ML20198K383
| ML20198K383 | |
| Person / Time | |
|---|---|
| Site: | Comanche Peak  |
| Issue date: | 05/09/1986 |
| From: | Baker W, Frankum D BROWN & ROOT, INC. (SUBS. OF HALLIBURTON CO.) |
| To: | |
| Shared Package | |
| ML20197J316 | List:
|
| References | |
| FOIA-85-59 WEI-4.6, NUDOCS 8606040008 | |
| Download: ML20198K383 (10) | |
Text
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h PROCEDURE BROWN O T. INC. NUMBER REVISION O PAGE I
( 1 of 4 J08 35-1195 WEI-4.6 4 4/15/83 TITLE: CRIGINATOR: h[ [ah ,
' INSTRUCTION FOR REVIEWED BY$;t, ,
/
CONTROL OF WELDING d'B&RQA/QC APPROVED BY: .hj g g p,4 CONSTRUCTION PROJECT MANAGER DATE I
0.1 TABLE OF CONTENTS 110 REFERENCE i:!
2.3 P
RESPONSIBILITY ENGHEGNBUSEONI .
3.0 INSTRUCTION 3.1 CMC BLUE CARD 3.1.1 General Requirements 3.1.2 Distribution of CMC's 3.2 DESIGN REVIEW 3.3 CMC REVISIONS '
3.4 VOIDING CMC's O.11 ATTACHMENTS !
Number 1 CMC Fonn Completion ,
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F0lA-85-59 GARDE 85 ,59 PDR 5 95/r7 -
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PROCEDURE EFFECTIVE
< BROWN & ROOT, INC.
NUMBER REVISION DATE PAGE CPSES ]
( JOB #35-1195 WEI-4.6 4 4/15/83 2 of 4 1.0 REFERENCE ,
1-A CP-EP-4.6. " Field Design Change Control Procedure". j l
2.0 GENERAL l
2.1 PURPOSE The purpose of this instruction is to set forth the method by which the provisions of TUSI Procedure CP-CP-4.6 are carried out by the CPSES Welding Engineering Group. l 2.2 SCOPE 2.2.1 This instruction covers the handling of CMC's for the removal and addition of welds and material, within the boundary of the oriainal desion, for welding problems, misfabrication, or misalionment,_
For ASME Class I application the addition cf new weld joints shall '
be the responsibility of Mechanical Engineering.
2.2.2 This instruction does not cover field design changes. ,
( 2.3 RESPONSIBILITY ,
2.3.1 Where a specific individual is designated by title in this - -
instruction, it is understood that his designee can act in his official capacity.
- 2.3.2 It shall be the responstbtitty of the FWTC Supervisor to assure the implemetation of this instruction, 2.3.3 The delegation of authority to prepare and approve CMC's shall be the responsibility of the Project Welding Engineer, Authority shall be granted on the basis of each persons work performance and experience.
3.0 INSTRUCTION
, 3.1 CMC BLUE CARD i
3.1.1 General Requirements 3.1.1.1 CMC's shall be drawn from DCC by the respective Welding Engineering File Custodian.
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l BROWN & ROOT, INC.
( CPSES PROCEDURE NUMBER REVISION ISSUE DATE PAGE JOB 35-1195 WEI,4,6 4 4/15/83 3 of 4
- 3.1.1.2 Individuals requiring CMC's shall draw then on an as needed basis, from the file custodian.
3.1.1.3 The File Custodian shall maintain a log of each CMC issued. The log shall include the folbwing information:
- a. CMC serial Number
- b. Document / Drawing number affected
- c. CMC originator's initials -
- d. Date issued /or date voided not issued
- e. Date revised and revision number
- f. Date original CMC transmitted to DCC ,
3.1.1.4 CMC's shall be prepared in accordance with Attachment 1 except as delineated herein.
- a. Item C.3 - The design drawin~g number is not required for pipe support changes except in cases where changes are required to supports for which a BRH drawing has not been '
issued.
- b. Item f - This item is not required for pipe supports.
- c. Item j - This item is not required.
l 3.1.1.5 A responsible individual authorized by the Project Welding Engineer shall apporve the change. Such approval shall release the change .
for construction.
l 3.1.2 DISTRIBUTION OF CMC's CMC's shall be distributed in accordance with the distribution schedule maintained by DCC for BRP copy holders.
3.2 DESIGN REVIEW 3.2.1 The file design review and the securi,ng of any necessary original design organization and/or vendor approval shall be the responsi-bility of others.
3.2.2. CMC REVISIONS 3.2.3 The original CMC may be revised by the following procedure:
- a. The appropriate revision number shall be placed adjacent to the serial number.
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PROCEDURE EFFECTIVE BROWN & ROOT, INC.
NUMBER REVISION DATE PAGE CPSES
( JOB #35 1195 WEI-4.6 4 4/15/83 4 of 4 Changes to the CMC shall-be clearly marked with the b.
revision number and the revised area shall be ballooned.
- c. All previous revision marks shall be removed.
3.2.4 When deemed necessary because of the complexity of the change, a new CMC may be prepared depicting the required changes. The card shall contain the statement: "This CMC voids and super-sedes document number revision _ _ ".
3.3 Distribution of revised CMC's shall be in accordance with Section 3.1.2. For pipe supports CMC revisions, the File Custodian shall j enter the revision into the hanger package and remove and destroy any voided or outdated revisions. When the hanger package is not available, the entry shall be made by the Central Document Center.
3.4 VOIDING CMC's When an occasion arises where a CMC has been issued and is no longer necessary, it must be voided. To void a CMC it must be revised and
- clearly marked " VOID - NOT SUPERSEDED".
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i PROCEDURE EFFB:TIVE I BRoldt & 14007, INC. ILIM8ER REVISION DATE~
PAGE CPSES.
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J08 35-1155 .
. . WEI-4.6 4 4/15/83 1 of 3 i
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AT*Ac1DGENT 1
, CMC PORM COMFLETION i
e The Component Nodification Form (Figure 2) is completed as follows unless I
otherwise stated in engineering instructions supplementing this procedure.
The card should be filled out using a black ink pen or " dark" pencil.
- a. Serial No. - Pr - h eed, or as established through detailed application
, instructions supplementing this procedure.
- b. Section 1. Application - State generic category of work (e.g., nach-l smical equipment, electrical equipment, pipe, pipe supports, etc.).
t liald Mod., Q, Bon-Q - Check appropriate block.
t Design Change Deviatdan - Enter N/A.
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- c. Section 2. Dwg. No. - Enter the completa number and revision of the
- . . .yg. affected. design basis and/or construction drawings as follower
- 1* Electrical - I
- ster design basis drawing numbers.
- 2. Piping and Instrtamentation - Enter the design and construction drawing . numbers for all design change / deviations; and construction
- drawing numbers for construction changes.
- 3. Pipe Supports - Enter the construction drawing muabers.
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- d. Section 3, Line No./ Component No. - Enter the specific identification
, number of"the component te be modified; spool number, equipment number, 8
etc. It is not rapistad t o entar the pipe support number in block 3.
If a number of ir4n 4.rc .ffected, enter "see sketch", and show all
, changes in block 5; I
- s. Section 4, Raason for Change - State briefly, but concisely, the reason
- for the change. If to implement a change properly approved by the Original
! Designer, clearly stata this fact (e.g., to implement DE/CD 8600) .
- f. -Section 5, Instructions - Describe completely and accurately the change to l be made.
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PROCEDURE EFFECTIVE
( BROWN & ROOT, INC. MJMBER REVISION DATE PAGE O.,c . CPSES n.)h JOB 35-1195 .
. WEI-4.6 4 4/15/83 2 of 3 AT w RM NI 1 ,
Sht. 2 of 3
- 1. Where there are no welds or matarial removed or added, enter "N/A" in the appropriate blocks.
- 2. For removal and/or addition of welds and/or material, check the appropriate block and enter all weld numbers and/or Bill of Material item numbers removed and/or added. It is not =andatory to dis-position the future use and/or storage requirements for deleted material.
- 3. IDE FIFING OELY AMD INTEGRAL MANN ATPANMNfS - if, after the original issue of the BRP drawing, a weld has to be removed and revelded, the weld number will be changed to indicate same by adding an "A" for the first removal, "B" for the second removal, etc. to the veld numbers, e.g., for the weld 6, the first removal /reveld. is 6A, and if 6A requires rework, the second removal /reveld is 65.
( q 4. FOR PIPING ONLY- When stainless steel materials are reused and the heat affected sons is not removed, the new weld number will include N.,' . .
, the next sequential latter of the item with the highest numerical weld number. For example, if .he pipe between velds 7A and 8C is deleted, and the remaining parts welded together, the new weld number
'. will be 8D, g 75. In the situation where weld 6A is cut and a puo 6
installad between the two pieces, the new welds will be numbered 6B
, and 6A-1.
- 5. FOR PIPING ONLY - If, after the original issue of the BRP drawing, an added weld is required which is not a reveld of an existing veld; the .new weld will be kayed to the lower of the two numbered welds and suffixed by "-1" for the first veld, "-2" for the second weld, etc; if a weld is added between weld "3" and "4", the new weld will be "3-1".
- 6. FOR' COMPONENT SUPPORTS - For material item changes, a new item number shall be assigned to the replacement piece.
' g. Section 6 - Provide a sketch indicating the new arrangement when necessary ,
for clarification. When more than one CMC affects a drawing, care shall '
be taken to avoid conflicts between the CMC's. This block should include specifications of itene added that are not listed on the affacted drawing.
It should also show new weld locations, and all required working point
.. dimensions (cut lengths for piping and hangers are not required) .
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PROCEDURE EFFETIVE l BR0tdM & ROOT, INC, REVISION DATE PAGE
[ leJMBER f h~
- k. ;/ J08 35-1195 WEI-4.6 4 4/15/83 3 of 3
) ATIACHMIDIT 1 Sht. 3 of 3 I i
i i h. Section 7 - Originator - Enter the name of the individual preparing the modification (fcr piping changes, foreman requesting the change should j , be entered).
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! 1. Section 8 - Approved By - Spyroval shall be obtained in accordance with paragraph 2.3.3 and 3.1.1.5.
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, J. Section 9 - Distribution - If not predesignated, the Engineer / Technician preparing the QE: shall estar the name of each agency requiring an i "Ta-4==% and Office Use Only" copy and shall f arlie =te the number of
, required copine for each.
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- k. General - Extra sheets may be used where necessary to adequately cover the subject.. All sheets must be marked with the CMC serial number and
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numbered page ' of .
! . ~; 1. Bavisions to a CMC card may be accomplished by changing the criginal fora l .'..
or by utilizing a new form (non-serialized) and filline it out as outlined
! above. The following additions shall be noted on the revised CMC, as
, applicable. ,
- 1. The,same serial immber shall be used.
- 2. The appropriate revision number shall be placed adjacent to the i serial tamber.
l 3. If the reason for the revision is different from the original, enter the additional circumstances in Block 4.
l f 4. The CMC card shall contain the following statement:
l "This revision voids and supersedes document Serial Humber , Revision "
i m. When an occasion arises where a CMC has been issued and for some reason j that card is no needed, it umst be voided.
2
- 1. To void a CMC, the original card must be revised and clearly marked
" Voided - Not Superseded",
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- 2. A void CMC shall not be reactivated.
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s T0: Ken Liford
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FROM: Fred Nichols
SUBJECT:
Welder Qualification 1 A 1Il The results of the training and requalification are as follows:
- NAME:
h LVM EZ k E N NA L DO SYMBOL: Ap/R g WQS MEM0- 10/v '
Ti$ DATE: ll-/ 9-8 J p,, ' '
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PROCESS: GTA h/
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( ) Passed - All qualifications renewed, ready to return to work.
- f (X) Failed requalification test - more training required.
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- i COMMENTS
- T*H lh WELOEK WA 5 GIVEN A 30 HQUA EVALUATION Ania OETEK htNED INC AP Adl.E of PEk FORp1/A16 A CCEA TA BLE
'0] Q" quALIT4 u!ELosivG IN THE FIELD. wELDEA SENT BACK f2 yo ptELL) wtT800T UFICAT/0WS gjPOW ODIN T WQTC~
Pope GEN. MEm Ant HENWing
,$ NOTE:
This memo shall serve as a Interim Welding Authorization and
- ]', shall renew all of the welders previous qualifications.
w Applicable standard test
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' This authorization expires effective tJA
.' Date 2
E, 7 Fred Nichols WQTC Supervisor cc:
W. Baker S. Deal A. Justice B. Reed S. Waynick h T. Neal G. Russell
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Distribution FROM: W. E. Baker
SUBJECT:
WPS Qualification Suspension In accordance with the Random R. T. Welder Surveillance Procedure, "
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- k. Welder 24N/?LdC lYl-VARFL , Stamp No. klUS
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has haki two consecutive rejects in one lot of welds and shall report to the
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".. $9/r 1;4? Walder,iQualification Technical Center for: '
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WPSi '- 1. ./.__ , -
until the specified evaluation, training and/or
. re-qualification has been completed with satisfactory results.
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W. E. Unker Sr. Project Welding Engineer (r "
WEB /FN/tn cet S. Deal .
F.' Hichols A. Justice B. Reed r'
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L TEXAS UTILITIES GENERATING COMPANY g i JO O F F I C I M E M O ?. A N D U M n Historical File cien nese. Tens sejm Re-ncrberine/Celetion of Procedures / Instructions This Procedure / Instruction d7 //' /! has been deleted as of this da te. ~7/ i s f;)(c ,yypp 4 ,s ,/ , /c,4,(;g az-se a ' O l d a G f /g <di,,f D.9siswrt s/,,
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l PROCEDURE '
REVISION ! ISSU,E :
PAGE TEXAS UTILITIES GENERATING CO ; NUMBER i , DAic ,
CPSES lCP-QP-11.11 2 l 1 28 % ; 1 f5 ,
si
- i PREPARED BY: /
e 0 ATE i REINSPECTION OF COMANCHE l
PEAK O!ESEL GENERATOR AUXILIARY SKID AND APPROVED BY:
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1.0 REFERENCES
Uh5160$h%'h;fa'?.3.1 P.3)f 11s vat uby 1-A AISC MANUAL OF STEEL CONSTRUCTION, Seventh Edition 1-8 AWS 01.1-1975 ',jj ;
4 m .. i 1-C CP-QP-16.0, "Nonconfonnanci e n <'Dedbie'ricie's"7/
d t-2.0 GENERAL jj fl f.] f t 's:9 % W% }Mt 2.1 PURPOSE AND SCOPE I This procedure delineates the procedure for reinspection of !
the auxiliary skid and support brackets for the CPSES Diesel Generators as provided in P.O. CP-034 by Delaval.
t 2.2 RESPONSIBILITY The TUGC0 Vendor Canpliance Lead Engineer shall have overall
- responsibility for the i,n cti'ggi fgquj red,A'y#yhgs p
- procedu re. g F 7 '
3.0 PROCEDURE N u a '- 3 O b h . O i
3.1 FABRICATION DRAWING Site Mechanical Engineering will make a conposite sketch of the vendor drawing (s). This drawing shall be approved by
- the Project Mechanical Engineer and issued to the TUGC0 ;
Vendor Canpliance Lead Engineer. All welds not specified cn ,
the drawing shall be a full strength fillet (both sides),
and shall meet the following minimum size requirements, except that the weld size need not exceed the thickness of the thinne r membe r.
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l PROCEDURE ISSUE NUMBER OATE PAGE TEXAS UTILITIES GENERATING CO. l REVISION l CPSES JUL 2 8 1981 l2 of 5 CP-QP-11.11 2
. Base Metal Thickness Minimum Size of Thicke r Membe r Fillet To 1/4" inclusive 1/8" Over 1/4" to 1/2" inclusive 3/16" Ove r 1/2" to 3/4" inclusive 1/4" Over 3/4" to 1 1/2" inclusive 5/16" Welds other than full strength fillets shall be so annotated on an as-built drawing by the inspector and shall be submitted to the Project l'echanical Engineer for review and approval .
3.2 MATERIAL VERIFICATION Material verification will not be perfonned by the inspector. Material certification will be provided by the vendor.
. 3.3 WELDER QUALIFICATION VERIFICATION Evidence of welder qualification (Certificates of Canpliance)
I have been provided by Delaval and Kaiser Steel. Consequently, l field verification of welder qualification is not required.
3.4 BOLTED CONNECTIONS The QC Inspector shall verify for all bolted connections:
a.
Minimum thread engagement is obtained. Minimum thread engagement shall be defined as the end of the bolt at least flush with the nut.
- b. Bol ting material is of the prope r size and type.
. c. Washe rs a re installed as required,
- d. If bolts are replaced, toque shall te verified by QC for at least 2 bolts in each connection.
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PROCEDURE REVISION ISSUE PAGE NUMBER OATE TEXAS UTILITIES GENERATING CO.
CPSES CP-Q P-11.11 2 JUL 2 3 1981 3 of 5 3.5 - VISUAL INSPECTION OF WELDS The QC Inspector shall perfonn a final visual inspection of all accessible welds. Welds which are inaccessible shall be so noted on tne IR. For purposes of this procedure, in-accessible shall be defined as those welds which cannot have the paint removed to facilitate visual inspection.
Questions to accessibility shall be resolved by the Lead Vendor Conpliance Engineer or his designee. The visual inspection shall verify that;
- a. All welds a m per drawing and Pa ragraph 3.1. All deviations am ma rked up on as-built drawing.
- b. The weld is free of slag, scale, and paint.
- c. The welds and surrounding base metal shall be free of a rc strikes.
- d. Weld profiles are either slightly concave or convex, with the degme of concavity or convexity not to exceed 0.1 times actual leg length.
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- e. Undercut does not exceed 1/32".
f". Reinfon:ement of butt joints is not greater than 1/8".
- g. Welds a re free fran ove rlap.
- h. Welds a re free fran lack of fusion and cracks.
- f. Full penetration butt welds have conplete penetration.
If inaccessible, the IR shall be so noted and these cases evaluated on a case by case basis.
J. Welds a re of minimum size as specified on the drawing and Pa ragraph 3.1. Welds are pennitted to be 1/16" unde rsize provided that the length of the undersize weld does not exceed 10% of the total weld length.
Welds may be oversized without/ limit except as noted bel ow:
l A. Amount of oversize does not cause excessive distortion.
l B. For edge welds, the maximum size requirements of l pa ragraph 2.7.1.2 of Reference 1-3 a re met. j l
f TUGC0 CA 3
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PROCEDURE REVISION ISSUE NUMBER DATE PAGE TEXAS UTILITIES GENERATING CO.
CPSES 2
JUL 23 1981 4 of 5 lCP-QP-11.11 i
- k. All craters are filled to the full cross section.
- 1. The sum of the diameters of piping porosity does not exceed 3/8 inch in any linear inch of weld and does not exceed 3/4 inch in any 12 inch length of weld.
3.6
~
OOCUMENTATION These inspections shall be documented on an inspection report, Attachment 1. Unsatisfactory items shall be so noted on the IR and returned to Construction for resolution.
Welds which have been noted as inaccessible shall be evalua ted by the Project Mechanical Engineer. Canpleted inspection reports shall be forwarded to the Permanent Plant Records Vault for retention.
3.7 WELD REPAIR Weld repairs shall be perfonned in accortance with existing Site procedures. Reinspection shall be perfonned on the repai rs as described in 3.5.
3.8 NONCONFORMANCES Nonconforming conditions (other than welding size and location dicrepancies described in Paragraph 3.1) will be reported in accordance with Reference 1-C.
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PROCEDURE REVISION ISSUE NUMBER DATE PAGE TEXAS UTILITIES GENERATING CO.
CPSES l
- C' 5 of 5 CP-QP-ll.Il 2 l JU 6.
ATTACHMENT 1 CCMANCHE FEAK STEAM ELECTRIC STATION war
- er INSPECTION REPORT [ao- ,
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smor. REsut,s O in-ccric,. ca atcreo , att in uciate irrus satisractoa, O i=snerica co .txtro, vasariw.etcar irs =. ustro esto. ,
INSPECTION ATTRIBUTES a; 3 oArt
.. . i sr.marunt,s Weld Free of Paint and Rust i i 1.
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- 2. I Weld Size per Drawing l l l i
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- 3. I Final Visual Inspection per Paragrapn 3.5 l1 i ll l l
I Bolted Connections per Paragraph 3.4 I i 4.
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% ' =- p PQ TXX-4187f
, , W/M{ g g g -
6/1/84 C.aA , t3
%cA./ P.pr
~. &
Allegation No. 16 It. has been alleged that non-conforming material has been used in safety systems.- Examples include:
AP G - a) Craft buttered pipe, material is weided 360o around the pipe to
- make it thicker, to achieve required wall thickness.
(Qkt " b) Pipe numbers have been changed in an effort to bypass NCR's. -
c) Out of round pipe was heated up by craft and made round without
- procedures or analysis.
j p 4,, d) ;MC's wou,ld be " lost" so that unauthorized work could not bej gf ffM 3 M
) traced - ..-
7 f.- - . ,
Evaluation of Validity . s.- -
- Our-investigation of the four. cited examples indicates the foElowing:
. . . . . ;& ~ ., .. . .. u : y., .
r ._ , ; m9s . ,
.; . i.;/4a,(,fiping which was identified. as being in violation of minimum wall ,
d D'#.2 f4 requirements has beeh repaired by. welding to achieve the required 1 : v;< Q ' '
. ~ 7:; waitihicknessd ' This practice was approved 'in' Construction
' ~
. Procedure CP'-CPM-6.90 and is considered a standard. repair method
! for such situations. The repair of minimum wall, violations was
- documented by a repair process sheet or by Welding Engineering adding additional steps on the Weld Data Card for the weld 4 involved. ' '
- b) ASME Section III requires' heat traceability for all pressure l
retaining materials. Heat number verification is documented on the
" ~
Manufacturer's Record Sheet (MIS) and verified by both QC ,
inspection personnel and QA Document Review personnel. There have
~
been some instances when QC inspections have identified mismatches between numbers on the drawing and on the hardware. . Pieces identified on the drawing have been incorrectly identified on the hardware, or in some cases, the fabrication drawing or Component Modification Card (CMC) would incorrectly duplicate piece numbers,
-1.e.', use the same piece number for more than one piece of the
- esusus e P
eb . . . . . .
r 4 - ~ c'..s.
.< s', Q ,**. . . . ..
I TXX-4187
} '
6/1/84 subassembly. In the first case, QC inspection personnel would have
. the craft correctly identify the spool. In the latter case QC would notify the craft that the drawing (or CMC) was in error. If engineering agreed and revised the drawing (or CMC), the. craft would correctly identify the piece, at which time QC would perform its in,spection. -
[
~
c) Our investigation of this allegation on safety related piping did
~
5 '
not substantiate. that this. has occurred. The basis for this I
g statement is: interviews with construction supervisors and numerous
{
~
QC inspectorra AdditionalTy, both TijGC0 and. Brown & Root NCR logs /
have been searched, and no evidence of th'is type; of activity was
[f encountered.
- .'^ s ,'+ D.y : ' dom 90kN Y0lN f ~
~
+ . d): . The. purpose. of.the CMC is t.o: docume. nt a. design change which is p: .. . _ . . ,. .. .-.m...... -
~
' r: required because of interference, ' minor fabrication error, etc. K I ,,
'* Tost
- CMC wouTd 'make an as-constructed condition appear ,
j nonconforming, rather than making " unauthorized work" untraceableh i g CMC's art issued to construction through the Document Control Center (DCC) and logged as they are issued. As an additional safeguard, the verification of design changes and the N-5 walkdown verify that the as-installed condition matches the latest design. -
3 Hardware which does not match the latest design is identified by QC
= .
L as nonconforming. ..
Safety Significance ,
None -
h Generic Impact on Other Systems or Contractors l
j ,
Not applicable '
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1 7/ N 1 (1) QC ness. inspect all remaining uninstalled pieces of heat #F11744 for round-
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9 (2) All pieces verified within roundness tolerance will be transferred and used for, piping systems.
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j (3) All remaining pieces out of tolerance for roundness will be used for supports as per DCA 14745.
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r 9 CP5A - AQP-2,A -3 Draf t 5 - 11/15/84 SSER
- 1. Allegation Group: Mechanical and Piping - Category No. 20 Assi,vg Nctf.autlost component modification cards A 09 f M
- 2. Allegation Number: AQP-2 I 3.
(I) Characterization: It is alleged that the x component modification card (CMC) related to a piece of pipe (No. 48) was missing. The alleger believed that the CMC was deliberately lost 50 that unauthorized work could riot be traced /A W-2) /Hvo(2) A piv 6 Otsc6 u u m 6 sd. r4n&d c9s* Ga10 iso Au sp To esvM v/ vu4creo,ta+eo 4,vaW.c A*"> ^ Mom uctt l 6+s us w n s,v Q o p-t). 4. Assessment of Safety Significance: The NRC Technical Review Team (TRT) found that this allegation pertained to a spool of pipe identified on isometric drawing (150) BRP-CT-1-SB-014 as one required for installation in the 10-inch CT-012301R2 line, in pump rcom 51 at the 778-foot - elevation. The TRT detennined the identification of this pipe from AW " related allegations in Mechanical and Piping categories 13 (AP-16)g 14 (AP-15), 6 The TRT reviewed 150 BRP-CT-1-SB-014, Revision 0 through the current revision (Rev.20) to determine if applicable CMCs were identified on and incorporated into the revised 150. The TRT then tracked the ISO revisions to establish that CMC 80104 was th'e alleged " lost CMC." The F01A-85-59 ... . ..
+m - _ _ .n
. TRT obtained CMC 80104 from the Brown & Root (B&R) welding engineering file. The TRT found that CMC 80104R5 was incorporated into the ISO by Revision 8 on November 29, 1982. Revision 20 of the 150, dated July 20, 1984,. contained a note which stated: " Piece (PC) #48 was originally documented as PC #38, Ref. CMC 80104 R-4."
A Texas Utilities Electric Company (TUEC) letter (TXX 4187), dated June 1, 1984, to NRC Division of Licensing also responded to this allegation. This letter stated, in part: "As an additional safeguard, the verification of design changes and the N-5 walkdown verify that the as-installed condition matches the latest design . . . ." The TRT found M that the CMC was incorporated into,N5 issue of the ISO as TUEC stated in their response. Accordingly, the TRT determined that the CMC and the work authorized by the CMC were traceable. l The TRT found that the document control center (DCC)vwas following B&R I t procedure DCP-3, "CPSES Document Control Program," and periodically l ponitored documentation and initiated any action necessary to retrieve I ! missing documents. i i I In a related allegation (Mechanical and Piping Category 21, AQP-1), the TRT reviewed nonconformance report (NCR) M40155. This NCR, prepared by the alleger on September 2,1982, identified piece number 38 as nonconforming. Revision 5 to NCR M4015, dated February 2,1983, provided documented evidence of a QC dimensional inspection (on July 7, 1984) of
piece number 48 (originally documented as piece number 38), which had been installed in the line. This inspection was performed to verify through physical measurements that the nonconformance identified on NCR M40155 did not exist. NCR M4015, Rev. 5, also included a dimensional inspection report of two pieces of bulk pipe (identified on the NCR as
" remaining bulk pipe") located in the yard at the iron fabrication shop.
The purpose of the inspection of the bulk pipe was: "To substantiate-nonconformance report M-40155, Rev. 5, which provided a revised disposition to use the bulk pipe "as is" provided that fit up requirements are maintained." The original NCR (Rev. 0) stated the nonconformance as: "10-inch S/40 stainless steel pipe heat #11744 is 1/2-inch out of round." Following physical measurement, the inspection reports essentially revised the originally stated dimensional nonconformance from 1/2-inch to 1/4-inch. The TRT raises no issue with the inspection reports other than the fact i that the inspections were perfonned on July 7,1984, after piece 48/38
- l. was installed on September 12, 13, 14, 1982.
The TRT found that the disposition of the four nonconforming cut pieces of the pipe for installation (Piece Nos. 38, 42, 33 and 41 of heat number 11744) was not accomplished per the direction given in NCR M40155 (Rev. 1), dated December 12, 1984. This NCR stated: " Transfer all pipe of the above heat number [i.e., heat number 11744] to the steel fab shop for use in the fabrication of pipe supports. l _. - . . _ _ ____ -
~
*^~ ^ ^
NCR M40155 (Rev. 3)g was closed out on January 5,1983. This NCR con'tained a B&R inspection report, dated January 4,1983, which indicated that all pipe with heat number 11744 (per the NCR) was transferred to the iron fabrication shop. The NCR also contains a longhand B&R memorandum, dated January 4,1982, which indicates that only the two pieces of bulk pipe, not the four cut pieces, were transferred back to the iron fabrication shop. NCR M40155 (Rev. 4), dated January 20, 1983, reopened the NCR to revise the disposition. It states:
- 1) "QC inspect all remaining uninstalled pieces of heat number 411744 for roundness. N
- 2) "All pieces verified within roundness tolerance will be transferred and used for piping systems.N4
- 3) "All remaining pieces out of tolerance for roundness will be used for supports as per DCA 14745."
NCR-M40155 (Rev. 5), dated February 2,1983, contains the inspection reports dated July 4,1984, for the bulk pipe (two pieces) and cut piece number 48/38. The TRT found no evidence in the NCR package to document the inspection of the other three nonconfortning cut pieces.
that the piece is still marked "38," although the MRS,150, and CMC identify the piece as "48." B&R Procedure CP-CPM-6.9E Section 3.15 requires marking the piece number on the pipe. Since the number for piece 48 is not marked on the pipe and both final inspection and acceptance are documented, this is v'iolation of procedure CP-CPM 6.9E.
- 5. Conclusion and Staff Positions: The TRT review determined that the alleged " lost CMC" was incorporated into the 150 and was accounted for in the N5 walkdown. Therefore, The TRT concluded that this allegation is not substantiated. Accordingly, this allegation has neither safety significance nor generic implication.
The TRT recognizes the B&R/TUEC effort to provide after-the-fact documentation (e.g., NCR M40155, Rev. 5; NCR 4942S; MRS markup; 150, Rev. 20 Note If of traceability and acceptance of installed piece number
- 38. Since the acceptance and traceability is evident, the TRT assesses no safety significance to the allegation; however, there is a generic implication since a nonconformance item was installed in violation of 10 CFR 50. Because of this violation, no infonnation is available
' covering the disposition of three other spool pieces: CTI-SB-017 ITT2 piece number 42, CT-1-SS-013, ITTI piece number 33, and CT-1-SB-004 ITT-PC, piece number 41. These items may also have been installed while in the NCR hold status. .
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- 8. Attachments: None.
- 9. Reference Documents:
- 1. Brown & Root procedure CP-CPM 6.9D, Appendix D, " Welding and Related Processes."
- 2. Brown & Root procedure WEI-4.6, " Instruction for Control of Welding Engineering CMCs."
. 3. Brown & Root procedure CP-CPM 6.9E, " Pipe Fabrication and Installation."
- 4. Brown & Root DCP-3, "CPSES Document Control Program."
- 5. Gibbs & Hill drawing 2323-51-0550, " Reactor Building Structure Equipment and Foundations."
4
; 6. Gibbs & Hill drawing 2323-51-0544, " Reactor Building Internal Structure S.G. Component Details and Reinforcement."
- 7. AFC0 Steel drawing 35-1195-303, Rev 2.
- 8. Brown & Root Rework drawing MRB-0550-013.
. 9. Isometric drawing BRT-CT-1-513-014 Rev 20.
- 10. Nonconfomance report M40155, Rev. O through Rev. 5 and NCR 49425.
- 11. TUEC letter TXX-4187, dated June 1,1984.
- 12. Component modification card 80104, Revisions I through 5.
- 13. B&R manufacturing record sheet 688143.
i
- 14. B&R weld data cards 688147 and 688148.
- 15. B&R NDE radiographic reports RT Nos. 28393, 28394 and 28403.
i
- 16. TUEC Procedure CP-EP-4.6, " Field Design Change Control."
l1 TrwksauPT of MUTitvl, n)lfH TnE A LLicER JECfMBEfl Ib iM+
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- 10. This statement prepared by: kpLb8JdN_
- j. 7:' =.au 7 " Date TRT Technical Reviewer Reviewed by:
L. Shao Date Group Lead Approved by: V. Noonan Date Project Director
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O' SEER WRITEUP DOCUMENT CONTROL / ROUTE SHEET T
- Y im Allegation Numbers N'[-[ ,[62[-g l E d k Mc"- "-
O~ 2 Subject of Allegation A. . m -- E - '---- - - ---o , TRT Group -
- Author:
This sheet will be initialed by each reviewer. It stays with all revisions to the SSER writeup and serves as a routing and review record. It will be filed in the work package when the writeup is published. Draft Number 2 3 . 4 5 Dra f t 1 Author [2d; Group Leader j j.: f. - Tech. Editor r /___ _. Wessman/Vietti
- J. Gagliardo T. I ppoli to Revision Number Final l 1 l 2 3 4 5
(, Au thor Tech. Editor [/,k
- Group Leader -
J. Gagliardo T. Ippolito g A s-, . c. ' \ 5, e. / [4 4' C \ Administrativ , # Writeup integ O m -> u . w . e. '._.,/' o s< tv J Potential Vio O..m.f .( e / .U Warkpackage F P, Wh&- f % , Workpackage R 4 ' ~~ ~ s *w y' p _. , u 4_
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F0lA-85-59 5o -
1 CPSA - AQP-2,AQB-3 e 'N Draft 5 - 11/15/84 SSER
- 1. Allegation Group: Mechanical and Piping - Category No. 20, Lost component modification cards
- 2. Allegation Number: AQP-2
- 3. Characterization: It is alleged that the component modification card (CMC) related to a piece of pipe (No. 48) was missing. The alleger believed that the CMC was deliberately lost so that unauthorized work
. could not be traced.
- 4. Assessment of Safety Significance: The NRC Technical Review Team (TRT) found that this allegation pertained to a spool of pipe identified on
! isometric drawing (ISO) BRP-CT-1-SB-014 as one required for installation ' in the 10-inch CT-012301R2 line, in pump room 51 at the 778-foot elevation. The TRT determined the identification of this pipe from related allegations in Mechanical and Piping categories 13 (AP-16),14 (AP-15) and 21 (AQP-21). 9 The TRT reviewed ISO BRP-CT-1-SB-014, Revision 0 through the current revision (Rev.20) to determine if applicable CMCs were identified on and incorporated into the revised ISO. The TRT then tracked the ISO revisions to establish that CMC 80104 was the alleged " lost CMC." The
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TRT obtained CMC 80104 from tte Brown & Root (B&R) welding engineering file. The TRT found that CMC 80104R5 was incorporated into the ISO by Revision 8 on November 29, 1982. Revision 20 of the ISO, dated July 20, 1984, contained a note which stated: " Piece (PC) #48 was originally documented as PC #38, Ref. CMC 80104 R-4." A Texas Utilities Electric Company (TUEC) letter (TXX 4187), dated June 1, 1984, to NRC Division of Licensing also responded to this allegation. This letter stated, in part: "As an additional safeguard, the verification of design changes and the N-5 walkdown verify that the . as-installed condition matches the latest design . . . ." The TRT found M that the CMC was incorporated into,NS issue of the ISO as TUEC stated in their response. Accordingly, the TRT determined that the CMC and the work authorized by the CMC were traceable. l l The TRT found that the document control center (DCC) as following B&R procedure DCP-3, "CPSES Document Control Program," and periodically monitored documentation and initiated any action necessary to retrieve missing documents. In a related allegation (Mechanical and Piping Category 21, AQP-1), the TRT reviewed nonconformance report (NCR) M40155. This NCR, prepared by the alleger on September 2, 1982, identified piece number 38 as nonconforming. Revision 5 to NCR M4015, dated February 2,1983, provided documented evidence of a QC dimensional inspection (on July 7,1984) of 1
, S piece number 48 (originally documented as piece number 38), which had been installed in the line. This inspection was performed to verify through physical measurements that the nonconformance identified on NCR M40155 did not exist. NCR M4015, Rev. 5, also included a dimensional inspection report of two pieces of bulk pipe (identified on the NCR as
" remaining bulk pipe") located in the yard at the iron fabrication shop.
The purpose of the inspection of the bulk pipe was: "To substantiate 3 nonconformance report M-40155, Rev. 5, which provided a revised disposition to use the bulk pipe "as is" provided that fit up requirements are maintained." The original NCR (Rev. 0,) stated the nonconformance as: "10-inch S/40 stainless steel pipe heat #11744 is 1/2-inch out of round." Following physical measurement, the inspection l reports essentially revised the originally stated dimensional nonconformance from 1/2-inch to 1/4-inch. l The TRT raises no issue with the inspection reports other than the fact t that the inspections were performed on July 7,1984, after piece 48/38 was installed on September 12, 13, 14, 1982. i , The TRT found that the disposition of the four nonconforming cut pieces of the pipe for installation (Piece Nos. 38, 42, 33 and 41 of heat number f 11744) was not accomplished per the direction given in NCR M40155 (Rev. 1), dated December 12, 1984. This NCR stated: " Transfer all pipe of the above heat number [i.e., heat number 11744] to the steel fab shop (, for use in the fabrication of pipe supports.
4-
, s.
NCR M40155 (Rev. 3 ' was closed out on January 5, 1983. This NCR contained a B&R inspection report, dated January 4,1983, which indicated that all pipe with heat number 11744 (per the NCR) was transferred to the iron fabrication shop. The NCR also contains a longhand B&R memorandum, dated January 4,1982, which indicates that only the two pieces of bulk pipe, not the four cut pieces, were transferred back to the iron fabrication shop. NCR M40155 (Rev. 4), dated January 20, 1983, reopened the NCR to revise the disposition. It states: s
- 1) "QC inspect all remaining uninstalled pieces of heat number
( 411744 for roundness.(E7E#
- 2) "All pieces verified within rcundness tolerance will be transferred and used for piping systems.b J;L,
- 3) "All remaining pieces out of tolerance for roundness will be used for supports as per DCA 14745."
NCR-M40155 (Rev. 5), dated February 2,1983, contains the inspection reports dated July 4,1984, for the bulk pipe (two pieces) and cut piece number 48/38. The TRT found no evidence in the NCR package to document the inspection of the other three nonconforming cut pieces. w.M".. *& *w> m"%wa M- -
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- 5-Manufacturing Record Sheet (MRS) 688143 recorded the inspection of the transfer of the heat number marking for piece number 38 on September 3, 1982. A correction markup (h AprijQ 1983) changed the piece number from 38 to 48. An entry in the margin references NCR 49425.
NCR 4942S January 2,1983 reported the installation of the nonconforming piece number 38 and the change in piece number from 38 to 48 per CMC 80104. The disposition stated: "use 'as is' based on acceptable fit up inspection results." This was further clarified by a statement added on February 2,1983 stating, "This is not a nonforming condition. See NCR M40155 RS." The TRT noted that disposition to remove the hold status (prior to installation) is not reported in any of the revisions to NCR M40155. B&R Weld Data Cards (WDCs) 688147 and 688148 covering the installation of piece number 38 reported that final visual inspection (VT) of FW11-4A and FW13-4A was perfonned on September 14, 1982. B&R NDE radiographic reports 28394 and 28403 indicate the acceptance of FW11-4A. RT 28393 reports the acceptance of FW13-4A. Both of these welds were accepted on September 14, 1982. Based on a review of the previously identified documents and a TRT walkdown inspection to verify that piece number 38 was installed, it is evident that at the time of installation a nonconforming item (material) was used. By visual inspection of the installed piece the TRT determined
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I that the piece is still marked "38," although the MRS, ISO, and CMC identify the piece as "48." B&R Procedure CP-CPM-6.9E Section 3.15 requires marking the piece number on the pipe. Since the number for piece 48 is not marked on the pipe and both final inspection and acceptance are documented, this is violation of procedure CP-CPM 6.9E.
- 5. Conclusion and Staff Positions: The TRT review determined that the alleged " lost CMC" was incorporated into the ISO and was accounted for in the N5 walkdown. Therefore, The TRT concluded that this allegation is not substantiated. Accordingly, this allegation has neither safety significance nor generic implication.
C. s.s The TRT recognizes the B&R/TUEC effort to provide after-the-fact documentation (e.g., NCR M40155, Rev. 5; NCR 4942S; MRS markup; ISO, 1 Rev. 20, Note ljf of traceability and acceptance of installed piece number
- 38. Since the acceptance and traceability is evident, the TRT assesses no safety significance to the allegation; however, there is a generic implication since a nonconformance item was installed in violation of 10 CFR 50. Because of this violation, no information is available covering the disposition of three other spool pieces: CTI-SB-017 ITT2 piece number 42, CT-1-SB-013, ITT1 piece number 33, and CT-1-SB-004 ITT-PC, piece number 41. These items may also have been installed while in the NCR hold status.
l l 1
- 6. Actions Required: TUEC shall perforin an investigation to determine if pieces 42, 33, and 41 were installed prior to release of the hold status.
This investigation shall also determine whether or not the dimensional 1 i inspections requested by NCR M40155, Rev. 4, were perfonned and j l documented for the three pieces (numbers 42, 33 and 41). The TUEC site l QA manager shall furnish a written report to Region IV detailing the results of the investigation. If the investigation indicates the need for corrective action, the TUEC report shall detail the corrective action initiated and the result achieved. W. a.?g . . i .,. 1: f;;.^, ,%..> c u '. r
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- 8. Attachments: None.
l 9. Reference Documents: i l l )
- 1. Brown & Root procedure CP-CPM 6.90, Appendix D, " Welding and Related f
- g. Processes."
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- 2. Brcwn & Root procedure WEI-4.6, " Instruction for Control of Welding f Engineering CMCs."
j 3. Brown & Root procedure CP-CPM 6.9E, " Pipe Fabrication and ! f Installation." , ! 4. Brown & Root DCP-3, "CPSES Document Control Program." i i I 5. GibbskHilldrawing ~2323-51-0550, " Reactor Building Structure i i ! - Equipment and Foundations." i 6. Gibbs & Hill drawing 2323-51-0544, " Reactor Building Internal Structure S.G. Component Details and Reinforcement." ' ! 7. AFC0 Steel drawing 35-1195-303, Rev 2.
- 8. Brown & Root Rework drawing MRB-0550-013.
- 9. Isometric drawing BRT-CT-1-513-014 Rev 20.
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- 10. Nonconfonnance report M40155, Rev. O through Rev. 5 and NCR 49425.
- 11. TUEC letter TXX-4187, dated June 1, 1984.
- 12. Component modification card 80104, Revisions 1 through 5.
- 13. B&R manufacturing record sheet 688143.
- 14. BAR weld data cards 688147 and 688148.
- 15. B&R NDE radiographic reports RT Nos. 28393, 28394 and 28403.
- 16. TUEC Procedure CP-EP-4.6, " Field Design Change Control."
- 10. This statement prepared by:
J. Melanson Date TRT Technical Reviewer p Reviewed by: A, ./ L. Shao Date Group Lead I Approved by: V. Noonan Date Project Director l l
W;. . . s.
, CPSA - AQP-2, AQB-3 Draft 6 - 12/7/84 SSER i j, -
- 1. Allegation Group: Mechanical and Piping - Category No. 20,
[' Lost component modification cards
- 2. Allegation Number: AQP-2
- 3. Characterization: It is alleged that the component modification card (CMC) related to a piece of pipe (No. 48).was missing. The alleger believed that the CMC was deliberately lost ,so that unauthorized work l could not be traced.
- 4. Assessment of Safety Significance: The NRC Technical Review Team (TRT) found that this allegation pertained to a spool of pipe identified on isometric drawing (ISO) BRP-CT-1-SB-014 as one required for installation in the 10-inch CT-012301R2 line in pump room 51 at the 778-foot elevation., The TRT determined the identification of this pipe from related allegations in Mechanical and Piping categories 13 (AP-16),14 (AP-15), and 21 (AQP-21).
l l The TRT reviewed ISO BRP-CT-1-SB-014, Revision 0 through the current i revision (Rev.20), to detennine if applicable CMCs were identified on and i [ incorporated into the revised ISO. The TRT then tracked the ISO revisions to establish that CMC 80104 was the alleged " lost CMC." The ; F0lA-85-59 nm : .,
s . - , .. TRT obtained CMC 80104 from the Brown & Root (B&R) welding engineering file. The TRT found that CMC 80104RS was incorporated into the ISO by Revision 8 on November 29, 1982. Revision 20 of the ISO, dated July 20, 1934, contained a note which stated: " Piece (PC) #48 was originally documented as PC #38, Ref. CMC 80104 R-4." A Texas Utilities Electric Company (TUEC) letter (TXX 4187), dated June 1,
- 1984, to NRC Division of Licensing also responded to this allegation.
This letter stated, in part: "As an additional safeguard, the verification of design changes and the N-5 walkdown verify that the as-installed condition matches the latest design . . . ." The TRT found that the CMC was incorporated into the N5 iss,ue of the 150 as TUEC stated in their response. Accordingly, the TRT detennined that the CMC and the work authorized by the CMC were traceable. During the course of their assessment, the TRT was unable to obtain a copy of CMC 80104, revisions 1, 2, and 4 from the B&R document control center (DCC). Because the allegation pertains to lost CMCs, the inability to obtain the complete CMC prompted further discussion between the TRT and a DCC area supervisor. When asked by the TRT if there.were any CMCs that were not available in the DCC record file, the supervisor replieo that some CMCs were missing from file, but that Section 3.2.2 of Procedure DCP-3, "CPSES Document Control Program," reouires the DCC to account for controlled documents (including CMCs) by periodic monitoring and initiation of actions to retrieve missing documents. The TRT saw
_ _ .. _._~._ .~..-_. ~ . . . _ . . _ . _ - . _ . . . _ . . ~ . . . ~ . .. .. . ~ . . . . _ ._. evidence of the monitoring activity in the form of a B&R Message and Reply fom longhand memo (dated July 19,1984) which tracked the retrieval of 17 missing CMCs. Since the DCC activity in accounting for CMCs is in confomance with procedure and the design basis documents (N5 issue) account for the applicable CMCs, the TRT is confident that missing CMCs are retrievable, and were not lost deliberately. In a related allegation (Mechanical and Piping Category 21, AQP-1), the TRT reviewed nonconfomance report (NCR) M40155. This NCR, prepared by the alleger on September 2,1982, identified piece number 38 as nonconfoming. Revision 5 to NCR M4015, dated February 2,1983, provided documented evidence of a QC dimensional inspection (on July 7, 1984) of piece number 48 (originally documented as piece number 38), which had been installed in the line. This inspection was perfomed to verify .
'through physical measurements that the nonconfomance identified on NCR M4015S did not exist. NCR M4015, Rev. 5, also included a dimensional inspection report of two pieces of bulk pipe (identified on the NCR as
" remaining bulk pipe") located in the yard at the iron fabrication shop.
The purpose of the inspection of the bulk pipe was: "To substantiate nonconformance report M-4015S, Rev. 5, which provided a revised disposition to use the bulk pipe "as is" provided that fit up requirements are maintained." The original NCR (Rev. 0) stated the nonconformance as: "10-inch S/40 stainless steel pipe heat #11744 is 1/2-inch out of round." Following physical measurement, the inspection reports essentially revised the originally stated dimensional
- nonconformance from 1/2-inch to 1/4-inch.
- .h a- --
l l l The TRT raises no issue with the inspection reports other than the fact l that the inspections were performed on July 7, 1984, after piece 48/38 was installed on September 12, 13, 14, 1982. The TRT found that the disposition of the four nonconfonning cut pieces of the pipe for installation (Piece Nos. 38, 42, 33, and 41 of heat number 11744) was not accomplished per the direction given in NCR M4015S (Rev. 1), dated December 12, 1982. This NCR stated: " Transfer all pipe of the above heat number [i.e., heat number 11744] to the steel fab shop for use in the fabrication of pipe supports." NCR M40155 (Rev. 3) was closed out on January 5,1983. This NCR contains a B&R inspection report, dated January 4, 1983, which indicates that all pipe with heat number 11744 (per the NCR) was transferred to the iron fabrication shop. The NCR also contains a longhand B&R memorandum, dated January 4, 1982, which indicates that only the two pieces of bulk pipe, not the four cut pieces, were transferred back to the iron [ fabrication shop. l l r l NCR M40155 (Rev. 4), dated January 20, 1983, reopened the NCR to revise the disposition. It states:
- 1) "QC inspect all remaining uninstalled pieces of heat number 11744 for roundness.
l
l
- 2) "All pieces verified within roundness tolerance will be transferred and used for piping systems.
i , 3) "All remaining pieces out of tolerance for rounoness will be used for supports as per DCA 14745." NCR-M40155 (Rev. 5), dated February 2,1983, contains the inspection reports dated July 4,1984, for the bulk pipe (two pieces) and cut piece number 48/38. The TRT found no evidence in the NCR package to document the inspection of the other three nonconforming cut pieces. Manufacturing Record Sheet (MRS) 688143 recorded the inspection of the transfer of the heat number marking for piece number 38 on September 3, 1982. A correction markup in April 1983 changed the piece number from 38 to 48. An entry in the margin references NCR 49425. NCR 49425 January 2,1983 reported the installation of the nonconforming piece number 38 and the change in piece number from 38 to 48 per CMC 80104. The disposition stated: "use 'as is' based on acceptable fit up inspection results." This was further clarified by a statement added on February 2,1983 stating, "This is not a nonforming condition. See NCR M4015S RS." The TRT noted that disposition to remove the hold status (prior to installation) was not reported in any of the revisions to NCR M40155. 4 l
-. . . . . - ~ . . . . -.
B&R Weld Data Cards (WDCs) 688147 and 688148. covering the installation of piece number 38 reported that final visual inspection (VT) of FW11-4A and FW13-4A was performed on September 14, 1982. B&R NDE radiographic reports 28394 and 28403 indicate the acceptance of FW11-4A. RT 28393 reports the acceptance of FW13-4A. Both of these welds were accepted on September 14, 1982. Based on a review of the previously identified documents hnd a walkdown inspection, the TRT verified that piece number 38 was ins:alled, it is evident that at the time of installation a nonconforming item (material) was used. By visual inspection of the installed piece the TRT determined that the piece is still marked "38," although the MRS, ISO, and CMC identify the piece as "48." B&R Procedure CP-CPM-6.9E Section 3.15 requires marking the piece number on the pipe. Since piece number 48 is not marked on the pipe and both final inspection and acceptance are documented, this is violation of procedure CP-CPM 6.9E. T 44- M k.L4 Md afAsAe$ $ CMY A CM%lSc M y I, A CP - -
- 5. Conclusion and Staff Positions: The TRT review determined that the alleged " lost CMC" was incorporated into the ISO and was accounted for in the NS walkdown. Therefore, the TRT concludes that this allegation is i
not substantiated. Accordingly, this allegation has neither safety significance nor generic implication, i I I
The TRT recognizes the B&R/TUEC effort to provide after-the-fact documentation (e.g., NCR M40155, Rev. 5; NCR 4942S; MRS markup; ISO, Rev. 20, Note 18) of traceability and acceptance of installed piece number 38. Since the acceptance and traceability is evident, the TRT assesses no safety significance to the allegation; however, there is a generic implication since a nonconforming item was installed in violation of 10 CFR 50. This violation is generic because no information is available covering the disposition of three other spool pieces: CTI-SB-017 ITT2 piece number 42, CT-1-SB-013, ITTI piece number 33, and CT-1-SB-004 ITT-PC, piece number 41. These items may also have been installed while in the NCR hold status. c lN A MffilhL WITH THE littf6EA DM PfCEMiifA!0l$ff7tti70 i h\iJLMTED THC AEJUL7J 0/* THE ASSE6SMLST of THE AttECA7/DN AtG) THE TAT / LetA011tv-A Ettitraistusileh iMJUElLt . ThERE WEM hu HAJDK ITLHb blQi//AtattCEMini M1 Hs N L W CDhliMu pf. ALLi4ATIM6 WERE IDEATinEli-
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- 6. Actions Required: AJOUC l
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- 8. Attachments: None.
- 9. Reference Documents:
- 1. Brown & Root procedure CP-CPM 6.9D, Appendix D, " Welding and Related Processes."
- 2. Brown & Root procedure WEI-4.6, " Instruction for Control of Welding Engineering CMCs."
- 3. Brown & Root procedure CP-CPM 6.9E, " Pipe Fabrication and Installation."
- 4. Brown & Root 'DCP-3, "CPSES Document Control Program."
- 5. Gibbs & Hill drawing 2323-51-0550, " Reactor Building Structure Equipment and Foundations."
l 6. Gibbs & Hill drawing 2323-51-0544, " Reactor Building Internal l Structure S.G. Component Details and Reinforcement." l
- 7. AFC0 Steel drawing 35-1195-303, Rev 2.
- 8. Brown & Root Rework drawing MRB-0550-013.
- 9. Isometric drawing BRT-CT-1-513-014 Rev 20.
- 10. Nonconformance report M40155, Rev. O through Rev. 5 and NCR 4942S.
- 11. TUEC letter TXX-4187, dated June 1, 1984.
l
- 12. Component modification card 80104, Revisions 1 through 5.
- 13. B&R manufacturing record sheet 688143.
- 14. B&R weld data cards 688147 and 688148,
- 15. B&R NDE radiographic reports RT Nos. 28393, 28394 and 28403.
16.- 'UEC Procedure CP-EP-4.6, " Field Design Change Control." l
*== - - . . , , , , ,
l l I l l l ! 10. This statement prepared by: l J. Malonson Date TRT Technical Reviewer i Reviewed by: L. Shao Date Group Leader l l Approved by: V. Noonan Date ! Project Director l l l 1 l l l I l l i
- l i
t I i l
. 1 1 - ,
/ / '
'. [g i SEER WRITEUP DOCUMENT CONTROL / ROUTE SHEET Allegation Numbers '[ _[ '
[@ -8 "U ' Subject of Allegation # - -e^ m . TRT Group - o Author: . This sheet will be initialed by each reviewer. It stays with all revisions to the SSER writeup and serves as a routing and review record. Itcwill be filed in the work package when the writeup is published. Oraft Number . 2 3 4 5 . Draft 1 e Author / Group Leader 4! /4 n - L Tech. Editor r/- Wessman/Vietti J. Gagliardo T. Ippolito Revision Number 4 5
'. Final 1 2 3
. / Author / N Tech. Editor /~
- Group Leader J. Gagliardo T. Ippolito Administrative .
Writeup integrated into SSER Potential Violations to Region IV , Workpackage File Complete l Workpackage Returned to Group Leader l 1
. o l
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--.--*-_-.-_ ~____._... _._i____ _
CPSA - AQP-2, AQB-3 Draft 6 - 12/7/84 SSER
- 1. Allegation Group: Mechanical and Piping - Category No. 20, in
- s s wcr Arc 4 A .o Lost component modification cards M 3 g b
- 2. Allegation Number: AQP-2,A-4/-/
8)
- 3. Characterization: It is alleged that the 3 component modification card (CMC) related to a piece of pipe (No. 48) was missing. The alleger believed that the C deliberately lost so that unauthorized work could not be trace AndlO4##88/CE
- M pg y gppager- n co VM sh' WNAuM <! 9 60 ** W w,o gays a si-* wermCe of-iJ-
- 4. Assessment of Safety Significance: The NRC Technical Review Team (TRT)
, found that this allegation pertained to a spool of pipe identified on isometric drawing (150) BRP-CT-1-SB-014 as one required for installation in the 10-inch CT-012301R2 line in pump room 51 at the 778-foot elevation. The TRT determined the identification of this pipe from po related allegations in Mechanical and Piping categories 13 (AP-16) p 14 (AP-15) The TRT reviewed ISO BRP-CT-1-SB-014, Revision 0 through the current revision (Rev.20), to determine if applicable CMCs were identified on and incorporated into the revised 150. The TRT then tracked the ISO revisions to establish that CMC 80104 was the alleged " lost CMC." The
1 TRT obtained CMC 80104 from the Brown & Root'(B&R) welding engineering file. The TRT found that CMC 80104R5 was incorporated into the ISO by Revision 8 on November 29, 1982. Revision 20 of the ISO, dated July 20, 1984, contained a note which stated: " Piece (PC) #48 was originally documented as PC #38, Ref. CMC 80104 R-4." A Texas Utilities Electric Company (TUEC) letter (TXX 4187), dated June 1, 1984, to NRC Division of Licensing also responded to this allegation. This letter stated, in part: "As an additional safeguard, the verification of design changes and the N-5 walkdown verify that the as-installed condition matches the latest design . . . ." The TRT found that the CMC was incorporated into the N5 issue of the ISO as TUEC stated in their response. Accordingly, the TRT determined that the CMC and the _ work authorized by the CMC were traceable.
;7 During the course of their assessment, the TRT was unable to obtain a copy of CMC 80104, revisions 1, 2, and 4, from the B&R document control center (DCC). Because the allegation pertains to lost CMCs, the inability to obtain the complete CMC prompted further discussion between the TRT and a DCC area supervisor. When asked by the TRT if there were any CMCs that were not available in the DCC record file, the supervisor replied that some CMCs were missing from file, but that Section 3.2.2 of Procedure DCP-3, "CPSES Document Control Program," reouires the DCC to account for controlled documents (including CMCs) by periodic monitoring and initiation of actions to retrieve missing documents. The TRT saw
r . _ . . t evidence of the monitoring activity in the form of a B&R Message and Reply fom longhand memo (dated July 19,1984) which tracked the retrieval of 17 missing CMCs. Since the DCC activity in accounting for CMCs is in confomance with procedure and the design basis documents (N5 issue) account for the applicable CMCs, the TRT is confident that missing CMCs are retrievable, and were not lost deliberately. N h a related allegation (Mechanical and Piping Category m 21, AQP-1)m"v y 6/" W h TRT reviewed nonconformance report (NCR) M401 s NCR, prepared by the alleger on September 2,1982, identified piece number 38 as nonconforming. Revision 5 to NCR M4015, dated February 2,1983, provided documented evidence of a QC dimensional inspection (on July 7, 1984) of piece number 48 (originally documented as piece number 38), which had been installed in the line. This inspection was perfonned to verify through physical measurements that the nonconformance identified on NCR M4015S did not exist. NCR M4015, Rev. 5, also included a dimensional inspection report of two pieces of bulk pipe (identified on the NCR as
" remaining bulk pipe") located in the yard at the iron fabrication shop.
The purpose of the inspection of the bulk pipe was: "To substantiate nonconfomance report M-40155, Rev. 5, which provided a revised disposition to use the bulk pipe "as is" provided that fit up requirements are maintained." The original NCR (Rev. 0) stated the nonconfomance as: "10-inch S/40 stainless steel pipe heat #11744 is i 1/2-inch out of round." Following physical measurement, the inspection reports essentially revised the originally stated dimensional l nonconfomance from 1/2-inch to 1/4-inch, i l l
The TRT raises no issue with the inspection reports other than the fact that the inspections were performed on July 7,1984, after piece 48/38 was installed on September 12, 13, 14, 1982. The TRT found that the disposition of the four nonconforming cut pieces of the pipe for installation (Piece Nos. 38, 42, 33, and 41 of heat number 11744) was not accomplished per the direction given in NCR M40155 (Rev. 1), dated December 12, 1982. This NCR stated: " Transfer all pipe of the above heat number (i.e., heat number 11744] to the steel fab shop for use in the fabrication of pipe supports." NCR M40155 (Rev. 3) was closed out on January 5,1983. This NCR contains a B&R inspection report, dated January 4,1983, which indicates that all pipe with heat number 11744 (per the NCR) was transferred to the iron fabrication shop. The NCR also contains a longhand B&R memorandum, dated January 4,1982, which indicates that only the two pieces of bulk pipe, not the four cut pieces, were transferred back to the iron fabrication shop. NCR M40155 (Rev. 4), dated January 20, 1983, reopened the NCR to revise the disposition. It states:
- 1) "QC inspect all remaining uninstalled pieces of heat number 11744 for roundness.
i
_.. . .. _... e.~... . _ . ,
- 2) "All pieces verified within roundness tolerance will be transferred and used for piping systems.
- 3) "All remaining pieces out of tolerance for roundness will be d
used for supports as per DCA 14745." NCR-M40155 (Rev. 5), dated February 2,1983, contains the inspection reports dated July 4,1984, for the bulk pipe (two pieces) and cut piece number 48/38. The TRT found no evidence in the NCR package to document the inspection of the other three nonconforming cut pieces. Manufacturing Record Sheet (MRS) 688143 recorded the inspection of the transfer of the heat number marking for piece number 38 on September 3, 1982. A correction markup in April 1983 changed the piece number from 38 to 48. An entry in the margin references NCR 49425. NCR 49425 January 2, 1983 reported the installation of the nonconforming piece number 38 and the change in piece number from 38 to 48 per CMC 80104. The disposition stated: "use 'as is' based on acceptable fit up j inspection results." This was further clarified by a statement added on _ February 2,1983 stating, "This is not a nonforming condition. See NCR M40155 R5." The TRT noted that disposition to remove the hold status (prior to installation) was not reported in any of the revisions to NCR M40155. _. . . . . . ::~. --. - ____ . - - - --
l l B&R Weld Data Cards (WDCs) 688147 and 688148 covering the installation of piece number 38 reported that final visual inspection (VT) of FW11-4A and f FW13-4A was performed on September 14, 1982. B&R NDE radiographic reports 28394 and 28403 indicate the acceptance of FW11-4A. RT 28393 reports the acceptance of FW13-4A. Both of these welds were accepted on l September 14, 1982. 1
/
Based on a review of the previously identified documents and a walkdown l inspection, the TRT verified that piece number 38 was installed, it is l evident that at the time of installation a nonconforming item (material) f was used. By visual inspection of the installed piece the TRT determined that the piece is still marked "38," although the MRS, ISO, and CMC identify the piece as "48." BAR Procedure CP-CPM-6.9E Section 3.15 1-l requires marking the piece number on the pipe. Since piece number 48 is I not marked on the pipe and both final inspection and acceptance are documented, this is violation of procedure CP-CPM 6.9E. l i 5. Conclusion and Staff Positions: The TRT review determined that the i alleged " lost CMC" was incorporated into the ISO and was accounted for in f the N5 walkdown. Therefore, the TRT concludes that this allegation is not substantiated. Accordingly, this allegation has neither safety significance nor generic implication. t L i p _
The TRT recognizes the B&R/TUEC effort to provide after-the-fact documentation (e.g., NCR M40155, Rev. 5; NCR 4942S; MRS markup; ISO, Rev. 20, Note 18) of traceability and acceptance of installed piece number 38. Since the acceptance and traceability is evident, the TRT assesses no safety significance to the allegation; however, there is a generic implication since a nonconforming item was installed in violation of 10 CFR 50. This violation is generic because no information is available covering the disposition of three other spool pieces: CTI-SB-017 ITT2 piece number 42, CT-1-SB-013, ITT1 piece number 33, and CT-1-SB-004 ITT-PC, piece number 41. These items may also have been installed while in the NCR hold status. P - IN A MffhM W11H THE flLLC6EA 0H.PfCffftYA14l$ffME TfW I"iti/LWTfD THc AEJ0 Lid of THE ASSEJSMLNT of THf AttfCA7/DN Arb TNC TMi WCA01/w-A Stutiskity.1sion irruz.11. THEM WEdi ho MAJDK lYLHb bf Gi//A&til/ Min? Ad Nt N L W CDMEMJ bf. Alli&A71CM6 WERE 10EATII'tEll-
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- 8. Attachments: None.
- 9. Reference Documents:
- 1. Brown & Root procedure CP-CPM 6.90, Appendix D, " Welding and Related Processes."
- 2. Brown & Root procedure WEI-4.6, " Instruction for Control of Welding Engineering CMCs."
- 3. Brown & Root procedure CP-CPM 6.9E, " Pipe Fabrication and Installation."
- 4. Brown & Root DCP-3, "CPSES Document Control Program."
- 5. Gibbs & Hill drawing 2323-51-0550, " Reactor Building Structure Equipment and Foundations."
- 6. Gibbs & Hill drawing 2323-51-0544, " Reactor Building Internal Structure S.G. Component Details and Reinforcement."
- 7. AFC0 Steel drawing 35-1195-303, Rev 2.
3,
- 8. Brown & Root Rework drawing MRB-0550-013,
- 9. Isometric drawing BRT-CT-1-513-014 Rev 20.
- 10. Nonconformance report M40155, Rev. O through Rev. 5 and NCR 49425.
- 11. TUEC letter TXX-4187, dated June 1, 1984.
- 12. Component modification card 80104, Revisions 1 through 5.
- 13. BAR manufacturing record sheet 688143.
- 14. B&R weld data cards 688147 and 688148.
- 15. B&R NDE radiographic reports RT Nos. 28393, 28394 and 28403.
- 16. TUEC Procedure CP-EP-4.6, " Field Design Change Control."
- 10. This statement prepared by:
J. Malonson Date TRT Technical Reviewer Reviewed by: L. Shao Date Group Leader Approved by: V. Noonan Date Project Director 1 I f i i
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Allecation No. 16 It'has been alleged that non-conforming material has been used in i safety systems. Examples include: AP85 7, a) Craft buttered pipe, material is weided as0o around the pipe to make it thicker, to achieve required wall thickness. l dQP- " b) Pipe numbers have been changed in an effort to bypass NCR's. c) Out of round pipe was heated up by craft and made round without A - lu - M edures or analysis. f'gpz-- l d) :MC's would be " lost" so that unauthorized work could not be yf fAld b traced. p Evaluation of Validity Our investigation of the four cited examples indicates the following:
.; a) Piping which was identified as being in violation of minimum wall requirements has been repaired by welding to achieve the required
. wall thickness. This practice was approved'in' Construction Procedure CP-CPM-6.90 and is considered a standard repair method for such situations. The repair of minimum wall violations was documented by a repair process sheet or by Welding Engineering adding additional steps on the Weld Data Card for the weld involved.
b) ASME Section III requires' heat traceability for all pressure retaining materials. Heat number verification is documented on the Manufacturer's Record Sheet (m S) and verified by both QC inspection personnel and QA Document Review personnel. There have been some instances when QC inspections have identified mismatches
- between numbers on the drawing and on the hardware. Pieces identified on the drawing have been incorrectly identified on the hardware, or in some cases, the fabrication drawing or Component Modification Card (CMC) would incorrectly duplicate piece numbers,
.i.e., use the same piece number for more than one piece of the
~
F0lA-85-59 pao L
Txx-4137
\ 6/1/84 subassembly. In the first case, QC inspection personnel would have the craft correctly identify the spool. In the latter case, OC would notify the craft that the drawing (or CMC) was in error. If engineering agreed and revised the drawing (or CMC), the craft would correctly identify the piece, at which time QC would perform its inspection, c) Our investigation of this allegation on safety related piping did not substantiate that this has occurred. The basis for this statement is interviews with construction supervisors and numerous QC inspectors. Additionally, both TUGC0 and. Brown & Root NCR logs /
have been searched, and no evidence of this type of activity was ' encountered. gon904 W YAfN W f d) The purpose of the CMC is to document a design change which is required because of interference, minor fabrication error, etc. A
/ , " lost" CMC would'make an as-constructed condition appear
; nonconforming, rather than making " unauthorized work" untraceable, S CMC's are issued to construction through the Document Control Center (DCC) and logged as they are issued. As an additional safeguard, the verification of design changes and the N-5 walkdown verify that the as-installed condition matches the latest design.
Hardware which does not match the latest design is identified by QC l as nonconforming. . Safety Significance None Generic Impact on Other Systems or Contractors Not applicable en. em W ,4 g g, e mm use-'". ,M.' 96... .wg m84 * *hh', , .4 m .46 p.N G N D'_.
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I ;;; *.:id ta'; N . '0-15-5 on tr* was out-of-round so badly it was egg-shaped.
-his piping.
a Ouality Engineer, called me "cn the carpet" and I confronted me with the NCR, and told me he wanted it changed for " clarity." protested, saying it could not be clearer...the pioing had been cut into four pieces, and I had put " hold" on that piping and the spool from which the piping in ng piece numbers and the critinM M said he wanted me to delete.the ; a m. I did revise it one time spool number from the N. %ri.. . . . , c, with the heat numbers as opposed to the piece numbers, under protest. J' The
'r:owever, the next time I saw the NCR, it was in Rev(ision) 5.
[ ' faoat*h engineers had revised the NCR ds cr more times, and, of course, they had delet reference to th,e specific numbers. I looked at the fiCR and found that Rev. 3 I also saw that they had
- had designated the pipe to be used as hanger materill; .
put into an Inspection Report (IR) that one of the pieces in question--Piece
- t
'.o. 38--had been sent to the fabrication shop and from there, it had been sent I
to. the Contai t Spray (CT) System. (At this point, the pipe number was Another piece from the same spool (No. CT-1 40-01 CT-1-53-14IfT 2. Piece 38.) ~
~
Itt 3) also ended up in CT piece 11, Weld 9-A. On September 13, 1952, I went to the pump room and noticed that Piece 33
" Buttering" is a had been installed and that craf,t had " buttered" the pipe.
peccess where the craft welds welding .. material 360" around the pipe to make it g thicker. This is usually af ter Qualij:y Engineering (QE) retuires thicker pipe. T
$ i could nct believe that non-conforming pipe was now being used in a safety system. Buttering the pipe only worsened the problem, but did nothing to correct it. This incident is not isolated.
I have knowledge about cases where craft received "out.o.f-round" piping, C t
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and then heated up the pipe, and put a cross-brace inside it, ;nd then pulled it s ; that the pipe would achieve rouncness. This is estre .eij bad for stainless , steel pipe since it destroys the chromium content, which ; resents rusting, and 7 it weakens the pipe. It also is a violation of the ASM~ Cste. I suspect that craft.,had subject Piece No. 38 to this process since it was "round" as opposed to egg-shaped as it was when I wrote it up. [ Ancther QC inspector and I looked up the drawing (af ter all this) and the CMC that changed Piece No. 38 to Piece No. 48 was missing. I believe that _,, this missing CMC changed the pipe number and was done deliberately by someone so 1 that the unauthorized work could not be traced. An inspector who went to do an inspection on this pipe, now No. 48, could not, tell,the history of the work or of 'the non-conforming condition it had been in. C)# __ D9 l l t a
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Sangart: was not involved with that at all. I don't know what the status of i ( { investiga' In thatwe instance, wespecifics. guided Ippolit6 and the group that was doing that tion, gave them We gave them NCR numbers that:need to N be looked at, we told them CMCs, we told them drawing numbers that were changed and this kind of stuff. We don't know what the results of thier investigation b
' was from the information that we gave them and until we see that information we # certainly wouldn't want to give anybody else the additional information. Till r
we know. See, in one case, triere's a piece of out of round pipe out there that is in concrete. What are they going to do about that? gb G have to do something about it because it's leaking and the concrete's wet.Somebody's g It's not something that we can just say blow it off.
,ADenise: The out of round pipe is leaking. Is that what you're saying?
The pipe is out of round where it connects to the other pipe and what they did to cover that up, there was an NCR written against the out of round pipe, and so once the, they couldn't solve this problem by changing it, cut the piece out and put a new piece in there, because it is inbedded in concrete. What 'they did is. change the docue.entation and as ycu are going along there and you.'re looking, you saw those massive amounts, and we only saw what was current. Now, we only was what was current. But if we had had in that same , package that I showed you, if we had g:ne back on that CSISB14 drawing, if we had gone back and pulled all the documentation against that, you'd see that l back at CMC 80104. CMC 80104 Rev 3 calls for a piece number 38. k' call for any piece at all. Rev 4 doesn't calls it piece number 48. Rev 5, which is the one that is current this time, So it changed the piece number on the drawing number and that made it all ok because all that spool pipe was out of round that piece number 38 came out of. So they said that in that C515814 that particular pipe, they just changed the number of it from piece number 38 to piece number 48. Denise: You were telling me the other day what level in containment that was on. Do I recall that was 840 level. 840. And he probably just went in there cause the wall's wet. is wnat kind of flows I had opened because it's .... This Denise: I can understand a piece of pipe being out of round but I'm not sure I can understand your direct connection with why that makes the wall wet unless the piece of pipe was leaking. M . Where that piece goes into the other piece, the joint. On one side of the joint is good pipe, on the other side of the joint is that pipe that's out of round and it's leaking. Where they interjoin. You can't match up like that. So it's. drip, drip, drip. l it's not always got water in it. Only when they hydro those, so you have to,
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/A. Der.i s t : To talk about more specifici:y, do you happen to know what kind of system that pice is associated with, fire water system, containment spray y system?
I CT15S14, that's the drawing number on it. That information has
., ency been turned over.
Denise: IsthatsomeoftheinformationyougavetoMr. Ippolito?
. Yeah. We don't know how they aduressed that problem. If they say tnat it didn't exist, how do they take care of it. In reference to this one right here, CTISE14, that's tne hours sheet on it. Here's the other pieces of pipe that were out of round in that system.
Denise: OK, this is the one you're referring to, NCRN4015, because it's from ~ the pipe fab shop. It's got a drawing and a~ heat number and, well, this is an NCR. It doesn't have anybody's name on it. I guess it's reported by
~
Yeah. That's your inspector. Denise:~ InspectorM~ Again this refers to a training category M13. It says a stainless 10 ini:h stainless schedule 40 steel pipe, heat number F11744 is one half inch out of round. Four piece of pipe were cut from the fault pipe. Pull tags have been applied to all four pieces remaining fault pipe. s Bangart: Period. j % .8 Denise: Yeah, period. ? in piece numbers listed below. So there's, we're unable to tell except it now says the disposition is CT1YD01ITT8
~
Under M4942 Denise: M4942. M49425. I put this on there, it's got my initials on it. Denise: OK, you've initialed these personally. That's af ter I got this out. Then we got further information. Denise: Did you disposition this? No. We have further information that this is how they dispositioned this. Denise: Ok, cause this,looks like an original piece of paper. l e l
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3:. 1C No that's not because it doesn't have any .... Denise: Xeroxing is so good these days. No, that I think is an original piece of' paper, but it is not the original that went through review right here. When it goes all the way through g it will look like that. See here, where it's signed off here and then it will / be signed of f by somebody else and then it goes through all of this stuff and it goes all the way down. This is on a'different problem. Denise: I was .just saying this looks like the original writing made in pencil, net just a xerox copy of it.
, It is. It is the original just as it is.
Denise: So this is the original turned in NCR.... - No, no, no, no, no, that is a copy of it that was handwritten as opposec to copied on a copy machine, 'so the original is in, the _ vault. Deni e: Ok, but it also has somebody's, that reported by on I was, it's good because it relates tc, this tren n thing that we talked about earlier. And this is the kind of stuff that some of this has been given to Mr. Ippolite but you don't know his disposition of it, b This is the kinds of things that we decided that would be important for them to have so that they wouldn't have to go through all of the rigamarole. Denise: You're certainly correct ther'e. There's not anything here that is illegal or immoral or anything else for anybody to own because there's no stolen documentation or anything like that here. This is parts of what are available, this is not an NCR as such because it's not signed off as a legal channels -and all this kind of stuff, this is a handwritten copy of an NCR. Denise: I just didn't understand it when you showed it to me. Bangart: Is that signature on there or is that somebody who just wrote down that ran was signed by them? M I don't know. M Denise: OK, we want to go off the tape now. v p
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. \ Comanche Peak Open Issue Action Plan m 1 Task: Piping and Bolts Material Traceability Ref. No.: AQP-2 Characterization: Material traceability removed from wall bolts and CMC I lost to avoid nonconformance. Initial Assessment of Significance: Lack of material traceability could j-lead to use of improper material or inability to properly document
- material.
1 Source: Mechanical & Piping Category 20 , l. > I Approach to Resolutions:
- 1. Review A-3 statement.
- 2. Review procedures and NRC requirements.
- . 3. Verify QA records for installation of bolts.
5
- 4. Walkdown the installed location and verify heat number marking on the heads of bolts.
- 5. Refer any examples of wrongdoing or significant deficiencies to the TRT manager.
- 6. Evaluate allegations for generic / safety implications.
- 7. Report on results of review / evaluation of allegations.
- 8. Evaluate generic / safety implications and potential violations.
y-
Category No. 20 2 Re. lated Open Issue Identification: Status: Not started. Review lead: Civil / Mechanical, J. H. Palonson Su ppo rt: Estimated Resources: 8 man. days Estimated Completions: 8/31/84 ( ., ( Closure: Reviewed By: TRT Leader s ,..
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DCP9 - cat 20 su:r.ary malonson 10/25/84 ALLEGATION
SUMMARY
- 1. Category No.: 20 TRT Member: J. H. Malonson
- 2.
Subject:
Piping material traceability i
- 3. Sunnary of Allegation:
A0P-2 - It is alleged that a component modification card (CMC) covering a changed pipe piece number was deliberately l lost.
- 4. Region IV's
Conclusions:
No Region IV documentation was found for this t category.
- 5. What the TRT Had Done: The TRT identified and reviewed drawings, other revisions of the lost CMC, nonconformance reports, and relevant documents, interviewed several B/R personnel and performed field examinations.
i
- 6. TRT
Conclusions:
The allegation was not' valid. The CMC which was alleged to have been lost was properly included on the related drawing and identified during an N5 walkdown. The TRT did find that a 1 l violation of 10 CFR 50 requirements did occur. One section of pipe was installed and three other sections of pipe may have been installed h h while still on a nonconformance report hold. The licensee has been requested to trace the three - n re to RT. 7 f-/W
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- 7. Hearings: The matters in this category have not been discussed in the
. hearings.
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-. ~ f,gitG On September 2,1982, 'I wrote a Non-Conformance Report (NCR) on piping I put hold ta'g No. 40-15-S onI t hat was out-of-round so badly it was , egg-shaped.
this piping. M a Ouality, Engineer, called me "on the carpet" and .
'I c onfronted me with the NCR, and told me he wanted it changed for " clarity."
protested, saying it could not be clearer...the piping had been cut into four i - piecesl and I had put " hold" on that oiping and the spool from which the ' piping _, oricinated. M said he wanted me to delete the gi i g piece numbers and the ~ spool number frcm the NRC. +%. .c s i;n a c.r. I did revise it one time .gd with the heat numbers as opposed to the piece numbers, under protest. gril j ll$Y The However, the next time I saw the NCR, it was in Rev(ision) 5. [ Soo?I!$ h I engineers had revised the NCR dier more times; and, of course, they had deleted all 4 reference to th;e specific numbers. I looked at the NCR and found that Rev. 3
\( p -( I also saw that they had
'"'- hEd designated the pipe to be used as hanger materill put into an Inspection Report (IR) that one of the pieces in question--Piece No. 38--had been sent to the fabrication shop and from there, it had been sent / to the Contai t Spray (CT) System. (At this point, the pipe number was . N. f l ^ Piece 38.) Another piece from the same spool (No. CT-1 40-01 I 4 CT-1-53-14-17T 2 , ' Itt S) also ended up in CT piece 11, Weld 9-k.' -
~
dW Q t r 4 Cn September 13, 1982, I went to the pump room and noticed that Piece 38 had been installed and that craf,t had " buttered" the pipe. " Buttering" is a 0 around the pipe to make it , prccess where the craft welds welding material 360 - thicker. This is usually after Quality Engineering (QE) requires thicker pipe. g I could net believe that non-conforming pipe was now being used in a safety' system. Buttering the pipe only worsened the problem, but did nothing to correct it. This incident is not isolated. I have knowledge about cases where craft c'eceived "out-o.f-round" piping,
~
F0lA-85-59 ws _
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[4 > and .then heated up the pipe, and put a cross-brace inside it, gnd then pulled it so that the pipe would achieve roundness. This is extremely bad for stainless steel pipe since it destroys the chromium content, which prevents rusting, and
, it weakens th,e pipe. It also is a violation of the ASME Code. I suspect that G .
cr. aft.,had subject Piece No. 38 to this process since it was "round" as opposed - to egg-shaped as it was when I wrote it up. #'d Another QC inspector and I looked up the drawing (after all this) and the CMC that changed Piece No. 38 to Piece No. 48 was. missing. I believe that
._ this missing CMC changed the pipe number and was done deliberately by someone so 1 "- An jnspector who went to do an that the unauthorized work could not be traced.
inspection on this pipe, now No. 48, could not tell[the history of the work or of 'the non-conforming condition it had been in. f/ p'gss;wpgI s ,a # # #
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, 1 Bangart: I was not involved with that at all. I don't know what the status of the report is.
Inthatknstance,weguidedIppolitoandthegroupthatwas'doingthat investigation, we gave them specifics. We.gave them NCR numbers that need to j N be looked at, we told them CMCs, we told them drawing numbers that were changed and this kind of stuff. We don't kno'w what the results of thier investigation ' g'I was from the information that we gave them and until we see that information we 8gJt we certainly wouldn't want to give anybody else the additional information. Till know. See, in one case, there's a piece of out of round pipe out there that is in concrete. What are they going to do about that? Somebody's going to g%b
'have to do something about it because it's leaking and the concrete's wet.
It's not something that we can just say blow it off. A O Denise:, The out of round pipe is leaking. Is that what you're saying? The pipe is out of round where it connects to the other pipe and what
. hey did to cover that up, there was an NCR written against the out of round pipe, and so once the, they couldn't solve this problem by changing it, cut the piece out and put a new piece in there, because it is inbedded in concrete.
What they did is change the documentation and as you are going along there and you're looking, you saw those massive amounts, and we only saw what was current. Now,"we only was what was current. But if we had had in that same package that I showed you, if we had g::ne back on that CSISB14 drawing, if we . ( had gone back and pulled all the documentation against that, you'd see that ( back at CMC 80104. CMC 80104 Rev 3 calls for a piece number 38. Rev 4 doesn't call for any piece at all. Rev 5, which is the one that is current this time, calls it piece number 48. So it changed the piece number on the drawing number " and that made it all ok because all that spool pipe was out of round that piece number 38 came out of. So they said that in that CSISB14 that particular pipe, they just changed the number of it from piece number 38 to piece nu=ber 48. Denise: You were telling me the other day what level in containment that was on. Do I recall that was 840 level. 840. And he probably just went in there cause the wall's wet. This s wnat kind of flows I had opened because it's .... Denise: I can understand a piece of pipe being out of round but I'm not sure I can understand your direct connection with why that makes the wall wet unless - the piece of pipe was leaking. here that piece goes into the other piece, the joint. On one side of the joint is good pipe, on the other side of the joint 'is that pipe that's out of round and it's leaking. Where they interjoin. You can't match up like that. So it's, drip, drip, drip. Only when they hydro those, so you have to, j it's not always got water in it. i S .
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Denise: To talk about more specificity, do you ha;: pan :: ar < knew what kind of sy; tem system? that pipe is asaciated ,<ith, fire water system, containment spray CT1SB14, that's the drawing number on it. alreaoy been~ turned over. That information has Denise: Is that some of the information you gave to Mr. Ippolito? Yeah. that it did We don't know how they addressed that problem. t ex st, If they say right here, CTISS14, how do they take care 'of it. In reference to this one hat'< the hours sheet on it. Here's the other pieces of pipe that w're out o' round in that system. ~ Denise: OK, this is the one you're referring to the pipe fab shop. It's got a drawing and a heat number b ecause it's from NCRN4015,j
,NCR. It doesn't have anybody's name on it. I gues d, well, this is an it s reported by Yeah. That's your inspector.
Denise: Inspector 99282. says a stainless 10 is one half inch out of round. ini:h stginless schedule 40 steel pipe, It he.at nu F11744 pipe. . Pull tags have been applied to all four pieces remaining faultF Bangart:. Period. doin 12'* Denise: Yeah,' period.
? in piece numbers listed below.
unable to tell except it now says'the disposition is CT1YD01ITT8So there's, we're der M49 Denise: M4942. M49425. ' 1 I put this on there, it's got my initials on it. Denise: OK, you've initialed these personally. . That's after I got this out. Then we got further information. - Denise: Did you disposition this? No. this. We have- further information that this is how they dispositioned benise: Ok, cause this looks like an original piece of paper.
. ,' No that's not because it doesn't have any ....
Denise: Xeroxing is so good these days. No, that I think is an original piece of~ paper, but it is net the origin that went through review right here. .When it goes all the way through it will look like that. See here, where it's signed off here and then it will be signed off by somebody else and then it goes through all of this stuff and it goes all the way down. This is on a different problem. Denise: I was just saying this 'looks like the original writing made in pencil, . not just a xerox copy of it. l
~
It is. It is the original just as it is. Dentse: So this is the original turned in NCR.... - No, no, no, no, no, that is a copy of it that was handwritten as opposed to copied on a copy machine, so the original is in the vault.
~
Denise: Ok, but it also has somebody's, that reported by n l 9/2/82. I was, it's good because it relates to this trending thing that we i f.alked about earlier. And this is the kind of stuff that some of this has been
~
given to Mr. Ippolite but you don't know his disposition of it. This is the kinds of things that we decided that would be important
- for nem to have so that they wouldnt have to go through all of the rigamarole.
Denise: You're certainly correct there. There's not anything here that is illegal or immoral or anything else for anybody to own because there's no stolen documentation or anything like l I that here. This is parts of what are available, this is not.an NCR as such because it's not signed off as a legal channels and all this kind of stuff, this is a handwritten copy of an NCR. Denise: I just didn't understand it when you showed it to me. - Bangart: Is tha ignature on there or is that somebody who - l just wrote down t at NLK was signed by them? M D I don't know. M s
-[~ .,\d Denise: OK, we want to go off the tape now.
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AF FICAVIT OF Page 3 v Y-J vsy.,_ A4 g cua. % c,gyng.cs%R "s -cpg a4 I puw hold tag No. 40-15-5 on N that was out-of-round so badly it was egg-shaped. this piping. Dick Pononi, a Quality Engineer, called me "on the carpet" and confronted me with the NCR, and told me he wanted it changed for " clarity." I protested, saying it could not be, clearer...the pioing had been cut into four , pieces, and I had put " hold" on that piping and the spool from which the ' piping originated. Pononi said he wanted me to delete the pjpjng piece numbers and the spool number from the NRC. r-r d..-- .c. . ; . u a . c. I did revise it one time with the heat numbers as opposed to the piece numbers, under protest. p\ However, the next time I saw the NCR, it was in Rev(ision) 5. The SQ 400! Y . engineers had revised the NCR d:iw(more times; and, of course, they had deleted all reft-er.:e to the specific numbers. I looked at the NCR and found that Rev. 3 , I also saw that they had h'ad designated the pipe to be used as hanger materill. . put into an Inspection Report (IR) that one of the pieces in question--Piece No. 38--had been sent to the fabrication shop and frcm there, it had been sent to the Containment Spray (CT) System. (At this peint, the pipe number was
.: 48
CT-1-SB-14IfT 2, Piece 38.) Anoth,er piece from the same spool (No. CT-1 40-01 Itt 8) also ended up in CT piece ll, Weld 9-X. o p3 hgab On September 13, 1982, I went to the pump room and noticed that Piece 33
" Buttering" is a had been installed and that craf,t had " buttered" the pipe.
prccess where the craft welds welding
- material 360" around the pipe to make it thicker. This is usually after Quality Engineering (QE) requires thicker pipe.
I could net believe that non-conforming pipe was now being used in a safety system. Buttering the pipe only worsened the problem, but did nothing to correce it. This incident is not isolated, b I have knowledge about cases where craft c'eceived "out-o.f-round" piping,
Page 4 and then heated up the pipe, and put a cross-brace inside it, gnd then pulled it so that the pipe would achieve roundness. This is extremely bad for stainless steel pipe since it destroys the chromium content, wh ch prevents rusting, and it weakens the pipe. It also is a violation of the ASME Code. I suspect that craft had sub'j ect Piece No. 38 to 'this process since it was "round" as opposed to egg-shaced. as it was when I wrote it up. 4, Another QC inspector and I looked up the drawing (a'ter all this) and _ the CMC that changed Piece No. 38 to Piece No. 48 was missing. I believe that y f[' h this missing CMC changed the pipe number and was done deliberately by someone so L that the unauthorized work could not be traced. An inspector who went to do an 6 . 3 T inspection on this pipe, now No. 48, could not tell the history of the work or S* o'f 'the non-conforming condition it had been in. Q{( .'
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Anothe serious problem on the site is upgrading of the code of the class j of material ord ed. I personally know that the iron fabrica shop illegally l upgrades the class o material. I,t works like this: ft will get a drawing
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that cahls for Class I,p , then they will ge Material Requisition form (MR) and look for the right plate. ' it can be found, a similar plate that looks ! like Class 'I, but actually is Clas or Class III is used. The pipe will be i sta= ped with a number on thep e that in crectly identifies the class of . material, and then uses as if it were <1' ass - The factory stamp is different from Brown & Root' tamp; both are stencils, but the re different, because fin the factory s* .p looks more professional. For a while, I t: _ J: circle the number t t Brown & Root stamped on them and then date it.
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