ML20138G638
| ML20138G638 | |
| Person / Time | |
|---|---|
| Site: | Wolf Creek  |
| Issue date: | 03/29/1983 |
| From: | Fortuna R, Griffin H, Hayes B, Herr R, William Ward NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV), NRC OFFICE OF INVESTIGATIONS (OI) |
| To: | |
| Shared Package | |
| ML20138G131 | List:
|
| References | |
| FOIA-84-291 4-82-018-01, 4-82-18, 4-82-18-1, NUDOCS 8512160365 | |
| Download: ML20138G638 (81) | |
Text
{{#Wiki_filter: ggjg g g trentr o 51 All e f t? C.t i AF. RI CUL A10M C.f e'.*.T.'.lbSION (4 I.( e Os *.vt sitt. AlsONS Iat t 3,08 lit t 51(.lDr. It .,,,.g'.- ARusc10N.1EXA5 MH I11 R) AN l'L AZ A oRivt. Fullt 1DXe I DATE May 23, 1983 REPORT OF INVESTIGATION TITLE: Wolf Creek Generating Station Counterfeit Safety-Related Pipe Hanger CASE NUl4EEk: 4-82-018 CONTROL OFFICE: OIFO: Region IV STATUS: CLOSED PERIOD OF INVESTIGATION: November 30, 1982 - January 14, 1983 REPORTING INVESTIGATOR: MA /t // H. BNo'ks Griffin, In@tigator 01 Field Office, Region IV PARTICIPATIf;G PERSO:iNEL: Donald D. Drisl:ill, Investigator 01 Field Office, Region IV Richard K. Herr, Director 01 Field Office, F.egion IV s[dh!44/ REVIEWED BY: Richard K. Herr, [irector 01 Field Office, Region IV ~ h b!'V/ / v WilliamJ.W$d, Director - r Division of Field Operations 01 T 2 21 S 'w* Rogerdortun'a,[e;utyDir tor Office of Invertiet.tions fw
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W, A*P 4Vil I'* Ben B. Hayes, * ' :: or[ f,$ r'512165365' B51107 OffIceofIs.:3i;rtions ~ F Hest 0282-p1 PDR [
O u.. S W. MARY t. An investigation was initiated at the Wolf Creek Generating Station, Kansas Gas and Electric Company (KGSE), Eurlington, Kansas, following the receipt of an allegation from a Daniel International Corporation (01) employee concerning the substitution lof scrap material by,a DI foreman for the original safety-related material in a pipe hanger. Another witness reported that a DI general foreman was made aware of a " bad hanger," but failed to take corrective action. Twelve past and present DI employees, believed to have knowledge of the inci-dent, were interviewed. A DI employee admitted removing the original bottom horizontal piece of a box hanger on March 16-17, 1981, replacing it with scrap material, and stamping heat and location numbers on the counterfeit piece utilizing tools in the field. This individual emphasized that he was only following the orders of the foreman. A former employee stated he assisted in replacing the piece with the understanding that the foreman had ordered this activity. Documents tracing the origination, fabrication, installation, and subsegent inspection of the hanger in question were requested and received. A revie, of the traveler package for the hanger in question documented repairs to the hanger, but did not document the discarding of a portion of the original t hanger or the installation of a counterfeit piece made from scrap material. The hanger in question was removed by D1 ecployees at the request of the NRC, Office of Investigations Field Office, Region IV. Subsequently, at the request of the tRC, the acting foreman of the DI pig hanger fabricatien shop examined " the suspect piece and stated the numbers stanped on the piece contained various irregularities and were not stamped by personnel in the pipe fabri-catien shop. One DI QC inspector who had initialed the traveler on March 17, 1921, examined the stamped numbers on the alleged counterfeit piece and stated the nur.bers looked somewhat suspicious, and commented, "I missed it." Review of KGLE documents disclosed that this particular hanger was identified on a list of hangers that were reinspected during the sumer of 1981. This reinspection project occurred after another counterfeit hanger, identified in April 1981, was brought to KG&E's atter. tion. The foreman and general foreman who were in ' charge of the crew that installed the suspect hanger were inter- ^ vie n, and they denied any knowledg v the fabrication or installation of a ccc-u rfeit hanger. 4 ,.,,y a n- -e
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~. 1 T Purrose of Investigation { This investigation was conducted to determine if untraceable, nonquality l . material was substituted in a safety-related pipe hanger at the direction of 1 - ccr. tractor's supervisory personnel, and'if a higher level of management for j the contractor failed to take corrective action when told of the deficiency. j e i i \\ t I 40 99 i 1 e l d 9 l I d f O uu--
a 2 Eackaround During an interview conducted in a separate liRC investigation ~ I j yfliegedthat I Ollie FRANKS, a DI foreman. had directed that scrap material be used in the fabrication of a safety-related pipe hanger at k'olf Creek.4 ) identified b thr. hanger as BG04C033, and stated in March 1981 the origibil bottIm piece (piece #2) of the box hanger contained defective welds which were not repair- ~ able. FRANKS, directed that the original piece #2 u- - beremoved.I ptated this hiece was destroyed during the cut out," and \\ ,f that' FRANKS directed him to fabricate a new piece from scrap I-beam. {( - .i s [__ FRANKS) instructions, prepared and placed the counterfeit piece f2 into the hanger with the assistance of ,[ Subsequently during this investigation, a relateb allegation surfaced wher'ein a ~ DI general foremar., Maxie PHILLIPS, reportedly became awe
- of the counterfeit hanger and failed tc take appropriate corrective action.
INVESTIGATOR'S !;0TE: The reference " piece f2" specifies the lower horizor,tal piece of I-beam in a box hanger as designated by the DI engineer's drawing. For the purposes of identification in this report, the original quality piece of I-beam will be identified tr. 'criginal piece f 2." The couterfeit peice of 1-beam will be ider.tified as " counterfeit piece #2." b 0 0
.. _=.. Q 3 Interviewod (Confidentiality Requested) / [ t On October 2E,1982< a't won Creek project, was interviewed,by NRC Investigators D. D. Driskid and H. B. GRIFFIN lI I executed a signed sworn staten.ent, Attachment (1), daconfidentia/it[agre(ment, Attachment (2). p,_/in the auxiliary building at Wolf Creekialleged th njer wh,1ch he had helped fabricat -l. was, Fred EA50k ( _{ stated EhSON Nas' later promo5d t[genAral ~ '~ foreman, and Ollie FRANK $ was brought in as the foreman of his crew, l said FRANKS assigned to remove t bottom piece of hangerh04C033,Ywhich was not welded properly. stated ( ] ut tHs piece out w,ith a grinder, destroying the riginal piece, k._.,'a.11egetthatFRANKS, to fabricate a new piece from scrap materi l and to transfer the heat /nd hanger numbers to the,new nonquality piece and iutell it in the hanger.d j FRAf(KS instructions, an,d that _,,,,_.helded the counterfeit piece into the L hanger. hurther 11eged that hRANK5i instructed him to place the ccunterfe.. L'e':e back in the hanger with the numbers up against the pipe so DC inspectors w:. id not be able to scrutinize the numbers. ~ }statec that about a month after they had put the counterfeit piece 72 j intothehanger,thewelder[w ] foreman lFRANKS.) got into an ar ument.p- _ stated that following the argument { l told him that, __v h iras' going fp report FRANKS for counterfeiting the piece in the a sa1Yty-relaE#e: hanger. . staked he went to FRANK $' and told him l, was going to report him'for ordering the counterfelt hanger fabricated, stated FiJ.'.K! told him that Fred EA50d the previous foreman, was actually r- - a I responsi!1t f:r the hanger. btated that later on that same day / RAND cametpt'- t-f told him the' hanger'was "OK," and had been approved, by Cf. r n:G: that FRA?ms told hir. he (FRANKS) etas going to tell Harc.1c i
y,.., 4 I, };C ll;filS his superintendent, about the situation. stated he last y observed the hanger on October 20, 1982, and it was 8 the# same condition as when he made the installation. . On December 8,1982,I )was reinterviewed at his residence and was asked to research any papeAork he had that could refresh his memory regarding the substitution of the counterfeit piece #2, particularly any additional witnesses that may have had knowledge of the incident'. %hascontactedtelephonicallyat {- i On December 11, 1982, his residence by NRC vestiga'to'rH.B[ GRIFFIN. . _,.'. stated he had taken ~ a time to recossider the contents of his signed, sworn state ent to the NRC regarding the fabri, cation and installation of a counterfei. hanger piece at Welf Creek.(IorigiAlal piece i admitted his memory concerning the dates he worked replacing th G04C03 'with counterfeit piece f2 might not be,_ accurate.I stated he did not reme ' er the exact date wheq, _Y ,j Wher asted whetherge had heard ay conver ations bepan it e Cyt-o t." lla).ie FHILLIFS..the g7,nera1 foreman, an{ _,_ the welder, concerning 3 M c'eplicate hanger,\\,, , stated he dTtFnot remembe[any such conversations x. } 'said although his mencry of the exact dates might not be accurate, he Inew 'for sure that 0111e FRANKS, his foreman had directed him to cut a piece cf scrar 1-beam from material in a nearby swap tin, duplicete the heet and han;cr numbers onto the new piece, and,use,.the piece te replace the original piece of I-beam that had been damaged. ( lemphasized again that rRAfiKs told him to place the nuybers up against the [ipe so QC inspectors could not see the numbers, b__ speculated that (RANK $ may have been repeating EA50N'A suggestion when he instructed him to fabricate the counterfeit piece.h furthtr stated he did not specifically remenber if anybody else heard his / c: versttion with FRANKS.
5 Ir.terview o.. Or. December 3,1982,(, was intervin ed by NR,C Investigators D. D. DRISKILL and H. B. GRIFFIN in Memphis, Tennessee. { .I er.ecuted a signed sworn statement, Attachment (3).. ,laftere>.amining the traveler for G04C033 which was provided to him by the reporting inv,esti-gators, recalled}' that his foreman (FRANKS)' had told. to ~ cut a defective bot}om piece (original piece #2),outY the har(ger because the weldswereporous.Q ispent a day and a half ,removingthepieceandthen',realizedthepiecelasdamagedbeyondrepair. a stated' fookthepiecetoFRANKS.andthathewaitedfo( to retufn._ stated he remembered that on the afternoon of March 17, 1981,' jreturned with a different piece of I-beam. I ')statedthey fitted the p'iece back into the hanger and welded it. i q g (, ,ls, aid that sometime in the sumer of 1981, he had an a7gument wit ( { RANKS},, stated he later discussed the argument with at 6hich time' ltold him about the fabrication of the counterfeit piece #2 _r!te fr,om n'onquallty material they had installed together in March 198,1. ~ [ said that during a second argument with f, RANKS, he told (P,A.)T that, w a ~ ,, seneone was going to do to him what they had done to Fred (EASON).,w ,,. s.r.it.d he did not mean he was going to teli DI management about the ccunterfeit hanger, but itpas his, impression that this was the way FRANKS interpreted hisstatement.q explained he meant he world complain to management that FU.'.l:S was harassine. him. I. said he later told JRAKS he wanted to talk i to the D1 general foreman, Maxie PHILLIPS, about their problets. stated he remembeged FRANKS told him he had already mentioned the hanger'to l FMILLIPS. alleged'that PHILLIPS subsequently cane around where he was,, drking an[ asked'him if he was threatening IRANKS'about a bad hanger. ~ stated he told PHILLIPSjhe did not know what he w'as talking about, and YT enly meant to warn F, RANKS that the crew would (omplain of haratment to DI r.snagement if he kept harassing them. 4tated he recuened a transfer w.- cut of ' RANKS' crew, and the following week h[was transferru :: another crew. l r .-r -_,--..--.-m. -n,.,- ,4,-.,.._- -,,,--,,,v.-,_
6 1 Review of Traveler Packaoe for BG04C03 I Or. October 26, 1982, the traveler package for pipe hangergE'400 was revie,ted by 1:RC Investigators H. B. GRIFFIN and D. D. DRISKILL at the Daniel Interna-tional document vault at Wolf Creek. The traveler documented that the original fit-up on welds '5' and '6' for original piece f2 were broken and rewelded on March 16,1961. The traveler listed' _ las the welder, and was ( 1 initialed 'WF" (0111e Woodrow FRANKS) 5Uhe /m_ployee making the entry. The traveler also documented that welds '5, and '6' were inspected for fit-up by QC Inspector Steve PRICE on March 17, 1981, with{______,jlistedasthewelder. The package ~further documented that these same welds were accepted by QC Inspector Ed SHEVLIN on March 19, 1981. A copy of the treveler package is included with this report aJ Attachment (4). 4 e 6 6
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. x. ~...:.-...... 7 Review of Foreman's Daily Time Cards for Daniel Ir. terr.aticnal On October 29, 1982, NRC Investigators D. D. DR'ISKILL and H. B. GRIFFlfi i requested from Daniel International the foreman's daily time cards for pipe-fitter crew PF-04 (identified as the crew assigned to the area where the t counterfeit hanger was installed) from March 10 through March 19, 1981, and for PF-19 (another crew under Fred EASON4 supra) for the dates of March 16 and March 19, 1981. The documents requested were unavailable for review because they were locked in a trailer that was being moved on the site. Carl PARRYj a KG&E representative, stated he would obtain the requested time cards when the trailer was available, and he would forward these time cards to NRC Region IV, Office of Investigations Field Office. During the week beginning November 1, 1982, the time cards requested from DI were received by Region IV, Office of Investigations Field Office, from PARR 3 A review of the foreman's daily time cards showed that on March 14, 1981, Fred EA50';,:es the foreman of PF-04. The time cards reflected that Ollie FRANKS 'became the new foreman for PF-04 on March 16,19E1.', The foreman's daily time cards also showed that Fred EASON was' transferred as the new foreman of PF-19 on 4' arch 16,1981, Copies of these time cards are included in this report as Attachment (5). 9 0 0
P Review of Personnel Records i On December. 7,1982, Steven FOLLICK, DI Perstr.nti Supervisor in Charge of Craft Hiring', was interviewed at his office by NRC Investigators R. K. HERR and H. B. GRIFFIN at Wolf Creek. EOLLICK.eviewed the personnel files en Fred EASON, Ollie FRANKS and Maxie PHILLIPS. FOLLICK stated the personnel ' files of DI documented that EASON had been promoted to general foreman on s April 6,1981, and was, _._,_,___...j FOLLICKstatedEASON'S ile contained no current address for him.-and his ~ whereab' outs are presently unknown. (Attempts to locate EASON through Burlington, Kansas, United States Post Office, during a previous investigation in May 1981, disclosed that E,ASON did not provide a forwarcing address to the local United States Postal Service.) Past and current ef'.rts to locate EASON, through personnel records and interviews of former supervisors and co-workers were unproductive. FO' LICK)said that FRANKS' personnel file showed he was hired on May 27, 1980, arid promoted to foreman ~ on 5eptember 22,19S0, t'0LLICK stated the DI personnel files did not reflect the date EASONj!nd [ RANKS exchanged foreman's positions. ~ FOLLICK said the DI personnel files reflected that PHILLIPS was hired as a ~ generaf foreman on April 13,1981k and is presently occupying that position. + .e 7 _y .__-y ,+- -.,.- -,
~".** c 6;, FeceiptofSuspectedCounterfeitPiece#2of[tBG04C033bythef;RC 4 /k / On December 7,1982, fiRC Investigators K. K. HERR and H. B. GF.lFFIli requested that KG&E and Daniel International arrange for the suspected counterfeit piece #2 of 04C03kberemovedfromthehanger. Piece f2 was removed and provided to the NRC. The suspect piece is being retained in the NRC, Office of Investigations Field Office, Region IV, evidence vault. e t .s==*
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D 10 Interview of Lenneth "Waldo" MORGAfi On December 7,1,982, Kenneth MORGkty the, acting forenan of the D1 pipe hanger fabrication shop was intervieized by NRC Investigators R. K. HERR and y H. B. GRIFFIK at Wolf Creek. tj0RGAfiwasshownthepieceofI-beam (counterfeit piece #2) recoved from hanger 04C53 at the direction of the NRC, and was asked to consent on the numbers stamped on it. Af ter examining counterfeit piece #26 MORGAN stated he was familiar with stamping procedures and dies used at the fab shop, and it was his belief that the 'B' in BG04 was not a statnp used by the fab shop. MORGAN iaid the 'B' appeared to have been made using a combinatic1 of a '1' and a '3'. He also stated the '4' was not a fab shop stamp, anc appeared to have been made with a stamped '1' with the rest of the number etched. MORGA) said that when new material was brought to the site, it first went to the northwest lay-down yard, and then was brought to the hanger fab shop. He said heat nurbers were transferred to the various pieces as they were# cut for the hangers. M0RGAtl provided a shop release form with hanger numbe 04CO33f Attachment (E), documenting the completion and release of a number of pipe hangers fror :ne DI pipe hancer fab shop including 04C033[MORGAfiamphasized he did not believe the heat or hanger numbers stamped on the counterfeit piece #2 were stamped at the fab shop. O f 9 e m
11 Review of Field Recuisit+cr. k' eld liaterial Records t, j On Decerber 8,1982, cc.;iu of weld materici fic1d requisition docur,ents, Attachments (7), (8) enc (9), used in the insta11ttion of piece f2 of G04C03 + were received by NRC Investigators H. 8. GRIFFil; and R. K. HERR from Daniel International at Wolf Creek. These requisitions did not specify the exact date and time the raterial was picke up and/or returned. The documents did show that weld material forkG04C033 as received b( i( ,, supra). The individual field requisition orders also reflected the eligible dates that the, weld material could be used, the amounts of welding material which could be received, and the dates when the weld material requisition expired. Field Requisition, serial number 135157, 4ttachment (7), showed that sometime after 1:00 p.m. on March 13,1981k '; received 5poundsofE7018(weldmateriel normally used to weld this type of hanger) weld rc.d that was scheduled to expire on March 15, 1981, at 1:00 p.m. This requisition documented returned 3 pounds of weld rod material before the expiration date. Field Requisition, serial number 135159,jttachment (E), showed that sometime after 16, 1981 ( .j 6:00 p.m. on March received E pounds of E7018 weld rod which expired on March 18,1981, at 6:00 d.m., and also documented the returned of 4 pcur.cs of veid rod titerial before the expiraticr. date. Field Requisitio.,
- j serial, number, 133694, Attachment (9), showed that after 6
- 00 a.m. on March IE,,
l C:C0(a.rt., aN also documented the returned of 2 pounds of wel 198) received 5 pounds of E7018 which expired on March 20, 1981, at before the ey;iration date. INVESTIGATOR'S NOTE: These records coincide with the dates the counterfeit piece !2 was installed.
12 Interview of Steven PRIC On December S. 3PL2,4teven PRICE a QC nicchanical welding inspector for Daniel Internationi, was interviewed by hRC Investigators R. K. HERR and H. B. GRIFFIN PRICE kas shown the traveler for BG04C033fand he conf at Wolf Creet. bore his signature f ar the fit-up inspection, dab March 17, 1981.. PRICE said that at that time he was a level-I QC inspector working under the direction of Ed SHEVLIN,. a level-p QC inspector. He said they inspected the welds on piece #2 o'f AG04C033)together. PRICE, stated he inspected and accepted the welds, and 1Yitialed the traveler. PRICE said $HEVLIP) also signed off on the fit-up portion of the traveler. PRICE ktated that at that time. QC inspectors were required to checked the heat numbers on hangers against the bill of material. PRICE, stated that if the heat or hanger numbers had been incorrect, he would not have " bought-off" the hanger. PRICE was shown, the counterfeit piece f2, and asked to examine the heat and hanger numbers. PRICE stated the stag numbers cr. ccunterfeit piece #2 looked somewhat suspicious, and he com.ented, "I missed it." , PRICE 2xplained that if he had had suspicions of an improperly starped r.u.ber, hc would have made inquiries about the numbers. ~ PRICE stated he knew Ollie FRANKS and respected his work. PRICE,said FPANKS
- eas a conscie ticus employee, and to his knowledge QC inspectors had n
- t had r.
difficulty with (RANKS trying to slip things by them. em 0 0 4 k
~ ~ _ _ _. _. -. 13 1 Interview of \\dward SHEVL1h 1 On Decenhr 9,19S2, Edward SHEVL1,N, a 01 welding inspector, was interviewed by NRC Investigators R. K. HERR and H. B. GRIFFIN at the NRC office at Wolf Creek. SHEVLIN' stated he presently worked as a :nonquality inspectos,, but that during 1981, he had worked as a QC raechanical wiiding level Il inspector, When BHEVLIN.was shown the counterfeit piece #2, he stated he would have "no problen" with " buying off" on this particular piece. SHEVLIN confirmed the traveler reflected the hanger was taken down on March 16, 198'1, and that he (SHEVLIN) sigr.ed off on the fit-up on March 17, 1981. After being provided an ~ opportunity to look at the traveler, SHEVLIN confinned he had done the final visual inspection on the two welds on' piece'f2 ofh04C03[on March 19, 1981. SHEVLIN stated he remembered a welder named! ..'had worked on that piece. ..J q ar.d he knew had trouble with his welding, particularly his corners. SHEVLIN tolur.teere'd the opinion that FRANKS would not know ingly use scrap materia'l or falsify a traveler. 89 9 9 d
14 Ir.:erview of Yalton RICHE
- 0. Ce: ember 9,1982, Dalton RICHE, a 01 nechanical welding QC lead inspectof was irterviewed by NRC Investigators R. K. HERR and H. B. GRIFFIN at the NRC office at iloif Creet.
RICHI said hc had been an employee of 01 since. November 1978, and l bc normally ir.spected work done by hanger crews. RICHC was asked to examine the l weld control record supplement sheet for; BG04C03/^ Attachment (4), beginning with the fit-up on the original piece f2, dated March 13, 1979. RICHE stated l that as far as he could see the appropriate entries were nade for the breaking of the tacks and the fit-up. He said the proper weld rod material entries and QC inspections seemed to be documented. RICHE stated the traveler, Attachment (4), - did not reflect the substitution of the counterfeit piece #2. He said that according to the traveler, the original piece from the fab shop should have been the piece still in the hanger. RICHE stated he believed FRANKS was a foreman who abided by the rules l and procedures. He said h'e did not think (FRANKS) would knowingly fabricate a l counterfeit piece from scrap material. l l l e ~ 1 l f
i- ~ / f 15 / Ir.terview of g hard 500TH Cn December 9,1962; Eichard BOOTH, a D1 mechanical welding QC inspection supervisor," was interviewed by NRC Investigators R. K. HERR and H. B. GRIFFIN at the I;RCrof fice at Kolf Creek. BOOTH stated he had been employed by DI as a 0C s ~ inspector sirce 157p BOOTH kas asked to examine the traveler forh04C03f Attachment (4), and coment on the entries made by QC inspectors. BOOTH said the fit-up on March 13, 1979, seemed,te be properly recorded. $00T$statedthat ir,his opinion, the breaking of the tacks on March 16, 1531, was correctly reported, and the follow-up QC inspection by FRIC8 and SHEVLIN was propeQy reflected. BOOTH stated the traveler did not' reflect tiie subit'i'tution of a new piece of I-bein for the original piece #2. BOOTH stated he believed FRANKS was a conscientious foreman, althou.gh he pushed 'his t$n for greater production. IBOOTH said he did not think FRANKS would knowingly violgteprocedares. r = 99 ya-v l q E a ^ r /;- s, / +, d' ,e s 6 e O )
~ = _ _ _. _ _ 16 Interview of Ollie FRANKS, On Decerr.ber 6,19E2, Ollie FRANKS, a DI foreman, was interviewed by NRC } Investigators R. K. HERR and H. B. GRIFFIN at Nolf Creek. FRANKS executed a signed sworn statetent, Attachment (10). If,ANK)statedhewashiredbyDIat Wolf Creet in '19,80/ and was later promoted to foreman of a piping x-ray crew. FRANKS, said ir2. arch of 1981, his superintendent. Harold MC INNIS, told him he t was going to be transferred from his pipe x-ray crew to a hanger" crew. FRANKS ~ said he was to replace a foreman identified as Fred EA50ff, and that EA50NAas going to assume his duties as foreman of the x-ray crew. FRANKS said he told MC INNIS he did not know anything about hangers, but MC INNIS told him, "you'll l'arn." '(RANKS stated that on March 14,1981. EA50tf a'nd he got together to e familiarize each other with their new jobs. FRANKS stated EASON told him he had scheduled about a weeks worth of work for the p'ipe hancer cr'ew. FRANKS said he took over as foreman of PF04 on March 16, 1981, DANK)s}atedhis on piece i2 of hanger G04C03\\intheauxiliarhuilding. FRANK 3lwere workin personal work records showed that on that dPte ' stated the next time he became aware of t is piece was on December 7,1982, when he learned that the NRC was having the piece re sved. FRANK $' stated he had never fabricated a hanger from scrap material, and had never knowingly falsified a traveler. QRANKS,ephasized he did not tell anyone to it.bricate counterfeit piece #2 of
- pC037from scrap material, nor did he tell anybody to transfer heat or hanger nurbers onto a new piece.
ERANKS stated he remembered that sometime during the surrrner of 1981, an individual, wt.ose name he could not remember, told him there was a hanger that had not been installed properly. FRANKS said he told his superint,endent (MC INNIS) about the information he had heard.' FRANKS saidMC INNIS, told him not to worry ar.d that an investigation was being conduc'ted, and if tMere was an improper hanger, it would be found.
4 17 L~ Interview ot Mtxie PHILLIPS i Dr. December E,1982, Maxie PHILLIP'S, a DI pipe' hanger general foreman, was interviewed by NRC Inves'tigators R. K. !! EPA and H.~ B. GRIFFIN at Wolf Creek. I PHILLIPS' ext:cted a signed, sworn statement, Attachment (11). PHILLIPS stated that or. April 13, 1981, he was hired b) DI as a pipe hanger general ' foreman, ~ and he h' d four crews working under him, including b111e FRANKS,' crew. a PHILLIPS stated he remembered that during the sumer of 1981. FRANKS and a welder on his crew by the name ofb ' had an argument. PHILLIP) stated he remembered the argument, but did not remember what it was abo,ut or whether he talkedto(- )about the problem. PHILLIPj stated { !did not tell him 'l m about a ba'd hange'r, and further stated he did not remeber talking toS j-un about FRANKS reporting to him t e existence of a bad hanger. fHILLIPS'said he only remembered that(. --.,ll FRANKS telling him about any bad hangers requested a transfer out of FRANKS! crew. PHILLIPS stated he did not reca and f that he [.ad not heard anything about bad hangers since XASON.A previous DI foreman,i ~ 4 -.__._.. 7_ PHILLIPS stated that on December 7,1982, a KG&E employee asked him for directions to hangerkO4C033bndhetoldoneofhiscrewmemberstodirect the KG&E' employee to the hanger. After the removal of the hanger piece in question, Phi'. LIPS examined the pim, and said he did not believe the heat ~ numbers on the piece were stamped by the authorized fab shop personnel. 2 W ) .f l i ? 6 .--,-.,-.,.,y ..,,.w., ,.,,..,,-7,-%.-,,_ ....,,,y7,.,.-
IS Interview of(Harold MC INNIS On Decerr.ber 9,1982,' Harold MC INNIS, 5 pipe hanger superintendent for DI was interviewed by NRC Investigators R. k.' HERR and H. B. GRIFFIN at the NRC office at Wolf Creek. MC INNIS stated that during 1982, he was the superintendent over a' number of crews in both the pipe and the hanger sections. MC INNIS was asked about a statement made by on,e of his foremen (FRANKS) concerning his lack of knowledge of hangers. MCINNIS>acknowledgedthatFRANKSlmadeacommentto him to that effect, and he said he told FRANKSp "yes, but you'll learn." ~ MC INNIS.was asked if FRANKS 'had ever mentioned to him of hearing talk about an impropedy installed hanger. Vic INNIS stated he did not remember any such conversation. MC.INNIS stated that he did not have any knowledge of the exis-s tence of a counterfeit hanger at Wolf Creek since the incident involving ( 't fabrication of a counterfeft hanger in 1981.f . MC INNI4 'was asked if he knew about any KG&E comitment for a follow-up inspection after the counterfeit hanger in 1981, and he stated "yes," he had been asked by DI to assemb,le a list that identified all hangers that had beeninstalledduringtheperiod( was the foreman for PF04. 'N ~/ 6 i 4 r l l } l {
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19 F.cinterview of Ollie FRANKS l On December 5,1982, Ollie FRANKS,,a D1 foreman of PF04p was reinterviewed by NP.C Investigators R. K. HERR and H. B. GRIFFIN at the htC office at Wolf Creek. After ' FRANKS was shown a copy of the weld control record supplement sheet for C033%ttachment 4), he confirmed he had written the inscription " fit-up broken and reverified incorrect gap" adjacent to each of the original QC fit-up inspections for welds 5 and 6 on piece #2. He stated he had initiated and dated the entry March 16, 1981. FRANKS said he later crossed out this entry because he had signed on the wrong' lines. He said he initialed and dated the corrections on March 17, 1981, and rewrote the above inscription on the_ proper line op the traveler. When asked what instructions he gave to ' fter t' hey had removed the original piece f2 from the hMger, F' RANKS a stated'he instructed ther. to try and correct the g:p by allowing a 1/8 inch space on each side. FRAfiK5 stated he remembered being told about a problem with the piece but did not remember seeing the piece after it had been removed. 'FFJNKS said he dic net renerber anybody brincir.g the damaged piece to him, but that if they had, hc would have asked for assistance from either EASON or his lead, Joe FISHER, to determine how it should be corrected. ' FRANKS restated he ~ did not instruct c'ytody to use scrap material to replace th'e original piece, he did not tell anybody to transfer heat numbers, and he did not instruct anybody to attempt to hide any counterfeit pieces from QC inspectors. FRANKS j stated that for the first week or so after his transfer, he did not know where all of his people were working or much about the fabrication of hangers. ' FRANKS said he ofter. had to solicit help fron his lead,'FISHERj and from the past forecan,,EA50!?. O r --,--,--,-,-c., n-.,-
._ _.. a 6 20 a interview o( Joseph FISHER, On January 10, 1983,, Joseph FISHER, formerly a DI pipe-fitter at Wolf Creek and presently a pipe-fit'ter at the Callaway Nuclear Construction s'ite, Callaway County, Missouri, was interviewed by NRC Investigator H. B. GRIFFIN in ~ Columbia, Missouri. FISHER executed a signed sworn statement, which is included with this report. as Attachment (12). FISHER stated he had been employed at the Wolf Creek site from August 1980 until February 1982. FISHER said he had worked as the lead on EASONS' pipe crew (PF04)7 and was on that crew whed EA50N and FRANKS switche'd jobs. FISHER stated he recembered EASON hame around often and helped FRANKS become familiar ? with the pipe hanger crew. When FISHER.was asked whether he~ remembered an incident involving the removal of a piece of a pipe hangee in the auxiliary 'g building duri.g March of 1981, he said he recalled a welde-named,I ~ had done such a !!d job on a weld it had to be cut down. YISHER} aid ( -,'the pipe-fitter, told him the welds would not be accepted, and they would have to s do something'about it. FISHER saidl and he went and looked at the s s 4 -s s hanger, and ts toldp to try to grind the welds back down and repair them. i FISHER said f.e remem&bered they tried to repair the welds several times, but eventually it t piece of I-beam was damaged beyond repair. FISHEF}saidhedid not remer.ber.h crcered the piece recoved, but it must have beer. the foreman, FRANKS'. FISiEi stated he did remember instructin 3 to use a portoban saw to cut the piece out. FISHER said he did not remember what happened it P t thee after it was taken out, and said he v.as not involved ir the replacert'.t of the piece. FISHER stated that durin'g that time, he and another welete were sent to work in a different part of the building. 1 FISHER stated it was his opinion that FRANKS kas so unfamiliar with the procedures used for pipe hangers he, did not think he would use scrap material to repair a ten;cr. FISHER stated that when he worked for EASON, it was EASON's hatt tc use scrap inaterial on nonquality repairs. FISHER; said he worked fcr [P.'I.ong enough to know FRANKS tried to follow the rules anc proceduru. ~:D.ER.: aid that ii' FFJ):KS,did instruct anybody to use screr-material Lt.:ciieved it was donc at EASON'y direction. n8 9
D 21 Status of Investigation This investigation is CLOSED. O e P 4 OT e O O 9 I
- a j,.., 22 't. Attachments s (1) Statement o (Confidentiality requested) 10-2E-62 _.,___ __es (2) Confidenticlity Agreement i r 10-26-82 _i._ / c (3) Statement of 12-03-82 L. ~ (4) Traveler package for BG04C033 10-28-82 (5) Foreman's Daily Time Cards for Daniel International 11-03-82 (6) Daniel International Pipe Hanger, Fabrication Shop 11-07-82 ReleaseFormcontaining(BG04C0331# (7) Field Requisition Weld Material Record No. 135157 12-08-82 (5) Field Requisition Weld Material Record No. 135159 12-03-82 I (F) Field Requisition 1: eld Material Record No. 133694 12-08-82 'K) StatementoiCilieWoodrowFRANKS 12-OS-82 ~~ (11) Statement of Maxie PHILLIPS 12-08-82 [ (12) Statement ofiTobert FISHER 1-10-83 1 I l
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s DATI : ..-.v-hereby r. ale the following 3 v{untarystate..ent to Mr. D. D. pristi3 3, who has identified hirse3f to r,c to a.n Investif tter with the U. S. Nucle ar herulatory C o-n.(ic.. 3 r 61 t tt.i s st ate:nent freely with no threats or pro:.ises of reward }.tving been z.ade to rie.
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O._:. ,... _. As.n::.:. r.., ..: _.s f 1 have infc=ation that I wish tr prereide in co-didence tc the U.S. !?a:Icar Ka-rela.=y Ccrrission thr), 1 reroert an e>: press pledge cf co. fide.ntiality as a car.dition of prcreiding e.it i-do: ration tc the ir.
- will not prtreide this i.forration voluntarily to the h% withoat su-h co-didentiality being e te_ided to re.
I Jt is rf understa-ding that, c=ristant with its legt2 ebligatiens, t5s hr, b.e c=.reeine. to this cc-Jidentiality, will adhere to the fc11oeing exditic.is: (1) Tne hX will not 56e.tify me by name cr gers=al 56enti!ier in any docament, conversaticn, er c:her c:rra.::ication released to the pablic. I understand the te=. "p blic release" tc eneccAs any distribution catside of the hr with the exception of c:her pablic agencies which ray re7 aire this inferration in furtheran::e of their resp =1sibilities under law. (2) Tne hX will disel'ose mf identity within in I I c.ly to the extant ~ ~ required for the conduct of hr activities. (3) Tne hT will avoid tf..ing actions that eo 16 be re.as. ably ex.ce:ted c allo. mf identit.y to be deduced b.y :>srs=s c=tacted b.v the ir or b.v incluh-=. the i-icrnation that 1 rrc:ide in an.v.rtlic doc =ent, crue.rsatic., er c:her cca : c.caric. in rach a ra..,er as tc a.11cw rf identity to be deduced.
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l TQ Oe.as issued by C3..*T.E Ci 3EW, heari",p bCa.*ds, cr si-ilar 3egal entitics. "he 3r will at:=..y. to in c=. re of any ra h a::icas bef: e cis: losing rj 3 ~C,. :. I als: t--ders.ani 9.a es E will cor. sider ne t: hree vaived =j righ tc cc.fiden iality if 2 ake any acticas that ry be reas= ably e:pected to dis = lese rf identity. I fu ther understand tha: the ?K will e=si6e re to h:Vo wdved : f righ: :: c=fidentiality if I pretide (cr have previcr.:Oy r : Ldeii ll~dC r a.i;5.~.: a :. ;L:- V. $2. c nt:L.ic.s Yse i.!C=aticn t2: 1
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e VihCl* lli( n. b ( l. /S**-ss y g e - ~.. ), . heret v male the followino voluntery stbr.: o H. Brool.s Griffipfiht his 'icentified himself to me 65 an Investictior with the U.S. Nuclear Recula' tory Conraission. 1 make this s ta tere !.' f recly with no threats or pror.ises of reward herine been madt t t mi. ..I - I ton vm b<r pie.re 1. /4,J 92I, G//h PrNN./[f t 6renp[/elef t,. ' ew ~ > to ca+ e, u + +4 e-s-L, p fi~r~e';~e,T ~~7-beos. c# pip Acaper G c <!- g e 5 y ).t .e !ra w i ^'9 ccw faiw&& is ths -l r a a>e l4 c' ~ Ye r f4:.s ,u ger id1Ai Fi < <.' +A e ,oteee k6e e u-t ca i a, . u m h.c r __,/ icek l e. day c c e _ _. c. h,/r s, t .4 fh ^pir<e. \\ ~~m c,(;cseaect - A, .rae-t c 7,. s f 4 c c rc.y.cvec, he> u lc/ <.u -- r i-f m . c-e c
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The above mont*2onec NCR/DR has been changed, s please destroy your old copies and replace with the .i one(s) attached. The' changed concerned: h_Shn M. Pn//22 7h DF /1'EIb hfFMIS A/Ef'#DY ,' /s;ps7xrA/ nA/ f)F An PPO A A/FE7. /DDF/) /AsADif ' ~ e. j j_f ///rf/27/tv/ To Dff27$ CA/13A SO503Mffr i e 92. r* s *'W. ? // A ,~7-j.rDA M f): /: r.$r. l l i I i i h-r.*.'*"~* p-Q ' tu n. sir 9 E ri 9,l J~ CU.rL', Y CONIEO'-- _ DOCU!.'.gui SECTION /. / ldil7~ n.h Y J - 7_fL. \\ // ft ~ D..c t.:(.ptitic : * 'einntgN S ~/ 2.-E{ e-c,.ange g, pc,, e 4ts y-f a r.c
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-t h e. heuv9ers. M hand.critte./.:p;af peces. y2ve re25 the foregoing state: ent censisting of .-2et rade and initialed any necessary cene ticas an5 hve siened r.f rarre in I r.? car e.s; the foreg:ir.; t r.rc.: is true i ir. he rz.: gir. cf ca:h p;e. a,i c: n e:.. Signed on /- /6 - P 3 a*. 9 *.IfA. h hd '~ SIG U.TJ.7 ,19 f3, Siscribed and Ecrn to 9. fore sie at 77(p, this /of LDay of 7.,.,
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= 1 - c. 4 1 c.., U.S. !;?;t. ~ gf3 W!!23 g;f. g' JUN 2 3 1983 ET[D:(y gnu, SIGC;.';;/ TIELycryfJ.T!f0lp' ~ In Reply Refer To: Docket: 50-482/83-18 .c Sil. f i; c.? n ~ kl Kansas Gas and Electric Company (GlennL.toester) Nuclear ATTN: Vice Pmsident - P. 0. Box 208 Wichita, Kansas 67201 Gentlemen: This refers to the investigation conducted by Messrs. Griffin, Driskill and Herr of the NRC Office of Investigations. Region IV Field Office during the period November 30,1982-January 14,1983, of activities authorized by NRC Construction Pemit CPPR 147 for the Wolf Creek Generating Station. This investigation was conducted to detemine.if untrr.eeable, nonquality material was substituted in a safety-mlated pipe hanger at the direction of the contractor's superd sory personnel. The investigation consisted 'k of selective examination o/ procedums and mpresentative records, interviews with personnel, and observations by the investigators. \\ During this investigation, it was found that certain of your activities were in violation of MRC requirements, ennearp=atly, you are required to i in accordance with the provisions l respor.d to this violation, in writing,f Practice," Part 2, Title 10, Code of Section 2.201 of the NRC's " Rules o of Fedcral Regulations. Your response should be based on the specific: contained in the Notice of Violation enclosed with this letter. In addition, your response should address the following items specifically: 4 Has hanger 8G04-C033 been reworked with traceable n:sitrit.17 Was hanger BG04-C033 reinspected in the sumer of 1981 following I identification of another counterfeit hanger? If it was, please explain why its degraded condition was not identified by that inspection. I \\ Has KG&E assund thet no other hangers in safety-mlated systems have been degraded by improper material substitution? !Lm4 c=.r 1 ? \\ i 'O E 4 ;p t.s si n ~ ? y w -W.B.P5 - C,,[,3,P,B,2,,,,, ,,,,,,, y,$P,g,P,b,j,S,,.7g,,,,, I e'"hl.WJohra.cn/.dj.WSe1.d1U.l3/ 8.......... 6 /.W.83.......... 6.0.7483........ AGa.gli.ardo.g..E4abnson...... walt. .. i.
,y Kansas Gas and Electric Company : In accordance with 10 CFR 2.790(a), a copy of this letter and the enclosures will be placed in the NRC Public Document Room unless you notify this office, by telephone, within 10 des of the date of this letter, and submit written application to withhold information contained herein within 30 days of the date of this letter. Such application must be consistent with the requirements of 2.790(b)(1). The response directed by this letter and the accompanying Notice is not i subject to the clearance procedures of the Office of Management and Budget as required by the Paperwork Reduction Action of 1980, PL 96-511. Should you have any questions concerning this investigation, we will be pleased to discuss them with you. Sincerely, = original S!gned byt
- w. C.' Sciot.E
W..C. Seidle, Chief Reactor Project Branch 2
Enclosures:
1. Appendix A - Notice of Violation 2. Appendix B - NRC Investigation Report Cover Page and Sumary Case Number 4-82-018 bectoDMB(IE01) bec distrib. by RIV: P.PB1 Resident Inspector RPB2 SectionChief(RPS-C) TPB J. Collins, RA C. Wisner, PA0 E. Johnson R. Herr, OI MIS SYSTEM RIV File Myron Karnan, ELD, MNBB (2) KANSAS STATE DEPT. HEALTH r 4 i c " " 4... ..............L q.- DATE f, .................,,,i.,
n. ,y .A ~ \\ APPENDIX A NOTICE OF VIOLATION g Kansas Gas and Electric Company Docket: 50-482/83-18 Wolf Creek Generating Station Permit: CPPR 147 Based on the results of an NRC investigation conducted during the period of November 30, 1982-January 14, 1983, and in accordance with the NRC Enforcement Policy (10 CFR Part 2, Appendix C), 47 FR.,9987, dated March 9,1982, the following violation was identified: Improper Substitution of Material in Safety-Related Pipe Hanger 10 CFR 50, Appendix B, Criterion VIII requires that, " Measures shall be established for the identification and control of materials, parts, and components, including partially fabricated assemblies. These measures shall assure that identification of the item is maintained by heat number, part number, serial number, or other appropriate means, either on the item or on records traceable to the item, as required throughout fabrication, erection, installation, and use of the item. These identification and control measures shall be designed to prevent the use of incorrect or defective material, parts, and components." Contrary to the above Piece 2 of Hanger BG04-C033 was removed on March 16-17, 1981, and replaced with scrap material which had been stamped with a heat number and hanger number to duplicate the numbers on the original piece. This is a Severity Level IV Violation. (Supplcment II) (482/8318-01) Pursuant to the provisions of 10 CFR 2.201, Kansas Gas and Electric Compan'y is hereby required to submit to this office, within 30 days of the date of this Notice, a written statement or explanation in reply, in,cluding: (1) the corrective steps which have been taken and the results achieved; (2) correc-tive steps which will be taken to avoid further violations; and (3) the date when full compliance will be achieved. Consideration may be given to extend-ing your response time for good cause shown. Dated: June 23. 1983 --m, --n. -,, - -,}}