ML20138G767
| ML20138G767 | |
| Person / Time | |
|---|---|
| Site: | Wolf Creek  |
| Issue date: | 01/26/1984 |
| From: | Frost W, Herr R NRC OFFICE OF INVESTIGATIONS (OI) |
| To: | |
| Shared Package | |
| ML20138G131 | List:
|
| References | |
| FOIA-84-291 Q4-84-002, Q4-84-2, NUDOCS 8512160391 | |
| Download: ML20138G767 (34) | |
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ALLEGED IMPROPER DISP 051*i104 0F DAf l FLD; - IMFis0FEh (UALITY CONTP.0L PRACTICES; AND IliTIlilDATI0h 0F QC INSPECTCR REPORT NUMBER: Q4-84-007
- 1. On December 20, 1983, the 01 Field Office, Region IV, received a telephone call frcm' Paul B. HALE} Quality Control (QC) Inspector, llolf Creek Nuclear Power Station and he made nucerous allegations concerning the Wolf Creek Nuclear Power Station. HALE! agreed to provide. documents supporting his -
technical allegation, nr.d cr Jervary 4, 1984, the 01 Field Office received documentation from/ HALE through the inail that he clainis supports his concerns. On January Id,31984, reporting investigator obtained a signed, sworn statenient frer/H ALE /concerning his alleprtions at the llolf Creek Nuclear Power Stzticn, and is identified in this report as Exhibit (20). On January 16,15U, the OI Field Office received additional docurientation frorqHALE ;thrcugh the mail concerning allegctions.
- 2. . HALE;provided the following information during his interview, utilizing
'various documents identified herein:
(6) H/LE cxrcuted a signed, sworn state::.ent, Exhibit (20), wherein he stated hi)s first concern was that in September 1983, he perforred a cicanliness inspection, both internal and external, of the loop ID piping systen located in the Pressurizer Room. During that inspectier . t defect in t; eld'No. FW51Po rqference Crav:ing f o. IM13-BB040, wr dircovered. According to HALE,: the visual dcfect that was noted in the weld was excessive penetrafion of unconsummed filler, that is conrnonly . referred to as a " melt throu5h " or " burn through." HALE stated he completed NCR No. ISN14769PW, describirp this visual defect. JH.LE expMned titt tre f CP vias dispositioned
- accept is is," with the i
backup for tLit decision being a radiograph thet ens on file with thc . Quality Contre'. (0C) deptrte:ert. ,
/ HALE stated the Nondestructive Exar.ination Report (GDE) s;hich referrec' to ttc recicgrapi. that was on file for weld hc.. Fl!512 described the radiograph as being for a weld that contained a pipe-to-elbow fit; however, in reclity, weld No. FWE12 is a pipe-to-pipe fit. :li/L E:
sitted te believed that his supervisors hcd used thc radiograph v," t different wac ii. croer to justify the dispositionire cf the fM.T;. , i llALE paid ; c r :/r
- ccyerts to ,suppvisers to hite i r.a r6ciicgrar.r. l
~
perf c n ed a '..t ! ie. Fl!512. (HA'. E) *,Oinicc' c et 0 if 1.is requests iu : nee , d.c3 <c ?ctirF t: 'i. i t ":rarvirors. 8512160391 B51107 PDR FOIA A BROSIUS84-PP1 PDR ~y- )
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% t/.L l's Oud ity / m r. i ce (0A) Superviso",' Ec' SPEYl /fi. l./.LE explainec tia . or. f.c vu t tr H . } c83. iSHEVLA!C told hiri .(H/ LL) ti:(1 f.e v.cs to cu grLie eith construction and tivt hc Bl;LYLAb) t cuid t.ct have at yucc wori t.i .h hir the ret '.d +* crrrr ate. e (plQ said 191 he wcs ii..inidated by t).is convertri cn i.e.d thtt hc wi.c w gr.yer i crieri d
his 6t, ties as a'QA inspector). HALE itatcc tc tFct,-resigned his ' position, witn L I cn Lecerober 23',~ 1983.
'(c) hiALL)rtriti re his third conccrn involved 114 tcchr.ical issue of -
the quenchirs of stainless steel welds witt _ wrter, chitt. '.e hit was imprope r. The velds in geestion are 1) IM03-BE0700ZECR-17hK308, . 2) IM03-BG230ECR-27RW315 and 3) IV03-EC21QECR-16L'012A, and are identified in this report in Exhibits (1), (2) and (3). (d) HALE expleir.cd his fourth concern dealt with potential QA s problems.' l HALE stated written QA problems should have been directed tc Ovality Engineering for a response fron. the QC group, but were short circuited by.D Supervisor, Richard BOOTH./ According to HALE. . as a result of(B00TH' decision to short circuit these requests', potential QC problems, identified in this report in Exhibits (4-9), were never addressed by a qualified QC engineer. t
, (e) kHALEIstated his fifth concern again involvedl DI Supervisor B001h.
HALE [statect he prepared a Surveilla e Report, as required by APVI14 that was_ closed-out by Richard E00TH with a messaae, "See attachcc r.cmo." ~ (HALE'pxplained[that tris of answer ty violated proteceu , identified in this report in Exhibit: (10-11 ) . vcrdersp)cols(f)(llALErtiatedhissixthconernrelatestoanincidentinwhic ere cut in half Frier to inspections by Quality Control . ; HAL said he felt that the traceability of metals vis lor.t because these spools were cut in half prior to inspection, identified in this repert in Exhibit (13).
~
(g)IHALF) stat-ed his stventh concern was the way that cht.r.rrs tc the ~ NDE tags cn site were processed. ) l his processing h h
,was handled violated AP-V1-05, whi(HALE fe t t at t e way tch is a procedure that subcontracters, and is identified in this report in Exhibit (14).
(F)[H/4LE'remarkedhiseighthccr. terr,wasaprcbiemwithgenw;cffp , vercris, and is ioentificd in this report in Exhibit (IE). . l 1 (i)(Half)scid his rinth concern relates to the inpropu cocuraenta . ion involvinc the heat number on a piece of traceable actgl ic Le s.ticec ; to a valvo. HALE' felt thr.t(Supervisor Richard BOOTH.cid not acequately 1 handle this d6cDnentation, and is identified in this report in Exhibit (16). (; , jn_Ef..' :ted crt hir. f or.th ccrcern~ involved the ese cf srcil e,r.nger pcrts '(6,; pins inc ccr; ice' t cchers). f HALE' felt thet theso r u t.cre i
. s- .m tccc v e r r cr i ith procedural rccjira ent s , t c ii n e..c,f 4ct c -t ir E7hi!;it! l ' ' ' ; t4 (ll'.
. s Oj i m t S t e n t- r. i t tit w ith ca tor c c.-li wit h t;ct.cc:;f t rr ,_ N at Nr. . Ml:lP865p. This NCR wPs vcidc( tu tusc it wcs f eit thct this ir; ci a; tcz .t eyone the r.oric.al sce; e cf t r,rality inspector's activity. H/L E f cit ti ct it.e disp'esiticr.ir.c of ar, NCL ir, t hir ecy ur.s ir.r i n.C i t ico.tificc in this rgen i'i E; tiL' t r ("'-?? ) . (1) f H/.H".scid his twelf th concern dcsit with the problen of using ccrreetino ribbon on a typcuriter to n.ake corrections on
'i,encuniorn.ance Reperti . 1:itLC felt that this practice did t ct r;cti
. procedures, tr.d is ic'entified in this repcrt in E> hibit (22). -
(m) HALE' remarked his thirteenth concern dealt with the inaproper use of Surveillance Reports. \ f/.LE l ) felt that improper use of Surveillance Reports ucs a generic problen at Wolf Crect, and is identified in this report in Exhibits (23-E5). (n)! MALE)statedhisfourteer generic technical probles. gth Halegncern said theseinvolves a wide problems range on are decisions made on technical items that he (HALE)> does not agree with, and are - identifiedinthisreportinExhib'its(26-37). (o)(HAllstatedhisfifteenthconcernrelatestoanincidentwherehC Inspector, David FLOWERS, tias called to do a firlal inspection in the reactorfuelpoolonapl)ateweldedtoawall.Q: ALE) explained!FLOWERSr could find no trcce of a heat number on this iten,'ar.c retescd to' sign
- FL0llERS' repervisor, T.o.:.the
'J
- Dalton final In pecticn RICHE Rcport.
ft.lsified - According final Inspection to(HALE,'(by verii'ying a heat Re' ports
- % umber that id, in fact, r.ot exist, and is identified ir. thir report inEghibit(38).
/
- 3. Or. Anuary 9,1984, thc 01 field Office contacted (Willier Scott SCHUL'.,
Resident Sjte Inspector, llolf Creek Huclear Power Statior.. ( SCHUID was advised of 0JALE'S) allegation concerning,the radiegraph involved of weld No. FW512. At OI's rcquest, SCHUM ', requested a ncw rac'iceraph be tat:en of weld !?o. Fl:512. ' On Janu(sry 16,.1984, SCFUI'Ac* ired O! that a .. rew rtdiograph of weld No. FW512 had been taker (, arid cu ; ered tc the original radiograph on file. [5 CHUM said a comparison revcaled that the two radiographs did, ir, fcct,
%tch and that the cricirtl rr.dibgraph of weld No. FL512 was authentic. SCHLM explained that a review cf the f4E reicrt revcF?cd .
that an error nisted on the report showing that the recicsicib ret " for a pipe-to-elbcw wcic, when in reality, weld No. FPE12 it a reld irvolving'a pipe-to-pipe fit. SCHUF. advised 01 that tc vas satisfied that the dispositienir.g of the hCR had been handled properly tr# that
.rc signs of wrong doing existed. SCHUN clso advised OI that DI had decided to replace weld No. FW512, even though they had deterr.ined that there was not a probiet with the weld. SCHUM remarkcd tttt DI Jecided te rcrirce the veeld to avoid eny future custicr.5 ccncerning the soundness of veld f;o. TUS~2.
- t. v.4 : re g rt it. p to ccc to Regier n w. te. hr.icM < t r im -ic-
. The OI, Vfice . e p e r n p t'a e:b.p .icri ci it.tn .* i ' '- ; o 1 r .
3
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4
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(U.tO. acia s itic 01 ice hqcr; c, i rc . s . l.r.* ft r T-c . 4 -El-C.:0.
. If techrical evaluetier, irrticularly ccncerns icentificc ir. Exhit,it (15),
.by Eti i'cr. IV tre the rer..ainder cijHALE'5)tetia.icr1 crrcerns results in suspected wrene dcir.9, ther., _ upoc request, the 01 F.icic Of fict trill inititte trprc p utt. action.
EXHIBIT 5 (3) Interoffice l'emorandun. 5-26-83 (2) 'Inttroffice Memorandun 6-05-t3 - (I.) Interoffice Memorandur. 7-01-03 (t. ) Three-Part Memorandum 9-23-63 (0) Thr'ee-Part Memorandum 4-09-83 (6'- Three-Part Memorancum 8-05-63 (7 Three-Part Memorandum 8-06-03 (8 Three-Part Memorandun - Ref: WP-V1-200 8-08-83
- . (9) Three-Part Memoranc;um - Ref: WP-V1-200 8-08-83 (10 Three-Part Memorandum - Ref: WP-V1-200 8-08-83 (11 Quality Surveillance Report 8-05-83 -
(12 Quality Surveillance Report 8-08-83
. (13 Quality Surveillance Report. 11-11-83 (14) Report Entitled: " Processing of NDE Reports" 11-14-83 (15) Six-Page Document Entitled: " Generic References" Undated Personal No.tes of Paul B. HALE) Undated (16) Quality Surveille e. Report No. SR-601-N 10-23-83 (17) Undated (16)- Personal Notes of Paul B. HALE (concernin QualitySurveillanceReportNc).SR-601-M)g (19) Nonconformance Report No. ISN12865P 8-25-83 (20l Signed, Swern Statement ofgALE' 1-10-84
_ (21; Interoffice Memorandum 6-20-83 (72) Interoffice Menorandur. s 7- 4-03 (23) Persontl- Notes ofj Paul B. HALE; - Undated (concerning problems) (24) Quality Surveillance Report. 12-15-83 (25) Quality Surveillcr.cc Report. 5-22-83 .. (26 Interoffice !!cncrerder' 8-14-83
-(27 Interoffice Memorandum 11-25-83 (28 QC Memorandum s 7-22-82
- (29}-QCMemorandumfromh7.TUl!ELtoMcRANEY/
7-13-82 (%) I;cr.orcr.derr fron(RHEA to McCRANEY 7-13-02 7-16-82 (31) Hemorandum . (32) Mcmcrandem ) 7-26-82 ' (33) Memoranduo to (J. AYRE 7: 7-26-82 (
Reference:
QCF7500, N.ra. a.4) (34) Metrorandum to(J. AYRES! 7-26-82 (
Reference:
QCP7500,Pera.4.6) (35) Interoffice Memorandum ' 6-11-82 (36) Interoffice Ecr:crtrdum 6-19-82 (37) Interof fice Merncrcndum 10-21-80 4
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. . 1 (N' J r,t e rr" ice !!ri c + . , .r ~. L-U-J (391 Porscrrl Fr tv i. ei, Paul L. HALE Undatec i j .
n REPORTED BY: . AAp_
.Wendel E. Frost, Inves'tigator O! Cicid Of1 ice APPROVED BY: /// A Richa*cf K. Her'r~, Director 01 Field Office cc: W. J. Ward, HQ:DF0 w/ettachments
- E. C. Gilbert, HQiDF0 w/ attachments -
'J. T. Collins, RIV w/ attachments T. E. Westerman, RIV w/ attachments V
O OW N O O d
+
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___ n- INT E R.O F FIC E COM M UNIC ATION poem 3 4,99 (Ste.. E FS) To: DM Keith Hollingsworth, PWE May 26, 1983 - FROM: David Mauldin, PQE FG y 27~i
SUBJECT:
Quenching of Stainless St el .
Dear Keith,
A potential problem in regard to the referenced subject was recently brought to my attention which warrants further evaluation. Quality Surveillance Report #SR-437H was initiated to document Craft Per-sonnel observed applying a saturated cloth to a stainless field weld for presumably " quenching" purposes. The Inspector noted that Wolf Creek
. construction procedures do not presently address this process.
Your s'ubsequent response indicated that this method of controlling distor-tion _and metallurgical damage was standard recommended practice and did not viclate code and/or procedural criteria. I agree on both counts but To further support my position, please make reference to B, Criterion IX which states in part:
" including Measureswelding. shall be established to assure that special proces ses,
. .are:
using qualified procedures. . . ." controlled; and accomplished. . . .. Based on the above noted quotation, in co'njunction with standard Nuclear Quality Assurance Program requirements, I strongly suggest that quenching of stainless steel field welds-be performed in accordance with an approved site procedure which addresses the following minimum parameters. 1.
- 2. Type ofquality Water application (i.e., cloth, soak, etc.).
criteria. ' 3.
- 4. Time of application (icunediateW following weld coi.pletion?)
Minicium duration of time required to complete the process. I am confident that your further investigation and subsequent evaluation will result in compliance with my suggestions. If you feel that present site feel procedures free to present and practices adequately address this situation, please your justification. Your usual cooperation is appreciated in this matter. YoursTruly,(. S' C.D. Hauldin [$1, Project Quality Engineer
,f.-7/-Ogg7(D
- .qpcdMW O
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&%EiE ap T E R O F F i C E C O M M () N 1 C A T 10 N io Distnbution DATE: June 9, 1983 F R O t/ . , K. Holhngsworth PWE #619 Cooling Stainless Steel Welds
~
SURJECT In-process stainless steel welds may be cooled by applying clean noist cloths or by spraying a mist of water on the weld and adjacent base metal. Only demineralized water is to be used. Base retal and weld shall be dry prior to subsequent welding. Please make all cognizant supervision aware of this. Please feel free to arttact Welding Engineering if you have any further questions concerning this practice.
% ingsworth Keith Holl
\-
Project Welding Engineer mysVls Distribution: J. Grabusky " J. Warren A. Early C. M: Donald cc: 6 , e e
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lY 1 PROCESSING OF NDE REPORTS (PT AND MT) A. TRAVELERS - NDE WITH AN A.N.I. HOLD POINT 1T.
- 1. Craft Foreman and Lead Quality Inspector obtain traveler and pink and yellow copies of the NDE Request Tag.
- 2. Lead Quality Inspector coordinates with G.E.O. and the
-A.N.I., gives G.E.O. the yellow and pink copies of the -
NDE Request Tag. ~ 3.' G.E.O. performs NDE, completes the NDE report and NDE
- Tags and presents them to the Level II NDE Inspector.
- 4. Quality inspector reviews the NDE report for accuracy
~and completeness, then accepts the NDE report by signing it.
- 5. A.N.I. signs NDE report.
- 6. hualityinspectorenterstheNDEreportontheapplicable WCR, ECR, etc.
- 7. Quality inspector attaches the original copy of the NDE report to WCR and returns the traveler documents to the craft.
- 8. Quality inspector forwards pink copy of the NDE request tag and a copy of the NDE report to the Quality Supervisor.
(NDE)
- 9. G.E.O. retains the yellow copy of the NDE request tag and other copies of the NDE test report.
B. TRAVELERS - NO A.N.I. HOLD POINT
~
- 1. Craft Foreman routes yellow and pink copies of the NDE
_J_ request tag to G.E.O. )
- 2. G.E.O. performs NDE and completes NDE report and NDE tags. *
- 3. G.E.O. contacts craft and D.I.C. Quality.
- 4. Craft obtains applicable traveler documents. . 1 l
- 5. Level II NDE Inspector reviews the report for accuracy and completeness, then signs to indicate acceptance.
- 6. Quality Inspector enters NDE report on the applicable WCR, ECR, itc.
- 7. Quality Inspector attaches the original NDE report to the WCR and returns the traveler documents to the craft.
{}(H 0 On n-ocR 1
PROCESSING OF NDE REPORTS (PT AND MT) Page 2
- 8. Quality Inspector forwards pink copy of the NDE request tag and a copy of the NDE test report to the Quality Supervisor (NDE).
- 9. G.E.O. retains the yellow copy of the NDE request tag and other copies of the NDE report.
For those times when all the necessary personnel / documentation - are not available at the weld, the following guidelines will assure that NDE results are quickly obtained:
- 1. G.E.O. will perform the NDE (PT and MT).
~2. IL., " ' when finished, will write the results of the NDE
'57(# ,
or Reject) at the bottom of the NDE tag. 3' ~.~ G.E.O. will fill out the NDE report, then drop the NDE report & pink copy of request tag off at the QC station for the area.
- 4. Craftsmen will check the HDE tag to see whether the NDE has been done. If the results are on the tag, craftsmen }
~
will contact Quality to make arrangements for a meeting of the Inspector, the traveler, and the NDE report. This meeting should be arranged.in one of two ways: Method 1: Craftsmen take the WCR to the QC Station in the area. The Level II NDE Inspector signs the NDE report, then enters the report on the Weld Control Record. Method 2: Craftsmen contact Quality in the same manner as for a .. QC hold point. The Quality Inspector must be told the NDE tag number; as well as the traveler number, the weld number, the location, and any other necessary information. The craftsmen are then responsible to stay in the described area, with the traveler, until Quality arrives with the NDE report. Quality personnel will respond to these requests . promptly, as with any other hold point request. , C. NDE ON MISC. STRUCTURAL STEEL WELD RECORDS
- 1. Foreman routes yellow and pink copy of the NDE request tag to G.E.O.
- 2. G.E.O. performs NDE, completes NDE report and then contacts craft and D.I.C. Quality.
3, Craft obtains M.S.S.W.R.
- 4. Level II NDE Quality Inspector reviews NDE report for accuracy and completeness then indicates acceptance by signing the report.
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PROCESSING OF NDE REPORTS (PT NAD MT) Page 3 l
- 5. Quality Inspector enters NDE on M.S.S.W.R.
- 6. Quality Inspector returns craft copies of M.S.S.W.R. to craft.
- 7. Quality Inspector forwards both original and copy of the NDE report and the pink copy of the NDE request tag to _
the Quality Supervisor (NDE).
- 8. G.E.O. retains the yellow copy of the ND'E request tag and the other copies of the NDE test report.
REF: PWE: 648 pb k.9.)h gg
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GENERICS FIJERTXES ' (W",ts , CAP s} p'4 f,
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s e,*., 1 ISN742EPh- This disposition is intended to be Generic in nature. Weld inspections performed prior to April 1, 1981 which were documented by non-certified inspectors are addressed in this disposition. Situations which fall within this general description should be addressed by annotation of NCR ISN 7426 PW in the remarks section of the appropriate WOR. (This covers groove welds, full and/or partial' penetration welds.) ISN6875PW- This disposition is intended to be Generic in nature. Weld inspections perferned prior to April 1,1981 which were documented by non-certified inspecters are addressed in this disposition. Situations which fall within this general description should be addressed by annotation of NCF ISN 6875 PW in the remarks section of the appropriate WOR. (This covers fillet welds.) m
~
ISN8023PW . ~__ It has been noted that Jrn many cases the preheat has been verified , - however neither the actual temperature nor the G1 instrument number has been listed. It is recomunended that this disposition be generic _ . to accept preheat'v'erifications whefe neither the G1 instrument and/or actual temperature has been noted. This generic disposition is to in no way supercede present procedure requirements (1-14-83) . y ISN8431PW- Preheat signoff was verified, however the actual tempreature or verifi- ' cation of ambient temperature being greater that 50'F was not recorded. The inspector's initials in the preheat signoff is basis for accepting this preheat verification and weld as-is. It is also recommended that this disposition be considered generic for similar cases. Inspections are currently being performed per procedure (2-4-83) . ISN6747PW
- Welding Engineering has investigated the reason as to why the Q .
inspectors noted the fitup as M/C. It was found that at the time this weld was made, it was a conunon practice among some of the in-spectors, at the direction of their Senior Supervisor, to N/A or N/C the Iltup for repairs which d'.d not go through the root. This was based on the fact that if the root opening was not re-established there is ne fitup of the joint to perform. When the fitup signoff was N/C'd it did not indicate that no part of the fitup inspection as described in QCF-VII-200 was performed, only that joint fitup was not checked. In fact the other parts of fitup inspection were performed as evidenced by the preheat, NDE and final Q.C. acceptance being signed off. This is not a current probler.. No action required. Ref.erence ISN 6197 PW and Quality Training Report dated 10-26-82. NOTE: For similar cases on a weld repair *where fitup was N/A'd or N/C'd and all other Q.C. holds are signed an NCR need not be initiated.
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- l Gr.NERIC RI.rD. gig (N Es , CART . etc.)
page 2 i ISN7017P- Para 4.1-6E of (CF-VII-201 R/1 thru R/4 states " Inspect during ; installation of piping components, items being joined for internal and external clea .liness, as per reference 2.6(WF-VII-203) piping, components. Items not meeting cleanliness requirements shall be documented per Ref. 2.1(AP-VI-02). Sign and date remarks column of weld control record for this inspection (accept or reject) . This is no longer a requirement of the referenced procedure: Per the requirements of paragraph 4.1-6B if a cleanliness violation ~ existed an NCR was to be initiated. Therefore to note in the remarks _section that the cleanliness is rejected would have been redundant. If the cleanliness is acceptable no NCR would be written and a comment would not be required. (System ID is Generic - dated originator 11-3-82). i CARWI-P-0016- Covers lack of material traceability on Special Scope items. (unknowp disposition.)
.1 - .:
CARf1-W-0019- Coveris 'firinspection'of fillet welds made prior to April 1,1981 o'n' ~ fabricated / erected e, supports (ASME and Special Scope) . ip$4M.* t F/f-92 Letter To: ASME Travelers; From: B. Scabury and E. Cannon (ANI); Subject j 2- d.ted , ANI Hold Points; In accordance with WP-VII-209, when Travelers 12-10-80: are reviewed by the ANI, if hold points are established, 'they will be indicated at the applicable in-process step. If no hold points are } desired by the ANI, no indication is necessary. However, the ANI is to indicate his review of all ASME Travelers and subsequent - revisions to the Traveler by signing and dating the Traveler Index Sheet of each Traveler reviewed.
- An in-house procedure has since been adapted as follows: The ANI will indicate on all in-process sheets his requirements for hold points or proof of his review when he does not wish hold points established. This is also followed by procedural. requirement to sign and date the Traveler Index Sheet.
This is in-house procedure, adapted by HSB personnel, took effect in , approximately May, 1S79. . I a o k. I ! s
- , ------,e- - - . - . - . ., - , - . , ~ ,, -n.-v-- c- . - - - - - - . . _ - , , . , , , , - , - - - - ,
1 . , _. . . _ ... a . . - -- -.- - - a - 1 CESEk1C RETERE3CES (NCRs. CARS. etc.) page 3 ISN7650PW-For WCRs which have no interpass temperature signoff for velds made prior to .lanuary 15. 1982, QC to enter N/C, sign and date. No NCR is required. For welds made on or after January 15, 1982, which have no interpass temperature signoff, initiate an NCR. i REF: ISD 9335 PW i ISN8037PV-PWHT documents were not completed in accordance with CWP-500. ! ' Rather than take corrective action against the responsible
' perso.nnel, a revision to CWP-500 (R/3) has been submitted. This revi_sion deltes the requirement for documenting controller numbers, and also deletes several requirements involving unneces-sary duplication of PWHT information.
! Upon approval of this revision, it is recommended that all PWHT i documentation be evaluated for compliance with revised requirements j only. Compliance with revised requirements shall constitute justi-fication for documentation acceptance. , ~ . j CARf1-G-0025 ! Material _ traceability of bulk bolting material and bulk catalog
~ - - -
{ items'for sa'fety related~and 's~pecial scoped items is questionable ! due to a breakdown in the color coding system. The color coding system is designed to segregate safety related and non-safety related material. ISN8631PW-W100's cannot be found. The cause for entry of these incorrect ] E100 numbers cannot be determined. Docssnentation review has *
;
- encompassed thou_ sands of W100 reviews, and, occasionally, is-
{ olated instances such as these are found. Due to the nature ! of this problem (i.e., occasional craft transpositio a errors), it is recommended that, in situations where a W100 cannot be .. i located but the beat number entered is valid, a note be added to
~ the recarks section of the WCR by welding engineering. This note ,
muld document any research performed and would verify the ac-1 captability of the materials entered based on the heat number entered. , , The number of this NCR (ISN 8631 PW) will also be entered
- on the WCR to provide traceability to this disposition. Entry *
} of this note would adequately address eac'. situation, and would ' provide a ceans of documenting a sisple explanation in these sit-i untions which do not warrant an NCR. e i i 1 - l
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IC EF.FEhENCES (KCRs, CARS, etr 4
, __GE rage 4 s, ISN 7162% Incorrect weld technique us d. Use of a carbon stec1 welding technique will not adversely affect the integrity of the tag, and will provide adequate strength to hold the stainless steel data tag in place. Use of a carbon steel welding technique is ,
l acceptable on the pipe since the pipe is carbon steel. An error l was cade in the detercira tion of the base u.aterial used. Re- ' sponsibility for this error cannot be conclusively determined. In the future, all data tags will be treated as stainless steel, unless specific documentation is provided which documents use of a tag material other than stainless. Tnis disposition is generic - in nature, and provides for acceptance "as-is" of all stainless steel data tags welded to carbon steel using carbon steel welding , techniques . 1538932 % violation preheat and interpass SA515 GR. to high carbon 3/4". i Technique not qualified for the welding of PC corponents.
- Itom 1: F002 is an ASME C1c.cs NC veld which joins a cme inch .
thick, SA515 Grade 70 plate to a 3/4 inch thick, SA333 Grade 6 penetration sleeve. 10466-H-204 (par. 7.6.a.), and Section III
- of the ASME Code (Table NC-4622.3.1) require a 2000 F preheat for this weld, only when the nominal thickness of these base materials exceeda-3/4 inch. ' Nominal thickness", as defined in NC-4622.3, ' ~~
is ... the thickness of the weld, pressure retaining material ) or the thinner of the sections being joined, whichever is less." For the cited instance, the thinner of the sections joined was
) .
3/4 inch thick. The recomunendation for 'bse as is" is based on the fact that neitler the requirements of the ASME Code, nor those of 10466-M-204 have been violated. Item 2: Entry of the penetration sleeve thickness on the WCR does not constitute a nonconformance . This item is considered invalid. Item 3:
- Technique N-1-1-BA-22 is approved for use on ASHE Section III, Class I, II, and III welds., Based on these qualifications, and based on the fact that this technique is qualified in accordance with ASME Section IX, it is recomanended that N-1-1-BA-22 be con-sidered a:ceptable for use on Class NC welds.
ISN6690 % Wrong revision weld technique N-1-1-A6. Welding Technique N-1-1-A-6 was? upgraded to Rev. 9 on May 11,1981. Rev. 9 of this tech-nique was not distributed to the field,until Feb. 24, 1982
- This discrepancy in dates w- addressed in audit finding 82-01.
'. In' the future, Rev. 7 and Rtv. 8 to N-1-1-A-6 are considered ac- , ceptable for all fillet welds made prior to }'. arch 1,1982 - I (This additional week will allow for distribution to the field). a l 1 t W. -
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C E' IC EEERI;CES (tiCRs, C/.Rs, et 5 Tage 5 ' 4 gc4An % WeQ Yd- AM O'M ConP b
, 15N72151% The change which was r.ade did aiot constitute a nonconforr.ance.
j - Certain changes to docut:ents are required at documentation re-l view, in order for the documents to accurately reflect the work that was done. Changes su'ch as the one n.entioned, howevt.r, should 3 be approved by Welding Engineering. The Project Welding Eng- , ineer will issue a letter delineating changes sich nay be cade J without Welding Engineering approval. Additional action will not be required. s ISNBE24 % Ur. authorized use of eite out. Current site procedures have clarified the policy concerning the use of white out. In future cases where white out is noted during documentation review it is recor nended (upon KG&E approval of this NCR) that the use of site out on Weld Control Records and Weld Repair Instructions be evaluated by Welding Engineering. If it is determined that Wite out was not used to alter or cover pertinent data, change field entered documentation, or delete Quality verifications, Welding Engineering to initial ard date dite out and reference q this NCR. No NCR need be initiated in these cases.- . 1 - 4 ISN8676 5 -Deletions and additions made: on final Quality acceptanced WCRs. -The. original W-100 numbers entered on these WCR's were "~ determined, af ter minor investigation, to contain juxtaposition i errors, i.e., switching of two of the numbers, or substitution ' of one number for another (i.e., 't" for "8"). W100 los sheets !) j were checked to find out which'W100's had been issued to 'thst par-ticular welder on the dates in question. In each instance, the proper W100 nunber was discovered (i.e., the 4100 had the same i 1 heat number as that entered on the WCR), and it was determined that craf tsmen had made a minor transposition error. This error l was corrected by line-thru, initial, and date. This type of error is not considered sufficient to userant issue of an NCR. It is reconcended that, een juxtaposition or minor transposition errors ' such as those described are located, the error be corrected by Welding Engineering line-thru, initial, and date. In each in- - i stance, a brief explanation will be added to the connants section of the WCR, and the nu:nbea' of this NCR (ISN 8676PW) shall be { referenced. Issue of an NCR will not be required. I 1 ISN8693 % White out on NDI report. TMs nonconforstarce wa: diceussed with the GEO Project P.anager, who stated that GEO procedures do not ad- ' ! dress the use of white out on NDE reports. The use of white out ,, by GEO did not, therefore, constitute a violation of GEO pro-cedur es. This nonconforcance was caused by a conflict between { CEO and D1C procedures. Per discussion with the CEO Troject i F.anager, use of este out on NDE reports is discouraged by site l policies. Due to the fact that CEO is responsible to KG6.E rather j j thatn to DIC, it is recoceended that evaluate the situation and determins Wether action to prevent recurrence will be required. i
\
6 .+t;c, ps. h: lor den on Geo CE Re. peds, prior, b pn. W 4"
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-rx,. +ec e4 .A def e a ms. / E .A 9 /.s ce.ned,,Tre T % A d Mbht<"8-4 N IS MSIe N% edesf,'og s Cb'Ibd',f* dd.o . p.g h l
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ISN8485PW- No GI f was recorded. Interpass temperature was verified and actual temperature was indicated, however the GI instrument , number of the pyrometer used was not recorded. It is recoc: rended that this interpass verification be accepted as is. It is also
,recoc= ended that this disposition be generic for all such non-conformances.
ISN8503PW- Visual inspection block crossed NFVT accepted. These welds are ASME Section III, Class 3 socket welds which require no hTE, only visual inspection, however these welds were inspected to NF visual examination criteria. It is recoccended that these welds be accepted as is since the NF visual examination criteria is more strigent than the visual inspection criteria. It is also recorcended that this disposition be generic for all such non-conformances. . ISN9209PW-
'TF" or 'TI not annotated. All welders zaking any portion of the weld must record thef.r I.D. Number, Rod Slip Nur.ber and the
- date the welding was performed. The purpose of the welding, .
for Installation or Fabrication, is suparflous information and '- -- meed not be documented. The WCR's in subject travelers are ac-captable. WP-VII-209 will be revised accordingly. h i l 1 i l l 1 l
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