ML20214E631

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Applicant Exhibit A-80,consisting of QA Program Audit CQA-368,Braidwood Nuclear Power Plant,830815-17
ML20214E631
Person / Time
Site: Braidwood  
Issue date: 07/10/1986
From: Vogt T
COMSTOCK ENGINEERING, INC.
To:
References
OL-A-080, OL-A-80, NUDOCS 8705220173
Download: ML20214E631 (18)
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QUAL'ITY ASSURANCE PROGRAM AUDIT CQA-368 BRAIDWOOD NUCLEAR POWER PLANT AUGUST 15 - 17, 1983 NUCttAR REGutATORY COMM11$10N b

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Submitted by:

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CQA-368 0> r, g,j' Audit Site Braidwood Nuclear Power Plant f

Braidwood, IL Audit Team Members Name Title Organization

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Ernie Yockey Eastern Region Mgr., QA/QC Services Comstock Engineering,Inc.

  • Thomas Vogt QA Engineer Corporate Staff, QA/QC Services Comstock Engineering,Inc.
  • Team Leader Purpose

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To conduct a programatic audit of the Comstock Engineering, Inc. Quality Program to verify Site Quality Control Procedures are being implemented satisfactorily and are in compliance with the requirements set forth in 10CFR50 Appendix B.

Sumary On August 17, 1983, the Comstock Engineering, Inc. Corporate Quality Assurance Audit Team completed the scheduled audit for the Braidwood Nuclear Power Plant.

This audit was conducted to essess proper implementation of Comstock Quality Control Procedures 4.3.3, 4.3.10, 4.3'.11, 4.3.14, 4.7.1, 4.8.2, 4.9.3, 4.9.1, and 4.9.4 to verify compliance of these quality control activities to 10CFR50 Appendix B, Criteria IX and XII.

An in depth review of Comstock QC activities revealed the Quality Program being implemented at the Braidwood site is in compliance with 10CFR50 Appendix B criteria except as noted by the finding and concerns identified in this report.

The written response to these findings and concerns is to be submitted to the Audit Team Leader within 30 working days from the issuance of this report.

The Corporate QA/QC Services Audit Team would like to thank all of those involved for their assistance and cooperation during this audit.

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AUDIT FINDING REPORT No. C0A-368-1

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LoCATIop Braidwood. IL AUDIT DATE B/15-17/R3 AUDITORS T_ Vnat 1 E. Yockey PERSONS CONTACTED I neWald. T. Enrenran. W-cardner. R-Renwn REQUIREMENT AND MFERENCES:

L. X. Comstock procedures 4.3.10 Rev. A and procedure 3.1.1 Rev. 5/1/80 10CFR50 Appendix B Criteria V Instruction, Procedures and Drawings.

10CFR50 Appendix B Criteria IX Control of Special Processes.

REVIEW FINDING: CATEGoE!

The use of interim procedures is not formally addressed by the L. K. Comstock

& Company QA/QC Program.

(See Attachment CQA-368-1).

Verified by Attachment REColetENDED CORRECTIVE ACTION:

Revise the L. K. Comstock & Company procedures to define the use of interim procedures and limit the number of interim approvals which can be issued against an ap? roved procedure.

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l CORRECTIVE ACTION TAEEN:

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h Attachment CQA-368-1 Audit Finding CQA-368-1 During the review of procedure 4.3.10 Rev. A, it was identified that the status of interim approval of revision B for procedure 4.3.10 had been granted by Commonwealth Edison Company.

Further investigation and review of L. K. Comstock procedure 3.1.1 Rev. 5/1/80, titled " Revisions to the Quality Control Program" revealed the status and use of interim approved procedures is not addressed by the L. K. Comstock QA/QC Program.

Paragraph 3.3.5 identified the status which is to be applied to procedures reviewed by the customer, they are:

Acceptable, Acceptable with Comments, Conditionally Acceptable, and Not Acceptable.

Therefore, the use of interim approval is in violation of procedure 3.1.1 paragraph 3.3.5.

Concern 1 In addition, paragraph 3.6.3 of procedure 4.3.0 Rev. 8/27/82, titled " Generating Work Instructions," requires all work instructions to be submitted to Commonwealth Edison Company (CECO) and Sargent & Lundy for review and approval prior to issuance.

Contrary to the above requirement, the interim approval is only being granted by Commonwealth Edison Company.

If work and inspections are conducted in accordance with an interim approved procedure for a given period of time and then S & L rejects the interim approval, what is the status of the work and/or inspections performed to the interim approved procedure?

If this situation occurs, who is responsible for work in-stalled and inspected?

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C AUDIT FINDING REPORT No. CQA-368-2 LT AUGgg;99329 E -JTOCKg PROJECT Braidwood Nuclear Power Plant COMPANY Comstock Engineering, Inc.

LOCATION Braidwood. IL AUDIT DATE 8/18i 17/83 AUDITORS T. Vogt. E. Yockey PERSONS CONTACTED I. DeWald, 8. Brown REQUIREMENT AND

REFERENCES:

L. K. Comstock Procedure 4.7.1 Rev. 6/18/8210CFR50 Appendix B Criteria IX Control of Special Processes.

Paragraph 3.10.4 of procedure 4.7.1 requires the use of Fom #88 to document the qualification of welders along with.

proper signatures by authorized personnel.

REVIEW FINDING: CATEGORY Contrary to the above requirement, Fom #112 has been used to document welder 7

qualifications and the forms have not been signed properly.

Certification re-viewed:

B. Breault, C. Gruenwald, K. Ott, J. Smith, and D. Ward. Breault and Gruenwald were in violation of procedure requirements.

Verified by Attachment f

REColeENDED CoRRECIIVE ACTION:

Review welder certification packages and correct documentation.

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CORRECTIVE ACTIoM TAEEN:

l Response Dece Author Attachment Reply Due Date In/ci/A1 DataItesj 10 h

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m LOCATION Braidwood. IL AUDIT DATE R /1 c;_17 /R1 E. C. Yockey, T. Vogt AUDITORS PERSONS CONTACTED I. DeWald, John Seeders REQUIREMENT AND

REFERENCES:

10CFR50 Appendix B Criteria XII, L.K. Comstock Procedure 4.9.1 Rev. B Control of Measuring and Test Equipment Paragraph 3.1.2 states, (See Attachment CQA-368-3)

REVIEW FINDING: CATEGORY (See Attachment CQA-368-3)

Verified by Attachment REColetENDED CORRECTIVE ACTION:

N/A Attachment CORRICTIVE ACTION TAKIN:

I Response Date Author Attachment P

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Reply Due Date 10/5/83 Date Item closed

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6/1/78 6/1/78 Form #1 OCROURE

Attachment CQA-368-3 continued

" Calibrated items received from manufacturers will require a certificate of calibration from the manufacturer with traceability to national bureau of standards or other LKC recognized test standard and filed in the applicable tool package in the Quality Control Records."

Review Finding:

Contrary to the above requirement, review of calibration records for the following measuring and test equipment indicated that traceability to NBS is not available:

a.

1" gage block s/n 611201-2 LKC #GB-1 (see a-1) b.

Starrett 1" micrometer s/n 436 LKC#786 (see b-1)

Evidence:

a-l.) " Certification of Inspections" supplied by Starrett, Webber Gage Division on 9-14-81 and 10-6-82 test numbers 738/224984 and 738/227675 respectfully do not indicate 1" gage block serial no. LKC control No.

or applicable P.O. No. to maintain traceability to Gage Block LKC #GB-1.

Traceability to NBS is not available, b-1.) Review of LKC calibration records'for Starrett 1" micrometer s/n 436, LKC #786 indicated that above referenced Gage Block LKC #GB-1 was utilized to calibrate referenced micrometer. Gage Block LKC #GB-1 not being traceable to Certificates of Inspection render calibration of micrometer s/n 436, LKC #786 invalid.

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AUDIT FINDING REPORT NO.

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COMPANY Comstock Engineering, Inc.

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REFERENCES:

10CFR50 Appendix B Criteria XII LKC Procedure 4.9.1 Rev. B Control of Measuring and Test Equipment Paragraph 3.3.3 through 3.3,6, reference procedure paragraphs.

(See Attachment CQA-368-4)

REVIEW FINDING: CATEG0KY (See Attachment CQA-368-4)

Verified by Attachment RECOMMENDED CORRECTIVE ACTION:

N/A Attachment.

CORRECTIVE ACTION TAEEN:

Response Date Author Attachment WM Reply Due Date 10/5/83 Data Item Closed

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Disposition Acceptable ap 3 g 9 t-. c., r. s Acv. oars anac pannanao apenovao nevisso mu op pa" 6/1/78 6/1/78 Form #1 TWP RCD PROCEDURES

Attachment CQA-368-4 continued Procedure paragraphs 3.3.3 through 3.3.6 reference the use of tha

" Control Card" (Fonn #77).

Review Finding: Contrary to procedure requirements, review of calibration files indicated that voided form #78, " Tickler File Card,"

which is no longer procedurally addressed is still being utilized.

Evidence:

1" micrometer #LKC-786, s/n 436.

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AUDIT FINDING REPORT No. C0A-368-5 d[: AUG 2619 Braidwood Nuclear Power Plant LK-Pron CT

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LoCAnoN Braidwood IL AUDIT DATE 8/15-17/83

/#6\\h AUDITORS E. C. Yockey T vnp I DeWald, J.' Seeders PERSONS CONTACTED REQUIREMENT AND RETHENCES:

10CFR50 Appendix B Criteria 'XII LKC Procedure 4.9.1 Rev. B Control of Measuring and Test Equipment Paragraph 3.3.7 states, (See Attachment CQA-368-5)

REVIEW FINDING: CATEGoKY (SeeAttachmentCQA-368-5)

Verified by Attachment RECoHMENDED CORRECTIVE ACTION:

Attachment.

CORRECTIVE ACTION TAEEN:

Response Date Author Attachment Reply Due Date 10/5/R3 Date Ices Closed Disposition Acceptable ary_tg poca enseanso anemovao navisso rm.s onio. oats nav.

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Attachment CQA-368-5 continued

" Equipment found to have an expired calibration date and/or found to be outside the acceptable tolerances will require the initiation of an " Inspection Correction Report (Form #30);....

Review Finding Evidence: LKC Pin Gage Set, LKC-785, s/n M-1 plus, was calibrated by PTL on 10-4-82.

PTL "as found" and " final" measurements of pin gages indicated two (2) pin gages - sizes.247" and.149" were rejected for being out-

ide LKC procedure requirements of +.0002".

To date, LKC Quality has not documented the reference pin gages on Inspection Correction Report Form #30 In addition, pin gages referenced have not been removed from service.

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COMPANY Comstock Enoineerino. Inc.

Braidwood, IL AUDIT DATE 8/15-17/83 l

LOCAHON AUDITORS E. C. Yockey, T. Vogt I. DeWald, J. Seeders PERSONS CONTACTED REQUIREMENT AND

REFERENCES:

10CFR50 Appendix B Criteria XII LKC Procedure 4.9.1 Rev. B. Control of Measuring and Test Equipment Paragraph 3.2.5, third sentence states, (See Attachment CQA-368-6)

REVIEW FINDING: CATEGORY (See Attachment CQA-368-6)

Verified by Attachment RECO)9 TENDED CORRECTIVE ACTION:

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CORRECTIVE ACTION TAEEN:

Response Date Author Attachment Raply Due Date I n / c; /91 Date Item Closed g

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. Attachment CQA-368-6 continued "L. K. Comstock Quality Control shall review certifications for acceptable results and signify acceptance by signing and dating on the certificate.

Review Finding: Contrary to the above requirement, which has been in effect since February 16, 1983 per Rev. A and Rev. B of procedure 4.9.1, review of certification records for the following measuring and test equipment indicated that LKC Quality Control has not signified acceptance of calibration certificates.

Certification of Calibration Evidence:

a.

In Line Volt Ammeter LKCE #840 from NWI dated 5-6-83; NWI Document C-0017038-CC b.

Dickenson Co. Temperature Recorder s/n U-14757, LKC #All46 -

Certificate of Conformance dated 4-21-83.

Torque Wrench Analyzer LKC #2221 - Certificate from Sweeny c.

dated 3/24/83.

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Thermometer LKC #A980 - Certificate (calibration record) from PTL dated 6/28/83.

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  • Attachment C0A-368-6 Concern 2 It is the intent of 10CFR50 Appendix B Criteria XII that tools, gages, instru-ments, and other measuring devices used in the activities effecting quality are properly controlled, calibrated, and adjusted at specified periods to main-tain accuracy within necessary limits. To achieve this, it is comon practice that these items be traceable to a nationally recognized standard, commonly NBS.

A review of calibration records for items listed below, did not indicate traceability to NBS through calibration records required by LKC Procedure 4,9.1 Rev. B or certifications supplied by subvendors.

Beam Type Torque Wrench - LKC-A180 1/2" drive 0-150ft lbs., Certificate of a.

Calibration supplied by Phillip Getshaw Co. on 3/22/83 indicates as found and final readings which are in conformance with procedure tolerances yet certification does not indicate equipment utilized to calibrate LKC's torque wrench was calibrated and traceable to National Bureau of Standards.

b.

LKC Stationary Rod oven LKC #4020 indicated that temperatures of rod oven has been checked on a daily basis and recorded on Form #63's yet calibration records do not indicate s/n or LKC control number of thermometer utilized to verify rod oven temperature.

Calibration records for crimper tools - LKC numbers A1037 and A1011 indicate c.

that calibrations were performed on required intervals yet records do not indicate standards / equipment serial numbers or LKC control numbers utilized to perform calibration.

Cases listed above are generic in nature and ilfustrate loss of traceability to NBS.

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i PRORCT Braidwood Nuclear Power Plant E

COMPANY Comstock Engineering, Inc.

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I.OCATION Braidwood.11 AUDIT DATE R /1 c 17 /R1 l

AUDITORS T. Vogt, E. Yockey PERSONS CONTACTED I. DeWald. D. Hol1v. D. Coss REQUIRZHENT AND

REFERENCES:

L. K. Comstock Procedure 4.3.11 Rev. 7/11/8010CFR50 Appendix B Criteria IX.

(See Attachment CQA-368-7)

REVIEW TINDING: CATEGORI (See Attachment CQA-368-7)

Verified by Attachment REC 0!GIENDED CORRECTIVE ACTION:

Attachment.

CORRECTIVE ACTION TAEIN:

Response Data Author Attachment Reply Due Date 10/5/R1 Data Item Closed Disposition Acceptable

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PREPARED ApptovED REvtseO TITLa,

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Attachment C0A-368-7 Recuirements:

Paragraph 3.1.1 of procedure 4.3.11 Rev. 7/11/80 states, "The stud welding eouipment shall be qualified as follows:

a welding system consists of a power supply, stud gun con-troller, a cable set and stud gun.

Each system with the maxi-mum cable length shall be required to weld ten (10) studs in each position to be used in production.

These ten (10) studs shall be bent by hammer testing to an angle of thirty (30) degrees from their original axis.

Findinos:

Contrary to the above requirements, the ten (TO) equipment qualification studs required for each position are not being bend tested as required by paragraph 3.1.1 of procedure 4.3.11.

Qualification conducted 1/19/83 for Joe Bakos in Example:

a.

the Turbine Building indicates 10 test studs were torque tested instead of bend tested as required by the procedure.

b.

Studs installed 12/9/81 in accordance with installation drawing 20E-1-3140, elevation 401' in the Turbine Building indicates 30 studs were installed but none of the equipment qualification studs were bend tested.

This is a violation of paragraph 3.1.1 of procedure 4.3.11.

Concern 3 Paragraph 3.2.7 of procedure 4.3.11 Rev. 7/11/80 requires two tests studs be wefded in the same general position on separate material.and pass the required 30 bend test prior to the start of each days production.

The checklists do not adequately address the documentation of the preproduction test as required by the procedure and AWS Dl.1-75.

How does QC assure preproduction requirements are perfonned and documented to demonstrate compliance to the procedure requirements ?

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PRE / POST AUDIT ATTENDANCE RECORD Audit Location:

Braidwood Nuclear Power Plant Date:

8/15/83 Audit Number:

CQA-368 ATTENDEES NAME COMPANY TITLE

  • Thomas D. Vogt Comstock Engineering, Inc.

QA Engineer

  • Ernest C. Yockey Comstock Engineering, Inc.

Eastern Region Mgr.

QA/QC Services

  • Dean A. Hoffer CECO QA Engineer
  • Frank Rolan L. K. C.

Project Manager

  • Irving F. DeWald Comstock Engineering, Inc.

QC Manager

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PRE / POST AUDIT ATTENDANCE RECORD Audit Location:

Braidwood t;uclear Power Plant Date:

8/17/83 Audit Number:

CQA-368 ATTENDEES NAME COMPANY TITLE

  1. Thomas D. Vogt Comstock Engineering, Inc.

QA Engineer

  1. Ernest C. Yockey Comstock Engineering, Inc.

Eastern Region Mgr.

QA/QC Services

  1. W. A. Gardner Comstock Engineering, Inc.

Central Region Mgr.

QA/QC Services

  1. D. A. Iloffer Ceco QA Engineer
  1. L. J. Tapella CECO Project QC Coordinator
  1. Frank Rolan L. K. C.

Project Manager

  1. I. F. DeWald Comstock Engineering, Inc.

QC Manager e

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