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NUCLEAR REGULATORY COMMISSION f*
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December 8,1983 E MORANDtM FOR:
T. W. Bishop Director Division of Resident, Reactor Projects and Engineering Programs FROM:
Owen C. Shackleton, Jr.. Director, OlF0,* RV
SUBJECT:
DIABLO CANYON - ALLEGAT10NS RE BOSTRON-BERGEN METAL PRODUCTS
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On December 6,1983, Owen C. Shackleton, Jr., Director, Of fice of Investigations, RV, interviewed by telephone an alleger who was fonnerly e@loyed by Bostrom-Bergen Metal Projects, 4700 Coliseum Way, Oakland, California, from January 1981 until January 1983. The alleger worked as a welding inspector.
The alleger stated that during the early part of 1982 there.were several truck loads of new pipe hangers shipped to Diablo Canyon on which he signed off the f\\
l QC welding inspection recortis without looking at the work. He described these hangers as belpg built for the plant's cooling system. He claimed he could l
not be more sFecific as'that was all he knew. The alleger stated he falsified the names of the welders and the fitters on these QC documents.
The a'lleger has requested confidentiality. However, should his name be revealed in the TV news broadcast at 6:00 p.m. on Channel 7, Station KGO, then SHACKLETON will detemine if NRC can openly use his identity. This is pertinent in tracing hardware received from Bostrto-Bergen as the alleger stated any QC inspection i
reports bearing his name are falsified. He advised that in the two years he worked at Bostrom-Bergen only on one or two QC welder inspection rtports did l
he verify every entry on the fom.
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tYbs' Owen C. Shackleton, Jr.
Director
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2 A.
Inspection at Diablo Canyon 1.
Visual Inspection of Installed Hardware '
The licensee, at the inspector's request, located and identified BBMp hardware installed in safety-related systems. The inspector visually examined these items for evidence of material damage and weld quality. Weld inspection was limited because all the items had received a protective coating of paint. No material damage was identif.ied. Weld location, length, size and shape were within construction specifications; weld reinforcement, appearance and type (butt or fillet) were as required.
Evidence of surface defects such as cracks, porosity, or slag were not inspectable due to surface paint. The' areas inspected during this walkdown and the type of hardware inspected are as follows:
(a) Turbine Building - CCW heat exchanger barrier, rupture restraints for CCW heat exchanger-barrier, leveling plates for the 4,160 volt vital Buss H in the switch gear room, and diesel generator 1-1 embed plates'.
(b) Auxiliary Building - AFW 1-1 pump missile shield, SI
_ pump 1-1 and 1-2 embed slaps, containment spray embeds, RHR pump 1-2 anchor bolts, and BIT anchor bolts.
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(c) Unit 1 Containment - Main Steam Generator FW line rupture restraint no. 1047/10RT, embed plates for fan coolers, embeds for pressurizer wall and platforms, and annulus platform beams.
The inspector did not identify any discrepant material.
2.
Review of Quality Records The following records, associated with the safety-related-items 1.nspected during the walkdown, were reviewed:
(a) Steam Generator Line Rupture Restraint No. 1047/10RT drawings which includes:
Embed Plates Job. No. 1818 Sheet 465 Main Steam Restraints Job. No. 2241 Sheet 1 Feedwater Restraints Job. No. 2241 Sheet 2
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Snubber Support Structure Job. No. 2241 Sheet 3 (b) BBMP Shop Inspect From F of 6-12-73 4
(c) Certified Material' Test Reports (CMTR's)'for the following items:
Embed Plate Mark No. B465, C465 & K465 Kaiser Steel Heat No. 147397; Mark No. A465 Kaiser Steel e
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4 Heat No. 69869; Mark No. pa 465 Kaiser Steel Heat No. 50117 Embed Plate Coupling Nuts Mark No. mb 465 Schmitt Steel Heat No. 330B292 (d) BBMP Inspection Form F of 8-20-69 (e) Main Steam /Feedwater Restraint Materials CMTR from the following suppliers (Heat Nos. listed):
U. S. Steel: 064552, 2G7399 Oregon Steel: D9160, D8430 Kaiser Steel: 77816, 350916, 20165, 86999, 61102, 346080, 69831, 252094 Schmitt Steel: 78T441, N71483, 1R1397 Bethlehem Steel: 402E4401 Republic Steel: 8875464 Jorgensen Steel: 081508 This review indicates that the material is traceable from the installation location-to the BBMP inspection reports and thesteelsupplier'sC$TR. The inspector did not identify any evidence of falsification of the CMTR's reviewed.
The following quality records were randomly selected and reviewed for evidence of falsification:
5 1.
BBMP Job. No. 2056 for Units I, II, Material for Containment Piping Penetrations. Documentation Reviewed: BBMP Shipping List of 11-3-72 & 11-8-72; Shop Inspection Form of 11-3-72, 10-16-72, 11-8-72; Hawley Forge CMTR/HT. No. LG; U. S. Steel CMTR/HT. Nos.
2P5112, 2P5194, 2P4563, 2P330 2.
BBMP Job No. 2057 for Units I, II, Material for Reactor Heat Supports. Documentation Reviewed: BBMP Shipping Lists of 1-11-73, 12-22-72, 10-10-72;' Shop Inspection Forms of 1-11-73, 12-27-72, 11-13-72; Pacific States Steel CMTR/ HT. No. 37166; Pacific Metals CMTR/HT. Nos.
M84018, 3279; Bethlehem Steel CMTR/HT. No. 401J7251, 485A2111; Kaiser Steel CMTR/HT. Nos. 244793, 69445 3.
BBMP Job. No. 2101' for Unit I, Material for Annulus Hanger Frames. Documentation Reviewed: BBMP Shipping Lists of 3-29-73, 3-1-73; Shop Inspection Forms of 3-28-73, 3-1-73; Kaiser Steel CMTR/HT. Nos. 146097, 246798, 69869; Bethlehem Steel CMTR/HT. Nos.153W422 4.
BBMP Job No. 2158 for Unit II - Material for Pipe Restraints. Documentation-Reviewed: BBMP Shipping List of 1-30-74, 2-1-74, 9-14-74; Shop Inspection Form of 1-30-74, 9-14-74; Kaiser Steel CMTR/HT. No. 50890; Bethlehem Steel CMTR/HT. No. 1742Z408 i
6 5.
BBMP ~ Job No. BB534 for Units I, II, Material for Pipe Restraints in Auxiliary Building. Documentation Reviewed: BBMP Shipping Lists of 7-2-75, 1-29-75, 1-8-75; Shop Inspection Forms of 1-29-75; Final Inspection Checklist of 7-2-75; Precision Heat Treating
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Company Certs; Ducommun Metals CMTR/HT. No. 20812; U.S.
Steel CMTR/HT. No. 94E619, 97E823.
6.
BBMP Job. No. BB538 for. Unit II, Two W14X370 Studded Beams. Documentation Reviewed: BBMP Shipping List of-9-14-74; Shop Inspection Fonn of 9-16-74; Kaiser Steel CMTR/HT. No. 351656; Nelson Stud Welding Company Product Certification of 12-2-74.
7.
BBMP Job. No. BB547 & 548 for Unit I, Material for Reactor Missile Shield. Documentation Reviewed:
BBMP Shipping List of 11-22-74; Shop Inspection Forms of 10-25-74, 11-8-74; Oregon Steel CMTR/HT. Nos. D465, D9745, E91; Kaiser Steel CMTR/HT. Nos. G1298,11870 8.
BBMP Job No. BB662 for Units I, II, Material for Pipe Restraints, Containment Structure. Documents Reviewed:
BBMP Shipping Lis't of 5-27-76 & 10-21-76; Inspection Traveler;ShopWehdingInspectionReport; Shop Inspection Fonn; Final Inspection Checklist of 5-28-76; Bethlehem Steel CMTR/HT. Nos. 3P804,1T0268; U. S.
Steel CMTR/HT. No. 91A053; General Pipe & Supply Company CMTR/HT. No. K33080; Signet Testing Labs'
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7 Charpy ~ Impact Test Reports; Consolidated Engineering Laboratories Ultrasonic Test Reports 12 through 21.
9.
Mill Test Reports A.
' Wide Flange (WF) Beams HT. No.
Size Length (ft) 1255299 14x455 59 173Z061 30x108 47 1R4790 12x161 45 70A017 14x103 60 75A025 18x96 60 79221 4x13 60 98E002 8x28 60 H08235 12x92 40 H90147 14x342 60 1
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~K16989 36x300 60 i
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K95397 14x202 60 l
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Channels
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HT. No.
Size Length (ft) 10P190 10x15.3 60 l '
12397 9x13.4 60 125S497 6x15.1 20 l
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8 3N638 3x4.1 20 65A217 12x20.7 60 92C510 15x40 40 g.
B13800 6x15.3 40 T05438 5x9 60 T31635 10x8.4 40 66A336 10x21.9 40 C.
Angle HT. No.
Size Length (ft) 105415 4x4xi 50 18E126 5x5x5/8 60 1P710
.3x3xi 20 20E241-4x3x5/8 60 252199 6x6x3/8 40 331P876 4x4x3/4 20 355460 6x6x1 910158 6x6xi 40 A8610 2ixlix3/16 1.
B8488 4x4x3/8 L
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Plate a
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HT. No.
Size-(Inches Thick) s 12001 31 l
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144338 1
18444 5/8 40237 3
42565 6
43484 3
60737-4 73D318 41 79666 4
95665 4
D1314 1
E1115 2
K8858 8
- 10. Weld Procedure Specifications The inspector reviewed four weld procedure specifications (WPS) utilized by BBMP to fabricate hardware supplied to the Diablo Canyon Project.
Attributes examined were material, welding process, filler metal, welding current, electrode size, preheat and interpass temperature. The procedures, identified below, were in compliance with the requirements of AWS D1.1-69 to be designated as prequalified joints.
WPS No.
Joint ?etail Groove Angle SM4 Single V-Groove 30
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(T' 10 SM-23 Single Bevel-Groove with 45" Backing Bar-SM-24 Single Bevel-Groove 45" SM-39 Single Bevel-Groove 30*
Conclusions No quality-related material problems were identified. Based on the inspectors examination of installed safety-related hardware and review of BBMP quality records there is not enough evidence, at this time, to support the allegati5ns, or to conclude on the quality of the hardware installed.
Action Required Perform investigation / inspection at the Bostrom-Bergen plant in Oakland, California in order to determine the validity of the allegations regarding QA/QC practices and to identify specific hardware items of concern.
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