ML20199H622
| ML20199H622 | |
| Person / Time | |
|---|---|
| Site: | 05000000, Comanche Peak |
| Issue date: | 08/24/1984 |
| From: | Matthews P NRC |
| To: | NRC |
| Shared Package | |
| ML17198A302 | List:
|
| References | |
| FOIA-85-299, FOIA-85-59, FOIA-86-A-18 NUDOCS 8607030408 | |
| Download: ML20199H622 (19) | |
Text
{{#Wiki_filter:.O d
- -*'-'***-~~----....%
g /0 / v"' - r J. q.>..1* TVlig 9'glo r g,#}cy f] /sc F A m 4: \\\\ (4, p / / < ' j q 'l Mc.mo h E \\ r_ 34. j i dqhma. loc.cv t<.w w A 'w 4 W 1 Cc <_cl b jp Acnc a \\s e.uC M A at ey _qsce r-7 ~ d::id ko a[ e ,x ,fNOgO'hus 4 \\s es 5 m f ku dc ach poas e 4,w Q = i T ewt A.%(m9cu_k vudw C \\ w e??*ew ' ek f.4 All s Q 6: A c p mca m add W 1. a l of 6Ph y % d en ew 6 D c A 's % l % e.s wect n ce ea a M c.g. ? A ' M r h,s w o. s u.. J c b p c c u, & p 5?e tm c s D E sTt1 swo. Q cat.c d h % 6 5 M s u w e as.c a k Y W 6 m <> u us s se W at o cc_u_.m v w n ( 0 O co c.'- A.ucR87 T '[ k 6 p \\T t.h E 6 K A. j c; 1 W% G.'M t.o. (- l s W D w %w o,T75%q/D&3es34 g _cq q & m,W m w.',, m[., ncwcr w y q t \\ of pecbaw~ne w+ n. I &. % ' t w sj a a c_g, u_ a Y M C# / m M ud,k 6 cr_. pri nu'Ij dA \\ 6ke w,.% 3 j ' }c casi c4 in,__; y 7 i i arc te o y %.3c sa amm tja, q,. Alje ulb #T be e M,sfyh5 4(j.:,3, a,,, 1 o &g hu-egg 70 g e esosaa GARDE 86 A 18 PDR
. p a. M... w ::. ~ a a .u...~.-m-....'a~~" '-w dch h o f u h s & A-s - m d' A UOt5- .\\ ( ~ -), u.> a. s L$ r at u. I o A 5 3 0 S P ' i.tW %j a im svc k a ca_se. ule_sc-c.-~ bspkt co.- wbc.it. a h wc n - sO_,i .j - to +Ju.e we ? oe do m e M +6ex-G a Mgrebut.tkd v.0 u>o ce_obed oA k b6 C_. t G._ '~ \\ c MM' b O h\\ C ( e&% l a I M hU O\\ U dE b 5 Qd-anne $a.u.-kther9cakt ~ s g-COM % uk u f@a. b d %,.143X.#rtowt% l 6 o W. DcA n-6ag* % ~ea_e u - w r: 1 ravs i e t t.~c, t, swuG ur <.. % Eleco\\t d e.s uis -Hv_ u d L - c e._ t c 4 3 J-. y ( i \\1 v_aA ct A u tclo w it f,, Vit oD , ed Tc c-s t t wag LD \\%.b % b,; N i CLb M d_5 5 W1.L w.k " W1t.P I t 6 C \\ Srl, c 0 (.A SiO O b WL4 7 < 5 {E.C.5E C -~~ Vs wl eco.JJuo J 4 evt i a m ac< La_raa W1 es sn -u,as gna w o w M e_., k h4_d wtMwu7_. %ue L Ocexdc mo u <rJ A De_.A. %,er oc u t, t. Q t. ~ ll .J.,'t dC.h U ) yM \\O6 .O CCLI ( FAd,, ( l % m[ w w w 'ftotc91_hh fiDf c.S< [ [ti A fa nam w to NW__ weste %cs goscDn M b t, K,. wc s J e- ., / ( I ) , U )\\hf M i J. p \\.s L, ' S1 ' 1 W C b-4 h \\ \\ 01 u F), \\NAoA \\
- c.
~..
4, _.4 a = e hw e a - M h n-arde
- =De 4.meh,MM'
&s e-N - m,6 eae e ehib ~- - ^ N S OtA d#c ] %1ht etded.;" %d ; RT6 og 6mweg 40 ] \\ o se o c vvt t s gf c.-c.a_./ A e c.we 5 F \\. P _L-Mu: wt t [1 gg i N k N cn-Pa%s a n' ~s 'M w a 4: d iM 54:A Tes.s i sa.t t c 6 w D46 M,,(x CL. i 6k.4 I (1_ AAc.s %' s-ns12p' Mf O (C t A 1 U.) s f j -f2 +of A m Hu.s 6 i tsf La be '00"kced m u%Occ i1 M.g J L w e ~ a'd,s a ~ so 'j d LA> $.'D'd d / D C. C /5, l./)&G!g f N o- <,c m w-v v. wu, k b q y-1 \\ Ms C / j. sw %t.s Mso_e 4 s.\\en col ( y' c-uc( G%de-n 2 *.*f M. s m c.e. ~ 15 c4
- v. < - b, sko
~ s
- i 4
} 7" ' Q$ go .g. ..: l ll p.:
- d; 1:o ihf]
p
/!J d s C..\\\\ C e '.
- b j 1. :+57th l.]
't e_1 t 9,. a. _LGc rv t o v ua s.s't s ~ L e m ~;.x_.-..t.f }buh.:-c._.1- ~ -w s.4.:.v-m ~- J.c,s. ra 5 o_.iq ".,.r } .L O o.p_ v.s g M. d:fi To l ]1 ce i w, ,. u.o-q. e p. c .x b..t_ $ m v_dt ;,st.:0.Gy...9 c.o:1 w,e e I c5-.s.c-t_ ;c g 5 c \\- Co va vQ_u _.su @d_ <-. v.u L. i.u' jl \\ n s 79 e-1.t. us A' sL.\\ ._\\ p s i C-w\\ '. t 1 ce me.cn ad.,..dT-w(. 1 e i. h%paM Qr c- \\a.a\\ .v a a e -l Crl 636l~ ~~' 'L.s \\ n7~c~.~ 's'si C' in Q %\\ \\;\\K
- h.,6 ';'.2 C"O
~ g \\ ~ M-d'.f_', \\ \\1 9 { d Y o C-O O'#1 LLO f b '_S I
- pczo5.:._ ca. u
'[ \\.u o s U. w -. 3-v__c.cn c_.s Du s it d .w a-s.s-s et.a.:_ T : w \\ Q P-8 5 w <,re, u.s _d ,i u -coide.- -^ .nt y cu O_ ;L4 S96.6 5 c-G.:Q;,:cle l.h,,,&\\ua}s.[ 29-ll dif' tv\\v_ te_. a DC./r i.q'a_s us.gIy b c.. cc-.Lv.n Ml _s ~ l l (1 pCO C.E 5UAr4_. d w _ <_ d %.t.c.:L.,<..._. , l., iq - r,s..s,,te.:-....- st.. (.,. v -. ~ vcu_:n.s.C 70 e D C.'5. c 5 t e _, y 1 , i c.~.1c w,c_x,e, m.:.=yp-r = r i s.,, c zn a c > _e.c-: _ - e-u . i i Ds. 9-e.u -\\ <a \\, e a,
- a u e.
T- _' u-c a. l % f e u.1L.*.},.suy \\.x 2.~, .e..'..t u ! - rE [,1 u\\e s-L'c., \\.,z -...- ~ =c.~.u..Q.::t_. s.v. x. -. a Cc t.A. JM. h.C .u _; ~'.r_i .<...> qj;...j [. 'I.rrcu-c.i]~~7. d c o i f-}.-. i,-.;t,. s A
- 1.,
t L,. .,a;.
- 7. s u,
i s \\ .,-(,.. $ u ' ' ~. *. s .2 - p.all.= I g l
- 1. --
,a'9, e age. A.D !h r Lw., . m..
- 3. -.-
ss ._._t, .._,........_____,,____._____a..______,_,.
a wu .m .1,__ _ _._.. _7 m_ ~~ p. 5_ p . n-f N0+, g g 1> qb.[]- hhh"4
- h_
^ ~N ! %y z g h.f pp a M-tewr3en(P,pF u W}e.5 i;M r:A e e y-- g o 4 A w 3 m~w <cg w*
- s# A Q s'l
~ k~ J. c ,pe \\ h P =i [-[$4%( E'@ ef pd o \\g< 9 pa c ' \\*. -l-jf N tl.fs ,_( Y& , [ c g g (L{[\\.ta!4 P q d_ s i as _e dill s~g.+ g ,rc e e[(d,efg[y j 1 r; ,g L e.e 2 s se,c s . t e a ;, g J p, e b'g p-g * ;+r n n g# 2 se y e ea w,c
- # ge c F;.~ F cy p q g -9
-t) j g c.ty n p g 6 4 wr, aqme ~- S ?lhw)$ c !~li at-{ew% oqe g wuph 5, # j,ij 7 b6~%y[rEn j OL. 6 - k33t 41.g e.t t i'C
- E?s, 1
G 6e E3yF4 g b >$g r ' f g# p U 9 2 m 6 - -f Cc g p g c
- a dl h, O f; if li
- i ;pI Q
> p) p g F t .i 9 r
~. - --,. - -~ u..=.- a ~._:..w__..... r-T l g_q'daTwj.h g g e.n) e q, d w y u,ge d fer. ( 'wr e4 %. t s ned t o ~ u o.c m p - a s
- wr r-L kha wt gg cxa n ?h %d d ass d'ma n!
su A ( G w a rk d i L.c O 5=u 'a. Td'as k'lu2 W h\\ 3 M $1,LL \\ d d -,. .~ k \\M L k b O b;' i ,f -Q 2 %-G a-m Hus tr . c..a s-2 s y i tds da be pro vuhd m &bs.a cro ' g, eodd sa ffMl ~' ^ a-t i e ric cd. w M is. .UJ e w':, 9,; t .o .l-L< D w, t k S k' M I j l\\,J.) M { b TC gq d _ lw \\ (\\v [ L s _.L twdte<.Ch'~ M I Wou._ o\\'be ko coa a,+quqes.W al ~dcc. $( l: ec %s 2.c a m 4 - 2_:.= e m. et i bg 3 \\h 7 \\N %( s e 9 i i .-g 4 [ w ,1 [f $-4 7 '3;,./. : , a,,.. - :, ;. ,,...g. .,;g ;,.y. p:.z.,3, , ;g.,;,3 3.. -, _., _,...,, .u
4 ],
- 4 '*E *h a h
-h-
- 'e he. + A.
, = e.. a we. .,,4, M es 41&seedkw a w MW4, k g J i. r5 ['(il i' A ovu2 Enh6{'\\l1 Ct L/ ua d '\\,g i L c. d d el b). pac,<_.ca Y Y L k\\ b' Q, [Echw, u n A h,t o m ceao c{ re a_l% t e .:s
- 6. a u
cuo.ccl, coa.> e a_# cw a..x. i \\ w syedet. r-k i-~ bwt t%:j1_c__ 44_k Y.a 1. t.u' j O\\ T 4 oi ceofte Eb nk.m e a % DCh 's rwc e %d u uct h c.cea u-p k A'MGas u.Jc 'v=lcR>3 ? pc=1cic pm m r, t i, t Sge'.C (t ) sC 5 DuA 5 \\ t il vho -s t.c\\ d WL C-c~- T ilA_.\\ \\** ,.<..i M D \\.0 6 Cf LL~ O A, h%&d 29-Q: Cu o[EN s i < r G u o,., w ' s J# u h a_pcA % ugs e c., cm.m!.. A_ peo ceAd< T i, _k$lO f_ll.4(d..y d. i .s \\C 9 Y\\( "bMJ A. I f. '~' h(' C ' ~ y n d (_ d M sto u_ d (.7 5 I [ DQ's.35us m c c . s d c w e. e m c m. o.._- . u.c y ] Of c th c.,a_h, evs,, s 2-< N m t 's e mc-- - -
- }i
%u recob 1 am..;_s ulcre. e c.c. a d( c.c.c__ pc '..tpTc.t.c d d. c x.<.. t v c c.<. i s ( c 3 c c.a _\\ ' 6 & & u. n. s < ? :: }. : .c r - 1 , to a,cd.e:ri. %..uz Case pwr hK-. w o \\ - u._+e Qye.. _ s (tu..t. o,.. e.: n.. ~. m e
- siI G..
5: N _..z._.__',.__..._._ _q ,..~_,_...w.__._ ~ 61 A ..' l ~\\ y-p 4l.t> 3 u t' ' " m, r ^ = b rk.teurm44upo 1 m? t. m N b ed as g. s,ho , em ~ c .m 3 f "f k 's k f -h f ' 19 g=4
- 3 n
4o a
- e
$,1,p y n m b, y,4 c< : -xP[n>y, F 6 h 17-b Scr P [ w. F+ g i n c ~ ' s ur #p p gg p q $J F -) = c e 4 g [ F ') - > 'K, f q u-w ;_ ep o +F 7 f p (.4 c .p L-9n q s-, g ,a o i u 1 a,_ n 4 ' - { >,g 'd. V .9 m,, P -) c . ( 7. + p-1 c- - p 4h v. a n 0 a t: 'f: t-g' o p i 7 3 g-3 t) f' -@ [dl J - p p( /I)'o ui ^ , ~ t f 7 g - q 15 hq o - L&[e g ! s [p ylo g A s a[, f { y, t s-E, fp)
- i j;
~' e y t l Jh b .f h f ' f b$2 k r wl/ f N y' n< e qq r a ~
. x.-. ~- w :..:- :....:..;-.... : : ~ ,,,a.,,,,g, ...e- ~ f} V q Lu2 dh tv- \\ '.0F h MA t S gco A 5 4 ed - h: Wp h n da A' " JTd ) em 3 -~. _ % vs e m\\ L. u -= 1 f, .) 1+"M 1 .I . E Y1mo Nkno W *-M2 l Cch & Ph %s J.s s a x ms sa.t A ( G w o Ac ad i A 5= d i e >. pu_dw pM tua.6 m,cudi N -%. 4.. q \\ A O s~.)s ~ Ne I -Q 2 + - f i e n-Mu.s fr- < c. s i M J a k e. p r o & ne d us Oc e b p u-.3 d w _. i ? & l w d -. e g w ^ 9 go \\ iW4 w Sc Clcd & iis.l M ji): G.:) i 'u;d N sG +c m dM~% tNH ~~ T twdtco 5%d T_ Weu / bo-d Ye \\ ec% cMypu wa ese e,-2_.wy_m. M. w ss l e ee e %w m-w Ao t , 3 l. $ledal..] L:-L ^ } y i ,1 ~] 4
- .. j I~
i ;<, L r.- m
- .,,,,,,._,q'
%N_{. ___.____~_.__'rm.,.. ? '_.'jF.py --'. ___... 2
.=~:- - = --- w...:.. 3 ;_ ; c - '-
- i 0
4 07 f. /$ gd 39/'W \\ -i Y Y f4 47^ /c wi.M et #h/d' 5 l W Y$ & hl 8 / i >1 fi - 9 I e 7 J +1 4 l' i ) i 4 i i d i 4 I l.. b' ) i L1 t ; ' l Il ,A ?** I ' 5 d . y f. j f '. h.q. y %; j m 3 lg(p E l l -.. -,. -..-.g r y,. y > r
..--~w. o
- i e8
)j
- 6..
D 6 C. W 's EllT bt) Ilt's /_.
- j i
~ Sff]E(y) Of'A=Hft 77of)f /?c.'s CGDuj?.Ls A-1 Document Control Process 2 .1 Example of How System Works. Welds 7] , Before a weld is made, it is issued a Weld Data Card (WDC) and assigned a number by Weld Engineering. This card tracks the history of the weld (who made $2j it and when, who inspected it, etc.). This is transmitted to the Quality 4 Engineering Reviewers (QER), who would review the cards and make sure that the i I welder was properly certified, that Quality Control (QC) had inspected the weld i "j properly, that traceability was maintained, and the like. If the card passed I i the review, it is transmitted to the Authorized Nuclear Inspector (ANI) for his approval, and then transmitted to the permanent records vault. If a problem existed, the card is sent back to the appropriate department for correction of the problem, i.e., if QC had forgotten to attach the results of a Penetrant Test (PT), the card would be transmitted to the QC department. Problems l. Storage of original, permanent records - These records are required to be stored in a fireproof vault. The onsite storage of these documents are alleged to be in a number of trailers hooked together. 2. In late spring of 1983 the documents in a single records control room j were dispersed to satellite control room in order to achieve better efficiency. Many boxes of documents were shipped to the satellite offices 'l } each day. Apparently this system did not work and it was decided to I return to the single document control room. It is alleged that one satellite J. j had lost 1,400 packages of permanent records and it is suspected that other J satellites lost records. ~ 3. Document Control Clerks are issued " controlled stamps" which they wou-14 use to certify that a document package contains the latest information and is i OK to be used'to perform work or inspections. It is alleged that these O stamps were is;ued to the QC Department and that they would stamp its own l ] drawings and declare i,t legitimate. w p.mp c _ gmymmgegw ~nn-r+m
,;,_w.~._..---.---.--~--.--. .l 1... -i ? 2 -- 4. It is alleged. that documents were reassigned from Q list items to non-Q
- l
,gd items to circumvent Authorized Nuclear Inspection (ANI) review. ANI does not review Non-Q components and systems, r There appears to be a concern regarding the number of CMCs (changes) on a 5. drawing; sometimes as many as 18 or 19 times and that some of the documents are falsified. One example is that a date was changed on weld data card .) by a QC inspector. The DCC issued an NCR on this. Subsequently, the QC inspector wrote " signed in error" and the NCR was voided, t 6. Craft " bootleg" rework by performing repairs without any documentation. An example concerns the switching of valves from Unit 2 to Unit 1.by .y lining through the "2" in Unit 2 and inserting the number "1" on -i U' documentation already signed by ANI. 7. Craft and engineers do not follow drawings by on the spot changes to ' make things fit as they please. The engineer would then write "as built" j on drawings. These drawings ar-e not sent back to Cibbs and Hill for ~ l !\\ evaluation. This appears accurate because CMC are also dealt with in this I ) manner. An example an NCR was written because material did not meet J 4 minimum wall thickness. A B&R engineer called by Craft would void NCR by ?l writing "as built." .g 8. QC inspectors not qualified or have insufficient training. f( 'i i 9. QC and construction are too friendly resulting in a compromise of the g, L,- y I independence of these two functions. 4 a Y 10. The N5 program is being revised to require that anyone who wants to get a ~q package out of the vault for review must get a signed note from QA manager. / 4 k This makes it impossible to review packages going into the vault, s J j:;- a- -*w, a,,->^ --,.i- .;c- \\ g., .g y j' fWQWJ?S?5&NQ@'G'."E'5W }ldlVji. ~ ~ O '-~A ? Q7~ Or L'QG;4!fl
7_7_-. ... rcq... P -,.,.. m%, ._g., .y 2.- A-2 Breakdown in the Document Control System Tj 1 4 &.DocumentControlClerkshaveissuedincomplete" packages"toQCand ~' l y i 9' violation of procedures. Some of these were demanded by Superiors. 1' l 2. Craft in making unauthorized changes in the field. They would do this a } ( by writinga " traveller" which would allow them to use an incomplete package l
- /
j in the field. \\ f' 3. The Document Control computer is not accurate in that it did not match the documentation. 4. Large backlog of work in Document Control caused backlog in the field. The lacklog was caused in some instances by not being able to find drawings. .i Instead of pursuing the DCC would write " Proof" on package which meant " Lost." No records are kept of lost documents. Craf t would find a way to (,'i get around lost drawings. This could be done through the computers by' calling I i up the missing CMC and had it deleted. 5. Poor training of Document Control Clerks.in that they had to learn on the I d( job how to handle " travellers" or other types of documentation. 1 l 6. An audit performed in 83 was flawed because the shift crew knew what was ls 4, j going to be audited. They should have gone to the field to review the ^3 C I packages that Craft was using. M } 'l q ' 21 -}.i 2 e b 'S. ' ' ' ~ _ _-. h N. "* ) y 's.=
' ; j. = ' ' _ _ J_g_ '.m e.. _ ;_,_ a. hu, A7 ._, w m.gA ~ 1 e l -{ A3 Quality Assurance Documentation Problems and Bypassing QA 's 1. Receipt of vendor parts and certification of vendor components. Exuple I i bolts shipped with vendor components were missing and fabrication shop .i.' g manufactured replacements without procedures. The loss of these bolts were a c j not reported. This has been happening for years. 2. Craft telephoned orders to fabrication shops in lieu of sending drawings as t reouired by procedures. This resulted in trial and error until piece was b suitable for installation. 3. Non-conforming material being used in safety systems. An example is that Craft " buttered" pipe'to achieve correct wall thickness. Pieces of material -l/ b' numbers changed in an effort to bypass NCRs. Also out of round pipe was heated up by Craft and make round without pro-cedures and at times altered control modification cardf(CMCs) or CMCs' were " lost" or missing. 4. Fabrication shop upgrades class of material to fill an order if material requested was not available. An example is that Craft will look for material p requested on drawings, and if it cannot be found, they will substitute a I similar looking material. The material will be stamped with a number that 9 .i { corresponds to drawings. This stamp looks different than vendor stamps. l Materials are upgraded through th'e use of interoffice memo (IM). There are ~ 1 i no records or control of these IMs. There are thousands IMs in pipe f 1 \\ 'J fabrication shop alone. \\6. Improper sign-off travellers (hold points). f .] 7. Craf t would satisfy a CMC on an inadequate weld by welding over it instead' < s .f - i.g i. .....i.g it -..tiv.. r.,.ir..... ...r.. ,e ~. -_ _ r : W % ~, M '.__""; -.5.'~7 ~_
a. ._w : - - ~.2 w:-- L-_a. L~-..:.u.- . : _ a h.=.% >s ~:? t 8. There are undocumented weld repairs or titey would make other attachments tst_
- l
/ h a hanger that QC had previously approved. .{ <\\ This is not an isolated case. 1 4 9. Weld inspections not performed in accordance with procedures. An example 14/84it failedon1[15f4. is that Weld Number 40-C-AFI was inspected on 1 7 Weld repaired with a weld tech (WT) hold point in lieu of QC hold point. I Y g WT is non-safety. Weld was dug out and rewelded on 1/16/84. Date of original inspection was crossed out and 1/17/84 date inserted. 4 't 10. Total lack of independence between QA and production. 1 / i \\ 4 11. Pressure on to not write NCRs. / 'i I a 4 i i i 1 1 !j 1 l 4
- \\-
rv: ...ww~n. tx
..-(
c l. 1 .l ,;.;m ~ i e I ~~ r 4. t v R.c,. a 1 1 I L+ <!n vvc mc. o (u l(4 L a '{ - a w -t la k wf c m,-(A <h 8 b.( j4 - 3 s v% tA a 1 a w u a, &. a ~u... ~ kk L'o b le r 7,\\p+. 4, c r -p u r lJers.av. 4-1 g r e e. f -l, w u.f wal +u. mtx O~c A is ye+ d 1 N. 0. w - m 4,g%. Tk 6 Move.d4, r R,k ut m Ac .ph s W L it a-A7 t sa;-)A 'pe T wEa o rl i>..% ,. ( p,.. kt 9 %( f.,' F kl Lk -Yo Ic.E.cp 41.4 E l k. hh.:, S &JJ LA .. re r s. av. 9, A g.% 3', wt-r.'.4 + s.J2 we b e r m 9. h v+i 1 ,1 n u ;. , y(! . a. m D (U oa.d t e is, tp A Tu % l 9m au we i ) %/ p k "O +*k D'
- +
[
- 'S8 qg$
( =% t
l1 - 3 " ' */ 6s %. N pe'- J AFFICAVIT OF Page 3 YOY @.f%9 Q-Q - W< w A }%%su w I pul hold tag No. 40-15-5 on N that was out-of-round so badly it was egg-shaped. j called me "on the carpet" and f this piping. I a confronted 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 l pieces, and I had put " hold" on that piping and the: spool from which the pip ~ I said he wanted me to delete the:pjpi,ng piece numbers and the criginated. 3 I did revise it one time spool number from the NRC. -r--r e.1. --.. with the heat numbers as* opposed to the piece numbers, under protest. \\, ~ The $p\\ However, the next time I saw the NCR, it was in Rev(ision) 5. n aa(E Y engineers had revised the NCR h more times; and, of course, they had d I looked at the NCR and found that Rev. 3 reference to the specific nu=bers. I also saw that they had had designated the pipe to be used as hanger materiil. i put into an Inspectica Report (IR) that one of the pieces in question--Piece No. 35--had been sent to the fabrication shop and frem there, it had been sent } to the Containment Spray (CT) System. (At this point, the pipe number was ~ Another piece-frcm the same spool (No. CT-1 40-01 ,p~ CT-1-55-14-I/T 2, Piece 38.) ~ Itt 3) also ended up in CT piece 11, Weld,9-A. y ~. N I went to the pump roem and noticed that piece 33 " Buttering" is a had been installed and that craf,t had " buttered" the pipe. i around the pipe to make it prccess where the craft welds welding material 360 l This.is usually after Quality Engineering (QE) requires thicker pipe. thicker. I could not believe that non-conforming pipe was now being used in a safety j Buttering the pipe only worsened the prciblem, but did nothing to corr system. it. This incident is not isolated. d. p . I have knowledge about cases where craft r~eceived "out-o.f-round" p ~< Ot 30 m z l.' s* g [. g.. ' j^ _ ~'
-... - ~. . ~... . =. - - - - ,.- ~ _~a-2 .,q ( 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 j steel pipe since it destroys the chromium content, which prevents rusting, and 12 weakens the pipe. It also is a violation of the ASME Code. 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. D . L-A\\ l ,.C ._f ~ 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 h this missing CMC changed the pipe number and was done deliberately by someone so d that the unauthorized work could not be traced. An inspector who went to do an T f inspection on t ais pipe, now No. 48, could not tell,the history of the work or i ' of ~the non-conforming condition it had been in. I Another serious problem on the site is upgrading of the code of the class of material ordered. I personally know that the f ron fabrication shop illegally i upgrades the class of material. I,t works like this: craft will get a drawing that ca'nis for Class I, plate, then they will get a Material Requisition form (MR) j and look for the right plate. If it cannot be found, a similar plate that looks i } like Class I, but actua11y is Class II or Class III is used. The pipe will be stamped with a number on theplate that incorrectly identifies the class of material, and then uses it as if it were Cliss I. The factory stamp is different 1, frem Brown & Root's stamp; both are st'encils, but they are different, because /fu the factory stamp looks more professional. For a while, I n-circle the number that Brown & Root stamped on them and then date it. I B h2g g g.. vg;u Te;-, 4.y<qiQ:f Qftl~.~ Q'. Q ;'.:;Q)'?,'!., .n
- m-
NsN s ~;. En c,n,d( Q e ( Oy, /pg I&g Og d# 4),*pg,R 7p .,~ 0 '6 Io 'dn 4 n 4
- hp Org O
4, 4, h ,e, lS, Oo
- O e
007 Cp '.
- ct
^7 ' op b&t 6p *s 'b 'O, ? 9 0,, 9 ds 0 e e o 4,, &p,
- e, 9
- g vg de O
'e, ' On, O^ 6 Co C, 4 Sp d., O y, ., s n j In, 4,. '/g $p
- c..
/G p O,, ,g ., /e 7,l8, R ~'9 9 4 'ts,
- e
.?, 0 9 4p, /s;'eg 4 N 3
h . I
- .1 1
FEB 2 21985 1 e. 4 4 Attempt contact with Alleger A-4 i - 1 11 Alleger A-4 contacted V. Noonan on 2/15/85 but was not able to speak with i Mr. Noonan at that time. I attempted to return the call to the alleger at 'l (201) 866-0400 Rm. 317 in order to arrange for a feedback interview. I i attempted to contact the alleger four times between 2/15/85 and 2/18/85 with .i 1 no success. During the last call at 1910 ET, 2/18/85, I left a message I l requesting that A-4 contact me collect at (301) 492-7903. 4 mr J.J. Zudans i i e l et .1 ,e L F0;A-85-59 a 3,, Q lA _hNN,NI[h;-khbf)i Ik,'-k-{h';e' ~ %I,' J, 5; h ' -~I N k(', i .}}