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*s .....~ NOV 5 1934 MEMORANDUM FOR: Larry Shao, Leader Civil & Mechanical Team Comanche Peak TRT FROM: Shou-nien Hou Mechanical & Piping Discipline Leader Civil & Mechanical Team Comanche Peak TRT
SUBJECT:
INTERVIEW WITH ALLEGER _
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A conference call was arranged by R. C. Tang during 8:00 to 10:00 p.m. on October 31, 1984. The purpose was to discuss with the alleger on TRT findings. Three persons, P. Chen, R. Masterson and V. Ferrarini from Mechanical and Piping Group of the TRT participated in the conference call with presence of other three persons from civil and structure group, ; which included D. Jeng, C. Hofmayer, and R. Philleo, and R. Bangert from Region IV. Highlights of alleged issues being discussed in Mechanical & Piping area and our suggested follow-up actions are summarized in the attached list. Discussions in Civil & Structure area are discussed in a separate memo by D. Jeng. f
'p N XM Shou-nien Hou Mechanical & Piping, TRT
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Enclosure:
As stated cc: V. Noonan R. C. Tang P. Chen 7
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R. Mastersof V V. Farrarini 8607100243 860630 PDR FOIA PDR GARDE 85-59
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g n a, - o . Interview with Alleger on TRT Findings Interview TRT M&P Allegation liighlights Alleger Date Person Cat. # # m/ 10/31/84 8-10 p.m. by phone Chen #11 AP-13 = Regarding mainsteam line forced into position
- Alleger does not agree:
- 1. Flushing line was connected to FW (shoul be to SG)
- 2. Chain was used during MS lifting by crane (not used)
- 3. Under engineering supervision during lifting (no)
. Action: Reflectwhat the alleger said in open issue and discuss with licensee.
,, Ferrarini #6 AW-45
- Regarding welding performed without inerting.
. Alleger indicated that inerting was not done for welding repairs. Wi .
Ferrarla ndicated that .e inerting was not required for repairs (;f f >j)
. Action: TRT should insist that inerting is ifot required.
Masterson #32 All-10 = Regarding bent bolts used for hangers 4 All-18 . Alleger indicated that holds in
- tube stocf.g s were enlarged by torch cutting for accommoda '
ting the bent bolts. lie personally replaced the tube steel on 3 supports. But he indicatj that similar cases may exist all over the plaf
= Action: TRT may agree with what allegtr said
~ . but shall emphasize safety significanch
'{theSSER.
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C FIELD WALK 00WN WITF On ll-7-84_the RRI, J. Cummings, and I went on a field walkdown with and the folloiwng items were discussed: (1) A feedwater restraint along the inner wall of the Reactor Building (RB) in Unit I was pointed out. During the installation the alleger stated that it was necessary to bend the rods that were screwed into the Richmond inserts. This bending was accomplished by heating and banging on the rods. Since the base plate for t.his restraint is very large and contains numerous holes this allegation has a high probability of being true even if the inserts were within their tolerance. (New Allegation) (2) .also pointed out the stainless steel line that he alleged nac unauthorized welding performed without a required purge, _He stMed that the welding was done by a welding foreman named M le, however, could not point out the exact weld tkt indicated one of three possibilities. (M/P CAT 6, AW-45:
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V. Ferrarini) (3) He also pointed out a restraint that had holes out of round in tube steel. He was not sure which Steam Generator _. : bay it was located in, however. he said a man namedM(SG) [
- cut 32, AH-36 them.' He statedNdid so under orders. M/P CAT
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R. Mastersiin)
/0 (4) The alleger pointed out a fit-up gap problem on a main steam (MS) restraint on the MS line from SG No. 4. (New Allegation)
(5) The alleger also showed us an area on the turbine deck where rebar was cut without authorization. Note the turbine building is a non seismic category 1 structure and therefore this problem is not a safety concern. (6) He also showed where the polar crane was attached to the No. 1 MS line and used to pull the piping to elevation. (M/P CAT 11, AR-13, W. P. Chen) The major new concerns that were raised are:
- a. How did the bending cf the rods affect the rod's ultimate strength.
- b. What effect did the heating and banging of the rods have on the Richmond inserts?
- c. What was the effect on the ultimate strength of the concrete insert?
Upon leaving stated that he has talked to the NRC numerous times C in the past ant has given them numerous names and nothing has ever happened. think tha_t. it is very important to point out that during our walkdown was approached by at least 12 construction personnel who were riappy to see'him. It appears that he is well liked by the plant construction personnel. This writer feels that in general, is very knowledgeable and a capable construction woiker
., , V. P. Ferrarini, TRT member 5-q -) l!:
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RESP 0ftSE FOR Al of ATIONS in h Mechanical /Pipi'ng Area Alleaation (1) Is is alleged that bolt holes in tube steel were cut over size with a torch to accommodate misplaced concrete inserts. (2) It is alleged that an unqualified individual was fabricating pipe hangers. (3) Welding repair was performed without inerting on the 832' El of the Unit One Reactor Building. The welding involved welding of a support lug on a stainless steel line. TRT Resoonse During Telechone Interview of 10-31-84 (1) The TRT reported to the alleger that af ter talking with site personnel, reviewing hearing records and other trans-cripts, and reviewing fabrication procedures, that no evidence could be found to substantiate his allegation. He insisted he could show the TRT examples of his allegation : , if allowe.d to go on site. . (2) The TRT was unable to locate the person alleged to be unqualified and therefore, could not substantiate the allegations. C (1) pcinted out a restraint that had holes out round in' tube steel. He was not sure which steam generator bay it was located in, however, he said - cut them under orders. The TRT has not had an opportunity to follow'up at the site on this new information. However, the TRT does plan to pursue this allegation and report the final findings in the SSER. (3) pointed out the location of the alleged improper weldino. Tlfp TRT reviewed the records for the systems that q pointed out and found that all those lines were /C
% droon st.eer wh:c does not require inerting. It should be pointed out that stated that the area had changed a great deal sincne lett tre site and therefore he was not sure as to the correct support, however, he stated that it was located in the area that he indicated. 1 The TRT will attempt to locate the alleged weld by reviewing the area during its next site visit.
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7c Ca tecory lio. : 32 TFT l'er ter: R. Mastersen
- . Sutiect: Hanger Fabrication Deficiencies
- 3. Sunr.ary of Alleca tions :
These allegations ( AH a , Au-9 through AH-ll, AH-lE, AH-20, AH-21) concern various hanger fabrication deficiencies such as torch --) cutting of bolt holes anc structural steel, using sledge harrers on
- supports during fabrication, welding of iters not on the design d rawinc and an uncualified individual fabricatinc supports. These
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4 Recion IV's
Conclusions:
Region IV inspectors did not address allegations AH-4, AH-18, AH-20 and AH-21. Region IV inspection report 50-445/84 AH-9 and AH-ll is a duplicate of allegations AP , j m n5p:igdgesses e n cc Ap-24 (see Category #31) and resulted in no violaticns or discrepancies. : Recion IV report 50-445/83-27, which addresses AH-10, concluded > that due to the lack of specificity and the un-corroborated testinony of the alleger, the allegation could not be substantiated.
- 5. What TRT Had Done:
The TRT interviewed the allegers for AH-4, AH-18, AH-20 and AH-21 and was unable to generate more detailed infomation. The allegations were nondescript and vague and did not pemit a review of specific hangers. The allegers either did not have firsthand knowledge of the incidents or could not remenber specific hanger numbers or locations. The TRT interviewed various fabrication and QC inspection personnel and reviewed construction and QC inspection procedures and detemined that in general the types of deficiencies described by the allegations were covered by procedures. The TRT also reviewed AH-9 through AH-ll and ciscovered that AH-9 was a duplicate of AP-18, 20 and 22 and that AH-10 and AH-11 concerned the sar'e incident which was associated with Unit 2. The TRT talked to one of the allegers and detemined that the hanger identified in the allegation had been replaced and he knew of no other similar hangers. Six other individuals also had been interviewed by Region IV and stated that they knew of no instances of using a torch to elongate telt holes. The TRT, as part of AC-31, inspected 150 anchors connecting tubuler steel to concrete and saw no evidence of torch cutting of bolt holes. ( ) C C t .% i
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- 6. TRT's
Conclusions:
(a) Not Valid - All allegations were revie,.e: a J r.a evidence coulc' be found to substantiate the ccmcerri. Tr.e TEI f ounc that the types of cutting operations ar.: f a r ric ctior. technic . , described by the varicas allegers were a::resse: in the pr c . Since the alleger stated that for AH-10 and AH-ll the supp0"*. has been replaced, the allegation cannct te substantiated. The TRT could find no further evidence of this use of torch cutting through personal interviews or inspections. _ (b) These allegations have neither safety significance or gencr4 implications. - (c) made allegatio in ar. interviqw and sworr. s ta tement in Septemter- 5.1983 made g
' egation in an 01 Report of Inquiry dated ry 9, th , .
which reiterated sworn _ statements of hovember 22,1922 au , January 26, 1984. repeated tre incident tc-pe TF1 if, l an interview on Sep~tember 11', 1984. !aade g allegations in a February 3,1983 affidavit and an interview on April 14, 1983. grepeated the allegations in the July ! 12, 1983. deoosition and_again. to,the TRT on Septe_mber 19, 1 984 madeMallegations ingaffidavit I of Parc?T 31, 1984 disc ~0s' sed the concern with the TRT on August M 1984 - 24 f bo m w~~s mene ~e ne. -~ ~ '
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lN you recall ever having seen that posted at Comanche Peak? A: No, I don' t. You've got bulletin boards in front of the main tool - I had room, one on the turbine deck, and one in the Administration Building. access as a Foreman to all of them, and I don't remember ever seeing it. I don't knoa what can be done about the waste, the materials, and There are $100 plus per the back-stabbing that goes on at Comanche Peak. There's wood, lumber, Hilti bolt that are scrapped daily by the skip pan full. There's no reason steel, and what it's costing the taxpayers, it's ungodly. for it. It's ridiculous, it's the misfits, it's the supervision you've got For instance, the general foreman on nights built a gold hat a out there. or six years, and_ t)e was a good ole boy. He could not handle his position. And here they were paying Now this man is a general foreman, underneath a gold him $14 or more an hour. The ran is uncualified, incompetent
;; M I hat, in charm pipe 3ngers on nights. aw, He's cut holes in hangers where if there were any kind of O l can't do his work. ,
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bvibration the nanger would fall off the wall; he used a cutting torch, and
+5ere d#A you're not allowed to use a cutting torch on any kind of material out.
on a pipe hanger unless it is done in the Fab Shop .under QA supervision. Wall, he cut holes in them so that sometimes he couldn't even figure out his And this man is now holes, he couldn't figure out the tolerances or anything. ' a general foreman on nights on big bore pipe hangers. out I can tell you lots of things. I was a there. Let me just give you a general perception of 'whats going on there. h Fo/A-3F 57
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1 I've,been in steel work all my life -- I've been a fabricator, I've supervised 2 a shop, and the whole bit. You've got people out there who do rebar tying. 3 You've got two pieces of steel to tie together with a piece of wire. This is 4 rebar people, all right? All they've got to do is to go up there and tie 5 the rebar, and pour the concrete around it. It's all a hidden object, right? 6 This entire rebar organization and building department has come into pipe h . 7 The entire rebar staff out there is a kind of clique, and they went into the - 8 hanger department. They suddenly became hanger geniuses.} There's one man g _ out there right now who,, three weeks before he was transferred from scaffold 10 and rebar said, " Man, I don't know how in the hell you read these blueprints 11
-- I don't know how in the hell you can make these things (pipe hangers)." >
12 And as God is my witness, three weeks lateF this nn vas a General Foreman o 13 pipe hangers. He was a general foreman next to a gold hat over pipe hangers. 14 15 t He suddenly knew all about pipe hangers, e suddenly' knew all about steel, And here was a man that has done nothing but concrete and ,ebar all his life . 15 But all of a sudden he is a ste'l e genius because he is in the clique, because 17 he belongs to the building department out there, because he is one of Billy
'8 Ward's little boys.
39 There's jokes floating all over that plant where t!.ey show a pipe hanger
'O tied together with wire or nailed together with wood because of the carpenters 21 and rebar hands that came over into pipe hangers.
They're coming over as ' foremen, ' 2 they're coming over as General Foremen and they're coming over as gold hats -3 (superintendents) . And all of a sudden they know everything about pipe hangers and about steel. 5 l'm just fed up with it, cause I've got to Tive here. I was here before pn '
N % I . [/ , 4 J a cutting torch on ha~ngers. I don't personally .,. 1 .,
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2 know, is it improper to use a cutting torch to tear un P. down or alter a hanger? .v . 3 t
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4 A Not to tear down and alter, but it's M)::; v. p. 5 illegal to use it in the containment building where 4in a I was the entire supervision, when I was hanging ( ,. 6 .: m .
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You drill everything and everything - " T-7 pipe supports. . qy - b. has to go on the wall according to the drill size. ,
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took down several hangers 2fik.' y, 9 I took down a hanger -- , M ( 10 that was put up by this general foreman out there i Nh i that I tried to fire, f c-11 Yd'h 12 O Which one is this? c
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13 A Oh, boy. @ .;
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was it your general foreman? p .m 14 0 b 15 A No, he wasn't my general foreman. &G: .L
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16 ~ jQ ' 17 m ...< J rre 18 0 You were a foreman? m 19 A cah. They call them cupervisors out .[MM F '? 20 there.& You got a supervisor, a general supervisor, l.E 'u Cr, 5 h,l a three-stripe general supervisor and then a ..gll5 21 L. 3;lyu x. 22 superintendent. . ). I see. Is a foreman higher than a .J 23 0 . .. .m 1.~u - 24 general foreman? g7m The general foreman's got two u{s{p 25 A Ho.
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! i 2 0 So thio guy was your boss? '
He later made general -( 3 A [ h [1.g.[.[]: ,
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I 5 l' i; and then he became a j. 6 _ I . 7 general foreman overnight over in pipe hangers. l 8 heard he got fired, which I hope he did. t k.. 9 He had taken a torch and cut the back sloe h
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10 of a tube out because a lot of bolts are put in like - 5-E 11 this, the holes in the wall. They are supposed to ~ W g 12 be straight, ninety degrees off the wall. They're 9 J4 13 anchored in the wall, poured into the concrete. :' MS. ELLIS: Richman inserts. .,
.t 14 i A Yes. And you go to hang a pipe hanger on 15 that and they give you a threaded piece of steel and l 16 f 17 you're supposed to stick it in there and it's- ().
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Well, @ 18 supposed to come ninety degrees off the wall. E. 19 they come off this way and come off that way and 2 1& 20 come off this way and this way -- 1
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For the record, could you p/ 21 11 S . ELLIS: ; , 4 a 22 kind of try to describe those angles that you a a' are talking about? That's kind of hard to do i 23 \ r 24 sometimes. : , Let me just ask you, maybe it would be 25 0 l
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49 i . . t. i 1 A But in the containment itself, you would-2 probably find them in the compartments would - 3 ._ probably be the major part of them, f 4 Q All right. Let's go back to this, the 5 use of the cutting torch. Is that -- 6 A That's what I'm saying. This hanger in 7 these compartments, if they didn't have enough 8 intelligence to find out what kind of angle it is 9 and how to drill the hole from the back and make it - 1 10 come out center from the front, what this foreman - 11 done out there or general foreman on nights, what he i 12 done was take a torch and cut about a three-inch : 13 hole. And you can see, if I cut -- if I got this ' 14 angle here and say we have another one here and the 15 back was at another angle, we just cut that sucker 16 out like that so we can move that thing any way we 17 want to to get it started. 18 Q How do they fill in the hole or is i t -- 19 A They don't fill it in; it's covered with 20 a washer. The only reason I found it out, the 21 hanger that was particularly put up by this guy was 22 designed wrong. I had to go down there and tear it 23 down. And I went to my superior and I said, 24 what are you going to do about this? I mean, I got 25 my butt tore up yesterday because I put something in Stanley, Harris, Rice 741-4567 Q-- - yy=+Q. u:. %-y-. _
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/,\/'l ' APPENDIX U. S. NUCLEAR REGULATORY COMMISSION REGION IV NRC Inspection Report: 50-445/83-27 i 50-445 Construction Permit: CPPR-126 Docket:
9 Licensee: Texas Utilities Generating Company (TUGCO) 2001 Bryan Tower Dallas, Texas 75201 Facility Name: Comanche Peak, Unit 1 _ Inspection At: Comanche Peak. Unit 1, Glen Rose,. Texas y 10-Jul d 1, and September 9-22, 1983 Inspection Conducted:
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m sy n A' ?~E<$# 5 Inspector: A Date f(. C. StewartV-RiPEctor Inspetor, _ Reactor Project Section A _. 1 i i N O 'N Approved: k N '=ttmM Date
- 0. M. Hunnicutt, Chief Reactor Project Section A
( TT - APERTUR$ CARD AJoe Avdahle on Aperture Card Li-P
?JIA-85-59 m/o.
f l l 3 Oetail_s l A. Persons Contacted Employees Texas Utilities Services Incorporated (TUSI) f B. G. Scott, Quality Engineering Supervisor G. Tanley, General Superintendent C. R. Hooton, Lead Civil Engineer R. M. Kissinger, Project Civil Engineer C. Fleming, Field Engineer
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Brown & Root (B&R) Emoloyees - W. Wright, Project Welding EngineerB. Hauser, Field Engineerin C. Osborn, Tool Crib Foreman tractor employees The NRC inspector also contacted other licensee and con ' during the course of the inspection. investigative Note: Prior to this inspection, separate ii and independent d May 20, 1983). 6Tfice of Investigatio iiiterviews were conducted by members of t s
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Office, Region IV (see attached Report A4-83-005, date B. Alleoed Imorocer Construction Practices . f Mr. R. L. Messerly's The NRC inspector, through an interpretative t ifically review oents during his interv alleged affidavit, dated February 3, 1983, and hi, sta emdetermined that t April 14, 1983, lated systems, component, matters that required a detailed inspection emerit and/or and structures. lleged to have occurred The seven areas of NRC concern which Mr. Messerly a are summarized as follows: i d holes that d cutting was
- 1. That B&R employees drilled undocumented documented and and done at the direction of supervisors.of a personal diary wh unauthorized drilling. ing the polar unsafe stressed
- 2. That crane,one of the thereby placingmain steamoflines the section pipe line in Unit in an1 was moved condition. directed by f i
3. That he had cut through concreted reinforcing steel asce with the app work. instructions that were not in accor an method of documentation. l
4. That tubular hanger / support steel anchor bolt holes were enlarged with a burning torch which he said was unauthorized. 5. That (Richmond) anchor bolts were not perpendicular to concrete surface and, therefore, unacceptable. 6. That stainless steel pipe attachments were welded on piping withou an inerting purge. 7. That NRC Form 3, " Notice to Employees" was not posted on thre bulletin boards. C. Insoection Findings . Allecation 1
- 1. Discussion Mr. Messerly stated that during his assignmen i ,
steel (rebar) during installation of cable tray and and/or drill undocumented and unauttJyriTed holes through rebar. To further support his allegation," Mr. Messerly named B&R employ responsible for the alleged improprieties and those who could
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substantiate his allegations. 1/ In addition, Mr. Messerly provided the NRC staff a copy of his He personal daily diary in which he logged drilling o stated that this diary also identified holes he drilled, in or thor-through, rebar and concrete without having documentation and au ization.
- 2. Chronological Findinos 1978-1982 In order to determine the magnitude of implication and the resu findings of Mr. Messerly's allegations.
d 1/ See attached " Assistance to Inspection Report," Report A4-83-005, May 20, 1983
14 Allegation 4
- 1. Discussion During Mr. Messerly's interview on April 14, 1983, and as stated in his February 3, 1983 affidavit, Mr. Messerly indicated that anchor bolt holes in tubular steel hanger supports were enlarged with a burning torch in order to compensate for the angularity of the previously installed (Richmond) anchor bolts, rather than redrill the holes.
- 2. Conclusion - Allegation 4 The results of the interviews of eight B&R employees, whose names were provided by Mr. Messerly and alleged' to have knowledge concern- -
ing the improper use of cutting torches on hanger material, is contained in the attached " Assistance to Inspection Report." 1/ Two individuals stated that they recall an instance during a redesign modification of a hanger where it was discovered that holes had been , enlarged by a burning torch, therefore, that portion of the hanger . was scrapped.
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During the onsite followup inspection concerning this matter, the NRC irapector discussed the use of cutting torches with the licensed's welding engineers and fabrication department engineers. The NRC
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inspector was informed that the use of cutting torches is not prohibited, provided it is done in accordance with prescribed B&R procedures and/or ASME, Section III, Subsection 4211 (thermal cutting). In the case of tubular hanger installations, the preferred method of correction for hole misalignment is to drill offset hole (s). This has been done on many occasions via the design change CMC document. The cognizant project engineer,. responsible for approving and issuing CMC's for hanger mcGifications, stated that he knew of no CMC that involved authorization of hole enlargement or hole relocation on tubular hanger supports utilizing thermal cutting; however, thermal cutting has been permitted as necessary on other types of carbon steel supports, base plates, etc. The NRC inspector conducted a walk-through of the containment building to examine accessible installed tubular hangers, specifically in the plant areas mentioned by Mr. Messerly during his interview. The inspector examined approximately 60 hangers at the 905' and 860' elevations in the containment building. Although limited in visual accessibility to each 1" or 1-1/4" drilled hole in each section of the tubular hangers, the NRC inspector did not find any hole that was enlarged by a cutting torch. In addition, the NRC inspector discussed the subject of thermal cutting with the cognizant QC supervising inspector who was involved with inspections of tubular hanger installation during 1980-1982. The QC supervisor stated, that neither he nor any inspector discovered 1
15 an installed tubular hanger hole having been enlarged by a cutting l torch. l, Based on the lack of specificity by Mr. Messerly, the lack of / corroborative testimony by Messerly's witnesses, interviews by the f NRC inspector with cognizant site personnel, and the (limited) examinations of installed hangers, this allegation could not be substantiated. There were no violations or deviations identified in this area of the { inspection. 1 Alleoation 5
- 1. Discussion During the interview on April 14, 1983, Mr. Messerly stated that -
f Richmond Insert anchor bolts installed between elevations 905' and 860' in the reactor containment building have not been installed perpendicular to the concrete surfaces and, therefore, are unaccept-.7 whatever an able. In addition, Mr. Messerly stated, ". . we would drill it at that angle so that it would come through the . tube (i.e. , tubular steel) and when.jt co_mes out the other side of the tube, it comes out as close to center as we could get it." Mr. Messerly also stated, "Just go out there and pull' any . studded rod out of there, pull thPee of them and two of them is [ sic] crooked."
- 2. Conclusion - Allecation 5 During the NRC inspector's onsite follow up of this matter, the inspector found.that the B&R Procedure CP-CPM 9.10, " Fabrication 12/28/78) is the of ASME-Related Component Supports," (original issue primary construction installation procedure toThe be implemented and
" General Fabrication followed by the hanger installation crews.
and Installation Requirements," Section 3.3.1.2 " Installation Tolerances," states in part,
" Field Fit Tolerances 1 "The tolerances discussed above shall be maintained for support However, if during the installation, fabrication the support won' t fit, members may be " field fit" provided activities. the the piping and elevation tolerances shown below have been maintained. All other tolerances regarding axial location, alignment, and base plate attachments must be adhered to unless otherwise noted on the drawing."
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\ ' (b operation without damage, it would probably not suffer damage in use since it gains strength rapidly while it is fresh and at a decreasing rate as it ages. Alf elements of the internals assembly were loaded
,- V the 860-ft. elevation. The(NRCTechnicalReviewTeam(TRT inspected all O**
h-the grouted plates at the 860 and 862-foot elevations and found no J evidence of grout failure. While the allegation may be true, all the grout survived the initial loading without damage. ypA H eget.&oaY"AC-31.uaa_that Richmond Insert anchor bolt inserts were installed between the 860 and 905-foot elevations in Unit 1 at angles not1 perpendicular to the concrete surface and that this non- perpendicularity , was compensated for by use of tapered washed. The ~allegatic,ndferred to discrepancies as great as ten degrees.' The allegation is dealt with . in NRC Inspection Report 50-445/83-27, ~shictr Uas reviewed by th NRC TRT. Brown &. Root Procedure CP-CPM 9.10 " Fabrication of ASME-Related Component. Supports" states in Section 3.3.2: Surfaces of bolted parts in contact with the bolt or nut shall have a slope of no more than 1:20 with respect to a pit.n normal to the bolt axis. Where the surface of a high strength bolted part has a slope of more than 1:20, a beveled washer shall be used to compensate for the lack of parallelism. F01A-85-59 %,
f 1 , Thus, inserts may depart 3* from perpendicularity without any com-pensation and may depart further if beveled washers are used. The procedure mentions no upper limit on lack of perpendicularity, but that
- is controlled by the fact that the predrilled holes in the tubular steel hanger supports may not, in the case of safety-related supports, be enlarged without prior approval. Th NRC TRT nspected 5,0 anchors IIvfd; between the 860 and 905-foot elevationW and found no violation of the " Lw 4.
n nie installation procedure. The allegation was correct in its assertion that b' some anchor inserts were not perpendicular to the concrete surface, but that in itself dfd not constitute a violation of the procedures. Allegation AC-36 was that trash from a Christmas party that took place on f December 2,3or4,1978,wasthrownin.5>hehrm'and"coveredvftli
-y- . . . . . .
concretewhileconcretewasbeingplacedhnhneofthetwocontainment structures. TheallegedincidentisextEnsiN1ydiscussedinNRC Inspection Report 79-20, whi*ch was reviewed by the C TRT Reported interviews with alleged participants cast considerab oubt as to l whether the party actually occurred. The d TR obtained a printout of all concrete placements on the containment structures and determined that l the only placement which occurred during the period reported was on the l dome of Unit 1 on December 3, 1978. eTET xamined concrete placement package 101-8805-002, that contains a complete narrative of the placing j operation by the placing inspector. Nothing unusual is noted. Both
3;,_ ... The infonnation preceding was given to CASE in the fonn 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 sane
- newspaper reporters, and an article ran in the FORT WORTH STAR-TELEGRAM on ri= January 7, 1983. A copy of that article is attached. After that interview, if I was shot at and have been on the run ever since and have been in touch with CASE a few times by phone from different states. One night when I came home, I found my 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 every 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 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.
~
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 some of these plates 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 .
- and water is drained out of the liner, the walls will spring back out, which 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 about the gauges being blocked off but he was concerned about the walls breaking 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.
Regarding Comanche Peak nuclear plant, there are safety violations such as A torqui ng. For instance, quality control is supposed to verify the torquing of gg ,, piping support that should be torqued at 130 lbs. The hanger is on a 20 foot 1 g .) 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 wrench and carried back up and placed on the nut before torquing. QC hears * 'v a torque wrench click twice on each nut and buys off (approves) the hanger. What _ , QC did 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 - -l
.at a low torque poundage such as 3 lbs. and they clicked it twice. Therefore, th ^
nut on the hanger was never torqued; only the nut on the scaffold was torqued. q I There were also violations such as pipe supports around the pipe. -For instan e, _ 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. F6r instance, a g4 2" pipe: a construction supervisor will climb on the pipe and get some of his f 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 each side of the pipe, they take a grinder and grind be' tween the pipe and tube steel, which in - - some cases results in a reduction of wall thickness of pipe. I believe this could result in a rupture of the pipe. Construction has also tried to straighten
.f.#...... a pipe support by using a sledge hamer; this is done quite often.) An employee AH-1 ?$ told me that while hitting on the hanger he also hit the pipe and caved in the f side of the 2" pipe 1/2 inch or more. He reported it to his supervisor who said wv M not to tell anyone and covered it up with I.D. tags.
L
- Another incident is improper personnel designing and' engineering pipe supports . For instance, one helper told me while he was employed at the plant
** W he designed many pipe supports for engineers. One day he wondered if.they 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 improperly. The helper said that he did not want to go to any NRC hearing but he would love to have a showing and he could show m'any things if he was allowed 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. 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 , 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. : 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 - Ar . it, concrete material in the early stages of the plant when the reactor core was A t. . w 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 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 tc,ld him to put it back in and use it and they did. My friend also told the investigating crew of some type of sampling machi,ne that tells whether there are good samples or bad samples in the concrete. It I had a, wire run to it while QC watched the machine to verify the use of good sampi Personnel would pull the wire to make it read good when it was not. My friend (A also told of other people that know of these violations and as far as I know, Brcwn & 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 NRC is aware of this statement, because it was in the FORT WORTH STAR TELEGRAM article (attached). Undoubtedly, they are not concerned about the situation. I have not been contacted and neither has my friend.
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r-- CONTROLLEO COPY COMANCHE PEAK NUCLEAR POWER PtANT ALLECATIONS AN0/0R 1HVGTICATTMNRY CROSS REF./0R COMPLETION ALLEGER-DATE RECEIVED TASK SOURCE TRACKING CATECORY 1-7 SCHEDULE SOURCE
& ALLEGATION OR CONCERN ACil0N/ STATUS ANON CONFID BN/DATE SYSTEM NO. LEAD OPEN COMPLETE DOCUMENT PAGE AQH-17 NCR written against a X 1 A-5 Interview hanger has not yet been IRT 5/18 P. 35-36 dispositioned. Concern that they will try to cover up with paper as oppose to fixing problem.
AH-18 General foreman in charge Open X 1 A-M Af fidavit of of night crew pipe hangers IRT 2/3/83 P. 6-7 is unqualified (no specific date, but predates 2/3/83). AQ C on f sX I ) I w t of AH-20 Violation of pipe support Open X 1 A-4 Affidavit of tolerances arourd the TRI 3/31/83 P. 3 pipe. AH-21 Pipe supports straightened Open X 1 A-4 Affidavit of using a sledge hammer. TRT 3/31/83 P. 4 CD w
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35 0915 ,2 g[gg REPORT NO. QUALITY ASSURANCE RECEIVING INSPECTION REPORT 7 0 4 3 9--p za; _ SYSTEM COMPONENT IDENTIFICATION / SPIN NO. DWG / SPECIFIC ATION & REV. UNIT j)t g MACH S t e.K Few ilmcsu Asas um, gl} gg;g.333g54p Re,,. J P.O. M'RR T CH ARdTERISTIC INSPECTION: Q [-Q Af OC!- 7, *2, - // f al- 9 'IS d[-[ M[M,) N -[fh SAT.l UNSAT. NCR HOLD TAG APPARENT RESPONSIBILITY FOR UNSATISFACTORY ITEMS: VENDOR OR VENDOR TRANSPORTER B&R l l zjjypfs oATe oePiCieNCv oiSCtOSEo ITEM QTY. D ESC RIPTIO N/ R EM AR KS X, j H 0$ M No-/55N7}a.) 4~ooff; xMO,497ATA I$oofts&,xis,.X% Akuute 2 *24y 7f~ , A-500 && . y 92o}hMRa955 Mp;M16 map.J $jf,x1875c-g , O ROOT, N ) [2k j {" *dceWED 9p7 ( PPRY siss A/R. rr sd-nn/rDA AUTHORIZEo NUCMA%SPECTOR NOTIFICATION: DATE: TIM E: MEDIA: N/A INIT. IY ANI WITNESS: SAT. *
- UNSAT. *
- WAIVED. I A DA c en W W AN1*S INITIALS REOU(RED ,, ,,
N N ER/iN s p cToR rete STORAGE LOCATION: / Id2r # / ~ 21 TYPE: ,p / <7p I Q C - 1.1/ 3 1
- - Ercienf5 Root,lr .
- () _ . OUALITY ASSURANCE DEPARTMENT
- QI-QAP-7.2-11 REVISION 0 FIGURE 1
" RECEIVING TUSI/G&H SAFETY RELATED EQUIP--[E0r4 2 2 63 S SAT. UNSAT. N/A
- 1. Check documents received with shipment
- a. G1H Quality Assurance Release (QAR) obtained? f
- b. Are " Review Checklist" items on QAR accepted? '
- /,
- c. Was final inspection performed by TUSI/G&H? ,ff
- d. ASME Code Data Report obtained? / y
- e. Authorization for shipment? /
- 2. Equipment Identification -
- a. Do Data Reports and Equipment Code Plate agree? /
- b. Do Data Report & G&H QAR agree? /
- c. Does Identification Tag / spin number compare with /
G&H QAR? /
- 3. Was there any damage?
- 4. Authorized Nuclear Inspector notified? /
- 5. Applicable QC receiving tags applied?
Comnents: std_.
> /
QC Receiving Inspector IUa
~
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- PPRV 1 4
r- -- 3, . . - c. i c. n i n i. R E C E I V E D h e. c u r. v b No. 35-1195 COMANCHE PEAK S. E. S.
, _ MM -- . d s.
s . . ~ s.. e . , j '1 s PAGE OF MR NO. B&R G&H F&N W TUSI OTHER \ SHIPPED TO: O REO.NO. O O O 3 0 M.eM * VENDOR: DATE: RP! IWet:5TtIts.tE l NFSTis,TEUS 1-N-79 SHIPPER: F.O.B.
$3R MI Partial O I Complete O QUANTITY UNIT ITEM MATERIAL DESCRIPTION LOC ATION
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O TEXAS UTILITIES GENERATING COMPANY 2001 HM) AN TI th EH D %I.L \%. TEN 4% 7.sJul ( 70439 -gEU gf- /8E TEXAS UTILITIES GENERATING COMoANY COMANCHE PEAK STEAM ELECTRIC STATION 1981-83 2300MW INSTALLATION PURCHASE ORDER NO.d#-004//, / AUTHORIZATION FOR SHIPMENT Bv copy of this letter TUGC0 Quality Assurance releases the following equipment to be shipped by A//S _Z'/O. /3/5 7/;v, /yc. . f 7'b ~7Y-SM-77///roA B ' d ~rt' ~x VN' St .J/f seso cx ;g Q p o ' 3 <y3 , 3g " ,, ,, < u ,i i t.! FORMATION 4 Final shioment inspected, QAR No. /j// 7
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nps induSU.-- - l TX-SN-7211/ TDT n,os l s H Texas Utilities Services, Inc. CP0046A.1 TUSI p C/O Brown & Root, Inc. ..e-.......-.. . _ -..... Comanche Peak Steam Elect. S Lte / U 4 J g . .,, 9 $ n o Glen Rose, Texas &EC s o Texas Utilities Services Inc - 1/25/79 SIKES 1 1
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T nps industries,Inc. 10420 metric boulevard i Ohb avstin,temos 78758 telephone 512 836-4161 Date: NPSI: J[rQ43 $h-1MQ j TX-SN-7211/TDA
Reference:
P.O. #CP0046A.1 CERTIFICATE OF COMPLIANCE This letter shall certify that the materials supplied on the subject purchase order comply with the requirements as specified in that purchase order, and A.S.M.E. Section III, subsection NF,1974 Edition, Winter 1974 Addenda, and Code Case 1644. This material has been processed by NPSI in accordance with our Identification and Verification Program. I A.S.M.E. Quality Systems Certificate (Materials) Number N-2048, expires on February 24, 1981. A.S.M.E. Certificate of Authorization (NPT) Number N-1883 expires on September 30, 1980. Certified' Material Test Reports Attached. h Yours Tru oOPY M. Fred Robin Manager of Quality Accurance CMH/lrw o Sub51dlary of ng;!ey po net &Of vlCellhC.
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Iwoice No. TEST REPORT 3S',(@j3_,, g, Customer: Specification: 6 Sq x 3/8 structural tubing NPS Ind. Inc. ASTM A 500 77 Grade B 10420 Metric Lane Formerly Running Bird Lane Austin, Tx 78758 CHEMICAL ANALYSIS, % HEAT NO. C l Mn P S SC$$. 63582 73SM7 .23 .75 .016 .029 502187 % p{.y .21 .96 .007 .019 61861 .21 .80 .014 .021 754g7-MECHANICAL PROPERTIES HEAT NO. LAB NO. p3 p3 NPSI. AUSTIN 63582 / wc i uo.73Sgf 51,400 60,000 40 502187 dj{p 66,900 76,300 31 61861 /7 60,200 67,300 24
, YIELD STAENGTm is 0 0% CrFSET - ELONGATION IN 2 INCHES Other Tests i' I . , oa ) thy k.k- th s ~"d df 10
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INDEPENDENc3 TUBE CORPORATION 6226 West 74th St. Chicago, Illinois 60638
, (312) 496-0380 70439'-232 December 12, 1978 Chicago Tube & Iron Co.
2531 W. 48th St. - Chicago, Ill. 60632 - Attn.: Test Report Area The following material shipped on your Order No. TS-0709 QA Invoic,e No. 15218 , meets the requirements of ASTM A-500 Grade B-77 6" sq. x 3/8" /' yield 60070 psi SFSI-AUSTIN MIC No. Heat #890427 Tensile 65270 psi slHJT Elong. 2" 36.0 % C Mn P S
.18 .90 .011 .011 000EW li 'HID si QA W DATER /kl%
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. THESE TEST REPORTS APPLY TO
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, Sold to: Shipped to: OCI 18 i377 Date: ros Inl. !ac. Sacc 10 12 77 AUSTIN, TEXAS 10^20 Ru. ming Bird I a nc. g Ain: t ir. , Taxar 79758 4 39"e32 3 3 Customer Order No. Regal Order No. Invoice No. 7A13?G 030109 S 59 038708 . Specification: Hollow-form electric welded structural steel tubing - ASTM - A-500-7G Grade B Heat SKHEMICAL ANAYLSIS Yield Tensile %Elong Size Gauge Number C Mn !P 'S (psi)' (psi) in 2" 4 sq 3/8 803030 .18 .74 . 011 .019 61,400 64,600 23 NPSI.AUSTLN mcno.
/-ffA- f The chemical results shown on this report represent mill certifications of ladle analyses as furnished to Regal byour suppliers or actual results of tests performed on samples of -
tubing taken from production rollings of the material. The above tests were made in accordance with the standards of the American Society for Testing Materials, and re-sults are on file at Regal Tube Company, o Copperweld Enterprise, 74015. Linder, Chico;o, Illinois 60638.
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AUSTIN, TEXAS Invoice No. TEST REPORT 70439--2@,4 7-12-78 Specification: 4 Sq x 3/8 structural tubing Ind. Inc. ASTM A 500 77 Grade B
- Metric Lane
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HEAT NO. l C Mn P S, NPSI-AUSTIN
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MIC NO. 58 .22 .64 .007 .019 l MECHANICAL PROPERTIES , YlELD STRENGTH TENSILE STRENGTH ELONGATION HARDNESS N O. LAB NO. PSI PSI g a
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AUTHORIZED NUCLEAR INSPECTOR dOTIFICATIONI ' ' # # # / MC .g-fCO$ DATE: TIM E: MEDIA: N/A INIT. d' f1 ANI WITNESS: SAT. W W UNSAT. W W WAIVED g
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- 1. Did all required documentation accompany shipment?
- 2. Is shipcent packaged satisfactorily? / '
- 3. Are material markings in accordance with specification '
requirements? t
- 4. Is certification adequate and accurate when compared /
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- 6. Have all MCE requirements been met?
- 7. Was shiprent accorpanied by a B&R QA Department Confor ance Certificate?
Was the Certificate signed by a B&R Surveillance Specialist? If nat, is a SLR QA Source Inspection Waiver Form available?
- 8. Applicable QC Receiving tags have been applied /
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~ CONFORMANCE CERTIFICATE OF 1 UNIT 1&2 PAGE I -
COMMANCHE PEAK Jos NO.: 35-1195 moaccT: L2) ADDRESS O F V ENDOR P AC3LITY tilVENDOR 2750 SW MOODY PORTLAND, OREGON 97201 NPS INDUSTRIES, INC. lRt V.
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L.8 SPEO PICATION N O. g M E V. (30 F U.1CM AEE O RDE R No. N/A l N/A l I 35-1195-30220 t
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MIC # A-39 ITEM #13 MIC #NT-131 ITEM 43 MIC#NA-246/ ITEM #14 MIC # T-149 / ITEM .5 MIC #NA-224 / ITEM #15 MIC #NT-206 / ITEM #7 MIC #NR-279 ! ITEM #16 MIC #NT-132 /7 MIC .NT-117/ ITEM #8 MIC 4 R-5 / ITEM 59 MIC FNW-436 / ITEM #17 MIC #NT-217 / ITEM #10 MIC #W-5 / t O.cument 0.t. She.g. _.m sn.. c.rti,ic... .. r.a..e=J us in. sr._n & R R.c s.s ch.ca I y ) be._ .r. b.ing ...n.m et. V6 .a ina ct n R.c.r.. XX M...r e C.rt...c.t n. O..r. ems El.c. T .st R.c .. 0.m.n .n.4 in ct. R .c .e h N.no..r.t.ng El.c. T.s. R.c.r.s M s.t T r.: R .c.r.. Cl ntin R.c.r.s g[ RT F.im & R.c.r P. e. T e R.c.r.s P.m.mgR.c.e.. g< 5 . Tignin.= T.st R .c.r.. PTIMT R.c.r.. P.ek.gmg R.c O{ P.rt.rm.nc. T t R.c.r.. S .. P ..t . (i.t g2 UT R.c.r.. Wm.. P.r nn.s c..s. C.rt A r. S r.a. R .r.
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I Q AT E: j 11 /12/79 N g;y *j i QA MANAGER
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4' 3 w, 1015 QUALITY ASSURANCE DEPARTAIENT SHIP 31ENT WAIV ER PROJECT: CPSES JOB NO.: 35 1195 UNIT [ PAGE / OF ! TO: N' M* EW's E C* # 5' U NM #
, 2750 s. w MWy, An','xs n'. 'tW
REFERENCE:
Purchase order / subcontract number 85'8N D#8M ; our telephone conversation this date concerning shipment waiver. Gentlemen:
! Con ng the telephone conversation between your f 8 MM '
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! and our 31s. M /7 N'/S'7M as referenced above, we have waived final e.samination at your facility of the following items only:
Order Item No. h. Description
$ //i".-n 2 S#Yi' 4 4 'k 2 3 r2 :
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Shipment of the above described items must be accompanied with Brown & Root, Inc. Form QA-045 titled " Quality Assurance Department Conformance Certificate" properly completed and signed by you. [includig tha right to reject the item (s) upon discovery of deficiencies during or after a Sincerely, j BROWN & ROOT, INC.
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J. P. Clarke lil I JCP.bj Vendor Surveillance Superdisor; , . g u , 7 'i'l e \{ , t ';ii$ V*d'i' cc: J. P. Cx<e la - G B&R Site Receiving Insp. Dept. B&R Site Purcha>ing Dept. .
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i . nps industries,inc. 2750 a.us moody portiond. oregon 97201 telephone 503 2261300 DATE: 11-12-79 NPSI: 8667/ NAP PAGE 3 0F 3 CERTIFICATE OF COMPLIANCE 1 CUSTOMER: BROWN & ROOT INC. I PURCHASE ORDER: 35-1195-30220 l 1 l We certify that the Items furnished on your P.O. #35-1195-30220, NPSI 1 Shipping Notice ?8667/ NAP are in conformance with ASME III Subsection l NF 2000, Class 2, Winter 1974 Addenda and the Material Soecifications listed: ITEMS: 2, 3, 5, 7, 8, 9, 10, 12 SA/ ASTM A36 ITEMS: 13 thru 16 A500 GR. B CODE CASE 1644-7 , i dNb t MANAGER OF QUALITY ASSURANCE QUALITY SYSTEMS CERTIFICATE (MATERIALS)
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NUMBER N-2324-1 EXPIRES ON JULY 13, 1982
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Distribution: ' Document Control
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