ML20099C274

From kanterella
Jump to navigation Jump to search
Further Evidence of QC Breakdown in Const,Installation & Insp of Stainless Steel Liner Plate.Condition of Entire Structure Indeterminate Due to Applicant Inability to Produce Adequate Explanations.Certificate of Svc Encl
ML20099C274
Person / Time
Site: Comanche Peak  Luminant icon.png
Issue date: 11/15/1984
From: Roisman A
Citizens Association for Sound Energy, TRIAL LAWYERS FOR PUBLIC JUSTICE, P.C.
To:
References
CON-#484-157 OL-2, NUDOCS 8411190454
Download: ML20099C274 (39)
v • d • e


Text

r. .T 16~l November 15, 1984

$3f53 UNITED STATES OF AMERICA .

NUCLEAR REGULATORY COMMISSION

/vDV Jg A10:37

- iDi BEFORE THE ATOMIC SAFETY OCCb AND LICENSING ER$ C" t;

In the Matter of )

)

TEXAS UTILITIES GENERATING ) Docket Nos. 50-445-2 COMPANY, et al. ) 50-446-2

)

(Comanche Peak Steam Electric )

Station, Units 1 and 2) )

i r

CASE'S FURTHER EVIDENCE OF A QUALITY CONTROL BREAKDOWN IN THE CONSTRUCTION, INSTALLATION AND INSPECTION OF THE STAINLESS STEEL LINER PLATE On September 27, 1984 CASE filed a brief delineating specific quality control / quality assurance problems which it had identified through review and analysis of documentation provided 3 during the operating license hearings on harassment and intimidation. (CASE's Evidence of a Quality Control Breakdown)

Due to the unexcused lateness of the Applicants' response to this CASE filing, CASE requested and was granted the opportunity to supplement its initial brief outlining the QC problems it had identified. It does so with this filing.

Subsequent to the September 27th filing CASE completed a more thorough document review and analysis of the regulations and l

industry codes and standards applicable to the stainless steel liner plate. The result of that review is attached as Exhibit 1 to this filing. This attachment delineates the brea'kdown of l

procedures regarding the stainless steel liner plates l

l installation and inspection.

8411190454 841115 PDR ADOCK 05000445PDR G

l

r- ^

. i .

Additionally, CASE asserts-that' Applicant continues to mischaracterize the major issue regarding the liner plate construction, installation, and inspection.

The stainless steel liner plate was constructed, installed

- and-inspected as an ASME (safety-related) function prior. to being turned over to'the non-ASME side, th'erefore Applicants improperly assert (apparently with the Nuclear Regulatory Commission Staff's ,

approval) that there is noL safety significance to the problems identified during construction, installation and inspection of the liner plate.

1 This characterization is not correct. (See NUREG-0404, Vol.

2; General Design Criteria 1, " Quality Standards and Records" of Appendix A to 10 C.F.R. 50; Reg. Guide 1.25, Reg. Guide 1.26; Reg. Guide 1.29; Reg. Guide 1.13 General Design Criteria 61; ANSI /ASME N45.2-1977, Section 2; Section 7, Section 9, Section 11; CP-QAP-ll.1, Rev. O, 1, 2, 3 and 4 Paragraphs 2.2 and 3.1) t Additionally, the Applicants' assertion that the wrong traveller was consistently used in the construction, installation and inspection of the stainless steel liners is untrue.

Exhibit 2 to this brief was obtained by CASE through its "

independent investigation of this matter, not through discovery in t'ais case.

The exhibit is proof that at least in one instance the proper form, as required by CP-QAP-ll.1 was used for inspection purposes. It is clear from a review of the liner plate package number 988 that the "old form" identifies the first four hold points as they were initially completed, and the "new form" O

_ry,,,,w,-sv,--+ ---e,nw ~ ~

  • .i incorporates those inspections by reference to pages 2 and 3 of the traveller.

Either Mr. Brandt's testimony of September 13, 1984 was erroneous because Mr. Brandt does not know what really happened during the construction, inspection, and installation of the liner plates. Or Mr. Brandt does know what happened and has failed to disclose to the Board the location, and existence or non-existence of the rest of the proper forms. (Hearing transcript, pp. 16,047-16,052)

Conclusion Applicant may be either ignorant or knowingly deceptive about certain irregulariteis regarding the stainless steel liner plate. Their inability or unwillingness to produce adequate, plausible explanations for the quality control breakdown of the

~

stainless steel liner plates int . i cates to CASE that our worst fears are correct -- the condition of the entire structure is hopelessly indeterminate.

Respectfully submitted, 3(b A _Ar-r-

I ANTHO Q J. ROISMAN Trial Lawyers for Public Justice, PC 2000 P Street, N.W., Suite 611 (202) 463-8600 Counsel for CASE ,

i

November 15, 1984 -

"i UNITED STATES OF AMERICA NUCLEAR REGULATORY COMMISSION BEFORE THE ATOMIC SAFETY AND LICENSING BOARD In the Matter of )

)

TEXAS UTILITIES GENERATING )

COMPANY, et al. ) Docket Nos. 50-445-2

) and 50-446-2 (Comanche Peak Steam Electric )

Station, Units 1 and 2) )

CERTIFICATE OF SERVICE By my signature below, I hereby certify that true and correct copies of CASE's Further Evidence of a Quality control Breakdown in the Construction, Installation and Inapection of the Stainless Steel Liner Plate have been sent to the names listed below this 15th day of November, 1984, by: Express mail where indicated by *; Hand-delivery where indicated by **; and First Class Mail unless otherwise indicated.

a

~

Administrativb Judge Peter B. Bloch U.S. Nuclear Regulatory Commission 4350 East-West Highway, 4th Floor Bethesda, Maryland 20814 Herbert Grossman Alternate Chairman ASLB Panel U.S. Nuclear Regulatory Commission 4350 East-West Highway, 4th Floor Bethesda, Maryland 20814 Dr. Kenneth A. McCollom, Dean Division of Engineering, Architecture and Technology Oklahoma State University Stillwater, Oklahoma 74074 I

/

~

Dr. Walter H. Jordan 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, Liberman, Cook, Purcell & Reynolds 1200 17th Street, N.W.

Washington, D.C. 20036 Stuart Treby, Esquire Geary S. Mizuno, Esquire Office of Executive Legal Director U.S. Nuclear Regulatory Commission 7735 Old Georgetown Rd., 10th Floor Bethesda, Maryland 20814 Docketing & Service Section Office of the Secretary 3 U.S. Nuclear Regulatory Commission

~,

Washington, D.C. 20555  ;

i; Renea Hicks, Esquire E' Assistant Attorney General 2, Environmental Protection Division it Supreme Court Building Austin, Texas 78711 d

g Mrs. Juanita Ellis President, CASE j

1426 S. Polk Dallas, Texas 75224 {

[q V

o 1

k. SA -

ANTHON W ROISMAN  % ,

f

--- , - - - . , - --,c -- --- ,-

" R

. -- 6 Exh? bit 1 6

. I 4

ANALYSIS OF LINER PLATE DOCUMENTATION P

l v-

5 EXHIBIT 1 INDEX PAGE PART I: MISSING HOLD POINT 1: Fit-up/ Cleanliness Of Backside (Concrete Side) Welds Goverining Codes and Standards that were violated 1 NDT chits insufficient to show QC verification of Step 1 2 Date and Signature on NDT chit used to verify step 1 is the same date and signature shown on traveler for Step 3 3 and/or 2 that are signed off, but step 1 is blank Additional welds that lack QC verification for Step 1 3 Step 3 and/or 2 signed off prior to date shown on chit produced to show verification of step 1 4 WFML's referenced on NDT chit used to show verification of step 1 for Embed to Plate, is not the welding procedure 5 .

required for Embed to Plate.

, i PART II: MISSING HOLD POINT 5: Fit-up/ Cleanliness Of Inside 4

(Waterside) Welds 184 welds that lack QC verification for Step 5 6 NCR's written against 48 welds that lack QC verification for fit-up and cleanliness of inside (waterside) welds. 6 I,

PART III: MISSING HOLD POINT 5: Final V.T. Of Inside Weld

. Welding performed that lacks QC verification of Step 7 7-8 PART IV: NO QC VERIFICATION FOR WELDS PERFORMED WFML's referenced on package - No QC verification 9 - 15 WFML's attached to traveler showing welds performed, 1 but does not have QC verification for re-welding 16 - 20 1 .

t 1

. INDEX PAGE PART V: INCOMPLETE WELDS SIGNED OFF AS COMPLETED NCR's written against welds signed off by James Cole on which he had N/A'd the vacuum box test 21 Failure to perform vacuum box and/or P.T. test 22

1. P.T. and vacuum box test not performed 23
2. No NDE report, no PT, and no vacuum box 23
3. James Cole N/A'ed vacuum box test - 24

~

4. PT test performed but no vacuum box test 24 PART VI: NON CONFORMING CONDITIONS DISPOSITIONED BY NCR's Welds signed off by James that had major defects 25 Major weld defects not detected by QC inspector 25 Steps 2, 3, and 4 N/A'ed and insufficient documentation 26 Lack of QC verification for fit-up/ cleanliness of inside (waterside) welds 26 Bjcking bar not installed but was accepted by QC 26 Welding performed without QC inspection ,

27 P.T. reports filled out using wrong procedure number 28 l

l '

F.- ,

Paga 1 PART I: MISSING HOLD POINTS:

Mandatory hold points that lack QC verification prior to completion of subsequent activities being performed violate the following Codes and Regulations:

10CFR50 Appendix B:

Criteria II: States in part that activities affecting quality are to be accomplished under suitable enviromental conditions for accomplishing the activity; which includes adequate Clean-liness; and assurance that all prerequisites for the given activity have been satisfied. The program shall take into account the need for special controls, which includes the need for verification of quality by inspection and test.

Criteria V: States that Instructions, Procedures, and Drawings shall include. appropriate quantitive or acceptance criteria for determining that important activities have been satisfact-orily accomplished.

ANSI /ASME N45.2-1977 Section 2: Requires that the quality Assurar.:e Program shall provide assurance that activities affecting quality are documented' and accomplished in accordance with written instructions and procedures The program is required t o assure that prerequisites for the given activities have been satisfied, and the program shall take in to account the need for the l

verification of quality by inspection, examination or test.

Section 11: Requires that work shall not proceed beyond mandatory hold points, and work shall not proceed without the consent of the designated representative before wok centinues i

.PART I: Micaing Hold Pointe 'Pcga 2 .

STEP 1: Fit-up and Cleanliness of Channel Side (Concrete Side) Welds A large number of welds lack QC verification of the required fit-up and cleanliness of backside (concrete side) welds. The failure to perform this function leaves the quality of these welds indeterminate. The S/S l Liner has been installed and it is now impossible to re-examine or test l i these welds to determine their acceptability. j NDT chits have been produced in an effort to show the fit-up/ cleanliness was performed, but there are facts that indicate the use of the chits is not sufficient to show this step was performed, since they may have been i intended for verification of other steps signed off on the traveler.

1. Many of the NDT chits produced to verify that step 1 was performed 2

have the same date and signature that was signed off on the traveler to 3

verify the performance of step 3 and/or 2 If all these steps had been verified the same day by the same QC inspector they would all have been signed off on the traveler at the same time, but step 1 was left blank.

It cannot be assumed that the chits included the verification of step 1 since the inspector did not sign that step off on the traveler.

a. There was no reference on the NDT chit showing what step was being signed off when Sue Ann Neumeyer was ordered to use the chit to sign off the missing hold point on the traveler.
b. The note "first fit-up and cleanliness" is in the handwriting of two people, it was not put on the chit by the inspector or the person who filled out the other information on the chit. The note was added to the chit when it was discovered that step 1 lacked QC verification and may not have been performed.
2. Although the travelers reference the WMR numbers on these chits as

! being for the fit-up and cleanliness it doesn't mean they were intended for that purpose. Travelers 398 thru 543 have steps signed off by the i QC inspector but the information side of the traveler is blank. This is sufficient to show the WMR No., Welder Symbol, Weld Procedure, and Hold Points are not always filled in when the inspector signs the traveler, and may not have been filled in until the chits were added to it.

t

PART It Mic2ing Hold Painto P2ga 3 j

. I Step 1: Fit-up and Cleanliness of Channel Side (Concrete Side) Welds The following welds lack QC verification of the fit-up and Cleanliness of backside (concrete side) welds. The Stainless Steel Liner has been installed. The welds cannot be re-inspected or tested to determine if they are acceptable. The condition of these welds are indeterminate.

1. Welds that have the same date and QC signature for step 3 and/or 2 that is shown on the NDT chit that was produced to show QC verification of step 1. It is evident the chits were not intended to verify step 1, weld but was intended to verify Step 3 and/or 2 only.

4 9 12 14 16 17 21 23 24 28 29 32 33 36 38 39 40 41 42 43 44 45 46 47 49 51 53 54 56 57 59 60 63 65 66 67 68 69 70 72 73 74 75 77 78 82 84 85 87 89 91 92 93 95 96 99 100 107 108 109 111 112 113 114 124 125 127 129 130 131 132 134 135 136 138 140 141 143 153 162 170 175 180 185 187 188 191 192 194 196 197 198 199 200 202 203 208 212 213 218 222 225 230 232 236 237 250 252 266 267 268 269 271 280 284 291 293 294 295 296 297 298 301 302 307 313 318 319 323 324 330 331 340 341 349 351 661 662 663 664 686 689 696 697 709 720 total 147 2 The following welds also lack QC verification for step 1:

weld 1A 3 6 10 11 13 15 19 20 22 25 26 27 30 31 34 35 37 48 61 62 71 80 86 88 101 102 103 104 105 110 115 116 117 118 119 120 121 122 126 142 144 146 147 150 151 152 154 156 158 160 163 164 165 167 168 169 171 172 173 174 176 177 178 179 181 182 183 184 186 190 193 195 201 206 210 all 214 215 216 217 219 220 223 224 227 228 229 2a9 231 234 240 242 244 246 248 251 253 256 257 259 261 263 264 265 270 273 275 276 278 279 281 282 285 286 287 288 289 290 292 300 303 305 306 303 309 310 312 314 315 316 317 320 321 322 325 326 328 329 333 334 335 336 337 338 339 342 352 660 687 688 691 694 695 698 699 700 701 702 710 711 729 842 851 852 854 855 856 857 858 total 170

,- -Pags 4 J i

\

QC verification of fit-up/ cleanliness-for channel side (concrete side) welds was not performed on the following welds prior to welding, which makes the condition of the welds indeterminate. This was a violation of procedure and 10CFR50 Appendix B Criteria V.

Weld 26 Step 2: V.T. of backing strip tack / fillet welds Signed off by S.M. McCoy on 9/8/78 Step 3: and backing strip Cleanliness Signed off byofS.channel, M. McCoyliner,/8/78 on 9 Step 1: Fit-up and Cleanliness of plate to plate NDT Chit produced to show QC verification of this step was signed off by S.M. McCoy on 10/13/78 after Steps 2 and 3 were c ompleted.

88 Step 2: V.T. of backing strip tack / fillet welds Signed off by S.M. McCoy on 8/30/78 Step 1: Fit-up and Cleanliness of plate to plate NDT Chit produced to show QC verification of this step was signed off by S.M. McCoy on 9/5/78 af ter Step' 2 had been completed.

146 Step 2: V.T. of backing strip tack / fillet welds Signed off by Larry Wilkerson on 8/11/78 Step 3: Cleanliness of channel, liner, and backing strip Signed off by Larry Wilkerson on 8/11/78 Step 1: Fit-up and Cleanliness of plate to plate NDT Chit produced to show QC verification of this step

'was signed off by Larry Wilkerson on 8/14/78 after Step 2 and 3 were completed.

195 Stop 2: V.T. of backing strip tack / fillet welds Signed off by S.M. McCoy on 9/27/78

?

Step 1: Fit-up and Cleanliness of Embed to Plate p NDT Chit produced to show QC verification of this step 6 was signed off by S.M. McCoy on 9/28/78 after step 2 J had been completed.

196 Step 2: V.T. of backing strip tack / fillet welds Signed of by Larry Wilkerson on 9/27/78 Step 1: Fit-up and Cleanliness of Embed to Plate NDT Chit produced to show QC verification of this step was signed off by Larry Wilkerson on 9/28/78 after s*on 2 had been comcleted

~

PART.It- Fit-up and Cicinlin2c2 of'backcida Waldo ' Paga 5 NDT chits produced for' Step one reference wrong procedure for Embed to Plate; Fit-up and Cleanliness for Embed to Plate:

The correct welding procedure used for Embed to Plate is 68025 The following welds were done using the wrong weldin Chits- used to verify Step 1 (Fit-up/ Cleanliness)g of procedure,Embed to or plate the are NIyf not the Chits signed off for that step of the welding operation.

i I

Welds: . ,

20 100 216 291 699 740 755 786 24 120 217 295 700 741 756 800 32 124 218 298 706 742 757 822 e

33 125 219 314 710 743 759 884 -

51 127 220 317 711 744 761 885 53 129 251 319 722 746 762 880 59 131 266 321 723 747 765 886

~

66 132 275 328 724 748 773 888 67 196 276 330 725 749 , 775 889 68 200 277 333 735 750 776 890 l

i 69 206 278 337 736 751 780 891 72 209 279 34 2 737 752 783 892 73 210 283 352 738 753 784 897 77 74 211 287 698 739 754 785 [

The above welds were done using welding procedure 88023 q

i

- ., , , . _ , , , - .-,..-,, _. ,. , ,, ,,w- , , - , - , , , - , r- ,,,,,,__--,n,w,-.~.,,me. n-. ,

PART II: Miccing H21d P into Stop 3 PagJ A 6 i

. 1

' MISSING HOLD POINTS: Continued Step 5: Fit-up and Cleanliness of inside (waterside) welds Inspection travelers for the following welds lacked QC verification for Step 5, fit-up and cleanliness of inside (waterside) welds. Welds have been performed; leaving the acceptability of the welds indeterminate.

welds 6 10 11 12 13 14 17 19 20 21 22 23 24 26 27 28 30 31 32 36 37 38 40 41 42 43 44 46 47 48 49 51 53 54 56 57 59 60 63 65 66 67 68 69 70 71 72 73 74 75 78 81 82 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 103 104 los 107 108 109 111 112 113 114 115 116 117 119 122 124 125 127 130 136 138 140 143 147 152 158 165 167 168 169 170 171 172 174 175 180 183 185 189 198 199 146 153 178 179 176 181 182 195 188 (196 202 203 208 212 213 225 228 230 232 2324 242

~

243 256 259 2 64 267 2 68 269 273 286 287 290 292 294 295 298 301 293 302 303 306 307 308 313 315 316 320 322 325 314 323 332 339 340 342 709 705 896 901 907 908 909 910 912 682 713 714 851 864 865 867 875 197 318 687 688 779 783 784 785 799 797 798 i

Inspection travelers for the following welds lacked QC verification for Step 5, fit-up and cleanliness of inside (waterside) welds. NCR's have been written for these welds making their acceptability contingent on the results of vacuum and hydrostatic tests.

welds 3 192 200 209 210 235 236 246 248 250 251 252 257 261 263 271 '

274 277 278 280 281 282 285 288 291 299 330 331 333 334 335 336 337 338 341 344 345 346 347 348 349 351 353 695 699 700 709 729 1145

.'? , pad 4 7

PART III

I

. MISSING HOLD POINT 7: Final V.T. Of Inside Weld Welding has been done but lacks QC verification for welds completed l l Welder' WFML Rods Welder WFML Rods j Weld Date Symbol Number Burned Weld Date Symbol Number Burned 4

%4 5/14/81 FF AEO A-007 1 5% 5/14/81 FF AE0 A-007 1 i

5/18/81 AE0 A-012 4 5/18/81 AE0 A-012 4

< 5/18/81 AYZ A-013 4 5/26/81 AEO A-036 6 j

5 8{

5g/21/81 g ggg g 5/26/81 BEN A-037 Total Rods Burned 1

19 5 AE0 A-032 5 5/26/81 AE0 A-036 6 555 5/14/81 FF AEO A-007 1 I 5/26/81 BEN A-037 8 Total Rods Burned 38 h/ f $f_of9 (

545 5/ /81 FF AE0 A-007 2 Total Rods Burned 9 5/ /81 BYZ A-013 4 556 A-007 1

! 5/ /81 BEN A-020 1 5/g81FFAE0 f Total Rods Burned 12 3/19/ h $0 f.if9 .I

%6 5/14/81 FF AE0 A-007 2 Total Rods Burned 9

, 5 18/81 BYZ A-013 4 557 5/14/81 FF AE0 A-007 1 i 81 BEN A-020 6 1 81 AE0 A-023 5 5/18/81 AE0 A-012 4

5 81 AE0 A-032 5 5/19/81 AE0 A-019 1 j Total Rods Burned 22 Total Rods Burned 9

%7 5/14/81 FF AE0 A-007 1 558 5/14/81 FF AE0 A-007 1 A-012 81 BYZ A-013 4 5/18/81 AEO 4 81 AE0 A-019 2 i 5 81 AEO A-019 4 5 81 BEN A-020 6 4 5 /81 BEN A-020 6 5 /81 AEO A-032 5 5 81 AE0 A-023 1 Total Rods Burned 20 Total Rods Burned 18

[ 551 5 /81 FF AE0 A-007 1 559 4/81 FF AE0 A-007 1 5 /81 AE0 A-012 4 5 8/81 BYZ A-013 4 1

/81 AE0 A-019 19/81 AE0 A-019 3 i 1

! Total Rods Burned 9 Total Rods Burned j 14 d;

! 552 5/14/81 FF AE0 A-007 1 A-007 1 q

. 5/19/81 AEO A-019 1 560 5g/81FFAEO 5 "

Total Rods Burned 5 5/19 E A 9 2 l 553 5/14/81 FF AEO A-007 1 jQg{ ggg 1 5

L AE0 A-012 i 5/18/81 4 Total Rods Burned j 5/19/81 AE0 A-019 i 17 Total Rods Burned 9 i 5% A-007 7 }

, A-012 l A-036

r Pago 8

,PART III: '

MISSING HOLD POINT 7: Final V.T. Of Inside Weld lacks QC Verification Welder WFE Rods Welder WFE Rods Weld Date Symbol Number Burned Weld Date Symbol Number Burned I 561 5/18/81 BYZ A-13 4 857 9/09/81 AUB A-417 6 5/19/81 BEN A-20 6 CFO B-192 Total Rods Burned 10 Total Rods Burned 6+

562 5/18/81 BYZ A-13 4 858 6/10/81 AUB A-425 15 5/19/81 AE0 A-19 3 9/09/81 AUB A-417 7 5/19/81 BEN A-20 5 Total Rods Burned 22 Total Rods Burned 12 853 9/24/81 AUB A-535 8 563 5/18/81 BYZ A-13 4 5/19/81 BEN A-20 5 854 9/21/81 AUB A-535 8 Total Rods Burned 9 1160 5/27/81 ABF A-45 4 564 5/18/81 BYZ A-13 4 5/ A 5/19/81 BEN A-20 5 5f 6/01/81 ABF A-61 74 Total Rods Burned 9 9/08/81 ABF A-412 134 9/09/81 ABF A-414 31 0 A 15 Total Rods Burned 468 10/5/81 ABF A-588 3 .

B-253 9/24/81 AUB A-535 7 Welds That Do Not Have WFE's Total Rods Burned 29+ In Package 852 9/24/81 AUB A-535 8 Welder. WFE Welder WFE 9/24/81 BKU A-553 4 Weld Symbol Number Weld Symbol Number 10/1/81 ABF A-582 6 B-@ 565 BMD D-5732 566 BMD D-5732 570 CFO B-214 573 BMD D-5739 Total Rods Burned 18+ 574 BEN D-5763 579 BMD D-5757 580 BEN BEN D-5763 855 9/10/81 AUB A-425 15 D-5763 CFO B-192 588 BYZ D-5740 585 BYZ D-5761 CFO B-202 600 AE0 D-5762 Total Rods Burned 15+ BEN D-5767 856 9/10/81 AUB A-425 10 AUB B-192 870 921 918 916 914 CFO B-202 898 899 897 890 1134 Total Rods Burned 10+

925 924

_ - . _ - - - - - , . -----n,-- ~- -,n, - - - - - -

---e- - - - - - - - - - - - - - - - - ,

PART IV:

NO QC VERIFICATION: ,

WFE's referenced on travelers indicate that new welding was done, but i there is no supporting documentation in the package to show there was any QC verification or involvement when the welding was done.

WFE WFE WFE Weld Number Step Weld Number Step Weld Number Step 6 D-4117 5 36 B-195 5 49 A-433 1 D-4187 5 B-173 5 10 *D-2073 5 B-332 5 37 D-4021 5 51 B-173 1 D-4007 4 11 B-317 5 D-40% 5 56 D-4007 1,4

'A-425 5 D-4021 1,4 12 D-1502 1,5 D-4063 1,4 D-1549 1.5 38 D-4063 5 D-4044 1,4 13 D-1477 1 57 D-3028 1 -

D-1502 5 39 B-241 1 D-3027 1 D-3035 1 11- D-1566 1 40 A-425 1,5 D-3046 1 D-1586 5 D-3047 5

' 41 D-3024 5 D-3075 5 16 D-0725 1 A-425 5 D-3088 5 D-5730  ?

42 D-2098 5

17 D-1284 1 58 B-180 1,5 D-1502 1,5 43 D-1507 1 B-193 5 -

D-1531 1 20 *D-4135 5 D-1547 1 60 D-1547 1 j D-1566 1 D-1531 1

21 D-4020 1 D-1582 1 D-1586 1 D-4046 5 D-1670 1 D-1602 5 1 D-4188 5 *A-425 5 D-1561 5 22 D-4188 5 I

% D-1317 1 63 B-1033A 1 ,

23 'D-4136 5 B-1038A 1

'D-4188 5 46 D-1355 1 B-1090A 1 [ih

' D-2033 1 D-1353 1 B-1577 5 D-1373 1 b 24 B-314A 1 D-1488 5 65 A-%0 4 f B-332 1 D-1837 5 66 A-%O 4 ,

, 26 D-1477 1,5 47 D-1317  ? A-452  ?

B-314A 1,5 48 D-4912 1 71 D-4903 1 D 27 D-1549 5 D-4925 5 D-4912 1 '/

D-4936 5 D-4925 1 28 D-1818 5 B-262 5 D-4936 1 j;

' bQ4 M PART IV: -

No QC VERIFICATION: For Rewelding WFE's referenced on travelers that do not show QC verification.

WFE WFE WFE Weld Number Step Weld Number Step Weld Number Step 74 D-4936 1 87 D-4022 1 103 D-1391 1 D-4945 5 D-4090 5 D-1413 1 D-4092 5 75 D-4936 1 D-4107 5 104 D-1444 1 D-4945 1 D-1461 1 8 D-W 5 77 B-329A 1 D-4022 5 105 B-502 1 80 D-021 1 107 *B-463 1 D-035 1 89 D-1178 1 B-477 1 D-043 1 D-1582 5 D-046 1 D-1586 5 108 D-1264 1 D-065 1 D-1945 5 D-1488 1 D-4298 7 B-580 5 D-1472 5 D-4302 7 B-590 7 90 D-4022 1 109 D-1284 1 B-599 7 D-5730 1 81 D-4283 1,5 111 D-5715 1 B-590 1,5 92 D-4945 1 D-5724 1 82 D-4992 1 93' D-1733 1 D-4107 1,5 D-1840 1 112 D-1301 1 B-532 5 D-1862 1 D-5730  ?

B-549 5 D-1837 1 B-568 5 113 D-1264 1 94 D-1945 1 D-1488 5 84 D-1204 1 D-1994 1 D-1472 5 D-4063 1,5 B-460 1 D-4090 5 114 D-1731 1 D-4123 5 96 D-1818 1 D-1767 1 D-4125 5 97 D-1840 1 115 D-1477 1 85 D-4009 1 D-1821 1 D-1633 5 D-4022 5 D-4090 5 98 D-1493 1 116 D-1731 1 D-4123 5 D-1493 1 D-1754 5 D-1710 5

86 D-1178 1 D-1733 5 117 D-1413 1 D-1187 1 D-1752 5 B-447 1 D-3046 1 D-3075 5 99 D-1862 1 119 D-1731 1,5 D-3076 5 B-460 5 D-1754 5 D-3088 5 D-1767 5 D-3096 5 101 D-1413 1 D-1801 5 D-580 5 D-1444 1 D-1818 5 ,

. D-1821 5 l

PagJ 11 PART IV:

l NO QC VERIFICATION: For Rewelding l l

WFML's referenced on travelers that do not show QC verification.

WFML WFML WFML Weld Number Step Weld Number Step Weld Number Step 120 B-447 1 142 D-1733 5 157 D-3095 1 D-1752 5 121 D-1508 5 B-407 5 158 D-1963 1 D-1633 5 B-405A 5 D-1983 1 D-1653 5 A161476 1 143 B-405A 1 A161732 1 122 B-392A 1 A161764 1 B-394 1 144 D-1461 1 A161784 1 D-1733 5 A161810 1 124 D-4254 1,5 D-1752 5 159 D-1963 5 125 D-4254 1,5 145 B-437 1 D-1983 5 126 D-035 1 146 D-1444 1 160 D-1532 1 D-018 1 D-1461 1 D-1908 1 D-043 7 A161475 1 D-046 7 147 B-629 1 A161733 1 D-065 7 B-644 1 A161764 1 ,

B-568 7 A161810 1 ,

B-580 7 150 D-021 1 A161843 1 J D-032 1 B-450 5 9 127 D-4275 5 D-018 1 i D-4283 5 D-043 7 163 D-021 1 l, D-046 7 D-032 1  ;,

128 D-4107 5 D-065 7 D-043 1 2 D-4125 5 D-065 7 t D-4211 5 151 D-4133 5 D-4404 7  !!

D-4124 7 D-4406 7 ij 129 B-532 5 D-4212 7 165 D-1263 1 9 130 D-4092 1 152 D-3059 1 D-1268 1 0 D-3076 1 D-1269 5 1 D-1282 {i 132 B-493 D-4267 5 5 y B-502 1 D-4275 5 D-4077 5 g D-4091 5 19 133 D-4107 5 153 D-4267 5 D-4124 5 .ij D-4125 5 D-4111 5 h 155 D-3095 5 l

134 D-3076 1 D-4133 7 167 D-4111 1- -

D-3087 5 D-4124 7 D-4124 1 D-4353 5 138 D-1933 1 156 A161476 5 D-4360 5 A161732 5 i 140 B-477 1 A161763 5 169 B-658 1 A161784 5 A161809 5 A161844 5

Paga 12 PART IV: -

NO QC VERIFICATION: for rewelding WFML's referenced en travelers that do not show QC verification WFML WFML WFML Weld Number Step Weld Number Step Weld Number Step 170 D-3059 1,5 182 D-1710 1 194 A-553 7 D-1892 1,5 B-339 7 171 D-1241 1 D-1249 1 183 D-1427 1 195 B-206 1,5 D-1263 1 D-1427 1 D-1268 1 D-1553 Si 196 B-219 5 D-1269 5 D-1945 5 D-1282 5 197 D-1548 1 D-1548 5 184 B-380 1 D-1565 1,5 B-649 1 D-1582 1,5 B-658 1 185 D-4298 1 D-1585 1,5 D-4302 5 B-339 1,5 172 D-1983 1 D-194 1,5 186 D-021 1 198 D-3034 1 D-032 1 D-3034 1,5 173 D-1878 1 D-043 1 D-1908 1,5 D-065 1 199 D-1390 1 B-366 1,5 D-4418 7 D-1427 1 B-450 1,5 D-4418 7 D-1427 1 D-4419 7 D-1427 1 174 B-366 1 B-379 1 187 D-433 1 202 B-379 1 B-437 1 D-4353 5 D-4360 5 206 D-4393 1 175 B-407 1 38 D-4393 5 B-405A 1 207 D-4411 7 B-420 1 32: '88 D-008 5 D-4212 5 208 D-4038 1 176 D-1862 1 B-599 1 D-4049 1 l

l D-1878 1,5 D-4076 1 D-1908 5 189 D-4203 1 D-4117 5 177 D-1710 1,5 190 D-4038 1 all B-72A 1,5 ~

D-1752 1,5 D-4022 1 D-1692 1 D-4049 5 210 B-169 1,5 D-4062 5 B-180 1,5 178 D-1427 1,5 D-4117 5

, D-4077 5 212 D-2045 1 1 179 D-144 1 B-339 5 D-2033 1 D-144 1 D-2057 1 D-144 1 191 D-3034 1 D-2072 1 D-3034 1,5 D-2087 1 180 B-380 1 B-599 1 D-2099 1 B-371A 1 D-3001 1 B-382A 1 193 A-535 1 5* B-72A 5 A-535 1.5 7' B-72A 1 181 D-1892 1 B-339 1,5

, D-1908 1,5 i .

~ ~ ~ ~ ~ ' ~

Pcg7 13 PART IV:

NO QC VERIFICATION: For re-welding WFML's referensed on travelers that do not show QC verification WFE WFE WFE ,

Weld Number Step Weld Number Step Weld Number Step 213 D-1477 1 229 D-4020 1 246 B-248 1 D-1477 1 D-4046 5 D-1477 1 D-4061 5 247 -B-112 1.7 D-1477 1 D-4188 5 B-900A 1,7 D-4062 5 B-905A 1,7 214 D-2057 1 248 B-237 1 D-2072 5 231 D-2033 1 B-225 1 D-2046 1 B-237 1 r

215 D-1585 1 D-2058 1 D-1837 1,5 D-2038 1 249 B-112 1,7

B-285 1,5 D-2099 1 B-900A 1,7 B-295A 1,5 D-3001 5 RBL-249 7 D-3011 5 216 B-71A 1,5 D-4201 5 250 A-727 4 30*

B-92A 1,5 20' A-735 4 35' B-71A 1,5 232 D-2046 1 A-750 4 20' D-2058 1 A-777 4 20*

219 B-260 1 D-2058 1 A-801 4 25' B-285 1 D-3011 1 B-295A 1 D-3023 1 2 52 D-4155 1 4r*

D-4201 1 D-4169 1 4

220 B-71A 1,5 D-4179 1 234 D-3023 4,1 A-750 5 10*

222 B-1038A 1 A-801 5 1*

B-1062A 1 237 D-1301 1 A-819 5 5' B-1090A 1 D-1317 1 B-1577 5 253 D-5775 5

. 241 B-35 7 D-5788 5

! 225 D-1317 1 B-39 7 D-5784 5 B-581 7 D-5788 5 I

227 D-008 5 B-591 7 D-5788 5 23' I

D-021 5 RBL-241 7

, N-010 5 254 B-581 7

D-032 5 242 A-883 1 15' N-020 5 A-891 1 13* 256 N-003 1 '

D-043 5 A-901 1 D-043 1 D-065 5 A-914 1,5 A-655 1 D-4148 7 A-667 1 D-4165 7 244 A-914 1 30' D-4175 7 A-922 1 20* 257 A-674 1 20' D-4187 7 B-214 5 A-675 1 20' D-4136 7 B-248 5 A-683 1 20*

A-695 1 12*

228 D-022 5 245 B-905A 1,7 D-0476 5 RBL-245 7 258 B-955A 1,7 51' D-4152 5 RBL-245 7 ,

l

s . Paga 14 t

PART IV:

-NO QC VERIFICATION: For Re-welding s

\i WFML's reference on travelers that do not show QC verification -!

WFML WFML WFML Weld Number Step ,

Weld Number Step Weld Number Step 259 A-675 5 17* 279 B-1034A 1 291 A-735 4 18*

A-683 3 30' B-1038A 1 A-777 4 20' A-695 5 11* B-967A 1 A-731 5 7* 280 D-008 4 i' RBL-291 5 1*

RBL-259 5 A-692 1 20*

A-683 -

1 20* 292 B-619A 5 260 B-939A 1,7 60* A-705 1 A-724 1 6* 293 RBL-293 5 1*

261 A-702 1 40' B-518 1 24*

A-738 1 B-521 1 294 A-727 1 A-705 .1 11* B-518 5 10* A-758 1 A-752 1 14* A-768 1 281 A-687 5 1* B-972A 1 262 B-112 7 A-675 5 16*

B-914A 7 2 295 B-967A 1 B-921A 7 30* 282 B-569 5 B-921A 7 1* B-617A 5 296 B-860A 1 B-569 5 263 A-717 1 20* 297 D-4169 4,1 A-748 1 15' >284 A-692 4 50*

A-754 1- 5* A-724 4 6* 300 D-4179 1 A-758 1 6* A-731 1 25* A-348 1 A-732' 1 16* A-350 1,5 265 A-791 5 10*

285 A-692 4 301 D-4194 1,5 266 A-791 5 10*

286 A-692 1 20* 302 D-4194 1 267 A-735 4,1 18* A-702 1 40* A-325 1 3*

A-786 4,1 2* A-705 1 11* RBL-302 5 1*

A-731 1 268 A-786 1,5 3* 303 D-5774 5 D-4169 4 D-5575 5 A-750 1,5 10' 287 B-972A 1 D-5783 5 A-801 1,5 2* B-1062A 1 1*

288 B-617A 5 B-1097A 1 34*

270 D-4156 1 B-6131 5 B-1099A 1 9*

D-4167 1 RBL-238 5 B-1106A 1 D-4179 1 290 A-717 1 40* 305 D-043 1 273 N-003 1 A-727 1 30* D-053 1,7 48*

D-043 2 A-741 1 18* D-056 N-024 1 A-748 1 15*

D-056 1 B-619A 5 306 B-530 1 A-667' 7 40*

A-679 7 90* 308 B-558A 1 37' B-569A 1 I

e

---.,-,-,e r ,.-----,e.- , ,

PART IT: j NO QC VERIFICATION: For re-welding WFML's referenced on travelers that dosen't show QC verification WFML WFML WFML l Weld Number Step Weld Number Step Weld Number Step l 309 B-569A 1 332 A-901 1 26* 352 A-750 1 20*

B-580A 1 66* B-418A 1 A-791 1 11' B-431A 1 RBL-352 5 1*

310 B-868A 1 32' B-472A 1 39' B-484A 1 696 D-1361 1 312 D-003 B-472A 5 D-1386 1 D-043 D-1402 1 N-024 333 A-854 1 10* D-1422 1 D-056 D-1437- 1 335 A-839 1 70* D-1456 1 313 B-530 1 A-854 1 19' D-1462 1 B-559 1 B-961A 1 33* D-1472 1 D-5619 1 314 RBL-314 1 10' 334 A-922 4 20*

B-94 4 26* 697 D-1361 1 315 B-537A 1 B-214 1 D-1386 1 B-546A 1 D-1402 1 337 D-578 4 D-5619 1 316 B-537A 1 B-821A 1 B-546A 1 B-831A 1 703 A-321 1 11*

RBL-337 5 1* A-325 1,5 28' 318 B-510A 1 B-520A 1 339 B-3 4 20* 709 B-137 39*

B-63 4 319 B-816A 5 5* B-76 4 721 D-5625 1,2,3 B-821A 5 B-225 1 D-5653 1,2,3 B-431A 1 D-5653 5 320 B-842A 1 B-499A 1 B-860A 1 B-510A 1 725 D-5625 1,2,4 RBL-339 5 D-5653 1,2,4 322 D-4193 1 D-5653 5 A-330 1 33* 340 B-053 1,4 29*

B-063 727 D-5626 1,2,4 323 D-4193 1 B-842A D-5653 1,2,4 l B-A46A D-5653 5 B-842A 5 B-846A 5 341 B-016 1 728 D-5625 1,2,4 325 D-4193 5 B-069 1 D-5653 1,2,4 RBL-325 5 30* B-076 1 D-5653 5 ,

B-225 1 330 A-866 1 55' 342 B-831A 1 331 D-008 1 B-835A 1 A-883 1 A-891 1 39' 351 RBL-351 4 5*

Pzg3 16 PART IV:

NO QC VERIFICATION:

WFML's attached to travelers indicate welding was done on the following welds but no QC verification or involvement is shown. WFML's attached to but not referenced on the travelers:

WFML Welder Welding Heat Rods / Spools Weld Date Number Symbol Procedure Number Iss. Rt'd 1A 5/3/83 B-2426 ABF 88025 463516 8 0 14 3/23/83 B-2427 ABF 88025 463516 2 0 16 3/22/83 D-5711 ABF 88025 463516 10 0 26 6/7/83 B-2428 BZG 88025 463516 5 2 28 3/17/83 B-2429 ABF 88025 463516 10 0

" " " 0 3/23/83 ABC 4

4/6/83 " CFA "

4 0 37 7/10/81 A-425 AUB 88025 463638 2 0 43 3/28/83 B-1869 CFA 88025 463516 6 0 44 8/6/84 B-2551 CDP 88025 463516 2 0 8/7/84 " CDP " 2 1 45 3/1/83 B-1768 ABF 88025 463516 5 3 46 8/6/84 B-1752 CDP 88025 463516 2 0 47 3/14/83 B-1834 ABF 88025 463516 10 5 48 3/1/83 B-275 ABF 88025 463516 5 3 54 3/23/83 B-2450 CDP 88025 463516 3 2 56 3/11/80 D-3061 BEY 99020 434788 2 1 65 9/12/81 'A-440 ACH 88025 463638 20 3 9/14/81 A-452 ACH 88025 463638 20 3 66 9/14/81 A-452 ACH 88025 463638 20 3 67 3/29/83 B-1873 CFA 88025 463516 1 0 1 1

68 3/29/83 B-1874 CFA 88025 463516 1 0 69 2/24/83 B-1756 ABF 88025 463516 2 0

  • Referenced on traveler ,

~

Paga 17 PART IV:

NO QC VERIFICATION:

WFML Welder Welding Heat Rods / Rolls l Weld Date Number Symbol Procedure Number Iss. Rt'd 71 2/28/83 B-1753 ABF 88025 463516 15 5 73 7/16/84 B-2547 BZG 88025 463516 20 10 7/17/84 " BZG 88025 463316 20 9 74 2/24/83 B-1755 ABF 88025 463516 1 0 80 5/1/80 D-4290 AUB 88023: 463638 40 10

" D-4293 AE0 88023 " 40 10

" 27 5/16/80 D-4303 AUB 88023 40 2/23/82 B-608 CFA 88025 463516 40 5 86 12/3/79 D-1187 BBI 99020 434788 2 r1 1 r1 3/17/80 D-3096 BEY 88023 1 r1 0 r1 89 2/14/80 D-1954 AWK 99020 434788 1 r1 i/2r1 90 2/10/82 B-511 CFA 88025 463516 40 34 2/11/82 B-522 CFA 88025 463516 40 36 91 4/20/83 B-1920 AIM 88025 463516 10 7 92 5/2/83 A-79 BEN 88025 463638 20 4 5/2/83 A-79 BFF 88025 463516 10 9 94 4/22/80 D-2003 AWK 99020 434788 1 r1 0 r1 95 2/11/82 B-524 CCG 88025 463516 40 0

"' 10 8 98 3/24/83 B-1862 ABF 88025 463516 15 1 100 1/21/82 B-368 CCG 88025 463516 40 19 101 3/29/83 B-1867 ABF 88025 463516 15 0 3/28/83 " ABF " " 10 2 3/29/83 AGF 10 0 i 104 3/29/83 B-1877 ABF 88025 , 463516 8 3 107 ,,2/3/82 B-463 CCG 88025 463516 40 0 108 3/14/83 B-1835 ABF 88025 463516 8 0 3/15/83 " " " " 10 5 3/28/83 " CFA " " 1 0 I

" " " 0 3/14/83 "

ABF 8

3/15/83 10 5 i

l

Pago 18 PART IV:

NO QC VERIFICATION:

I WFML Welder Welding Heat Rods / Rolls

! Weld Date Number Symbol Procedure Number Iss. Rt'd i

109 3/16/83 B-18% ABF 88025 463516 4 0 3/17/83 " " " " 10' O 111 2/19/81 *D-5724 BYZ 83025 463638 40 0  ;

2/19/81 " " " " 40 0 1

" " 10 3/22/83 ABF 463516 5 113 3/9/83 B-1816 CFA 88025 463516 10 6 115 3/31/83 B-1881 ABF 88025 463516 15 3 4 83 " CFA 20 12

" " " 10 4 83 BBU 3

" " " 10 0 4 83 CFA 4/19/83 CFA "

4 0 116 4/18/83 B-1916 CFA 88025 463516 9 0 117 4/18/83 B-1917 CFA 88025 463516 9 0 122 3/30/83 *B-394 ABF 88025 463516 5 0 143 1/27/82 *B-411 CCG 88025 463516 40 14 1/28/82 *B-424 CCG " "'

40 20 147 2/26/82 *B-644 CFA 88025 463516 40 9 2/25/82 *B-629 " " "

40 7 163 5/30/80 D-MO4 AUB 88023 463638 40 0 6/2/80 D-%06 AUB " "

40 11 168 6/27/83 B-2161 BZO 88025 463516 20 3' 169 6/7/83 B-2117 BZO 88025 463516 30 3 6/8/83 "

ABF

" 10 4 s 6/8/83 BFF "

25 10 173 5/3/83 B-355 ABF 88025 463516 40 11 175 1/27/82 B-407 CFO 88025 463516 40 2 1/28/82 B-420 CFO 40 7 177 4/19/83 *D-1692 CFA 88025 463516 4 0 179 6/28/83 B-21% BZG 88025 463516 .20 2 183 4/19/83 B-1918 CFA 88025 463516 10 0

  • Referenced on traveler

Paga 19 PART IV:

s NO QC VERIFICATION: WFE's Attached To But Not Referenced On Traveler.

.,. Welding was done with no QC inspections.

  1. FE Welder Welding Heat Rods / Rolls Weld Date Number Symbol Procedure Number Iss. Rt'd 199 4/20/83 B-2433 AIM 88025 463516 15 7 200 3/2/83 B-1773 ABF 88025 463316 5 0 201 3/07/83 B-1772 ABF 88025 463516 5 2 202 4/13/83 B-1908 CFA 88025 463516 3 0 216 3/28/83 B-092A CFA 88025 463516 2 0 217 3/29/83 B-0307 CFA 88025 463516 1 0 218 3/09/83 B-1814 ABF 88025 463516 2 0 3/17/83 CFA 3 0 3/28/83 " CFA " " 1 0 219 3/15/83 B-1838 CFA 88025 463516 2 0 220 3/15/83 B-1839 CFA 88025 463516 2 1

! 222 3/09/83 B-1815 ABF 88025 463516 2 0 i 223 3/02/83 D-1355 ABF 88025 463516 10 4 l 253 3/09/83 D-5788 CFL 88025 463516 2 0 257 4/21/83 B-RBL-257 ABF 880P5 463516 15 0 l 237 3/02/83 B-1774 ABF 88025 463516 10 5

( 3/09/83 CFA 2 1 l 200 3/02/83 B-1773 ABF 88025 463516 5 0 I

697 3/15/83 B-1831 CFA 88025 463516 5 0

" " " 0 3 1/83 CFA 2

" " " 0 4 4/83 CFA 8

" " " 10 0 4 4/83 CFA e l

Total Rods Burned 25 l 713 7/12/84 B-2545 BZO 88025 463516 5 3  ?

l 714 7/12/84 B-2543 BZO 88025 463516 20 19  :

i

litg'J lb

~

PART IV:

NO QC VERIFICATION: WFML's Attached To But Not Referenced On Traveler Welding performed with no QC inspections.

WFML Welder Welding Heat Rods / Rolls Weld Date Number Symbol Procudere Number Iss. Rt'd 852 3/29/83 B-1875 CFA 88025 463516 1 0 853 3/16/83 B-1842 CFA 88025 463516 6 1 854 3/16/83 B-1843 CFA 88025 463516 6 0

" " " 2 0 3/17/83 CFA 3/21/83 " CFA "

3 0 857 3/01/83 B-1770 ABF 88025 463516 5 1

-3/17/83 " CFA " " 1 0 858 3/01/83 B-1771 ABF 88025 463516 5 0 3/16/83 " CFA " "

3 0 1217 5/20/82 B-1068A AAR 18013 50067-1 25 13 5/20/82 AAR " 10 0 i

h I

eb

- -,., - - . . -- - -- - _ - - -- .. -- . -.w..-. -y--- -- - . . , , . , -

~ ^

- ' PART Vaj -Idproper Sign'Off of Inccmp15to Waldh Pag 3 211 l

JAMES W. COLE

., In 1981 James W. Cole signed off the following travelers as complete.

Step 8 (Completion of Weld Inspection) was signed off but the required

[ vacuum box test were not done. The PT test had been performed but the i vacuum box block was N.A'd.

Several NCR's were written against these welds because they are pressure boundry welds and require vacuum box testing. The NCR's referenced l QI-QP 11.14-6, Para. 3.4 4. The disposition of the NCR's re-established the holdpoints and required that these welds be vacuum box tested. The NCR's and weld numbers are as follows:

NCR M-84-00647 dated: 2/24/84 Weld: 1098, 1099, 1100, 1101, 1102, 1103, 1104, and 1105 NCR M-84-Oo669 dated: 2/27/84 Welds: 1087, 1088, 1089, 1090, 1091, 1092, 1144, 1145 NCR M-84-00670 dated: 2/27/84 Weld: 1111, 1112, 1117, 1118, 1121, 1122, 1123, 1129, 1127, 1130 1132, 1133, 1134 and 1128 l NCR M-84-2-OOO38 dated: 7/30/84 Weld: 1082, 1083, 1084, 1096, 1097, 1106, 1107, 1108, and 1109 NCR M-84-2-ooo39 dated: 7/30/84 Weld: 1085, 1086, 1093, 1094, 1095, 1110, 1113, 1114, 1115, 1116 1119, 1120, 1124, 1125, 117.6, and 1131  ;,

l i:

,.-._,_,..,_,,m- --

yr.,._ ,. % , y ,., . , . _ , , , , _ . , .e,- - , - , y, , . . . , - _ . _...,-,,_.,w . . . , _ . . . _ _ _ - . _ , , . - _ ,

PARTlV:  ; Inprcper Sign Off Of Inccaploto Waldo Pag] 22 PART II: Failure to Perform and Document Inspections VIOLATIONS OF: 100FR50 Appendix B Criteria V ANSI /ASME N45.2-1977 Section 2 Procedures: CP-QCI-2.11-1; QI-QAP-10.1-4; QI-QAP-ll.1-4 l Procedures require the QC inspector to inspect all interior surfaces of the Stainless Steel liner and document the results on the S/S Liner NDE Report.

NDE on Seam Welds:

Procedure requires a final visual examination of seam welds; a final liquid pentrant examination of seam welds; and final vacuum box test of seam welds.

Final V.T. of inside welds has been signed off on the following welds without the vacuum box and/or pentrant examination being performed as required by procedure.

No NDE Reports included in package: 655 713 714 719 NDE Report for V.T. only: 665 804 805 847 848 849 850 V.T. and P.T. examination performed: 690 888 887 989 The final V.T. of inside welds were signed off by James Cole for the following welds without the P.T. examination or vacuum box test being performed.

354 355 356 359 360 365 366 367 370 371 373 375 378 381 383 385 386 387 396 392 567 571 572 575 576 583 584 586 587 590 591 594 595 596 597 598 599 601 602 603 604 605 The final V.T. of inside welds were signed off on the following welds, by other inspectors.

610 612 613 617 778 1229 1263 1264 1265 1266 1267 s

PART V: 1 Icpr:per Sign Off Of Incomplcto Wbid2

~

, Page 23 {

1

~'

I PART V: IMPROPER SIGN OFF OF INCOMPLETE WELDS, FAILURE TO COMPLY WITH MANDATORY HOLD POINTS, AND LACK OF NDE S/S LINER TEST REPORTS VIOLATIONS OF: 100FR50 Appendix B, Criteria II and V ANSI /ASME N45.2-1977, Section 11 and 18 CPSES SITE PROCEDURES 1/9/78 - 3/26/82 The following welds have the completion of weld inspection block on Attachment 1 signed off as completed prior to the completion on welds prior to vacuum box testing and/or P.T. inspection being performed.

1. NDE report sheet was included in package for V.T., but P.T. test and vacuum box test was not performed.

t 678 679 680 681 682 683 684 685 712 718 933 937 938 1139 1140 1141 1142 1146 1147 1148 1149 1150 1151_ 1152 1159 1169 1170 1171 1172 1175 1176 1177 1178 1179 1181 1182 1183 1184 1185 1186 1187 1188 1189 1190 1191 1192 1193 1194 1195 1196 1197 1198 1199 1200 1201 1202 1203 1204 1205 1206 i

1209 1210

2. No NDE report sheets, no P.T. examination, and no vacuum box test 5 7 8 715 716 889 890 891 892 896 900 934 936 939 940 941 942 943 953' 953 954 955 956 957 958 959 960 961 962 963 964 966 967 968 969 970 991 992 993 994 995 1154 1155 1156 1157 1158 1218 1219 1220 1221 1222 1223 1224 1239 1240 1241 1242 1243 1245 1246 i 1247 1248 1249 1250 1251 1252 1260 1261 1262 l l

~

. . PA C V: Fc11ura to Perfcrm Vacuum B;x and/cr P.T. Tc;t Page 24! l IMPROPER SIGN OFF OF INCOMPLETE WELD _S:

3. Signed off as complete by James Cole with vacuum box test N/A'ed Many NCR's were written for welds that James Cole had N/A'ed the vacuum box test on, The vacuum box test has been re-established on all but the ones below.

722 723 724 725 726 730 731 732 733 734 735 736 737 738 739 740 741 742 751 752 753 754 759 760 761 762 765 766 770 773 774 775 776 779 780 781 782 783 784 785 786 787 800 807 820 821 822 823 824 825 826 827 828 829 830 831 832 833 877 878 879 880 881 882 883 884 886 913 915 932 996 997 998 999 1135 1137 1138 1161 1162 1163 1165 1166 1167 1168 1211 1212 1213 1215 4 P.T. test has been performed on these welds but vacuum box has not 901 902 903 904 905 906 907 908 909 910 929 930 944 945 946 947 948 950 961 952 971 972 973 974 975 976 977 978 979 980 981 982 983 984 985 986 987 988 990 1230 1231 1232 1233 1234 1235 1236 1237 1238

r .. Paga 25 t

PART VI: NON CONFORMING CONDITIONS DISPOSITIONED BY NCR's 2

i NCR M-83-Oll88 WELDS SIGNED OFF BY JIM COLE THAT HAD MAJOR DEFECTS:

2 Welds involved 324 and 694 PROBLEM: Documentation in the vault indicates weld 324 (plate D-32  ;)

to angle C-6) is complete. Contrary to the above, weld  ;

! 324 also continues around the corner to join plates D-32 '

to A-7 as shown on the attached sketch and is not complete.

Welded portion of weld 324 is 3/16" short of corner.

Documentation in the vault indicates weld 694 is complete.

Wold 694 is not complete as shown on the attached sketch.

I Welded portion of weld 694 is one inch short of the-oorner.

i Incomplete fusion was also noted (see sketch) l

, DISPOSITION: 1. Complete weld 324. Inspect and document the weld as required.

. 2 Repair weld defect with RPS. Complete weld 694. ,

I Inspect and document the weld as required.  !

! NOTE: James Cole either did not inspect these welds before he signed them off, or he did not have the ability to perform j inspections properly. It is clear to see that the welds i were not properly done and were not completed.

i l

i NCR M-83-01847 dated 7/7/83 Weld 166 and 154

) PROBLEM: While performing a cleanliness inspection of welds 166

and 154 the following conditions were noted.

! Condition #1 The backing har at the intersection of welds 166 and 153 has been ground through.

j Condition #2 The backing tar at the intersection of

! welds 154 and 151 lacks 3/8" of running the full length of the weld. Hold tag '  !

{ Applied i DISPOSITION: Issue RPS to repair hole in backing strip. The area of weld without backig shall be prepped for dispos-l ition of a- full pen veld without backing using the l GTAW process. .

l \

__ NOTE: The NCR wMs written in 1983 and a hold tag applied. It has

! not been dispositioned yet, and there is no copy of this NCR j in traveler 151. There is no RPS in package for weld 154.

t, S.M. McCoy, for steps 2 3 l~

154 and 4. wasJimsigned Coleoff by Don Voh1 inspected I on 4/20/80, and 153 on 47,24/80. '

'i l

f

~._ _ __, _ . _ ___ _._, ___ _ .,__ _ . _ _ _ . _ _ _._ _ _., _ ,_ _.._ _ .._._ __ _ . ..___ _ ,_-.~ , _ _____

'e '

Paga 26 M-83-00907 QI-QP-11.14-6 Rev. 3, para. 3 3/28/83 The quality of field welds 243, 859, and 871 is indeterminate due to the following:

ITEM 1 - Steps 2, 3,/A'ed.and have been N 4 on (inspection These attributestraveler) weld No.to are applicable 243weld 243, and it cannot be determined whether this work was previously accomplished and accepted by QC.

ITEM 2 - On (inspection traveler) weld Nos. 859 and 871, hold points have been previously signed by QC personnel. No controlled document can be produced delineating the location and/or orientation of said weld nos., and piece to piece entries are incomplete or incorrect, therefore, indeterminate (these welds are not identified on any design document).

Disposition: Steps 2, 3, and 4 are covered on welds number 859 and 860 Per CCP-38 craf t shall assign weld numbera to relds and the numbers shall be shown, on marked up copy of the drawing.

After completion of the liner, the drawing will be submitted to the vault.

Attach. I M-83-00795 QI-QP-11.14-6 Rev. 2, para: Step 5 3/17/83 A review of Stainless Steel Liner Travelers, for RB#2 Cavity welds, has found that the required Fit-up/ Cleanliness inspection of inside (waterside) welds cannot be verified as being performed. Quality of welds indetermin-ate.

Disposition: Subject welds are seam welds utilized to provide leak tightness of the linor. Acceptability of welds shall be based on vacuum box and hydrostatic tests.

CP-QP-16.0 8 2.2.1 M-83-01316 QI-QP-11.14-6 Rev.3 para 3.4.1 5/11/83 During inspection of refueling liner, weld seam #256 weld repair found l backing bar not installed as required. Area ground out has concrete in l contact with plate in required weld area. Review of travelers and doc- <J unentaion on 256, dates on fit-up and cleanliness, VT of backing strip i tack / fillet welds is inconsistant. '

DISPOSITION: prepar base metal Issue RPS to install for deposition of full back-up bar andweld.

penetration edge, Chip concrete of required, up to t" deep behind back-up bar to facilitate back-up bar to facilitate back-up bar installation.

a .

Pcga 27 PART VI: NON CONFORMING CONDITIONS DISPOSITIONED BY DCA's AND NCR's NCR M-84-01969 & DCA 20,814 WELDING PERFORMED WITHOUT QC INSPECTION 15 Welds involved Problem: Per the NCR referenced below the following welds shown on Bostrom-Bergen drawing 24bl-A sheet E2, did not have their fit-up inspected prior to welding: Weld Numbers 622, 623, 624, 625 626 627, 632, 618, 650, 619, 651, 620, 621,653.

652, and. Thereforethe1rcon,formance with SS-18, Sect. 6.6 is in question.

Solution: The requirements of section 6.6 are waived for the above welds. The welds listed are acceptable without a QC inspection of their fit-up. All other QC inspections remain Applicabe.

See Exhibit #1 NCR M-84-00498 P.T. REPORTS FILLED OUT USING WRONG PROCEDURE NUMBER 41 Welds involved i

Problem: During review of Documentation of welds and Inspection in S/S Liner in RB#2 it was noted that PT renorts were filled out using procedure #QI-QP 11.14-1 rev. 1 as a NDE Procedure. At this time QI-QP 11.14~1 was in Rev.

3 The proper procedure to be used at that time was QI-QAP 10.2-1 rev. 1. These reports were used in closing NCR# M-82-00059. The following welds are i affected by this error: 1169, 1170, 1171, 1172, 1175, 1176, 1177, 1178, 1179, 1181, 1182, 1183, 1191, 1193,1184, 1185 1186, 1192, 1194 1187, 1188, 1187, 1197 1195, 1196, 1188, 1189, 1198, 1199 1190, 1200, 1201, 1202, 1203, 1204, 1205, 1206,, 1207, 1208, 1209, 1210, ,

1355,and1356.

Disposition: QC shall correct PT Reports to show proper NCE ,

, procedure number and reference this NVR number on those reports. "4 NOT: There was no copy of NCR M-82-00059 in any of the packages.

Rev. I was issued for the above NCR to delete welds 1355 and 1356.

See Exhibt #2

-

  • Paga 28.

Lack of QC Verification for Fit-up and Cleanliness - No QC Surveilance at all.

NCR M-84-01969: The following welds did not have the Fit-up Inspection required prior to welding.

DCA NO. 20,814: Per the NCR referenced below the follesing welds shown on Bestrom-Bergen dwg. 2401-A sheet E2, did not have their Fitup inspected prior to welding: Therefore their conformance with SS-18 sect. 6.6 is in question.

Solution: DCA waived the requirements of section 6.6 618 619 620 621 622 623 624 625 626 627 632 650 651 652 653 NCR M-84-00498: P.T. Reports filled out using the wrong procedure No.

"During review of Document of inspections it was noted that QI-QP-11.14-1 was used as a NDE procedure. The correct procedure at that time was QI-qAP-10.2-1. These reports were used to close out NCR M-82-00059 The following welds were affected by this error."

1169 1170 1171 1172 1175 1176 1177 1178 1179 l 1180 1181 1182 1183 1184 1185 1186 1187 1188 1190 1191 1192 1193 1194 1195 1196 1197 1198 1199 1200 1201 1202 1203 1204 1205 1206 1207 1209 1210 t

t e

EXHIBIT 2

. /: ' 1,

' Etc.*mf5 ? c,!.T. .~ . ..

N I.'hI$s w $;; _ ,j :LQ

~

~

.;gga ;;o, 3&R Stainless Steel Liner Inspecti:n Trave.ler .

0 JECT
CPSE5 J05 n3
35-iii5 utili O PAGE / OF J Oj,=/foog $ l A).Trws . CA uA L.

EA . ~ /t.ts ??cci I/A ~ Aa.</e to $- Au f Or: wing io. Pool r.etal i e t'.tl . Inx. FC. to PC.

l l Plate to Plate l I Insert to Plate Angle to Plate l I Other Velder tiFnt. 'deld Hold Syr. col No. proced. Point 1. Fit up and Cleanliness of Abcve:

AE0 0 -010 f2023 5- HA A/A

/ OM $

2. V.T. of Backing Strip Tack / Fillet Welds:

, ,%c zy tsr Aca3 1 l Ajp . ,rn c. pA. 1

[AF & 2.C MON 9 Results inspector Signature Cate

,84 G O-9/1 *

3. Cleanliness of Chan'nel, Liner,'ind B. Strip: '

AA S D-lT'? ! N#22 i' W Resul .s PA inspec= r Signature PA Oa *..

. /JA G & I45! O "21 ]

l

] 4. Final V.T. ,of Channel Fillet Weld:

h/A PA NA BdOWN & ROOT.  ; Results inspector signature Date I;

RECEIV

I 5. In ide Fit Up nd Cleanliness:

' MAR 101980 . ,gx, _

j gg7 77 rei.es No. a I Results inspector Signature Cate

( 6. V.T. of :lliet Price to Grinding:

Uf LITY ASSU R ANC[

Ai^ Aa is Results inspector Signature Cate

.r ..ecT.accono, n w u a m ... . d P'" $$CW

[ " *" ~ ~ '

74)

Aesuits (QM2 $l inspector Signatur 4 24*10 Da te j

'l

3. C:=cletten of 'Jeld Inspection: CICE P200) l l l Ab An'MC4 - Mu t,To j  ; i w :s p nstecur m .3:ure

.-- Giu;.r;2%/a W.VLw:.va . Ct-QcI-2.it_.i g d, _ cn '- p _

R3Yizien 1 C'C. . . - '*

e  !

.u QUALITY ASSURANCE DEPARTf?.EflT l STAltil.? SS STEEL LIl.IR INSPECTION TR.WLER/NDE REPORT a M C.

l

\p .

~S . 3 * (o l)

.C?SES J03 NO.: 35 1135 'U:!!T ~ PAGE I OF PROJECT: , .

PCOL dorA HTL n~?E MTL. THICC.*ESS D?.V.*I:-:G

, c, a 3 i t v.

  • M I' f3 0 0 9 3 1- lO.t t TLtdlcaod-Plate'to Place
  • TLD/ITI:: 50. ?C. TO PC. Insert to Pla:e Ci R ? - A O c,.t < TD k . A 4f l / A.ngle.to Plate 43M o 3 %40LG eu nit *W 9 4 6M(40 L,( L 7 L-

!.7:R ::0. 84 19 D's grfo23 no2 t 39032 %_ _ n 13 aco.,1 _ JPon Fr Go 2.3

.TI.D PR. OC. ID 3.E OcP AW 84-7*~ A p u:_

  • TELCIR e 3?.2CL Ai9 r= # 4 n w P. -

ST. ACE 07 :*;'~C?r .crI p;v-en _ r u r m e Tnm u. cim1. A eaf A /,- /> a B s. , o C-WD5S?ECTORh u.d AV bo"*"R RESULTS SIC: ATURE DATE .

  • ISCRIF-~ '.::(s) r.nd I' S?ECTION' RD*GR(s) _

o

1. Tit up of Liner @ :s plate,@ ".

insart. Cl**-hss of liner and backina .5 n r- ,m  % c5 - a .W -

j h. V. I. - f ':t-: :. .; 2 ::i;@. fi;1t.: .::.'. d s . A 4 r- <"h , _ _ .\ 'l 14, c:. . , .-w 1*:. C:c.. .liness of channel, liner and backing @ 8' s::1-. .s m - & ,,_.,X LO- y,  ; . 2 ., p

3. Tin s._ V.I. :: '"h t ne l '.Te ld s . c;a .; Jm,QfR_ _ g.. ., _, f _

~ -

t'~

/.

4 I.1.ar 71 -

-' 'i.:s:ir .. ~~.istliness Verifica:1-- . _ _ . . .

4

-a .- . . ~ y y y 1 i l A:v. :..: n -

. i

, ... . u. . ... ..,_.t....

Il Ihtell Ti:22

?c.:.: rant l'f;. >*zgr.afle.-5;;;: hack-Batch I

C '. . : i.: I'! .: . .'.2,- .E f kn-: -: ::.2:h-2:: h Devele; ng Ti::a re. ci:;ar :'.*;. ::a nsflun-Spatcheck-3atch ED: . roce,f t:2 Surface 3*T *.;;-5350 A:cach. 63 As !!cided Creur- Other .

Tin:1 P.T.

5: . 1.s : .c- hn uhe: " pe -

Solution Type

._. . . b .: -_

?.c..s: Cic:.in;, Prcessure Tc... 'rature ND Procedure 600

  • S.".lon Applies:10. ::a:h. d _ - Post Test -a n in g 1

0

  • Scrisi ::enbcr Precs.uurc Differen. -1 1: sin'. J 4 for --

ec. - !in.

b . . . .

r. ... s . ., . - . - . - .

/

-  :' ': Appli 61.-

1% :15 '.w.o ry 1 :..% :.CIW.! ____ j DATC. C F.~;T . L:.V!:Lj

. O ry l l

s.,

PAGE b or S* ,

p-,~ ,

+

h- (([ ,

Weld No.

Acceptance Std. -

Gibbs & Hill 2323-55-13 .

~

5b. Fenetrant Mfg. Magnaflux-Spotcheck .

Cleaner Mfg. Magntflux-Spotcheck Developer Mfg. Magnaflux-Spotcheck NDE Precedure
  • 200-NB-5350 Attach. 53 -

Final F.T. t.evel II G T- 28taf 2 ' t- 2t, -yo RESULTS INSPECTOR SIGN. DATE Sc. Vacuta Sox GASKET TYPE SOL'JTION T(PE

'2- Y by E .fwoe f Pretest Cleaning M Pre ssure 2-ITemocrature7ptedNDE Precedure 600 Solution Application Method h d , Post Test Cleaning d 6 e e i Gauge Serial Nu=::er fff Preassure Of fierential Maintained for 2e Sec. , Min. - -

Finaf V.S. Im 4/4 M- .

r N/A - Not Applicable Level II Satisfactory _ Jnsatisfactory Inspec ,we Cate 7#fe

/ .

e

!

Retrieved from "https://kanterella.com/w/index.php?title=ML20099C274&oldid=2780114"