Text

Discusses Allegations by Daniel Intl Personnel Re Intimidation of QC Inspectors.Personnel Willing to Talk to NRC
	ML20128Q599
Person / Time
Site:	Wolf Creek
Issue date:	10/20/1982
From:	Johnson B; NRC
To:	Johnson E; NRC
Shared Package
ML20128Q564	List: ML20128Q560; ML20128Q577; ML20128Q582; ML20128Q599;
References
	FOIA-84-291 NUDOCS 8507270016
	Download: ML20128Q599 (12)
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~~DATE: September E, 1983 REPORT OF INVESTIGATION TITLE:~~

~~WOLF CREEK NUCLEAR GENERATING STATION ALLEGED INTIMIDATION OF DANIEL INTERNATIONAL MECHANICAL QC INSPECTORS CASE NUMBER:~~

~~4-82-016 CONTROL OFFICE:~~

~~DIF0: Region IV STATUS: CLOSED PERIOD OF INVESTIGATION:~~

~~December 1,1982 - February 18, 1983 REPORTING INVESTIGATOR:~~

~~H. Brooks Griffin, Invejtigator Office of Investigations Field Office, Region IV PARTICIPATING PERSONNEL:~~

~~Donald D. Driskill, Investigator Office of Investigations Field Office, Region IV REVIEWED BY:~~

~~7 li~ chard K. Herr, Director Office of Investipations Field Office, Region IV~~

/

~~//l YW Wi'lliam J. 66erW Director Division of Field Operations Office of Investigations r~~

j

~

~~em T1%o F.oge r tuna,~ Deputy Director Office f Investigations APPROVED BY:~~

~~Eer. E. If tyes, Director Difict 4f Investigations I7~~

~~/ G,,~~

~~rrr:T' ~ -~~
Fo in tu9-
Sumary During October of 1982, four QC inspectort previously employed by Daniel International (DI) at Wolf Creek made an allegation to the NRC Resident Reactor Inspector at the Zimer nuclear construction site in Moscow, Ohio. The inspectors alleged that QC inspectors at Wolf Creek were not given adequate freedom to report nonconfoming conditions. An investigation was initiated regarding the allegation, and six former DI QC inspectors were interviewed, including the original four inspectors who made the allegation. The six fomer DI inspectors provided testi-mony that DI QC management personnel had instituted a policy of management review of nonconformance reports (NCRs) before allowing inspectors to formally issue NCRs.
The former DI inspectors testified that numerous nonconforming conditions were not reported because DI QC managers voided NCRs, thereby, restricting the inspector's reporting of violations. The former DI inspectors further statec that DI QC inspectors were threatened with termination if they failed to adhere to this policy.
During February of 1983, six DI QC inspectors, one DI QA inspector, and three DI QC lead inspectors were interviewed at Wolf Creek.
These inspectors reported numerous instances of DI QC managers directing inspectors to ccnduct their inspections to instructions contained in three-part memorzndums which conflicted with procedures. These DI inspectors related numerous instances where NCRs and DRs (Deficiency Reports) were " voided" or " closed in process," which they felt restric-ted their freedom and allowed nonconforming safety conditions to go uncorrected.
Four of the DI QC inspectcrs provided the NRC with copies of NCRs and DRs they identified as " voided," NCRs " closed in process," and three-part memorandums. These inspectors stated that the abcve documents were examples of nonconfoming con-ditions and/or constituted violations of procedure.
Two of these inspectors indi-cated they kept these documents to " cover themselves" should questions be raised as to the validity of their inspections.
These DI QC inspectors rc;ortec that many of their concerns about freedom to inspect and report noncc: ~crmir.; conditions had beer alleviated since 1982 by DI management's response tc 1%.
u plaints.
Furthe, r.cne of DI QC inspectors
i interviewed indicated they felt threatened with termination from the instructions received by supervisors concerning the policy of NCR review. The inspectors stated that four DI QC supervisors primarily responsibile for the restriction of their inspection freedom had either been transferred to another site, taken out of the chain of command, or terminated.
The DI Project Quality Inspection Manager, the DI Senior Quality Supervisor, and two DI QC supervisors were interviewed, and they explained that the review policy for NCRs at Wolf Creek was implemented to avoid invalid NCRs. They emphasized this policy was not an attempt to curtail the reporting of nonconforming conditions.
They further testified that three-part memorandums were used to clarify or interpret procedures, and were not intended to circumvent approved procedures.
They explained that many of the NCRs soided by DI QC supervisors were not legitirate violations. The above supeivisors explained the QC inspectors were told that if they continued to write invalid NCRs, retraining would be initiated, and inspectors failing to re-qualify would be terminated. The DI Project Quality Inspection Manager stated that this policy was not intended as a threat, but was meant to emphasize the need for a professional insoection effort by all QC inspectors.
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-Purpose of Investigation The purpcsc cf this investigation was to determine if Daniel International (DI) management persennel at t.'olf Creek intimidated DI QC inspectors through: (1) newly implemented policies and instructions which restricted their freedom to report non-conforming conditions and/or conduct independent inspections, and/or (2) threats of tennination for not following newly implemented policies.
2
~~Background~~
During October 19E2, four QC ingcciors who fonnerly worked for Daniel Interr,ational (DI) at Wolf Creek, made an allegation to the NRC Senior Resident Inspector at the Zimer nuclear construction site where they were employed. These inspectors alleged that DI management personnel at Wolf Creek attempted to intimi-date QC inspectors by restricting their freedom to report nonconforming conditions.
The former DI QC inspectors alleged that DI QC management personnel conducted a meeting in which they told the QC inspectors that if they refused to sign off on an inspection step, they were to call their QC supervisor.
It was further alleged that.
DI QC managenent personnel instructed the QC supervisors to perfonn the inspection and sign off on the inspection if they disagreed with the inspector's evaluation of the situation.
It was alleged that DI QC management personnel indicated that QC inspectors could be retrained and required to be retested for their cert'fications if this happened too often. The fonner DI QC inspectors alleged it was implied by QC management personnel that those inspectors might fail to recertify, and as a result be terminated. On or about October 20, 1982, this allegation was also tele-phonically reported by thest same DI QC inspectors to the f2C Senior Resident Inspector at Wolf Creek. On or about October 29, 1982, the Region IV Regional Administrator requested Ol's assistance in investigating this allegation.
INVESTIGATOR'S NOTE: During the course of this investigation, two examples of potential restrictive measures placed on QC inspectors by DI OC mar.agement
~
were identified; namely, (1) conflict of QC procedures (QCP VII 200-204) and (2) improper use of white out.
These examples were previously reported as separate technical issues to Region IV under A4-83-002 and A4-83-004 respectively.
_ _. ~
i 3
Teicphonic Interview of s
Cr. t,ovember 30, 1982, a QC inspector, y s telephonically inte rviewed by tJC investigator D. D. DR15 KILL.
stated that when he anc Marshall SE)T0!, (esigned as quality contro~1 inspecfors from Daniel Inter-national (DI) Corporatier), at Wolf Creek, they contacted the NRC Resident Reactor Inspector regarding their concerns that DI QC inspectors did not have t.he freedom to perform their duties as required by procedure at Wolf Creek.
stated he believed that QC inspectors at Wolf Creek were being intimidated by their super-visors in order to force them to sign off on inspection documentation for work which was not properly done.
stated that DI QC supervisors forced inspectors to deviate from ins'pecti'on requirements by writing three-part memo-randums authorizing deviations from the appropriate inspection procedures.
He stated that conducting an inspection in accorrance with a three-part memorandum, rather than the appropriate procedure, restricted the Q'. inspectors from document-ing nonconfoming conditions.
AlsostatedthatQCinspectorswererequired
~
to submit their nonconformance repor{s to QC supervisors for review prior to the i
NCR being submitted into the corrective action syster stated that frequently an NCR was disapproved by management resulting in the nonconforming condition going uncorrected.
' stated that Larry ADKINSON, a D1 trainir.g 7
coordinator: currently employed 1n the D1 trainir; ce;r,:r.ent at W0lf Creek, jcule provide documents which would corroborate his statements.
additionally identified faul HALE, Ron FRIAR and Alan Ci.lFFORD as other current,,
D: QC personnel who coulo provide information relating to these concerns, stated he preferred not to be interviewed in person, nor dic he wish to provide a statement concerning this matter.
INVESTIGATOR'S NOTE:
seemed hesitant to discuss in detail the above concerns over the telephone.
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Reinterview of On DecedE r 2, 3962, (supra) was reintervier.eC by NRC Investigator D. D. DF15 KILL at thegimer Nuclear Project, Moscow, Ohio.
employed as a{DI QC inspecto; at Wolf Creek from stated he was,_
andduringtysJime,was
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related that in early September 1982, Ron McCRANEY,' DI Senior Mechanical Welding Q'ality Supervisor, had called a meeting of _QC leads and super-u visors, and instructed them that if QC inspectors refused to sign off documentation approving a QC inspection, then the QC lead was to approve inspection by signing the documentation.
stated that he along with other QC' inspectors were subsequently told by supervinrs tfiat if they did not sign off documentation approvinginspections, their lead inspector would be responsible for signing the documentation, kstated the supervisc" adriitionally told him, along with the inspectors, that inYcco/ dance with McCRANEY's instructions, repeated situations involving inspectors not signing off inspections would result in their being sent for training and recertification.
indicated that if an employee failed to recertify, he might be terininated."
stated these instructions were a direct effort or, the part of OC r.anapement to reEce the number of rejectable inspection reports by QC inspectors.
stated during the time he was a lead QC inspector, he v.ar sery close to his $borc/inates and never refused to alio,. them permission to write a rejectacle inspection repcrt.
. stated another of his concerns related to the use of white out on official documents, stated in the sumer cf 19E2, or.e of his inspectors had identi-fied a hangF traveler which contained white out.
stated he talked with Ron McCRANE)'about this, and was told to disregard the white out on the document.
j He stated >McCRANEYiinstructed him to draw a line through the white out and place i
4 his initials on the adjacent line, which in essence would give QC approval to the change on the document.
ftatedMcCRANE) explained that.a formerly dis-positioned NCR approved such co'rrective acticn on documents.
stated his concerns regarding this matter were twofcic.
He stated the use of Sne NCR as a basis for varicus types of corrective anic: v.:s a poor policy, ano secondly that approval c.f the usg of white out coulc rm.; in inaccurate dita being approved on a doeur..c nt.
again declined to ext: vie i signed, sworn statement.
5 Interview ci Rcy STUDDARD Or, Decertet 1,1582, Roy STUDDARD, forr.erly a QC inspector at Wolf Creek and preser.tly a,00 inspector at the Zimer site was interviewed by NRC Investigators D. D. DR15 KILL and H. B. GRIFFIN at the Zimer site.
STUDDARD stated he had been employed by Di at Wolf Creek as a QC inspector from September 1981 through October 1982.
STUDDARD stated he felt the DI QC management personnel at Wolf Creek were inter'fering with the QC inspectors' performance of their jobs. 'STUDDARD. Indi-cated his biggest problen at Wolf Creek was the conflict between training and the work instructions given ty QC management personnel in the field.
STUDDARD stated that Larry PHILLIPS, a DI QC supervisor, told him, "you don't work the way training tells you, you do what we tell you."
STUDDART, was asked whether he attended a meeting during the sumer of 1982, concerning inspectors calling their leads when they discovered a nonconforming condition. He stated he vaguely remenbered the meeting.
STUDDARD stated the contents of the meeting did not cause him to change his inspection procedures.
STUDDARC said he did not write many NCRs, but instead had craft correct the problem, thereby, avoiding a lot of " hassles." STUDDARD stated he knew that having the defects repaired and not writirg an NCR was in violation of procedure, but he bclieved "it got the job done."
STUDDARD recalled that on one occasion, he had a problem with a three-part memoranum that QC inspectors werc given which instructed them to do their inspec-tions on hanger locations under QCP VII 200, as opposed to QCP VII 204.
STUDDARD stated he had not been trained to determine the locations of hangers, and he felt he was not qualified to sign off on the location criteria.
STUDDARD stated the QC inspectors at Wolf Creek were required to work to three-part memorandums.
STU,DDARD further stated that of the tctal NCRs he wrote, many were voided and the c:nconforming condition never reporu f.
STUDDARD stated he had not retained copies rf NCRs that had been voided, anc tit rot provide specific details.
6 Interviev; of Vernon DREWES On December 1,1982, Vernon DREUES, a mechanical welding QC inspector at Zimer y was interviewed by t;RC Investigator H. B. GRIFF1ti. DREUES stated he had been employeo as a mechanical welding QC inspector by D1 at the Wolf Creek site from 3
October 1981 until October of 1982..i)REWEM stated he was one of seven QC inspectors who gave notice to DI during October of 1982,and was promptly fired.
DREWES stated that DI did not pay the inspectors their severance pay.
DREWES was asked whether he attended a meeting on inspection policies regarding NCRs held by QC management personnel during the sumer of 1982. He stated he had not attended the meeting, but was later given instructions by a co-worker to call his lead when he identified a nonconforming condition. DREWES stated that during his last 4 or 5 months at Wolf Creek, a policy was implemented that no NCRs were to be written without supervisory permission.
DREWES stated that when NCRs were written by QC inspectors, they were sent to McCRANEY, the senior QC supervisor.
DREWES stated McCRANEY voided many of these NCRs, and they were not issued. DREWES itated that initially these ICFs were sent back to the QC inspectors with a writter.
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explanation, but later when the supervisors (not further identified) found out the QC inspectors were keeping copies of these voided NCRs with the explanations, they ciscontinued writing explanctions.
DREWES stated the supervisors started verbally explaining to the QC inspectors why the NCRs had been voided. DREWES, stated he had only two of his NCRs rejected at Wolf Creek. OREWES stated that rather than write t;CRs he often had craft empic.yees correct the problem, thereby avoiding the issuance of NCRs which he believed would be voided anyway.
DREWES stated he also had difficulty with a three-part memorandum which instructed the QC inspectors to sign off on locations of hangers, as described in QCP VII 200.
DREWES -tated he understood that the lead QC inspectors were responsible for determining location, but that OCF VII 200 required QC inspectors to sign off on location.
DREWESl stated he cid not think he was qualified to verify a location, because he did not have c r-danical certification.
DREWES'further stated that QC supervisors corplicated tt,i iu;ections by instructing QC inspectors to conduct work
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that was sometimes in conflict with training..DREWES 5tated he was told by a DI supervisor, Larry PHILLIPS,. "to hcil with training."'
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8 Interview of Thor.as O'CONh0R On December 1,1952, Thomas O'CONNOR, a QC inspector employed at the Zimmer site, was interviewed by NRC Investigator H. B. GRIFFIN.
O'CONNOR stated he had been employed as a level-II piping and welding inspector f'or DI at Wolf Creek from June 1981 until October of 1982i O'CONNOR, stated he left DI because he had been offered a more lucrative job at the,Zinner, site. 0'CONNOR stated he had been one of seven QC inspectors who had been innediately terminated at Wolf Creek by DI after he had given two weeks notice of his intention to resign. O'CONNOR stated it was common practice at Wolf Creek for the employees to be terminated on the same day they gave notice, so they would not influence other employees to leave.
0' CONN 0R. stated that since QC inspectors were terminated on the day they gave notice, they were entitled to two weeks severence pay. O'CONNOR said he and the other fomer DI inspectors had not been paid.
O'CONNOR, stated that QC inspectors at Wolf Creek were often required to work to three-part mer.orandums. 0'CONNOR said he recalled one' memorandum directed that inspections of r. ngers be done under QCF VII 200, which requirec QC inspectors to sign off on the location of hangers. 0'CONNOR stated it was his understanding that under QCP VI: El, these locations wculd later be inspected during a final inspection.
O'CONNOR stic rc thcught he was only inspecting welds, as per 04, but later realized he was signing off en hanger locations, as per 200. 'O'CONNOR stated he believed the three-part ma crandum instructing them to conduct their inspections under QCP VII 200, relieved him o' the responsibility for location, because he was not traircd or cer-tified to deter.ine location.
O'CONNOR stated he felt he had freedom to write NCRs at Wolf Creek, and saic that most of the defects identified were addressed by engineers. O'CONNOR also stated he relied on his lead to keep up with the constant changes in procedure. O'CONNOT.
stated he hac cifficulty with the difference between what they were taught ir. the training clastu and what they were instructed to do in the field.
O'CONNOR nic inspectors w ( teid by supervisory personnel that by the time they started :: u.
with a prect u: iney had been taught in training, it would probably alread,s hm been change 6.
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Interview of Marshall D. SEXTON j
On December 2,1982, Marshall D. SEXTON, former DI QC weld inspector at tte k h Creek project, was interviewed by NRC Investigator D. D. DRISKILL at the 2irres -
Nuclear Plant, Moscow, Ohio SEXTON executed a signed sworn statement which is f
included in this report as Attachment (1)., SEXTON stated he was employed as a DI
~QC welding inspector at Wolf Creek from June through October 1982; He stated that subsequent to his giving 2 weeks' notice to DI, he was tenninated. SEXTON said he contacted NRC Resident Inspector, Tom VANLAL, and discussed with him several of his concerns regarding the practices of the DI QC department.
SEXTON stated that Ron McCRANEY the DI Senior Mechanical Welding Quality j
Supervisc y instructed the inspectors that if they rejected a weld, their lead inspecto: would come to their location and if he disagreed, he would instruct them to accept it. He stated McCRANEY; said that if the inspectors refused to accept the weld, che lead inspector'would approve it by signing off the inspection record.
' SEXTON stated McCRANEY, said that if this type situation occurred several times, the inspector inuived would have his QC certification revcked.
SEXTC!. stated, however, that his lead never disagreed with any of his (SEXT0N's) findings subsecucr. to that meeting.
SEXTON,,tated another concern he had at Wolf Creek was the use of three-part memore duns by DI QC supervisors to authorize a deviation from inspection criteria.
SEXT0; -ta Ec he believed this practice resulted in ncrcenforming conditions,not being cc rected.
SEXTON additionally stated he was concerned about the,use of white out on travelers and other documents., SEXTON stated that Larry PHILLIPS, DI Reactor Building QC Supervisor,, instructed DI QC inspectors to draw a line through white out and place their initials on the documents. ' SEXTON stated, however, that this practice would give the appearance that the c'hange on a document had been approved by QC.
SDiC n iec he felt DI QC inspectors were also denied the authority 1: s. ;
t NCRs.
m mn: nspectors were required to submit each of their NCR drafts ic a c w--
10 respective supervisor prior to obtaining an NCR number. SExiO. relatco t i t on or.e occasion his supervisor, Larry PHILLIPS, had refused to allow him (SEXT01, to submit an NCR concerning a precated welding rod material requisition.
5!.7T0; s u.ed he believed this policy created a situation wherein some nonconforcing cor.citicns were left uncorrected; however, he could not provide any specific conditions.
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II Interview of Scott SENFl On February 2,19C3, Scott SENFT, a DI QC welding inspector us interviewed
. at Wolf Creer by NRC Investigator H. B. GRIFFIN..5ENFT,ttatic he had been a p
DI employee for four and a half years, and presently held e uleing certifi-cation and an NF (fillet weld inspection) certification.
SEGFT identified his supervisor as Richard BOOTH, and his lead as Dalton RICHE.
SEr,FT stated he was presently working as the laad on his crew,'because Dalton RICHE had failed to qualify on his last certification test. When SENFT was asked if he felt free to write NCRs, he stated that in the past he had not, but he now felt free to do so.
SENFT said that three former DI supervisors, in an effort to speed up production, had pressured the QC inspectors not to write NCRs and encouraged them to sign off on defective work (not further identified).
SENFT listed these supervisors as Ira JAMES, Charles GOINS and Nilliam FLINT.
Hg said these supervisors had either been terminated, as in the c,ase of or transferred to other sites, as in the cases of INVESTIGATOR'S NOTE:
Daniel Personnel Department records confirmed that JAMES, GOIN5 and FLINT had either been terr.inated or transferred to otner Daniel jobs.
These three individuals were not interviewed.
A fourth supervisor was identified as Larry Fri!LLIFE ohc was transferred to a different position at Wolf Cre'ek anc was intervie ed (infra).
These 1rour individuals are identified within this Report of Investigation as "former supervisors."
When asked to identify specific NCRs that were not writter., SEhFi stated he could not provide specific dates or identify document numrers, but he remembered a welding rod material requisition on which a QC inspector named Marshall SEXTON had wanted to write an NCR because the recuisition predated.
SENFT stated a QC supervisor by the name of Larry PHILLIPS told Marshall SECTON not to write the NCR, because the prcdating was a typographical error.
SENFT said he believed that it was r.rt a typographical error, but instead, craf t personnel were predating the avl rod requisitions 50 they could obtain the rods in a more timely manner.
1
12 SENFT said he also knew of an incident in which Paul HK.E e QC inspector, conducted an inspection to close out a defect on a hanger (not further identified). SENFT said the N~.R (ncreeer unknown) stated the inspection was c?' under QCP VII 20', and he (SENFT) believed it should have been under QCF VII 200.
SENFT -said he was acting as the lead at that time, and HALE called him for an NCR nurter as required by pclicy.
SENFT said he agreed with' HALE's request for the NCR, and he left a hold tag on the SENFT said that Ronald McCRANEY, a senior quality supervisor, called him and hanger.
told him to " keep things running." SENFT.said he told McCRANEY he would be glad to comply when the NCR was changed and the work was done properly.
SENFT said McCRANEY told him that he (McCRANEY) would change the NCR in the vault and that he (SENFT) should tell HALE to go ahead with the work. SENFT said he lined through the entry that said 204, then initialed and dated it.
SENFT $ aid he s
later heard from RICHE, that McCRANEY indicated he (SENFT) 'would not be the acting lead anymore because of his fSENFT's) resistance to McCRALEY's suggestions.
SENFT was asked if he attended a meeting conducted by Neale SCHRYER, DI Project SENFT taid Quality inspection Manager, and McCRANEY concerning th writing of NCRs.
he had attended the meeting and' understood from the coments SCHRYER nade that if a
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QC inspector wished to write an NCR, he first had to call his 1ead.
SENFT said the lead wcuid evaluate the problem, anc if he agreed, he would then assign it an N E SENF1 number, or if appropriate, try to convince the inspector it was not a problem.
stated the leads were instructed to sign off on the inspection if they felt the con-dition did not terit an NCR..SENFT stated that while he was the acting lead he never tried to talk anybody out of writing an NCR if they felt it was a valid problem.
SENFT said that as the lead, even when he disagreed witn the QC inspectors, if they felt strongly enough about it, he permitted them to write the NCR.
SENFT SENFT related another incident which he stated occurred in November 1982.
said that ironworking crews (identification unknown) were installing whip restraints in his area, but they did not have the blueprints icentifying the pieces at their work locations.
SENFT said procedure required i t u " : the blueprints at the said the ironwed cr:'
locatiens !efcre they could proceed with the worL
H general foreman, whose name he could not recall, calicd Dalton RICHE, a QC lead, and RICHE then called Richard BOOTH, a QC supervisor.
SENFT said SOOTH then calicd him (SENFT' and told hin to " buy of f" cn thc ironworkers wcrLir g withcr.
blueprints and that Paul HALE, a QC inspector, had already signed off on the fit-ups.
SENFT said BOOTH told him the ironworkers had the blueprints at the D1 document vault.
SENFT said he knew the inspection was a final inspection, and he told BOOTH he would not sign off on the QC inspection until the prints were at the location as required by procedure. SENFT said the next day the ironworkers still did not have the blue-prints, so he wr6te an NCR on the condition. SENFT said BOOTH voided his NCR, thereby not allowing him to receive a number. SENFT stated he later learned from other employees (not furthEr identified) that B00TH had made an agreement with the general foreman of the ironworkers to go outside of procedure regarding the blueprints. SENFT said he had no other problems regarding lack of freedom to write NCRs, but he believed many of the other inspectors did.
14 i
Interview of Faul HALE On February 14, 1983, Paul HAli, a DI QC it :pcctor, was interviewed by hec Investigator H. B. GRIFFIN at Wolf Creek.
9 ALE was asked whetter he had received instructions on a policy implemented in the sunner of 1982 requiring QC inspectors to call their leads when they discovered nonconforming conditions. HALE said this policy was enforced on his crew. HALE said he felt that a QC lead's signature authorizing an NCR constituted an affront to the inspecter's expertise, and he did not believe this policy was in the spirit of the QC program.
HALE related the circu.nstances of a meeting he attended with other QC inspectors, on August 5,1982, in which' Larry PHILLIPS, a QC supervisor, said that QC inspectors who failed to work to instructions contained in three-part memorandums would be fired. HALE said that during this meeting, PHILLIPS was asked whether copies of three-part memorandums could be included in the traveler package when they were used as instructions when conducting inspections. HALE stated PHILLIPS told the QC inspectors they could not include copies of three-part memorandums with traveler packages. HALE stated that most of the QC inspectors did nct follov 5HILLIPS' instructions. HALE said the QC inspectors rebelled against PHILLIP's instructions and some of the explanations that PHILLIP's wrote on voided NCRs and DRs, and as a result, complained to a higher level of mariagement.
HALE stated PHILLIF5 was subsequently reassigned to a different position.
HALE stated he had trouble with rany of the three-part memorandums circulated among the QC inspectors. HALE said one such memo required QC inspectors to sign off on locations of hangers. HALE stated that without the proper equipment and proper training, he did not think (C inspectors could verify hanger locations.
HALE stated in addition, he did net believe that QC inspectors were qualified to determine the middle one-third of plates to which hangers were welded.
INVESTIGATOR'S NOTE:
The reference " middle one-third" relates to the centr:1 e t; rr a plate to whicr a piece of metal is to be ec~ n e maximum strength.
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i 15 HALE stated that until the latter part of 1982, there were four, former QC
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supervisor $ (JAMES, GOINS, FLINT and PHILLIPS [ supra]) who voided NCRs and wrote memorandums containing instructions wr.ich were in direct conflict with procedure.
HALE said these tour supervisors.i5c either been terminated, transferred to other sites, or taken out of the chain 'of command during the last 6 months of 1982.
HALE said work conditions at Wolf Creek were much better now.
HALE stated that under these previous supervisors he had not been personally intimidated. HALE stated he had ignored the instructions given by SCHRYER during a meeting regarding the reporting of nonconfornming conditions, and added he did not know anyone who had been intimidated or anyone who had failed to report a nonconforming condition.
HALE stated his main problem was that many of the NCRs written were voided by QC supervisors or " closed in process" by Di quality engineers.
HALE stated there were numerous dispositions of NCRs with which he disagreed, and at a result, he kept a few copies of some of them just in case questions were raised by anyone in the future regarding his inspections.
HALE provided the NRC with copies of NCRs and DRs he said supported his verbal statements, and are are included with this report as Attachments (2) through (13).
16 Interview of Gaines Ronald FRIAi On February 15, 1983, Gainer FF.l AR, a D1 QC ins;cctor, was interviewed at k.'olf
(
Creek by NRC Investigt.' tor H. Ercoks GRIFFIN.
FF.IAR ttated he was aware of the policy regarding the verification of NCR conditions by leads. FRIAR stated that when he found a nonconforming condition, he would write it up on an NCR along with a hold tag and give it to his lead, Dalton RICHE.
FRIAR stated that if RICHE agreed with him, RICHE would sign it, and then one of' the'm would obtain an NC'R number.
FRIAR stated he had not had any trouble with his NCRs being voided, but had heard from co-workers that a QC inspector named LLOYD (infra) had his NCR voided by RICHE, TRIAR remarked he had heard from other co-workers (not further identified) that RICHE had voided their NCRs.
. FRIAR, stated that QC inspectors at Wolf Creek were required to work to three-part memorandums. FRIAR iaid these memorandums were often used in anticipation of revisions for as long as thirty days at a time.. FRIAR further stated that many ICPs (Interim Change Procedures) were never incorporated as revisions, and in these instances the QC inspectors were required to continue working to three-part memorandums. FRIAR recalled one three-part memorandum with which he disagreed, concerning QC inspectors being required to sign off on hanger locations.
FRIA" said he did not have a mcchanical certification, and had not been trained to detennine locations.
FRIAR said he did not think it was right for DI to require him to sign off on an inspection step he was not qualified to do.
i 17 Interview of Ja es Luta r LLOYD On February 15,19C3, Jares LLOYD, a D1 QC insrector, was interviewed by NRC Investigator H. Brcols GRIFFIN at Wolf Creek.
LLOYE was asked about the SCHRYEL meeting and the implenentation of a policy req; iring QC inspectors to call their 1
leads on nonconforming conditions. LL,0YD, stated he had not attended the meeting,
{
however, he did adhere' to' the policy, adding that this policy was implemented on his crew. LLOYD stated that some of the supervisors in QC did not adhere to this policy.
LLOYD stated he had seen numerous three-part memorandums at the Wolf Creek site.
LLOYD said he remembered Larry PHILLIPS, a QC supervisor, wrote a three-part memorandum which said employees could be terminated if they failed to comply with the instructions contained in three-part memorandums.
LLOYD stated that memorandums were primarily used to interpret procedure, however, there had been a recer.t decline in the use of three-part memorandums.
l LLOYD statec' his lead, Dalton RICHEj had destroyed about six of his NCRs (rct furtheridentified). He said most of these NCRs had to do with weld defects or design problems. When asked about his freedom to report nonconforming conditions, he said he new fcit free to write NCRs, but in the past had not felt frec c de sc l-because of instructions given by the four "fomer supervisors" (supra) who werc nc longer employed at Wolf Creek.
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18 Interview of
.6 ry Dean ADKINSGN On February li,19E3, l.arry ADKil.50h, a DI training coordinator and former OC inspector, was irterviewed by NRC Investigator H. Brooks GRIFFIN at Wolf Creek.
When asked about the freedom of QC inspectors to report nonconfoming conditions, ADKINSON said that in the past there had been many attempts by supervisors who were then employed by DI to curtail the writing of NCR's. ADKINSON Itated that many of these supervisors were no longer employed at Wolf Creek, and that QC inspectors were not having as many problems as they had before. ADKINSON stated that while he was a QC inspector, he had many of his NCRs and DRs " voided" by "foriner supervisors" (supra) on " closed in process" by quality engineers.
ADKINSON said he disagreed with many of these dispositions, and subsequently provided docu-ments to support his concerns which are included as Attachments (14) through (37) to this report. R KINSON Indicated he kept the documents to cover hir.self should these conditions later be found to exist.
ADKINSON was asked about the use of three-part memorandums, and stated that inspectors v.ere instructed to work to three-part memorandums at Kcif Creek.
ADKINSON said the memorandums often instructed QC inspectors to conduct their inspectiens outside of procedure.
INVESTIGATOR'S NOTE! ADKINSON was circumspect in his coments during this interview; however, on February 17, 1983, hc provided numerous NCRs, DRs, and three-part memorancu s.
Attachment (14) through (37), which represented examples he believed proved DI QC management personnel had attempted to restrict the insp;ctors' freedom to report nonconforminc conditions.
19 Inteisit. c' Ervce Edward MUNROE Or ft.trut j 17, 1983, Bruce MJNr.0E, a 01 QA inspectcr, was interviewed by NRC Investigster H. Brooks GRIFFIN tt Wolf Creek. When MONROE was asked whether he felt he had the freedom to report nonconforming conditions, he said, "no."
MUNR0E related an incident that occurred in the sunner of 1982 in which he had inspected a longitudinal weld that was " sharp" on a condensor identified as EAD01-A. MUNROE stated he refused to sign off on this inspection, and that his lead, Tom STUCKEY, told him he would get three days suspension if he did not sign off. MUNROE stated he continued to ref'Jse to sign off and the lead eventually signed off on the inspection..tiUNROE stated he was not suspended for not signing off and believed that the lead'was just " bluffing."
INVESTIGATOR'S NOTE:
Daniel International's personnel records indicated dTUCKEY was no longer employed at Wolf Creek and his whereabouts were unknown. STUCKEY was not interviewed.
MUSRDi related another incider,t in which he wrote a generic t.CR (identification unknown) on the breakdown of a traveler containing numerous supports. (13NROE stated he wrote the NCR because there was no procedure at Wolf Creek to break down a traveler into " mini-travelers.".a10NROE stated there was ar unsigned three-part memorandum instructing the traveler preparation group as to now to break down such travelers. MUNROE said that because the memorandum was an unofficial document, he wrote the NCR on it (identification unknown). MUNROE Atated his NCR was " closed ir, process" by the DI quality engineers (QE). MUNROE stated he did not think this was a valid closing of his NCR, however, he did not elaborate.
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( t view: of (ztrrine PARRI5h 6
F(truary 17,19E3, rathrinc PARRI5". a DI QC inspector. was interviewed by s
.: Investigatcr H. Br;;ks GRIFFIN at L'olf Creek.
PAPR15h was asked whether shc.
feit free to report nonconforming conditions, and !she, stated she did at the present t i r,e.
PARRI5h iaid that in the past, under her,"former supervisors" (supra),,she felt intimidated because of her supervisors instructions regarding the reporting of nonconforming conditions.
PdRRIS'H stated that in the past 'she had a number of her NCRs voided and disagreed with the explanations given by her QC supervisor.
FARRISH provided Attachment (38) as an example of this problem wherein she, dis-agreed with the disposition. ! PARRISH provided copies of NCRs she felt are examples of improperly voided, and/or reflected DI policies which restricted the reporting of nonconforming conditions. These NCRs are included with this report as Attachments (38 through 40).
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21 Interview cf-Alan J. CLIFF 0PD On February lE, 19f3, Alan J. CLIFFORD, a DI QC lead inspector, was interviewec by NRC Investigator H. Erooks GRIFFIN at Wolf Creek.
CLIFFORD,vas asked about the policy speech given by SCHRYER;in the sumer of 1982.
CLIFFORD stated he attended the policy meeting, and he confirmed that inspectors were instructed to call their leads to verify nonconforming conditions.
CLIFFORD stated that in spite of SCHRYER's instructions, his crew did not call him to get NCRs or verify NCRs.
CLIFFORD stated his supervisor had not implemented the policy, and the QC inspectorsonhiscrewgottheirownNCRnumbers. When asked if he had seen any three-part memorandums at Wolf Creek, CLIFFORD stated that three-part memorandums were often used to interpret procedure. He said that in many instances, the inspectors were required to work to instructions contained in three-part memo-randums.
CLIFFORD further state d it was understood that if an inspector did not follow the instructions in three-part remorandur.s, he might be teminated.
CLIFFORD said he recalled an incident in July of 1982 when he received a three-part memorandum on the HVAC (heating, ventilaticn, and ti" conditioning) syster.
CLIFFORD stated this three-part memorandum instructed him to inspect using the paper-work he'had in his possession. CLIFFORD stated this paperwork did not include the corrective acticr. report (CAR) and he disaGreec with these instructions because he wanted to read the CAR and not be told what corrective action had taken place. He said this issue was satisfactorily resolved.
CLIFFORD itated he did not remember seeing any three-part memorandums since July 1902 vAich were in conflict with procedure.
CLIFFORD stated that one of his biggest problems as a QC inspector at Wolf Creek was the absence of heat numbers on hangers he inspected.
CLIFFORD said the inspectors inspected for heat numbers and wrote NCRs when they were unable to find them; however, most of these NCRs were " closed in process" by hanger engineers. CLIFFORD said it was the hanger engineer's reasoning thEt since QC signed off on these pieces during fit-up, they must have a heat number on ther even though the inspector could not find it C' IFFORD stated he continued tc tt';te NCRs when he could not find the
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-heat numbers in spite of the f act they were all " closed in process." CLIFFORD said that in the last month and a half he thought-he had written at least fifty l -'
NCF,s on this cc,ndition. -He stated he did not retain copies of these NCRs.
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i 23 Intervin. cf 2titon RICHE Or. Ecbruary 2,1953, Dalton RICHE. a D1 QC lead inspector, was interviewed by NRC Irvcstigator H. B. GRIFFIN at Wolf Creek.
RICHE stated he worked as a lead on Richard BOOTH's pipe hanger crew. When asked about a meeting conducted by SCHRYER in the sumer of 1982, RICHE stated this meeting implemented a policy in which the QC inspectors were instructed to call their lead when they identified a noncon-forming condition.
RICHE stated the leads were instructed to verify the condition before issuing an NCR number. RICHE stated the leads were instructed to sign off on inspection steps if they were able to verify that the condition identified by the QC inspector was not, in fact, a nonconforming condition. RICHE admitted he had signed off on inspections in this manner but did not think it happened very often, and could not recall any specific NCRs QC inspectors, and/or inspections that he handled in this manner.
RICHE was asked whether QC inspectors were instructed on how to inspect by instructions contained in three-part memorandums. RICHE stated that three-part r.e crandJms were used to clarify er interpret procedures and not take the place of established procedures.
1:her, asked whether there was c c~.i'erence between instructions given in training versus instructions inspectors wcre told to employ in the field, RICFiE explainec he believed the difference between the two was simply an interpretation problem.
RICHE stated he did not have difficulty with the difference between what was taught in training and what was practiced in the field.
RICHE stated he liked his job, and he felt QC inspectors hac adequate freedom to perform their duties.
24 Int (rview of Jeffery BROWrilNG Gn February 17, 1983, Jeffcry BROW'ilt.G, a DI QC lead inspector, was interviewec by NRC Investigator H. Brooks GRIFFIN at Wolf Creek.
BROWNING stated he had atter.ded the 1962 late sumer meeting in which SCHRYER (supra) implemented the policy that when QC inspectors found nonconforming conditions, they must notify their leads.
BROWNING stated the leads were instructed to sign off on inspection steps if they disagreed with the QC inspector's assessment of the problem.
BROWNING stated he believed there were instances in which he signed off on inspections when the QC inspector did not agree with him. BROWNING stated that most of these instances were differences in the interpretation of procedure. BROWNING stated that Larry PHILLIPS, a QC supervisor, reviewed NCRs before a number was authorized.
BROWNING said that if ?HILLIPS disa' greed with the NCR, he would write an explanation on a yellow stick-on tab and ser.d the explanation back to the QC inspector. ~ BROWNING stated that after a while, (rHILLIPS discontinued writing these explanations and started giving the explanations verbally, when he learned the inspectors were keeping copies of the voided NCRs and DRs.
BROWNING, stated he often hac difficulty with some of the previous supervisors.
,sROWNING related an incident in which a fomer' senior supervisor, Ira JAMES (supra),
instructed the inspectcri rci to release pieces of pipe from the fab shop, but to release only spools. 'BROAING. stated that one day PHILLIPS (supra) told him to release several pieces of pioe.
BROWNING stated he' asked PHILLIPS to give him a
' memorandum explaining whj te shculd violate JAMES' instructions. PHILLIPS refused, and he (BROWNING) asked to see Ira JAMES, 'BR0WNINGj said that the next morning he found a memorandum in his box from PHILLIPS authorizing the release of the pieces, beforehehadachancetotalktoJbES, BROWNING' stated he also hac difficulty with Wil'liam FLINT and Charles G0lNS ; supra),
(former DI QC supervisors a e,o he believed ignored many of the procedures. QROWNINI stated these supervisort neuired the QC inspectors to inspect more to their ideas of hcu inspections sh 6.' ': done rather than following procedure.
3.
v 25 BROWNING stated his crew did not always follo,. the instructions from PrilLLIPS, FLINT, or GOINS when they conflicted with a procedure.
BROWNING said the inspectors usually followed procedure instead. $ROWNING stated that af ter a nurder of these conflicts occurred, wherein PHILLIPS instructed his crew members to gc out-side procedure, he jBROWNING) went to, Larry BRYANT, the QA Project Manager, and complained about PHILLIP5'. attitude and instructions.
BROWNING stated that about a week later, PHILLIPS was transferred to a different position.
BROWNING stated that in the past six to eight months, the inspectors had " rebelled" a number of times against former supervisors in the QC program at Wolf Creek, and as a result of their complaints, a number of supervisory peqsonnel changes had been made.
BROWNING specifically related that (supra)hadbeenterminated,and (supra) had been transferred to 'other sites.
BROWNING stated he felt hatsomeo'fth'eQCinspectorsmayhavebeenintimidated,butthatotherinspectors helped bolster etct other's confidence enough to resist following improper instructions given t,, the former QC supervisors. BROWNING stated he believed the attitude of management toward proper QC inspection was much improved since the end of 19B2.
~
_ BROWNING provided the NRC with a voided Deficiency Report which he stated was an example of his cc :c~.s regarding DI's eclicies which restricted ir.spectc-s' f reed:-
to report non:c ':
n; conditions. This scided DR is includec witr this re; at Attachment (41).
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26 Interview of Richard E00TH Or. March 10, 1983, Richard BOOTH. e D1 QC supervisor, was interviewed by NEC Investigator H. Brooks GRIFFIN at Wolf Creek. h00Tiwasaskedaboutapolicy meeting conducted during the sumer of 1982 by the '01 Project Quality Inspection Supervisor.which required QC inspectors to call their leads for verification before reporting nonconfonning conditions.. BOOTH stated he did not attend this meeting, but was made aware of the policy as it affected his job.
BOOTH said this policy did not apply to any inspections other than hanger welds completed prior to April 1,1981, (Corrective Action Report 0019). BOOTH explained that a decision was made by Kansas Gas & Electric that DI hanger inspections prior to that date had not been properly inspected, and DI was comitted to a reinspection of all welds on the related hangers.
' BOOTH statec that QC inspectors were free to report all other nonconforming con-ditions without calling their lead, and are authorized to obtain NCR numbers from the DI Quality documents section without DI supervisory approval.
BOOTH explained to: the supervisory review policy was initiated because an excessively large number of NCRs were being generated on the reinspection.
BOOTH stated that D1 management cecided many of these NCRs were invalid, because many were " closed in procest" L; ne D1 Quality Engineers (QE).
BOOTH stated he instructed his inspectors tc continue reporting defects in spite of the number of NCRs "closec in process." BOOTH stated that one of his inspectors, James LLOYD. wrote a lot of unnecessar, !:Es, and he transferred K 0YD to the fab shop.
BOOTH statte inspectors on his crew normally obtained an NCR number, anc then sent the NCR te hir for review.
B00THistated that if he chose to void an NCE, he wrcte an explanaticn on the NCR and forwarded the document td McCRANEY, the Senior Quality Surcrvisor) (B00THistated that even if the NCR was voided, it became a
" Quality" re:crd because a number had already been issued.
, BOOTH w : i: u about the use of three-part memorandums at Wolf Creek. N ttrier he hsc n:
~~c. randums that direct (d which procedure was to be used whe" : -~~
27 procedures were in conflict.
BOOTH stated that Quality Centrol Procecure,;:it',
were of ten vague, and left much of the interpretation up to the inspectors.
BOOTH stated he had a big problem with the number of NCRs " closed in proc (.1" by the DI Quality Engineers., BOOTH stated it was his opinion that many defc: t were not being corrected, and that the QEs were setting themselves up as the ones to sign off on inspections.
BOOTH stated that Bechtel was the only one who could authorize "use as is" as a disposition on a defect, but by closing the NCRs "in process," the engineers were bypassing the intent of the " Quality" program at Wolf Creek.. BOOTH stated that when an NCR from his crew was " closed in process," he had his inspectors make reference to the original NCR in the nondestructive exami-nation (NDE) block on the weld control record in the traveler.
BOOTH was asked about an incident in November 1982 in which an ironworker crew was installing whip restraints on site.
BOOTH stated there are normally two sets of documents identifying the pieces to be installed. BOOTH,said he remembered that the ironworkers did not have a copy of the vendor cut sheet available at t * ( i.- work location, so he verified the piece numbers with the ironworker's general foreman (identity unknown) at the DI vault.
BOOTH said the project was a rush job, ard the pieces were verified rather than making a copy of the vendor cut sheet.
'::h, also stated it was permissible to install the pie:es using the Bechtel crawing.
BOOTH stated this was an isolated incident, and that normally the crews had the cut sheet on location.
I E00TH stated he believed many of the DI QC inspectors felt that several former DI CC suttrvisors (supra) had restricted the inspectors from repcrtin; nonconforming conditions, but the fact that these "former supervisors" had beer. replaced improved morale.
BOOTH stated he believed that DI QC inspectors at Wolf Creek had adequate f reedom to write NCRs.
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28 Intervies of: Larry W. PHILLIPS On February 17, 1983. Larry PHILLIPS. Daniel International Construtt'en Quality Engineer, was interviewed by hRC Investigator H. E. GRIFFlf; at Wol' Creek.
,PHILLIP5 executed a signed, sworn statement which is included with inis report as Attac'hment (42).
,PHILLIPS stated that during the sumer of 1982, Ira JAMES, (supra), implemented a DI policy in which QC inspectors were to call their lead when they identified non-conforming conditions.
PHILLIPS stated the leads were instructed to verify the nonconforming conditions, and if they agreed with the inspector, they were to authorize an NCR number. PHILLIPS stated that if the lead did not agree with the inspector's opinion, the lead was to try to change the inspector's mind and make him understand that it was not a nonconfonning condition. PHILLIPS stated that if the lead and the inspector continued to disagree, the lead was instructed to sign off on the inspection step.
PHILLIPS stated the policy directed that should a QC inspector be "over-ridden" by his lead on a continuing basis, he might be retrained.
TVILL,IP5, stated he er. forced this policy on his crew, and be told his leads.,(Dalton.
-ICHE and deffery BROWt:ING to operate under this policy.
PHILLIPS stated this pclicy was in effect until he was transferred from his position as a QC supervisor
.: his present positicn.
.,PHILLIPS stated that while he was a QC supervisor, the inspectors regularly used irree-part memorandums to explain conflicting procedures such as quality control pocedures "versus work procedures.
PHILLIPS stated that r.enorandams were also used to in'terpret or clarify procedures.
PHILLIPS,said these memorancums were used to instruct the inspectors on how they were to inspect accorcing to DI's interpretations.
PHILLIPS stated the number of three-part memorandums used at Wolf Creek increased after a oecision was made by DI management to decrease the use of Interim Change Procedures (ICPs).
PHILLIPS,also stated that tremorandums were used to tell the inspectors how to inspect when a change was ardcipcted.
PHILLIPS said that until the revisions were actually implemented, tr-:
uscc the three-part emorandums to identify the inspection criteria to be follt. ' t.
r 29 FHILLIF5 statec he remembered one memorandam which instrcrier inspectors to
" buy-off" on hanger locations during fit-up as described in QCP VII 200 rather then usinc QCF VII 204 PHILLIPS stated he held a mechanici ' ccrtificatien, bci believed that a QC inspector holding a welding certificaticr. hac sufficier,t knca.-
ledge to verify the location of a hanger at the time of a fit-up.
When PHILLIPS was asked whether he told any QC inspectors that they might be terminated if they failed to follow the instructions contained in three-part memorandmns, answered that he could not recall making that statement.
PHILLIPS stated he remembered one meeting he conducted, during which ar inspector asked him if they could include his (PHILLIPS') memorandums in the traveler package when tney were required to sign off on inspections based on his (PHILLIPS') instructions.
PHILLIP5 stated that he told the inspector that memorandums were not to be placed fn the traveler, but if they desired, could keep a copy of his memorandum.
THILLIPS stated he remembered another occasion following a traveler class, when Marshall SEXTON, a QC inspector, was having trouble with instructions concerning traveler decute~ts. PHILLIPS, stated he remembered that in this training class the inspectors were taught that certain entries were to be made on travelers.
PHILLIPS said he told 3EXTON that if the absence of these entries kept him from performing his inspecticr., then he should disrecard the trainine cleis instructions and proceed with tne inspections using existing proceaures. PHILLIPS stated he told this to all the inspectors on the crew, and that the other inspectors did not seem to have any problem with the instructions given in the training class in relation to his instructions.
PHILLIPS stated he remembereo SEXT04.old him that his instructions were in conflict with the training he received, and that he (SEXTON) was not going forward with the inspections because of the conflict.
PHILLIPS stated that he remembered that although SEXTON did not agree with his instructions, he (SEXTON) spparently went ahead and followed his directions, because he did not hear about it anymore.
l
3D Interview of Ronr.ie F. McCRANEY On March 16,19E3,'McCRANEY, the Senior Mechanical Kelc'ing Quality Supervisor,
was interviewed by NRC Investigator H. Brooks GRIFFn at Wolf Creek. McCPAN[
was asked about the sunner 1982 policy meeting, and stated the policy rccuirir.g inspectors to call their leads for verification prior to getting an NCR number was instituted by the DI Project Quality Inspection Manager, Neale SCHRYER McCRANEY 3
stated the inspections made on hangers prior to April 1, 1981, were being reinspected under Correction Action Report 0019 (CAR 0019). 'McCRANEY stated that since these previous inspections were conducted by level-II inspectors, it was SCHRVER's reasoning that defects found during the reinspection should be more closely scrutinized before an NCR was authorized. McCRANEY stated he did not think this policy was restrictive or an attempt by SCHRYER to ignore nonconforming conditions, but rather was an attempt to assure that unnecessary NCRs were not generated during this reinspection project.
McCRANEY stated that the inspectors were told that retraining was a possibility if too mar.y instances of their leads countem.ar. ding their decision to write NCRs were identified. McCRANEY stated this was not an attempt to threaten the inspectors, but rather an' attempt to lessen the number of invalid NCRs. McCRANEY, stated he prcbarl;. averaged voiding two NCRs a mcnth. 'McCRANE'i stated that an NCR voided by QC management was sent to QC Engineering for review, whereas a routine NCR usually went to Construction Engineering for dispositioning.
INVESTIGATOR'S NOTE:
NCRs prepared by inspectors for which numbers were not authorized were not reviewed by engineers, but rather were destroyed or returned to the inspectors with a written explanation.
A number of inspectors interviewed stated these written explanations ceased when DI QC management learned the in~spectors were retaining copies of the NCRs containing these explanations.
v,cCRANEY was asked about the use of three-ptn Tyrr.cums at Wolf Creek.
He statec the memorandums were primarily used t.-
7
~~recedures ur.til rr sions~~
-r h1
-vt ie inade. He stated instructions contained-i'
~~ortrdums were not intendct.c supplant established procedures or replace Interim Change Procedures-(ICPs).~~
f4cCRANEY stated he believed DI QC inspectors e' WIf Creek had ' adequate fresdor i
to inspect and report nonconforming conditict.s.
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Interview of Neale A. SCHRYER On February 18, 1983, tieale SCHRYER, it t DI Project Quality Inspt: tier.I'.ar.ager, was interviewed by NRC Investigator H. E.ooks GRIFFir; at kolf Creek.
SC 4YEE was asked about the DI QC policy of inspectors calling their leads for' verification on NCRs, and he said he instituted this policy.
SCHRYER stated that many of the invalid NCRs written at Wolf Creek were on the inspections conducted on CAR 0019.
$CHRYER stated that too many invalid NCRs were being written, particularly on procedural violations. SCHRYER said that in September of 1982, he called a meeting of the leads and supervisors and told them that in the future, QC inspectors were to call their leads when they discovered a nonconforming condition.
SCHRYER stated that leads were either to go look at the condition or inspect the paperwork furnished by the QC inspector.
SCHRYER said that if the leads concurred with the call made by the QC inspector, they were to authorize an fiCR netter.
3CHRYER stated he further instructed that if the leads disagreed with the QC inspector's call, they were to try and explain to the inspector where they were wrong and encour-age them to sign off on the inspection. 'SCHRYER' stated he instructed the supervisors and leads to sign off on the inspectica.1 if the inspectors wc -( not willing to sign off on the inspection. SCHRYER stated the leads and supervisors were more experienced than the inspectors, and the enforcement of this policy was meant to avoid unnecessary and invalid f4CRs, rather than discourage inspe: tors f rom reporting nonconforming conditions.
SCHRYER further stated that before the implementation of this policy, there was a significant problem with the number of NCRs written which were being 'c'.cied in process" by the er.;ineers 'because they were not legitimate, reportaHe problems.
When SCHRYER was asked whether the inspectors were told they might be required to be retrained and/or recertified if many of their NCRs were declared invalid,(SCHRYER stated "yes," they were so instructcd. sSCHRYER was asked whether failure to recertify would result in dismissal for the inspector, and he stated that if the inspector was not certified to inspect, he i Act V:Lably be terminated.
When asked about the use of t-e-:
. r.orandums at i;
~~Seek SCGYET said they were used to clarify or interret ;- :rcure and not meant tc circumvent procedure.~~
T 21 SCHRYER statec ne had not wr'.".;(-
try v.emorandam! t(iiing ir.spe: tors how tc inspect, but thought he had seen such memorandums written by engineers.
SCHRYER' said he did not believe that it
! rec-part Ferrrcr.dur.s vcrc intended to take the place of Interim Change Procedurst (ICPs).
SCHRYEk stated that since he had been put in charge of the DI Quality program a't Wolf Creek, he has made a number of personnel changes involving supervisors, and as a result many of the inspectors' morale problems had been alleviated.
SCHRYER stated he had an open door policy for the inspectors, and he believed the inspectors had the freedom to report any nonconforming conditions they identified.
INVESTIGATOR'S NOTE: GCHRYER was asked whether his policy of calling leads for verification of NCRs applied only to reinspections done under CAR 0019, and he said "nc."
SCHRYER explained that the reinspection program was the cause of the origination of the policy, but the policy was also applied to Other QC inspections.
34 Referral to Recion IV During the course of it u it.vestigatien, documer.s wcre received fron D1 employees who were inttryieaed, and are ir.clocec at, attachments to the report.
These documents were provided by the employees interviewed as examples of possible procedural violations.
Copiesofthesedocuments(Attachments [2]through[41]),
were provided to the NRC technical staff, Region IV, for timely review and evalu-ation. These potential procedural violations are not addressed in this Report of Investigation, but are referred to Region IV for action deemed appropriate.
~~Further, it is pointed out that the inspectors interviewed identified most of Attachments (2) through (41) as " voided," however, the word " voided" does not appear on the documents.~~
These documents were represented to be " voided" or " closed in process," or were conditions wherein the "former supervisors" vrould not permit the inspectors to report their findings.
" Voided" mea 1t the supervisor refused to forward the documer. tut-mitted by inspectors.
" Closed in process" meant the document was forwarded by the supervisor, but closed by an engineer.
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Status of Ir.vc:.:.: ;tn The status of *is 3r.ststigation is CLOSED.
l 4
M Attachmer.ts (1) -
Ste!..!.'s Signec Sworn Statement 12-02-E2 (2) - It c.ti.ncms by Ft.ul H;.LE.
10-1E-82 10-26-82 11-06-82
-(3)- Deficiency Report (voided and unnumbered) 8-17-81 (4)- Fonconfonnance Report number ISN4960PW 6-07-82 with attached Disposition and Letter (5)- Memorandum signed by William FLINT 6-16-81
~
with three Deficiency Reports (voided and unnumbered dated 6-04-81), and or.c Deficiency Report (voided and unnumbered dated 2-11-82)
(6) - Surveillance Report
>;ith attached Memorandum tigntd by MESHAW 9-03-81 (7)- I;cnconformance Report number ISt:4972PW 6-07-82 (8)- Nonconfonnance Report number ISN5596PW 7-28-82 (9) - Suneillance Report and f:emorandum 9-03-81 (10) - Deficiency Report (voided and unnumbered) 4-27-81 (11) - Deficiency Report (voided and unnumbered) 7-18-81 (12).
Ltficiency Report (voided and unnumbered) 3-02-82 i
Ccnformance Rei!"' (Voidedandunnambered) 2-23-82 s '. ' l
37 Attachments (14)
Deficiency Report number ISD7078M 6-04-81 and attach (d change sheet (15)
Deficiency Report (voided and unnumbered) 7-01-81 (16)
Four Deficiency Reports (voided and unnumbered) 6-04-81 and memo from FLINT (17)
Two Surveillance Reports (voided and unnumbered) 11-16-81 (18)
Deficiency Report (voided and unnumbered)
UNDATED (19) - In-Frecess Welding Surveillance Report (voided and unnumbered) 9-23-81 (20) -SurveillanceReport(voidedandunnumbered) 4-16-81 (21) - Surveillance Report (voided and unr.uchered) 1-17-81 (22) - W ;randum ic. Ira JAMES 6-03-81 (23)- Deficiency Report (voided and unnue ered) 11-19-81 (24)- Deficiency Report (voided and unnumbered) 9-28-81 (25)- Two Deficiency Reports (voided anc urr. umbered) 11-19-81 (26) - Two Deficiency Reports (voided and unr. umbered) 10-14-81 i
(27)- ItficiencyReport(voidedandutc
~~td) 7-18-81 f.:.:enformanct Rt. port (voided e r :.~~
.-bered) 7-29-82 (2E:
9 38 Attachments (29)- Deficiency Report (voided and unnumbered) 12-09-81 s
(30) - Deficier.cy Report (voided and unnumbered) 7-21-81 (31)- Deficiency Report (voided and unnumbered) 11-18-81 (32)- Unsigned Notes of Mechanical Welding Supervisor's Meeting Notes with attached Memorandum 6-04-81 (33)- Deficiency Report (voided and unnumbered with an unidentified signature) with attached Memorandum 12-01-81 (34)- Deficiency Report number ISD'i640M 12-05-80 (35)- Deficiency Report (voided and unnumbered) 8-05-81 (36)- Deficiency Report with attached Memorandum s
(voided and unnumbered) 2-20-82 (37)- Nonconformance Report (voided and unnumbered) 11-17-81 (38)- Nonconformance Report number ISN8552PW 2-09-83 (39)- Nonconformance Report number ISN5716P 8-04-82 (40)- Weld Control Record Undated (41)- Deficiency Report (voided and unnumbered) 11-21-81 (42)- PHILLIP!' Signed Sworn Statement 2-17-83
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, hereby make the following voluntary statement to Mr. D. D. Driskill, who has identified himself to me
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I make this freely with no threats or pro:nises of reward having been made to me.
statement
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f. WlOI U MM Supervisor Nectint '6-4-01 7lP t,, ff, f / r/l - 4 n~-Ul e 1. We do nol Dispect to trenos: Enphazise to personnel that re-c. :n c used
~~for the purpose of clarifying procedures only. Procedures a.r! m ocifi-cations outline inspection criteria.~~
2. Weld Prep as' per ISO (Sq. butt or 37h ): Pipe to plate bcect.:.r prep will be in accordance with the designed specification. Althe : :a *.he prep is not depicted in MS-6 Spec., an approved drawing is aco.p-2 :c. 3. Do not rotate valve unless specified on drawing: Valves are in-stal cd to specifications and any deviation must be addressed. i.e. arbitrary rotation to facilithte installation. 4. Check 1000of W-100's on crmpleted welds: There is no requirrenis to verify all W-100 forms during final visual inspection. Random che::k during in process surveillance is adequate. 5. No CC hold on pre-heat prior to tack welds: Preheat verification prior to tack weld is not required. There is only one CC Hold Point for veri-fication of pre-heat in=spect.ive of the time span from fitup to final. Additional pre-heat may be checked during in process surveillance. - 6FJob assignments in fielci: Inspectors are assigned and report to the Lead Inspector who reports to the supervisors. Moveme:nt and assigr2ent of inspections will be handled through this chain of supe.%. ion. 7. CC will not estabiish inspectica standards: Inspection criteria is cut-lined in procedures and specifications. Individual standards outside this criteria will not be interjected. 8. MSSWR with DRA CR: A weld bontrol record generated as the result of DR$CR must reference the DR/NCR nunber. A copy of the weld control reccu.-d is placed in the original DRACR. 9. DR.- List the s ucedure and paragraph of violation: Effective this date, when writing a DRMCR, reference the procedure, paragraph and item the deficiency /non-conformance is in violation of.
~~10. Timely processing of paperwork: '1he time frame to process weld control records that have been returned to the field for correction is excessive.~~
Enphasis should be placed on getting them corrected and returned. hAttendees: f 1-- {T.Stuckey I. James B. Flint J. Depaepe T. Nevitt L. Phillips, M. Plunb R. Arment R. Cook V. Napier C. Goins R. Booth W.Reinier cc: L. Bryant D. Dennison i L.' Tnompson
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~ NS[xx II/I FEV. et DATE ~ S System IF Purchase Order / Traveler No. ^~ nob 1231 DESCRIPTION: h'gld sheets (S-10lH) for C205/123 (II/I) are misnumberec; H-5 A,B,0,0, do not refer to a sheet H-5, each centains weld nurbers that appear on no Othe Neither S-101 H heading block ner hanger suffix shcus this to be a II/fEa'@ but the design sheet (crawing : page lof2) shows this to inceec ce a II/I ite.. Action Taken.to Control DeficAency: Ref: 153-S601 F. Hold tag attached to travler, S/N:.2. 9 m jf, s. %.rt t $ h b '*~ (* / **),, R /t/ f1 f M 726 0 S W W I f h 9'., c.n D A n u Ice '*dlS'l . ORIGINATOR
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't,r. F.077.1-3 (Rev.1/21/E i ~~ w/o c:tachment @EWM NONCONFORMANCE REPORT (7CR) PRiECT NAME / NUMBER ACTION REQb BY CONTROL METHOD Q N NCR NUMBER Wolf Creek - 7158 2-13-83 11692 X ISN8552PW OLSPOSITION: IMPACT STATEMENT INCLUDED OVES GNO @ APPRDED AS RECOMMENDED i ,I I O_oiSPoSmon Revisto as Pottows, i The recommended disposition to use the subject support "as installed" will not affect the integrity or operability of the system and is considered acceptable. All work performed should have been done in accordance with approved procedures and Specification 10466-M-204. \\ This NCR coordinated _with B. Gwin,I Plant Design Supports, of Gaithersburg and K. Barris on February 15, 1983. gvo DOCUMENTS TO BE REVISEdi" ~ None / t 1 5NUPP5 UNITS 1 2 \\ Newcomer % APPLICABLE (V) / l. g Asst. Lead Liaison Engineer MB 151983 N/A N/A N/A APPfCVAL TTTLE DATE SNUFPS OR UTILITY APPROAL TTTLE DATE DISTRIBUTION: .s_,__ _m,m
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tion Taken te Control Deficiency: h Ce d C LL T(46,il 2 9 2. 0 k s JRIGINATOR ' bh d /* E QCE I DATE LISPOSITION: O Justification: REWORK C.suse of Deficiency and Action to Prevent Recurrence: Potentia 0-55e/P g 21 Proiect Dis.cipline Encineer Date AMWORITED' 2W5PECTOR N RCUTE.70 (FOR CORRECTIVE ACTION): "~ & sedo,a 6Ae isefo<mawoo 19 hove sue 6 notArve a,wocedorn/ Wolekon. (Ut do Aa<e a o~4'c/.behew 4 o-l Skeel nad G,e e/m,Wrelo're la Deu o/ e. D/t(, c, eve,asc. ct su,oearaxc,epo<-t,s/ak~fd' ear,A o/ -tk S2v &oa. Responsible Supervisor : .. _ //-ft,ff/ CELN JPECTION: ~"" SNN REWORK REwong ~ ~ SATISFACTORY UNSAT. DATE-Q.C. INSPECTOR D ATE. 'tPLINE Q.C. EhGINEER - DATE 's, -... RIS UTION: PROJECT MANAGER X OOCUMENT CONTROL 'SECHTEL SITE LIAISON CONST. MANAGER y ORIGINATOR 191
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~ rm SUPPLEMENTAL SHEET DR NUMBER it te. M E l l 'si j o )b f tv:fi 1N b F W Mt whi[h is on i s ts,3,c. mu o sec, _u r.s, z a. L e u r.co : bu -Age s ect e % s % e L m down yaca. G e,#, ( \\ 0 l O 9 I I thtE u.!t l40 l** f *[L i Goet e< bond h sch 4c. e
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1 WelF Cree.h Place: P arlt.*.; den, Nca p s Date: a F3 I, 1.c4 r r is W k h i /rY,0 s , hereby make the following voluntary statement sto H. Brooks Griffin, who has identified himself to me es an Investigator with the U.S. Nuclear Regulatory Comission. I make this statement freely with no threats or promises of reward having been made te me. 1.' s; ~.
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