ML20198K489
| ML20198K489 | |
| Person / Time | |
|---|---|
| Site: | Comanche Peak  |
| Issue date: | 07/27/1985 |
| From: | Douglas Dodson, Opelski E, Scott R TEXAS UTILITIES ELECTRIC CO. (TU ELECTRIC) |
| To: | |
| Shared Package | |
| ML20197J316 | List:
|
| References | |
| FOIA-85-59 QI-QP-11.18-4, NUDOCS 8606040038 | |
| Download: ML20198K489 (88) | |
Text
.
TEXAS UtutES GENE.9AENG CO.
gg
. AEVISICN PAGE CPSES I
i
//
!QI-QP-11.18-4 0
1 of 4 L F, Jut 2 a 1982 l
kdm 1-l'1-31 l
ULTRASONIC PRE?ARED BY:
LT OLTS APPROVED SY- [/?
2 7-fd '
i y
Air AFP VED
.Th TATE e
i
1.0 REFERENCES
I 1-A CP-CPM-13.1, " General Calibration Procedure" f
2.0 GENERAL f
2.1 PURPOSE The purpose of this instruction is to provide detailed I
instructions for inspection personnel to determine the l
length and type of Hilti Bolt after it is installed by use l
of the ultrasonic examination test method.
i i
F"R INFORMATON ONLY 2.2 SCOPE This instruction applies spec'fically to Hil ti Bol ts installed where the length and type cannot be detennined by l
the letter or numbe designation r.ormally stamped on the end j
of the bolt.
f 2.3 EQUIPMENT AND MATERIALS j
2.3.1 Instruments i
i Any commercially available pulsed, reflection-type instrument with an A-scan presentation may be used if it meets the following requirements:
I l
a.
The instrument shall be capable of generating frequencies of at least 3 MHz through 5 MHz.
e b.
The instrume provides linear presentation (with 5
I percent) for at least 75 percent of the screen height (sweep line to top of screen).
l c.
The instrument shall be maintained and calibrated in t
accordance with Referdnce 1-5.
1A-oo-bo l
- GCO CA 8606040038 860527
GARDE 85-59 PDR L.
l INSTRUCTION ISSUE REVIS!CN PAGE NUMBER DATE TEXAS UT1UTIES GENERATING CO.
CPSES l
Ql-QP-ll.18-4 o
JUL 2 8 ISc2 2 of 4 l
2.3.2 Calibration Blocks Calibration blocks should preferably be made from the same material as the material to be examined. Other blocks may be used provided they are proven to be acoustically equivalent to the items being examined and meet the following requi rements:
I a.
The calibration blocks shall be uniquely marked for identification.
b.
The calibration blocks are marked with material identification traceable to certification papers.
c.
The calibration blocks shall be marked with thickness verified by mechanical measurements (traceable to a National 5tandard).
2.3.3 Couplant Any commercial grade couplant such as uncut glycerin, heavy oil, or Exosen-30 may be used.
2.3.4 Transducers Any commercially available longitudinal wave transducer may he used if it meets the following requirements:
All transducers shall be internally grounded.
b.
Transducers used shall be in the frequency range of 1 MHz through 5 MHz.
Transducers shall be operated at their rated frequencies.
c.
d.
The diameter of transducers shall be as follows:
1.
The diameter of the transducer element shall not be greater than the diameter of the hilti bolt being examined.
l I
i TUGCC CA
INSTRUCTICN ISSUE ESION AGE NUMBER DATE TEXAS UTILITIES GENERATING CO.
CPSES QI-QP-11.18-4 0
R 2 3 1982 3 Of 4 l
2.
For hilti bolts up to and including 1" in diameter, the diameter of the transducer element shall not be less than 1/4" smaller than the diameter of the hilti bolt being examined.
3.
For hilti bolts over 1" in diameter, the diameter of the transducer element need not exceed 3/4".
3.0 INSTRUCTION
.6 3.1 SURFACE REQUIREMENTS The transducer contact surface shall be such that good sound resolution is obtained.
Surfacing the end of the bolt may be required.
If surfacing is required, it shall be done in a way that will leave the bolt end as flat as possible.
3.c CALIBRATI0ft SEQUENCE The following secuence shall be followed:
a.
Connect the transducer and other necessary equipntent to the instrument and energize, b.
Apply couplant to the calibration block as described in paragraph 2.3.2.
c.
Select two steps on the calibration block.
Position the signal from the thinner step to the left of the screen and the thicker to the right. Adjust the screen divisions using the range and delay controls so that the horizontal screen divisions represent inches of metal i
path. Set the sweep range to read the desired thickness l
range.
i d.
After calibrating the instrument as described above, l
the inspector shall select a Hilti Bolt of the san:e diameter, length and type as the suspected hitli bolt being examined and shall make necessary fine adjustment to ensure that the instrument is calibrated to measure the desired distance.
4 i
1 l
i l
t Tucco cA
s
?,
l a
INSTRUCTICN ISSUE RESION PAGE NUMBEA DATE TEXAS UTluTIES GENERATING CO.
CPSES QI-QP-11.18-4 0
JUL 2 3 1982 4 of 4 3.3 INS 0ECTION SEQUENCE f
The follcwing sequence shall be followed:
a.
File the bolt end, if necessary, to meet the requirements of paragraph 3.1.
b.
Apply couplant and place the transducer on the bolt.
Ensure that good sound resolution is obtained and that the bolt presentation is presented on the CRT screen.
c.
To ensure that the ultrasonic presentation on the CRT screen is being interpreted properly, the inspector shall compare the screen present1 tion of the hilti bolt being examined to the screen pr:esentation of the hilti bolt used in the calibration sequence 3.2(d).
The characteristic geometric reflectors must be clearly visible on the CRT screen.
d.
After the inspector has determined the type bolt installed, it shall be documented on the Material Identification Log, Operation Traveler or Inspection Report as being determined by 31trasonic examination.
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Dimensions of the members shown in the shop bill of fab drawings are approximate dimensions to get the material. These may be altered to fit actual field conditions.
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sser aw-68 srt-8 Draft 7 1/30/85 SSER 1.
Allegation Grouo: Mechanical and Piping Category No. 19 Undersized welds and loose nuts.
2.
Allecation Number: AW-68 and SRT-8 i
3.
Characterization:
It is alleged that the supports on tanks for the Vertical Residual Heat Exchangers (VRHE) have undersized welds
>A te (AW-68) the support bolts for the VRHE nuts were loose (SRT-8).
V 1
Jg 4.
Assessment of Safety Sicnificance:
AW-68 The NRC Technical Review Team (TRT) discussed the allegation with the TUEC Supervisor of Mechanical Engineering to see if he was aware of this problem. The TUEC Supervisor said that the allegation must have come from repair work done on the VRHE.
y L,L.y o ;,.'d CL k 3.'-; M b p
~
DuringBrown& Root's(B&R's(prese in a rface examinaticg the j
s)kk u g
f W
residual heat exchanger, various(weld defec were dis overed.
Non-k (i[p 4/
uA igaks confonnance Report (NCR) No. M-9918 R-1 describes these weld defects
' hM' '{*
in detail. AThe disposition of this NCR required repair work to be fG J
/
j performed and provided the methods to be used for the repair process f
f j
j
/'
and the requirements for final examination of the repairs. The TRT 9 eJx[ch;etk%xt%{[.%
4 ; G g. w e j A W % y w. M L )r' found that the documentation for this repair wo m
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l NCR M-9918 R-1 did not identify any of the alleged under d welds.
P 4deti# icd caly thus= weids Ui.Nuni.. ned d:fect:y' The TRT measured A!f the accessible welds \\an&ound df hat th y met the size
}'f8
/
requirements shown on the design dr6 wing.
~
This allegation was from an unknown source, therefore, an alleger interview was nct possible.
SRT-8 The TRT reviewed the NRC Region II report " Comanche Peak Special Review Team Report" for its references to the VRHE bolting. The report stated that a few nuts were very loose and that there were many exposed threads between the nuts and the surfaces against which they would be tightened. The report also noted that the threads between the loose nuts and tighting surfaces had been painted,(apparently inadvertently). The Region II report pointed out that the support 1
bolting and welding records were not 'readily retrievablel I
- Co.Bh
^
The TRT reviewed the records for this support d found that the records for the support bolts lackediproper dadumentatiod. The TRT also learned that the lack of proper documentation for these support bolts was discovered during the N-5 preparation and was reported on NCRs M-14243 and M-14244.I These NCRs have not yet been closed out, as B&R ordered new bolts to ensure proper documentation during
[
installation. The NCRs will be closed out upon the installation and t
properdocumentationofthenewglts.
i Ms.
T"b h d tkM ot' b4t?) A h bDd Try 04 o b d5 4 t d
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. 5.
Conclusion and Staff Positions:
% W3 ib 1%i AW-68 w% a.
Based upon the size of the defects, location of defects, the ne mber of A-defects and the type of loading (primarily shear), the TRT6cncludis) %M.
]
that the weld defects that were found would not have had an impact on s
r safety or function of the VRHE had they gone undetected.,In addition, 1
- v
]
base on the review of supporting records and inspections of the
^
installed welds, the TRT concludes that the allegation that the welds were undersized cannot be substantiated and that the welds which contained defects were corrected. Since the defects were corrected this allegation has no technical merit. Accordingly, this allegation has neither safety significance nor generic implications.
gMS
~
SRT-8 Based on a review of applicable NCRs with the Region II assessment that thnec./ords on the bolts were not readily
/
@rievablphewever, the QA System did, in fact, pick up this deficiency. Since this NCR is still open, it must be closed-out
(
l
-rom. N
/
before the plant goes into operation. The TRT concludes that upo ' g @
,/
closing of this NCR there will be no safety significanc[r ;=ricm C ( G" "u -- + ne L g g bbin % ew Q w W or wot
~
Nt pct. ts M od.L b.1,%i 1.
g,g p NT Y
- c. y d. ]: m.
~
6.
Actions Recuired: None.
j u_
i
.,/'
(
8.
Attachments: None.
9.
Reference Documents:
1.
NCR No. M-9918, R1.
i 2.
Westinghouse Drawing No. 5774 Rev. 5.
3.
Westinghouse Drawing No. 5773 Rev. 3..
4.
Gibbs & Hill Drawing No. 2323-SI-0654.
5.
NCRs M-14243 and M-14244.
- 10. This statement prepared by:
V. Ferrar1ni Date TRT Technical Reviewer Reviewed by:
L. Shao Date Group Leader Approved by:
Date V. floonan Project Director l
I
-=
..__n Nq gk b
CP5 SRT-1, SRT-2, SRT-3 4
d
$,7 Draft 5 1/30/85 SSER l.
Allegation Group: Mechanical / Piping Category 36 Ofbb'p
- piping Analyses Preblems found in Region II Report.)
2.
Allegation Number: SRT-1, SRT-2, and SRT-3 i
[
3.
Characterization: The following issues, which are discussed in this
}
SSER, are not the result of allegations, but were found during an NRC Region II Special Review Team (SRT) inspection at Comanche Peak Steam Electric Station (CPSES).
.h
~
f The SRT found that a component modification card (CMC) apparently was.not considered in the small bore piping analysis (SRT-1).
l s
6 M-Z f.
The SRT partially reviewed piping system AF-1-SB-007 and discovered that one CMC was not properly addressed (SRT-2).
1 fj g
The SRT raised concerns about the design considerations that should be implemented when a piping system goes from a safety-A related building to.a nonsafety-related building (SRT-3).
4.
Assessment of Safety Significance: The NRC Technical Review Team (TRT) discussed the SRT's concerns abcut CMCs (SRT-1 and SRT-2) with l
the SRT member who was responsible for this area of the SRT's report.
y J
His concern was that engineering judgment may have been applied to
(
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""J piping analyses when a calculation was required. The SRT randomly selected 50 systems and instructed Texas Utilities Electric Company (TUEC) pipe support engineering (PSE) personnel to review and report on the methods (i.e., engineering judgment, calculations, etc.) that,
were used to accept the CMC changes. S M M h b
- MMP M#M' V
The TRT also reviewed system AF-1-SB-006 and CMC No. 90567, which were the subject of the SRT's concern.
TRT agreeed with the SRT
'issessment that PSE useddigTiieering Juoggnt and that this judgm
~
4 j
'was, indeed, conseCv
' The degree of conservatism of the
'N
/
engineeririg ~jadgment was determined by hand calculation and by
' ' ~
g 4Q rigorous mputer analysis, und that the hand cilculath I
J AT resuliis showed higher stress levels than the computer solution by a
)ph &Y
~~
b d g % h c4 % 4 $
i i factor, of 2r dcvh.
7 We g
The TRT reviewed 0 of the 50 systems in detail to determine if the t, A.gc.7 1
/,
PSE engineers incorp'orgted all open CMCs into their analyses and to N
.d g detennine if they were usin%ineering judgmenboo liberally.
The TRT found that the analysis packages whic k reviewed were complete
,j neering judyh f
and easy to follow. The TRT also found.r.at was used only for minor changes in the 10 systems reviewed and that hand calculations were used for the remaining changes. The TRT reviewed the calculations and found them to be accurate and
.a conservative. The TRT also found that all outstanding CMCs were incorporated into the analyses.
2 :.ra,
c:'m==r!Mem1=n~==tmc== maw-m:N=== v t r % =.x v-a
. ?
f t appears that the CMC that was not incorporated on piping syste AF-1-SB-007 was an isolated case since the TRT found no similar roblems during their re,vipw.[RT also determined that-thi I
r A ~~
fncorporated CMcisesM have been picked up when the final review was performed on the
' isometric for this system.
J/
gg w amu i s.
s y
The TRT called the New York office of Gibbs & Hill (G&H) to determine the status'of their response to the SRT concerns regarding the design of piping systems which go from safety-rela;ed to nonsafety-related buildings (SRT-3). The TRT found t had done nothing to answer the SRT concerns. G&H stated f "all went well," the concern uld be addressed by the end of September or the beginning of
~
sThe TRT agreed with the SRT that piping lines going from a seismic Category I building to a nonseismic Category I building could cause damage to :,upports and the piping system on the seismic Category I side. The TRT detennined that these effects must be considered unless an isolation anchor was provided between the two buildings.
Piping systems at CPSES, such as those for the main steam auxiliary steam and feedwater systems, are routed between the electrical control building, which is seismic Category I, and the turbine building, which is nonseismic Categcry I, without any isolation. To be acceptable, 0
W e
a
- each nonseismic Category I piping system should be isolated from any seismic Category I piping system by separation, barrier or constraint.
If isolation is not feasible then the effect on the seismic Category I piping of the failure in the nonsaismic Category I piping must be considered (CPSES FSAR 3.78.3-13.1).
In the case of CPSES, the FSAR, Section 3.7B.2.8, establishes that the Turbine Building is a nonsaismic Category I structure and failure is postulated during the seismic (SSE) event. The effect of turbine building failure on any non-isolated piping routed between the turbine building and any seismic Category I building must be considered.
@ 6 ua4 u d dA.utsee 'is b fe d.
f 5.
Conclusion and Staff Pos tions:.]After reviewing the TUEC treatment of
'CMCs for small. bore piping isometrics (SRT-1; SRT-2), the TRT concludes that TUEC performed reviews according to procedures and used /
~
r s
methods that ar widely used in piping stress analyse out the
(%tyj. The TRT concludes, therefore, that TUEC has addresse the 4
SRT concerns and demonstrated that they have neither safety significance nor generic implications.
~
Since G&H has not addressed the original SRT concern regarding piping system design (SRT-3), the status of this item remains undetermined.
The TRT concludes that this concern could have safety implications; however, until G&H completes their review, a final determination of the safety implications cannot be made.
WHAT AecdT DTHER sysTE4%-
Y.J.5CMuit c3c..
i
~
NL('
.r /
f-6.
ActionsRequired.:/TUECshallprovidedocumentaio'n'thatthepiping s
s ystems between seismic Category I and nonseismic Category I buildings j
meet the stated FSAR criteria.
-/
~.,.-/
)
l N
8.
At'tachments:
None.
9.
Reference Documents:
1.
PSE Piping Calculation Numbers (a) CC-1-EC-001 (b) CC-1-FB-002 (c) CC-1-SB-001 (d) FW-1-RB-005A l
(e) FW-1-SB-018 (f) MS-1-SB-007 (g) RC-1-RB-012 (h) AF-1-SB-007 (i) RH-1-SB-006 (j) SI-1-RB-035 I
2.
G&H Procedure AB-5, Revision 5, "A Simplified Method for Design and Analysis of Small Size Piping."
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- 10. This statement prepared by:
V. Ferrarini Date TRT Technical Reviewer Reviewed by:
L. Shao Date Group Leader 4
Approved by:
V. Noonan Date Project Director
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g COMAtlCHE PEAK STER 1 ELECTRIC STATION h
DESIGN CHANGE AUTHORIZATION
('m) (WILL NOT) BE IftCORPORATED IN DESIGN DOCUMENTS DCA flM 1.
SAFETY RELATIO DOCUMENT:
XX YES NO
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ORIGIt:ATOR: CPPE XX ORIGINAL DESIGNER 3.
DESCRIPTION:
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APPLICABLE E9GC90WG/00CGiEAT W 1554E32 REY.
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OETAILS PROBLEM: Due to the as-built location of the large SI restraint in Looo 4 the 1" fillet weld cannot be performed on the northeast side.
RESOLUTION: A 1" chamfer will be ground to facillitate acolying a 1" groove weld as shown on the attached sketch.
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September 24, 1981 Joe No. 35-1195 Tom Parker r-t
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Pittsburgh, Pa. 15230 28 1981 COMANCHE PEAK STEAM ELECTRIC STATION ECEIVEd 10" S.I. Line Restraints Ref: 1. W Dwg. 1554E33
- 2. W Owg. 1554E35
- 3. CPPA-12,719
Dear Mr. Parker:
Please find attached four sketches. Sheet 1 shows the as-built relation-ship of the restraint with the check valve and S.G. Lower Lateral Support Beam in Compartment 2. The modifications made to the restraint to clear the check valve are identical to those requested for the restraint in Compartment 4 (Ref. 3). Sheets 2 and 3 show the as-built relationship of the restraint with the check valve and S.G. Lower Lateral Beam in Compart-ment 1. The proposed modifications to the restraint to clear the check valve are identical to those requested for the restraints in Compartment 4 (Ref. 3). On sheet 2 please note the interference with the 1554E35 restraint.
Sheet 4 shows a proposed modification to this restraint to alleviate this interference. Sheet 3 shows a section view of the restraint in Compartment 1.
Please note in order to center the restraint around the pipe, the restraint had to be placed such that a 1" fillet is not possible. We have proposed instead a 1" groove weld as shown in the sketch.
To summarize, we request the following approvals:
- 1. In Compartment 2, modify the restraint identical to that as requested j
in Ref. 3.
- 2. In Compartment 1, modify the restraint identical to that as requested in Ref. 3.
- 3. In Compartment 1, modify the 1554E35 restraint as shown o Sb,ee,t 4.u,
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- 4. In Compartment 1, change the weld from a fillet to a groove on one e
edge.
s These sketches were previously telecopied for approval on 9/21/81~.
I If you have any questions, please contact thi o f fi ce.
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P O. BOX 1002 GLEN ROSE. TEXA5 7g September 24, 1981 JOB NO. 39 -1195 Tom Parker
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COMANCHE PEAK STEAM ELECTRIC STATION d
ECEIVEW 10" S.I. Line Restraints Ref: W Owg. 1554E33
Dear Mr. Parker:
Please find attached four sketches showing this restraint in S.G. Compartment No. 4. Sheet I showsthe as built relationship of the restraint with the check valve and S.G. Lower Lateral Support Beam. Sheets 2, 3, & 4 show proposed modifications to the restraint to get it to fit as shown on Sheet 1. Please note these modifications only apply to compartment 4 as the others have not been laid out yet.
These sketches were proviously telecopied for approval, and this approval was given verbally. However, please provide written approval for documentation purposes.
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My name i better known as I live in Glen Rose, Texas.
I orked for Brown & Root for approximately ten years, including about s n years at the Comanche Peak nuclear power plant.
During that time I was a about three or four years. While I was performing my duties as a I saw j
a lot of things at the Comanche Peak plant which were not according to' procedures and travelers, many of which could jeopardize the health and safety of the public.
I knew that something needed to be done before the fuel came in for the plant.
I thought it over and decided that I would go to Houston to the Brown
& Root main office and report these violations to the President of Brown & Root j
direct, Mi. Thomas Feehan.
I went to Houston and met with Mr. Feehan.
I told him of some violations that were going on and told him that after ten years of
+
experience, I thought some of those people might know better and show better craftsmanship and intelligence than they had used at the nuclear plant in
~,
Southport, North Carolina.
I told him about working at the North Carolina plant on some weld seams that were not supposed to lose more than an ounce of radiation per year (we were told). These seams, some.of which were approximately 100 feet long, were in some instances leaking as much as 65 lbs. every three seconds, according to what was indicated when we turned the gauge off and watched the gauge drop.
At first we took the test channel off and started repairing the bad welds, which took several days. We were getting approximately 28 pin holes and indi-cations per foot.
This was taking too much time to repair properly, apparently, so somebody in Brown & Root's organization came up with the brainy idea of having us take the first foot or eighteen inches off, repair the weld, replace the eighteen inches of test channel, block it off, and just hydro the one-foot-area. QC assumed.,
we had the whole 100 feet under pressure and bought it off as is.
In my opinion.
that is lack of craftsmanship or experience or just downright sabotage. Personally, I think some of these people should go to prison for this, and I told Mr. Feehan I
l that.
i; I also gave Mr. Feehan a letter with some things I knew about and that other '
l people had told me about. He said he would send an investigation crew to investi-gate the Comanche Peak charges, and he did.
I know of much more that I did not t
tell him or the investigative crew and have not in the past reported to the local NRC office because I feel the NRC is not interested in protecting the people's welfare and.it will be covered up.
I have been told by CASE (Citizens Association for Sound Energy), the intervenor in the Comanche Peak operating license hearings, that I am required by law to report any problems which inight affect the health i.
and safety of the public to the Nuclear Regulatory Comission.
I am therefore asking CASE to send this affidavit to the NRC as my method of reporting it, in
/
the hope that.by doing so it will force the NRC to really look at the problems l
I've identified.
I would like to get this information to Congress or someone i.
I who's really interested in the safety and welfare of the people of Texas.
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'i n Some of the stuff that goes on, for instance: My superintendent had us install some light poles.
These poles are underwater lights inside the stain-less steel liner around the reactor cavity.
They are used when unloading the reactor undemater so the people can see what they are doing.
They are nothing but stainless steel pipes with one end capped off and holes drilled in them.
As we were drilling the holes, drill shavings fell.inside the pipe. We also used some cutting oil. My superintendent came out to the shop where we had the holes drilled and said "You don't have those poles in the hole yet?" And I
I said, "No, we're going to take a pencil grinder and deburr them, and take a steam hose and steam all the oil and shavings out."
He said, "That's bull.
Get those poles on down to the hole so the electricians can install the lights on the poles." By our not taking about 15 minutes a pole to clean them right, the poles are now installed in the proper location. They pose a serious safety problem. When tney're refueling, the shavings can be washed out of the pipe.
l by the current when removing the reactor head undemater, and also, removing the j
old fuel cells causes. a current. The shavings can be washed inside the reactor, I
which can jam the fuel cells, could even fuse to the control rods and possibly cause a meltdown.
I feel that their doing that is lack of sense, lack of ex-j perience, or sabotage. Maybe Brown & Root's got an explanation for it, but I'd like to hear it.
I also have infonnation which indicates that during tile early.st' ages of i
construction around the time when the reactor cavity was being poured, concrete aggregate material from a reject pile was used. My concern is that if the 700 ton reactor is sitting on rejected concrete, it could result in the weight shif ting to the loop pipe, causing it to crack or shear off, which could resuit in a meltdown, t
I am convinced that because I went to the Brown & Root Houston office I
~
with my concerns about the safety of the Comanche. Peak plant and also the one in North Carolina, I am no longer employed with Brown.& Root. They already had my name pulled off the board as General Foreman when I got back from Houston before the investigation group ever got to the plant. My future was already decided before I ever got back and before the investigation was ever started.
1.ater I was confined to one area of the shop for five weeks.
I called Mr.
Rice in Houston and asked him how long I was going to be confined and told him that if I was going to be confined, the people I had made the charges against should also be confined because they were still violating procedures.
I had called TUGC0 before I called Houston and they removed me from standing in the shop and put me in a little tool room in the sihop. Mr. Rice said, "As far as I'm concsrned, the investigation has been over with and furthermore, you called TUGCO.
If I worked for Brown & Root, I'd call Brown & Root.
If I worked
{
for TUGCO, I'd call TUGCO..lf I worked for the federal government, I'd call
-i the federal government. But you called TUGCO." I said, "I tried to call you guys first, but you weren't there."' He replied, "You think we're going to sit I
by this G.D. phone and wait for you to call?" I said, "Well, maybe they're try-ing to discourage me here until I quit." He said, "Maybe you're finally getting the idea."
I said, "As long as you guys can pay me General Foreman's wages, i
l'll sit in this little tool room forever." And he said, "We'll see about that."
Then the next Monday morning, I was given the choice of eithdr working as a pipe journeyman, which would have greatly reduced my salary and relieved me of all my responsibility as a supervisor.
So they ROF'd me (laid off as part of reduction of force').
But they were increasing my department at the same ~
,7 time and after I lef t.
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The information preceding was given to CASE in the fann of an affidavit on December 18, 1982.
However, I did not want them to turn it in in the hearings or to turn it over to the NRC or the utility'.
I gave the information to scme newspaper reporters, and an article ran in the FORT WORTH STAR-TELEGRAM on j
January 7,1983. A copy of that article is attached.
Af ter that interview, I was shot at and have been on the run ever since and have been in touch with CASE a few t-imes by phone from dif ferent states. One night when I came home, d
I found my cat; its head had been cut off smooth and its body was missing.
l Since the article appeared in the paper, I have had a front-end problem with 1
three different vehicles (one truck and two cars); thpy all appear to have the same problem -- the nuts were just about to fall off the tie-rod ends.
I've
. f-
-been scared to go back and sign up every six weeks for my unemployment because l
I'm scared someone may shoot me.
Some of the reasons I'm scared is because of the things I know about at Comanche Peak and another nuclear plant where I've'sorked, the South Port, North Carolina, Brunswick Project Nuclear -Plant. As I mentioned before, there. are
(
weld seams around the Reactor Core and new spent fuel pools which we were told were not supposed to lose 1/2 ounce of contaminated liquid per year per seam.
These seams were approximately 100 feet long;when we tested these seams, some of them were losing approximately 65 lbs. a minute Instead of repairing some of these seams, the gauge was blocked off and pressure was put on the gauge only.
1 When the inspector passed the weld seam, he thought the whole 100 feet was under pressure, not just a few inches. Also, some of the stainless liner walls broke loose from embedded plates that are in concrete walls which scme of these plates j
were improperly welded. By these walls breaking loose they sprang out several inches from concrete wall; therefore, when refueling the reactors, the stainless steel liners were flooded with water. Of course, the weight of the water will push the liner walls back to the concrete. After 'the refueling process is over.
i
~
and water is drained out of the liner, the walls will spring back out, which l
could result in welds cracking or walls splitting. When I reported these viola-tions to Brown & Root's Vice President, he told me he was not that concerned i
i about the gauges being blocked off but he was concerned about the walls breaking 1
loose.
If I had told him of improper welding on these walls, I wonder if he would have been concerned at all? I feel these problems should be repaired.
[ torquing.Regarding Comanche Peak nuclear plant, there are safety vio For instance, quality control is supposed to verify the torqui:19 of L
piping support that should be torqued at 130 lbs. The hanger is on a 20 foot N
ceiling with a scaffold built to them. Quality control is on the floor; the torque wrench is sent d'own to get QC to verify the number and setting of the torque j wrench and ca'rried back up and placed on the nut before torquing.
QC hears a torque wrench click twice on each nut and buys off (approves) the hanger. What QC di'd not know was that the construction personnel' had a second torque wrench and also had a nut welded on the scaffold. The second torque wrench was set at a low torque poundage such as 3 lbs. and they clicked it twice.
Therefore, the,
((nut on the hanger was never torqued; only the nut on the scaffold was torqued.
There were also violations such as pipe supports around the pipe. For instance, 3/16" clearance is supposed to be maintained on each side and on top and the pipe is supposed to be resting gently on the bottom of the support.
For instance, a l
2" pipe: a construction supervisor will climb on the pipe and get some"of his j
crewmen so when QC comes to, inspect the support, the weight will push the pipe to the bottom.
In so'me cases, the pipe was binding so tight they would use a timber to jack the pipe down from the ceiling while QC bought off the pipe.
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[ In some cases, when they can't get the right clearance on ebch side of the i pipe, they take a grinder and grind between the pipe and tube steel, which in so' e cases results in a reduction of wall thickness of pipe.
I believe this m
could result in a rupture of the pipe. Construction has also tried to straighten a pipe support by using a sledge hamer; this is done quite of ten. An employee told me that while hitting on the hanger he also hit the pipe and caved in the i
<l side of the 2" pipe 1/2 inch or more. He reported it to his supervisor who said l t not to tel1 anyone and covered it up with I.D. tags.
e i
Another incident is improper personnel designing and engineering pipe i
supports.
For instance, one helper told me while he was employed at the plant he designed many pipe supports for engineers.
One day he wondered if.they
- g.-
were using his engineering and if they were then checking his work, so he decided that he would design a hanger improperly and send it to engineering. The engineer passed it on to construction which built the hanger and it is presently installed l
improperly. The helper said that he did not want to go to any NRC hearing but
'L he would love to have a showing and he could show m'any things if he was allowed
.I '
to take investigators and actually show them the supports in the plant. Other
]'
helpers have also been involved in making major decisions for which they are not qualified.
'i Another violation is a sensor in a dam was run over and broken by a bulldozer. -
i4 I understand that these sensors are placed in the dam in a vertical position in
'i order to tell whether the dam moves or not. This sensor was not removed or re-paired.
It was held up and dirt packed around it while being embedded in the dam.
Li The construction company, Brown & Root, lost a $3 million contract at Crystal River Power Company in Florida, by a dam breaking I was told by one of the Vice Presidents of Brown & Root. What concerns me is that if this dam
~
breaks, they will lose more than a $3 million contract; it will endanger many li ves.
There is also a violation that concerns me regarding the use of rejected concrete material in the early stages of the plant whe'n the reactor core was poured. A friend of mine told Brown & Root's Vice President's investigating crew that he was a front end loader operator at the concmte plant and one day y
a QC inspector told him that the concrete should be thrown away because it
- l was hard and dried. The inspector walked away and my friend started throwing it away and a supervisor told him to put it back in and use it'and they did.
My friend also told the investigating crew of some type of sampling machine that tells whether there are good samples or bad samples in the concrete.
It" l
had a, wire run to it while QC watched the machine to verify the use of good samples.
Personnel would pull the wire to make it read. good when it was not. My friend also told of other people that know of these violations and as far as I know, Brown & Root did not. contact any of these people, but talked with one of their supervisors and his brother that worked at the batch plant; they, of course, told,'
them that they knew nothing of this incident and since the superintendent is deceased, it they did not see any further investigation of this incident.
I am sure that the
- i NRC is aware of this statement, because it was in the FORT WORTH STAR TELEGRM4 l
article (attached).
Undoubtedly, they are not concerned abo'ut the situation.
~
~
I have not been contacted and neither has my friend.
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ny
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u if indeed a 700 ton reactor is setting on rejected concrete, you have a very serious problem as the reactor gets hot and begins to move around, the 1
concrete can give putting stress on th~e reactor piping, which could cause it to shear or crack, which could even result in a meltdown. -This could also be 1
~'
a problem in case of an earthquake.
I know of many, many more problems and violations than I can remember right
'j What is funny to me is the big deal everyone made of Russia's 300 lb.
now.
nuclear satelite falling back into earth's atmosphere, when we have a possibility
's of a 700 ton reactor setting on rejected concrete and no one is concerned.
If all nuclear power plants in the U. S. are built the way the ones that I have worked a t a re, we are in trouble. We'd better make friends with Russia so we will have somewhere to go.
- {
But speaking seriously, I think this should be investigated by someone with a little construction experience or common sense..It has been drawn to my attention
~j' that I am not a civil or a mechanical engineer and that it is not up to me to decide whether these plants are safe or not.
But I feel it does not take a civil i
or mechanical engineer.
Even a 6-year-old would know these violations should be corrected.
I have read the foregoing 5-page affidavit, which was prepared under my personal direction, and it is true and correct to the best of my knowledge and belief. The thoughts and words. expressed therein are my own thoughts and words (with the exception of minor grarnnatical changes, either to correct spell-g
,j ing or to clarify what I rneant, which did not change the in m
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,ii Date: March 31, 1983 li l
STATE OF TEXAS this, t7e 31st day of March,1983, personally appeare i
j
, known to me to be the person whose name is subscribe
~. regoing in ment, and acknowledged to me that he executed the same for the purposes there n. expressed.
Subscribed md sworn before me on the 31st day of March,1983.
1 Notar3NRublic iri a the State of Texas My Commission Expires: 8,
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- .*y
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TC Ms w r My name is better known -a l live in Glen 7c Rose, Texas.
I ~ orked for_ Brown & Root for approximately ten years, including l
about s n years at the Comanche Peak nuclear power plant.
During that time J
I was a for about three i
or four years. Whil was perfonning my duties as a I saw a lot of-things at the Comanche Peak plant which were no accor procedures and travelers, many of which could jeopardize the health and safety of the public.
~
I knew that something needed to be done before the fuel came in for the plant.
I thought it over and decided that I would go to Houston to the Brown
& Root main office and report these violations to the President of Brown & Root
- I direct, Mi. Thomas Feehan.
I went to Houston and met with Mr. Feehan.
I told.
I him of some violations that were going on and told him that after ten years of i
experience, I thought some of those people might know better and show better
~
craftsmanship and intelligence than they had used at the nuclear plant in i
Southport, North Carolina,,
t I told him about working at the North Carolina plant on some weld seams j.
that were not supposed to lose more than an ounce of radiation per year (we were told). These seams, some of which were approximately 100 feet long, were in sone instances leaking as much as 65 lbs. every three seconds, according to what was ' indicated when we turned the gauge off and watched the gauge drop.
At first we took the test channel off and started repairing the bad welds, which took several days. 'We were getting approximately 28 pin holes and indi-cations per foot.
This was, taking too much, time to repair properly, apparently, so somebody in Brown & Root's organization came up with the brainy idea of having us take the first foot or eighteen inches off, repair the weld, replace the eightee.n inches of test channel, block it off, and just hydro the one-foot area. QC assumed,,
we had the whole 100 feet under pressure and bought it off as is.
In my opinion, that is lack of craftsmanship or experience or just downright sabotage.
Personally,.
I think some of these people should go to prison for this, and I told Mr. Feehan that.
I also gave Mr. Feehan a letter with some things I knew about and that other :
people.had told me about. He said he would send an investigation crew to investi-gate the Comanche Peak charges, and he did.
I know of much more that I did not tell him or the investigative crew and have not in the past reported to the local j
NRC office because I feel the NRC is not interested in protecting the people's welfare and.it will be covered up.
I have been told by CASE (Citizens Association for Sound Energy), the intervenor in the Comanche Peak operating license hearings, that I am required by law' to report any problems which inight affect the h.eaith and safety of the public.to the Nuclear Regulatory Comnission.
I am therefore,
~.-
asking CASE to send this affidavit to the NRC as my method of reporting it, in
/
the hope that by doing so it will force the NRC to really look 'at the problems I've identified.
I would like to get this infonnation to Congress or someone.
,.. i who's really int'erested in the safety and welfare of the people of Texas.
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Some of the stuff that goes on, for instance: My superintendent had us install some light poles.
These poles are underwater lights inside the stain-less steel liner around the reactor cavity.
They are used when unloading the reactor underwater so the people can see what they are doing.
They are nothing but stainless steel pipes with one end capped off and holes drilled in them.
As we were drilling the holes, drill shavings fell inside the pipe.
We also used some cutting oil. My superintendent came out to the shop where we had the holes drilled and said "You don't have those poles in the hole yet?" And I said; "Nd, we're going to take a pencil grinder and deburr them, and take a steam hose and steam all the oil and shavings out."
He said, "That's bull.
Get those poles on down to the hole so the electricians can install the lights on the poles." -By our not taking about 15 minutes a pole to clean them right, the poles are now installed in the proper location. They pose a serious safety problem. When they're refueling, the shavings can be washed out of the pipe.
]
by the current when removing the reactor head ' underwater, and also, removing the old fuel cells causes.a current. The shavings can be washed inside the reactor, i
which can jam.the fuel cells, could even fuse to the control rods and possibly cause a meltdown.
I feel that their doing that is lack of sense, lack of ex-perience, or sabotage. Maybe Brown & Root's got an explanation for it, but I'd like to hear it.
I-also have infonnation which indicates that during t'e early stages of h
construction around the time when the r;eactor cavity was being poured, concrete aggregate material from a reject pile was used., My concern is that if.the 700 ton reactor is sitting on rejected concrete, it could result in the weight shif ting to the loop pipe, causing it to crack or shear off, which could i'
resuTt in a meltdown.
I am convinced that because.1 went to the Brown & Root Houston office with my concerns about the safety of the Comanche. Peak plant and also the one in North Carolina, I am no longer employed with Brown.& Root. They already l
had my name pulled off the board as General Foreman when I got back from Houston before the investigation group ever got to the plant. My future was already decided before I ever got back and before the investigation was ever started.
Later I was confined to one area of the shop 'for.five weeks.
I called Mr.
i Rice in Houston and asked him how long I was goin'g to be confined and told
~
him that if I was going to be confined, the people I had made the charges against should also be confined because they were still violating procedures.
I had called TUGC0 before I called Houston and they removed me from standing in the shop and put me in a little tool room in the shop. Mr. Rice said, "As far as I'm conc 6rned, the investigation has been over with and furthermora, you called TUGCO.
If I worked for Brown & Root, I'd call Brown & Root.
If I worked I
for TUGCO, I'd call TUGCO..If I worked for the federal government, I'd call the federal government. But you called TUGCO."
I said, "I tried to call you guys first, but you weren't there."~ He replied, "You think we're ' going to sit by this G.D. phone and wait for you to call?"
I said, "Well, maybe they're try-
)
ing to discourage me here until I quit." He said, "Maybe you're finally getting the idea." I said, "As long as you guys can pay me General Foreman's wages, I'll sit in this,little tool room forever." And he said, "We'll see about that."
Then the next Monday morning, I was given the choice of eithfr working as a pipe journeyman, which would ha've greatly reduced my salary and relieved me of all my responsibility as a supervisor.
So they R0F'd me (laid off as part
~ ',. -
of reduction of force).
But they were increasing my department at.the same -
N'e time and after I left.
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- 3.,J The infomation preceding was given to CASE in the fann of an affidavit i
on December 18, 1982.
However, I did not want them to turn it in in the hearings or to turn it over to the NRC or the utility.
I gave the information to some newspaper reporters, and an article ran in the FORT WORTH STAR-TEl.EGRAM on January 7,1983. A copy of that article is attached.
After that interview, I was shot at and have been on the run ever since and have been in touch with CASE a few t.imes by phone from different states.
One night when I came home, I found nty cat; its head had been cut off smooth and its body was missing.
Since the article appeared in the paper, I have had a front-end problem with three different vehicles (one truck and two cars); thpy all appear to have the same problem -- the nuts were just about to fall off the tie-rod ends.
I've been scared to go back and sign up ev.ery six weeks for my unemployment because I'm scared someone may shoot me.
Some of the reasons I'm scared is because of the things I know about at Comanche Peak and another nuclear plant where I've' worked, the South Port, North Carolina, Brunswick Project Nuclear plant.
As I mentioned before, there, are weld seams around the Reactor Core and new spent fuel pools which we were told were not supposed to lose 4/2 ounce of contaminated liquid per year per seam.
These seams were approximately 100 feet long;when we tested these seams, some of them were losing approximately 65 lbs, a minute Instead of repairing some of these seams, the gauge was blocked off and pressure was put on the gauge only.
When the inspector passed the weld se'am, he thought the whole 100 feet was under j
~
pressure, not just a few iriches.
Also, some of the stainless liner walls broke loose from embedded plates that are' in concrete walls which scrne of these plates were improperly welded.
By these walls breaking loose they sprang out several inches from concr-te wall; therefore, when refueling the reactors, the stainless steel liners were flooded with water. Of course, the weight of the water will push the liner walls back to the concrete. Af ter 'the refueling process is 'over.
and water is drained out of the liner, the walls will spring back out, which j
could result in welds cracking or walls splitting. When I reported these viola-
'j tions to Brown & Root's Vice President, he told me he was not that concerned l4 about the gauges being blocked off but he was concerned about the walls breaking i
loose.
If I had told him of improper welding on these walls, I wonder if he would have been concerned at all? I feel these pr,oblems should be repaired.
[ torquing.For. instance, quality control is supposed to verify the torquing of Regarding Comanche Peak nuclear plant, there are safety violations such as
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piping support that should be torqued at 130 lbs. The hanger is on a 20 foot
~
'N ceiling with a scaffold built to them.
Quality control is on the floor; the torque
$ j wrench is sent d'own to get QC to verify the number and setting of the torque i
wrench and ca'rried back up and placed on _ the nut before torquing.
QC hears a torque wrench click twice on each nut and buys off (approves).th,e hanger. Wh'at
[
CC di'd not know was that the construction personnel' had a second torque wrench and also had a nut welded on the scaffold. The second torque wrench was set at a low torque poundage such as 3 lbs. and they clicked it twice.
Therefore, the,
nut on the hanger was never torqued; only. the nut on the scaffold was torqued.
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There were also violations suc'h as pipe supports around the pipe.
For instance, 3/16"' clearance is s'upposed to be maintained on each. side and on top and the pipe is' supposed to be resting gently on the bottom of the support..For instance, a 2" pipe: a construction supervisor will climb on the pipe and get some of his crewmen so when C, comes to, inspect the support, the weight will push the pipe to the bottom.
In so'me cases, the pipe was binding so tight they would use l
a timber to jack the pipe down from the ceiling while QC bought off the pipe.
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in some cases, when they can't get the right clearance on each side of the
, pipe, they take a grinder and grind be' tween the pipe and tube steel, which in g
L some cases results in a reduction of wall thickness of pipe.
I believe this
)
j could result in a rupture of the pipe. Construction has also tried to straightenj La pipe suppo_rt by us_ing a sledge haniner; this is done quite of ten. [An employee i
tolo me Inat whi te titting on the na7RJeTle also nTI tne pipe antTav d in the e
side of the 2" pipe 1/2 inch or more. He reported it to his supervisor who said not to tell anyone and covered it up with I.D. tags.
1
- Another incident is improper personn designing and engineering pipe s upports.
For instance, one helper told me while he was employed at the. plant
\\
f he designed many pipe supports for engineers.
One day he wondered if.they y
l' were using his engineering and if they were then checking his work, so he decided that he would design a hanger improperly and send it to engineering. The engineer i
passed it on to construction which built the hanger and it is presently installed i
improperly. The helper said that he did not want to go to any NRC hearing but l
he would love to have a showing and he could show m'a'ny ' things if he was allowed I
to take investigators and actually show them the supports in the plant. Other I
helpers have also been involved in making major decisions for which they are not
!t Another violation is a sensor in a dam was run over and broken by a bulldozer.
I understand that these sensors are placed in the dam in a vertical position in l
order to tell whether the dam moves or not.
This sensor was not removed or re-paired.
It was held up and dirt packed around it while being embeddtd in the dam.
The construction company, Brown & Root, lost a 13 million contract at l
Crystal River Power Company in Flcrida, by a dam breaking, I was told by one of the Vice Presidents of Brown & Root. What concerns me is that if this dam
. breaks, they will lose more than a $3 million contract; it will endanger many li ves.
There is also a violation that concerns me regarding the use of rejected concrete material in the early stages of the plant whe'n the reactor core was poured. A friend of mine told Brown & Root's Vice President's investigating crew that he was a front end loader operator at the concrete plant and one day
'I a QC inspector told him that the concrete should be thrown away because it was hard and dried. The inspector walked away and my friend started throwing it away and a supervisor told him to put it back in and use it and they did.
My friend a' Iso told the investigating crew of some type of sampling machine that tells whether there are good. samples or bad samples in the concrete.
It*
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had a. wire run to it while QC watched 'the machine to verify the use of good samples..
i Personnel would pull the wire to make it read. good when it was not. My friend I
also told of other people that knw of these violations and as far as I know, Brmn & Root did not. contact any of these people, but talked with one of their supervisors and his brother that worked at the batch plant; they, of course, told /
them that they knew nothing of this incident and since the superintendent is deceased, they did not see any further investigation of this incident.
I am sure that the l
NRC is aware of this statement, because it was in the FORT WORTH STAR TELEGRNi article (attached).
Undoubtedly, they are not concerned abo'ut t}ie situation.
I have not been contacted and neither has my friend.
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-5 go If indeed a 700 ton reactor is setting on rejected concrete, you have a 4
very serious problem is the reactor gets hot and begins to move around, the concrete can give putting stress on-the. reactor piping, which could cause it to shear or crack, which could even result'in a meltdown.
This could also be i
a problem in case of an earthquake.
f I knos of many, many more problems and violations than I can remember right What is funny to me is the big deal everyone made of Russia's 300 lb.
nw.
I nuclear'satelite falling back into earth's. atmosphere, when we have a possibility i
of a 700 ton reactor setting 'on rejected concrete and no one is' concerned. If l
all nuclear power plants in the U. 5. are built the way rue ones that I have worked a t a re, we a re in trouble.
We'd better make friends with Russia so we will have somewhere to 90.
But speaking seriously, I think this should be investigated by someone with a little construction experience or common sense..It has been drawn to my attention tha't I am not a civil or a mechanical engineer and that it is not up to me to decide whether these plants are safe or not.
But I feel it does. not take a civil or mechanical engineer.
Even a 6-year-old would know these violations should be corrected.
~
i l
I have read the foregoing 5-page affidavit, which was prepared under my personal direction, and it is true and correct to the best of my knowled'ge and belief.
The thoughts and words. expressed therein are my own thoughts and words (with the exception of minor grarnnatical changes, either to correct spell-ing or to clarify what I meant, which did not change the' intent of my thoughts).
II Date: March 31,1983 7C -
ll STATE OF TEXAS
- this, e
31st day of March,1983, personally appeare known to me to be the person whose name is subscribed to the j
egoing ins ument, 'and acknowledged to me that he executed the same for the j
purposes therein'. expressed.
~
Subscribed and sworn before me on the 31st day of March.1983.
'~7 Notar N ublic in a the State of Texas j
My Commission Expires:
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l ;XAS UTILITIES SERVICES If CPP S/C0 '~
OFFICE MEMOR ANDUM
~
G. BuncT,Hal Goodson, Bil1 Padon 7,
Glen Rose. Texas
(
subject COMANCHE PEAK STEAM ELECTRIC STATION 1981-83 2300 MW INSTALLATION "H" DESIGNATIONS Please hold the issuance of any traveler packages or the installation of any hangers which have typicals with "H" Designations detailed on Gibbs & Hill paper. These are being revised and will be mammed shortly.
R\\rmso J
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