ML20215B259

Rev 4 to QC Procedure DCP-2, Silicone Room Installation. Partially Withheld Related Info Encl

ML20215B259
Person / Time
Site:	Diablo Canyon
Issue date:	11/01/1984
From:	PACIFIC GAS & ELECTRIC CO.
To:
Shared Package
ML20215B173	List: IA-87-128, Responds to Telcons & 870121 Meeting W/Pp Narbut Re Concerns Over Practices at Plant.Encl Statement of Concerns Will Be Addressed During Upcoming Insp ML20215B169 ML20215B202 ML20215B243 ML20215B259
References
FOIA-87-128 DCP-2, NUDOCS 8706170274
Download: ML20215B259 (112)

Text

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>. . 4 PACIFIC GAS AND LLECTR'!C COMPANY 'I .

GENERAL CONSTRUCTION )

DIABl0 CANYON PROJECT l 1

yaktiit (DH1HOL PHpCLDUHL Procedure DCP-2 Rev. 4 TITLL: Sil]Sotte,.1,qom int},allotigit _. Page 1 of T l

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T 1.0 RQP( P co 1.1 This procedure outlines the method, requirements and responsthilities

'n for the installation, repair, and inspection of sllitone foam, lead-impregnated silicone foam, damaynd flrostops, flama barriers and l O radiation barriers.

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te 2.0 B,L5 PONS 181LITY

?.1 The Senior Site Representativo is responsible for implementing this procedure.

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?.? The Lead Electrical Supervisor is respoulblo Ior nulgning the  !

construction work, and for providing the construction installation a requirements per the latest approved design dorunents.

?.3 The G.C. Qual ~ity Control Supervisor is reponsibin f or assigning qualified Q.C. Inspectors to witnem work and review documentation..

l l .4 In all areas of this procedure, supervisory personnel who have been assigned responsibility for a task have the authority to delegate perf ormance of that task to subordinates, this delegation shall be by written job description or by specitic written assignment.

3.0 APPLICATION ,

3.1 This procedure applies to all tire stops using stitcone foam, lead-impregnated silicone foam and flame barriers.

8706170274 870611 PDR FOIA PDR I

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4.0 PROC 100RE .

4.1 New installations, repairs and alterations to silic' ) foam firestops, flame barriers and lead 4 impregnated rr' lon barriers shall be identif ied.on a Silicone f oamh tre Barrw inspection l Report (Diablo Canyon form [-21)~  !

4.t.1 The t.ead L lectrical supervisor shall assign the f orm a serial number, enter the number in a log, file a copy of the fonn, and f orward the oridinal to the individual responsible for performing the work.

4 . .' Prior to installing alther type of sillrone foam, the areas where g f oam is to be applied shall be c leaned and a dam constrin led.  :

Il 4.2.1 For penetrat ion and rable t ray, the dam shall be runt,trurted

$ as follows:

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.f1 gn 4.2.1.1 All doming malet ial to be cut, shall be marked for r 1

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• cult Ing singhtly larger (+1/4 in. for blanket type J and st/tt" in, f or board-type) on all edges. Ihis '

,,, will f ai llitate a snug fit of the ilaming materials  !!

in the penetration and help prevent leakage of c, 11 auld materials from insido.

4.2.1.2 Care shall be taken while rutting and Ittting not If to bcnd, crack, break , or mar the daming materials.

, 4.2.1.3 Damming material f or floor ponotrat ions shall have anchors inserted through the houd-type and c -

blanket type doming materials spared one anchor '

f or every 3b *.quare Inch sect ion of daming

. , material, using a minimum of two anchors per

'3,.

C) section.

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4.2.1.4 Cables shall be separated in penetratlens, as much J'

. as prac t Ical, and looso I ther daming material i

shall be packed tIqhtIV betwoon cables. The dam shall be one inch thlik and even with the rest of the damming motorial.

4.2.1.5 The board-type damming material. shall be fitted into the penet ral ton l lrst . Crevices around the edge of the penotrat ion and bolween sections of the board-type damminq materials which unevenly butt up against each other shall be tightly packed with loose fiber daming material, All joints shall be covered with topo spanning the entire length of the penetreation plus 10 inches on each end. Tape shall be on the outside surface of the da ming materials only.

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4.2.t.6 t iemible blanket-tvpe daming material shall be t inserteil into the rethaining open space at the top of each dam for wall penetrations. Crevices around the e(lues of matertels used for damming shall be patkod with loose fiber daming material and taped to stiengthen the overall dam.

A 4.2.1.7 Whers lioxing is requireil to extend the overall thhkness of the penetration seal, a wooden box

.S$ shall he const rurteit around the penetration. The Ec

.j' ins hle dimensions of the hnx 1. hall be approximately tt im bes wider atul longer than the penetratlon.

renter the hos around the penetration and tape all

.loints thoroughly using topo wounit (nepletely arounil the bos several t imes.

Haniling matorial may be subst ituted f or tape.

Secure the lion to t he I innr us tny ilur t tape, the box shall be lined the entire thickness (depth) of m the seal with board-type damming material.

9- a.2.2 For conduits, the dam shall be constructed as follows:

l O 4.2.2.) Conduits and sleeves in walls shall have 1" of loose fiber-type doming material stuf fed between l s all the wires and the wall of the conduit and/or

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. t ts sleeve to a total depth of approximately 9 inches trom the end of the conduit or the condulet

+A opening. (The entire thickness of the seal will jig . ,'

only be 9 inches; 1 inch of damming material, and a wy' -

minimum of 8 inches of solid silicone foam). After

' the dam is in place, tape the end of the conduit

[', forming an outer dam. An open space approximately 1/2 inch shall be left at the top of the dam to 74 O , dispense the foam.

4.2.2.2 Conduits and sleeves in floors shall have loose fiber-type damming material stuffed between all the wires and the conduit or sleeve walls for a total thickness of 1 inch. If possible, the damming material shall be stuffed into the conduit a minimum of 8 inches below the floor surface level.

In sleeve 5 or conduits that extend more than 10-12 inches. damming shall be stuffed a minimum of 8

. inches down from the end of the sleeve or conduit.

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W 4.7.?.3 Conduits and sleeves in ceilings or cabinets shall

,1 have Inose fiber-type daming material stuffed between all the wires and i:cnduit wall a minimum of 11 inches troen the anil of the sleeve or conduit.

lape shall be useil as a dam placed over the bottom enti of the fondutt or sleeve. An opening of approntmately 1/? inch shall be made in the das for illspens ing t he t oam.

4.2.3 Dams shall be inspui t ed t ot iompilante to the above requirements prior to installing roam, lhe inspection shall be documented on the 511100n, f oam/l lame llarrier Inspection l q Roport (Diablo l'anyon Form I .?l)

D.' 4.2.4 icor mechaniidt penetrations, f ollow the directions provided

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on PGantil Ordwings #054117 and #054176 and steps 4.2.1 through 4.2.1 I of this procedure.

4.3 The silicone foam shall'be mixed in accordance with the following, A as applicable:

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4.3.1 Due to the development of hydrogen gas during foaming and curing, the f oam shall not be mixed or applied near sparks or open flame.

4.3.1.1 Special forced air ventilation shall be provided if areas of installation have less than two cubic feet in of free air space per pound of liquid mixture being foamed.

"7

" 4.3.2 If tubes of foam are used, the two components shall be mixed

. until the mixture is uniform in color (approximately 30

,,,, seconds).

O 4.3.2.1 A small piece of foam shall be removed from the-4 fire stop and inspected. Foam samples shall be compared to vendor supplied photos #1, 2 and3 for cell structure and #4 for color (Attachment 7.3).

These are the acceptance limits, smaller cell structure and darker color are acceptable. If a penetration barrier is composed of good cell structure for 75% or more of its volume, the installation is acceptable.

4.3.3 If automatic dispensing equipment is used, parts A and B

. shall be thoroughly agitated prior to use. The equipment shall be checked a minimum of once daily, prior to startup, to assure a proper ratio balance and thorough mixing. No other ingredients shall be added to the mixture unless specifically approved for use.

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page . .. r , 7 4.3.4 1he comp.cnts for lead-impregnated silicone foam shall be hand mixed. The amount of lead powder to be added shall be determined by test to attain the density value required in paragraph 4.4.2.4. One half of the amount of lead powder sh411 be added to equal parts of A and 8. The parts shall be agitated separately to evenly disperse the lead, then i mixed until a uniform color is obtained. A catalyst may be I added to adjust the snap time as required.

4.4 If automatic dispensing equipment or h'nd-mixing a methods are used, a small test pour shall be made at least once daily and when a new lot of maternal is added. The test shall be made in either a 1.ily cup l 761.T6 or a five-sided metal box measuring 3" x 3" x 3". The following tests and-insperttons shall be documented on a Silicone Foam Test Report (Diablo Canyon Form QA-8. Attachment 1.2).

4.4.1 The snap time shall be between one and three minutes long for silicone foam, and less than 30 minutes fnr em lead-impregnated s t itcone foam. Snap time is defined as the

.n time from mixing to when the foam starts rising.

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. 4.4.2 The density shall lie determined by the following methods:

r-) 4.4.2.1 The toam shall be trimmed flush with the top of the j container after the sample has cured a minimum of IS minutes for sillrone tonm and 45 minutes for lead loam.

4.4.2.2 The density in pounth per rubli toot of the sample taken in the Lily iup shall be romputed by e subtracting the gram weight of the rup (b.t10 grams) from the total gram weluht of the sample and mult lplying the result by 0.?ll'4.

O 4.4.2.3 The density in pounds per cubir f oot of the sample taken in the metal bin shall he computed by multiplying the gram weight ni the sample by 0.141.

4.4.2.4 The density of silicone foam shall be 17 pounds per cubic foot or greater. The density of lead foam ,

shall be 150 to IHO pounds per cuhtc foot. 1 4.4.2.5 The scale used to measure the welght of the sample L' shall be calibrated in accordance with the 4-~

requirements delined in General Construction Quality Assurame Program Procedure GCP-10.1

" Control of Measuring and Test Equipment".

4.4.3 The lead-tree foam samples shall be inspected per paragraph

, , 4.3,2.1 above.

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4.5 The silicone following foam shall be installed in accordance with the requirements:

4.5.1 the Itquid mixture shall not be continuously added for a time interval (shot) that exceeds 30 seconds for silicone foam and 15 minutes for lead foam.

l 4.5.1.1 As site permits, small fire stops shall be  !

completely loam sealed with one shot application.

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4.5.1.2 large tire stops that require several separate ij i

shots shall have a minimum of fifteen minutch curt I time fielween each shot for silicone foam and 8 hours9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br /> f or ledd foant.

, b 4.5.2 Pipe penetraltons shall be foamed or directed in drawings

- J 054176 and (1$4111 As directed by these drawings, pipes

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& exhibittny avtal movement in the penetration shall be

,. ; lubricated prior to placement of foam. .

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[ 4.5.3 Changes. modtt trations, or addition of new penetrating '

se components shall he perf ormed in accordance with the requirements of this procedure.

4 . 'i . 4 Foam shall not he installed when the temperature of either liquid is holow $$*l or ahnvn titl't . {I 4 . 'i . 5 The foam shall be allowed to sure a minimum ut 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> '

prior ta removinn ihe dansning torms.

j fa 4.4.5.1 Itre retardant dansning f orms shall he telt in place l

and shall havo the tape removed. {

,l o 4.5.6 After a minimum of .'4 hours4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br />. the itro stops shall be I

. inspected for tightnev. of seal. Ihose areas which exhibit gaps or cracks greater than 1/t1 inch wide or greater than

@,?' one inch deep shall be reapired with Dow-corning 96-081 adhesive / sealant to a minimum depth of one inch. The inspection shall be documented on Form 0A 21. Attachment 7.1.

4.5,7 When the fire stops or barriers have been repaired, the method of repair. date and time poured, lot numbers of the silicone foam. requirements, date inspecttad, and signature of the inspector shall be entered en the form. The log i

shall be updated to indicate that the item has been repaired, l

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h 4. fi The installation of flame barriers on cable trays is to be done in 7 accordance with drawing 050029. The material to be used in 1/2" 4"

marinite "Al Panel" or 1/2" knowool N board of ceramic fibers and i j flamemasttc 71A or engineer approved equivalent. 4 d a.6.1 Flame barriert shall be inspected when completed to verify j(2,; ,

comptIanse to detatis in drawing 050029, i i j

M's b 5.0 QOCUMENTATION -

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\ j a 5.1 Documentation required by this procetture shall be filed by Quality 3.',

y Control for disposal oi- inclusion in the Records Management System.  ;

5.2 A minimum of 10% of the sample tests shall be witnessed and '

documented by Quality t,ontrol; the remainder shall be witnessed and documented by the A u tuned inspector. A minimum of 10% of all fo4m O installations shall be inspected and documented by Quality Control.

, the remainder shall he inspected and documented by the Assigned l N Inspector. All test and inspection reports shall be reviewed and initialed by Quality Control and shall reference the number of this t Work Assignment Sheet.

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6.0 REFERENCES

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t,3 6.1 Dow corning Application Guide Spestitcations for 3-t048 Silicone RTV Foam Penetration Seal System. .

i 6.2 Ord Corning Sylgard 110 A & B Stitcone Elastomer information &

M instruction Sheet.

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6.0 Dow Corning Application Guide Specification f or 96 081 o Adhesive / Sealant.

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l.0 ATTACHMENTS 7.1 Diablo Canyon Form E-21. S11trone foam /Flamo !!arrier Inspection Report 1.2 Diablo Canyon Form QA-8. $11trone Foam test Neport 1.3 Dow-Corning Color and Cell Structure Comparison Photos (originals on

-file with the original of this procedure) 0106m . . . .

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.. . PACIFIC GA3 AND ELECTRIC STATION C0dSTRUCTION' DEPARTMENT,,g I

OIA81.0 CANYON PROJECT

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INSPECited REPORT ,

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Type of work: New Work ( ) Repair [ l Firestop Cable fray Tray No. <

Flame Barrier Conduit Conduit No.  ;

Radiation Barrier Wall filockout Floor Blockout i A __

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16 1"3 Ofscription of work:

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_ , . , _ l0AM CONSTRUCTION 4.2 l l _

t i 1 58mple Number l SILICONE FOAM INSTALLA110N 4.b l l In1Dected by I I h,;.  ; "@5 i l CELL STRUCTURE 4.3.2.1 l

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DIABLO CANYON PROJECT 9~

UNIT 1 ..

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$ DIABLO Pn001.t" CONTROL'$HEET ',' '/,

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• 6 OATE June 1, ten. ,..

A ORIGINATOR _R W fi. Cook

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SYSTDi W/A 4 MEM10N: '

Myron Leppke/J. Gibbs 5AN/TASU_ A,/ A '

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PROBLEM DE3CRIPTION:$(1jeen, pg,, _

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configuration accc.-ding to the Dow Corning representative.Th '

BThis configuration is being used on several heat traced Qhedieselgeneratorstacks. .

pipes main steam lines and I.

'Please verify that this configuration is acceptable.

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CEL. tid - IN Ott1% 9{LCEn, to.t% -F12% yyuueper(Me tv O .

Response Required By_:_

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Date Reviewed By;_

Approved B [ fcc f d, ,

DATE l Refiqrtnt gnagne,p '

Igj PROBLDi RESPONSE L '

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1) 1/19/84 Internal Bisco mem documentino inhial concerns with the silicone foam quality in penetration Non. 26tl, 68, 10, 13 H .

100,117,122,133,134,105 and 140, Also identitled ter)y contacts with Ben Harvey of Plant lhorpe and Bob teach, ten Dukes and Ron Harris of PlGC.

2) 1/26/84 - Internal Bisco memo Survey of adttitional penetrating items in j aren EW-1, elevat ton 05'-0", including Nos. 216, 218, 222, 234 and 236. Informed in meeting these would not require 81sco g pressure seals. i j to l

O 3) 2/24/84 - Bisco . letter to Frank Germano, San Francisco - Attached Bisco internal memo. "Diablo Canyon Closing Report," which detailed concerns in the following: Unacceptable foam cell structure, 1

excessive shrinkage, penetration seal design, lack of fire seals and lack of sound QA practice.

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4) 3/16/84 - DCP 10M G. H. Moore to D. A. Rockwell - Transmitted Bisco letter l of 2/24/84 to site for investigation and action.

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5) 3/17/84 - MVR E-2824 written on poor cell :tructure in penetrations 238, 117 and 122; shrinkage gap found in penetration 238; and no fire barrier in penetratlon 216.

6) 3/11/84 MVR E 2825 on foam pushed out of penetration.

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4) 3/23/84 - 1R6 co'vened on NCR.

lhe Il penetrat%0ns identified by SIBCO . ...

(letter $ated 2/24/84) to b9 thlpected. Repair /rtpleC# 48 needed. . k.N$. . $ l t

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3/26/84 - DCP ION from Glascock to MotkWell + Addrettet the inspettlen &E*iOf M.' . 3 .

the 19 penetrations, the findings and the actions taken. '

10) 3/27/84 -

TRG held to assign action items for further investigation: '

f ,.

' Removal of 81sco boot #96, mechanic 4) penetrations, responsible i companies, h

11) 3/29/84 - @:h TRG held - Inspection results presented.

O . Roccamended additional ;GMAjf.

inspection of 25 penetrations each done by Chemtrol. Tech-Sil. : a -

and Plant-Thorpe.

Le

?

, 12) 4/6/84 -

1RG - Second survey results presented showing potential significant problems of shrinkage and bad cell structure.

O

13) 4/13/84 - 1RG - Presentation made by Dow Corning representative of new acceptance standards for cell structure. shrinkage and gaps.

c. ,

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, '*3 TRG toncluded that Bisco criteria was outdated and that DCP-2 should b- J y,c,3y

'whed to include the new criteria from Dow-Corning. .,

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s Bisco identified penetrations reinspected to new criteria, no ,

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out-of-tolerance condit ton found.

14) b!3/84 - - )h.w%;0 aw Letter to J. Gibbs from Dow-Corning - Written direction from .-

SQ .vj.p" Dow-Corning for new acceptance criteria.

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= = , T .ie DEPARTMENTAL CORRESPONDENCE o,y _ 1/19/84 suesser FLOOR SLAB 8.5'- 0" Page 1 of 2

) .ro JOB FILE NO. 3:69 Das. v DIABLO CANYON ,

y, Lance Simms o,.y _

Wednesday 1/18/84 -

i 9 After lunch BISCO was informed that the small penetrations on the floor alab were released an.1 could be booted. i.e., plant Thorpe had completed requirements hadinstallino been met.foam and all applicable quality assurance floor elab and instructed Marie During that afternoon I stopped by the Don Lat'rabeeStockness to NOT clamp the boot Oh penetration No. 96.

j

• in No. 96 was representativa o f theinformed me that the cell structure g

that plant-Thorpe had installed in all cellofstructure the smallof the foam penetrations that stab,

e. foam in penetration No. 96I then informed Ken Dukes that he should go look '&t the on

penetrattons were in fact released It wastothen BISCO. reiterated to me that those clamped on every released boot except No. 96.

Consequently Merle O

Thursday 1/19/8 4 -

In the morning Ken Dukes takes the following people to observe the cell structure in penetration No. 96 with him to Ben Harvey - Plant-Thorpe General Foreman e, Bob Beach - Q. C.' Man - PdhK Klectrical Department who is responsible for foaming Q. A. Program.

C) These people tration NO. viewNo.

96 and the93 foam(No.and Bob tteach rejects the foam in pene-Plant-Thorpe begins the removal of_the93 had not yet been released to BISCO).

sends Bruce Kerby down to adjust the foam in these penetrations and a good cell structure. 18FMP gun so that it will produce trained B.P.C.) at S.O.N.G.S. he was certified to pump foam .

at S O

. . . . for I

N C S(Bruce Ke Later that morning Ken Dukes tells me that penetrations 93 or 96, but that Bob Beach had not released released. the others on the slab had been g

of poor foam in the plant.Right af ter (unch Ken Dukes directs me to show him som where seals. bad foam was removed to allow the installation of the pressureI direct Don goes into the plant and finds the following: y*

v4 Scraps of foamfoam unacceptable on the cellfloor below penetrations No. 68 & *10, structure.

Scraps either No. of foam on the floor of the soffit, should be from 117 or 122 unacceptable foam cell structure

'

• Scraps of foam were found on the scaffolding on the 73'-0" elevation.

from the removals of either Nos.These had unacceptable cell structure and were 133, 134, 135 or 140. ,

t. .

DEIPARTMENTAL CORRESPONDENCE ~C ~ 'j sussacy_

Days 1/19/84 i FLOOR SLAB B5'-0* l CONTINUED To - -

• PAGE 2 of 2 Derv =

o ,.y -

The gang abovebox area. scraps were shown to Ken Dukes when he came to 32SCO's worked as the Q. C.

Ken brought with him Ron //end of PG&E who had Ren then asked to see some examples that were still Iin placeInspecto .

asked if he wanted us to remove a boot from the floor slab.

This revealed unacceptable foam cell structure.I directed . 100 an insula agreed to remove thatthethefoam.

foam was no good, Ken directed the P. T.All people there .

Insulaters m .No(andalso no Q.observed C. visual a void that was inspection't) and acaus.admassivebyca poor foaming technique

• • in the blockout in the safety injection pump room.se et femm shrinkage showed this blockout to Ken Dukes, John Gibbs, I had previously O Al Freeman. Bill Slover and Poor foam cell structure was also observed in No. 238.(10 days later n .

g Foam shrinkage was also observed in penetration 265, when I last saw Ken Dukes area in search he had of D.taken the samples of bad foam in to the " Bullen" A. Rockwell. P e9 Friday - 1/20/84 -

- Ken D%es not on site. I do not know concerning this matter. if a H.C.R. has been writt en

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DEPARTMENTAL CORRESPONDENCE 046406 oays 1/26/84 Sunnct 60 NEW PENETRAgg -

To- JOB PtLE 3269 - DIABI,o Ogggg g,,, y ,

Faou LANCg gyggs Ose T -

On January 18th while looking at Plant,-Thorpes copy of the fire protection drawings, I make a statement to Ken Dukes that "we may of missed come conduli s" that are next to the floor alab.

On January 2 4th, Ken Dukan told us following sketch is a stila view of t.hene to survey these new items. The penetra tions t

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O The BISCO survey revealed that some of these penetrations were full 1 depth high e'ensity material (although some of the penetrations had substanti: voids in the material) . BISCO's Engineer Henry Tracewski reported tnat air could be felt rushing into tho EW-1 area through some of the following 4" open ended conduits:

Nos. 216, 218, 222, 234 s, 236. These are the newly assigned penetration numbers.

On January 26th a meeting .<as held in which I was is*ormed that B'43C0 would not be installing pressure seals in these new items. (refer to attached meeting notes).

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blSCO 1/26/84 10:00 Meeting hrend

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Industrial

, John Gibbs sore nnpe, . anon servieee, gas, noose Bill Slover otnseersoo Bob beach " "' 888 * *'*"' "

Randy Cook

~'

1. Lance Simms Henry Tracewski Ken Dukes re. below grado on the 85'-0" elevation of the CW areaPresentat .

arts e John Gibbs asks electrical department installed. if they have foam anals

,, They respond that all penetrations that require a fire seal have been installed from the opposite side ofathe w ll g .

The electrical department confirms that open on the 85'-0* elevation (chemical I.ab), some of these conduits elevation (480 volt switchgear room) . and on the 100'-0" ,

tn John diamond Gibbs plate states steam pressure. that covers will*

theadequate offer combination protection of aagainst foam e seal and th 1

- Sisco throughpoints some out that conduits.

of these air can be felt rushing into the CW area' O

Bill Slover of the work.asked when Bisco would ba completed with the remainder Bisco saturday Stated ni that they would be completed with production y b that time. ght, but that the paper work would not be done at John Gibbs thanked Bisco for performing the survey of thes conduits, but that no Biscoseal would be needed. e i

John out in Gibbs then the field saidthese to see that he would meet Bcb Beach ando Randy Co k penetrations.

confer with John Gibbs and Bill Slover. Bisco was excused from the mee '

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3 February 24, 1984 brand industrist soevdeos. lee, im renamenee sww

) pere ringe, nhen 80088 43th M 90s0 twa ser ar areat saw Mr. Frank Germano MC45-23 Pacific Gas & Electric Company c/o Bechtel Power Corporation P. O. Box 3965 -

San Francisco, CA 94119

Subject:

Diablo Canyon Nuclear thnita 1& 2 BISCO Job 83269 .

Dear Mr. Germano:

p.

As promised, we are enclosing reports prepared by DISCO

.. employees who worked at Diablo Canyon.

O These reports reflect the concern many' of us have conveyed to you what we consider f aulty workmanship associated with the installation of silicone foam fire barriers. Some of the existing barriers are based on improper designs, m existing materials have been improparly installed. seals

- presently being installed are incorrectly designed and the actual application of siliconom down not meet manufacturer's standards. .

We

- have met repeated opposition while attempting to convey this information in a sincere cooperativa manner. It is our O belief that some of thoso problemn have been recognized by Bachtel construction poopin on aits since they attempted to hire every BISCO employee except our Pro ject Manager. This attempt continues to the extent of calling those same employees already reassigned to other 01:100 projects. If the concern for proper workmannhip is of this magnituda ther, the ethical approach would be to hiro tho company who dnvaloped the techniques and trainad their omployees in tha specialized nature of this work. I cannot non the loqic in PG&E retaining a contractor to inntall fico barriers who in able to perform this work must pirato experinnend peoplo from another company.

If you with to dincuns any or tho information on the reports please feel froo to call Al Frcoman or mycoif.

Sincerely yours, B

, _INC.

9 AL

/ p' '} VICES __ _

clayton . Br esident BISCO Construction Group CWB/vo - Enclosuros cc 3111 D. Cichy, L. Sim g A Fgm4n

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DEPARTMENTAL CORRESPONDENCE Dars 2/23/84 Suquecr~

DIABLO CANYON CLOSING REPORT PAGE 1 of 3 h Clavton W. Brown _ osy, Park Ridge Peo Lance Simrns - _

o,,,_ Diablo Canyon in the1 course Unit Auxiliary ofBuilding.

installing pressure seats in a portion of the i

{

several oonditions were observed that i made me barriers.

seal fire question the integrity of Diablo Canyon's existing penetration These conditions include: l Unacceptable sitteone foam cell structure Shrinkage of ettieone foam seals Questionable penetration sent desion control

-to No fire seal in place ca Lack of sound quality assurance practices i

• • As the above five conditions are generalities, o my the concerns followingabout Diablo canyon's penetration seatino program withI further supplem UNACCEPTABLE SILYCONE FOAM OE1.1. STRUCTURE M WHILE INSTALLING PENETRATION SEALS, IT WAS

. OTTEN FOAM SEAL NECESSARY REMOVED. TO HAVE 3" OF THE EXISTING THIS WOULD THEN ALLOW TllE

. e. INSTALLATION ON MANY OCCASIONS, OF A BOOT OR BISCOSEAL PRESSURE SEAL.

I WOULD RECEIVE WORD FROM BISCO'S -

QUALITY REMOVED. CONTROL INSPECTOR $ THAT

• BAD FOAM" WAS BEING O

WHO WOULD TELL ME TO IGNORE THE PROBLEM TINUE TO INSTALL THE PRESSURE SEALS. BY THE TIME I WAS REQUESTED TO POINT OUT THESE PROBLEMS, BISCO HAD COVERED ATTACHMENT "A" THE FOAM WIT!! A PRESSURE SEAL.

LISTS ONLY THE REMANENTS OF CONSEQUENTLY, , BAD FOAM THAT 1/19/84.WERE OBTAINED AND TURNED OVER TO Tile CUSTOMER ON PERHAPS MORE IMPORTANTLY, ATTACitMENT "A" DESCRIBES THE EVF iTS AROUND BISCO DISCOVERING UN-ACCEPTABLE FOAM CELL STRUCTURE IN MANY NEW SEALS THAT WERE INSTALLED AND RELEASED TO BISCO. THIS INCIDENT WAS SIGNIFICANT IN THAT IT REVEALED ET*.NER A NON-CON THE TYPII OF WORKMANSHIP THAT CAN B SILIc0ME roam suRT m cr

• THE WORST CASE OF SILICONE FOAM SHRINKAGE WAS ODSER A

ROOM.BLOCK-Otfr IN THE WEST WALL OF THE SAFETY INJECTION PU S11RINKAGE WAS SO BAD THAT YOU COULD STICK YOUR MAN INTO THE CAP BETWEEN THE TOP OF THE FOAM AND THE CO

- THIS WALK. PROBLEM WAS SHOWN TO THE CUS*tOMER ON OUR 1/9/84 NO CORRECTIVE ACTION 000 . . HAD BEEN T m4 -e- mmi. 4. .

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'a 46406 DEPARTMENTAL CORRESPONDENCE 1 DAvs 2/23/84 Suasset DIABLO CANYON CLOSING REPORT - CONTINUED PAGE 2 of 3 To D w T-Fasons Dev QUESTION ADLE PEN ET RAT ION SEAL DESIGN CONTROL DURING THE MONTil OF JANUARY, THE UNIT I DIESEL GENERATOR WAS STARTED.

CONSEQUENTLY, THE SILICONE FOAM PENETRATION SEAL THAT WAS INSTALLED AROUND THE DIESEL GENERATOR EXHAt'ST PIPE BEGAN TO SMOKE.

THIS IS AN EXAMPLE OF PIPE TEMPERATURE NOT BEING PROPERLY CONSIDERED WHEN THE DETERMINATION OF PENETRATION SEAL TYPE WAS BEING MADE.

4 PIPE MOVEMENTS AND TilEIR AFFECT UPON PENETRATION SEALS I$

ANOTHER AREA OF CONCERN.

O THE PIPING THAT PENETRATES THE NEW FLOOR SLAB ON Tile 85' - 0" ELEVATION SERVES AS AN

.. EXAMPLE OF PIPE MOVEMENT NOT BEING TAKEN INTO CONSIDERATION WHEN THE LEAL TYPE WAS BEING DETERMINED. SOME OF Tile PIPES n ARE GOING TO HAVE 1/2" OF PIPE MOVEMENT AND ONLY 8" OF SILICONE FOAM WAS INSTALLED AS A FIRE SEAL. DOES Tile PLANT HAVE THE TESTING TilAT CAN SUBSTANTIATE THE USE OF 8" OF SILICONE FOAM IN MECllANICAL PENETRATIONS?

M

. PIPE MOVEMENT CRITERIA HAS OBVIOUSLY NOT BREN TAKEN INTO CONSIDERATION OR SOMEONE TilINKS Tl'AT SILICONE FOAM CAN r WITHSTAND FOUR TIMES Ti!E AMOUNT OF PIPE MOVEMENT TilAT BISCO WILL WARRANTY WIT!! TilAT TYPE SEAL.

NO FIRE SEAL IN PLACE O

ATTACHMENT '3" PERTAINS TO Tile MEETING IN WillCll BISCO WAS INFORMED THAT THAT NO SEAL WERE ADDITIONALLY FOUNDWOUI.D DE REQUIRED IN Tile 60 PENETRATIONS IN Tile PRESSURE DOUNDRY.

RISCO POINTED OUT THAT AIR COULD BE FELT RUSHING INTO THE ROOM THROUGH PENETRATIONS NO. 216, 218, 220, 234 and 236.

AIR DOES NCfr RUSH THROUGil FIRE SEALS. CONSEQUENTLY, I BELIEVE THAT NO FIRE SEAL IS INSTA1,1.ED IN TIIESE PENETRATIONS.

LACK OF SOUND OUALITY AS$tlRANCE PRACTICES P=i THE PENETRATION SEALING PROCEDURES AT DIABLO CANYONgEITHER DO NOT REQUIRE A FINAL VISUAL INSPECTION OR THE INSPECTION NAS FROM BEEN BAD. PERFORMED BY PERSONNEL WilO DON'T KNOW GOOD FOAM N

THIS PROBLEM WAS MOST EVIDENT IN THE UNACCEPTAB S FOAM CELL STRUCTURE THAT WAS INSTALLED ON 1/17/84 IN M THE FLOOR SLAB AND WAS STILL IN PLACE AS OF 2/1/84.

BEYOND TIIE BREAXDOWN OR LACK OF QUALITY ASSURANCE FROCEDURES THAT ALLOWED THIS TO HAPPEN, IS THE PEP. SON WHO INSTALLED THE BAD FOAM. MR. GEORGE WALSH, OF PLANT-THORPE HAD NOT RECEIVED

• PROPER TRAINING. MR. WALSM TOLD MR. DON LARRABEE, OF BISCO w QUALITY C,OgyROL, THAT *NO ONE EVER TOLD RIM WHAT TO LOOK 2CR AS FAR AS'THE CELL STRUCTURE SHOULD LOOK LIEE".

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DEPAR l' MENTAL CORRESPONDENCE'

- nays _ 2/23/84

'suasset_ __

DIABLO CANYON CLOSING REPORT - CONTINUED PAGE 3 of 3 Ta -

owv--

Paoed -

Owv -

BASICALLY.

BISCO QllALITY CONTROL POINTED OUT THE DIFF BETWEEN DOW CORNINGGOOD CKLL FOAM ATRUCTURE AND COMPARISON DAD FOAMCHART. BY SHOWING AL WHAT OTHER AREAS dr THE PLANT HAD MR. WALSH STRUCTURE ID0KKD LIKE7IN PRIOR TO DISCO MllOWIN ON 1/16/84 IT WA:t' BROUGitT TO MY ATTENTION THAT BIS A HAD BEEN ITTILI*ED DY PLANT.TilORPE IN INSTALLIN THIS SEALSTILL HADDE BEEN TURNED -OVER ASTHE BEING FIRECOMPL e PROBABLY IN PLACE TODAY, HAD NOT MARSR U OFFICE DISCOVERED TilEIR FIELD INSPECTIONS. THE IMPitot'ER INSTALLATION DURI ACAIN TilIS WAS ANOTHER CASE OF C A SECOND SEALING PROGRAM.PARTY FINDING FAUI.T WITil THE EXISTING P

SUMMARY

y

.- THE PROBLEMS OF BAD CELL STRUCTURE - FOAM SilRINEAG VOIDS US RIGRT ININTHE SEALS FACE. WERE BUT Tile MOREEASY TO SPOT DECAllSE TilEY W e

WITH NEGLECTING THE AFFECTS OF PIPE MOVEMENT AND TEMPERATUkF UPON AFTER THIS ?LANT BEGINS SILICONE FOAM SEALS WILL O OPitRATION.

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INTEA0fflCE MEMORANDUM 1

DiabloCanyonProject '

PACIFIC GAS ANO ELECTRIC COMPANY BECHTEL POWER CORPORATION l T. MlW IWkwull cm M uch 16, 1984 a

s .., G. H. Ptere mw ~

o, Pttject Enqirwet - that 1 3,%., Penetrations a, 45/10/C09 ,.,,,,,,,,,, N'M 1 Attactml is a egy of Itimo' a = lnt tnr fim Mr. Clayton W. 3rawn to F.M. Cermana datM r%btwtry ,*4 l '111 4 .

l l

e 'This letter documnnts the nownin that Blmv had previously identified  ;

while instaning the pressui. tvint y penetration seats at Diablo Canyon. l

• Per our discussico, and prevtoun mrtwspwinnew (sita nuoting minutes and l telecons) an of those cornum have been twviewed by field Q.A., NPO firs  !

narshal, Gere.ral Constructhu afst thim Orfim 1%Jineering. All parties j ngtwed that the concerns ha.1 been nAtressed sist 0.A. requirenvints twt been n cotplied wift:h.

l In order for us to prepare a fonml temwne to t!w ninco lettet', please l 8 prepare a draft written re:qmno npnettli ally addreaming all itene identified in the Bisco lotter with the amvption of the item identified as "Questianahle Penetraticn Goal Donton omt. tot." Dy a copy of this letter.

I am requesting that E.C. Onnnell atxt 8. cittnis res,ws! to that concern.

m General Corstructicn's responso sint1d reflect the cnneurtwnce of Q.A. as well as NPO.

. P n.

RC: sip G.11. POORE Response Required: Yes, by March 30, 1984

Attachment:

Lettor from C.W. Brown of Bisco

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cc: Schitnist w/attachtents "T" -

• s ECO:nnoll w/attachtent J1hanning w/o attachment R.Wmberry/RKfout w/attachtent SMSkittfore w/o attachtent R'Arxbrson w/o attachtent *W 4 Jnhiffor w/o attachtent imsci:0::i 000 13111

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0ZC MINOR VARIATION RDORT 'A '[h.biY

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O 5 'OTablo Canyon l E' 1 2552 ' 1

• 1 owe.i[.,

G. Electrical c.at.ners Am.en No. m.ns N/A uva na. E-tSt4 s as conv $e ceawwie, Ov "*"*

@ ** gg OGSCRIPvtoN oP DeScREPANCY i wn

.scr; Cell structure, shrinkage of silicone foam barrier in penetration, and no fire 2nor emit structure was found in 3 oenetrations. Bisc@ oenetration nos. 238, 122, 117.

P Silkone foam shrinkage was foiind in penetration 26B (Bisco No.) 1/4" to 1/2" gen

q. , , , was'found. No fire barrier was tnund in penetration 218 (Bisco No.)

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,, '"** '7/,M q , LP a, ( l 3/17/84

, yS-F,stT6014 n Remove silicone foam that has coor cell structure and replace with good silicone foam.

[ Fill (ap in oenetration that has silicone foam shrinkage.

O Install fire barrier in penetrat ton 21f1.

o All work to be done oer DCP.2.

4 This MVR is superseded by NCR DCO.84-RL N004, tn.

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nosht:PicATioN 6.a ua.i n.uz.; p -

Diablo Canyon N. I am u. .2552 1 1

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~ DGSCRIPTION OP Ot9CKtPANCY so.m \

Silicone Foam' Damage i s .ame J

1111 cone foam was cartly pusheMt_jjf a penetration in the west wall of the safety

> ts jection pump room which degraiteit t he fire barrief.

7

'*' *7/,dA c A /t 0*

l .V 17/IM

. ,,Mteon g Remove. danaaed silicone foam anit Install new s t) t rone foa) Imr DCl' ,*,

h This MVR is superseded by NCR-DCO- 14-RE-N004,

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Diablo Canyon Project rat://IC Goln .1ND ELECTRIC COMPANY pt rur[L YY\\1 H CORPORATION v .. D. A, Rockwell P a'

• March Jn, ) up.I

• "-G.t, etl a ncock **'D'

o. PTGC

".h~'Statum of :lllicone hiam

,J A11eqat.lon noview Diable. ennyon i . . . o. - 3103 i We ha ve s evlawed the allegation as follows: I A. .

VHaveoktable cell Structure

~  %.

Disco states that penet is/, tion 93 and 96 were unacceptable upon turn-over to Bisco. Review han f oun,'

t, hat the penet. rations were not ready g ,., for turnover because inspection had not been performed in accordance with the procedure. The foam was subanquently rejected during inspection.

O

Unacceptable foam was noticed by Disco in penetrations 238, ,100, 133, 1 14, 140, 122 117 68 and 10.

foam in ponotratlona 230, 117 andPTCC 122. inspection revealed unacceptable g MVR's+E-2824 and E-2825 were Ineued, work completed, reinspected and accepted. Penetration 140

. has been inopoeted. found unacceptable and an MVR issued. Penetration 100 was found to be acceptable. Ponetrations 135, 68 and 70 have ca, Disco sonin on both ends and cannot be inspected at this time. Pene-trations 133 and 134 havo Bisco seals on one end and are inaccessible

- to inspection at the opposito end, such that they cannot be inspected nt this time.

O n. Sigt.nwooo

1. Disco noted shrinkage in penetration 26n. Inspoetion of penetration 26B revealed a gap of approximately In to inch between the top of the blockout and the foam scal. The gap extended approximato.ly 6 inchos into the blockout. MVR E-2824 was issued, work completed, inspoeted and acceptod.

2.

Disec noted shrinkano in the ponotration through tho west wall of the asfoty in$cetion pump room. Inspection revealed a gap of % to 3/4 insh between the top of the blockout and the foam seal. The gap cxtended 15 inchow into the foam seal which is 20 inches deep. MVR E-2825 was innued, work completed, reinspected and accepted.

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1. Bisco noted air rushing thtough penetrations J16, 218, 222, 234 and @.

236. Penetfations .ila. 2'34 and 236 will be reinspected upon issuamm of a clearanes by.NPtl. lumpection revealed no seal in place for d.f; j 3;

penetration J19.. MVW lt-J8J4 was issued, work completed, reinspecte4' '

and an...pt ed. Penettaits.n 222 was fontnd to be acceptable.

D. Daelin Co% tot

1. To be addiensed tiy i.theim, E. gality Assurane, Pla.41ees

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INTEROFFICE MEMORANDUM '

4 Diablo Canyon Project -

l'ACIFIC GAS AND ELECTRIC COMPANY

!!!THTfL POWER CORPORATION 3..

File n ..,

Aprl) 4, 1984 v.

. , N .,

Ron Narris NCR-DCD-84-RE-N004 G.C. Quality Cortrol " " '

181G Neeting Minutes Jobsite '""'**"

3044 Ell: March 29, 1984 Y

ATTENDEES:

m R. Kohout - MPO (Chairman) R. Tinkle - 0.C.

W. Stover - SFHO Engineering W. Kessinger - NI'0 t r-M. Dobrzensky - QA T. White - Q.C.

P. Stewart - NPO J. Gibbs - Stil0 ingineering O R. Beach - G.C. D. Rockwell - 8.C.

R. Cook - G.C. R. Harris I G.C./Q.C.

in. CONVENED: 1300

& Rick Tinkle reported that he had contacted Bisco and they will not warranty their work where PGandE removes and replaces a Bisco boot. Bl co did confirm,

_ however, that penetration #96 had been filled with good quall'.y foam by Plant-Thorpe prior to the time that the Bisco boot was inst lled.

O Paul Stewart (NPO) and Bob Beach (G.C.) presGnted the results of their inspection of the penetrations identified by Bisco. (See attached chart)

Seven of the penetrations to be inspected wore not accoulble without special tools and, therefore, were not inspected. The conent ttee agreed that these seven penetrations must be inspected in order to verify the quality of foam installed. Additionally, the conunittee agreed that a larger sample of penetrations should be inspected to determine the scopo of shrinkage and cell structure problems of foam installed in the Plant. Paul Stewart and Bob Beach, together with NPO Q.C., will inspect seventy-five more penetrations.

This sairple wt11 be a random selection and will include 25 penetrations each i installed by Chemtrbl, Tech-sil and Plant-Thorpe. The results of this sample Will be reviewed at the next meeting of this TRG to help develop a Cause and torrective Action for this NCR.

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File Page 2

• April 4. 1984 John Gibbt will contact 5.F. Mechanical Engineering to find out what action Mechanical is pursuing in regards to the general Plant use of silicone foon.

This infonnation Actibn portion of may be helpful in determining a response for the Corrective this NCR.

The TRQ will reconvene on Friday. April 6, 1984 at 2:00 p.m. in Trailer #15.

AD,10MRNED: 1430 OM)$

Ron Harris 0.C. Quality Control Reply' requested: No m

Attachment:

Bisco Chart RHarristkih

cc: All Attendees R. Hobgood O

(All with Attachment) to Y

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• • INTEROfflCE MfM0HANDllM 3.4N#.%m.m

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~ ' a-n Diablo Canyon Project PACIIIC G*\S AND El.ECTRIC COMPANY RfCHT[l. 00WTH CORPORATION File "**

April 13, 1984 Ron Harris '* '*" NCR-0CO-84-RE-N004 I Q.C. Quality Control 5"*'" 1RG Meeting Minutes

)

n' Jobsite~ t*""'" 3044

)

QAJ1: April 6, 1984 i

O A11[NDQ1: R. Kohout - NPO (Chairman) P. Stewart - NPO o M. Dobrzensky - QA R. Cook - G.C.

R. Harris - G.C./Q.C. H. linkle - G.C.

J. Gibbs - Engineering, S.F. B. Kessinger - NPO

0. Kornberg - G.C./0.C. R. Beach - G.C.

CONVENT 0: 1400 hours0.0162 days <br />0.389 hours <br />0.00231 weeks <br />5.327e-4 months <br /> En

' Paul Stewart presented the results gf a second Penetration Barrier Investigation conducte selfp pBob Beach, and accompanied by NPD-0.C.

" The investigation reve nificant problems of shrinkage and bad cell

~ structure for both Chemtrol and Plant-Thorpe barrier installations (copy attached).

O Rick Tinkle suggested that due to the investigation results, a meeting should be arranged between NPO and G.C. on-site management to discuss the ramifications of a possible generic problem with' mechanical barrier

• j penetrations.

l Randy Kohout agreed to contact NPO on-site management, and Rick linkle agreed $

.to contact on-site G.C. management to arrange this meeting. Bill Kessinger will consult i.icensing supervision for direction in regards to lech Spec requirements.

the' Committee agreed *to reconvene on Monday, April 9, 1984.

S. Yowl 53 Ron Harris G.C. Quality Control

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Memo to File April 13, 1984 Page 2 _'

Reply requabled: No '

E

Attachment:

Barrier Installattons(*e(l Wi h of'3-) N RHarris:klh _g cc: All Altendees R Huhuuod a

NOTC:

_t The April 9 meeting did not sono-ce, the f otnetnus of the Comittee was that empert opinion would be helpful in deturmining the adequacy of on-site penetratton barriers. John Gibin will arranuit to have a Dow Corning repre'.entative survey Plani t.arrier penetration Installations. this informat ion will be necessary lor on s tto manausment to review this problem. "

_ 1he THli was rescheduled f or Weilnesday, April II, 19tl4 tius to w heduling problems with the Dow-Corntnq representaltve, lho April 11 mostIng wn F' post-poned to Friday, April 13, 1984, lh t'. i eu heiluling will allow t ime f or the Dow-Corning representat ive to sur vey I'lant penet rat ion barrier

', =i installations, r.

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4, INTIRi11IItT MEMORANDIIM *

, ._~.

Diablo Canyon Project ~

o'.it 'll/C GAS AND FL ECTRIC COMPANY

ll t'll!!I POWER CORPORATION

v. Ilie

.... May 4, 1984 '

... Ron Itarris . NCR DC0 84-RE-N004 o, G.C. Quality Contiol ,,%,,, IRG Meeting Minutes

,, Jobsite ,,,,,,,, 1044 QML: April 13, 19111 g A111NORS: R. Kohout - Npu (Chairman) l' Stewart NI'O R. linkle G.C. R. Cook 0. r. .

O J. Gibbs - Inuineering, S.I IL . Beach b,C,

, M. Dobkruensky DA R. liarris G.C,/4.0 B. Kessinger N t'O r~

C O,NV L N.I. D : 1400 hours0.0162 days <br />0.389 hours <br />0.00231 weeks <br />5.327e-4 months <br />

f. a lhe meet ing began with a report by John Gibbs and Randy kohout t euarding the results of an evaluation of plant penetration barriers a*. ionduited by g Mr.lakahashi of Dow forning.

Mr. lakahashi's otnervat ion and comments were catergortled as f ollows:

O Ct.lt 51RUClURt; the Dow Corning Cell Structure Comparison Chart (form bl 339-7b) used at plahlo Canyon for inspecting sillione loam cell structure does net r et let t rec ent Dow -Cc.rning f ind ing . . As a result of Dow-Corning inve,t igat ions and tests of sllirone f oam lustallations at the Hope Creek Nu(

', car power plant Dow Corning has retognlied the need to update their asicplante triteria. Sperillrally, the silicone foam installed at inope f reek was mixed by hand and installmt only B" deep with very poor cell strutture;yet,the quality of silli one met or exceeded penetration requirements. Mr. lakahashi stated that 11 a penetration barrier was c ompo'.ed of good tell st ruct ure f or 1% ni more of its volume the barrier would he adequate.(Good tell structure was defined as Cell structure wille vo;.is smailer than those in Sample #,* un Dow-Corning Form Algo,Mr.

bl thttk 339 Itg)'D' led ent Irely with siliconc loami wou t l mTakahashi stated that a penet ration wall -

requirement regardles', of ieIi strurture stre. eet our three hour

I II ____

. .;g.w -

- "; d , -

NCR DCO-84-RE-N004

'$ NQ .......

. Page ?  %"" *

-J%

May 4, 1984 A C

$1IRINKAGE: In regards to shrinkage. Mr. lakahr.shi stated the silicone team shrinks up to u within twenty-four hours after installation. This -

l shrinkage does not pose a giuntlicant degradation of the barrier as the  ;

j foam will swell for a tiuhl son) if heated as.during a fire. Visual gaps =

she *1d be repaired usInu a minimum ?" depth application of Dow-Corning Cauk. _

) GAPJ: Penetrations that inntain pipes which display aiital fnovernent require the pipes to be ut eased hetore f oom Instalistlien to enaintain a light seal. Penot rat ions that have pipes which dispidy lateral movement require that the pipe'. not lin greased befuse foam installalon to maintain '

a tight seal. Lateral movemont should not ru end one tenth the dhtance between the penent ral non wall and the pipe. Also, visual gaps greater than one-eighth inih wide ni qaps deeper than lashould be repaired ustnu llow-Corning Caulk. .

USAGE: Mr. Takahashi advised that st.ec ial iain shoulit he taken to provent o misapplicatton of silliuno Ioam. Ihamples of intorreti @ue1hatwere >i sited were penetrat ion. with pipes where tempointures esteed S00* degrees

)

I f or two hours or more, or where a temperat>,;re of 4h degrees is sustained. Another eunmplc was Installatton of sliit onc t oom f or separation of cont rete bioi k walls. Lise of hand mised pow t'otning cartridges should be ionlined to smali sepatr'.. Insuo ropalis should all r be made using the au!umated mlxinq endl mwnt i .

With this new information provided hv the Dow foining rreinsentative, the IRG g made the f ollowing conc lu .lon : -

CAust.

(.

1. the cell s t ruc ture and shrinkaip' pr oblem. Ident il led by tilsco were inspected to Bisco requirement *. and istierta and not to the O manufacturers latest inspec t ion and aii cplain e e i lterna .

Spec if ically, the Dow Corning tell '.t rni t ure t omparl .on Chart (Form bl -339 -ib) is out-dated and doe'. not retlett sustent ni c ept ance -l criteria with regards to lat llude'. of at i ept able i rli st ructure. l

?. lhe PG&L procedure for Siliconc loam In. lallation (DCp ?) does not provide the latitude of acceptable icli .truiture anil shrinkage ,(

ident if ted by t he manuf ac t ure RtSOLUJ1,0N

1. Dow-Cornifig, the manufacturer of sillione loam used at Diablo Canyon.

Was contacted to obtain a technis al evaluat ion of penetration barriers installed in the Plant. Dow-Corninq responded by providing the services of their lechnical Development Ingineer. Mr. Takahashi.

, . . . .3 M ,

. - h PY NCR 000-84-RE-N004

. Page t 3.

May 4, 19M4 S

?. Information provitted by Mr. Inkahanhl was u*ett as the basis f or a thorough reinspot t ton of penetrallens ident it led by llisto as having poor cell strui tut e or visual gaps No Instantes of unattoptable cell st ructure or shrinknue exteetling the namulat tut et s cultielines were noted for these penetrations duttuu this reinspeitton.

3 An additional sample of thirty nine bairlers were randomly selected inr reinspection Of thea.e thitty nine, two penetratinos tontetned unacceptable t ell st ructure anti seven penetrallons had sillrone foam harriers against thermal Insuldf lon in what appenrs to be an unapproved contiguintion. Iwo ut these seven harriers nho have gaps that exceed the manuf acturer*. ag ggtant e critoiln. 1he barriers with unacceptable cell structure anti, To lnkage were repaired.

4. Disco identified Penetration 6' lit as not having a penetratiotl barrier installed. A review of penet rallen ( tre barrier drawings revealed that the penetration was not reipiired to be lonmed as a fire barrier.

c' S.

Ihrough-out the investigation of the Cause for this Nonconformance,

~~ roving fire patrols were provided to comply with fire barrier requirements as specified by leth. Spec. 3.7.10.

.e CORRIC11VE AC110N 10 PRLVtNT RECURRlNL:l:

1.

PGILE Engineer. John Gibbs, to obtain the manuf acturers' (Dow-Corning)

current inspection and acceptance criteria for the installation of silicone foam as penetrtation and fire barriers. This information will reflect Dow-Corning's latest test results.

ca 2. The on-site StafI Iteld Engineer, R. Tinkle shall revise Procedure

- DCP-? to clearly reflect the manuf acturers current inspection and acceptance criteria for the installation of silicone foam.

O 3. The installation of silicone foam against thermal insulation will be addressed on Mechanical Engineering NCR-DC1-84-EN-N006.

Ron Harris G.C. Quality Control Reply requested: No RHarris:klh cc: All Attendees

• H. Hobgood

,, y I '7dd.h

( g.

I. ~y; ty

'h DOW CORNING U.S.A.

MIDL AND. MICHICAN 40640 Telephone: t3l?) 444000 March N. 1984 TO Wil0M IT MAY CONCI:RN:

SUBJr.CT: DOW CORNINO" l-rNR 811.lCONE HTV l0AH Silicone elastomerte mat es tain in general possean many unispie phymtent

" characteristics not unnalle found in organic einatometa. One of them is relatively higher degree of coeffletant or t hermal expansion than organic elantomers. Listcd-in the nitached mio ivpteal valuem or.Iineat k coef ficient of thermal espana ton ot atticone and orgente etantomera measured at 0 to 100*C.

t Isotropic materia 1H Much am of thermal expansion espian t o threemilicone elmatomern hnVe Volumetric coefficient volume coefficient of t het mal expana ttwen Itucar coefftetent. Conversely the range of 8 to 10 x ton of t he ailicone elastomern in in y 10' cu. cmieu em* *C, Thim means one degree

- cent igrade temperature dif f erence toi 1.H degreen tu rahrenheit) will result in approximately one tenth ot one percent volume change in a mass of O a allicone elastomer. To t ake 1-tN3 Silicone MTV foam for example, it will undergo one percent volume change (expannion on contraction depending on whichever way temperat ui e moveni when ambicut temperature changes by 1 K

• V.

Furt hermore, the f oaming icnction ol

~t-h'nB Silicone RTV tonm is mildly exothermic. Temperature i nne foaming procean in typtrativ 36*F. on the mntertnl during and shortly af ter the Annuming ambient temperature stays conntant during and reach equilibrium withafter the foaming, the stitconc foam will eventually ambient drop in a mass of the 911 leone temperature, which meann 36*F temperature foam. An ..ncunned earlier, the temperature change of this.mngnitude l e. translat ed to 2*. volume contraction in the ollicone foam. Should there be a decrenne in ambient temperature at a site where the r.ilicone foam in i ns t .il l ed , it will be reflected as additional thermal contraction of the toam.

l Se I v..

. March 22. 1984 .

, 9p;9pM,

.m.: gyg ~q.,Q '

Page 2.

O A tvpical appearance of the mIiicone foam aftar undergoing thkraally-induced contraction )

napa at the edges of in a lianetration opening. is a concave surface or small a penetrarton opening.

isotropic, the thermal contrartton would not Although theinailicone take place foam is an equilateral manner in an actunt penetralton opening due primarily to adhesion of the milicone foam to the oldes or a penetration opening. Various factora including bonding nt rength bet ween t he silicone foam and a material .

conatituting the penet t at ton opentnr.. tuternal stress within the foam, a degree of thermal renttarlton. etr.. tufluence concavity and gap formation.

,l liecause of the t' art thetmal cont rart ton and expanulon are a reversible procean. a conenve mutface will dinnppear au moon as ambient tamperature risen to a point to ortnet pelvtone thetmoi conttartion. If temperature continues to inerenne bevonit t his point. n conven surface will begin to appent. Thia in.typtrally observed in t hu alltrone toma subjected to an AS'th E-114 f t re endut ance I eat . }

Based on the eyewitnoma nerount of a recent Atrtit 1-119 fine endurance teet \

in that the 20 days old nt1trone f oam wit h a concave surrece successfully passed the all tent ertterta, it can be mately concluded that thermal contrnetion which may he ohnervsd an a result of init t a't temperature drop in the foam itself and nuhmoituent amhient temperature doeresse would not 'l '

have any adverse ettert on t he fire endurane, properties of t he willeone

~

foam. Sali' fire tcut w a r, Illinoin f or Dow Corn tur, on reinshirt Ma u b e t at potIland t'ement Ammoctatlon. t;kokte,

.'n. l utt i . (ker. Tent !: lab No. t'lt 'il 4 2 ) .

l e..  !

. \

s- ,#

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1. C.-c8 r d[.: '

1

} 11. "Tak' Takabashi Sr. Technical Service Specialist Techotcal Service & Development I C phone: ('il7) 496-4664 Attachment 1

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11$AR COEFFICl(NT Or THERMAL EXPANSION OF DOW CORNING'SILICONE it A5TOMElQ AtiD GLNERIC ORGANIC RUBBER i O l 14t AR C0lff ICIENT PR000LI/LOMM00lTY of DE S lyt,A1 t o'; IIHRigtLAPANSION

,, p,_lo-' im Rm'OC) _SOU' ICE DOW C0kt< LNG

• 3-6b4t; SILIC0til RTY FOAM 3.?

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SYLGAko* 170 5 IL 1 CONI LLA510MEH '

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DOW C0l(NING' 3-65P/

DIELECllilt GEL .t . .I I)

POLYIhol'RE NL . . ;'

2)

BUTA0!!NI , . .t 2)

,, SBR c0  ?)

BUT 1.7  ?)

ETH'lla.NL PROPYLENE 1.7  ;')

HYPAL0 tit r.3  ;')

NE00f.iNL 2 ,;>  ;')

NITRILE 2.0  ;')

ca PO'.YACRil 2.3  ;')

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FLUOR 0 KlitiGER 2.0  ;')

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FLOORD hil.lC0 tie '

(Heat Vulcanized) 2.5

.)

DIMElllYt SILICONE '

(Heat Vulcanized) 3.4 .)

C0hCRLil 4 - 3 b x 10'8 cm/cm*"t 4)

SOURCIS:

1.' Do., Corning s'roauct dat a sheet >

I 2) l "Elastoner Selection and bervice Guide" (1977) . Seal lastern, Box

$19. Reo Bank, New Jersey

.O 3' l'ortlanc Cement Association. Skode. Illinois

wrx

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May 3, 19e*

Mr. John Gibbs dechtel Power torpurntton P.U. Box 117 Avila Beach, t.n V.14 i'4 keterence: OuW LuRnint.* J-utoin S l l it one kl V Fo am Uear Mr. Gibbs, lhls is to htation Nuclear f ollow up on the Apriltilul/.uss ions we hall at the Utablo Lanyon I Vildl .

bilicone foam tell htructurg.

In Dow Lorning Literature no,61-339, the opt imum cull . structure (

v of the sil': cone team is indicated. It is, however. rernuntred by )

Dow Lorning as well as users of the silit.one team that the optt- ]

~ mum cell structure may not always be obtainable at a runstruction site, and that there is a middle ground of acceptable t. ell struc. l

~

j s ture f alling bi wean Pictures 2 and 3 on Literature No.61-339. 1 Attached please find two sets of pictures showing acceptable cell j r3 structure of the silicone foam which represents the.firestop  !

assemblies successfully passed the AblM t-118 fire and hose stream tests'at Portland Lement Association. Skokie. IL. The pictures of a team sa.mple marked No, 4 are also enclosed to

\

clarify an acceptable color range. (Refer to uow Lorning Litera- i ture No.01-347). j c- F1restop assemblies constructed with the silicone foam having cell structure end/or color equal to or better (= finer in cell sizes or darker in color) are expected to perform just as good as g the one with the optimum cell structure and color. 2 Allicone foam Lontraction Smal1 gap 1ormation or concave surface may be observed on tne silicone toam as a result of pressure reitet after completion of the 1oaming and thermal contraction thereat ter. If such gaps are no more than one third of the total depth of the silicone foam, there should be no adverse ettects on the tire resistant performance of the gilicone toam tirestop assembly. If. however,

~

gaps are deeper than that. some repair work is recommended, applying twads of DuW LuRNANb'96-081 Adhesive / Sealant to fill ,

gaps in approximately one inch depth is the recommended repair d procedure. tnclosed please tind a copy of the product data sheet on 90-vbl adhesive.

DOW CORNING CORPORATION, MIDLAND, MICHIG AN 4a640 TELEPHONE s17 496 4000

-~

i 1

3'/ 'py Wf g ;yp;;g May 3, 1984

~e BLCHTEL l

.' Page 2 Seismic Joint Seallna 3 bb48 Siliccae Rly Foam,in six inches depth is reconsended to construct 3-hour rated seals for seismic joints on a ficor.

However, wall or ceiling. the product may not be practical for sealing joints en a A combination of mineral wool backing in 3 inch thickness and DUW CORNINb' 790 Silicone building Sealant -in 1 and 1/2 inch thickness'is believed to work in a floor or ceiling situation.

mineral wool Dow Corning has 2 hour2.314815e-5 days <br />5.555556e-4 hours <br />3.306878e-6 weeks <br />7.61e-7 months <br /> rated sealing designs (3 inch and 1/2 inch Laboratories. Northwood, IL.790 sealant) listed by underwriters 3 inch mineral wool have not been However. I 1/2 to subjected inch a 3790 sealant hour rated and t ASIM pleaset-119 find afire andofhose stream tests to this date. Enclose 3 copy scalant. the product data sheet on 790 building Should you have anv additional questions. please feel free to contact me.

. fo a

Yours Truly 1 z@ sdd:

^

, \

H. lakahashi (l ak )

.b r . Tech. Service'Spe(IAIist lechnical Serv ire & Development Attachments e- i cc: U. Llark 069 \

J. tlias LU2310 )

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Dow Corning

• 3-6548 i Siicone RTV Foam Cell Structure Comparison Chart

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q[f f.Ut b C g, .qf J INTER ()t flCl hilMORANDUM Diablo CanyonProject ' PAClflC GAS AND ELECTRIC COMMANY BtCHTEL POWER CORPORATION 1 i t le w. May it, 1984

                             ..       Hon Harr h                                           e              NCR DCO-94 RC-le004

o. G.L. Quality Conttol  %. IRG Meeting Minutes

                               ,,      Joinite               ,,,,,,,,,,,,
                                                                               ,1044 QA_T1:               May .*3. 1984 A11[ N01.t.'s -              R. Kohout            NPO lthattman)             H. Cook     G.C.

R. linkle L. . r tt tiesc h - Q,C .

               ,,                                    M. Doberensky                 QA                P stewart       NPO

8. Kelly - NPD W . Itarrh 0.C./Q.C.

v CONVENtD: 0900 hours the IRG was reconvened f or the t ollowinq f c.nons:

1. During our previous meeting of April 1.4 19H4. the IHb estab)hhed that the

i. - Installation of siliconc tons against theimal tenulation would be addressed by Mechanical Engineering NON 00104 IN N00t>. Since this concern was not adequately addressed by Mm hanical Ingineering, the lleid htaff Engineer, Nick finkle, will initiate a Desinti Problem (DP), the DP will identify this type of installat lott aqaitat theimal itnulation to the Onsite Pro, ject

              ..                              ingineering Group (OPlG) tot their icwlew. John Gibbs will follow-tlp.te a nure an adequate response.

(3 (N0ll: the Meeting Minutes of April 13. 1984, have been revised to show this new step.)

                                       /. Handy Kohout, the IRG Chattman, asheit tot afi update on the revision of DCP ;'. which will include Dow Corning's latest approved installation requirements. John Gibbs has received the Dow Corning information and will transmit to Rick Tinkle / Randy Cook to incorporate into DCP-2.

Ron Harris G. C. Quality Control Neply requested: No kHarrIs;klh ti' All Attendecs N. Hobgood

                                         .I      Gibbs 0.'HtW g                      - - -                                                              . . . .

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( Januery 5 meeting in San Francisco st FG & E offices. I On donday, Jan. 5, a meeting as held in San Francisco at PG& E of fices. In attendence were ( ), { { ), (2 i L 3.c u - , and several others. The purpose of the meeting was to decide on a course of action vis a vis the NRC concerning the letter frem the alleger in the .QC department. In review -- cencerns of harassment and interf rence of job perf ormance

    ,in the- QC department had been invastiasted by(                    ) a r.d (             J --

to the an6er of Plant management and(. ), { ). These problems had been going on f er same time -- as much es two years. The alleger ( ) had gene araund( )(Tho'wasthenthe immedist, source of harassment) to .) and, v': iced his concerns . thento(~ Notiins was dene. Eventus117 s .ic worker complainedtoa4Aauditor',whotookittol ),whomadepreliminary inquiries and then leunched a full scale investizat*on with the backin6 of( ). As a result of thisreport,{ y was mnved to anotherjeb(atonepoint[ )hedtocallsecu:sitytohave c ( ') removed from the plant because he was' so out of control) and

                                                                                    )gavetwo upon receipt of the report, written 3 months eco, (

f,()inchargeofQA. L. Write an open directordersto{ letter to the department (QA) and let them know exsetly what is beins I done about their concerns, and 2. Have )ir. vite QA into his office, express mana6ement support of men, and reinf orce mans 5ement's oppositton to any harasament. ( hgytpn fh s # cord wa de eted the letter. in accordance with the Freedom of Information TI&M q' Act, exemptions A mm. S 7- / 3 S' G/I

12 Letter on-Janusry 5 meeting in San Francisco Page two ( .)ca Aled G int o '-is of fice end demanded o knew "wh o did this" and en de im;. lied threats . Mothin6 '"as done to close the open items of 2 years standing. The above response is the backbone of the " larger, peri-heral issues" in this matter. More on th at la ter. < At the start of the Jan 5 meeting re P URC and alleger's letter, ( ) exploded and called the QA depa rtm-nt - "Those bastards at the plant -- what )cotveryemotional and the hell do they want me to de ," { algain accused ( } and( ) -f doing a Pa tche t job and writinr a re;, ort of no substance - said assin this u.s no problem - just an attempt at empire buildi .6 The upshot of the mes:ing rasth?t( ),( ) and( )sre to prepare a ris;or.se t- the enp ected 3RC inquiry. ( )vigortuslyo;;osed( *')partici;ation-( )cver-fulcd him and insisted QA be prt of it. iie knows G w!:.1 not allow ( j to cover up the frustrat'.ons and cencerns of the GC area. It l cas also decidad that the response muld be directed at a man at the NRC named [ ),notat ). They are sfraid of( ),knowhe will get to the bottom of it s13 and will e7 pose the "I srger peri;heral inauss". i.e. Lock of su . ort for our QA people in the present manegement cero rg ement, sepsretion of QA fr . QC, QC new reports to menagement chose com=itment is to ae'*.edule. QC and their man' 5ement are in direct conflict of interest because of the mindset of their u per management, pa rticularly, [ f

(_ . L IS, Jan. 5th meeting in San Frt ncisco Pace 3 The NRC cannot mandate the t Pok E change this bu: they can make life very dif ficult f er them u.-til they chunne it. ' I This is the crux of the matter to the men in the QC de partment. There is not mans 8ement sun; ort for them. Don' t make a wave is the unwritten j law and thers is no one to whom au can take ce neerns withnut serious risk. As QC peo,le--do vou feel present manag ..ent stsporta you. Ask ), what d.id 7 u do, about heressment and intimidation? There may be no threat to sa fe 7 f ound in the ecmmere:tal grade procuremant traceability situation -- it may all be a paper problem. But '-hat haunts QC and QA personnel is we den' t know, and the funds and personnel recuired to do the jobasrecuesetdb( 7 )were denied. So it jus t sits -- and ve d on' t knen. wC did not know abaut the open items of 2 years standt ag because ( )concealedthemfr6m( -- a p.urely politi esi --my turf--moveon( pa r t . And QA is now dependent on ( ) cnd his men to alert tt:m to ;robisms. QA has en urhill fight and the bare minimum of cooperation. And the good QC professions 1s who care cre contairs d under the thumba of manantement, 'cemmitted to schedule l I sad profit first. I

                           .                                                              ]

As mentioned earlier, { ')isadamantthet[, )beavoided. He is afraid of bim. Please pass this inf ormation I have 51ven you ( l col ).

                                                                                           \

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m, m$,s IQ < Lotter F ur Received Jan 10, 87 dill begin ensin well into the IP. er to rottet t he . inf orma nt , j l 1 If ( )interviewsthemenIhavenamedIknowhewillfind i th'o substance.. I imagine he will find some real ecor.orstion. Those GC professionals ero so demorslited by their treatment -- particularly

                                ). He.is actively responsible for the                          f harassment and non-followup on QC concerns.          At mach ritk, job-wise, those men hvo been leakint inform tion to the QA d partment --

( issuposedtopassQualit7eenetensto{ } in QA or a t-loostkeep( ) inf ormed -- he does not do so) . Eat:h time th ey hav e tazen ":he drastic and disloyal. path of civine intornc. tion to ( ) l pocple, QA has taken action. That's +.c t is so painf ul about this.

  -Thore is FO & E mana.ggm9nt th.a t erres and will ts ke action.            It's             ;

l tho present manerement setup that crity.les efforts. QA mann rement -( f - come 4 own r:n Wed, to held a regular meeting with the QA --QC people or. site and purposely prebed.- "Are there any concerns you peaple have?" It was obviaus he was tryine to discover if anythinst had been rithheld from him and QA. ,A men neced ( sp) told about problems with " work pa ckages" -- documents prepsred to ortenise check lists, etc., procedures when rope trinn work on the plant en e definite schedule. QC is supposed to have these packares well in = odvance to work so that they con insert checkpoints of Quelity concerns. It takes time to do this. Operations routinely sends men to QC hours boro're work begins - a form of haressment in itself. Sometimes when th37, operations, get these packsees back they line out what QC has required or fill it in falselv. Fow Md4 Q ' 0/4

m- 'l

       .i~                                                                                   (5 Lotter Four, Page two

{ ./knowsthis,.but( i

                                                     ) won' t back him up. He has had his priorities' made clear by(               ..

( )hasoftenreferred to his 40 people ao those bastards, those trwblemakers, thase 30B's. { also told ) would make QC sen, or ask

                                          .) tha t (

them to, intern hira first ~hnt it wss they wanted to audit and then M could decide if it was OK and let t' em know la*.or. Thrt is criminal. ( ) knew, he was told, and went t o [' )-- nothing. This has been goina on for t~o years. If ( )is not afraid of the company polities -- he' is a manager ind ( { ).andbe12 willine to take the res] abuse for gettinginto(

                                   ' ) turf, he'll afet (
                                                                    ) to a;;. rove an audit of QC files to find out if what he has been told is true. Wite.out(                        )

backing, directin- to GA to audit 20, there would be a terrific blowup. So far 1.wmdation and harass =ent ha sn' t seened to stop M people bocause )bseks them .up, but t' is is really a hard one. He l 1s a risk. Plosse get this to(

                                        ).Withoutpropermanrrecent, God knows what the problems,ere.                                                                          I I

Ahmu -

by "cisanirs up" of' rep ort . $, ,

  .i                                                                                      )

4 Roceived Jan.12, 87 On several occasions,

                                         ) rewrote an audit :seper.t by Once, he rewrote the report 3 times beforo(                      ),

who was shown each draf t, felt it was going to be acceptably mild onou6htosuit{ ). He broke the law. My God, no wonder the QC men want to be part of QA -- their own management, especially {

          ) who publicly calls them all bastards, conspiros to cripple their efforts.

I

                                                                                          \

one f ormer QC man who is new with QA, , say:n that( ) " is beginnin6 3 deep audits of QC -- he didn' t wait for( bad ing. He,

                                                                             )

1 is furious and if he gets back a report that is obviously cleaned up/ rewritten from the 40 people - he's going

*for bloed."

Someoneshouldlookintoharsssmentb( )--anemotionally unbalanced person -- to put it kind 17. {. )repor':edtohimI think. Ask about his incredible tirsdes and making one 4C inspector por week wear or hang "the rubber chicken." h jis actively looking for another job. ,[ )issaid to want him out of the way. The sad part is that it may be very difficult to trace this incredible manPgenent attitu'!e to( } h will c ome out l'ooking incompetent but clean -- maybe. i Ceuld he be held accauntable in some way for what happened to(. h-he wasn't moved out of the plant and out of nuclear operations -- he cas given a promotion. A better job at better pay. i pg g-81 A B/7

 *~
   - .i
    .   < . ,                                                             1-( (7, PC6e two      Jan 12                                                          !

e now in @, sa7s the CA people think GAP will Set into this and it may go to hearings. They also have a certain fear of

              ) They sa7 he will ar9 ally bore in."   I hope sc>.

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  .,u.Ildi.i ,:.a-
 -2 QCI NO.       64-0601 FILE NO. 507,M NUCLEAR PLA*ff OPERATIONS O!ABLO CANYON POWER PLANT SURVLILLANCE REPORT

Subject:

Witness of Fire Barrier - Silicone RTY Foam - Walkdown Date Perfomed: April 4 & 5, 1984 p By: Daniel T. Farnan

      & Department (s) Involved: PTGC, Bechtel, NPO Fire Prot.                                             ~       j C Scope:                                                                       '
       ' Yerify the location of the penetrations and witness and verify that the PTGC and WO v personnel complete the walkdown. The walkdown was done as a partial resolution en               >-

NCR DCO-84-RE-N004. {

7* _ Persons Contacted: w R. Kohout - Safety Coordinator

      ""~C. Johnson - Plant Fire Marshall oR. Beach - Inspector P. Stewart - Inspector

Conclusions:

Identification of penetrations in the plant.is unacceptable. R. Beach >W P. Steuert performed an in-depth inspection on a random sampling of forty-nine (49) penetrations, however, none of the penetrations sealed were uniquely identifed as required by  ! PGandE Specific 6 tion 2552, paragraph 3.4.2. In addition, of the forty-nine peastrations sampled, drawings were available for twelve (12) penetrations. The codinatten of no markings and lack of drawings made it impossible to verify penetration locations. See Nuclear Plant Problem Report DCl-84-QC-P0354. Observations /Recomendations: # PGandE 049047 depicts the location, size and geometric configuration of the known penetrations. Without unique identification of the penetrations in the field it r; I then becomes an extremely difficult task to correlate the penetration with its ~l assigned drawing identification. Additionally, it precludes positive assurance of compliance wlth Technical Specification 3/4.7.10 surveillance requirement to / assure each penetration to be functional at least once each 18 months. { Detajls: See the attached Surveillance Plan and supporting documentation Performed By L s '> _,2- s Approved By h t di uc mneser n

i,

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                                                                                                                             >s NUCLEAR PLANT opt. RATIONS Page 1 of 2 DIABLO CANYON P0tER PLANT
              . . _             ._ Ti_3Ji,, J ALITY CONTROL SURVEILLANCE PtAN
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Prepared By . Ih _ Date:_ .9 4 ,,,,s Approved By:_)lrou/A A biske Quality Control Level III Date: - s/ 4/.A%/ Description of Surveillance: Fire Barrier - 51?icone RTV foam walkdown of 25 ra _ penetrations for breakdown of fire barrier during heat-up. Monitor inspections

• __ conducted by PTGC and NPO engineers per the attached memo.

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• 3-65L8 O Silicone RTV Foam  ;

Cell Structure Comparison Chart l Unacceptable Cell Optimum Cell Structure Range Structure Range O .- .

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• 3 6548 Silicone RTV The cured foam celi structure is too Foam has an optimum cell structure targe and non uniform in both sam-a range a$ Shown in 3 and 4 stmo plesi end,2 above Che k y0gr equip- when properly cured.

ment m6 ratio You sh iund atso check

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These temp 3rature readings should be between ** F and 80 F and the snep time betne.cn 1 and 3 minutes fo' Ori mum eriguttg e e,. o een ==

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to APPLICA8ILITY: At all times. O ACTION: O a. With one or more of the above requimd fire berrier penettettees

• non-functional, within one hour either, establish a continuous fire

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                     "*                    required by Specification 6.9.1, prepare and submit a Specisi Aspert             i to the Commission pursuant to Specification 6.9.2 within the mest

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penetration (s) to functional status, O The provisions of Specifications 3.0.3 and 3.0.4 are not applicable. b. SURVf!LLANCE REQUIREENTS 4.7.10 Each of the above required fire barrier penetrations shall be veriffed to be functional:

a. At least once per 18 months by a visual inspection.

b. Prior to returning a fire barrier penetrations to functional states a following repairs er maintenance by the perfeteence of a visual l.

inspection of the effected fire barrier penetrations. ), 1 0!A8t0 CANYON - UMtT I 3/4 7-46 I i l L . . . -

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a> . a.re uniqur'l / identified in accordance with PG&l c.pecificati.it - t , i . a yW. .1. In .i.idition, drawings were available for only ta lve (12) oi

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                                       $PECIFIC ITEM JUST1FICATION 9

Budget Year: 19V Bt.1 # 29 0.4.1 PROGRAM . '106 NPG PR10RITY Budget Dollar ** ? 0.~4 ;; s 40.55M . If? , N Item

Description:

P Additions to Fire Protection System: i

  )                                                                                                 !

Additional pyrocrete requirement for structural steel

• Themal Insulation and fire protection support e

c

• Unit 2 TuMne Building sprinkler hydraulic evaluation N
• Miscellaneous additions to fire protection system, CD 3cstification:

1 To cogly with Appendix R requirement and other Mgulatory requirements. Reviews and audits have indicated that improvements need to be implemented in the area of fire protection systems and structures. These improvements are necessary to meet the requirements of 10CFR40, Appendix R. l Consequence of Deferrel or Deletion: Non-compliance of regulatory requirements. l l 1 1 l

                                                                                                  !  l 8

Contributing R/C's* See Attached Table. 10/20/R5 030eR/0019R-7

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NONOCNPORMNCE R

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r cel't structurc yas idirq1,1f led at nenetrattuns 2311. w.,

' -ht " ;                 feas), shrinkage was identified at penotration 268. Penetration 218 was misste
                                                                                                                                                                                 .g$

A ~ during foam installation. h ee page 2.). 4 L ~T l"""eens - 3/h/l4 "JRBratton *>(E.h % hj S f oa'oiNAtto .My Control I ~ , C'""'

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mesentasitivv meviewso uwoem t by,"4 @ $',','.',*. g, d E,"g "T6 E* N ReponTA4L87 bytt Oseo O Tno occitioN EPLIT: Revitw Restanto fot V n aAs4 pon 0800mtimo 13Nor merontimo t penetrations to be repatred prior to seven clays V C upon discovery and fire watches were established as per TS 3.7.10. h n E P O n --m^m M T ouattty --- = ^**** OInfA {O-g instiAL nero#f- II: --'* l"** ["'"

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f Iactuatmeronti poLLow4r meront anta oRapont maouintowitwin Actual neront i \ t

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ofwen acencies asouiniNo Notification om R$ PORTS; o This NCR supersedes MVRs E-2824 and E-2825, 11 ADDITIONAL REMARKS b x /! ./ - '

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com "espection niAO y h g /f t l dvs sciion.nettestion and espert6ns are sempless N BY' QUAL.lTY ASSURANCE Allreeotutlen. 14 VERIFICAT)C o.e_l7 /70 / b .

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                                        \1                                                                                                                   O Seeurity 3 Mont Mgr. and / or Mont Sept.

16 O Authorised tempector (for ASME items) O Meterials _ O Ergneering messerch , O Nuclear Power Gweration 3 (heitty Assurents O Centreeter O Ene6neering O Sofety Hennh andceims - 0 Other O Stat 6en Construction S

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(. DCD-64-Rf-N004 Pete 1 of 3 DESCRIPTION (Con't): Silicone foam has 'stu, pushed out 3' at a penetration in the west weil of the safety injection 1; n ronm. The penetration is sealed with less than the required 8" of silicone foes. GMlH2

1. 1he cell structure and shrinkage problems identified by Bisco wre inspected to Bisco requirements'and criteria and not to the' manufacturer's latest inspection and acceptance criteria.

Specifica11y, the Dow-Corning Cell Structure Comparison Chart (Form bl-339-lb) is out-dated and does not reflect current acceptance

                   . criteria with regards to latitudes of acceptable cell structure,                                         i l

2. the P%t. procedure for Silicone foam Installation (OCP-2) does not j

   . ,'              provide the latitude of acceptable cell structure ano shrinkage                                         j g                identified by the manufacturer, w                                                                                                                       l K501.UT10u:

c silicone foam used at Diablo Canyon, . l

1. Dow Corning, the manufacturu was contacted to obtain a ted.atcal evaluation of penetration barriers installed in the Plant. Dow-Corning responded by providing the m wrvices of their Technical Development Engineer, Mr. Takahashi. l '

77 ,

2. Information provided by Mr..Takahashi was used as the basis for a i O thorough reinspection of prnetrations identified by Bisco as having poor cell structure or visual gaps. No instances of unacceptable cell l

      ~                 structure or shrinkage exceeding the manufacturer's guidelines were noted for'these penetrations during this reinspection.

e

3. An additional sample of thirty-nine barriers were randomly selected for reinspection. Of these thirty-nine, two penetrations contained unacceptable cell structure and seven penetrations had silicone foam barriers against thermal insulation in what appears to be en unapproved configuration. Twr, of these seven barriers also have gaps j that exceed the manufacturer's acceptance criteria. The barriers with  ;

unacceptable cell structure and excess shrinkage were repaired. 1

4. tilsco identified Penetration #216 t.s not having a penetration barrier I installed. A review ci penetration fire barrier drawings revealed that the penetration was rot required to be foamed as a fire barrier. <

through-out the investigation of the Cause for this Nonconformance, f S. l roving fire patrois were provided to comply with fire barri.er ' requirements as specified by tech. Spec. 3.7.10.  ;

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                     .NCR DCO-84-RE-W004 GQRREC11VE AC1106t to PREVENLlllMERLEL1

1. , PG&t- Engineer. .lohn htbbs, to obtain the manuf acturer's (Oow-Corning)

                                     ' current inspection and acceptante criteria for the installation of silicone f oam.as penetration and fire barriers. This information will reflect Dow-Corning's latest test results.

P. the on-site Staf f I told Ingineer, 6t. Itnkle, shall revise Procedure DCP-2 to clearly ret let t the manulat turer's current inspectinn and acceptance criteria f or the lustallation of stitcone foes.

3. 1he installation of silicone team against thermal insulation was thought to be addres. sed on Moihauhal Inutuperin0 NCO DCl-84 1.N N006.

                                         $1nce the concern was not adequately addresud, the livid Staf f                                      ;

fngineer will initiato a DP to a n ure an adequate res;.onse. PO

14. VERIFICATION BY QUALITY ASSURAk g e

te 1. The latest installat ton and acceptance criteria was obtained from Dow - Corning, t he manuf acturer of silicone foam that is used at Diablo Canyon. O 2. The information from Dow-Corning was incorporated into the Plant testallation j procedure (DCP-2) and was used as a guideline for the reinspection of j the penetrations identifled by Bisco. No discrepancies were identified daring the reinspection of the penetrations identified by Bisco. l te q 1 A separate question concerning the installation of silicone foam against thermal Diablo j

                        '                    innulatton surfaced during the reinnpectton previously mentioned.

Problem 1-4044-E was written to assure that the Onnite Project Engineering C Croup (OPEC) would review this type of installation.

4. The OPEC review found the installation of silicone foam against thermal ,

innulat ion t o be an unaccept able inntallat ion. Design Change Notices j o DCl-EA-25510 Del-EA-17921, and DCl-EA-192'l6 were issued to correct this l defictency. ('- Ums _. iz/zo/#

                                                                                                  'Date' l

J. R. Itarris I

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                           -MANAGEMENT ACTIVITIES AND TRENDS'CONCERNING QUALITY CONTROL A
                                                                                                                                         ^

l H_istorv

        ,           1...'Past conditions.

a) :The forming of the QC division- ' Prior ^to the. spring of 1983 company'sanagement realized that there , were' fundamental probless in the QC division, with discharging its ~ { duties at DCPP. .I b) The sanning of the' QC division ..: *

                                                                                                                                                            ..                    a
                                                                                                    .      4
              .                         At that time the QC division was manned at about eleven people. The                                                                                                                  '

sorale of the division was very low. There was little respect ,

                                      'between QC' personnel and others sesbers of the plant organization.

c) Internal str' ife within the 'QC division I.I - ' There were open and loud arguments between individuals within the QC division. Such open disagreements was very damaging to what sorale and professionaliss that remained.

                                                                                                                 ..        i.            .
                                                                                                                                                           . c. , ,             .,,.
                   '2.

Decisions made to correct . ..:.. -

                                                                                                                                                   '...             t     .

u ., a , . a) Use of a sanagement consultant ,

                    ?                   A seasoned sanager with credentials in organizational development                                                                                                         ,,
                                      . was temporally assigned to the QC division to. evaluate the
                                       ' situation.                                                                                                                               ....

b) 'Developinga.newiCorganizationplan . After about six weeks of observation the above person wrote an ,

                               .'       organizational plan that would reorganize and restaf f the QC department. This plan when implemented would revitalize the QC division.                                            ' '                              ' '                                   '         '        '

c) , . The validation of the new organization plan A QC engineer was sent to a similar plant at TVA to observe a QC , . s.

                             ' -        department in action at an operating n.uclear power plant sisitar to DCPP. This observation essentially validated the plan as a good one.
                   ,3.., Corrective Action                                                                              ,            .                      .
                  *~                                              . . . . ..                ..                  --      :,
                             . a)       The requirements review                  .        .

i. .

A part of the plan was to develop a comprehensive QA requirements - review that would identify the requirements placed on DCPP , operations by higher tier documents. This sacrix would then be used to develop a Quality Control Progras on site. .: f b) The progran redevelopment .

                                                                                    .         ,       ,,          ..      4..., ,.             :... . .,
                                . ,, As the abovp satrix was dev,elo, ped. Quality Control Procedures ,_.                                                         .

(QCP's) were written. This method would take a requiresent trace it .

     ,                     .,           through QAP'S NPAP'S and AP'S; write the requirement into the QCP.

assign it to'a responsible position. After this the requirement ' would be written into an individuals job expectation worksneet. By i this method we assured ourselves that all requirements [ d duals are evaluated as to how well the requiremen grggdthis record was ddeted n accoIdance with the Re dor.10ilr. c) Act, exempibns MEE The resultant reorganization of the QC department During this time some aanpower support. it was decided by the QA sanager that QC FOIA- E 'P M K needed h were hired to augmentLthe this QC* was a wise decision. department.) By"thitot!Ed# Twelve cortsultants divisinr. was changed en i deoar+w-* *ad -

                                                                                                                                     - na-t H e 8 0 D"'"

• 1.b ,

i I

4 j.- ., *An energetD; e,tring program uas implemented which resulted in'the ( hiring of U '8r the 43 pe pie that was projected as needed by the original pla" A hiring freete was instituted resulting-[n the

                                  . incomplete implementation of the plan.
                --                 As the consult, ants lef t the depa. tsent began to function on its own.

However as w will see, not completely without problems. .

• Present Situation

1. Hanpower Decision'

                                                                                                             '                                                J a) The use of con s.ultants                                             -

The decision t6 use consultants, while not made on site was a wise, 1, j decision. The consultants were used efficiently. However the aandate ' by plant sanaqoment was made to get rid of,all consultants by December 31st 1985, was a poor decision for two reasons; first the , i QC department had a well managed plan for attrition of consultants. Most consultnuts were to be gone by the December deadline. However there was a llued to keep a couple for the ef ficiency of the transition. 'id':end it was mandated by plant management to get rid of _ all CC consultants without regard to its impact on the QC dep rtment ,. i this was perevived as intimidation of QC by management. While, there . is no way to evaluate managements motives, coming the way it did I i-rf' N Intimidation was perceived, sorale was af fected. b) The freezi g of hiring permanent PGandE personnel - The original sanpower projection for QC was 43. In late 1985 it was

                    .              sandated that the QC sanpower level would be 33. This decision was

• sade with out consultation with QC. When QC sanagement objected we '

were told how it was going to be; thereforg the perception of intimidation of oc by plant sanagement was reinforced.  ; c) Effect of budget considerations on hiring practice , > During the vigorous hiring program sentioned above, a special hiring consultant was assigned by company personnel for use by NPO. This l worked very well in the hiring the experienced people necessary for , the QC department to gain credibility within the operations environment. J td,O 4 t*P --DThe M future hiring of qualified replacements is already affected by . *

   'l #pf$                         budget considerations..An offer was made to a well qualified l     1
   < Q/<l           AW pay increase could not be made with the of fer. Yet if we go o                                                                 :
   $(                 p.hy.
                                . the company to hire, we will be able to offer as auch as 10 to IS:                         e                        i d sore, plus incurring the cost of a sove.                                                                                        I (dge?t'. it.evel_frettes                               will cause attrition. This with the situation h     !

5 personnel Within the QC department.cascribed above will hav . anD.103cnneleenacer is iust as !moortant to cuality as any 8h.deoartmenLJ!Luacer department on site. Yet, his. loyalty is to the corporate } This means. H= is graded in the long run by his professional peers. . DCPP. The that he has to maintain the company line in hiring at . which will eventually lead to a mediocre organization which w '

                            .. cause a shutdown, like the ones at SMUD and TVA. With these high stakes there performancu       of theis no obleetive personnel    manager at     criteria DCPP. in which to sensure the 2.
                '         Quality related docisions a)

Hanagement As a result of adecisions chronic prelated

                                                                   ~'             to Quality verifications ' effort to assign this  any     QC to prefors a 100s surveillance on th'e STP               s. While fileA missed STP'S' m does not holdappear to be a correct decision, it has flaws. First it l

the appropriate line management responsible for doing E.A.i__

3 '

                           "the . job rignt.- Second with the budget restraints, this decision                            [

commits to such of the OC sanpower resources 'o a single tesk with no relief in sight. Fewer inspections

                           ' accomplished in otherimportant            and surveillances will be
          .                  set up                                to safety areas" Third. QC is being to take the blase for future missed STP*t. ! Meed this has already      happened neatly sidestep            with a missed STP. The responsible sana,gers can u l lo the issue.
                '                                                                                                              i b)                                                                                                        !

Ef fect of budget constraints on Quality verification ef forts As our satrix indicates ;C has responsibility for quality related , requirements that are fixed. Our manpower projections was for about 10 sore people than we were allowed. The original projection would have over sanned QC for low work periods while under sanning for outages. With decisions to cut overtime and assignments to long ters [ j surveillances QC will eventually get into a lot of trouble in  :

• discharging their duties. This portends trouble for the plant and -

i

          -                  department reorganlZation. similar to the ones described above which brought about c)

Plant annagement's f ailure to support quality verification efforts. * { Plant. sanagement does not fully support the QC ef forts. If they were i asked if they supported our ef forts they would probably reply; don't

   .                         be ridiculous, of course we do. However their subtle actions betray their real feeling toward quality ef f orts. For example; One sanager wrote a "I an outraged" seso directed toward a QC surveillance ef fort. This seso questioned the ability of a QC Specialist to arrive at some conclusions during a surveillance. A seeting was

alled whereby some Reactor Engineers informed.the QC attendees that the Surveillance was in reactor physics therefore, we could not understi.nd the process. 1.ater, when it was discovered that the QC

                .            specialists main conclusion was correct, not a word was heard fros plant sanagement handled  by             about the situation. This seso and the way it was management was a form of intimidation to QC personnel.

3. Examples a) Past procurement probl.ess "

                                                                                                    'i Procurement has always been a probles at DCPP. When the present                                !

procurerent procedures were eritten, QC had to get a bootleg copy to review-., Af ter our revteu san, comments were made, sost ignored. Our a in consent was the grcgram was much to complicated to administer.  ; This cessent was disregarded. Consequently, progras is cusbersose and should be overhauled.the present procurement

• During a March 1985 seeting in the plant sanagers office the QC -

sanager 'was told how QC would review procurement documents. This .

 ..-                        decision was again ' perceived by QC'as intimidation.resulted                          -

i f On another occasion a QC specialist was refused access to records in . the procurement (procurement section until his " audit

• plan was approved by the Supervisor. '

1, ,AndaQCengineerwasthrea[teneooythe-)procurementsupervisor during the legitisate performance of his duties. This situation was never resolved to the satisfaction of the QC engineer. Present procurement problems In the recent past there was objective evidence that*a high , percentage of procurement documents are leaving procurement with errors. Fortunately i there are enough checks and balances in the . system installed into the plant. are corrected before hardware is actually that 10st sistakes

c) Future procurement proDiems _ i

             ~                                    It is just a matter                                                                                                    v of time before a piece of indeterminate hardware is installed into the plant. A surveillance was conducted to                                                             -

determine if any questionable hardware was installed in section } '

         .                                        eleven, safety related systems during a recent twelve month period.

f Hon was identified. However on,e piece of hardware that was :creened 1 out because used in a pressure of subsequent boundary,inspections was re" classified to not to be - ( related feed system, was later used in the non safety enture Consecuences of Past Actions

1. Predicted impact on Quality Organization a)

Deterioration of QC qualifications Because of budget, sanagement - ' support and lack of upward mobility within the quality department we l are already starting to lose some very qualified people. - ) b) Inability to fill key positions l We are already experiencing difficulties in filling vacancies as a l result of budget and personnel policies. Further we are developing a Will not apply. reputation of not having management support. As a result good peop'le \ c) High attrition l Our specialist and engineers are feeling dead ended. Some are j i . already soving to cther positions within the plant. Such movement

• j

! would be healthy if QC were able to hire personnel equally i qualified. QC lost one choice because we were not able to hire a I well offerqualified a 5: payreplacement from on site. The reason; we could not  ! i raise. Yet if we hire from away from the company we will have to pay 10 to 15: more, plus moving expenses. Several of our people a looking at other companies for employment. l It will out of be control. just a matter of time before the rate of attrition gets i ( 2. Predicted impact on Quality Program l ' l a) '3 Inability to maintain- up-to-date program . With a high loss rate of personnel, inability to hire well qualified replacements with the attendant training requirements, plus long term surveillance assignments, it is just a satter of time before QC starts sissing some key responsibilities. b) ' Decrease of inspections, surveillances and management reviews . As sanpower constraints and sandatory coverage requirements converge other apparent lesser items will not be looked at, this will bring attention to the QC department frry outside groups, c) Regulatory fines because of ineffective management controls , As coverage. decreases and the above problems become apparent the NRC I . will eventually get into the act. Such activity will bring fines and possible shutdowns at great expense and to the company. 3. Predicted impact on availability a) Deterioration of safety I As QC problems increase a deterioration of safety is predictable. 5 years the plant will probably be shut down for safetyThis de considerations.

           ,,-        b)* Deterioration'of reliability Inattention to detail will lead to a deterioration of reliability.
                    -c)     Non-availability of plant due t-o regulatory actions I

Non availability is the expected outcome if the problems and trend of probless are not corrected. Such loss of gene, ation to the grid

              ,             could cost as such as a billion dollars.

1. Proensed'Correctiva Actions Make sanpower decisions based on need '

a) QC needs have been known CC has never kept its sanpower needs a secret. It is well known that QC needs to recruit and keep highly trained people. QC cannot accomplish its mission if the present trends continue. b) Overall total's are about the original sanpower estimate QC total requi, ements have not changed from the original estimate. The original estimate was not padded'and was validated by actual site observatica.

2. Make Quality-related decisions based on what's right a) It is right to recognize symptoms Symptoms of.probless should be analyzed by management-in an effort to determine what probles needs to be solved.

b). It is right to treat the probles instead of the symptoms ' Once symptoms are analyzed and the probles is identified, the probles should be resolved. Often-symptoms are treated while the real probles continues.  !

              * ' c) It is wrong to kill the'sessepper
                         '   Intisidation no satter ifr its overt or covert is another way to kill the sessenger.- Such actions are against the law at the least.

However, in a sor;e subtle manner sessengers quit bringing bad news. ThisLis when sanagers really get into trouble.  ! 3. Make all decisions based"on solid strategic planning a) Plan the progras-  ! The QC' department has a good solid program in place. In fact it is probably unsurpassed any where in the industry. j b) Work't.he program All'QC needs to do is be able to work the existing program without undue interference. QC is not asking for a license to work without sanagement control. QC is asking for the freedos to report probless to sanagement without harassment,a+1 to 44 ab/.e go puwkt*M e //uvP

                                          ^

c) Review the plan and progras Off d Q W.

                    ,.        In order to keep its progran current we have a plan for self review.

Usually some aspect of this self review is in process at all times. , We change our progras as a need is identified. As a result the QC progran remains current. Therefore. QC has a high degree of confidence that when probless are identified, they are valid and should be resolved. *

    ,. ;,                                                        -s                                -
          ..                                             Racommandatieni                                                 10
             ' program.

Plant.sanagement.uould probably argue that they

betray evidence of their. support. However managements as dayThey sight e their real motives toward quality. These sotives sees to. Jeto' don't day decisions often

               .to           do. But, in doing'it this way we are placing the company'in serious jeopardy of e   the ~ futu    i
            ' Current problems in, procurement sust be resolved lamediately a
            .lowersupportlevels   for theof management quality program. must not be allowed to display any sort of non Finally it say be conclusively demonstrated by
           ' consideration should be' given tdepartment cannot function well in the o corporate QA- department.-                 o placing site QC under the control of the i                                                                                                             .

e e es e l I e

   ., p ;;.a -

i. Latters enclosed' followed a phone call to the Mothers for Peace I from the informsnt. Cenversation concerned Unit II. Two areas of eencern. 1

1. Procurement of materials and components.

g-a.. Items being insts11ed in safety systems that aren't  ! safety grade -- this problem goes back 'two years. ,

b. Paporwork for items being installed not beine done according to NRC regulations. Reports changed.

12 Management Structure

a. Diab 1'o is only US plant that is structured so that QA is below VP level. No direct access to PG & E Pres.

b. Depertment is castrated, harassed, no independent.

i

e. QA is allowed only to take a re-active stand, not a pro-active stand. No allowed to fix problems as chey ,

see them arising. Only allowed to react when a problem is discovered. l The informant in writing has asked th at information be used in whatever manner will holp to bring about change. To the NRC, i the prenn, mention of GAP cruing in was made. Information in this record was deleted in accordance with the freedom of Information Act, exemptions ~lm) 4 lMi ' f0.1 97- /28 8/2 f i J. , l i ( . ._ _ . - . . .o

y Qw.; '

   &/

2. - l

   ').

L T Lbtter ' 1 I Daar( f -

                                                                                            )
     -I hope. these two documents will enable you. to begin action again en Unit 2. - Unit 2 is ' due ;to shut down soon for refueling and if you
     'hsve- a good question / ease bef ore the NRC, that body will not allow Unit 2 to start up assin until the question is resolved.

l i Tho 2 unin issues are procurement and political, pressure within F 0 & E management. This ' pressure" has taken the' form of actusi heransmont of. GA employees, and, more subtly, but much more important, kooping SA management .below vice presidentici level thus literally costrating the department. QA is supposed to report directly to the _ president.. In reality, its manas;er reports to the assistant to the ] president ---direct access is thus blocked. The QA manager -is not able 1 to implement his programs or even express his concerns unless the j VFs above him concur -- if he wants to keep his job, tha t is.  ! The QA department tries to take a g-active stanc on Diable. The

    . VPs and president will allow only a n-setive stance. For example,                   '

QA 'ean't fix problems as they see them arising -- they are only allowed to react when a problem is discovered --TMI mentality. Even TMI mansgement geve treir M department equal power with QC(Quality Centrol under angineering/ by making the head of wA equal VP with Engineering. All the major utilities with nuclear plants have QA at the VF level. 3.

1 3 ) 1 Letter l' continued. Page two I i The procuremont troblem is now crucial to plant safety. As. parts I cear out they must be replaced and if they are in a safety related , function the part must be safety dedicated -- there must be a complete gonooloey of the t part's testing. Is it able to tolerate the stress asked of itt There is the paperwork to prove it? Did it come from Ace Hardware -- did Diablo manuf acture it themselves? The QA Department had a budget arri plan worked out to answer this procurement problom and the budget was slashed and the staff cut to less than 20 percent of what was needed RW e haveult had a problem yet so forget

• it".

This( ) follows orders but he knows that is wrong. Ho in trying to establish industry-wide standards for this pro'olom. ( hare interested and participating. His own cotcpany is not. When we were down investigating s11erations of harassment of QA Oudit people it became obvious that the complaints were based on fact. Accordingly, a report was written by( f ) cod ( ( -.

                                              )outliningtheproblems.

{ )whotestified

                              )had been harassed was fired and(              )

cas accused of just doing a " hatchet job." That report should 'have cone to the NRC and should be public domain. Please do comothing to make this public. The complacency at the hishoot level management of PG & E is frightenin6 In the procurement problem they were told they were sitting on a time bomb and they told QA do not pursue it until there was a problem -- another fdI maybe. Cnoto on lotter Quality hotline should be direct to QA VP level. It is not. it goes through engineering VP . Not the intentions of gov't reg.

                .g:

7

          'Socond Letter                                                                     i The first thne paragraphs again addressed to me,                     1 cre porconal. in : nature and philosophy     and have been deleted for the eshe of the intermant.

The lower level people, desien oneinters, quality control audi or s, quality ' assurance department, etc , overspecify requirements -- they ' I care. ' Soalsodoes( (but he ha s been ordered to cut expenson drastically -- and he ba's to, to the detriment of QA/QC

          .ecncirno). The seroty problems now lie in middle mana6ement and in panagemont. structure. I think with the information I am giving you,         .

it will be possible do force PG & E to ebsnge the menagement -structure cad philocophy. i

         . Again, Foderal law required that the Quality Assurance department be completoly independent of G other departments and that it report to the president only.      It is the function of QA to Audit ell areas of the plent operations to insure thnt all Federal guidelines and company commitments are met. To achieve this toal, QA needs access to plant
                                                               ~

operations .-nuclear and non-nuclear. All other nuclear facility . utilities have the head of 4A at the level of VP so tht he may attend all VP level and presidential staff meetings. He is equal to other '

 ,        VPc and roceives first hand information when problems or potential                 ;

problemn arise. He is also available to advise the other officers when f ho esso potential problems and can stop them before there is act tally G problon --Pro-activo.

X .. o O

• Second Lotter Pagi Too At P G & E, the QA head is a manager, below VPs, is not included in staff stetings, is seldom briefed on problem areas until there is a  !

reel problem, and is carefully and deliberately kept out of staff Ecotings . He relies on VPs telling him what they went him to know, . I cod tht in darn little. At P G y B, quality Control does not report to QA -- a situation olnest unique to PG & E. These people report to VP Engineering. It hns hpponod, sony times, the t there is a serious nonconformance problem with RC orri QA is not notified, or is denied access to information.

   *Ehy?    Because VP Engineering does not want the problems laid on them--

so there is extensive pressure to oever them up and the QC people havo no ono to go to with their concerns. They, Should, they must, report to QA whose only function is to solve problems. The lotter I sent you from the Diablo employee to the NRC was written by a ( f) named He is o good ( ). He wrote that letter because he received no satistsetion Cn concerns about safety, procurement of commercial grade items for une in safety related functions, ard the serious harassment he and othern received when he mentioned these concerns. Some of the open t itemahemontionedtotheNRCare2yearsold.hooneinEngineerirg , managemont wanted to deal with it. He could not go to QA vithout being fired. He and his entire QC depa rtment should report to SA, obviously. . I I l

   .e       .    .

i 3 - 3econd letter Page Three - ' ( 1 The non to whom l did tske his concerns was,his su ,erior i i in' Encincering,( ) This is the man who followed his superiors instructions to bury the problem, stee it, eerig .

                                                                                          )

And ( tried -- with obvious and very haavy handed harassment. He was so bad

         'th at it did leak out to(
                                                 ),{                    who immediately held 'aq investigation (because in thie case it involved harassnent or 44      .

poroonn'o1 as well as QC people) and it was found th e.t, ihdeed, there ccre all forms or harassment. ( ) report got that man,( coved out of that area, and it also brou6h t criticism and certain harass-

                                                                                            )
    . mont to {                ')departmentby(

ot(

                                         )(         a) ealied it a "ha tchet job", screamed
                      ) and started a non-step barassment and direct interference in[              QA department.
                                                                                                 }
                                                                                                 )

Thisman( ') is supposed to keep GA abreast of all problems--since { }hasplacedthismanbetweenhimselfandhis(

                                                                                   ). The-situation is leughable.                                           '
                                                                                                 )

To return to [ )for a moment--this man feels he was sacrif. iced b upper-management. That he only did what he was told to do and that has icf t niin to 'oving slowly in the breese". File { )is somewhat unstable, he is correct -- and be has vowed to take them all down with , him if given a chance. Supeeca him and you will have a hup osse on

                                                                                                  \

P. 0 (4 E for deliberotoly ignoring the Federal . law to revesi all 1 utn-o'enformanco problems and deal with them in a timely sonner. l will add good solid, unemotional corroboration. i i

I lo. Socond letter Page four

                                                                                   )

This whole proh' h w uld not have occured if(~ )snd QA had been  ! , 511 owed to _ pursue and solve the commercial grade problem which he identified last year. He knows the potential for problems is real I and serious and his hands have been tied by direct ins truction of (. f He will never pass the blame off for net completirsj tho investigation unless he is asked directly - "were you instructed to stop1" I' hor.e you can follow all this. I am not editin6 it -- just streams cf consciousness. The NRC is clear ab9ut the independence of QA and

  'obout acting in a timely manner and about harassment. {                ) at the NRC would love to get a hold of this.

If you have some way of getting this to the public by usingh . ) Cr the NRC wnuld be compelled to act quickly and probably terce the matter into public hearings. I know we are triking about a somewhat gray area of mantgement philosophy, but here it is coupled -ith direct danger to public sofety. I hope you can do comethin6 l i l

                                                  =

m P GovE FOO INTCA - COMP ANY USES . h,*,le'n'f"' DIABLO CANYON POWER PLANT ,, , - s To Division or Depeerment p  ! MLE No- 507.012 RE LETTER oF L sus;Ecv ' Chromate Spill Report QCS 85-0115 C - January 2, 1987 ( 7

   -                              J                                        M This eport was filed at the request of               f                                                                1 I

no open concerns regarding report QCS 85-0115. u / ~ m - There were no findings and if there were ave issued a Nuclear-Plant Problem Report. The NPPR would havI gone by a different flowpath through the department so even' if the report were to be misplaced, the problem would still get a review. m annot, at this point, prove that the report was issued. jonly an observation, not a violation of any procedure requirements that could find at the time. The observation had to do with the manipu ation of valves within a clearance boundary by I & C. Operations was not required to' check these valves and it caused the CCW head tank to over-flow. 1 & C had no pro, ure (loop test) to control what they did. Since this has happened elieve an NCR was issued requiring Loop Test instructions to be sued. QC checks for the I & C engineer signature when watching loop tests, b f eel what'ha d was that the report was held up for changes and

  - ost tra            .o f.        need to do a reconciliation of our 1985 Surveillance Log like           di     for 1984 to make sure no reports have fallen through the-cracks.         '~
                                                    - - - ,                                                                   1

[% # _ M 1 Information in this record was deleted in accordance with the freedom of Information Act, exemptions 6 F0IA f * /2 F 8/3 i

b on 2/17/87. Mr. Cruz, (sic) I am aware that you were present at a meeting ~ on Wed. at Diablo Canyon - and ' that you are with the NRC. Regarding the information I am going to relate to you - I cannot come forward and) prove / testify to this.)wouldhave ..... (I heard him talking to Be me of thefired as hemee Wednesday did( tings ( ~ ?and( absolutely furious and they intend to )get rid of that B')arefurious-

d. ( ;

{ ), our corporate [ . .)) . I have known for a long time that our operations management hates the QA/QC ) people. is on Quality)wereteam "ly something done to pacify thej( players". ThecurrentL NRC anTaTT previous

         ", .. .%. gA
                                                                                                                                                  }is
                     %seen and(.. . as an intruder,.a            (sic)(towhomL          disloyal .S troublemaker reports) have been  - not    a team player.) ( him atid harassing undermining in)an effort to bring him into line. ('                                                   )(sic) is over here            '.

constantl )howtohandleC They have discussed many ploys to pu blatant.)y, They usedor on the phone, discussing with( spurious sexual harr(assment suit) from personnel to involve (" in a t him in his p and interviewed disgruntled together a damagirig performance review, they are constantly c(onfering ont )Jpeople budget and personnel and what they can get cut out* - they have seen to it aht

         *           (personal information              ) is forbidden to travel and now they are trying to find damaging to use against him.   "

will receive favorably anyone with damagin(g information.Jehasmadeitclearthathe (It seems incredible, I know, that I and others should know all this, but(. jandQ

                                                                                                                                                       )
          ,            are so sure of themselves they don't bother to be discreet).                                                                  '

Thenewestplanistomake( (* Iand to make( . d 3equaltol at then have him "in control" and tha)VP of corporate' Quality. They feel they will t( Jwillthinquit. i ' I wouldn't care about their silly corporate policies and persecutions but QA and QC perform Safety functions and what is happening is wrong. I hope you can read this - I could not type this at my desk so I handwrote it at home. But if anyone in my area sees this, my writing will be recognized and I too will be fire. Please, if you must keep this, have it typed and destroy sy original - PLEASE !!

                       *They are going to try and see he doesn't get an annual bonus, or at least a very small one.

Information in this record was deleted in accordance with the Freedom of information Act, exemptions - la) el '7( g - F0lA 9 7- /A S' 8/2 I,

p ,. - g 9-

            ~'

Mar 5 87 1 I write'you again to clarify some issues raised in the Board notification. .. RE: Statement of concerns-I Procurement'-- When PG&E buys an item from a qualified supplier, they -(PG&E) do an audit of that supplier, to ensure that all safety requirements, stress tests,.etc, have been performed and that there is proper and complete documentation to prove it.(the proper paper i work was not-performed during the time PG&E was madly stocking its warehouse .in order to put the. cost for these rep 1& cement items .into - the capitalization cost of the plant, get it'into the rate base. It w ' haswarehouse insisted that the

                      ' paperwork the(as be done, period.

during thiswas jharrasment period allowed.of" ( fill the no mat PG&E asks that the supplier do an audit of their suppliersi and . that chain theeffect second whisupplier doanywhere'in an audit of the.world. their suppliers, ch can lead PG&Eindoes a d&isy random audits of secondary - tertiary acc. suppliers to ensure the - system i is working. (In all the hundred and hundreds of audits performed on material purchased . from 1981' on, no' probbms have been found. . Eventhe( finds that strange. -(Prior to 1981 PG&Ehadno.commitm)enttotheNRCtodocumentalltheprocurementso it was not done.- has been denied funds to look into i procurement prior (to 1981}, so it is not done. The warehouse items being:used from that period are NOT quality verified.. i II QC Documentation While some work gackages have been physically altered, the biggest problem is that 30LD POINTS were worked through.-i.e. A hold point .

               ..        requires.the si noff6    by the appropriate QC person indicating that                   An all the prop &reprocedures/ safety requirements hage'been net.

audit. performed by QA the 1st 2 weeks of Feb. on the'maintenence department revealed many instances of this. Ask for it at the hearing. Safety procedures were not followed during maintenence done during Unit 1 downtime for refueling. !La_nI "open items" - '

                         -This AR's,.NCR's,      QE's was the basis     were left unreso)lved for{                1etter. - completely unaddressed Unit II is about to go down for' refueling and the same lackadaisical attitude exists in operations. .In fact, the                                                 , ,)

has prepared a letter in which he states the(number of open NCR (non confobist reports - as serious as you get) Quality evaluations

                      ,, and Action Requests he is going to allow toThis        remain       open. I think is outrageous. He says it is 30 NCRs, 250 AR, as PLANT POLICY.

it will be expensive to close them out so the plant will only address a certain number. The[ [isoutragedandpowerlessbecause

         .                the QC does not report t'o him.                           .

This letter from Ihasnotbeensignedyat,butitwill no further. be proof positive ( that safe 5y isto beggogy sg fgr 1,n accordance with the Freedom of Information Act, exemptions '7(as - I0lA S7aMS--A/p I [' ~

                 ..             o.      7                                     -
           ' b i}[                  -

y j r 7 Page 2 Mar 3 letter =

                                 .(-

training). 'The new man,isbeingeasedoutas( _ i. He has gone for 6 months NCR"a should be left ope (n. He),is being put in there to satisfy theprepa t LMRP and other'intervenors. Don't buy it, he's the same mold) III~ PG&E Support for- Quality 1

                                 'A. See;above. Investigating procurement prior to 1981.
                      *        . B. 'QA technically, reports directly to the Pres. and Chairman of the Board. In                                                               wants po do is
                                ' channeled t,hroug (practice, everything.QA dogs             -

J. t This man, A was 3 during the time-the pro lems' lea # ding to UP. came' about. e is loud, bullying, overbearing and pathetically-out1of his lea Likef )(' only ) listen will not tolisten his( to his manager,[gue in . , will

             ',                                                          He[}    tee ) truth does not, get through because                              ,

(.

                                               )is the    f: Liter.

Also, IN DIRECT CONFLICT WITH FEDERAL LAV the QA budget and activit6es. are reviewed Power and a pproved by apother line, organization. Nuclear-Generation - ( )('). A conflict'of-interest at the least. Breaking'the~ law definitely. -( )wants the- QA budget, which is at the Manager,'s Level, reviewed by an officer.of the company -- VP Level. He could mako QA VP Level, but then it can't be controlled- j so completely.- ) a {

    ,u
                                -c.        Staff meetings X                ,               QA is         mgr. has been 1.nfrequent.           But   noinvited other    to NPG VP's         stafformeetings include          brier              by(which an)d  Qt,there      -

1 are multitudes of problems. so He: I doesn't have Staff Meetings a(nymore. )( lved the problem.)is the only onI ' constant access. , e F. #2.( .)didinviteQC(notQA)personnelintohisoffice - kunt but 'it was to ask who leaked, not to express support. G. Right " don't bother us, we're making Megawatts". I IV QA stopped its investigation of procurement prior to 1981 because funds were cut off. By procurement problem do you mean harrasment by Procurement management of QC personnel? ,This is true. QC k\de.

                               . management-at the plant knew about it (                                 ') and W<i but did nothing_ and never informed (
                                            -        ~

The in(,fo was les)ked

                                                                                                . ' . As to resolution of , *D*P3 une date.

problem (Procurement prior ti1981) there _i_s, no resolution to P[ip, ;

                                                                                                                                        % mg c.

Spec (ialty Group members - not QC personnel.' ) tirades Created atmosphere of soft fear and "just do the j'ob - with or withoug proper paperwork - FILL THE WAREHOUSE." ( Jwas( jboss.

    . . _ w.                                                                                        '

Mar 3 letter - page.3 F. Rewriting reports - confirmed by_ testimony in the Harrasoent, R eport File 707 and letter attachments

              .                   V-   Non Conformances. See Above (IIQC documentation)                           -

c QC knows of serious NCR's and passes information through the present It is QAchain of command that does to their not get the inforespective bosses in As from operations. OPERATIONS) ( if he ever requested to be put. on the circulatin6 list of QC so he could be kept informed. The anser is YES and FIRST TIME HE WAS DENIED. Reason? Our Zerox costs are too high. SECOND TIME he

                                . demanded.                                                                          J at This time they agreed to give a copy           to( der no j, but un                                    .

the plant whou could circumstances would forward they, the it ' to(t planmanagement, communicate directly with QA. (Turf issue vs safety). - I hope this will calrify some issues and help you ask the right

     , .                          questions when you get the chance.                          ,

PS One of the important audit functions of QC is to perform management reviews - MR's. j It is essential to find out if management ' is doing its job in a TIMELY, safe way. The answer in previous MR's has been "No no- timely - not supportive of Quality. So management has solved the problem. They have forbidden QC to perform any more MR's and since QC reports to them, MR's are not stopped. (See( )letterandtestimony. p .' e O e 9 4 9 e t i e, . ... . . g

~ . w s , , , ;2T&, ;;;--- - -- I. -. ( POWE-POR INTR A - COMPANY U$78

        . L' p"',U% "  DIABLO CANYON POWER PLANT
        - To D v+on o< Oepa'imeet                                                                              )
                                                                                                               /

ntE No 507.012 ' RE T LETTER OF - { j

        . SUBJECT           Resolution of QCI 84-0601 Concerns                                                               1 i

Jardary 5,1987 ' ,g  ;-) 1 l i 1 I, l Concerns noted on QCI 84-0601 were documented on flPPR' l DCI-84-QC-P0354. 8 At this time, to the best of l knowledge, concerns have -. been resolved and were handlrd i properly. I'ad,dition,- duriga t performance of this surveillance that, hindered in any way. - J o not feel. L e 'l I i f '

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r

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                        %,                q
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Attachments __ ( !' Inf9tmation in this record was deleted , 1 { in accordance with th Freedom of Informatio Act, exemptions F01A M - M 7 Y L - ' _ __ __ _}}