ML20098F074
| ML20098F074 | |
| Person / Time | |
|---|---|
| Site: | Comanche Peak  |
| Issue date: | 09/27/1984 |
| From: | Roisman A Citizens Association for Sound Energy, TRIAL LAWYERS FOR PUBLIC JUSTICE, P.C. |
| To: | |
| Shared Package | |
| ML20098F075 | List: |
| References | |
| CON-#484-166 OL-2, NUDOCS 8410020290 | |
| Download: ML20098F074 (68) | |
Text
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p September 279((9FS UNITED STATES OF AMERICA
NUCLEAR REGULATORY COMMISSION BEFORE THE ATOMIC SAFETY AND LICENSING BOARD In the Matter of
)
)
TEXAS UTILITIES GENERATING
)
COMPANY, et al.
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Docket Nos. 50-445-2
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and 50-446-2 (Comanche Peak Steam Electric
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Station, Units 1 and 2)
)
CASE's Evidence Of A Quality Control Breakdown Ms. Sue Ann Neumeyer testified that on March 3,1983 she was instructed to " sign off" on approximately 140 travelers which were missing signatures. (See CASE's Preliminary Proposed Findings.of Fact (PPFF) Nos. 1 - 20,)
She did so, under protest, noting with an asterisk and explanation what her signature on certain lines did and did not mean.
As a conscientious quality control inspector she was deeply concerned about the implications and impropriety of the task put Defore her.
Applicant's explanation, of f ered through C. Thomas Brandt, is that Ms.
Neumeyer's concerns were without foundation -- even if she had oeen pressured inte signing the missing hold points. (See 4
prefiled testimony of C.T.
Brandt, dated August 16, 1984.
8410020290 840927 PDR ADDCK 05000445 g
. i Applicant's argument is without foundation.
After the
-production of the travelers for Unit 2 Refueling Building there
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is no question that Ms. Neumeyer had every reason to De apprehensive abouti the condition of the liner plates and the specific assignment she was given by her supervisor.
Months before Ms. Neumeyer's testimony in July 1984 on this
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incident in tine Atomic Safety and Licensing Board ' hearings on harassment and intimidation she reported the information to the Nuclear Regulatory Commiss' ion's Office of Investigation (OI).
OI investigators apparently never reviewed the stainless steel liner plate travelers which were the subject of her concern, neither
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did th'e Technical Review Team (TRT).
During the September 1984 hearings on this issue Applicant produced approximately 1300 travelers, including some of those 9
signed off by Ms. Neumeyer and another Quality Control Inspector Fred Evans on March 3, 1983.
A review of the travelers demonstrates that at least as to the fabrication and installation of the stainless steel liner g
J plates there has oeen a complete quality control breakdown.
We find no evidence that the Dreakdown is limited to the Unit 2 refueling cavity, since the construction and quality procedures y
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control' apply to Unit 1, Unit 2, the transfer canal and Refueling SBuilding.
.In fact there is increasing evidence that the problems
$I-identified below regarding Unit 2 are equally applicable to Unit 1.
(see Attachment 1, Interview of Avril Dillingham ny the
-Office of Investigations (OI), August 24, 1983; Attachment 2,
. -i9 t
I i;- !
'j Handwritten memorandum of James Cole and Larry Wilkerson, dated August 13, 1982, which appear as Attachment "H" to Brown I Root's internal investigation of complaints raised by Mr. Dillingham; i
and also Staff Exhibit 120 regarding a 1979 IE inspection into allegations by former welders of problems with the fuel pool, i
etc.)
This evidence also indicates that Doth the NRC and Applicant I
have been aware of the significant problems regarding the construction, inspection, and documentation of the liner plates a
t.
in both unito since the beginning of work on this project.
n Finally, CASE asserts that neither the Applicant's explanation nor their resolution of this problem are credible.
In particular, our preliminary research into the technical merits reveals that the vacuum box test and penetrant test are unacceptable substitutes for insuring that the weld was clean --
i that is, free from foreign materitls.
These welds must last the i
lifetime of the reactor and the damage caused oy impurities in a weld cannot De detected Dy vacuum Dox, hydrostatic or penetrant test.
The impurities may not manifest themselves for months or f
years, out when the impurities " eat their way out" of unclean
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welds it is likely that the impurity will extend to the liner plate also.
7i The importance of the welds in the refueling cavities cannot I
k De underestimated.
On August 24, 1984 IE Bulletin No. 84-03 was i
issued regarding the refueling cavity water seal.. Its purpose was to i
d 1
1 4_
k (1) notify addressees of an incident in which the refueling cavity water seal failed and rapidly drained the refueling cavity, and (2)- request certain actions to assure that fuel uncovery during refueling remains an unlikely event.
Although the incident involved the f ailure of the refueling cavity water seal it nonetheless draws attention to the dangers which could result f rom water seal failures.
3 No fuel was Deing transferred at the time of this seal failure.- If, however, fuel had Deen in transfer at the time, it could have been partially or completely uncovered with possible high radiation levels, fuel cladding failure and release of radioactivity.
In addition, if.the fuel
),
transfer tune had Deen open, the spent fuel pool could have drained to a level which would have uncovered the top of the fuel.
The, liner plates are also susceptiDie to Deing hit or Jr jostled,Dy the fuel' as it.noves through the canal, and refueling cavity and into the spent fuel pool.
Because of this it is i
e important that the Fr.ructural integrity of"the welds De adequate.
Further, the NRC requires that the fuel pool and other cavities De seismically qualified, and therefore dictate that all quality 4
assurance requirements of Appendix B to 10 C.F.R. Part 50 De Q
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j applied to these structures and components.1/
k 1.
Violations of Federal Regulations
' Applicant violated at a minimum of three specific criterien of 10 C.F.R. ' Appendix B.in 'its failure to adequately control the
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, jwork, inspections, and documentation relating to the stainless r
steel liner plates.
4 A
1/
NRC Regulatory Guide 1.29, Revision 3, September 1978.
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10 C.F.R. 50 Appendix B - Criteria V, Criteria VI and Criteria VIII states:
Criteria V:
Instructions, Procedures, and Drawings.
Instructions, procedures, or drawings shall include appropriate quantitive or i
acceptance criteria for determining that important activities have Deen satis-factorily accomplished.
b Criteria VI.
Document Control.
These measures shall assure that documents, including changes, are reviewed for
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adequacy and approved for release Dy authorized personnel and are distributed to and used at the location where the prescriDed activity is performed.
Criteria VIII: Identification and control of Materials, d
Parts and Components.
These measures shall assure that identi-fication of the iten is maintained by heat nusber, part number, serial number, c
or other appropriate means, either on the item or on records traceable to the d
item as required throughout f abrication, erection, installation, and use of the ites.
a.
The failure to use the cor;cet S/S Liner traveler testified to Dy Brandt was a violation of Criteria V, VI, and VIII.
F$
D.
The lack of sufficient documentation violates H
Criteria VI.
c.
The lack of QC verification and supporting docunem on violates Criteria V, VI, VIII,,and includes
=all the s..wgories.
d.
The f ailure to include all supporting documentation WMRs and WFMLs in the welding package is a violation of Criteria VIII that requires identification and traceaDility of materials used, and to prevent the use of incorrect or defective material, parts, and components.
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. I e.
There is no adequate traceability for any of the welding packages reviewed.
2.
Violations of CPSES Procedures Applicant disregarded the clear instructions contained in 3
its own procedures for the conduct of inspection on the liner plates.
a.
From at least 11/29/77 until 1/4/79 Applicant used the wrong traveler form (admitted by Brandt), failed to l
enter NDE chits on the traveler each day when used and j
failed to put the chits in the QA vault daily as required Dy L
CP-QCI-2.ll-1 Rev. O,1 & 2, Section 3.1.1 (no te) and used a chit for fit-up and cleanliness when no chit for that i
inspection was authorized oy the procedures in effect for that period (see CP-QCI-2.ll-1 & 35-1195-CCP-3d).
L D.
No QC procedure published since 1/4/79 authorizes the use of MDB chits to record fit-up and clear 411 ness t
inspections having Deen performed.
Procedures require that i
y sign-of f for all inspections included on the eight line traveler ce on the authorized eight-line traveler (see eggz QI-QP-ll.14-6 (Rev. 1) Section 3.8) although this was not followed in many instances and even today unauthorized
)
and uncontrolled chits are Deing used to record inspections, c.
With adoption of QI-QAP-11.1-4 in 12/26/79 b
Applicant had no QC authorized traveler form for stainless steel liner inspections and no chit forms for any inspection f
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- W a"
since this procedure deleted any reference to 35-1195-CCP-38
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and does not include any traveler or chit forms.
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d.
As of March 26, 1982 and per QI-QP-ll.14-6 (Rev.
0-6), Section 3.5 (in Rev. 0) the issuance and distribution of inspection travelers were to De governed by 35-1195-CCP-38, which contains no instructions on issuance or k
distribution of travelers (see Section 3.4.. (p. 5 of 2
18)).
In addition the March 26, 1982 instruction for f
inspections is woefully inadequate compared to the level of detail and guidance on the conduct of the inspection contained in its predecessors and successors.
e.
QI-QP-ll.14-6 (Rev. 4 & 5) does not contain any traveler form at all although it is allegedly included as
)
an attachment.
See pp. 3 of 6 - 6 of 6.
This condition continued f rom June 17, 1983 until January 10, 1984 (Rev.
k 6).
f.
All forms authorized and/or used for inspection of t
stainless steel liners and all instructions required a fit j
ug and cleanliness inspection for all welds.
The NCR dispositioned the inspection deficiency only as to r
cleanliness and not as to fit-up.
Thus the NCR does not fully address the entire problem.
2
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9 QI-QP-ll.14-6 Rev.1 through 6 requires QC Inspections to be dccumented on the S/S Inspection Travelers, and that NDE performed for holdpoints not included on the S/S Liner Inspection Travelers is to De documented on NDE sheets.
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- _ N Prior,to this procedure CP-QCI-2.ll-1 required QC verification to De documented on the traveler, and the test h
results for VT, PT and VB test were to be documented on S/S T
Liner NDE reports.
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Supporting documentation showing the results of VT, PT and VB test are missing from over 50 percent of the S/S Liner Travelers. (They are too numerous to list, Dut see r
J travelers 2A, 221 and 589 for examples.)
v 3.
Specific Categories of Discrepancies in the 7
Stainless Steel Liner Plate Documentation a.
Category One J
The five line form (hereaf ter referred to as Case Fora A (CF-A),2/ an example is attached as Attachment 3) was signed in numerous different ways.
These differing approaches included double signatures, dates different for the signatures, different explanations for what the signatures meant, and single signatures with no explanation of what inspection the single signature denotes. (Examples of four traveler packene:: ere included for j] ~,
ease of explanation only, Nos, S2,15,118,1091)
)
2/. :The first form (Case' Form A) is a construction' form which is h
-3esignated_as Figure 3:first' appearing in Interim Change Notice 2
- to Construction Procedure 35-1195-CCP-38,1 Rev. 2, issued in AugustflS78.
Prior to the issuance of the form the QC hold points were designated on Page 5A, Section 3.4.1, "QC Hold Points" in Rev. 2 of the same procedure issued December 8, 1977.
Case Fora B is the fora designated in Quality Instruction CP-QCI-ll-1, Attachment 4A.
Case Form C is the eight-line form first ' appearing in 1 Interia Change Notice 3 to Construction Procedure 35-1195-CCP-38, Rev. 2, issued in August 1978.
p Case Form D is the eight-line form appearing as Attachment 1 to Rev. O of QI-QP 11.14-6, March 26,1982.
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5-Examples of this can De found in 15,110, ll8(incl.), 6, 7, 8, 36, 84, 130, 142.
f As a result of this discrepancy it is impossible, on the I
face of the document, to determine what inspection the signature V
l (or signatures) in line one on Fora A is supposed to indicate was E
performed.
According to CP quality control procedures (QCI 2.11-1), in effect f rom Deceaner 1977 through January 1979 (incorporating the g.
time period of Construction Procedure 35-1195-CCP-38 Rev. 2), the quality control inspectors were supposed to be inspecting the work done on the liner plates and documenting the inspections on Stainless Steel Liner Inspection Traveler MDB Report (Attachment A to QCI 2.11-1, hereinaf ter referred to as Case Fora B, incorporated as Attachment 5).
The QCI required a tive step, two point inspection of fit-up cau cleanliness as follows:
e E:
1.
Fitup and Cleanliness Inspection a.
Verify that the fit-up gap netween plates or plates to angle or plates to inserts, etc. is within a miniana of three-sixteenths inch (3/16")
and a nazimum of three-eighths inch (3/8") or as otherwise specified on f abrication drawings.
7 O.
Verify that the plates, angles and/or inserts.to lDe welded have Deen mechanically cleaned a miniaua j
of one inch (1") nack from the weld prep and that a minimum of three inches (3") has Deen degreased,
'c.
Verify that the piece being fitted into place is p
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the correct piece and that it conforms to jy applicable drawings.
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Fit-Up and Cleanliness Verification Af ter Concrete Placement a.
Verify that the fit-up gap between liner material
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has been maintained within a minimum of three-sixteenths inch (3/16") and a maximum of three-
~ eighths inch (3/8").
b.
Verify that the linear material to De seam welded has been mechanically cleaned a minimum of one inch (l") and degreased a minimum of three inches from the weld prep.
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As a result of the discrepancy between the spaces provided on Case Form A and the requirements of the quality control instructions, there is no assurance, Dased on whatever Case Form
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' A ind,icates,. ~ that the inspections required by ' the QC instructions 7
were ever performed.
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O.
Category Two Welds were signed off as completed without QC verification t
u for Step 5, which requires Seam weld Fit-up and Cleanliness verification.
The traveler (Case Form A) shows that welds were done for Step 5 oy indicating " SAT", 'but no QC verification or
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signature is shown.
These weld travelers indicate the original I
1 Fit-up' and Clean 1'iness was done in 1979 and welding resumed in 1983 without verification 'and preparation required ny procedure.
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' Examples of this can be found in 15, 52, 118 (see also TR.
I 16,748 and 16-7L1-752).
This is a violation of Criterion V, VI, and VIII of 10 q<
'l C.F.R. Appendix B (inf ra).
It is also a violation of CPSES QC
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- procedure 2.11-1, Section 3.1.1. (4) and (5),
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Category Three t
Not all travelers have attached chits which are alleged to e
verify that the QC inspections were performed, although there are signatures on line one of Form A which indicate QC has performed t
an inspection on that weld.
1 Examples of this can be found in 7, 19, 81, 877, 878, 879 (see also TR. 16,748).
Even if one would accept the argument of the Applicant that inspections are verified on construction chits (Figure 3, Rev. 2 (CCP 35-1195-CCP 38, Dec. 8, 1977), the failure of the inclusion of-the chit is a violation of CPSES QC procedure 2.11.1, Section f
3.1.1: (note) which required that NDE Reports (although not the same chit used Dy QC) De forwarded to the vault daily as " status indicators".
L d.
Category Four
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Almost all of the chits reviewed have the explanation of the inspection allegedly performed written on "the chit" (Figure 3, e;
j.
Rev.
2, 35-1195-CCP-38, December 8, 1977) in one of two tr handwritings.
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Examples are incorporated as Attachment 6; tallies for weld j
F A
numbers 1-175' appear at TR. 16,751.
i The " comments" section on the chits occasionally does have
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what appear to De original comments on them. (See TR. 16,751 for Qy numbered examples) i 1
M s. Sue Ann Neumeyer testified that the explanation was not q
on the chit on March 3,1983. (TR. 59,773)
The absence of that f
a e
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' comment at that time would be consistent with the prescrined purpose of that chit in CPSEC 35-1195-CCP-38, Rev. 2, December 8, 1977, Section 3.4.2 which states:
The form shown in Figure 3 shall be used in the above noted hold points as notification to QC to perform inspection.
The use of this form to verify the completion of an
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inspection is a violation of Criterion V, VI and VIII of 10 C.F.R. Appendix B, as well as a volation of CPSES QCI 2.11.1.
e.
Category Five
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Inconsistency of the use of Case Form A or Form C to
. document QC inspections f rom 1977-1982.
Case Form C, an eight-line traveler issued by craf t in Interim Change Notice 3 to 35-1195-CCP-38, Rev. 2 was apparently also used by QC inspectors during the 1978-1979 to 1982 time f rame.
The use of this form also violated CPSES QC instruction.
In t
numerous cases there are no craft NDT chits attached to these
. forms at all.
n'l' Examples of the use of the eight-line Form C can De found in 2A, 15, 52, 118, 1091(incl.), 205.
As with Category Numbers 1-4 the use of this form violates Criterion V, VI and VIII of 10 C.F.R.
Appendix B.
f.
Category six h
The documentation provided is not complete.
That is, the
~" traveler packages" do not contain all documentation which is required Dy regulation and procedure to substantiate that work
was done as prescr10ed, with correct materials, by certified welders, and inspected oy qualified inspectors.
There are P
numerous instances where traveler packages either do not contain weld filler material logs (WFMLs) at all, or penetrant test verification reports, or no weld material records (WMRs).
Examples of those are found in 877, 878, 879 (see also TR.
k 16,752-753).
This is a violation of Criterion V, VI and VIII of 10 C.F.R.
i k
Appendix B.
It also violates noth site quality control procedures and the Applicant's explanation.
f g.
Category Seven A review of the weld filler material logs indicate some instances where inspections were performed on a certain hold point prior to the issuance of the weld rod which would precede the making of the weld.
Examples of this include 2A,15, 34, 52(incl.), 61, 62,110, 118.
'this is a violation of noth 10 C.F.R. Appendix B and of all F
g relevant CPSES quality control procedures.
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b.
Category Eight Signatures are of ten missing from lines on the travelers (all Forms) which indicate
- SAT".
The " SAT" seems to indicate N;
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the hold point has been complied with out there are nct signatures, therefore it is impossible to accept that the y
. inspection was performed, and totally impossible to determine who performed the inspection or test.
The result is that those welds must De considered indeterminate.
Examples of this can De found in 15, 52(incl.), 115, also 126,137 - Lines 7 and 8 on the Form C/D with " SAT" Dut no
. signatures, 62, 81, 205, 225 - Line 5 says SAT for the VT inspection but no signature. (see also Category One) 1.
Category Nine Jimmie Duncan, Jim Cole and Jack Hawford's signatures appear frequently through groups of nundreds of the travelers as the sole QC inspector on this project, as well as the weld rod issues.
It appears incredulous that either Mr. Duncan or Mr. Cole could have actually performed the large measure of inspections they have verified, or that Mr. Hawford could have issued thousands of controlled weld rods in a single day.
l Further, if their work was a document review and correction there is no explanation on the f ace of the documents or in any of
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the supporting documentation which would suggest a legitimate i
explanation for the bulk work performed by Mr. Duncan or Mr.
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. Cole.
Fu th' r, ne'ither Mr. Cole nor Mr. Duncan's name appears on e
the ASME QC inspectors list raising the inference that the work, whatever it was, is totally rejectable since the liner plates were designated as safety-related and therefore required at least the original work to De performed by qualified ASME inspectors.
. r Finally, we understand that Mr. Cole was terminated for falsification of documentation.
If that is correct, and we have f
a good faith Delief that it is, all of Mr. Cole's work on these travelers is invalidated.
l Traveler nunoers 400-499, 500-599, 600-699, 700-799, 800-899 should ne reviewed in their entirety.
4.
Failure to Properly Disposition NCRs Regarding Discrepancies With the Stainless Steel Liner Plates Applicant has failed to adequately address the indeterminate status of the affected welds on the stainless steel liner plates, g
even. though' the condition has Deen. identified at least four E
separate times since late March 1983.
a.
NCR M83-00795 3/
This NCR identifies that 'the quality of the forty-eight -
f waterside welds in Refueling Building $2 are % determinate l
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necause the Fitup and Cleanliness inspections cannot De verified
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as neing performed.
M The NCR does not ident.ify the discrepancy as a generic
.,3 pronlem, which it was.
Nor does the disposition require that the f
review of welds pe expanded to determine the root cause of the pronlem, or include engineering evaluation of the requirements for the pot'ential for rust-through during the lifetime of the '
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weld if 'the weld could not have passed cleanliness.
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Also Brandt Exhibits 18 and 19, another revision of this NCR dated in August 1984 is attached with Attachment 4.
It is y;
unclear why the revised NCR (Brandt 19) was again revised in 3
August 1984.
Et 9.i
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.. A review of the Stainless Steel Liner Travelers D.
disclosed that an NCR has recently Deen written against welds that had Deen signed off years ago as " late entry" using old NDE chits as verification that Step 1 had Deen completed for the required Fit-up/ Cleanliness inspection of the inside (waterside) welds. The NCR stated that the use of these old NDE chits was L
not suf ficient to verify QC inspection, making the condition of the welds indeterminate.
R Yet,. the disposition of the NCR stated only that the welds are seam welds utilized to provide leak tightness of the liner, and that their acceptaDility would De Dased on the outcome of s
I' Vacuum Box and Hydrostatic Test. (NCR M83-0079, dated 3/17/84, g
?, )
Another NCR was written that also applies.
This h
c.
NCR states that Step 5 (inside Fit-up and Clesniiness) of these
(
welds lacks QC verification, again leaving acceptanility of the welds indeterminate until they are Vacuum Box Tested. (NCR M83-r 01000, Attachment 4) gga h
d.
NCR M84-00669 Rev. 1 M
On June 11, 1984, during another document review of the stainless steel liner welds "it was noted that step 7 on Form D had not Deen performed as required."
Yet, the next step was signed as complete.
The disposition again was to perform the j$
vacuum Don test, although curiously the disposition says to JA
" reestablish" the hold point for that test.
Also the two
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k travelers for veld number 1091 reveal several unsettling Si discrepancies.
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First, the traveler (a Form D) does contain signatures of j
lines one, seven and eight. Those signatures make it appear as if the inspections were performed in the proper chronological order
-- that in there appears to De no Dasis for this NCR.
Yet there is also a traveler (Form C) with no signatures or dates which contains the explanation Dy asterisk that "This traveler originated to satisfy the requirements of NCR 384-00669.*
Since the NCR wasn't written ~ until June of this year the new attached traveler form must have Deen included in the package af ter June 1984, af ter the original traveler had already been placed in the permanent plant record vault on January 13, 1982.
The discrepancy, whatever it was, was not discovered until a June 1984 document review.
e.
NCR 6200087-200088, NCR 684-200018 As late as August 1984 numerous proDlens were being discovered on these welds.
A document review on Field Weld 452 discovered that (1) welding has resumed in 1984 while the cleanliness requirement was ignored (NCR #200087): (2) that the i
Dacking' slip had a gap Dehind it (NCR $200088); and (3) that the 1
Dacking -slip was ground through exposing concrete from 5 on FW53 (NCR 684-200018, Rev.1).
The Septemoer 5,1984 disposition does not address the reason the cleanliness issue was ignored or the extent of the i
proolen, out only requires a PT test for the particular weld in question (652).
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. 4 The travelers in this package, Form A reveals no signature on line one, although the NMR log indicates the first fit-up was done during this time period and the chit indicates "First fitup and cleanliness" done September 13, 1978, but includes a comment, witnout signature of date, that on 7/18/79 cleanliness was verified "where accessable."
Form D contains tro signatures, and Form C contains two signatures on line one with two dates.
5.
Quality Control Breakdown in Construction Inspection and Documentation One thing is undenianly clear about this incident.
Ms. Sue Ann Neumeyer's fears about not being involved in highly irregular and possinly illegal activity were well grounded.
It appears from a review of the documents, the NCRs and their individual resolutions, the internal Brown & Root investigations of welder i
complaints and the Staff'is review of Brown & Root explanations that since the welding and inspection on the liner plates negan I
there nave Deen serious proolens with construction, inspection, quality control procedures and documentation.
More significantly, in each case the Applicant either delinerately or negligently failed to recognize the seriousness and extent of the problem.
Instead Applicant engaged in, and h
continues to engage in, " damage control" and cover-up of this quality control creakdown.
r The seriousness of the delinquent and callous manner in f
which this incident has been handled cannot be explained away by Applicant.
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_ 19 _
CASE Delieves that it is not mere coincidence that Applicant has refused to provide the remainder of the Neumeyer-Evans travelers.
Neumeyer testified she and Evans signed off documentation from the Unit I fuel pool and transfer canal.
Ooviously Applicant is continuing its attempts to delude the public and the NRC by creating the f alse impression that the quality control creakdown was limited to only the Unit 2 refueling nu11 ding.
Yet, the testimony of employees since 1977 is to the contrary.
In the f ace of the indeterminate and potentially dangerous situation which would be created by fuel t
loading in Unit 1 Applicant continues to disregard its responsioilities toward both the public and the Nuclear Regulatory Commission.
This attitude is illustrative of this Applicant's gross disrespect for the regulations which could have and should have prevented this situation from ever existing.
Ironically, on the eve of fuel load, Applicant is n
discovering that the unheeded claims and warnings of both construction workers and quality control inspectors were indeed s
y like canaries in the coal mine.
ry Respectfully submitted, i
hW M ANTHONY Z.'ROISMAN Trial Lawyers for Public Justice 2000 P Street, N.W., Suite 611 i
Washington, D.C.
20036 i
(202) 463-8600
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Counsel for CASE g.
cca Service List-r
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UNr*Eo STATES M
NUCLEAR REOULATORY COMMISSION y*
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CFFICE OF INVESTCATIONS FIELo CFFICE. KEGl:N IV
'""E"EcE.TE Cpw c S
ppg DATE:
March 7, 1984
' I UCI ~1 A10 :57 REPORT OF INVESTIGATION C =r..
T c;;, Q g, TITLE:
COMANCHE PEAK STEAM ELECTRIC STATION:
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ALLEGED INTIMIDATION OF QC PERSONNEL SUPPLEMENTAL NO.
DN 50-445/50-446 J
CASE NUMBER:
4-8'4-006 CONTROL OFFICE:
01 FIELD OFFICE: REGION IV STATUS: CLOSED DERIOD OF INVESTIGATION:
August 3, 11iB3 - October 27, 1983 REPORTING INVESTIGAT6R:
N. b
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H. Bfooks Griffin, Tnvptigator Office of Investigations Field Office, Region IV PARTICIPATING PERSONNEL:
Richard K. Herr, Director Office of Investigations Field Office, Region IV Wendel E. Frost, Investigator Office of Investigations Field Office, Region IV REVIEWED BY:
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- sA Ricnard K. Herr,' Director Office of Investigations Fielc Office, Region IV WM Willia J. Ward, Director \\o Divisioi of Field Operatiods Office of Investigations f
-l NAYMfM Roder Tortona,'Depup
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35-1195-CCP-38, Revision 2 l
ICN #2 m
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Sheet 2 of 3 000 :'I T ED UEC
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'84 OCT -1 AfD 57 ir, I ;ii:,
FIGURE 3 6 N0.
j 7B&R'STAIMLESS STEEL LINER INSPECTION TRAVELER PRNECT: CPSES JOB NO.: 35-1195 UNIT PAGE OF DRAWING NO.
POOL METAL TYPE MTL. THICKNESS '
PC. TD Pt.
Q PLATE TO P: ATE O InstRT TO PtxTE O anctE TO PLATE O orxER g WELDER WELD HOLD SYte0L WMR NO. PROCED.
POINI
- 1. F1t up and cleanliness of above:
RE5 ULT 5 IMSPECTOR SIGMATURE DATE
- 2. V.T. of backing strip tack / fillet welds:
RL5ULI5 IM5PECT0R 51GMATURE DATE
)
- 3. Cleanliness of channel. liner, and backing strip:
RE50LT5 IM5FECTOR SIGNATURE DATE
- 4. Final V.T. of channel fillet weld:
RuuLT5 IK5PECTOR SIGNATUP1 QATE
- 5. Final T.T. er tastde weld:
RE514.T5 IMSPECTOR SIGNATURE DATE
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Congletion of weld inspection.
RuutI5
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~ DATE 0
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. -. Insert to Plate,,
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WELD PROCEDURE
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WELUra STriBOL sw e or us., ra r. mr asPfCIOR
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DESCRIPTION (s) and INSPECTION REMARK (s)
RESULTS SICNATURE D.\\TE 1.
Fit up of Lirger Plate
,,o plate, angle, insert t
Cleanliness of liner and backing
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V. T. of backing strip tack / fillet wekds
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cleanliness of channel, liner and backing strip i
3.
Final V. T. on Channel' Weld's 4.
Liner Fit-up Verification Cleanliness Verification Sa.
F nal V. T.
I Acceptance Std.
Gibbs & Hill 2323-SS-IS Mk BatchT.,k 55.
Penetrant Mfc. Marnaflux Spotcheck I
C1cancr Mfg. Marnaflux Sootchech Batch j
Developing Ti=e -
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s NDE Procedure Surface 300-NB-5250 Attach. 6B As Welded Ground Other Final P. T.
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I Preassure Differential Caune Serial Number Maintained for Sec.
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Unsatisfactory INSPECT 0tt DATE CCRT. I.CVEI._ l 7
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35-1195-CCP-38, R'; vision 2 ICN #3 Sheet 2 of 2 d
i I-o FIGURE 3 l'
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Emmes;h.'T WELD 4.
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's, BaA Stainless Steel Liner inspection Travele.-
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FEhd,EI 6 CP5E5 JOB NQ; 33 1193 UNIl PAGE _,OF s
F*
Wannag No.
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PL. to PG.
C Plate to Plate Insert to Plate Angle to Ma*= [~] Other
! Hold Walder l W.M.R.
l Weld
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- 1. Fit up and Cleanliness of Above:
i ;
~
I assults Inspector 5tgnature Date k-
- 2. V.T. of Backing Strip Tack / Fillet Welds:
b Results Inspector 5tgnature Unte
- 3. Cleanliness of, Channel. Liner, and 8. Strip:
Results Inspector strature ante
~
- 4. Final V.T. of Channel Fillet Weld:
l Resulta inspector signature sete t
lj I
- 5. Inside Fit Up an,6 Cleenliness:
I mesuits Inspector 5 gnar 7 ante j
- 6. V.T. of Fillet Prior t' Anding:
Assults Inspec*
signature ante
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assults Inspector 5tgaature Date f-t i
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INSTRUCTION REVISION ISSUE NUMBER DATE PAGE TEXAS UTILITIES GENERATING CO.
g QPSES L
o QI-QP-11.14-6 0
ME 2 6 B32 3 or 4
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ATTACHMENT 4 OxKETED U3tu; WELD NO.
B&R Stainiess Steel Liner InsidJti68IT/eveg57 PROJECT: CPSES JOB tiO:
35-1195 Utill h - PAGE I
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Weld Hold Syrnbol No.
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in_e_1.s_of Above:j p g
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/J6A) j{ /671/l ff02 J L.,
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b~ 035 E90LT 2-b
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Sc.c D-cy3 98oT3
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fe6 6-/95 YEo25 I5 t in Unl i
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Q-204 y8025 InspectorSb'natyre Date
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s J/)9
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- 7. Final VlT.
Weld:
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S/9T Results.' k p tor Signature Date A
k' l.
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L FIG'J.E 3 62 i
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ILP. STAD LESS STEZ L2;IR I' SFE: TIC:: TEAT 7 FROJECT: CF5ES JOB ;0.: 35-1.1 5 C;IT
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' HOLD 3DGOL ER NO.
,PROCED.
PODIT g
1.
Fit up and cleanliness of above:
AAE A 0/7/t).-
??ok3 N RESULTS ESPECTOR SIGNATlaS DATE
'5d.
AfD Aol72/o Woza 22 4
- 2. 7.T. of backing strip tack / fillet valds:
AM A O / 9.2 l#7 880'2.3 2.
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RISULTS ESPECTOR SIGiATuns., -
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~ PROJECT : C?SES J05 t40: 35-1195 U;ili 2
PAGE' GF 1
Reacror Liner 2 MicLEsbrc. Mn h "OP M6(E To d 20 a
B B - 2 /A l - A Drawing No.
Pool Metal Type Mtl. Thck.
?C. to PC.
Plate to Plate Insert to Plate
/ Angle to Plate Other i
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Welder WFML Wald Hold Synbol No.
Pmced.
Point 1.
Fit up and Cleanliness of Above Resclts Inspector Signatura Date
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V.T. of' Backing Strip' Tack / Fillet! Welds ~: -
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Results s
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Resul ts inspector Signature Date f
5.
Seam Weld Fit Up and Cleanti, ness:
x
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Comp etion of Weld Inspection: QI-QP-11.14-6 s
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Cleaner Mfg. Magnaflux-Spotcheck Developer Mfg. Magnaflux-Spotcheck i
NDE Procedure 1.
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Results Ins;E r-Mgnature Date 5.
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Results Inspector Signature Date 7.
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,GA"0N OLYj jy WELD NO. ILR ST/INLESS STEEL LINIR INSPECTIO?! TRAVELIR PROJECT: CPSES JOB NO. 35-1195 LRilTgg 2 PAGE / OF S 8 8 2VO/A 8m2% $ WL [A $/ TAf VW,^ 7i h 5tzb Drawing No. IOOL MEIAL TIPE MTL. ' LEK. PC. to PC. INSIRT TO PLATE ] ANGLE TO PLATE 20EIR E b25 TD 4. /}37 b uIEIOFwJE E WELD . HOLD IIMBOL kTR NO. . PROCED. POINT i 1. Fit up and cleanliness o above: /VAfJ A00 '75l9 88023 [ W ]. A07b A'S'S REULTS DiSPECTOR SIGIATURE DATE YAA'Al Aoo9S1L //O23 hl
- 2. V.T. of backing p tack / fillet valda:
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Tr - t t -78 l.dA. d 3 /8 )(gozs l SFr N 4 RE ULTS DISPECMR SIGiATURE DATE l l
- 14. Final V.T. of channel fillet weld:
34 T sVLu tb Fr-lt ~7& RE ULTS ' DIS?ECTOR SIGiATURE DATE
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$AT RESULTS INSPECTOR SIGNATURE DATE mm Completion of weld inspection: 4 REULTS DISPECTOR SIGNATURE DATE %g l
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ns g .a WELD NO. 3 ~ ~, B&R Stainless Steel Liner Inspection Traveler lp/ t. QI-QP-ll.14-6 REV._ ~ PROJECT: CPSES JOB N0: 35-1195 UNIT 2 PAGE OF ) Reactor "inern2 h blEMhtfL ~% ' 86TRM AIXrLE TD 0T BB-2Ln1-A Orawing No. Pool Metal Type Mtl. Thck. PC. to PC. Plate to Plate Insert to Plate / Angle to Plate Other A 3777 D2 8 i Walder WFML Weld Hold Synbol No. Proced. Point 1. Fit up and Cleanliness of Above Results Inspector Signature Date 2. V.T. of' Backing Strip Tack / Fillet Welds: Results Inspector Signature Date 3. Cleanliness of Channel, Liner, and B. Strip: h b Results Inspector Signature Date 4. Final V.T. of Channel Fillet Weld: Results Inspector Signature Date 5. Seam Weld Fit Up and Cleanliness: Results Inspector Signature Date p. 6. Final V.T. of Welds for Surface Preps. Results Inspector Signature. Date i um 7. Final P.T. and Vacuum Box of Seams (See Weld Inspection Sheet) Results Inspector Signature Date 8. Completion of Weld Inspection: QI-QP-11.14-6 Inspector Signature Date L' [
MlMAT 0% I18 WELD NO. B&R Stainless Steel Liner Inspection Traveler Weld Inspection Sheet Page of Acceptance Std. Gibbs & Hill 2323-SS-18 7a. Penetrant Mfg. Magnaflux-Spotcheck Cleaner Hfg. Magnaflux-Spotcheck Developer Mfg. Magnaflux-Spotcheck NDE Procedure Final P.T. Level II t RESULTS INSPECTOR SIGN. DATE I-GASKET TYPE ' SOLUTION TYPE 7b. Vacuum Box by Pretest ' Cleaning Pressure Temperature NDE Procedure Solution Application Method Post Test cleaning Gauge Serial Number Pressure Differential Maintained for Sec. Min.. L Final V.B. ~ N/A - Not Applicable Level II h Satisfactory Unsatisfactory Inspector Date .f N
7 J2K IWONATION oncJ~' .gg. b ~. /01/ WELD NO. B&R Stainless Steel Liner Inspection Traveler Weld Inspection Sheet Page of Acceptance Std. Gibbs & Hill 2323-55-18 7a. Penetrant Mfg. Magnaflux-Spotcheck Cleaner Mfg. Magnaflux-Spotcheck h Developer Mfg. Magnaflux-Spotcheck NDE Procedure 5 k Final P.T. Level II RESULTS INSPECTOR SIGN.. DATE p. :-:. 7b. Vacuum Box GASKET TYPE ' SOLUTION TYPE k by Pretest Cleaning Pressure Temp'erature NDE Procedure, jf.'. Solution Application Method Post Test Cleaning Gauge Serial Number Pressure Differential Maintained for Sec. Min.. g-- Final V.B. ~"G W " Y'~, g ";:s~g. s; ,,.,/.y. N/A - Not App 11 cable m,y Level II Ii Satisfactory, Unsatisfactory Inspector Date m .f _1 L l
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~gg); - .;~ ~ ~ ~ ~ ~ ~ ~ WF.LD NO. c k ( B&R Stainless Steel Liner Inspection Traveler QI-QP-11.14-6 REV._ ~ PROJECT: CPSES JOB NO: 35-1195 UNIT 2 PAGE OF g, Reactor Linera2 4TAIAEM hTEL ft/#ro M O To N BB-2401-A Drawing No. Pool Metal Type Mtl. Thck. PC. to PC. k Plate to Plate Insert to Plate Angle to Plate Other AA16F70 kW,e-Welder WFML Wald Hold S.pbol No. Proced. Point 1. Fit up and Cleanliness of Above_ Results Inspector Signature Date E 2. V.T. of Backing Strip Tack / Fillet Welds: Results Inspector Signature Date 3. Cleanliness of Channel. Liner, and 8. Strip:.: k Results Inspector Signe ure Date 4. Final V.T. of Channel Fillet Weld: a Results Inspector Signature Date a 5. Seam Weld Fit Up and Cleanliness: 4 Results Inspector Signature Date E ._.s. 1 E).' ^ .T 6. Final V.T. of Welds for Surfade Preps. g Results Inspector Signature Date g 7. Final P.T. and Vacuum Box of Seams x (See Weld Inspection Sheet) ?$ p Results Inspector Signature Date ,hs 8. Completion of Weld Inspection: QI-QP-11.14-6 p ef Inspector Signature Date ., rm rower weam ro << nwu Meo wrm tm w iI e c. H M - m t t.9 \\
~ }~UK IbfOMCON ONL'8 ^'^""'** L DNFORMANCE REPORT (PR$*" " NeR N,' -(
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.i UNIT STRUCTURE /SYST EM ITEM M PONENT TAG /lO NUMBER LOCATION OR ELEVATION RIR O. 2 hkOwb $s. w &s-24iA 860' fN 27 A/4 t y NONCONFORMING CONDITION Pt OC.b4. A4 M e4J O W6., S OO 6 IC45 d O O. 5 on &Ae boer seek ofLhw :.A w "0 Yid' tad de Ocuum e fg fCd-6f hO $ CL O I sd kes e d a n a-yht. 4 0a o M sco 8 pressure-sadnas iza ys q,,a2 C As lAca ~ &cM~d f W N8-S AM $$ce AS -h to87,toropoq ion,i/44 eso/se ~ i w rg m k i ? ,,,,,,,c,,,co,,,1. rf.IV/4[/4-4 ~ 4 s.,,,, s.4.4 ,,y REPORTED BY: DATE: o u I,5 $$$$? ? /E7lbh ' N ' Y,*: Npy d -b 37.. i O ACTIO'N ADDRESSEE ff DEPARTMENT K i S S i rtco e v-p DISPOSITION: l REWORK REPAIR USE AS IS SCRAP l. R The holdpoint for performing vacuum box inspection shall be reinstated and the 1 g vacuum box shall be performed by QC. E E f .<8 . ;., 5 ~ '}fkf * '? #S . m e.a.r w. . e,-,.u m, ~ 4 ,.-1 k Y.' i ". A '.~* l '.., c p o k 4 ) n DATE. -l ENG. REVIEW / APPROVAL y U ~ DATE: J0.T&h l QE REVIEW APPROVAL: ~~ 'l ilti W I DISPOSITION VERIFICATION & CLOSURE: DATE: / / il O l14 5 Dsweck k de.he. W l i
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2NFORMANCE REPORT (N I g 44q UNIT STRUCTURE / SYSTEM ITEM /COM PONENT TAG /lD NUMBER LOCATION OR ELEVATION RIR NO. %s,. toe his 2 LN Ss. G wr T32Ao m %c! L'az N_is ,Q.+ ) 0 NONCONFORMING CONDITION wq h mtmaa a oass.G - ch, ~ #- N Slep7 bdadL Pa,,Cendm eguilabsp.:sd,oA us s$ndas d l &>y/.2. & ucAf it,e,m., san Au~d,h wh Myw:e hmm& 3 5 % d' Wl UCa S W8 et* S ! $0"l0 l l /0 90, to9/, totg ocl//44, TAe. Med/ A 4lell #Afd We %. F uJ REFERENCE DOCUMENT-REV PARA s DA REPORTED BY: l-ok /653/er' e-YMM/E $_%.O e - A/ CAW di/' 4 i Q j * ^,,',',' g;% ~-h;~..:43 3 ACTION ADORESSEV ' ~ DEPARTMENT O DISPOSITION: REWORK REPAIR USE AS IS SCRAP f THE HOLDPosMT VDR. PEkFDkmtAl6 tincuuht SDK TEST 5 H A LL BE' y RE-GSTh&LDSHEb Mb Y+4G l/htud)n BDX TEST PER.PDRMED i B1 &C.. 8< x.. :.. m.,. Y.i VJ._, .; y h . i-6 t: t k - - xpw e,u QE REVIEW APPMVAL-DATE: /t/ c7. cOM ' iri7ifry ( DISPOSITION VERIFICATION & CLOSURC: DATE: w COMMENTS: ? g pae) & QQ yyA-y45
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- 2. V.T. of Backing Strip Tack /Flilet Welds:
-.n. 3 ~ $ naoWN i p,4".7%- ram) t.3_ . Inspector. Signature CaIt- .a.nl [ RECEIV:D.5 ci, .m . A.c1.eanu.~ ness o6. Channel Liner.cand:IQstrip:. 1 u 7.y .g r r.;wg w g:. .,. w c - \\ '~... - *~' Results' Inspector Signature - date ~ I en re.., - -., u
- 4. Final 'V.T. of Chan.ael Fillet '.' eld:
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Attachnent 5 gsummmmmmmmum CASE: Ebrm E I 35-1195-CCP-38, July 19,1977 u ns REVISION 2. Decenber 8,1977 PAGE 17 of 17 s_ '84 DCI -1 A10 3 7 ...d . t ,:n.. % h.fi,sEs.'. FIGIRE 3 DM;cH TIME DATE N0mESTRUCTIVE TEST l 6 INSPECTION RESIEST,, i ELDER: 4 DRAWING h INSP. CLEAM FIT-UP FIELD ELD M f REQ. VISUAL L.P. V.E. m. m.. e kll;; INSPECTOR: ACCEPT: DATE: 4 .S.Y ~ ^__ ' u.u, ! I M -i- - E L. c ~, w V +, ,3 9 '- t ' :. 1, A + i: ~ r .s 's s '? ,+1 T 4 Y t p
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r: e Sep te mbe.r 27, 1984 P' UNITED STATES OF AMERICA ^b4 OSI -l Al0 :57 NUCLEAR REGULATORY COMMISSION LFr k. mn BEFORE THE ATOMIC SAFET1 AND LICENSING'rBOARD stj< cn. w uCH In tne Matter of ) ) TEXAS UTILITIES GENERATING ) COMPANY, et al. ) Docket Nos. 50-445-2 ) and 50-446-2 ~ (Comar.che Peak Steam Electric ) Station, Units 1 and 2) ) CERTIFICATE OF SERVICE 3, By my signature Delow, I hereby certify that true and correct copies of CASE's CASE's Evidence of a Quality Control Breakdown hs.ve been sent to the names listed Delow this 27th day of September,1984, by: Express mail where indicated by *; Hand-F delivery where indicated Dy **; and First Class Mail unless otherwise indicated. Administrative Judge Peter B. Bloch U.S. Nuclear Regulatory Commission 4350 East-West Highway, 4th Floor Bethesda, Maryland 20814 Herbert Grossman Alternate Chairman ASLB Panel 3 - U.S. Nuclear Regulatory Commission 4350 East-West Highway, 4th Floor Bethesda, Maryland 20814 7 Dr. Kenneth A. McCollom, Dean Division of Engineering, Architecture v and Technology Oklahoma State University Stillwater, Oklahoma 74074
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _. _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Dr. Walter H. Jordan y 881 W. Outer Drive Oak Ridge, Tennessee 37830 Ms. Ellen Ginsberg, Law Clerk U.S. Nuclear Regulatory Commission 4350 East / West Highway, 4th Floor Bethesda, Maryland 20814 Nicholas S. Reynolds, Esquire Bishop, L1Derman, Cook, Purcell & Reynolds 1200 17th Street, N.W. Washington, D.C. 20036 Stuart Treby, Esquire Geary S. Mizuno, Esquire Of fice of E'4ecutive Legal Director U.S. Nuclear Regulatory Commission Maryland National Bank Building Room 10105 4350 East / West Highway, 4th Floor Betnesda, Maryland 20814 Docketing & Service Section Office of the Secretary N U.S. Nuclear Regulatory Commission Washing ton, D.C. 20555 Renea Hicks, Esquire Assistant Attorney General Environmental Protection Division Supreme Court Building Austin, Texas 78711 Mrs. Juanita Ellis p President, CASE [ 1426 S. Polk r. Dallas, Texas 75224 b OA s h p ANTHONY Z'T ROISMAN y Trial Lawyers for Public Justice 2000 P Street, N.W., Suite 611 Washington, D.C. 20036 (202) 463-8600 I p l -}}