ML20129A475
| ML20129A475 | |
| Person / Time | |
|---|---|
| Site: | Diablo Canyon  |
| Issue date: | 12/11/1984 |
| From: | Geske D M.W. KELLOGG CO. |
| To: | |
| Shared Package | |
| ML20129A429 | List: |
| References | |
| FOIA-84-745 NUDOCS 8506040620 | |
| Download: ML20129A475 (22) | |
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DIABLO CANYON NLCLEAR PROJECT
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JOB #7177 SPEC #8711 QUALITY ASSURANCE REPCRT OF ACCCHPLISHED JOB TASKS (Raf: DR 3370)
THE E % mwr-C(MPANT AVILA BEACH, CA o_
PREPARED BT
.h D. Gese.e NDE Supervisor APPROVID BY e<w s
J' ?. nunyan Pield QA/QC Manager I
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8506040620 841211 PDR FOIA DEVINE84-745 PDR
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QUALITY ASSURANCE REPORT r.
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ACCGELICHID JOB TASKS (Raf:
DK 3 '70)
PURPOSE To de--at all job caska perfermed as result of deficiencias noted during review of radiographic. film required by DR.3370, steps to prevent recurrence.
SC0h This report is z w..at 4 to those items listed in our letter to the customer dated April 7.'.1977 (see Attachment #1), and supple =ents our previous report by J Runya:. dated 4-22-77,
Subject:
Quality Assur-ance Report of Docume 4 tion and Radiographic Film Revier.
FIIM RETIIVED K. BECK E 'LJTST/ ISO E
- 1..:. 68 a03 O
1-4-130 1051 1-7-1
- 201, 204R1 1-7-4 19, 243 1-7-5 27 1-7-6 28, 31A, 32, 283 1-7-8 39A, 41R2 1-7-14 64 1-7-15 65, 66, 68, 69, 70, 71, 84A 1-7-16 72, 73 1-7-21 98, 101, 132 1-7-22
- 106, 107, 106, 109, 113 1-7-23 116, 117, 120 1-7-24 122, 123 1-7-95 166, *170 1-7-29 183 1-4-1 15, 15A, 516, 2222
-l 1-8-41 274, 273 j
1-8-56
.499, 500, 37211 1-8-61 533, 535 1-8-71 547 1-8-72 550, 552, 554, 23523 1-4-349 1312R1
'1-6-705 1830 1-9-2 17 1-9-3
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190A, 290, 293, 322, *338, 345, 348 1-9-16
- 279 1-9-18
- 123, 126R1, 127
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1-9-19 141, 145R1 1-9-21
- 155, 158R1 1-9-23 h
173, 267, 268 1-9-25 182, 183 1-9-37 280, 281 1-9-40 283R1 1-9-42 250 1-9-61 333, 336 1-9-209 104 1-9-216 157 14-23 102, 20R1 1-04-500136 25311 1-04-500137 279R1 1-03-500146 228 1 03-500146 f" / 229 2-03-75 532 2-04 *
- 15, 22, *28, 29 2-04-4
.41, 54, 55 2 08-8 49 2-08-17
- 111 2-08-25
- 185C, 185D 2-08-31 222, 233 2-08-32
- 243 2-08-33 249, 249A, 2486, 2487,
- 390 2-08-35 266, 267, 270 2-08-36 272 2-08-548 1479 Q
2-10-10 78, 585 2-10-12 110 2-14-63
- 532R2 2-04-501014 351 R. BARBER
_UTIT/SYST/ ISO
_FW
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1-7-1 1, 2 1-7-10 SR2 1-7-2 7
l 1-7-17 78, 79 1-7-18 80 7-15 68 1-14-81 564, 568A, 568, 579 1-9-38 230, 231 1-9-5 48, 47, 45, 46R1 1-9-20 150, 151 i
K 'SHCRE INf1T/SYST/ ISO E
1-7-5 25, 24, 295, 26, 23 1-7-8 22 1-7-21 100, 102, 103, 104, 105, *99 1-7-16 V
74, 75 1 9-18 124 1-9-19 138, 137, 142 1-7 *188, 189
R. SEARS UNIT /STST/ ISO g
8 2-3'-14 165 2-4-12 138 O-2-4-501016 323.
2-8-61 445A 2-8-480
. 848 2-9-13 117 2-9-32 196, 197 2-12-8
' 91 2-12-11 119 2-14-62
$20, 814, 843, 861 M. CCSTLEY UNIT /SYST/ ISO g
1-7-1 209, 211, 215, 213, 4 1-7-8 39, 40, 242 1-7-24 126, 129, 124
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1-7-28 180 1-8-1 13 1-10-5 56E, 56F i
1-14-35 181 1-14-81 691, 574, 583A, 576 J. RUNYAN UNIT /SYTT/IFO g
i 2-3-19 232, 237, 427 O.
2 3-501023 333 2-4-27 294 2-4-501018 158 2-7-15 106 115 2-8-9 55,-56, 57, 567, 569 2-8-16 105,,576, 577 2-8-63 451 2-8-65 650 2-14-62 512 E. MARTINDAI.E UNIT /SYST/ ISO FW
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1-3-500146 499, 500, 501, 502, 503, 504, 505, 506, 307, 508, 509 1-3-6 349, 348 1-7-14 62, 63 1-7-15.
67 1-7 77, 76 1-7-19 82, 83 2-4-47
- SQL 2-8-60 437A 2-9-32 302 2 14-62 505, 517, 818 88aview required job tasNs.
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FIIM RESHctr FOR QUALITY / CLARITY UNIT /SYST/ ISO E
COMMENT 1-04-500136 hly l.!
255 Compared to original film -
j no defect noted.
1-04-500137 W i 282 Compared to original film -
no defect noted.
1-04-500138
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320 Compared to original film -
no defect noted.
1-04-500139 348 4
'4 Compared to original film -
~
gacmatric difference noted, 1-07-1 saa DR 3423.
201 Drop thru shot in cross-section and determined to be within
, code after customar review 1-07-21 5-19-77.
99 Rashot for lighter density -
1-07-22.
no defect noted 5-27-77 106 Rasbot view 3-4
- Original, fi1= missing - no defects noted 5-27-77 1-07-25 170 Rashot due to rou5h surface -
FW ground for inser rica - no 1-07-29 defect noted 5-18-77.
188 Rashot view 2=3-4 for full coverage - no defect noted 1-09-3 5-16-77.
O 388 Unconsumed insert noted during' fi a revi
. Repatz inclu ed with DR 3400.
1-09-16 279 Rashot view 0-1-2 to verify root fusion - no defect noted 1-09-18 5-25-77.
123 Rashot view 8-9-0 to verify root fusion - no defect noted 5-25-77 1-09-21 155 Rashot view 4-5-6 to verify removal of surfaca condition -
no defacts noted 5-26-77.
2-04-501013 347 Compared to original film -
no defects noted.
2-04-301014 364 Compared to original film -
no defects noted.
2-04-501015 379 Compared to original fil: -
no defects noted.
2-04-501016 329 Compared to original film -
no defects noted.
2-04-47 501 Rashot view adjacent to repair
~
area - no defects noted 5-13-77.
2-08-17 111 Repair completed and accepted 5-13 -77 2-08-25 185c Repair completed and accepted -
2-08-32 DR 3383, 5-20-77, hydre open.
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'243 Repair completed and accepted -
I IR 3385, 5-26-77, hydro open.
2-08-33 390 Rapair complaced and accepted -
DR 3384, 6-3-77, hydro open.
2-14-43 532 Repair completed and accepted -
DR 3382, 6-3-77, hydro open.
OfMIR JOB TASKS e
C' UNIT /STST/ ISO W
COMMINT 1-03-500146 828 Penetrant ~ tested seal weld at coupling installed to repair 2-04-2 N 197 28 Visual inspe.-Aion verified surface condition within code.
CONCI,USION The above data reflects all actions completNd as result of film review required per DR 3370 and constitutes final action as indicated.
covered during fi1= review generated the requirement for 1007. radiographic fi1=
Defects dis-review.
DR 3400 documents review of Unit I and DR 3409 concerns 1 Attachment 9
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- DI"81CE CORRESPCNDENCE
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To J. Rou,EY DATE APRiT 22,1977
.FROM J. P. RUttYAN
$UsJECT R95.5.G.M3 U.S.13 D..L 3.379
' As result of P.adiographic Fil:s Review, conducted per D.R. 3370, the 4
ctt;iched lists present our proposed action.
Requist your reJiew end eenents at the earliest possible date,
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J. P. Runyan
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Field q.A./Q.C. Hacager Jrn/=k
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NDE WORK D.R. 3370 IINIT II p
D ;T - SYSTEM s
TSO F.W.
WORK R:!DUTRED FREPARATT0t! REOUTRED v
2-04-501013 347 Reshoot Mainsteam 1.
Scaffold at top of steam generator.
2.
Not insulated.
Recommend R.T. from inside of steam NOTE:
generator and P.T, of I.D.,of welds.
2-04-501014 364 Eashoot Mainsteam 1.
scaffold at top of steam generator'.
2.
Not insulated.
NOTE:
Recommend R.T. from inside of steam generator and P.T. of I.D. of welds.
24 4-501015 379 Reshoot Mainsteam 1.
Senffold at top of steam Cencrator.
2.
Pull insulation.
NOTE:
Recommend R.T. from inside of secem
~
generator and..P.T. of I.D. of welds.
2-04-501016 329 Reshoot Mainsteam 1.
Scaffold at top of steam generator.
2.
Pull insulation
. 6.
~*.. NOTE:
Recommend R.T. from inside of steam generator and P.T. of I.D. of welds.
-U4-2 28 Visual for surface
- 2.. Pull insulation.
1.
Scaffold or ladder.
. Linear 3.
Match linear or; 1
4.
Raishoot.
. ~.
2-04-47 501 Reshoot adjacent view 1.
Modify. existing sesffold.
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.to repair area.
2-08-17 111 U.T. for lack of 1.
None Penetration.
l 2-08-25 185C Repair gas holes 1.
None 2-08-32 243 Repair gas holes 1.
Erect scaffold on top of liquid '
hold-up tank 2-1.
2-08-33 390 Repair unconsumed ring 1. - None.
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2-14-63 532 Repair porosity 1.
Scaffold platform for access.
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, NDE WORK D.R. 3370' UNIT I dir
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110 F.W.
WOP.R REOUTPED PREPARATION RKOUTROD 1-04-500136 255 Rashoot Mainsteam 1.
Erect' scaffold o'n top of steam M l'!
! 2.
Pull temporary insulation.
generator.
NOTE:
Recommend R.T. from inside of Steam Generator and P.T. of I.D. of welds.
1-04-500137
. 282' '
Rashoot Mainsteam 1.
Erect scaffold on top of steem
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generator.
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-2 2.. Pull temporary insulation.
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MOTE:
Recommend R.T. from inside of Steam Generator and P.T. of I.D. of welds.
1-04-5.00138 320,'
Reshoot Mainsteam 1.
Erect scaffold on top of steam generator.
2., Pull temporary insulation.
MDTE:
Recommend R.T. from inside Ef Steam Generator and P.T. of I.D. of welds.
303139.
' 343 '
- Rashoot Mainsteam 1.
Erect scaffold on top of steam h
[.'- -[ - W..
generator.
g.
- 2. ' Pull temporary insulation.
.., NOTE:
Recommend R.T. from inside of Steam
./
Generator and P.T. of I.D. of wolds.
.1-03-500146 828 Penetrant Test 1.
Scaffold in place A.I. Witness-2.
Pull ec:cporary insulation.
3.
Power bruch to clean.
1-07-1 201 R.T. Drop-Thru at 1.
No scaffold required.
i view 3-4 2., Pull insuletion.
1-07-21 99 Rashoot - Original 1.
Scaffold for access.
Density 4.0+
2.
Full insulation.
T 1-07-22 106 Reshoot - Original 1.
Scaffold for access..
view 3-4 missing 2.
Full insulation.
, 1-07-25 170
~ Reshoot - Original 1.
No scaffold required.
Rough surface 2.
Pull insulation.
1-07 188 Reshoot - Original 1.
No scaffold regizired 2-3-4 missed weld.
2.
Tull insulation.
)L9-3 338 Repair incert 1.
No scaffold required.
- i. Not insulated 3.-
R.T. repaired area.'
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- 11 PAGE 2 of 2 E E WORK D.R. 3370 e
O A-MET I hT - SYSTD(
T!0 7. 57 t.'ORK nmtITIID PnnAnATTott protrTnrp 1-09-16 279 U.T. for possible 1.
No scaffold required.
lack of. fusion 2.
Not insulated.
1-09-13 123 U.T. for possible 1.
Scaf5old in place.
1ac.k of fusion 2.
Not insulated.
1-09-21 155 Reshoot - Original 1.
No sesffold required.
with possible slag 2.
Pull insulation.
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FARTI4ENT OF INDUSTRIAL. RE./TIONS
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S'8" c' ****^' 5m asumw san evoeus, saa reANCISC3 toca:bar le' 1974 g,.
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L.. Kellogg Company Amedme97.i P. C. Een 367 Avilt. 3each, CA 93212 Attention J. P. Runyan, CA/QC Manager
Subject:
Q2a.lity Assurance at DLablo Canyon helear Plant Construction site Ge=tleman l
Cn Cecec:ber 3rd I discussed with yet and Mr. J. it. Ryan the recer:t %.1 b/ y=r P=dtetien Pe.s==nel of the thermowa"_s f=m the Reacter Ccelant L:sp, which had to be m od because they had been improperly installed by
.r =r Cc=pany.
A F.old Tag had been applied at each location and Deficien:f Empert 2137 had been issued which outlined the corrective wo:v. a=4 also clearly stated that the Q:ality Assurance Mansssr was to be notified before begnning any c:rrective work.
Productics failed to notify you and failed to fc11cv the D. R.
In doing so they viclated the Her4nfer::ance Section f your Cuality A=:ursnes Manual.
KTP-10 of your QA Manual assigns to ycu the resper=i'"11ty to assure that its provisions are adhered to.
You will recall that at the same tine the repair of Steam Generator 1-1 feedwater nczzle was +2 W ! place.
A crack extending circ.m.ferer:tially 3600 had been caused by your welders when they welded with:ut the use cf preheat.
':he welders had been assis=ed to the job by their supervision before ycu were in possessi:n cf a qualified weldi.g precedure for P 1 to P 12-3 Materials.
The installer in possessien of the proper ASME symbol sta=p and CeM.ificate of A:theri:stien is roccired to operate under a centro 11ed syste:s b NA 4451 er
/
Sc: tion III cf the Cede..We would therefore req 2est that nessures be t&sa te assure that conditions that-cansed be. violations icL11 be p.%s.17 4 da " *4 ed.
and corrected to preclude-I y.:.itie:ia It is also reg:ested that, in accer:iance~
- ith NA LSDO, the ider:tification and canse of failures affecting qu'*ty and the co..
uve-acticar be dne===w+=t- 04 Tory trcly y=rs P. J. Carosella
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' 3 Senior Safety Engineer f
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J. L*. Ry:n, Cc=struction Manager /
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INTEROFFICE CORRESPONDENCE EDUhElT' R '{D..
gg g TO P. RUNYAN CAff APRIL 5,1977 PltCM S. L. ENGLER SUtJECT MBHMT19.N,_,Q.T MM.Q@,MS,7,gGO,!JS,g,,,Lyggg,,,,g K. BECK (PULU4AN KELLOGG)
Reviewed 24 seams that were previously accepted by K. Beck.
These seams were reviewed by other Pullaan Kellogg personnel before I arrived.
They broke them into two groups: Acceptable and Questionable.
During my review of the Questionable Radiographs I found a lack of under-standing by the film interpreter of the Severning acceptance standards, such as:
A.
Acceptable inclusions not noted on inspection report.
3.
Acceptable surface indications not marked on inspection report.
C.
Inetusions and surface conditions where accepted that should have been rejected.
In my opinion some of the seams will have to be repaired or at least re-radiographed.
Some film can be accepted by ecmparison with the surface of the weld.
My review of the films interpreted by K. Beck that were re-reviewed by Pullman Kellogg personnel, and determined to be acceptable, consisted of a l
random sample. In the process of that review no rejectable film were found, l
During the inspection I found that all other aspects of the program such as; Contrast, Sensitivity, Density and Processing we.e acceptable.
l If you have any questions on the above report please contact me.
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Stephen L. Engler SLK/ak i
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E. 3. Curcio J. W. Ryan S. Handler G
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THE M.W. KELLOGG COMPANY wIr
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A oeviesoN oF PULLMAN 080CompomATE.
o.A. No.
3370 OI iso. mo.
500166 DISCREPANCY REDORT uMIT NC.
f CODE No.
M/A
' man:
PeeIfle Gas & Eisetric SPtc. No:
8711 OATE:
3/23[77 l
PROJSCT Olaelo Canyon Joe No.:
7177 INsPtCToA: 1 P_
Runvan l
DescasPaw? '7tw r.v. #197. Line Kt6-4%-16-IV. Steam Generator 1-1 Norrie to oloe EXPLAMAftom op CISCREPANCY As the result of a crack In F.W. #212 at the Feedwater nozzle on steasi Generator 1-2 (Asf. D.A. 3366), a review of the radiographs of the same welds on the remaining three (3) generators was performed by the N.A.C.
In addition, the nozzle to pipe welds on the main steam leads were reviewed.
'The review revealed a questionable indication in F.W. #197 on the feedwater lead to Steam Generator 1-1.
The Indication appears to be a burn through which centains
!!nearly oriented volds. The accompanying radiographic report accepted the weld but did not Indicate the presence of the burn through.
Further investigation revealed that a second set of radiographs, shot at a later date, exist. This set also shows 4
the burn through which was recorded on the radiographic report as acceptable (see copies attached),
(Continued on Page 2) t RECOMMENote otSPCs TICN:
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Revision I See page 3 Reviaton II 588 Page J M.D.E Plow CLA. Monmeer A
osse Cweener M.Q.K Plow CLA. Man.ese c.ee3 M U wtomer
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C STEPS 70 8# EVENT mEcummoneC3 C Nee Aeoileshi.
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i ATTEd)e FLTinRO iF LYNTYG7
Page 2 of 3
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' THE M.W. KELLOGG CO.TIPaNY
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A osvessofe 4F Pul.USAN tfeCoRPot A733 sec. sec. 6001866 OtSCREpANCY REPORT UN17 Mo.
l Coat Mc. M/A
,,y pasItie cas & Electric sPsc. Peo:
8711 cats: 3/23/77
,g,,
olasie Canyon a uo,:
7377 ius,ge7en.
J. P. Runyan M
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_ge,..c mw F.W. #197, Line x16-5516-16-IV, steam senerator I-I wezzie to otoe Exolanation of Discrepancy:
To determine the severity of the Indications in the burn through, we have made ad-ditional radiographs of the burn through area. These radiographs Indicate that the volds are probably contained within the burn through and do not extend into the i
weld. There is no indication of propagation of the Indicat.lons.
U.T. of the weld by P..G.sE. does not Indicate any indication within the weld which is outside the acceptance criteria, Attachments I, 2 & 3 R commended 0isposition:
To eliminate the possibility of a potential problem,at a later date, it is recom-e mended that the burn through be removed.
(
The following procedure is to be followed for removal and reinspection:
1.
Weld a 2" threaded coupling to the pipe as shown on the attached sketch using weld procedure 88/89 or 92/93. (TW f 827) 2 M.T. per ESD-209.
3.
Post weld he,at treat th's weld - ESD-218.
4 Perform a hydrotest on the weld prior to drilling into the pipe.
5.
Following satisfactory completion of the hydrotest, cut the hole.through the pipe well with a hole saw (Ref. ESD-230)
NOTE: Additional reinforce. ment of 2". opening is not required per P.C.& Z. calculations 6.
Using an extended shaft grinder with a cene shaped rock, grind the burn through flush with the pipe surface.
7.
nadiograph the area to assure complete removal of unacceptable indications.
8.
Install threaded plug and seal weld (F.W. #828).
This installation is to be made in accordance tiith the Nacional Board Inspection Code and ASME Section I Reviewed by A.N.I.
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'/THE M.W. KELLOGG COMPANY ryg a OtVIS40N oF PULLMAN INCQaPCmAftD O a. NO.
3370 Il d _
IsC. NC.
SOO1td pg* /*
DISCREPANCY REoORT UNIT NC.
6FF CtCE NQ.
T/A
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Pacifle Cas & Electric IPtc.NC-8711
___ D ATE:
3/23/77 wpen.
Dianle canyo" ma No; 7177 iNssac cm-L7-hm peamcT:
i osseme*aNTrttu:
7.W. d197. 1.ine E16-554-16-IV. Steam Generator 1-1 Nossle et pine R NISION I Se following action was taken.
Add to "Recomunended Disposition" the following stape.
A.
To determine if there exists an ambiguity with other welds accepted" by the M.K. Nellogg film interpreter who accepted F.W.197, the following action was taken:
1.
Review qualification records of this individual co' assure compliance with
. SET-TC-1A.
)
2.
Eeview all radiographs which were accepted by the individual.
NOTE:
The findings of the review will be reported as a seperate report and attached to this D.R. before the D.R. is closed.. No revision will be required to the D.R.
J O I I f!8 E d
CQ sTrrs to Furmer 1rcunnzscr In addition to the above action it has been determined that a random review cf accepted film from all other M. W. Kellogg interpreters was required. Twenty sets of film were reviewed from each of seven other interpreters. No rejectable
)
indications were noted (See Q.A. report of film and dos.amentation review dated 4-22-77 Attached).
}
Subsequent to the above a review of additional Unit I film was perfor=ed
.5.i'.:
investigating the accept / reject rate of welders. Another rejectable indic:c u.
ras noted in F.W. 346 Iso 1-4-5001-39 (Ref. D.R.3396).. At. this time P.G.& I.
l requested that a 1007. film review be performed of all design class'I radiograpna in Unit I and II, This will be performed and documented in accordance with D.?..
l' 3400 Rev. I for Unit I and D.R. 3409 for Unit II.
I To further assure that all welds radiographed subsequent to this data are properly interpreted; each set of film will be interpreted and then reviewed by a second qualified film reader. Reference q.A. instruction 101 Rev. I.
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