk F011cwers, recet:t, s :rt;e in: t s:e:tt:n dccuments, MLS actf en dccuments an:/or o: car rec:r:s esittin; ::

a:cve e:ut:- cent snculd be stan:ed "E.O." and forwarde: :s the on-site _*, "co-48-i : q !bn* eita a c:coleted Re::r: Manate ent System in:u: #er.~ e-- 3-3 Neitbie : Cies i::e:.1;;e;. 5/32

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