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January 21, 1984 (,0 MEMORANDUM FOR: Ben B. Hayes, Director - Office of Investigations FROM: John B. Martin
- Regional Administrator, Region V
SUBJECT:
REQUEST FORINVESTIGATION OF ALLEGATIONS OF INTIMIDATION OF PULLMAN POWER PRODUCTS CORPORATION PERSONNEL Region V is in receipt of several recent allegations of intimidation involving personnel of the Pullman Power Products Corporation (Pullman) working at the Diablo Canyon Nuclear Power Plant. By letters of January 2,1984, to NRC, and of January 9,1984, to the 4 U.S. Department of Labor (both attached), Mr. Steven Lockert, former Ouality \/ Control Inspector for Pullman, alleged that he was terminated because he was " active in reporting non-conformances" and because he was
" unwilling to look the other way" when be identified work he believed could become a hazard to public health and safety.
By letter of January 12, 1984, to Commissioner Victor Gilinsky (attached), - Mr. Harold Hudson, former Pullman Ouality Assurance Inspector, alleged among other things that he was directed by his OA/QC Manager not to
!Qi\
identify quality assurance discrepancies "...unless specifically ordered k to do so by the QA/QC Manager. If I did I would be gotten rid of." \ By af fadavit of January 12, 1984, given to Mr. John Clewett of the .
-Government Accountability Project by an unnamed Quality Control Inspector a presently employed at Pullman (attached), it is alleged among other things g gi l that Pullman quality control inspectors were subjected to threats and l intimidation "...by contruction personnel and by our management, and reprisals
! against those QC inspectors who follow the code too closely." ! i While my staff has initiated a technical review of these and other allegations received by the Commission stemming from the project at the l Diablo Canyon Nuclear Power Plant, investigation by your office of allegations of intimidation and harassment of Pullman personnel at the Diablo Canynn l plant is reauested. i l l I
~
B603310005 860123 p$ nh -744 PDR lU
. ; B:;n B. HayIs .
Any additional materials, documents or information which may relate to your
- investigation which is available to my staff will be made available to your office as soon as practicable n f
u -k
- 1. s.
John B. Martin . Regional Administrator, Region V cc: W. Dircks, EDO H. Denton, NRR R. DeYoung, IE T. Bishop, RV
- 0. Shackleton, OI 9
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- u.s wuatan nicu . cony censsioN w: : r- m ALLEGATION DATA FORM nie wiwiu. onre e .so.
f
- I!ECENING OFFICE Docket Number (if oppiscable)
.. Facility (re ) Involved:
tst en:rs tw 3. or a 3.n.nc. wit. GENERIC) (N. moi i /O bum lk O 5 'D C Ol'2 7 s hY 0 h 7 & l .
- 2. Functional Area (s) Invofwed: .
stCh.d appropri ie boatesi i _ operations _ onsite health and safety _ construction _ offsite health and safety _ safeguards _ emergency prepare:! ness _ other esp city
- 3. cascription: IPlui(llI 4 olnl I r>l #1 H c,I c l w l ,,1 A Il I (1 -1 y ,125,1 (Id l e x io ne e w .es. ,i l g g ijo; ; ; ; ; ; ; ; ; ; ; ; ; ; ; .; j l glj j ll IIl1II IIIIIIIIIIII IIIIII IM ulW blel rl 1115171 IIIIIIIIIIIIIIl
- 4. Source of Allegation:
ICheck .ppeepe'.te
. bout _
contractor employee _ security guard _ licensee emplojoe news media _ NRC employee _ private citizen i' _ organization ispecitri other esp. city: I % .[t buk i MM OD YY
- 5. Date A!!eg tion Received: g ( g, ,
g g i
- 8. Name of Individual trir.: wo initi t. .ns i.. n m.
h .")n'" - _ - f;nJ.E ( Receiving Allegation: ( ,' 7. Office: g y ACTION OFFICE
- 8. Action Office
Contact:
tri .i me inri;.i. .ns i.. n...: b- EF S. FTS Telephone Number: y g , g 7 g q
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- 10. Status:
gew on - Open,if followup actions are pending or in progress _ Closed. If followup actions are completed MM DD YY 11 D* CI***d: l l l 11.1 Docurnent Nos.
- 2. R.marke: l l l l l ; ; ; ;;iii i l l ; ;;iiiiiil (Umit to 50 ch.e.ct.rst IIIIIIIIIIIIIIIIIIIIIIIIIJ If.1 Man-h
- 13. AllegationgrgDate omc. Y .., Numb.e er: , g g g I76 p i
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" : 'e *" ALLEGATION DATA FORM I"*8 i,.i, eton. .n en. a. _,
E RECENING OFFICE Docket Number (if applicable) f
,. Facilitylles) Involved: IN mel g . tg i/ 6 C 2 71 \
tW enore thea 3. or N F I A f)/ O Wyw ,-I/1 O S 0 gen.nc, wrh. GENERICI - _
.r-O cr _J J J 'h 't 3
- 2. Functional Area (s) Involved:
Act=ct appropriaie bear ) _ operations _ onsite health arid safety construction __ offsite health and safety _. safeguards .. _,,, emergency preparedness _ other Esp cityi ,
s. Description:
1 A oII la Iw I Inle l H si cininId ll l;inlil(Iml ilW I I
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- 4. Source of AIIegation:
scheck app <op te boil contractor employee security guard _ licensee employee __ news media NRC employee _ private citizen I organization especityi (W t other esp. city) hf l MM DD YY
- 5. Date Allegation Received: g g , _ g y E. Name of Individual trirst two initi.e. .no ..: nom.:
Receiving Allegation:
- 7. Office: g y i
ACTION OFFICE
- 8. Action Office
Contact:
tri,.i sw in;ii.i. .no i.. n. .) - 0^
- 9. FTS Telephone Number: q g _ q7 g g
, _ Open, if followup actioris are pending or in progress Closed,if followup actions are completed l MM DD YY
- 11. Date Closed: 11.1 Document Nos.
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*2. Remarks: l l l l l l l l l l .l . l l l l l l l l l l l \lII
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- ALLEGAT, ION DATAo FORM in. ..: y. on r .e.
7 __ RECE!VING OFFICE Docket Number lif appficablel
- s. Facility (leal involved: (Nemel
.t m ~ is, s. or n Didlo C% m 1/z o y o o 0 2. 7[
e=nenc. w'ne GENERICI O f M O d 'h '2 3 2.# Functional Ares (s) Involved: onsite health and safety tchecA approp4ie be.t : operations construction offsite hee'th and safety _ safeguards ____ emergency preparedness . _ other especity 3.
Description:
I PI all I i Inl olnl IM ,.I 1Id l i I nl ol I il 5 Isl al <lsi II1
',"'"*'"'"' I Al ll\ l el alalM il oint lalu lmlblel rl si li 12_l71 1 1 J li ftis l loi nl Al I t hio l l +1 ol 111;l21 I I I I I I l l IIIIIIl !IIIIIIIIIIIIIIIII
- 4. Source of Allegation:
contractor employee security guard (Check opp op .ete boat _ _ licensee employee news media NRC employee _ private citizen
? organization aspecityl E other tspecity [h hka f 5%fD MM DD YY
! 5. Date Allegation Received: , , g
- 6. Name of Irdividual trirsi swo init;eis and to. nomes Receiving Allegation:
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- 7. Of fice: g y l
l ACTION OFFICE M . L . C o.vtfer
- 8. Action Office
Contact:
tries two initions and rest nome S. FTS Telephone Number: y g 3 , g g q
- 10. Status: Open. if followup actions are pending or in progress gewen on ,
Closed. If followup actions are completed MM 00 YY
- 11. Date Closed: 11.1 Document Nos.
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'2. Remark.: l l l ; ; iil i;;il l ; i ; i i ;;iii;j ILirrni to 50 chenecieral IIIIIIIIIIIIII IIIIIIIIIIII offic e Year Number II l Man-hours er:
- 13. A!!egation NumfDate j , g g
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u s nuettu cvalone c:,vvnes ALLEGATION DATA FORM
$tt inwoet.n c,n >>,... ne l_ _ ii, #,
RECEIVING OFFICE Docke.t Number (if appi;catte)
- 1. Facility (ies) Involved: i fe 5 $r11e GEntnic 0 l* - N 'l Q f $__ [ $ Q ? )
" o /A n e r o A 1 2 Ils __
- 2. Functional Area (s) Involved: .
r (Ct=ck .pp,opriate beatest s operations onsite health and safety construction _ offsite health and safety __ safeguards _ emergency prepared iess other tspecityl 3.
Description:
l3l6.ll!l/ lM Tirlo l/Dl lflff.jplpj l Plu l t. l4 lAlA lt'l lidf] - - _ pma io no cur.ei.re jg l, g; lg. g jgg ggj;ggl ;plg.j /] IEJ IclolWITR.IniclT1 15Vl61cisl I/ldlDI I41/S1 Ifl I LMI6JLIDlil/Ad IRIEl&la li IflFJmle-In471SI I I I l
- 4. Source of A!!egation:
Icheck app,opriate boas _ contractor employee security guard
.i _ _ _ licensee employee news media i
_ NRC employee private citizen organization tspecifyl t[M/c ~ bM /' other tspecity) [
/
/ (/d
/
MM DD YY
- 5. Date Allegation Received:
j
- 6. Name of Individual trrs, two initials and i.si namel *'T Retelving Allegation:
7.' Of fice: . - ACTION OFFICE ,
- 8. Action Office
Contact:
tririt two init;.i .no t. ri.m.) e - M '
- 9. FTS Telephone Number: g g ,,,
7 gg
~
- 10. Status:
ICheck onel Open, if followup actions are pending or in progress l
.__ Closed, if followup actions are completed MM DD YY 11 Data clo=*d: 11.1 Document nos.
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'2. Remari .: ..
l l l l l l l l ;;il ; ; ; ; ; i l l ; l l l ; 4Limet to 50 characteral l IIIIIIIl l l l l l l l l l l l l l l l l l 15.1 Man-hours /Date
- 13. A!!egation Number:
ottie. Y. r Numb.t R v 73 -
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.esfa AMmeets (' r-To: Hon. Victor Gilinsky, Commissioner United States Nuclear Regulatory Co= mission 1717 H Street Washington, D.C. 20555 From: darold Hudson - Former fullman Power P'oducts r Quality Assurance Inspector, Quality Control Inspector, Qua:it:.
Assurance Program Internal Auditor and Lead Auditor. Dcte: 1-12-84 lubject: -Report #3 Quality Assurance Discrepcncies Associa +c With Pullman Power Products Internal Audit #101 At The Diablo Canyon Nuclear Plant. Pullman Power Products' Internal Audit #101, performed on _-16-S2, identified significant conditions adverse to quality which were not promptly corrected and resulted in corrective action which was not adequate.
- 1. Pullman Power Products' Internal Audit #101, Audit Action Re. quest #1 findings have not had adequate corre: -
ive action implemented. A. Five NDE Procedures were identified on I. A. #10'.:r not having evidence that'the special processes were controlled and accomplished using qualified procedures or that qualification records were maintained te document and assure quality of materis.1 and wo:k. There are no Procedure Qualification Reccrds docu-menting Procedure Qualificatich Tests for these fra NDZ procedures. The five NDE procedures are:
. 1. ESD 234 - UT Inspection Grcove Welds AWS-31.059, ASME Section '.*III and Section V. Used to examin+
full penetration groove welds on Pipe Rupture Restraints prior to July 1979.
- 2. 'ESD 241 - UT Examination of Safety Yoke Re J on 3707 RAX 6-21 Safety Valves.
l
- 3. ESD 246 - Magnetic Particle Procedure / Dry /Continu-l cus Coil - E31.7. Usefunkown.- .
r ~. - y- ! 4. ESD 247 - Magnetic Particle Procedure / Dry / Contin-uous Coil - 331.1. Used to examine crack repair welds on Feedwater Nozzles to Unit # 1 Steam Gen-erators.
- 5. ESD 270 - Liquid Penetrant Examination Procedure.
Use unkown, i
- ? n ' U4 n tf o nyn uw'u,l -[*23pp.
i l er
- (, ; 2 )
. 3. Two Ultrasonic. Material Thickness Measuring Procedures were identified as not having evidence that the special processes were controlled and accomplished using qualified procedures or that qualificati.on records were maintained to document and assure quality of material and work. There are no Pro-cedure Qualification Records documenting Procedure Qualification Tests. These procedures are:
- 1. ESD 236 - VT Thickness Measurement of Boundary Valves.
See P.P.P. Unscheduled Internal Audit #34 and . H. Hudson's Report #2 to NRC Commissioner V. Gilinsky, dated 1-2-84.
- 2. ESD 244 - UT Thickness Gauge Procedure. This procedure widely used by Pullman.
It was determined in'I. A. #101 by Pullman QA/QC Kancger H. Karner that these two ultrasonic procec-ures were not nondestructive testing procedures but it were used to measure material thickness and therefer+ did not require " Procedure Qualification Records" (Procedure Qualification Tests). This was not a valid determination. All special processes, not just welding, heat treating and nondestructive tes:- ing, are to be controlled and accomplished using qualified procedures (Procedure Qualification Tests;. The determination that ESD 236 and ISD 244 were not nondestructive testing procedures does not exclude the procedures from qualification requirements for special processes. It is alleged that QA/QC Manage: H. Karner's deteruination that ISD 236 and ESD 244 did not require Procedure Qualification Records covers up a serious breach in the Quality Assurance requirements for special processes as required by
- 10CPR50 App. B IX and XVII and PG&E C.S. #8711 Section 4.3.23 and 4.3.29.
l Ko corrective action has been initiated by P.F.F. 1 concerning use- of ESD 236 and ESD 244 without
- Procedure Qualification Records, i
C.L.ESD 234, ESD 246 and ESD 247 NDE Procedures had Procedure Qualification Tests performed as correctite action to I.A. #101, A.A.R. #1 (see attached PQR's). These PQR's are after the fact qualifications of these proced ures. The actual use of these procedures were ! not controlled and accomplished using qualified procedures. It should be noted that the PQR's for these procedures i do not have approval signatures 'of either P.P.P. or l PG&E Management authorities. The only signatures I I
3 ' s L,> on the PQR's is that of the individuals conducting the qualification tests; 'It is alleged that these PQR's have not been approved by the appropriate management authorities.
- 2. ESD 270 did not have a Procedure Qualification Test performed as p t of the corrective action to I.A.
. #101, A.A.R. pl. QA/QC Manager H. Karner determined that ESD 270 used similar penetrant materials and examination methods as ESD 210 - Liquid Penetrant Procedure ( ANSI - B31.7) and that ESD 210 had Pro-cedure Qualification Records which demonstrated the ability to detect the specified discontinuities.
QA/QC Manager H. Karner directed that ESD 270 be revised to incorporate the PQR's of ESD 210 as the corrective action to be taken, (see I. A. #101, A. A.R.
#1 Corrective Action Taken). The use of ESD 210 PQR's does not provide a proven demonstration of ESD 270's ability to identify discontinuities. ESD 210 and ESD 270 must have some differencies or there
, would be no need for two procedures. It is alleged c that QA/QC Manager- H. Karner's directive to use ES: 210 PQR's for ESD 270 does not provide proper or 3h )i adequate corrective action to the Audit finding and that ESD 270's lack of proper PQR is still a conditicn adverse to quality. No investigation was performed to determine where ESD 270 was us.ed.
$. ISD 241'did not have a Procedure Qualification Test 015 performed as corrective action to the Audit finding.
A Procedure Qualification Record was suppose to be
- prepared per A. A.R. #1 Corrective Action Taken but i
this corrective action was never implemented and A.A.R. #1 was closed out and approved by the QA/Q: l Manager without the PQR being generated. l The bases for this _ action was a memo prepared by Internal Auditor J. Gyyler, dated 1-13-83 (see
~ attachment to A.A.R. F1) that stated: "There is a pending DR involving ISD 241. This is a special
- procedure created cto supplement PG&E and manufacturers examinations. PPP has accomplished this per instrue -
ions from PG&E. It is evident that a nonconformance does not exist and a DR is not necessary. A written response indicating this will be considered basis l" for closing this portion of AAR". QA/QC Manager r- i H. Karner indicated on AAR #1 that this memo by I. A. J. Guyler would be uses to close out that portion , of AAR #1.
4 (3 , Internal Auditor J. Guyler's statement that "it is evident that'a nohdonformance does not erict and a DR'is not necessary" is not a valid statement. It is alleged that I.A. J. Guyler and QA/QC Manager H. Karner have covered (:_ up serious breaches in the Quality Assurance Program and are in noncondorman:ce to 10CFR50 App. B IVI and PG&E C.S. #8711 -Section .4. 3.2e ( requirements that all conditions adverse to quality are to promptly identified, reported l l and corrected. It should be noted that during a conference to formulated a revised response to AAR#1Karner , on 9-14-82, attended by QA/QC Manager -H. NDE Leadman P. Dawson and I.A. H.. Hudson, it was agreed that a Discrepancy Report would be sent to PG&E identifying that there was no PQR fortthe procedure and that the UT exa=ina-ic of the Yoke Rods was performed prior to 'ES3 241 being issued by M.W. Kellogg (Pullman) and approved for implementation by PG&E (see attached interoffice Correspondence of 9 1 to I. A. #101, AAR#1 Tile). QA/QC Manager H. Karner later reneged on this agreement when he approved I.A. J. Guyler's memo and approved the closing of AAR71. QA/QC Manager H. Karner_ har i covered up significant QA discrepancies in the use of ESD 241 by refusing to forward the proposed DR to PG&E. The proposed Discrepancy Report, dated 11-3-51, prepared by H. Hudson, identified the followin-discrepancies (see proposed DR attached to .,..
- # 101):
A. ESD 241.did not have a PQR as required by C.S. #8711 Section 4.3.23 and 4.3.29. B. The UT examinations of the Yoke Rods were performed prior to ESD 241 being issued t;- M.W. Kellogg and approved by PG&E. The examinations were , performed between 12-17 ~ 12-20-73. ESD 241 was issued on 12-26-73 and approved for construction by PG&E on 2-12-74. C. The PG&E Field Change Order directing M.W. Kellogg to perform the work required inspection per the Dresser Instruction an.' a PG&E Memo by J. Sale. The Sale Memo specified the part of the Dresser Instructi: to be used was paragraph 12, " bolts and i 4 e O
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- - Studs (Greater than 2 inch Dimmeter.Up to 4 inch
. Tiamothr)" Dresa VSP-32-166, paragraph 12.1 states "all bolts and studs'shall be examined x
etI PFa=qt = 4[ prior to threading". The yoke rods UT examined by M.W. Kellogg were threaded. The examination of these threaded yoke rods is a nonconformance to the requirements of the Dresser Instruction. Ds. The " Report of Ultrasonic Examination" used'to document the description of equipment, procedure used, and the results of7the examination was not a form referenced in ESD 241.18.. It did not-include certain required information.
- 1. It did not include the surface or surfaces from which the test shall be performed as-
; required by ESD 241 and the Dresser Instru :1c ,
- 2. It did not include a description of the'
- calibration block (size, material and-basi
calibration reflectors) and calibration - method as required by ESD 241 and the Dresser
+
Instruction. t 3;. The equipment calibration frequenciesreferenet on,the " Report of Ultrasonic Examination" werc not as required by ESD 241 and the Dresser Instruction. - It should have been noted that ESD 241'and the Dresser Instruction. procedure
/
/ re'quirements for equipment for calibration gp34 'Ng . frequency were for' production runs and not for individual rod examination. -The two procedures did not meet the needs of the type examination being performed.
E. The " Ultrasonic Examination Report", Appendix A, Form F-66, referenced in'ESD 241 was not used :: [ record the required information of ESD 241.15.3. F. There were differencies.between ESD 241 and the Dresser Instruction concerning information used to determine the reference point for sensitivity and criteria used to report questionable items. G. PGEE ikt , by J. Sale stated that "in addition :: 7
- the I T b spection, a back up inspection should ba
- lei ?ttrN with the dye penetrant technique to
. cnock'sta yoke rod ends for indications of crack-ing that might extend into thethreaded area of the yoke ends".
- 1. The Ultrasosic Status Reports indicate that no dye penetrant inspections were performed.
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- 2. ESD 241.17;l did not stipulate the same ..
requireme~hiras Yhr PG&E Wem6. ~ESD 241.~17D. ~ stated ~"I,iguid Penetrant or Magentic Particle will be used on rods which aressuspected of containing discontinuities whichtmay extend inn
' threaded areas or to support areas where UT-tests indicate discontinuities with lengths in excess of la long". .
No Corrective Action wasttaken on the audit findings for ESD 241 The proposed DR concerning ESD 241 QA discrepancies was not approved by the QA/QC Manager and was not forwarded to PG&E for' disposition. This is a nonconformance to 10CFR50 App. B IVI and PG&E C.S. 8711 Section 4.3.28 Corrective Action.
- 4. Only two of the seven procedures identified on I.A. #
101 not to have PQR's were . identified to PG&E on 4 Discrepancy Reports for their disposition. C.S. # 8711.Section 4.3.28 and C.S. # 8833XR Section 3.4.121C require Contractor to assure that all conditions adverse to quality are promptly identified, reported, and corrected. P.P.P. did not report al19the conditions p' r . adverse to quality identified in I.A. #101 to'PG&E.
- s This is a nont'onformance to the C.S. requirements.
- 5. ESD 246 and ESD 247 were identified to PG&E on DR #4662 (see attached) as having no Procedure Qualification Records. DR #4662 identified that ESD 247 had been used to MT examine the inside diameterof Feedwater Nozzle welds to Steam Generators 1-land 1-4 during the repair of cracked welds. PG&E accepted as is.all work exanined by ESD 247. Because DR #4662 did not identify any locations where ESD 246 had be used no reference was
, made to accepting any work performed by~ESD 246. '
During the Internal Audit investigation into the use cf ISD 246 and ESD 247 I was ordered by QA/QC Manager H. Qgc 19( Karner to cease the investigation once it was known rea where ESD 247 had been used. I was not allowed to IM* continue the Audit investigation to determine where cd *, ESD 246 was used. This resulted in DR #4662 having lini information concerning the discrepancies being reported. i There are two questionable Quality Assurance issues reht-to the useof ESD 247. A. ISB 247 spec' i fies that it is a Magnetic Particle Procedure / Dry / Continuous Coil for B31.1 Code. C.S
#8711 Section 2.2.1 specifies thtt portions of the feedwater piping from the steam generators to the isolation valves are to be designed, fabricated, and erected per ASME Section I. The MT Examination 4
Records attached to DR #4662 (see attached) indicate t
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' the.Acceptanca..S
- 4=rds-to be.4SME.Section I. This raises the question can a B31.1 Code. MT procedure be used to examine ASME-Section I~ piping and obtain results which are reliable.
B. TheMTExaminationRecordsattached!toDR#4662 are dated 10-19-77 and 10-20-77 and 1;he MT's were
>erformed by D.R. Geske. The M.W. Kellogg (Pullman) 4
,3ersonnel Testing Record for D.R. Geske (seeattached)
! Indicated with a composite he wasgrade certified of 98%. a Level II MT on 8-23-76 But the Testing Record under Examination Grades in Percent does not record any scores for the General, specific,
/ Practical Examinations. It is not understood by this (30 % writer how a composit grade of 98 when there are no recorded percen% talcould be obtainei scores for the General, Specific, and Practical Examination. Both the SNT-TC-la and M.W. Kellogg ESD 235 (NDE Personnel Qualification and Certification Procedure) require '
General, Specific arid Practical examinations to qualify for Level II MT. The Personnel Testing Record for D.R. Geske does not provide the necessary
;. information to verify that Gaske was properly qualifie as a Level II-MT Technican.
4 g4 The NRC should investigate these issues to assure that there are no QA discrepancies associated with the use of ESD 247 and the examinations of the Peedwater Nozzles !, to Steam Generators. ESD 246 and -ESD 247 had Procedure- Qualification Tests performed on 11-9-82
~
The Corrective Action Response to I.A. #101, AAR#1, by M. MacCrae (see attached) states "As both ESD 246 and ESD 247 have been withdrawn from use and the equipment listed in both procedures is no longer available for use, the equipment used for ljg these PQR's was the Magnaflux Model P-90 for the coil technique only". The Procedure Qualification Test was performed using different equipment than specified in the original procedures. The Response does indicate that P-90 puts out lesseamperage than the equipment listei in ESD 246 and ESD 247 and that acceptable results were obtained. But a questioneis raised. Is.it acceptab]e
# to qualify MT procedures after the fact using different
$O0 equipment than listed in the procedures? This is an item of concern that the NRC should investigate.
- 6. The most important issue to raised by this report and ARR#1 findings is can NDE procedures be qualified after they ha've been used? 100FR50 App. 3 II and PG&E C.S. #
8711.4.23 and C.S. #8833IR.3.4.128. require special processes to be controlled andzaccomplished using qualifie procedures. The seven procedures identified in I. A. #101 were used without being qualified by Procedure Qualificati test and are nonconformances to the above requirements.
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*g e This is a major breakdown in the PPP Quality Assurance Progrant;- --In- my opinion, the use of unqualified procedures puts the work examined into a questionable status. The NRC should investigate this issue to assure that theraare no conditions existing which would adversely
. affect qualitynand tend to cause failures or
. malfunctions in the r work examined;by these s2r Procedures.
eumA Ce#*#"" 2. The In'ternal Audit #101, AAR#1 findings were not promptly corrected r5 required by 10CFR50 App.B IVI and PG&E C.S.
#8711.4.3.T8 and C.S. #6833XR.3.4.1210 requirements. It is alleged that QA/QC Manager J. Xarner deliberately procastinated on these findings to avoid identifying these
_ g g73 discrepancies to PG&E and Pullman Corporate Management. and b.ecause he was unable to formulate a proper corrective action. It is alleged that Pullman Corporata Director 23L/ f Quality Assurance, A. Eck, failed to expedite i corrective action once he was made aware that the on site i
\ QA/QC Manager was not providing a prompt response to AAR#1 finding.
Internal Audit #101 was performed on 1-18-82. AAR#1 findings were not formalized until 3-22-82 due to additional investigation requested by the QA/QC Manager. AAR#1 findings were acknowledged by QA/QC Manager H. Karner on 3-23-82. Corrective Action Taken response was 2h,' due on 4-5-82 and was received and approved. Before the follow up audit to assure activities complied with approved corrective action, QA/QC Manager H. Karner i requested AAR#1 back so that a revised response could te l prepared due' to addition finding being identified. CM I additional finding was that ESD 241 had been used. It l 7Ayt had been decided under the original response that thir procedure had never been used. AAR#1 would not be returned to my possession for a follow up audit until ik 15 0 3-22-83. Prompt corrective-action was not implecented for the findings of AAR#1 as required by 10CFR 50 App. 1 XVI and PG&E C.S. #8711 and #8833XR. I would spend the next year tryingsto get QA/QC Manager H. Karner to provide a revised corrective action response i so that AAR#1 findings could be closed out. Following L is a narrative of action takenkby me to try to get a revised corrective action response from the QA/QC Manager. A. On 5-18-82 I send a PPP Message (see attached) to the QA/QC Manager requesting he provide an immediate revised response and return it to me.
- 3. On numerous occasions I verbally request the QA/QC Manager for a revised corrective action response.
. . 9 L: 1 C. On 6-14-82 an Interoffice Correspondence (see attached' A was ' send'4trA;-Tek, ' Corporate Sirectorc of-Quality 4 Assurance , stating that an AAR'(NDE procedures without PQR's) directed to the .QA/QC Manager, which per ESD 263 was to,7be responded to in 10 chlendar days, was taking weeks' for a response g fg ( D. On 7-6-82 an Unscheduled Internal Audit # 31 (see attached) was performed and addressed to A. Eck, Corporate Director of QA. The knecheduled audit was performed to identify to Management personnel a deficiency in the implementation of corrective actic:.
i to Internal Audit Reports. The Audit finding was that the QA/QC Manager was not promptly implementing corrective action to Internal Audit Report findings.
- 1. A response from A. Eck, dated 7-16-82 (see atta:: hec did not address theiissue of Corrective Action not being implemented in a timely manner. Instead, A. Eck reprimanded me for incorrect application y> ggo of ESD 263. U.I. A. #31 was not responded to by
/
the Director of QA. MP _ M45EifuFA/TZg M7OED_ It appeared :that the Director of QA was more concerned with the so called inproper application of ESD 263 (Internal Audit-Procedure) than with getting corrective action implemented to an Internal Audit finding that NDE procedures did not have Procedure Qualification Records. It should be noted that< A. Eck's reprimand directed me to assign resolution of no formal PQR's for NDE procedures to the responsibe NDE Supervisor. l 2 On 7-22-82, QA/QC Manager H. Karner conducted a meetin,g with me at which time-A.Eck,'s reprimand was discussed and Mr. Karner laid out ground rules-for future Internal Audits. ' It should be noted that no mention was made as to when a revised corrective action response would be forth coming. (see attached). E. On 7-28-82 I send an Interoffice Correspondence (see attached) to QA/QC Manager H. Karner asking what Corrective Action is being takentto resolve audit.
' [t( " -t findings for AARO1 Also I asked Mr. Karner if he wanted me to readdress AAR#1'to the NDE Supervisor per A. Eck's directions. Mr. Karner verbal response was no that he would provide a resolution to AAR#1 findings.. At this time I recommended that the AAR#1 g 90 findings be identified in a Discrepancy Report to PG&E for review. In addition, I stated that sub-sequent investigation of ESD 236 - UT Thickness Measurement of Eoundary Valves may be required to have a PQR. ~w=w-y,u , ,-.,-.-,,,-,,,.,,weyv.-.4y,,,-,,vw --y,w,em
.- lo
(.
.. . 3 F. On 9-15-82~ I prepared an ' Interoffice Correspondence to I.I. #ID1',Tf171"le- alia to the-QA/QU 'Manag'er doans&&ttng a' o'oriference held 'to formulate a revised responsetto'AARW1.t(see attached). The'to11owing action waaragreed on by the QA/QC Manager, NDE Supervisor and'the Internal Auditor.;
- 1. ESD 234 would have a Procedure Qualific& tion Test performed.
2, ESD 241 would be reported on a DR to PG&E identfying that there was no PQR and that the UT examinations were performed prior to ESD 241 1 being issued by fellogg and approved by PG&E. 3. ESD 246 and ESD 247 would have additional inves :- igation performed before a decision as to correct-ive action would be made.
- 4. ESD 270 would haye incorporated into its proced-ure the PQR of ESD 210
- 5. ESD 236 would be withdrawn fron use and again the QA/QC Manager stated he felt no PQR required.
G.. On 10-13-82 an Interoffice Correspondence (see-attacht was send to the QA/QC Manager requesting a " Revised. Written Response to AAR#1, I.A. #101". It was , stated in this 100 that PG&E C.S. #8711 and #8833XD. required all conditions adverse to quality to be pronptly corrected. H. On 11-3-82 a proposed Discrepancy Report concerning ESD 241 was prepared by me in compliance to the .
- 9-14-82 conference to formulate a revised response to AAR#1. (see attached)
- 1. This proposed DR=was reviewed by QA/QC Manager H. Karner andche wrote comments concerning the DR (see attached).
- 2. The proposed DR was reviewed by n. MacCrae and he wrote comments concerning the DR (see attached' ,
- 3. On 11-22-63 I send an Interoffice Correspondence to QA/QC Manager (see attached) responding to Karner's and MacCrae's comments of the proposed DR.
I It should be zioted that subsequently QA/QC Manager
.i P 33 H. Karner would refumetto submit the DR to PG&E identifying ESD 241 discrepancies. . -. , , w. : - . - - . . - - . - . = , . . - . - . - . . - - - . . . ~ . _ . . . . - . - _ . _ - _ _ - . _ . . . . . . - --
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. 11 i
(. I. On le12-83 m FP29tessage (see *ttached)-was-eend to QA/QC Manager H. Karner requesting he provide revised' corrective action to AAR#1. At this time the QA/QC Managerrwas informed he was in nonconformance to 10CFR50 App; B IVI.and EG&E C.S. i
#8711 Section 4.3.28 and #8833IR Section 3 4.1210.
J. On 1-21-83 and Interoffice Correspondence (see attached) was send to the QA/QC Manager indicating that Corporate Audit #7177-1-83, AAR$10 had identified that the required number of Internal Audits for 1982
- - had not been closed out and that a revised corrective ~
action response was needed for AAR#1. g It should be noted that QA/QC Manager 'H. Karner did not provide any responses to any of the many correspondences requesting a revised correctitecaction. It is alleged that W- QA/QC Manager R. Karner deliberately procrastinated in providing a revised corrective action;to AAR#1 to avoid identifying these discrepancies to PG&E add Pullman Corporati i Management and because he was unable to formulate a proper corrective action. It is alleged that QA/QC Manager H.
, Karner deliberately violated 10CFR50 App!B IVI and PG&E C.S.
#8711 Section 4.3.28 and #8833XR Section 3.4.1210 require-(
j ments that conditions adverse to quality be promptly identifie reported and corrected. It is alleged that Pullman Corporate
$ . 5 .-( Director of Quality Assurance, A. Eck, failed to expedite corrective action once he was made aware that the onsite QA/QC Manager was not providing a prompt response to AAR41 findings.
- 3. On~1-28-83 QA/QC Manager H. Karner and myself had a violent 1 verbal confrontation concerning AAR#1 and another'. issue.
WY.pgd During review of Rupture Restraint Documentation for inves:- igation of Unscheduled Internal Audit # 35 I identified three full penetration welds that had NDE by MT instead of the C.S. required UT process. While preparing to report these dis-crepancies, Mr. Karner confronted me at.1ny desk and vanted to know what I was doing. I informed him that I had identified Rupture Restraint NDE discrepancies. Mr. Karner then asked me if I had been directed by him to identify these
.- problems. I stated that he had not directed me to identify N\ the problems. Mr. Karner at this point began to screac and shout at me that I was no longer the Internal Auditor (I had been replaced but given permission-to conclude two audits in progress, one of which was U.I. A. #35) and .that.I was only to do what he told me. In effect, Karner was telling me'that l
I as a QA/QC Inspector could no longer identify discrepant conditions unless specifically order tor:do so by him. Mr. Karner screamed at me that if I did this again be would get 3D ( rid of me. l t&e r- v' gr 9 w w e eg wp--%Wqw.-r -i----. gy.--g e e- - p - - - -.wqye--u.,p7wgwg.,.-v-m'wwy-er*s-4-* --Y**rr8 W e------t-'W-P-----*--4---~7eP-WW-'---->*w=r'-D+ N
{. n- i t Karner then accused me-of g W g to unscheduled audits to get arciund-'his~appoVal o! the madit checklistr Be accused me of being' adverse to quality. At this point I screamed at his that he' had been sitting on AAR#1 of g I.A. #101 fir a year' ahd that he was. violating 10CFR50 l App 43 IVI and two PG&E Contract requirements by not t l promptly ciorrecting problems adverse:to quality. QA/ QC Manager Karner at this p61nt stated that it was 07.
%, for him to violate the Code and Contracts. He repeated l
this statement twice. Mr. Karner also stated that one of.the reasons why.i..didn't have all the required 1982 audits done was.because I investigated items not on a-checklist or irrelvant. ..I responded to this by saying one reason was that he had been si'tting on an audit (AAR#1, I. A. #101) for a. year.
-I should point out thattthis tim'e we were toe to toe, face to face; screaming at each icther.
F l ' Mr. Karner again repeated that If,was only to do what he told me to do which I interp24ted to mean that I could not identify Quality Assufancetdiscrepancies unlessspecificallyordere!dtofoso. This confrontation was witnessed:.by numerous persons in the QA/QC Office. . This confrontation produced two ;significant conditions adverse to quality. p
- 1. As A QA/QC Inspector Iwas ordered by the QA/QC Manager not to identify QA discrepancies unless j specifically order to do so by the QA/QC Manager.
yNo\ If I did I would be gotten rid of. This was
. an attempt to intimidate me from identifying
,' discrepant conditions. This violates 10CFR50 App.
3 I requirement that persons performing quality l l 87
/
(p]( assurance functions shall have sufficient authori v and organization freedom to, identify quality problems l
- 2. TheQA/QCManagerstatedhekdidnothavetocomply i
with 10CFR50. App. 3 and C.s 7 requirements to promptly correct conditions adverse to quality. This is a base violation of: Quality Assurance. requirements. elQA/QC Manager H. Karner has demonstrn this disregard for this of corrective action forQA1r I.k.equirement in his mma #101, AAR#1 auditla:'.- datne Etn#8D W b, findings, in a' timely manner. l Internal Audit #101 identified.si icant Quality Assurance discrepancies in the qualification ~of and UT thickness meas-uring procedures. Subsequently, sig61fi t QA discrapancies l took place in the imp 1'ementing 'of correc1 1ve action to the audit findings. The issues identified in this report and I.A. # 101
- should be investigated ^by the NEC to assi re that quality assurance
! has not been compromised at the Diablo Ca nyon Nuclear Plant. l w swwee.
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w..:. ..,n .~ pdure_js OCEDURE SPECIFICA74CMJ"*i .M #ht
- MBAf f'* MET 11-TN Tcrwret. T .L ng. and gieee,wltte backJng
- Lag,.e-Tyh-N.me.L2IgQg'SU.bs-we,ldhgundlelad 4 - - MSEM5NanADirgur_aCamenees undige_ AW1. requJ re-ept.e>
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f t l let wel ds . - $MW- - -- -- -liments.When welding to ASME requirements. the
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.5E' METAL: The bas 5 'mIitiirF stsith. ir tsW memT'MZ"*T4'.J Fo6PWNTLthe.appilcable ttiRknesecodesneT.T be .Ri8W standard shalI '
sp ct fications for ASHE, Section ,fXO P-1 i :ricts. ngovernessminums thickness In the as welded ,
- condition. . g masaJ_AhaD sno-
- PREPARATION CP' 8A$E MATERIAL: The edges M.ER #ETAL: 2he #f f f o6surfacasaof'.the.p' arts to be Joined by 1 to ASME F111er Mstal SpecificattorWhm6er a weldin@halp.be@repared by. flame cutting, 51- for ferrous filter metal irr Group?Mue '
F-4
.plaisessar%.Igrliuling, machining,.or any c:mo-
.- .. . s binft!'orspoMpet. hods.t:r essarstf ally form the to chamelal composition of the wetd l,Iiposit.: l . geiism]dsort/,theidttache'd skatches. and. shall6iyf Il fall within the Ifmits of weld.,metalC ~' ' ' ;f..talla lief chiacin'd6 fpal} oll. or grease and excass-lys is, Nisaber A-1.
Iv famountit.ofGcale-or rust.
. ELECTRICAL:,.CHARACTERIST1CS: The current AS FCA TORCI SHIELD: None .
usedrshati;be OC SMW - Reverse Potarity 3 MINT. INC PROCEDIRE: The welding-15 FOR SACK-UP PURCE: None ! technique,.suchf as electrode sizes,.and voitages; and: currents for each electesde, ACK VELOS FOR SET-Up: Same as for weld (.se sima of the welding tip and filter rods,. 4 shall be substantially as shown on Page 2. o 2) . APPEARANCZ OF WELDING LAYERS: The weld-I 'CS ITION: The welding may be done in all Ing. current and menner of depos-ItIng the
.Itlens.
' weld metal shall be such that there shall
3 be practically no undercutting on the side
'P' walls of the welding groove or the adjoin-
??.DIEAT & DIT12 PAS 3 50* F minimum. 175, F Ing base estarial. See job specifications at:=nn fer matarial that has a carbon contant for spec!fic undereutting iTmitations.
excess of 0.30T. and L" thicknesa. (See Es3 J for AUS Velding). CLEANING: All slag or flux rimsining on any head of ' welding shall bn re,oved be for s PCs? 11ZAT T'ri-wnr: 1100*.1200, F, I hour laying domes the next successive bead of r inch sin 4== (see Job specifications for welding. cle and thicknesses requiring post hast encsant). DEFECTS: Any cracks or blow holes that
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appear on the surface of any bead of i. eld-1AC'.CNC STRIP: The weidad jointa ahall util- Ing shai1 be removed by chipping geIndIng,
- o o becking strip. , - or. gouging before depositing the next suc-A cassive head of welding.
VEL SPIID: SMAW - 1" - 8" per sitiuta -
/!2.DUIC Pr.DCr.SS: The welding shall.'besdona his~ procedure is a rewrl'te of and com-ths SMAW process with a backing scrip /'us-- bfdest .
2g manual equipment. , . , , .". .
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SPECIFICATION FOR LOW-CARBON STEEL EXTERNALLY AND INTERNALLY THREADED STANDARD FASTENERS , SA-307 (Ideaucal uth ASTM $p ctficanon A 307 74 encept that Grade A Bolts and Nuts have been JeteteJ Scop
- Chemical Requirements 1.lf a) This specification covers the % 3. (c) Steel fur bolts ar.d nuts shall chemical and mechanical requirements of conform to the fulfowin:; cheinical re-carbon steel externally and internally q'ittentents:
threaded standard fasteners, in sizes % in. .- (6.35 mm) thru 4 in. (104 mm). This specification does not cover requirements ',,,",',".'",,
. for externally threaded fasteners having In heads with slotted or recessed drives. The g, ,,i, ,, . .,
fasteners covered by this specification are re reas , 8A4 o.l* frequently used for the following applica. 8"jf "'* F o (,5 0 15 tions: __ . Crede B Botti, for flanged icants in piping systems where one or both stinges (b) Re: !fndeed n steri-! i< ac* r:$.'s. t
'o re t et'cet '" *-1 a, c%'t t u! % k r are cast iron.
(b) Noaheaded anchor bolts, either 13&l!E straight or bent, to be used for structural. (c) Bolts ans! nuts are eJstemar.!y anchorage purposes, shall conform to the furnished from stn.k in wNch c. :: requits wents of- the S pecification for individust heats of steel :annot :.e Structural Steel (ASTM Designation: intentified. A.36), with tension tests to be made on the bolt body cr on the bar stock used for Mechsnical Rctuitement: making the anchor bolts. 4. (d) Bolts r. hall meet f:? hard .?ss rerguirements specided *n Table L Tins Materials and Manufactus, shall lie th.t only requiren: .t io 'e.!ts i are too rtor & W emecq-
- 2. (c) F:cef fnr bolts sh:.!! be ma.i: by cient threacts for te:taion testt ::g er wm:..
the open 14 earth, b$ tis -cryr,en, or e:ce. !iave iltitled or undersize he;14 tha'. c.re trie-furnace pr: cess.
'(5) Steel for nuts shall'ar made hv t! e Tant.n t.-II.ct!*S:H ttrqt*Incar.dTs open.hea th, he.sk oryr,en, efrotr$ fe:- init uor.Ts.
nace, or bessemer proce:.s. i u.,u (c) Belts in.ty be preilueed by hot or -- - cohl forgir,:: cf the hearla er macliining **""** "' """" M" ' from 1,ar stuck. - u : : Iu.. seu (4) Itolt threadt may 1,c rn!!rd or eut. i . .
^3'"""'
(t) . Nuts may be pioduted by hot
**' # i "# '"
pre: sing, enld pur.ching, col.1 forg:ng, os-
;r.achining frem !cr tock.
weaker th.in the thre:n'cii tr :ti:n of tt hoit. 333 Attach. 3
r SA-307 SECTION !! - M ATERIAL SPECIFICATIONS (6) fiol *. other ih:.a thme excepted in t, a. sir ea. r. inia.. Parai;raph (a). sha!! he subject to a ten- '" "**'""** sica test as specified in Section 6. Whe e cesde a co ti . . . . . . t,o nno . s tn w. both hsritue:s smi t' erisino tests are 5,er, too o W rams
- formed, acceptsace no the basis of the temite requiremcuts r.lcll take preced. (c) Nuts sha!! meet the hardheu re.
ence where the minimum requirements quitement 'oetified in T.ble III. Hard-are the subject of controversy. ness shall be the uc!y require ment for (c) lloits 1( in, anel unt!ct in diameter fim, slotted and cast!e nuts and for when testeil in full size shall meet the nuts Isriger than Il in. in size. requiren:ents for tensile stren;:th speci. (f) Nuts !! in and under in size shs3 ficil in Table II. meet the pront loads specified in T.ible . (d) Duits Il to J in. in aliameter, III* isclusive, shall be tested preferably in (t) Nuts !! to li in., inclusive, in tize full r.ize and shall meet the requirements shs!! preferably meet the recuire::ents for tensile strength specified in Table II. for proof losel specided in Table 111. but But when equipment of sudicient espac. when equipment r,( sSciant (spatity ity for such tests is not available, they for such tests is not available they shall meet the hardne?s requirements spe:itieti T.u!LE tr.-TENstLE .tEQUtnESIENT.1 in Tsble III. FOat FtlLt. .wizt; Bot.73. Dlaiensions y T oi. su a. . S. (a) Unicss otherwise speciGed, su'. '"nu.*lsm
'"
- threads shall be the Coarse Thread l ". t'*- 7 T.' Series as specifird in the 1.stest irsue of the USA Stsadstd for (* sided Screw k
M is o or s
}$
4 c:o 7 7:o Thrcstis (USAS 111.1), b. ving a c!.v. 2A tofr-suce for bolt sad :!sn 211 ise 14 0 1*D 6* 10 G:0 talcrance for nu.s.
!1 is n. 4ta s :co 14 too (b) Un'ess otherwise specified. Grade
'{. :: o.162 it w is :20 B bolts shall be Heavy Hex Boits with S o.:24 .1 .m :2 00 dimensions as given in the !stest issue of f,' :j:
l
$ $$ $$ USA Standard B18.2.1.
i a a..4s :n to ao e,co 7 TABLE It!.- MAltD*;:"'r3 AND FitnOF I.( 0. 7.*.1 43 401 !a .00 t!( 7 n.tna as it,o o.s 900 WAD ItCQU!!11 MF*iT3 > Oft Nr.*T3. Ih 4 1.tas f3 300 t13 5o0 j nrwts i Pre.f toad, gg 2m2 l A I.lCs s L .*cn 14o soo
3 '** i'* iba [,,,,
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- e. = ther.ds per inch. .
- Da.ml e,a 9o.cno p.i msafett stresa for aus di ** Demel U * * '"en#too""" fart D *'ps.. sissa 8( to 24. in Inclu.sve; g
and 07.o00 p for 3)( to 4 la..fr.ooo ;si ter 3 in. hariusive. b g shsli meet the feitorzic;; requirements (c) Unless othermse specified. nuts for u.i machincil specimen tcn: ion testst Crsde B bolts shall be Heavy Hex Nuts l 334 a Attach. 4
- Lt .
, e ' ;L.
3 PART A - FERROUS MATERIALS SA.307 with dimensions as given ire the latest issue ,,,, g',, . of USA Standard for Square and Hex Nuts (USAS B18.2.2). $[s N'.l.'7[ 7[ I. ! . i 8481 to 22 it0. . . . . . . . . . . . . . . . J 3gethods of Test Over JJ 000. . . . . . . . . . . . . .... 3 ;
- 6. (4) tlc material shall be tested in (t) If. any atachined test spreimet:
' accordance with S,appi: ment III of the shows delettive machining :t r.tay be dC.
Methods and DeGnit;ons for Mech:mcal cardd ud moder spcin.m mani. Testi=g of Steel l'roducts, (AST31 tuted. Designationt A 370). W Siiouldany sq!e f.d! to wet de (6) Standard square and . hesagon ,g,,,nents of a specified test, eins.ule bolts only shall be tested by the wedge the number of s.imiki from tl.c sa:ve tension nr.ethod. Fracturc sh.JI be m the Int shall be tested, in which c;.se all of body or threads of the bolt without any t!.e additional sarnples sha!! meet the fracture at the funcuon of the head and *E"gg;#*".' ' *
- bcdy. Other headed bolts s'.all be test:d by the axial tension method. Marking (c) Nuts shall be tes.ed by the asial 8. Bolt heads shall be marked (by proo!!aad method. raised or deprested m trk at the op!!.;n et (d) Speed of testing as tietermined the manufacturer) to identify the manu.
- with a free running croa6 cad shall be a facturer. The manufacturer reay time musianum of 1 in. per rr.*n for the te: site additional marking for his own use.
nrrength tuts of bolts and the proof load determinatiim on nuts. Insp etion Number of Tests and 3tetects
- 9. (J) If the inspmtion. .l.s::ib-1 :n
- 7. (s) The requiremects of tinis specin-l' ara,raph (al is teluira.I by th.: 1.or. ,
. cation shall1,e niet in cor.ti twiur mass chaser at shall b,r sneu,lled ,in the ingsary, per. duction for stock, amit the manuire. ""I". *' '.ontract.
turer shall make sample insoections tu (6) ne tasputor reper:nt..g; the ensure that the product conforms to the purti,2 me shall have f.ee ent f. at all
- pecined requirements. Additional tests tintes wldte wnrk nn tic cantcact o.* the of individual shipments of material are purcha:r.r is I,cin;t Iwrfurm-1, to all g not ordinarily Conten: Pl ated. Indiv; dual part! nf the manuf e turc# Kr.r.,11 at heats of ste-I are not identi6cd m the cnncern the scanufactusc ci tiv rouer;:1 tiru<neo cro uct. ordered. 'Ih taanufacturer shr'! .dard W Wh:n speci6:d in the order, the the *uirpector .til r:2: mmc fxiliti:,,
manuf:.cturer shall turnish a test report wit.mit charge, en at!,iy hint tl at the certified to be the last cou:pleted set of material b hein;; furail.ul in armnd nce mechanical tests for each stoch size in with t he<e rpe-:iiati..cs. Ni tem
- sch shipment. (,w.pg c;,,;,,( n:,;7 is) a-d n::I c. tio (c) When additional te.es are speciGed . haft be :v. ail at ti e ;L.e ..f .a.mui c.
on the purchase oriler, a lot, for pur' tam p6>r tii dit -ai nt. t'A '. e ib '.c poses of selecting test samp!rs, shall con
- sped:M. a 'l . '4 1,<* : ' w.i c ' t a sist of all material ofered for inspection at one time that has the followmg com. t in int ifere in e.m 't'h .vi.'s ti.-a mon characteristics: , ocerat.i. t, 'if Ihe ~uits.
(1) One type of item, that is, bolts or evia,
;;,y,,gg,,
(.?) One nnminal size, and in, t,fnle:,i otherwit: spriied, any (.i) One cominal length of bo!ts. rejn:tices Ir:tel on
- cat: .!u!Iest hr.ein (d) From each lot, the number of slu!I 1,e eported to itic n .in afa.: tut r tests int each restuirement Aall Le as within thi:ty workin;: .ia .
- fri.m the fol!nws: aucipt nf ::nple by i!.e ;n.rr!.aer.
av r.,eone uwa or nuns noen tar.: na rearw,, ,, r.,sa , . on retors e u., one ,as.J.or or ser . aano r. nro an eennetraen shareween, enut The stoneeseen Soe,rry of weenen res t,quneres Jers ner unervenar en llEnar* enyOnt tresli8nnt une gennaleral eggsnst le,6egegy f or snfrerartengnug of 40,y $,ecters farent nur 422nnseet en,y ants lanheilly 335 Attach. 5
4E M. W. KELLOGG COMPANY * [.*'Y. . Page 1 Cf 4 i Olvision of Pullman incorporate # T b Wald Procedure Coce No. 7/8 Iping Fabrication --. T % ,--E Spec.- No. PI -9 R-Ff+-S HA's-2 G-5 G tillansport, Pa. 177017 .s .d Data 11/25/69
? "/ I1/20/70 e/11/7i S > -
U r y- q . T p ..- *' y ... Revision. Dates:hwd 4/19m getvoea- t i/28/73 i .
- t Re 10/13/76 9 77
- l ROCEDtJRE SPECIFICAT40N FDP- N+- % =1 _.A_ RASE METAL THICKNE131_Ih ;_procedur.e_Is_ .
ing. and grlate.wl-t> bacidng-sing.os. b.ar hutic rque,l.1f.Qd;to .al_ low.weldingof un t_Inf tied thicle- , flllct welds. SMAW- - - -- - - - -- Laesa pAstcactura4_ members..under. AW1.requJ re ,
- l meats.When-welding to ASME requirements. the ASE' METAL: ' The base' metaf"shaIT cinshipsrto<siexTm6'tMickness sNeiTe be 3.IS":-
i specifications for ASME, Section IX,. P-1 For PWNT,. the applicable code standard shall ' arlois. govern <menianam thickness In the as welded { condition.
% LER A 2he J.I.12mr asisaj.abaij cno- ' htEPARAT!0N OF SA5E MATERIA 1.: The edges os surfaces of the parts to be joined by m to ASME Filler Metal Speelfication Number -
Hir.1 for ferrous filter metal irr Group Nw-
'.plasma-ars, welding-shal.1 be. prepared.
grinding. machining,by flama or anycutting. can-
- FA.
- . binat!on-of' methods. ta essentf ally form the
- ' to chamelai camposition of the weld
- depoelt gammust# ofhthe weld .shones ars Pege I as de-all fall within the !!alts of weldlestal# . tal'ledien!thei-attached slastches sed. shall siyals, Nummer A-1. I be- slaaned of 'all of.) or grease and escass-two ameumet of scale or rust.
, :A5 FOR TCRCH SHIELD: None - ELECTRICAll. CHARACTERISTIC 3: The current j esed shelt. be DC SNAW - Reverse Polarity ! ),15 FOR BACX-UP PURGE:. None .238NT WELDIN
G. PROCEDURE
- The welding technique, such as electrode sizes,.and voltages and currents for each electrode, TACK VELD 5 FOR SET-UP: Same as for weld (,as slas of the weldtng t!p and filter rods,.
g3 2) . shall be substantially as shown on Page 2. i APPEARANCE OF WELDING LAYERS: The weld-POSITION: The welding may be done in all Ing current and mancer of depositing the
,s i t t ens . *
' weld metal shall be such that there shall 9'r. walls be practically no undercutting of the welding groove or on thethe side adjoin-PREHEAT 4. D TERPASS: SO* F M n4 == - 175, F Ing base material. See job speelfications LM = = for material that has a carbon contant for specific underr.utting 1 Imitations.
s execss of 0.307, and 1" thicknasa. (See E3D r.3 for AWS Welding). ' CLEANING: Al1 sIag or f1un rameIning on any bead of ' welding shall be removea befors POST DlC T"'iN: _ 1100*-1200* F,1 hour laying down the next sucesssive beac of 5 or inch .miMenn (see Job specifications for welding. yelo and thicknesses requiring post beat recenant). DEFECTS: Any cracks or blow holes that
. '. A appear on the surface of any head of ' weld-1ACKING STRIP: The welded joint.: shall util- Ing shall be rimaved by chipping. : grinding,
.za a backing strip. 3 os gouging before depositing the next suc-
- s cassive bead of welding.
VII, 5?EID: SHAW - 1" - 8" per minute.
/ELDntG PncC:53 The welding shall'he. dona This ' procedure is a rswel'te of and ecm-the S:!AW process with a backing strip,us- b fnes :-
.ag manual equipment. .
CODE. ND'. 7', ..PI-5R-Ff+-SMAV-12-1G
- N& 3-
- JC00E1)l0W:8kP {4R-F4-sMA'J-12-5G.
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NDN,s 3Ri4,..hd[hj'* y d< $'b. n w. .. .. a -n.:.m w % + ~. '
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- THE M.W. KEl.LOGG COMPANY ( . h[I** %5 ,
Page
.Wald Procedure Code No. 7/8 2 of ( '"
A Division of Pullman*in@tpoe, Pipa,ng.Fahrfemtion ' . %, .
";' a. di . Spec No. PI'-6R-Fb5 MAW-2G-5G Williamsport, Pa. 1770!. , ,.
Date 11/25/69
-S .-k I y----- .Rawlslon Datas:. II /20/70 6/II/71
, ,%n...-. ,,. ., E 'i . ^6/19 m I/29/74
. o.y.rr . .
k . JOINT DETAlt AND WELDING TECHNIqt!ES ,-
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/ AND METN. TYPE METAL AMP 5 Vol.T
- POLARITY f. FLO RATE SIZE Atl0 PROCISS 0;rf10f tat. SIZE RAM (d -
-(MIN.) POL 4RITY All E7015, 3/32
- 65-110 e ;.
SHAW 16, o~r 18 1/8 10 -165'. . g_.,y . Reve rse - - 5/32 14-leo . 3/16 180-275 s
, .-y-,,._ -..w,. - . + - , . - , , - - - .,-_..O ,,,,,%_ . _ . . _ . . _ , , -. ,
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.e esuses enseeenstre PIPIES FASSICATICs 4
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itECIDtitE30ED Fultt! Q.I stA5Cl4CTURCl*5 nEconD Or TELDt.NC P!t0CEDU As vel.DED Qt%IJFIC.\ TION TE3Ti - y/7//;y * . 3,se.ne .w P1-4R-3 *-SMAu-tc . 3 ,t1/25/69. AewI'te'd 6/11/71 Teddams 18emeeen SN . ueseen er ueena N udA 3sensami Speandeeman A=4Cb=4 ,b= 4 0tp-4
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- FU3ee W C#==v'.h F=b TWd Mesme Amadysse No. A. I . FLI.:2 CE ATMQ1Pu1AE Ffee Tende Ne== e Ca-ooenese ""'"
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ese wome ee e _ _e FOR DtfoquaAT:QN CMt.Y FuterTL .c _ 1/19" and f/'II" TmiteG TEC:coqurs Tsedo Nemm, acces ar. 70ld ja ct.seekee reewe .im $heet 7 e# IC Type et senting P ' ** emos 80*I 84esas 16- 3!e ;,, ,v, ,,,, es ,,,e.ge,serta==d - C====e 0 C- Pw.miey R*ve es e SEDt:CZD SECT:CM TE.'f3ft.E TT.3T (Fise. Q 4 and qN 41 e- e- -e y,, I ,,,, c .- e~,s.e vu.e imo.ee e i l u-r;;e.a . m l, s.eees. lc % - u .,re. ese - e. i - l l l l 3C 2-1 I .f61 l3roma en Sase l
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. fo l 6 12?.6001 71,200 l l4rcua en Sage l IMetal I l
CUIDED BEND TE3T3(Fige. Q.F.1. Q 7.2. QM.T.3. QP6 7.2. qN.F.31 Type a=d I g,og, Tree and I FIswo No. l Figwe Me. anews l 5801 51h0 l l o 33-1 180* 0.X. 1 sl0F. 5130 1 I " SE-3 1 180 0.X. l I
$3-2 180' O.X.
" $5 !* l.
180 0.K. Esemies ed Futee==ed Teeee. Fis. Q 'Mel Tedder's Nemme E* CSI"' C'.est No. *
. uness No.
Stee by wisene of these eeses meere ==44 e w
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9e amenify shee abe amusammene le shie sewed ese essesse and shes she eene usede oeve p , ed. eehded ard erseed e'm aseesdaare eish she c y. _ e af Seeseen !Z ei she ASdC Caes. sg,,,4__ TH E N.*J . RfLLcc:: CP49ANY Dese II/7T/69 l' J. Rich 8FeS De (Deve.I ed eevoed ed ewese- see illenweetes endy and met be sendi43ed se essen.as se .no eype .ed a meee et seere evammeeed by ihe C.aie. Rar - El F== Q 4 ie ==ed M. Ime pwww en Asastliemeareenees.3
- leOTEa Any esseuse 4 eneseMee le adJiaame se dessesee e eheat he raroesed.
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gg7 397,7 PIPIst F48SICAften Press. Csde 7/. - ItEC0111tE3DED F'0!!18 Q.1 \l.\3CF.\CTt:HER*5 nECann OF ttEI.DI fG PROCE QU.\l.! Fit'\ TION TEiT.i 4 se se 71 44-s8n-s w .23 . f/3//77 4 . i Uheese P==ees a ~3nien o 7/12/64. RevitEd 6/11/71 we==naerm.m e annuaf , animenense== msomen A M . A-406-< w pwen, t ,
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- FG8e W Csump .h. F- b
- t 5tsid Mount Analyons Ma. 4 I FLUX 05 473aJspelF.AE N w Name see -
l Denevolue Fillee Wees J *e .metened ie Table Q*48.2 laure Ces Caugsmeeseon - ergle41.2 Tando Meme -=.= pas , __ ' eew y Smase J Fillee 'eseat is an&= Ffew Race --== la Seen mg Sees, ensei Y*S isme e ademnaume hilled. Pseeses Tempmeemme aange TO F. '91 'I . TELalanc PeoCEDuas Immnees. T-- __ _ am " " { gegie
- 1hmiase* Pues Mtal tIele pessmous T , ,m.as iICCQf.3 M C T w/T **. . no hs g 4 e,u a,;,e ,4,, 1ineie _
pas norizoneae aZ3 oos.1 Se.e pw a Ptes. o. a Q.s. e, qs.z a gro.1) cy m d c-me., - . _ _ e - !. ..e-.- . i FOR ll4 FORMATION ONLT pgg ,ys nr. _ l/I and T/32 7, se , atiza arc 1046 TEL313C TECDd(CUE 3
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! 77-2-1 0.715 .*e7 .7527 58.820 76.520 !srska in vald 77 2-2' O.735 .**7l.7527 $6.6c0 75.200 t r%e in weld etansD stNo TEIT31Ften. Q.7.1. Q.r.2. qmt.1. Qw.F.2. qw.r.n
- l Type and F1apsetea. g,,g, Tyy. and pigume ree.
Side tend 2-r 0.X. 2-3 0.X. i Side BentJ 2- 0.X. 2h l 0.X. sesalem ed 75tteessed Tema. Fie. 4 stel 9 seder's Name
- taMen I
Cash Me. Sanne No. O The nur visame ed eksee seere ausse needse puedmummonewe. 7,,,e - by M.V.X. t.Ae .> , __ y,,, 3,,,
- 8 t Jr.'a JJ R-t c y,, C. 0\ent
, , wees,eis,ene se - u le sie seemd ese ( e and e.e .e. wee = sed. =ese p e, d. esed.d ad esened le ameadamse eien the regassamunes ed $ semen IX si she ASMS Cads.
- g THE M.V. WILLOCO C*NSdNY
_-e i on,, 6/17/71 g, F. J. A Icear.fs f (Deven ed evened ed sessa ese illenweeJoe endy and any be amended to eundese se me ene end amanse ed tesse ' seemused by the Code. Revammmended Fann Q.4 is .i.ede ime pu,ehsee se AssE Iteede nees.)
' NOTE: Amy eensamea4 eerimedes is ed.iese== to mesesem=e en=441se eereseed. * * *
. ~ . '. .
. :.' : : ' . l* L
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Feinsed ie U.S.A. (11/64) This Form is ohnseeable a is== the ASME. )d1'L 47e St * .'le;= {arW.' Ng.*J00lf *.s.' . ../.<w g \ L .* '.. .. .. . . . . * * ' = Attach. 9
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TWe Fe e le abra.m.Me fe.=n the ASkt.141 L 474 St pYeet. 4.L 100l? 3 ,i 4 ,;. . , . Attach . 11 ' N .
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j ttEl.2814G TEC11:1149E SPF.CIF10sTIC:: r*3 M'*t I-t I y * }s document f.as been fericulated to clarify tfie techi.!ra.e for . :pliqErf ons of Veld Code 7/0 pecendurts as applied to AW welding emly. This tech:1ique will be used In accordanca with Pullman Power Products Process sheet. CATE: f/17/78 d REY l:IC.*f: 85 CATE: 12-20-79
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i a starTr,aT!:= Pq:t(s): reem.a l t ried Techette in Mef fient ion 't;,; Sh ier : Jed V.e ta l t re '.'c i d in e o f A STit A-36, A M I , J A-:i77. ca. 50, t.-:52, A-il5 cnd A-Sl6 In scy appile. ble scnuination in ac:cedanca with AV3 01.1-79.
] 9=ss petsl: The I asa enta s shall co.1(cru to these ll:ted above. Other matsrisit 3
5 usy se suostituted witti the approval ni" the Cogniza,nr Velding Engineer. j Cap r :es t Th r ' nus : This r:::hni<r.e != er.=llff ed 8:r eerld!ne of ret:rie ls of unlimites tnicane:s in accordesca with Aus 01.1-79. rtitee steent: 'The fil ter metal shall conform to AV5 SF", 5.1 ?/pe E-7Ct 9
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P telen of 'fe8dt nt Velding will be done in all positions. Veld progrc:s*cn wi e l ac vertica s - up. a [ Pechene and lat er**ess T-centuret Praheat and interp4:3 tenTersture shall ci,,nre m to tr.asu spec ried belewt [ . .! : *ASE ltETAL T111CCICS " MINIF.Ct Fr. CIT./iT IllTE?.f%CS TAerunil 0F . A:s!!'t.::t,F
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jl 50-F. Sw'F. i (hrer 3/14" through 1 1/2" 150 % . SOC"F. i Cver i 1/2" through 2 1/ " 225'F. SCC F. I Cver i 1/2"- - ' 3cc*F. SCC F. 3 8 i j Vhen ental temperature is below 70 F, material will bc fisc.e def ed. Oic prehest 3 reaut rement of a Joint Is c:tablished by the thief.ste a..J.cr being joisietf. Ui: prehes; applies to betta sleles of the joint and to the entire length of the joint I a, minimum distance as shown .*aelow: 4 T*:'E OF VELD l'ATCllAt. TillC3Jf:5(t) l ; - Hllill"?t O l.*.TA :C7 r".C:! POf fl7 CF UELD OE70$1T i i Filiet, Partial l { Pen.f.1/f4 t, and f3Inchc 3 Inches
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'/ VP$ No. AWT l-l PACE 2 QF 3 Cleanliness: All weld press will be free of rust, scale, grease, and other contaminants for at least I" from the weld prep edge. ,
Veld Parameters: VeldI*tg parameters are specified in the table on page 3 of 1 Veldine Technioue: The welding technique shall .bc as follows: A) Ef.AO VICTH - All welding will be acecmolished using the stringer bead
. technique. Veaving is allowed on the cover pass caly to a .maximure of 5 times the electroca diamter.
- 8) INTERFA33 C1.EANING - All weld heads will be free of all slag prior to continuation of .velding. NEEDI.F. CUNS shall not be used for any cleani.19 operation. ,
C) DEFECT 3 / All visable defects, I.e. , porosity, crater cracks, ccid lac, shall be removed prior to the continuation of welding by grinding or
.or filling.
- 0) RUN-OFF TA85 A343 EACXIN*. STRAPS - Run-of f tabs and b cklng strags will be used whenever possible. .Run-of f taas should be removed. Backing straps need not be resraved *unless specified by the owner or his desig-nated representative. Remeva l o f run-o f f ta bs sha l l b e ace =mo l i g nert sy
. thermal cutting wi thin I/8" of the weld.-.c.t and then blended into the base metal by grinding. Al terna tively , removal may be entirely ace ==-
plished by grinding. Removal of backing strass will be ace:molished by grinding or gouging to sound metal, and then back welded as needed. Mien any *thermel process is used, the acoIIcable pr. heat escuirements
. are mandatory. Prehent may be maintained during grinding as desired.
E) 8ASE hETA!. SUIL2-UP5 - Sase metal build ups will c=nform In all assect: to this procedure. F) WE!.3 PROFII.13 - Veld proflies will be as follows:
- 1) Cicove Velds - maximme reinforca$ene of 1/8" and snall blend secoth-i ly into the base metal In accordanca with thn typict ! joint details and weld profiles, page 3 of 3
- 2) Fillet Velds - size in acc=rdance with the field drawing (+3/S,
-l/16 for 10' of wald , length) and profile In acecreance with the typical joint details and weld profiles, page 3 of 3
- 3) The final surface will be smouth enough as not to interf ere wi th N.D.E. operations. Prehe' s t may be maintained during final surface conditioning operations.
l)i T-Joints and Corner Joints Croowo Velds - maxienan reinforcement of
, I/8" and shall beend smoothly Into the basa metal with reentrent i configurations in accordance with the typical joint details and pro-fIlcs, page 3 of 3 Attach. 13
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Prepared by: Mh /~2-24-7hcognizant Veld!n.1 Encincer Approved tay,f, /'/g.. , &V / / s t./ 2' of 79
- q. A. t1anagar A:nreven by: 4,., j.,* - 4 et.s M. P. C E. Representat,ve
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y b# oAL JIM THOMPSON - 1/10/84 S CHOENBERGER: Will you please stand and raise your right hand. Do you swear the information you are about to give' will be the truth, the whole truth and nothing but the truth, so help you God. THOMPSON: I do. SCHOENBERGER: For the tape recorder would you please state your full name and address. THOMPSON: Jimmy Hill Thompson, 219 2nd Street, Buellton, California. KIRSH: Prior to getting started, do you wish confidentiality of information, in other words, that we retain your information as confidential and not release your information on or transcript up to the point of law under which we would be required to release it? THOMPS ON: Yes, I do. 4 KIRSH: Okay, with that statement of confidentiality request, let's get started into the questions that I have. First question, is the current document review effort under your supervision, and if not, who is in charge of this effort? THOMPSON: The current review is under my supervision. The actual mechanics, the day-to-day work, is being conducted by some supervisions, Gary Boling, Carol Rodini... KIRSH: Any others? THOMPSON: There was a man who was directly involved with it, Don Sheeley. Currently he's not as involved in it, he's on , special assignment, but I would like to mention his name anyway. Thompson /1-10 1 l$0
- THOMPSON: We have Phase II of the civil structural, we have Phase I and Phase II review of the circuit packages, electrical circuit packages, and the other areas we only have the Phase-II review. _-
KIRSH: Okay, Phase II and other areas. Okay, describe your involvement in the current document review effort. THOMPSON: Well, I've been currently providing direction as - far as rewriting the cuality instructions that people use for document review, and coordinating whatever requirements the Quality Director wants imposed upon these people. I don' t review records myself, I don't sign of f review of records, I'm more or less involved with just the staffing, the manpower, and tryino to give some sort of a direction through the quality instructions and coordinate that direction between people. KIRSH: Has the OA organization audited that document review effort? THOMPSON: No, not since it was implemented. KIRSH: How long has it been implemented? THOMPSON: The organization was established in about May of 1983. It went through a learning period trying to-determine what records to review, what to review them for, to teach the people the ins and outs of this plant, and really became effective r probably some time in the summer of '83. KIRSH: Is there any particular reason why the Quality Assurance organization has not audited the effectiveness of the document review efforts on the post September 1981 records? i Thompson /1-10 3
- THOMPSON: The Quality Assurance auditors. have not been active for a number of months, until about, I think it was' September, and I have some new auditors that have been assigned other areas of concern. Thesecondreasonisthatthhprogram has been fluctuating somewhat; the written program hasn' t been firmly established.
KIRSH: Okay, the audit program was stopped, essentially, for a number of months. When was it stopped? THOMPSON: I believe it was stopped some time in March or April of '83, and it was supposed to be for a period of 90 days, and I believe we started it back up some time approximately September of '83. KIRSH: The original stoppage was supposed to have been 90 days... THOMPSON: The original stoppage was supposed to be for 90 days and was at the direction of the Quality Director. KIRSH: I think that we just forget something here on this , tape. My name, the interviewer, which is from Nuclear Regulatory Commission, is Dennis F. Kirsh. My name is Dennis Kirsh, and present also is Lou Schoenberger, a regional attorney, who administered the oath to Mr. Thompson. Okay, were you directed not to audit that quality ... the document review, an analysis effort? THOMPS ON: I don't remember. KIRSH: You were not directed one way or another to audit or not to audit? THOMPSON : I don' t remember. 1 Thompson /1-10 4 __ _ _ _ _ . , _ - _ . _ L_--._.___ . - _ . . _ _ . __ _ - _ _ __ - _ . _ .
s
- KIRSH: Okay. Are you aware of any deficiencies in-the pre-
~ September 1981 Foley records which could render the' quality of field work as questionable or' indeterminant?
i : THOMPS ON: I'm not aware of any as far as inspection records. KIRSH: How about records other than inspection recordr,?
.. THOMPS ON : I don't believe so, no. -
KIRSH: In your opinion, is the quality of the post-1 September 1981 record review acceptable? Or should more be done, and'if more should be done, what? THOMPS ON: I'm not really sure of your question. Do you 4 mean that we'should include more in the review after '81 or are you talking about time periods? You mean we should include the records before 1981. KIRSH: I'm talking about post-September 1981, in other
- words af ter September 1981. Is the quality of the review being performed on those post-September 1981 records acceptable, or should more be done, in your opinion? And if in your opinion l'
[ more should be done, what should be done? THOMPS ON: Well I can speak for the administrative review I and I don' t see any real problems with what they're doing as far as the administrative review. As far as the technical review, I really can' t speak for that. i l KIRSH: The technical review is being performed by Quality Control-people? THOMPSON: Right. Thompson /1-10 5
, KIRSH: ... who are under Ted Canning and not under your
- s'pervision.
u
-THOMPSON: Right.
KIRSH: Are you aware of any quality problems regarding the i Foley procurement process and documentation, considering also the l Foley approved suppliers list? THOMPSON: . There's been considerable confusion involving , that procurement, specifically the approved suppliers. The confusion really stems from different' direction as to what's required to get a'. supplier approved. Yeah, there's a lot of confusion in that area. t ,
- . KIRS H
- May I have a copy of the approved suppliers list that's. under . .. that is confused?
THOMPSON: I'll let you look at any list that you want to look at. I have it here in the file. If'you want a copy of what 1 I have, you can have a copy of it. KIRSH: How did Foley go about establishing the, approved suppliers list? , THOMPSON: Well historically, approximately in 1970, when Foley first came on the site, they submitted products to PG&E, ! catalog products, for approval, by letter. And PGEE would I approve or disapprove various products, by letter, and then, in > 4 approximately . . . I believe in 1974, PGsE conducted an audit where they determined that we didn't have a current suppliers list, approved suppliers. I'd like to point out that I wasn' t 4 here.during_those days. This is only from what I'm able to piece J together from the records and through correspondence files. I Thompson /1-10 6
Som'etime approximately 1974 this audit, the result of the audit was that Foley had to submit a list of supplie'rs and the products that they were buying from each supplier to PGsE for approval and
'from that point forward PGsE has submitted various suppliers ...
I mean, Foley has submitted various suppliers to PGsE for approval by letter, by different types of correspondence. KIRSH: And then PGsE would act on each of those letters?
~
THOMPS ON: They would either approve or disapprove them. Recently we've had numerous EDRs telling us what ... an EDR is an Engineering Disposition Request signed by PGsE ... telling us ... . can we go off record for a second? KIRSH: Sure. KIRSH: Back on tape. The time is 4:20 PM, January 10, 1984. The next question that I have to ask is, Have all Foley records regarding field change orders been closed and are these fully acceptable? THOMPSON: I really don' t know the answer to that question. I heard that there are some field change orders in file several years back that the QC manager, the ex-QC manager didn't have copy of it at the particular time. And.went to the front office and got copies of this information put it in the files. . KIRSH: This information is based on your saying that you don't know whether they've all been closed? THOMPSON:- I don' t know whether they've all been closed. Thompson /1-10 7 e
KIRSH: Have you ... has your organization ever conducted an audit of ' the closure of field change orders? Class 1 field change orders in particular. THOMPS ON: No. KIRSH: Okay. Related gues tion. Do you know of any field change order inspections which were not performed or acceptably documented? And if so, please describe these. THOMPS ON: I don't know of any numbered field change orders
. . . any numbers. Generically it may have existed because FCOs weren't on file in OC. It had to have been forwarded to OC for a certain time period. In fact, in the past the OC manager was here. And when they were finally given to the QC manaaer, I don' t believe they were revi'ewed before being filed.
KIRSH: What time period is that? THOMPSON: I'm not sure. I really don' t remember time periods. It seems to me that it might have been in 1981 because of a problem where the topic came up, but I don' t remember. KIRSH: Okay. Do any field change orders include cuality j documentation? And to your knowledge is this documentation fully acceptable? THOMPSON: I don' t understand your question. l KIRSH: Do field change orders, quality Class 1 change 1 orders in particular, include with the field change order package quality documentation that is applicable to that field change l order? THOMPSCN: Yes, I believe so. 9 l l Thompson /1-10 8 i
KIRSH: Do most of them contain that quality documentation or do most not contain cuality documentation to your knowledge. THOMPSON: I couldn' t place a number on it. I c,an tell you thatthereweredifferentperiodsoftimewhentherehasa different system of running work. The current system I believe is with a field change order or, ... not a field change order, a work order and a traveler of inspections in a package. There was a time when that package concept was implied. And the inspections were filed separately f rom the work order.
'KIRSH: So it's conceivable then that some of the field change order packages do not contain quality documentation regarding the inspections performed _ pursuant to that field chance order.
THOMPSON: I would hesitate to say yes today, but in days past that may be remotely possible I'm sure. KIRSH: Okay. Have field change orders been reviewed by Foley document turnover analysts? THOMPSON: I don' t kno'w. t KIRSH: Are they planned to be reviewed by document turnover l-analysts? l THOMPSON: If the date of the field change order is,after September of 1981, yes, that would be part of . KIRSH: Okay, they will be included if post-September '81. THOMPS ON: Right. KIRSH: The next area that I have to go into is, to the best of your knowledge, are all Foley records of electrical , modifications closed and are these fully acceptable? l Thompson /1-10 9 l
THOMPSON: _ I don' t know. KIRSH: Don' t know. Has Oualify Assurance organization to your knowledge ever performed an audit of the electrical modification packages? _ THOMPSON : I believe there was an audit of electrical work initiating documents. I don' t remember the number but I can look it up. KIRSH: Okay, one audit may have been done then. THOMPS ON: That's true, may have been done., KIRSH: In the same area, do you know of any electrical modification inspections which were not performed or acceptably documented? THOMPSON: Not to my knowledge. KIESH: Next question. Have DCN's been worked in the field without first having an approved work request, or an approved authorization to work this in the field from PG&E? THOMPSON: I'm not sure. KIRSH: Have DCN's, to your knowledge, been worked in the field, which were later cancelled by a different DCN? THOMPSON: I've heard that DCN's have been revised considerably. May include cancelling. But I don' t know of any specific numbers, any specific DCN numbers. KIRSH: Have you ever performed an audit in this area of DCN work in the field? THOMPS ON : I believe so, as part of a internal program audit, but not a specific audit on DCN's alone. In other words, j it would be part of an internal program audit. l Thompson /1-10 10
KIRSH: Okay, next question. Are you aware of any non-color coded black cable which has been used in safety related circuits, and if so, where may this cable be installed? THOMPS ON: I'm not aware of any circuits that I ,ecall. r I have heard second-hand that this may have happened. KIRSH: Did you take any action to find out the substance of that hearsay information? THOMPSON: Not any specific action on that particular point. We have audited electrical work and as part of these audits we've checked for wire traceability on a sample type basis. We have never had, to my knowledge, specific circuits identified. KIRSH: To the best of your knowledge, are the pre-September 1981 records all in order and in accordance with 10 CFR 50 Appendix B? THOMPSON: To the best of my knowledge the records are legible and they are filed in some sort of an indexing manner. I wouldn' t be -able to comment on the intent of 10 CFR 50 Appendix B. KIRSH: So, as I understand it, your answer is you don' t know. THOMPSON: Okay, I'll accept that, I don' t know. KIRSH: Have you ever felt intimidated or been threatened
- with retaliation caused by your identification of quality related l problems?
THOMPSON: Specific problems are hard to identify. I i haven' t had anyone approach me and say directly that if I Thompson /1-10 11
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reported something that I would have any sort of retaliation taken against me. KIRSH: If ... you pointed a letter back in 1979 regarding the inclusion of 10 CFR 21 requirements in purchase order , documentation. issued by Foley, that you indicated could very well have cost you your job. In light of thac letter, is your response still the same? THOMPSON : In light of that letter, I heard such a statement second-handedly from my manager at the time, that it upset too management and may have jeopardized my position. KIRSH: Are you aware of any inspection reports which document problems which should have been recorded on non-conformance reports, and were not? THOMPSON: Yes, I believe that there may have been some inspection reports written for problems that probably should have been on a non-conformance report. KIRSH: Does any one particular item stick out in your mind? THOMPS ON: Not off the top of my head. l KIRSH: Is there anything else that you feel that we should be made aware of regarding the Quality Assurance program and its implementation at H.B . Foley? THOMPSON: I think I mentioned to you the other day the _ practice correcting existing records and I believe you should be aware of that practice. , KIRSH: Okay, that's the end of the interview. SCHOENBERGER: Could I follow up? i KIRSH: Go ahead, Lou. i Thompson /1-10 12 l l
r . SCHOENBERGER: In response to the guestion before the last one, you said you didn' t know off the top of your head about any items that should have been reported but were not subject of a non-conformance report. Is that correct? - THOMPSON: Mm hm. S CHOENBERGER: Do you ... if you were able to review your records or to think about it for a while would you be able to come up with specific circumstances?-
, THOMPSON: I could probably come up with some circumstances that PGEE identified in one of their audits. - Yes, I might be .
able to. SCHOENBERGER: Are there any others? THOMPSON: I don' t know. The ones I was thinking about would be the PGEE audit. S CHOENBERGER: That's all I have. KIRSH: End of the interview. 1 i i Thompson /1-10 13 i L- - - __. _}}