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UNITED STATES g NUCLEAR REGULATORY COMMISSION gy .e ADVISORY COMMITTEE ON REACTOR SAFEGUARDS .
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x MEMORANDUM FOR: Ben B. Hayes, Director O(fice of nves gjtions
'n . -ggg',6 Jesse C. Ebersole, Chairman, ACRS FROM:
SUBJECT:
ALLEGATIONS REGARDING CONSTRUCTION PRACTICES AT THE DIABLO CANYON NUCLEAR POWER STATION This memorandum is to confirm conversations between you and Mr. Raymond F. Fraley, Executive Director, ACRS, regarding allegations received by
- me concerning the Diablo Canyon Nuclear Power Station.
On January 16, 1984, Dr. Henry Myers, Science Advisor to Congressman Morris K. Udall set up a conference call between himself, me, and an unnamed person who appeared to be a person knowledgeable with respect to electrical work at the Diablo Canyon Nuclear Station. He desired to bring to my attention various allegations which had been identified by this unnamed alleger. I am bringing them to your attention so that
( they may be considered and resolved with the numerous other allegations identified with respect to this project. It may be that you already have some of these allegations under consideration. The items discussed are as follows: ,
. Inadequate planning and routing.of cables within the plant giving rise to a potential fer' inadequate separation of redundant safe-ty-related cables and loss of traceability.
. Transfer of cable to alternate reels - short sections of cable were frequently transferred from their original reel to other reels of cable as a convenience resulting in confusion regarding specific documentation of cable characteristics.
. Improper clearing of cable ways before pulling cables. Failure to adequately clear the cable ways could have resulted in damage to cables when they were pulled through the cable ways.
. Inadequate control of tension levels when pulling cables -- inade-quate control was exercised in pulling electrical cable through cable ways and could have resulted in damage to cables during installation.
. Changes from interim "as built" drawings to final drawings --
inadequate control has been exercised over the transition from interim drawings to final drawings of the station as actually con-( structed. ,
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8603280174 860123 PDR FOIA i DEVINE84-744 PDR
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Anchor bolts (torquing'of " red-head" bolts).
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. RHR pump' suction line valve control. Potential damage to JRHR purrps due to loss of suction as a result of a single failure.
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R. C. DeYoung, IE H. Schierling, NRR
'J. B. Martin, Region V H. H. E. Plaine, 0GC W. J. Dircks, EDO 7 .
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'o UNITED STAT ES .
l, NU EAR REGULATORY COMMISSION
, .e ADVISORY COMMITTEE ON REACTOR SAFEGUAFivS ,
WASHINGT oN, D. C. 20555 g [ ...
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MEMORANDUM FOR: Ben B. Hayes, Director O(fice of ves gjtions .
% . fws',4 FROM: Jesse C. Ebersole, Chairman, ACRS
SUBJECT:
- ALLEGATIONS RECARDING CONSTRUCTION PRACTICES AT THE i DIAELO CANYON NUCLEAR POWER STATION This memorandum is to confirm conversations between you and Mr. Ray =ond F. Fraley, Executive Director, ACRS, regarding allegations received by me concerning the Diablo Canyon Nuclear Power Station.
On Janoary 16, 1984, Dr. Henry Myers, Science Advisor to Congressman Morris K. Udall set up a conference call between himself, me, and an unnamed person who appeared to.be a person knowledgeable with respect to electrical work at the Diablo Canyon Nuclear Station. He desired to bring to my attention various allegations which had been identified by this unnamed alleger. I am bringing them to your attention so that they may be considered and resolved with the numerous other allegations identified with respect to this project. It may be that you already have some of these allegations under consideration. The items discussed p., are as follows: ,
54, . Inadequate planning and routing of cables within the plant giving W 59, rise to a potential for inadequate separation of redundant safe-6 2. , ty-related cables and loss of traceability.
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. Transfer of cable to alternate reels - short sections of cable were P g frequently transferred from their original reel to other reels of cab.le as a convenience resulting in confusion regardin;, specific j
f documentation of cable characteristics.
. Improper clearing of cable ways before pulling cables. Failure to adequately clear the cable ways could have resulted in damage to j
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[4 cables when they were pulled through the cable ways.
Inadequate control of tension levels when pulling cables -- inade-MN ( . quate control was exercised in pulling electrical cable through cable ways and could have resulted in damage to cables during installation.
g# 4.6 Changes from interim "as built" drawings to final drawings -
M h) inadequate control has been exercised over the transition from interim drawings to final drawings of the station as actually con-
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pb J*. Anchor bolts (torquing of '#' red-head" bolts).
. RHR pump sucticn line valve control. Potential damage to RER pumps .
,i l .3 3 due to loss of suction as a result of a single failure.
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R. C. DeYoung, IE H. Schierling, NRR J. B. Martin, Region V H. H. E. Plaine, OGC W. J. Dircks, EDO I
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Task: Allegation or Concern No. 171 F Fr F J 0 l*Fw4\ N AITS No. RV-84-A0007 BN No. N/A .
9 Characterization:
Inadequate planning and routing of cables within the plant giving rise to a potential for inadequate separation of redundant safety-related cables and loss of traceability.
Implied Sianificance to Plant Desian, Construction or Operation See statement below.
Assessment of Safety Sinnificance This concern is addressed in Allegation or Concern Nos. 54, 59 and 63 of SSER-21, including supplements thereto.
Staff Position L
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See Allegation or Concerns referenced above, i
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y.,. ov4'.g4Y Task: Allegation or Concern No. 172 %[g' AITS No.: RV-84-A0007 BN No.: N/A Characterization:
The transfer of cable to alternate reels - short sections of cable were-frequently transferred from-their original reel to other reels of cable as a convenience resulting in confusion regarding specific documentation of cable characteristics.
Implied Significance to Plant Design, Construction or Operation See statement below.
' Assessment of Safety Significance This concern was addressed in Allegation or Concerns .54 and 59 of SSER-21.
l Staff Position See Allegation or Concerns referenced above.
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Task: Allegation or Concern No. 173 [ ;
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. ATS No: RV-84-A-0007 BN No: N/A Characterization:
Improper clearing of cable ways before pulling of cables. Failure to adequately clear the cable ways have resulted in damage to cables when they were pulled through the cable ways.
Implied Sinnificance to Plant Desian, Construction or Operation Pulling of cables into cable ways which have defective conditions, such as sharp edges on conduit or junction boxes, could result in unacceptable damage to the cable being pulled.
-1 1 Assessment of Safety Sinnificance i
During an inspection at the site on January 31 through February 8,1984, this concern was pursued by the staff. The staff's examination of QC records of the H. P. Foley Company, the electrical installation contractor, revealed that there were instances when cables were pulled into raceways prior to QC inspection and clearance of the raceways. These instances were documented in nonconformance reports (NCR's) by the contractor's QC department.
Dispositioning of the NCR's required thorough inspection of the raceways to i
determine their acceptability and that conditions did not exist which would Eli6
have resulted in damage to the cables which were installed. An example was NCR No. 8802-975, dated December 12, 1983. In this instance cable had been repulled into a conduit following modifications to the conduit. The modified conduit was inspected on January 20, 1984 and found to be accept ble in terms of size, type, identification, support placement, installation detail and workmanship. Based upon the results of the raceway inspection the cable installation was accepted as installed. The quality records also include the results of satisfactory post-installation continuity and megger testing of the cables installed.
Staff Position The licensee contractor disposition of the nonconforming conditions identified appears acceptable.
Action Required None. '
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P6andE Letter No.: OCL-84-187 ENCLOSURE g Petition at 5.
It is alleged that: :
In November 1981 P6&E also accepted out-of-code practices when PG&E official Robert Torstros overruled an inspector who found that engineering drawings specified a weld not recognized by AWS. The drawing called for a fillet weld.
Due to the fitup angle for the weld, however, AWS does not credit it as a fillet weld. Instead, contrary to the design, the weld can only be considered as a partial penetration groove weld. In this instance, Karner backed the inspector, but Mr. Torstrom blocked corrective action with the unexplained conclusion that there was 'no need" for it. (citina 2/25/84 Anon. Aff. at 5 and related Exhibit 4.)
The significant difference between the Petition and Attachment 2 is found on the sketch located on page 2 of Exhibit 9 to Attachment 2. The sketch indicates that the allegation is referring to an open, accessible weld root connection rather than an acute intersection. Therefore, the discussion of root fusion and effective throat in the original response to this allegation contained in the second half of paragraph 107 is no longer relevant and should be deleted.
A review of the sketch provided substantiates the original symbolization as fillet welds and supports Mr. Torstrom's disposition of the Discrepant Condition Notice (DCN) initiated by Mr. McDermott. The sketch shows that a right angle intersection for a fillet weld exists at the root and for a portion of the fillet weld leg permitting full penetration and fusion at the root. For the condition as sketched, there would be no deduction from 02240 , bl4 .
symbD1ize this particular weld joint in more than one way. The meaning of th2 effective throat. As discussed in the original response, it is acceptable to weld symbol used in this instance is clear and there was no out of code practice.
GAP #183 and 184, Petition at 7.
It is alleged that:'
In 1981 PG&E neutralized a corrective action program by accepting welds that failed an NT (magnetic particle) test, based on results from previously-discredited tests that had
. accepted the same welds. The current selector switch on a testing machine had erroneously been installed backwards, to run at alternating current (AC) rather than on direct current (DC). AC, unlike DC, cannot datect subsurface cracks. Pullman and PG&E both require the use of DC for .
this reason. After 80 welds had been approved with the sachine in an AC mode, the problem was discovered. When a sample of eight erroneously approved welds were retested, three failed because of subsurface flaws. Nonetheless, PG&E directed Pullman to accept these three welds, based on the earlier inadequate approvals with AC. (citing 2/25/84 Anon. Aff. 'at 9-10 and related Exhibits 15-19.) One such weld had " linear indications", suggesting possible cracks, as long as.3 inches." (citina 2/25/84 Anon. Aff. at 9-10 and related Exhibits 17 and 19.)
In the same case, PG&E directed Pullman to accept welds that had never been properly tested. Rather than ratesting the remainder of the 80 welds that had been erroneously ,
accepted using an improper testing method, PG&E directed Pullman to accept all of them without retesting, based on the AC tests. The reason PG&E gave for this was the cryptic statement that "the ability of DC to detect subsurface defects is limited in our configurations."
(citina 2/25/84 Anon. Aff. at 9-10 and related Exhibit 18.) As described above, PG&E offered this excuse in spite of the fact that a retest with DC had failed more than a .
third of the sample, a result that PG&E's Torstrom called
, " inconclusive" (citina 2/25/84 Anon. Aff. at 10 and related Exhibit 18.)
The difference between the Petition and Attachment 2 is the reference to the memo from Mr. McDermott to Mr. Spanner, dated August 26, 1981, requesting an explanation of the Disposition of Pullman D.R.'s 4350 and 4352 and the 02240 I
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ATS No: RV-84-A-0007 BN No: N/A Characterization:
P Inadequate control of tension levels when pulling cables - inadequate control
- was exercised in pulling electrical cable through cable ways and could'have 4
resulted in damage to cables during installation.
t Implied Significance to Plant Design, Construction or Operation Inadequate control of pulling tension during the installation of electrical cables could result in unacceptable damage to the cables.
t Assessment of Safety Significance The allegation in this instance was not accompanied by detailed supporting information. However, during the staff's examination into other allegations at the Diablo Canyon site information of a related nature was obtained as follows.
i The staff's review of H. P. Foley quality records revealed a condition identified by the QA department's review of quality records wherein it had not been documented that pulling tension had been measured directly by QC l
inspection as required. These instances, which involved the pulling of five circuits, were the subject of a nonconforming report (NCR No. 8802-1027) dated I
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. 1 January 19, 1984. All cable pulls in this case involved high temperature resistance (HTR) cables with " soft" Jacket material - thus the requirement for direct measurement of pulling tension. The disposition of the NCR in this
' instance was " accept-as-is," based upon successful post installation electrical continuity and resistance tests and the fact that all pulls were made by hand.
Staff Position The staff concludes that there were instances when QC inspections were not conducted in accordance with QA/QC program requirements regarding QC monitoring and witnessing of special cable pulls. These conditions were documented by the H. P. Foley QC department and acceptable dispositions were made regarding the nonconforming conditions identified.
Action Required None.
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FOR INTRA-CCMPANY Usts STATION CONSTRUCTION h '%, """D d'*""
Of ablo Canyon Project FtLt No. ,
Rt LLTitR or Audit of the H. P. Foley Company e-su ner '
,, ,, m Tool Calibration s o m ,n.at, Audit Report DCO-82-027 -
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August 13. 1982 C
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'o Attention: D. A. Rockwell Fron May 14 through June 10, 1982, Quality Control conducted an audit of tool calibration performed by the H. P. Foley Company.
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The scope and results of this audit are outlined in the attached
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c report. Discrepancies were identified which required the issuance of Minor Variation Report E-2375.
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JAMES R. BRATTON Lead Quality Control Enc'res-Atta:r. ent: Audit DCO-82-027 JNystror.: 1gh 2 6*L-
PACIFIC GAS AND ELECTRIC COMPANY
- STATION CONSTRUCTION DEPARTMENT DIABLO CANYON PROJECT Audit of H. P. Foley Company _ .
Tool Calibration Audit Report DCO-82-027 C June 10, 1982 N
D. A. ROCKWELL I from May 14 through June 10, 1982, an audit was conducted by the Quality Control Department of H. P. Foley Comp'any tool calibration.
m SCOPE
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This audit was conducted to investigate tool calibration performed by the H. P. Foley Company to verify compliance with H. P. Foley Company Quality Assurance Manual Section XII and Quality Control Procedure QCP-8.
C AUDIT POINT ONE Verify that procedure QCP-8..as a minimum, contains the following QA Manual requirements:
a) Item identity name and/or number.
b) Frequency of calibration and the applicable procedure used for calibration.
c) The date calibrated and the due date for the next calibration.
d) The name of the person,.or subcontractor, performing the cali-bration.
e) Responsible authority review of calibration results.
Results A review of QCP-8 verified t' hat these requirements have been addressed.
Corrective Action No corrective action is required. ,
AUDIT POINT TWO Verify that tools are being recalled in accordance with the requirements of
( procedure QCP-8.
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Audit Report DCO-82-027 Page 2 O
Results A review of approximately 20% of the Calibration Log (form SF/CR Log)
. and the active recall memo file verified that tools are beirig recalled
"_ in accordance with the procedure. ;
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. Corrective Action N
No corrective action is required.
- AUDIT POINT THREE 1 Verify that calibrated tools that have been returned to production have current calibration stickers affixed to'them.
Results
.. All but two of the 47 tools inspected in the tool crib had current cali-bration stickers. Two torque wrenches (HPF #1014 and HPF Al) had exceeded their calibration periods. Further investigation showed that the calibration stickers affixed to the wrenches incorrectly specified a one month calibra-7: tion period instead of the required three month period.
Corrective Action Minor Variation Report E-2375 was initiated to document this discrepancy.
An exit interview was conducted with D. A. Rockwell, the Electrical Resident Engineer, to discuss the scope'and results of this audit.
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hJOHN NYSTROM ob Electrical Quality control Engineer 4
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Diablo Canyon Project FILE No.
CE LETTER or cu.ncr Audit of the H. P. Foley Company h 7, o ,
Soldering Activities s o im.at Audit Report DCO-82-029 '
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N August 13, 1982 N
9 R. D. ETZLER 1
,3 Attention: D. A. Rockwell From June 10 through June 16, 1982, Quality Control conducted an M audit of Class One soldering perfomed by the H. P. Foley Company.
7 The scope and results of this audit are outlined on the attached report. Minor Variation Report E-2376 has been issued for the
outstanding deficiency identified.
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JAMES R. BRATTON -
Lead Quality Control Engineer
Attachment:
Audit D00-82-029 JNystror.: 1gh E
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PACIFIC GAS AND ELECTRIC COMPANY
' .. STATION CONSTRUCTION DEPARTMENT DIABLO CANYON PROJECT 6' . June 16, 1982 u
I Audit of H. P. Foley Company -
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D. A. ROCKWELL t From June 10 through June 16, 1982, Quality Control conducted an audit of Class One soldering performed by the H. P. Foley Company. "
n SCOPE
... This audit was conducted to verify that Class One soldering performed by the H. P. Foley Company complies with their Quality Control Procedure QCP-18
" Soldering".
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AUDIT POINT f Verify that soldering is being performed and documented in accordance with procedure QCP-18.
Results No soldering has been performed per procedure QCP-18, and there are no HPF/ Solder Reports in the H. P. Foley QC files. -
However, Class I s:1dering has been performed by the contractor on LOCA splices. This soleering was documented on an Electrical Process Traveler for each splice in accordance with procedure QCP-17, paragraph 4.3.2. A review of all travelers for the LOCA splices verified that H. P. Foley QC had inspected the soldering in accordance with the included procedure, with the exception of one splice. Traveler #34 for Flow Transmitter 1-FT-532 does not have a QC sign-off for the soldering.
Corrective Action ,
Minor Variation Report E-2376 has been initiated to document this deficiency.
An exit interview was conducted with D. A. Rockwell, the Electrical Resident Engineer, to discuss the scope and results of this audit. This included a discussion that FT-532 and its LOCA splice have been removed from the plant as part of Design Change Notices DCO-E-M-556, 764, and 1108.
9 JOHN J. NYS1 ROM Quality Control Engineer .
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IN TEROFFICE MEMORANDUM .
o DiabloCanyonProject *WMQ=jm C
PACIFIC GAS AND ELEC.TRIC COMPANY BECHTEL POWER CORPO. RATION To " R. D. ETZLER / D. A. ROCKWELL om December 31, 1982 F rom -James R. Bratton F4 No- Audit Report DCO-82-049 0 2 ~
o, Quality Control s,we Audit of H. P Foley Conpany
' Welder Qualification m DCPP [*,* 69-1466 7 .
ATTENTION: W. E. COLEY f
On December 6-10, 1982, Quality Control audited the H. P. Foley Company for confomance to the welder qualification requirements of their Quality Control Procedure QCP-5, " Welder Qualification and the Qualification of Welding Procedures". The scope and results of the audit are outlined in the attached report.
The qualification records for one welder indicated that insufficient tests were perfomed to qualify him for indirect butt splices in reinforcir.g steel. This has been documented on Minor Variation Report E-2437. No other discrepancies were identified.
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JAMES R. BPATTON Lead Quality Control Engineer I
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PACIFIC GAS AND ELECTRIC COMPANY STATION CONSTRUCT 10N DEPARTMENT DIABLO CANYON PROJECT b Audit of H. P. Foley Company c
Welder Qualification Audit Report DCO-82-049 ,
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December 31, 1982 C
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, W. E. COLEY On December 6-10, 1982, Quality Control conducted an audit of the H. P. Foley Company to verify confonnance to the welder qualification requirements of the
- contractor's Quality Control Procedure QCP-5, " Welder Qualifications and the Qualification of Welding Procedures".. -
SCOPE This audit reviewed welder qualification procedures, test records, and docu-mentation providing objective evidence of welder qualification continuity.
AUDIT POINT ONE Review H. P. Foley Quality Control Procedure QCP-5 for conforinance to the welder qualification requirements of the American Society of Mechanical Engineers (ASME) and American Welding Society (AWS) welding codes.
Results The technical and administrative requirements of Procedure QCP-5 comply with code requirements.
Corrective Action No corrective action required.
AUDIT POINT TWO Examine welder qualification test records to verify that qualification tests were performed and documented in a'ccordance with Procedure QCP-5. Detonnine the limits of each welder's qualifications.
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Results' The qualification test records of all seventy-three H. P. Fo' ley welders were examined. The welders have perfomed qualification tests to qualify for various welding processes (i.e. shielded metal-arc, gas ' tungsten arc) to be used for welding requiring compliance with the ASME Boiler and
(, Pressure Yessel Code, the AWS Structural Steel Welding Code, the AWS Sheet Steel Welding Code, and the AWS Reinforcing Steel Welding Code.
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' Audit Report DC0-P2-049 i
G The following discrepancies were identified: '
a Discrepancy "
Welder ,
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H. Dutton I.D. symbol is not referenced consistent-
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- ly.^ Pacords indicate "S" or "D2".
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'(2) D. Estrada AWS certification dated 11/4/82 was not
' signed by Quality Control.
-(3) W. Haines AWS/ certification dated 11/4/82 was not signed by Quality Control.
7 (4) J. Lavoie AWS certification dated 11/19/82 was not signed by Quality Control.
(5) L. McFadden AWS D1.4 certification dated 1/13/81 ,
indicates insufficient macroetch tests were perforined.
(6) C. Smith AWS D1.4 certification dated 10/8/82 does not indicate bar size used in test.
(7) D. Waller AWS certification dated 11/19/82 was not signed by Quality Control.
The limitations of each welder's qualifications, with respect to code, process, thickness, diameter, position, backing, filler metal, and date of original qualification, were compiled for later comparison with the H. P. Foley Company Active. Welder List, in-process inspection reports, and production inspectior, reports.
Corrective Action Six of the discrepancies identified above were corrected during the course of the audit. Minor Variation Report #E-2437 has been initi-ated to document the remaining unresolved discrepancy.
Discrepancy Corrective Action
' Dutton's symbol was confirmed to be "S".
(1) Records indicating "D2" were corrected.
Certification was signed by Quality Control.
(2)
Certification was signed by Quality Control.
(3)
Certification was signed by. Quality Control.
(4)
(5) Reference MVR #E-2437.
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Audit Report DCO-82-049 Page 3
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- Discrepancy Corrective Action
., i (6) Test bar size was entered on ce,rtification.
(7) Certification was signed by Quality Control.
AUDIT POINT THREE Review the H. P. Foley Active Welder List to verify that the welders listed
.e are qualified and that the limitations listed are correct. Review past lists to assure that the list is revised when there is a change in welder qualifi-cation status.
I Results The Active Welder List effective at the beginning of the audit contained the following discrepancies:
- 1) Welder V. Matties had successfully completed an AWS qualification test on 12/3/82, but was not identified on the Active Welder List.
- 2) Welders H. Dutton and A. Schofield are qualified for unlimited
. thickness groove welds. The list limits these welders to materials 3/4" thick or less.
A review of superseded lists indicates that the Active Welder List is revised to reflect changes in the status of welder qualification.
Corrective Action The discrepancies identi'ied above were corrected /explainec as follows:
- 1) The list was in the process of being revised to reflect the addi-tion of V. Matties as a qualified welder. Prior to the conclusion of the audit, the revised list was issued.
- 2) The Quality Control inspector supervising the qualification of
. welders preferred to list welders H. Dutton and A. Schofield as limited thickness welders. This does not represent a violation of codes or procedures.
AUDIT POINT FOUR Rev'iew the contractor's program for monitoring welders to assure that each -
welder's qualification in a given code and process is maintained.
Results The contractor performs an inspection of a welder's production work
( prior to expiration of the welder's qualification, documents this
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Audit Report DCO-82-049 Page 4 0$f inspection on an "In-Process Inspection Report", and files the inspection '
report with the qualification records as documentary evidence of welder
. qualification continuity. The records on file were not sufficient to maintain qualification of welders D. Backes and K. Parke to the present
",, date.
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Corrective Action i During the course of the audit Quality Control located documentation m providing evidence that welding was performed by these welders on dates sufficient to extend their qualifications to the present. Copies of this documentation were then filed with each welder's qualification records.
AUDIT POINT FIVE Review a random selection of production weld inspection reports for all types of welding to assure that welders have not exceeded the limits of their qualifications.
Results Approximately 50 weld inspection report's from work packages involving the welding of structural steel, sheet steel, and pipe were examined.
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No discrepancies were identified.
Corrective Action No corrective action required.
An exit interview was conducted witr the Electrical Resident Engineer to discuss tne secpe and results of this audit.
DEREK BELL Quality Control Engineer Audit Team Leader T s.
TER . PIE CE Quality Control Engineer
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iniELOEEiCe ueuORA~ovu Diablo Canyon Project
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PACIFIC GAS AND ELECTRIC COMPANY BECHTEL POWER CORPORATION T. - . D. Etzler em January 24, 1983 -
,,,,, James R. Bratton ru so Audit Report DC0-83-001
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Quality Control 3 ,, Audit of H.P. Foley Company o,
Welding Electrode Control DCPP ,,,
69-1466 1
ATTENTION: W. E. COLEY On January 20, 1983, Quality Control audited the H. P. Fo'ey Company for confctr.ance to Quality Control Procedure QCP-4A, " Welding Electrode Centrol". The scope and results of the audit are outlined in the attached report.
Several c':-crepancies in the control of welding electrodes were i-denti'ie: Minor Variation Report #C-1238 has been initiated te doce era -.ese ciscrepancies and assure that corrective action will
.be F:si: .
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JA'1ES R. SR ~ TON Lead Quality Centrol Er;'+:.
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A: .? +- Au-it DX-E3-001
c-PACIFIC OS AND ELEC!dIC CC".;ANY '
- . STATION CONSTRUCTION DEPARTMENT DIABLO CANYON PROJECT (k '
Audit of H.P. Foley Company Welding Electrode Control ,
Audit Report DCO-83-001 .
January 24, 1983 O .
e W. E. COLEY N
_ On January 20, 1983, Quality Control conducted an audit of the contractor's practice for control of welding electrodes to verify confomance to Quality 3
Control Procedure QCP-4A, " Welding Electrode Control".
-- SCOPE This audit was conducted to assure satisfactory control of welding electrodes
,, at issuance stations and in welding areas. The audit was limited to the issuance station in the Unit One Turbine Building and the welding areas in the Unit One Fuel Handling Building.
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AUDIT POINT ONE Observe the issuance of welding electrodes to assure that accountability of electrodes is established prior to use.
Results Issuance of electrodes to several swing shift welders was observed.
The attendant counted the electrodes and made the correct er.tries on the Weld Electrode Requisition Form, recordine the oven tempera-ture, the welder, the work location, the amount issued, and the tire of issue. No discrepancies were noted.
Corrective Action No corrective action required.
AUDIT POINT TWO Inspect welding areas to assure that welding electrodes are not left un-controlled at the work location.
b uits Inspection of the welding area revealed five uncontrolled electrodes; three used and two unused.
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.- , Audi t Report DCO-832001 Page 2 O
Corrective Action a
Refer to Minor Variation Report #C-1M8 for the details of the I
discrepancy and corrective action. '
AUDIT POINT THREE
- ' Observe the return of welding electrodes to assure that accountability of electrodes is maintained.
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Results Return of electrodes by several day shift welders was observed.
3 The attendant did not count unused elettrodes or stubs; the
~ welders discarded their stubs in an open bucket, placed their unused electrodes in the oven, and apparently inforried the at- ,
tendant of the amount of each. At no time did the attendant handle or count returned electrodes. Although no procedural
.7 requirement exists, this does not constitute adequate control of welding electrodes.
At the end of the shift, the attendant locked the ovens and left the station. The swing shift attendant did not show up until twenty minutes later. During this period, two welders returned their electrodes, waited for an attendant, placed their electrode containers on the table, and left. The electrode containers were not traceable to the welders. This is in violation of Procedure QCP-4A, paragraph 4.4.1.3.
The Weld Rod Requisition Foms were reviewed at this point and showed that all outstanding electrodes had been returned; this indicates that electrodes are being documented as returned to the station orior to their physical return. Discussion with the night shift attendant confimed that this practice occurs fre-quently. This does not confom to the requirements of Procedure QCP-4A, paragraph 4.4.1.2.
Corrective Action Refer to Minor Variation Report FC-3238 for the details of. the l discrepancy and corrective iction.
An exit interview was conducted with the Civil Resident Engineer and the Structural Steel Group supervisor to discuss the scope and results of this audit. '
DEREK BELL l
l
(- Quality Control Engineer
~~~ ...; ,....-......,.,..m..,.. . ...,.r_ ..
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_ Dl ABLO ?dA*ff ON PROJECT - - - ' ~INTERFERENCE Hos M- 1 ~2cD
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3HNGRS PIPING OHVAC O ELECT OCivil. aiuST OuECar TAGGING: l PINK l l RED ] BLUE ];
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- CREEN)
DESCRlPTION OF INTERFERENCE: /4/d A4use;ck s#7eWrecoze ~s s.s/r#
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NEED 101 REMOVED BY: 4 - E 7' - #5 w (DATO g*p,</7. //A/o~A '
IT ' NATED TIME To jg Cou.PLETE INSTALLATION AFTER LOCATION - n-P.EMOVAL OF INTERFERENCE E &c0ty , j t DAYS / WEEKS C
__ 1a. Q
. ARE A: /7 *
' ELEVATION: // 7 h .2 /5'J .77 LINE ,NO:- #A
' HANGER NO: 2 /.5" T - J '1
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SUCGES'TED SOLUTlON: AinopW WA4/&K . Me*Dd3MA/ ro A77AM' ro asu ' sarke. ram om. '
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2
, , Attachment'.1 PI-23 Rev.
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INTEROFFICE CORRESPONDENCE g
DATE
- November 2, 1983 {I h -
R S- ..
TO All QA/QC/ Redliners FROM Bob Hosman/QA Supervisor -----
SUBJECT AS-BUILT DISCREPANT CONDITIONS- ~~
~
SMALL BORE - DISCREPANT CONDITIONS l '. Changes to A/B - within ESD tolerance
- corrective action -
~
- Redliner to correct A/B - initial and date change. -
QC to verify correction - initial and date verification.
__ Also, QC shall note correction / changes on the back of the F.P.S. - -
and the method of justification.
7 (Ref. ESD 254)
. autho'rization.
- corrective action -
- QC shall verify actual field condition.
QA shall initiate DCN (per ESD 253) requesting PSDTC for authorization.
The QA reviewer has authorization to sign " Contractor Receipt" on the
. PSDTC. ,
- 3. Documentation problems, i.e. missing or discrepant information on the
~~
F.P.S., snubber checklists or other record documents.
- corrective action -
- l Problems can be resolved by locating objective evidence which provides
! sufficient proof to rectify the discrepancy. This may entail checking QC dailies, logs,. or physical verification. Corrections / changes eqn be made when justified and shall be noted on the F.P.S. (Ref. ESD 254).
LARGE BORE - DISCREPANT CONDITIONS
- 1. Copy of A/B reflects field condition but there is no PG&E authorization (PSDTC).
- corrective action -
g QC shall verify field dondition.
QA reviewer shall initiate a DCN to obtain PG&E authorization (PSDTC)
.h g N,' s, Page 1
~
~
, 47
._. _. _ ., s - - . _ . .
-~ ---- , , _ , p , y + - - - -
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- 2. Copy of A/B does not reflect Field condition and the discrepancy is outside ESD tolerance (includes missing information) corrective action -
Oc shall verify Field condition. -
QA Reviewer shall initiate a DR. .
- 3. Documentation problems: Same as Small Bore.
4 0
4 un
. Bob Bosman*
QA Supervisor ,
BH:jg
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.. INSPECTION
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f ~ RZ2TRENC2:S 2 .- ,. . . ITEMS To BE r wrt 1tT'n g. OTHER THAN NCIh M G INS?EC"'IGN ESD T23 INITIAI. O TTNA1, . Common To AllHangers/Supporte: . hN[-lhh h
- 1. Raneer I.ocation td. thin ESD 223 Tolerance
- 2. 3:!t.ng Su: cert to Structure / Adjacent Anchor Spacing '
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- 3. Prehest of Structural Steel if Recuired .
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, 4. AI!!tems in B.O.M. InstcIled 6 Are Correct Type N/A - /M
- 5. A111tems in B.O.M. 'rhthit the Correct Dimension 1 y/i f/2)I
- 6. C=nfig':reton as Per Design Dwg, l )(s.8-l 7. Mc=cer Cc rymg I.med (fr r- -me TorciSupport) i 8. AU Weids Co=clete and Accectchie N/A l l(N i
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, G. Inte;. Att==h. ML No.& F.W. No. noted on Process Sheet I j% IM
.10..Three:ied Connectons Se=ure l
- Q u(/ N/A l [fA i 11. Threed En;=gement Adecucte - l 4~ m i JM i 12. Gu2dt Cecr=nces Ac== tchie -
l AY N/A l LIMA
- 13. Erec=sion Offset Ce:reet as Desiened (Therme!) l 49 i M A~
- 14. C===ing Config. Correct '
,W l N/A l' AfA l Reviesr Package for Desi.gn Change Approvals .%' l C I lllM
. I 16. Mc=ger P. ,4 Identified . No. Written on Hanger AV l '
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- 17. Mc=iger & Pine Cecrc:nces are Adequate for Thermc! Movement . l-
- 18. Configuranon is Tree from Are Stnkee N 'D l l~5/A IN l ~N/A '
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- 19. Configuration is Tree from Wald Spatter ev. fQ) l N/A lOC
' 20. Weep Holes Instclled l
l AN l N/A l A/A I 21. Ac=^ent to Other Su=ocrts As. Built NS' I I MA~ ' Sprmy Cans: .- .- - '
- 22. Scring Can!.D. Plate Complete "" " '
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N/A [De
' 23. Imed Column Not Bound on "T" Cans GV ! N/A l4 i
'24. S=ri=g Ccn Set Per Dwg. T l
1 L 25.'Threcd Engagement Adecuate en Sermg Commenents li \l N/A l i' I 25. Het 6 Cold I.modIndicators Attached l 'i i
' Stock Supports /Swcry Struts /Speciais: .
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'27. High Strength Nut & Bolt Met 1. Properly I.D. Q/A ^ l
- 28. 51cking of Ball Bushings Complete- N/A Nh I
- 29. Mech. Shock I.D. Plate Commlete N/A *l 'N I l 30. I.oed Stud Centered on Ocmo N/A I
- 31. Shocks Protected N/A I~
- 32. Verify Thread Engagement on Rod Ends N/A
- 33. Welds in Ac=ord, with Esn m -
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- 34. Het 6 Cold Settmq Per Dwg.
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Racord Fitter & Walder Bad a No.; *
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tw; bum >wmMW:M+--'_w31mi=ms=mniev= es:m-mraxsw:myn t?- JANCARY 14, 1983, INTEROFFICE CORRESPONDENCE
.v_GCE 9, 19S 3, i
APRIL 25, 1953, AND DATI JL*LY 21, 1983 ' To ALI. FIELD SiyIRINTE: CISTS
~
FROM p. STIEGER/R yAULL
.M.'ECT ARC S31KIS GRI:OER COL'GES AND FUNCH M.GKS.
? LEASE C0500CT A TRAINING SISSION WITH ALL CRAFT ?ERSON';EL CCSCERNING THE TOLLOWING:
~
4 In the recent past we have had :co =any are s:rikes and grinder gouges on 'ipes, hangers, rod asse:blies, e:c. In crder :c eliminate these cenditions, each person cust take the following precautions:
- 1) Do not ground to pipes, hangers, etc.
, 2) Protect sur:cunding pipe hangers and c:her ecuipmen: in work area
, .frc= veld splatter, grinding and ther al debris.
- 3) 3e, careful not to let stingers are pipe, hangers, etc., when
. hanging stingers, se: ting the= down or;during other movements of stinger.
[( 4) Do not drag leads ever pipes, etc; if they have bare spots or open cennectors they cay arc.
'5) 'biscennect all leads frc grids befcre pulling or rolling the: up.
[ 6) Use extre=e caution when grindin; in close prcxicity of piping. Protect the pipe prior to grinding. It is ycur responsibility
. :o follow these steps and to'eli:ina:e arc strikes and grinder I gouges on piping and other =e=bers.
- 7) Se sure cables are connected with =atching cennectors. Do not use a Cze-lock connector with a Jackson as they do not fit properly.
s
- 8) Check cables for broken insulation on bare spots.
- 9) All velding are starts shall be confined to veld preparatica area.
Center punches shall unt be us'ed on piping where the punch mark will
~
10) not be removed by ' i'ecuent cutting or grinding. A lov stress sta p or vibrorte" is an acceptable nethod of marking. .
?. Stiege Y ,
Residen: Construe:1on Manager R. Taull Assistant Resident Ccastruction Manager
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ITEMS TO BE CHECKED ' REFERENCES PREINSPECT
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- 1. Can Hanaer 8e Installed At The Procer Location 6.2 kjh
- 2. Is The Adjacent Anenor 50acine Acce0 table 6.4.1 WA
- 3. Can All items 8e Installed And All Welds Made '
R1b i 4 Are All Weldino Symbess Accurate And Comolete ' 6.8 fu$ l
- 5. Is Old Work As-Built, Acceotable, Or To Be Reworked PG&E Memo 4-11-33 M4A i
- 6. Discosition DR No. 4678/4730 (As Acoroorlate) I utA l'
- 7. Is Pre-Heat Or 5t uctural Steel Red. & Noted On Process SnJ 6.8.2.2 l 4LA I S. Are All 0.C. Hold Points Noted On Tne Process Sneet i ESD 264 I JM i
- 9. Have All Tne Necessary Forms Been Oriainated (Pipe Atten. IDI,Insl. C-51) I tit $ i
- 10. Have All Ine Interferences Been Resolved I i ti/h I
- 11. Pre-Insoect Packace Complete (Reed. Checklists Attached) I itOS i RE INSPECTED BY: '
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. . ITEMS TO BE CHECKED REFERENCES FINAL INSPECT l :
.f .-- ESD 2E3 CHECKLIST I
.J:0 OTHERS l hancer Location W1 thin E50 223 Tolerances 6.2 I c or r .Ji -@f 2 Ao3acent Ancnor Soacina Acceptable 1 6.4.1 I . #4 'g
. Inr_eaded Connec-tions Secure /inoacement Acecuate I i c- e,*r JL6
- 4. All items in B.O.M. Installed And Are Correct Tyoe 1 6.6 C c=w f i 5. Confiouration As Per Des 1on Owo. *- 1 i eew _,;-
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- 8. Pice :nd/0r Guide Clearances ACCeDtacle 1 6.7 i CCW
- 9. Base /lates, Fisn Plates, & Stiffners installed Per ESD 223 6.3.7 L 6.3 i s/A-
- 10. nancer Procerly Icentified. No. Written On Sucoort i I 'e ew -
- 11. Attachments To Otner Sainiaom l_cen ti f i ed 8 t cs"
- 12. 3PEC3465 Rod Succorts N T-303 aola.nuMvl' stalled 6.5. 6./.: i .W2-
- 13. _ Sorino Can IM"aB e5 9lCoi@EMim sYr@w.6 i m R 44 1 mean . - __~J+
- 14. Jaay atruts Correct SUte Ma'faBd (RB 5tRd575Entet'Nti iMW Ef 4 il
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REFERENCES PREINSPECT , I ITEMS TO BE CHECKED . ESD 223 CHECKLIST AND OTHERS 6.2 - I ff>b i Vs i
.. Cen Haneer Be Installed At Tne Procer Location 6.4.1 2.
is ine Adjacent Ancnor Scacina Acceotable HJS 1
- 1. Can All Items Be Installed And All Welas Made 1 6.8 i h13
- 1. .
Are All Welcina Symbols Accurate And Comolete 1 PG&E Memo 4-11-E3 g1 A
- 5. Is Old Work As-Built, Acceptable. Or To Be Reworked i 1.t4 A i
- 6. 01scosition OR No. 4678/4730 ( As Acoro::-1 ate) i 6.8.2.2 I uf l.tt I
- 7. Is Pre-Heat Or Structural Steel Rod. & Noted On Process i ESDSnt264 i MfL
- 8. Are All 0.C. Hold Points Noted On Ine Process Sheet i MJ6 I
- 9. Have All Ine Necessary Forms Been Oric1nated (Pice Atten. l IDl.Insl. C-51) I (tj$
- 0. nave All Ine Interferences Been Resolved i I Itt6 1
_i. Prc-insoect Packace Comolete (Reed. Checklists Attacned) he e DATE: 7hD RE INSPECTED BY: / HANGERFINAL.IhSPECTIONCHECKLIST .
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REFERENCES FI*iAL INSPECT ITEMS TO BE CHECKED ESD 223 CHECKLIST i i
- -- AND OTFE:ts i 6.2 iMtr o/14tB3 I
~! Hancer Location Within ESD 223 Tolerances 1 6.4.1 i ac h/Id/e.3 1 ~ ~
- c. Ac3acent Anenor Soacina Acceotable i i U. t t / /4 / 63 1 6.6 ; Ut 8//#P I
- 3. Inreaced Ccnnec:1:ns Secure /ineacemen: Acetuate 1 I ut.Bl/W A2
- 4. All items in B.O.M. Installed And Are Correct Tyoe i 1
- S _8, i 5. Ccnficuration As Per Desien Owe. 1 6.8 IMt s f(R i
- 6. All aelas Comolete And Acceotable -s.R -;- Confict; ration) I 6.3.2.4 iM tR r er /e_3 . i i 7. Confic. minimizea From ARC Strinces. Wela Soiatter, Etc. i 6.7 I w/A -
- 8. P1oe And/Or G.- #%aignhes 4,:ccoie _6.3.7 L 6.3 i Mterres3
- 9. B as e P l ates , Wes t IF.* 'L 5*Wf ftg s . . .J:ii .9theed5e d23.3 i 1
l El T 5 #% a r IL.t s//We I i 10. Hancer Procer5' iC#iES. Nc5 M MM R_ Bk?Mirne 6ll W M 4 4 N1 3 W E E FU Si .t %/ v/r_ 4/S3 : i 11. Atta:nments To Otner SL"b ,rts McE4 9ei 1-2. I JPecid8s 6.4.3 ~ ~ lac Succorts. t wA T-i I 13. _ Sorine Can Instaliec And CQFRh m:'msts 4er.Qwe. 12.'s c 3 h 4? E's-l_14. away acrans. Correct Size installed Beg.R$-Bc N SS klist i A 6.6.2.2 I vt W r +!G AR-do..P W.itnin ToleranceE B N iig M i I tv A 1 15. m/n l 16. anoct suppohs Meetanieal Snock 1.0. 71 ate L... , _te i 6.10.2 I
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6.6.2.2 ' t./A L 18. P To P Witnin Tolerance Atten. A & B l o/A i 19. Alionment Acceotable (Cla'*:0 & Rear Brkt.) - I. 9/A I 20. - All Hardware Comoatible l
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LNGER NO.: 2.3 3
- S S E f L we ' ., I-K-50 3 8 -4 ELEV: 65 5 ' AREA: E DWG. NO. 04C)2%55 SHT. I~/ U DCN NO. - REV. I
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PPP ENGINEER: Mdf DATE: '7 fl7 81 PGfr E ENGINEER: //d _,% DATE: 7-/ P - 7 3
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THE FOLLOWING WORK IS REOUIRED TO COMPLETE THIS PIPE S'JPPORT: ' h kJi a % t dee m Ew.1
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.. W sTEDE.9G4'ED SL/PA34r To serMovr
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SHEETS ASSIGNED TO THIS HANGER SYMBOL (TOTAL _2 ' SHEETS) ---. a
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NO OF ASMERiB8tE8 REQUIRED
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.0= .s . .... ~
[ ~ I I' REFERENCES PREINSPECT ITEMS* TO BE CHECKED" (' .. ESD 223 CHECKLIST r AND OTHERS 6.2 '
.N
- 1. Can Hanaer Be Installed At Ine Procer Location 6.4.1 i N/A
- 2. Is Tne Adjacent Anenor 5Dacina Acceotable ' -
44tJ
- 3. Can All items Be installed-And All Welds Made '
6.8 +%)
- 4. Are All Weldino Symools Accurate And Complete PGLE Memo .'.-11-23 O/A
- 5. Is Old Vort As-Built, Accectable. Or To Be Reworked u I
M/A
- 6. Initiate OR he. 4678/4730 & 01soositioned ( As Acorocriate) 6.8.2.2 N/A
- 7. Is Pre-Heat Or Structural Steel Rod. & Noted On Process 5ntit E50 264 i .ffw
- 8. Are All 0.C. Hold PointsForms Noted Been0n IneOrto1nated Process Sneet (Ptoe Atten.101,lnsl. C-51) i NA
- 9. Have All Ine Necessary t >
N/A
, 10. Have All The Interferences Been Resolved i titJ
- 11. Pre-Inscect Package Complete (Recd. Checklists Attacned) '
- h. Nea DATE: "Ml7[Ps PRE INSPECTED BY:
HANGER FINAL INSPECTION CHECKLIST n. REFERENCES PREINSPECT
- - ITEMS TO BE CHECKED ESD 223 CHECKLIST '
- - - - AND OTHERS ,,
6.2 n e e o' W h
- l. Mancer Location Within E50 223 Tolerances 6.4.1 h 49-l 2. Adjacent Anence Scactna AcceotaDle c. cw JL-j( 3. inreaced Connections Secure /inr:acement Adecuate 6.6 ca c" 1
- 4. All items in B.O.M. Installed And Are Correct lyoe e een
- 5. .Conficuration As Per Desien Dwo. 6.8 I c a ,,-. VL:
- 6. All Welds Complete And Acceotable (Size, Confiouration) J 4-
.' 7. Confieuration Free From ARC Strites, Weld Solatter, Etc. 6.8.2.4 e to 6.7 c c="d W
- 8. Ploe And/0r Guide Clearances Acceptable 1
6.3.7 & 6.3 i e
- 9. Base Plates, Fish Plates, & Stiffners installed Per ESO 223 d
- d"'o
- 10. Mancer Procerlv latatifind. N L W 'p a a _OrlfomWr; um EM & MM A E E c' cw e
- 11. Attacnments up wiielE5dWD'J$rts B =*_'3flF5 M M il XP W%MS MR R R E E E%E
- 12. JPec W5 Red a .. Erg,l.-=4nced ".*l"6- BrgeMIR4&Niabit tE5.d@.3 E W
., /4 SorSo CWIng: Sled End MlE LohAEe5 N, MF '818 tM4.9 * " "I M
- 13. i T c'
- 14. away uru's Correct Stre Installed (Ref. Attached ChecUistl l -
6.6.2.2 e& P To P Witnin Tolerance er n R E E EX t l 15. _ _ I a/h
- 16. anoc.t auppor 65 Mechanital Shock 1.0. RIRERE eteW '
Hot & Cold Settine WiBiB BW"-- E 6.10.2 i I ii- 17. _ 6.6.2.2 i 8
- t. 18. P. To P Within Tolerance"
. Alignment Acceptable (Clamp.& Rear B.-tt.) Attch. A~& 8 '
I/
- 19. .
4/ i h i 20 ~ . . -
-- All Hardware Compa ti b l e > - - -- ---- -- - , - - - - . - . ' 21. Package Reviewed For Ccrnoleteness (Design Chance Acor. Etc)
C <cW l
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- 3) C1z:p size: (e::er pipe dia.) 4" C) " Coupling type: solid / socket veld %1'A _
- t. :CI V : DGICA~IS AC:::i"_'ANCE
- 2. Clz=p bolts *-etalled z d ti st [
- 3. 01:=p spa:er ' *:alled a:d tict / -
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41. C=:ter p1:s f=117 spread /
- 12. Spherical bear.' g vashes/ spacers 1:s:s"ed itere rec. 1 ed, red::1:g teral side.clea.z:ce to less hz:
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