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hf y d - DiatHo C?ayon Nuclear Progen Post Cihce Sos 387 Avde Bee'en. Confomie 93424 Telepnene (805) 895 2356
, , MINUTES OF MEETINC HELD DECEMBER 22, 1983 I
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?y A meeting was scheduled this date at 11:00 A.M. for
) the purpose of clarification regarding Mr. Steven D7 Lockerts termination and subsequent grievance.which
$ was origina11y' presented and denied by Pullaan' Power ij -Products on December 19, 1983.
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%ue Those in attendance today were:
Ogj Paul Stieger, Resident Construction Manager g'j Bob Fau11. Assistant Resident Manager Frank.Lysutey, QC Manager T4 Harold Karner QA/QC Manager y Russ Nolle, Supervisor ip; Tony Paget. Office Manager Q Joe Watson, Area. Ten. Veld Test QC Inspector W Jeff Charboneau, Supervisor
@ Jim Cunningham, (C Leadman Mj Sid Stolper, U.A. Business Manager jai Craig Heagher, U.A. Steward fd Steven Lockert, QC Inspector N
% Following introductions. Mr. Lockert was given the
.d opportunity to read his termination slip and also j read his version of events preceeding the termination.
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A Q The primary disagreement appears to lia'in the testimony from Mr. Cunningham who states he notified Mr. Lockert on 113 two separate occasions'for work assignment to Area Ten
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'4 and Lockert's concertion of being told only one time. The termination slip identifies a time of 8:10 A.M. when Jim
.] Cunningham was still searcEing for Mr.'Lockert.'who had i not reported to Area Ten. Testimony from Mr. Lockert. states i that at approximately 6:50 A.M. he indeed was told'to report to Area Ten and _ he alleges that he, told Mr.?Cunningham there was other work to complete first..namely two STPR's.-
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pt Craig Meagher, U.A. Steward,~ read his account.ofLevents.on-4 the day; prior to the~ termination, December 14,'1983, and
$'3 the record will show December- 13th was a Tuesday 'and inot d Wednesday, as written. Correction.was acknowledged. A
(#- lengthy ' discussion follove ! es to what time .of day the 3@ notice was given to Mr.-Lockert to report to Area Ten and how much work remained for Mr. Lockert:to complete, namely- ~
@4 the two STPR's.. Lockert also contends he' informed'Jia- '
I) 1.g Cunningham of additional paperwork that required-attention-prior to reporting to Area Ten, but. . Jim Cunningham contends b
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- 9,i he was aware only of the two STPR's, which could have 'l di been completed in a reasonably short' time.
s ..a Ay The lapse of time from the first notification at
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approximately 7:00 A.M. until 9:20 A.M. when Mr. Lockert
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/ There being no further discussion or testimony, it is Pullman Power Products position to deny grievance and
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$ This document lists (or directly references) each allegation or concern j brought to the attention of NRC personnel. The purpose of this statement .
g{ sheet is to assure that all points raised by the alleger are covered.
r(W If the probicn statement is not clear as to who, what, where, when, or why f" regarding the issue, the cocsentary section will amplify the statement. The
.i corraentary section will al'so be used if there is apparent conflicting p(j .
information or if there is no or very little original information available i ff.ht which describes the concern (s). (This can occur if, for example, a line
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HUDSON - 1/9 /84
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KIRS CH : The time is 7:08 p.m. , January 9,1984. The place, the Howard Johnson Conf erence Room at the Howard Johnson's Motel in San Luis Obispo, California. Present f rom GAP are John Clewitt, attorney, address,19010 Street Northwest, Washinoton, D.C. 20009. Telephone Number (202) 667-7904. Mr. Clewitt's client, Harold Hudson, # 3 j esent u- .. . _ . . .
f rom the Nuclear Regulatory Commission Region 5 are Gonzalo Hernandez, Lou Schoenberger, Phil Morel, and Dennis Kirsch. The address of Region 5 is 1450 Maria Lane, Suite 210, Walnut Creek, California 94 596. Area code is (415) 943-3700. Okay, the purpose for this interview, Mr. Hudson, was to make arrancements I
for you to present to the Cmmission staf f additional concerns j that you have in sme particular area, and I'm not really all that sure which area it is.
HUDSCN : Okay, what I have done is I have prepared a second report. I'll turn over a copy to you now. What I would like to do is during this meeting is go through this report, familiarize you with what my concerns are, and then hopefully some of you will take this report and review it and investigate those items that I think are significant to determine their validity or decide that they' re not that valid.
KIRSCH: Okay, in preparation for all of this so that the typist that runs through this, listens to this tape can recognize
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one another's voice sounds, my name is Dennis Kirsch. Gonzalo...
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- O g HERNANDEZ : My name is Gonzalo Hernandez.
S CHOENBERGER: I' m Lou Schoenberger.- ._;
MOREL: Bill Morel speakin'g here.
CLEWITT: This is John Clewitt from GAP. _
HUDS ON: Harold Hudson.
KIRSCH : Okay, without further ado, let's get on with your concerns.
HUDSON:- Okay, I have prepared a report. I address it to Mr. Wallensky, but at this time it is not being oresented to him, I am presenting it to this NRC meeting. The subject of.this-report is quality assurance defibiencies in the ultrasonic measurement of reactive coolent pressure boundary valves for minimum wall' thickness requirements as requested by the Atomic Energy Commission in their letter of 6/20/72 to Pacific' Gas -and Electric Company of the Diablo Canyon Nuclear . Power Plant. The United. States Atomic Energy Commission in 1972, requested Pacific Gas and Electric Company to verify the Diablo Canyon Nuclear' Plant that valves important to nuclear safety installed or 'to be-installed at the facility meet the minimum < wall thickness requirements of' the specified codes or standards.' Major auality assurance program deficiencies have been identified in the PG&E' and W. Kellogg Pullman Power Products L quality assurance' records for the ultrasonic thickness measurement of these' valves. The Nuclear. Regulatory. Commission should review these deficiencies and determine if the use of these valves, important to nuclear safety, will1effect the safe opera, tion of. Unit l'and Unit 2-reactors of the Diablo Canyon Nuclear Plant. The United' States- ~
H udson/1-9 2
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. Atomic' Energy Commission Region 5 letter dated 6/20/72, reference and dockets no. 050-0133, 050-0275, 050-0323 states:
"Information obtained during inspections conducted by the Director of Regulatory Operations disclosed a number f -
facilities have. been equipped with valves with wall thickness below the minimum requirement specified by the applicable code standards and specifications. In other instances,
' licensees have not been able to document whether or not the.
valves met minimum wall thickness requirements. The AEC' letter requested PG&E "to verify, through manufacturer's records or other suitable means, that valves important to nuclear safety, installed or to be installed at your f acility, meet the minimum !
wall thickness requirements of the specified codes or standards." The AEC letter indicated that " sufficient demonstration of acceptable wall thickness" would be ~ " documented results of ultrasonic measurement of wall thickness in comparison to specific minimum wall thickness. DocumentationLthat the U.T.
measurement technique is demonstrated to have a maximum error on !
repeated delete an ' accuracy of not more than_50%(?) of' the wall i
thickness." Because PGsE did not have the manufacturer' ;
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Westinghouse's - records concerning valve minimum wall thickness,.
it was decided to' ultrasonically measure the valves to determine k minimum wall 'thi'ckness. - PG&E l initiated discrepance report
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No.103-R1 which stated that individual valves' measured: as shown:
i o'n Westinghouse letter No. PGsE28. - The valves identified in the i
Westinghouse. letter are called out: as Class-11 valves which make
,q up the accurate fluid pressure. boundary and are- part of piping ~y Hudson /1-9 3
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9 system designated by PG&E as Seismic Class-1. M. W. Kellogg.
Pullman Power Products initiated engineering specification Diablo ____
ESD No. 236 ultrasonic thickness measurement of boundary valves. It was approved -by PG&E and . implemented the valve body .
wall thickness measurement by ultrasonic method as requested by the AEC. Anytime during this meeting, if the'four'of you have a question, just go ahead and interrupt. ... you have a chance to familiarize yourselves with it. There are.. major quality assurance program deficiencies in the cuality assurance records of the ultrasonic thickness measurement of Unit 1 and Unit 2 boundary valves as performed by M. W. Kellogg Pullman Power Products.
There is no documented evidence that the ultrasonic thickness measurement were a control and accomplished using a qualified procedure. In addition, an audit of 254 valve wall.
thickness data reports bound at the traceability of the thickness readings obtained and the calibration of such equipment cannot be assured by the existing documentation. Section (A): The ultrasonic thickness measurement of reactor'coolent and pressure boundary valves has not been controlled and accomplished usino a a
qualified procedure. One, there is no evidence from the !
l Procedure Qualification Record, PQR, documenting ' that. the .
4 ultrasonic measurement procedure, ESD-236. is qualified by c a- !
proven demonstration, procedure qualification test, of valve wall thickness measurement. This a non-conformance to '10 CPR 50. ,
A'ppendix B, 9 and 17 and PG&E' contract specification st711, _
Section 43.23 and Section 4.3.29, ref erence, ESD. 236. Two, there ;
- l is no evidence of a procedure qualification record documenting. -l l
Hudson /1-9 4 i
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that the ultrasonic measurement technique ESD 236 procedure is demonstrated to have a maximum error c( repeatability and ;s_. _ _ ),
accuracy of not more than 2% of the wall thickness as reauired by )
the AEC' letter of 6/20/72. It is alleged that PG&E, A. W.
Kellogg..__
Pullman Power Products, did not- perform .a procedure l
qualif1 cation test as demonstrated 'that- ESD '236 had a maximum 1
error of repeatability and accuracy of not more than 2% of the !
wall thickness. There is no' documentation POR that ESD 236 documentation packages that records the procedure qualification 3 i
test. About the.PQR, PG&E, M.W. Kellogg Pullman Power Products, does not comply with the AEC requirements 'for ' documentation.
Three, there is no documented evidence of- procedure' verification-tests, as' required by ESD 236.6.7 to determine that transducers will be of a suitable frecuency, size, adoptiveiof shoes, wedges or saddles as each valve measurement requires. It is;. alleged that PG&E, M. W. Kellogg., Pullman Power Products _ did not perform the procedure _ verification test to determine transducer requir ements_.
Without the procedure verification test documentation, there is no assurance that the transducers used ,
were of a suitable frecuency, size, in adapting. the shoes, -wedges '
or saddles as each valve measurement requires. .Complicatina the issue is an M. W. Kellogg interoffice correspondence dated 4/17/73 that ' states: "The transducers available are adeaunte 'for '!
flat surf aces, flat smooth surfaces.- There are no adaptors,. '!
shoes or wedges available should them: be ~ necessary." Item f our ,.
at this time it appears that the transducers supplied ~may not be '
the correct type for thickness reads. If this is - true, we'll- - - 4 Hudson /1-9 5
have to order new transducers. Item five, effect of surf ace contour and roughness must be tested prior to making any .
recordable results. The absence of documented procedure verification tests to determine the proper transducer to be used, the interof fice correspondence report of the absence of adaptor shoes or wedges, that tranducers supplied may not be the correct type, raises serious OA questions about the transducers used to perform the UT measurement. There is no documented evidence of the testing of surf ace contour and roughness for ef fect as referenced, as referred to in the IOC. This testing should have been part of the procedure verification test for which there are no records. The interoffice correspondence concludes that it is doubtful that any meaningful results can be obtained at this time and it is definite that none can be reported until the above major problems are resolved. Without documented records of procedure qualification tests and/or procedure verification tests, there is no assurance that these problems were. resolved.
Item numt 4 four. Pullman Power Products Internal Audit No.101, I
- 1 dated 1/18/82 identified an ESD 236 ultrasonic thickness 1
measurement of boundary valves and ESD 244 ultrasonic thickness i gauge procedure did not have any evidence that the special-processes were controlled and accomplished using qualified _ '
procedures or that qualification records were maintained to j document and assure quality of material and work. There were no !
. procedure qualification records on file for these two '
procedures. It was determined in internal audit No.101 by the 1
Pullman QAQC Manager, H. Connor, that these two ultrasonic ~
Hudson /1-9 6 l
procedures were not non-destructive. testing procedures but were used to measure material thickness and therefore, did not recuire procedure cualification records, procedure cualification tests. ]
This is not a valid determination. Since CFR 50 Appendix B-9, Control of Special Process, states: " Measures shall be established to assure that special processes including welding, i heat treating and non-destructive testing are controlled and l l
accomplished by qualified personnel 'using qualified procedures in accordance with applicable. codes, standards, specifications, et cetera and other special reauirements." PG&E contract specification, No. 8711, Section 4.3.23 Qualification of Processes and Personnel states " Contractor shall assure the special processes such as welding, heat treating and non- i l
I destructive testing are controlled in accordance with applicable
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codes, standards, specifications et cetera, and that special processes are accomplished by cualified personnel usino cualified procedures. All special processes, not just welding, heat treating and non-destructive testing are to be controlled and accomplished using qualified procedures, procedure qualification tests. The determination that ESD 236 and ESD 244 were not non-destructive testing procedures does not exclude ,the procedures '
f rom qualification requirements for special- processes. . The ultrasonic measurement of reactor coolent pressure boundary '
valves for body wall thickness, curved surfaces, is a special process. ESD- 236 as well as ESD 244 did not conform to 10 CFR 50 Appendix B-9 and PG&E Contract Specification 8711, Section 4.3.23 requirements for special processes to be controlled and.
Hudson /1-9 7
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accomplished using qualified procedures. M. W. Kellogg Pul,lman Power Products ESD 236 and ESD 244 do not conform to 10 CFR Appendix B, Section 17 and PG&E Contract 8711, Section 41.3.29 requirements to maintain records such as qualification of procedures and equipment, adequate to document and assure quality of material and work. Pullman Power Products QAQC Manager, H. Connor, was wrong in his determination that ESD 236 and'ESD 244 did not require procedure qualification records, procedure qualification tests. It is alleged that this is hopeless rationalization by a QAOC Manager to cov9r up a serious breach in the cuality assurance' reauirements for special processes as required by 10 CFR 50 Appendix B and PG&E' Contract' Specification 8711. No corrective action'of any sort has been i initiated by Pullman Power Products concernina the use of ESD 236 and ESD 244 about procedure cualification records, procedure qualification tests. The Nuclear Regulatory Commission should investigate this quality assurance deficiency and assure a proper corrective action. Without a procedure . qualification record there is no assurance that the ultrasonic thickness' measurement of the reactor coolent pressure boundary valves.have1been )
controlled, accomplished using a qualified procedure. ,
Section B. Pullman Power Products' unscheduled internal- i audit no. 34 of 254 valve. wall thickness data reports found the
'l traceability of the thickness ' readings obtained could. not be assured as required by ESD 236.4.1. . And 'the traceability where certification of equipment calibration and manufacture:or any ~2
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calibration organization, could. not bef assured:as recuired; by '
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ESD 236.4.2. The valve wall thickness data reports do not provide the proper information necessary for traceability. Th'e ,
.I more signifipant quality assurance' discrepancies are listed j i
below:
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- 1. None of the 254 data reports audited listed the size, shape or type designation, manufacturer's designation or i description of the transducer used to perform 'the valve wall thickness measurement as required by. ASTM Ell 4-63.6.1.2 reference 1 to ES D 2 36.3. 2.5.1. l
- 2. Most of the data reports do ' list a transducer serial number but ESD 236 documentation packages dol not provide 'any I 1
information or description for transducers by serial number.
- 3. Seven data reports do not list a serial numbe'r of the' U.T . thickness tester used to make. the measurements.
- 4. Nineteen data reports .do not list the testing frequenc.v or frequency of the transducers used to make the i
inspection. !
- 5. Nineteen data reports list both the Nortec NDT-120 '
serial number 1224 and the Bronson sonorav model 303D,. serial number 18060 as a U.T. thickness- tester used to make the valve-measurements. But, there is only one set of calibration-l information and valve body wall measurement; results1for each data . ,
report. .The actual U.T. equipment used to make-'the ' valve measurements cannot be determined for- the purpose L of !
replaceability. -
- 6. 207 data reports reference serial numbers for U.T.
thickness test equipment- that could no't be traced to i
H udson/1-9 -84 ' =9
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' documentation for certification of eauipment calibration f rom either the manufacturer or any calibration organization as required by ESD 236.4.2.
- 7. Fourteen data reports do not list serial num ers for the. j micrometers used to set the. calibration (coughing, couple words 1
unintelligible) on the valves by a mechanical means.. Micrometers i used to make the valve measursments cannot be determined for - the -
purpose of traceabilfty.
- 8. Eighty-four data reports referenced serial numbers for-micrometers that could not be traced through documentation for certification and equipment calibration f rom either the manuf acturer or any other calibration organization as reauired by ESD 236.4. 2.
- 9. Six data reports do. not list any informat' ion concerning the step wedge blocks used for calibrating the U.T. t' ester j equipment.
- 10. Eleven data reports do not list pre- or post-operation - l calibration information.-
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- 11. Forty-two data reports indicated' the valves as below the :
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_ , < . '- minimum allowed wall thickness. The -data report ; forms' were . J
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signed in'the item number seven space that indicated:the valves were physically marked as acceptable. l
- 12. Many data. reports were found to have~ original information whited out' and new information : inserted. : There are ;
no signatures of the persons making the changes. or. explanations. l for the changes.
' Hudson /1-9 -84. -: 10
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- 13. Eleven data reports do not have a complete measurement-inspection of all areas of the valves as required by the _ !
procedures. There is no documentation authorizing the incomplete measurements. _
- 14. Fourteen valve locations listed by Westinghouse letter No. PG&E 2080 to be measured had no documented evidence of data reports of being UT examined. .Two of the. twenty valves physically checked hpd serial numbers that did not match the data report serial number.
Section C. The Atomic Energy Commission lett'er of 6/20/72, page 3, paragraph 6, states: "In' certain instances, you may wish to repair valves found to have wall thickness below the- specified limit. In such instances, you are requested to provide to' this office for our review, the. proposed repair procedurer.includino a description of techniques to be used to verify the acceptability of the repaired components. There is no documented evidence. in ESD 236 documentation packages that M. W. Kellogg . Pullman Power Products or PG&E complied with' this AEC reauirement.
- 1. There are forty-seven data reports that indicate that -
valves were below- minimum wall. reauirements. Unscheduled internal audit no. 34, audit' action request no. 8, identified two- l valve s , loca t i on N o. 2-P CD-4 4 5 A , an d N o. 2-P CD-4 4 5B th'a t 'wer e !
O w' ell repaired to meet the minimum wall reauirements. ESD 236 documentation packages do not specify which 'of the- valves were s .
1 wel4 repaired. It is an item of -concern and- the NRC- should investigate as to which valves were welk repaired or replaced. i j
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- 2. The ESD 236 documentation packages dot no provide any information as to the walls for use, the well repaired ,
valves in locations No. 2-PCD-4 55A and No. 2-PCD-455B and any other valves that might have been well repaired. The e is.no-documentation available to assure that the' agency reviewed and approved the wall procedures used or the description of techniques used to verify the acceptability of 'the repaired
, valves.- The NRC shopld determine what valves were well repaired,
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if- the _ wall procedure used was acceptable, and if .the technioue used to verify acceptability was accurate, adecuat'e. 'There is.no assurance in the ESD 236 documentation packages that va.lves, ; wall-repaired, meet the AEC-requirements. I' d'like to- inject a note here.
The two valves that were identified as being well repaired are Uni't 2' valves. I would like to suggest that,there:are well repaired valves in Unit 1. As I stated there is: no ~ specific-record listing what valves were .well repaired. I identified these two . valves of f a series of data reports' that. stated ' that they were well repaired. These are the only two I' know of specifically that were repaired,- but I suspect; that there were probably others, and I suspect maybe some included in Unit 1- -
coolent boundary pressure system.
- KIRS CH: What leads you to expect that' there-'are some in Unit 17 HUDS ON : The f act - that 'there are forty-seven data reports..
KIRS CH: Why would the fact that there are forty-seven data-reports lead one to conclude that Unit L1 -valves 'had been1well '
repaired?
H udson/1-9 -8 4 . - 12
1 HUDS ON : Because these valves, in the internal audit that I performed, some valves marked as Unit 2 were installed in ,_
i-Uni t 1. Now, I don' t have a list of the valves that werd well repaired. That is a problem. To my knowledge, no li t of valves that were well repaired.- I have only identified two valves that were.
KIRS CH : How do you know, how many valves were well repaired? ,
HUDS ON : That's just it. There's . no. . . The ESD 2 36 documentation packages do not specify how many valves were well repaired.
.I KIRS CH : Is it possible that only one or. two valves were well repaired? I . e . , no. 2 -P CD-4 55 A and B .
HUDS ON : It is possible. But that is why I 'am . sugoesting to the NRC that perhaps this is an item of concern and should be investigated because there are valve data reports that listed valves'below minimum wall and these valves were eventually ~
installed. Now, I do not know. The data reports are listed by valve location, not by individual serial numbers.- S o, if you have a valve location that was originally below minimum ' wall, that valve either' had to be replaced or repaired and subsequently that valve had a valve installed in that valve ' location.- N ow ,
we, the documentation that I reviewed, I was unable to determine in same areas if these valves were well repaired or- if they werei repla ced. That is why I am raising it as an it'em 'of concern.
KIRS CH : Did you try to obtain that documentation, Harold?
u H udson/1-9 .13 -
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' HUDS ON : I reviewed the exi' sting documentation that Pullman Power Products had on'the ' job site. _.
KIRSCH : All of the existing documentation regardino this-job? eg 15UDSON : Yes, that Pullman had, yes. Now, I do not . have access to PG&E records or Westinghouse Records. What I reviewed i
were the Pullman Power Products, M.W. Kellogg ' document ation.
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Within that documentption, there is no specific list 'of valves .
that were repaired and/or replaced. N ow , there are a number of s l'
discrepancy reports generated by Pullman. That's an issue that's ad, dressed in the internal audit report that is attached to this report no. 2.
MOREL (?) : Excuse me, Harold, how many data: reports are there altogether?
HUDS ON : I would say 254 data reports because I reviewed y every one of them.
MOREL ( ?) : Does that cover both Unit 1 and Unit 2? j i
HUDS ON: Unit 1 and Unit 2. '
MOREL ( ?) : When-were those actually done or when was-that work actually completed.
HUDS ON : The work? Well, the work began in the spring of l 1
'73 and there are some data reports marked '76 as having?I think I
valves, these PCD-4 55A valves. There's -a series of.
data . reports on those and their very last -date is labout 1976. .;
Date of installment.
MOREL (?):- Thank you.
4.
. H udson/1-9 -8 4 - 14 4
HUDS ON : Section D. In reviewing the AEC letter of 6/20/72 1
and the Westinghouse letter No. PG&E 2080. of 7/25/72, a cuestion _
is r'aised as to what is a relevant code and/or standard of reactant coolent pressure boundary valves to conform ko and in relation to specified minimum wall thickness. Page 2, j paragraph 4 of the AEC letter states: "Specified minimum wall thickness as used above means the wall thickness required by the relevant codes and statutes. E. g. , ASAD311, 19 5 5, US AS D3110, 19 6 7, US AS D165 MS S-S T-6 6, in effect on the date of the purchase order." Page 1 of the Westinghouse letter states: " Note that the pressure riser safety valve of Diablo Canyon Unit 1 and Unit 2 were designed to meet the requirements of Article 9 of the ASNE Boiler and Pressure Vessel Code, Section 3, 1968 edition.
The valves were not designed to meet the minimum wall thickness requirements of ANSEB16.5. The Westinghouse supplied reactive coolent pressure boundary valves, pressurized with safety valves, were designed to meet the requirements of Article 9 of the ASME Boiler and Pressure Vellel Code, Section 3,1968 edition. This code is not ref erenced in the AEC letter which . specifies relevant codes and standards. Westinghouse states that the valves were not designed to meet the minimum wall thickness requirements of ANSEB16.5, which is referenced in the AEC letter as one of the i
relevant codes. This raises.
, the .a.u. estion of whether 'the Diablo JCanyon reactant _coolent pressure boundary valves, pressurizer safety valves, meet the AEC NRC code requirements.
The NRC should investigate this issue to assure that the Diablo Canyon reactor coolent pressure boundary valves, pressurizer saf ety Hudson /1-9 15
'. l valves, comply with the relevant codes and standards as established by the AEC, NRC for valves within the reactor coolent .. .
pressure boundary as defined in subsection 50.55A Codes and Standards of 10' CFR 50.
The Westinghouse supplied pressurizer safety valves, the reactor coolent pressure boundary valves do not comply -to the PGsE Contract Specification 87.ll, Section 2.2.1 Code Requirements to be designed, .manuf actured and 1 f abricated to an ANSB31.1. PGEE Contract Specification o l
Section 8711.2.1 states: "The reactor _ coolent piping and i l
pressurizer surge' lines and the reactor- coolent systems have been j 1
designed, manuf actured and f abricated- to ANSB31.1 with applicable .
nuclear code cases and will be furnished by Westinghouse." i Contract.8711.2.1 and 2.16 states: The reactor coolent system )
except for main coolent loops and the -pressurized surge lines, are designed, fabricated and ' erected for ASNE Boiler ' Code Section 1. The Westinghouse supplies pressurizer safety valves, the reactor coolent pressure boundary valves as referenced' in the Westinghouse letter'No. PG&E 2080, do not comply with the' PG&E code requirements to be designed, manuf actured. and f abricated to ANSB31.1. This is a nonconformance to PGEE Contract-Specification .8711, Section 2.2.1. The Westinghouse supplied ,
a valves were designed to meet Article :9 of ASNE Boiler and Pressure-Vessel Code Section 3,1968 edition. Note: - PG&E-l Contract Specification 8711,' Section 1.1.1 defines. piping to' include valves, hangars, and spores. Valves are consideredito be!
part of the piping system. The apparent 'nonconformance of.
Westinghouse supplied pressurizer saf ety. valves, reactor coolent
)
H udson/1-9 -84 ' - 16 i
1 s
l
' pressure' boundary valves, PG&E contract specification 8711 code requirements indicates noncompliance with 10 CFR 50 Appendix B, ,
Section 3 Design Control, Section 4, Procurent Dockument Control, Section 7, Control of Perfect Material, Equipment and Services, Section 15, Nonconforming Material Parts or Components. The q Nuclear Regulatory Commission should investigate the -
nonconformance of Westinghouse supplied valves with PG&E codes with a reactive coolent piping pressurizer surge line. of a reactor coolent systems to ' assure .that the properly designed, manufactured and fabricated valves have been installed at the Diablo Canyon Nuclear Plant that the appropriate 10 CFR .50 Appendix B requirements have been complied with. I'd like to-
' inject here I am comparing the PG&E contract 8711 code
-j requirements to the piping as opposed to a Westinghouse letter which specifies what the valves were . designed to. I do not know if there are any relevant nuclear code cases or any other. PG&E generated documentation that would allow a deviation f rom the -
code requirement. That might be a possibility. I do not have l access to that; I do not know. I KIRS CH : Have you reauested that information f rom PG&E?
HUDS ON : I identified this problem as aL pipefitter af ter 'I )
quit my association with CHUC so I do not have ' channel of-communication to' request that type of rinformation. The. internal i audit, of course, was perf ormed while I1was - a CHUC member. . The.
last two sections of' this report have been' formulated af ter I l
terminated my employment with CHUC. '
Oh
. 4 Hudson /1-9-84 -- 17 1 i
v.
KIRS CH (?) : Has the code data report on the reactor coolent system been. repaired and submitted? ,
HUDS ON : I have not had access to that' documentation so I do not know. Like, I say, my whole basis on this partic lar item is you have a PG&E code requirement and there appears to be an apparent nonconformance of that. Now, like I say, there may'be nuclear code cases or - there- may be other pertinent information that I do not have apcess to which may rectify this apparent nonconf ormance. But I, at this point feel it is an item' that should be looked at because there appears to be' a nonconformance to the contract spec which is the procurent document. 'In closing, this report Pullman Power Products Unscheduled Internal Audit, No. 34, Internal Audit No. 101 has identified significant quality assurance program. deficiencies and PG&E, M. W. Kellogg Pullman Power Products cuality assurance records on -the ultrasonic thickness measurement of Unit 1 and No. 2 reactive
.l coolent pressure boundary valves as reauested by the Atomic Energy Commission. 10 CPR 50 Appendix B, Section 17 specified l that sufficient records shall be maintained to f urnish evidence of activities affecting auality. This . requirement has not been i i
implemented. In addition, the ~ auestion was - raised as to what j code or standard the reactor coolent pressure boundary- valves :
pressurizer safety . valves shall be ' designed, manuf actured and fabricated. The Nuclear Regulatory ~ Commission should ' investigate the identified deficiencies to ' determine if tha. use of these:
valves which are important to nuclear' safety will affect-the': safe operation of the Diablo Canyon Nuclear Plant. There is attached' Hudson /1-9-84 .18 i
to the report a copy. of the Pullman Power Products Unscheduled Audit No. 34. Within this document there are copies of-the AEC . ___
letter, the PG&E discrepancy report, the Westinghouse' letter No. PG&E 2080, Pullinan Power Products ESD 236 procedure.
Also-attached is' Pullman Power Products, a portion of Pullman Power Products Internal Audit' No.101, and a couple of the pages out of -
the PG&E contract spec. 8711, which references the code requirements for the, reactor coolent pressure boundary valves. )
KIRSG : Okay, let me see, Action Audit Request. . One audit date was November,1982. , j HUDSON : This audit had not been when I terminated my employment with JVC Department, the audit had not had corrective action identified at.that time.
KIRSG : You terminated your employment with QA Department when?
HUDSON : May of 198'3.
KIRSG : May of 1983. I do not what corrective action-Pullman has implemented as f ar .as taking care of' this audit report. I made - an allegation in here that ESD 236 'Ur thickness measurement is a special process and should have.:been performed; using a qualified procedure. There is no documented evidence that that is the case. There. is no POR for this procedure. The-QAOC Manager determined that since the procedure was_ not a non-disruptive testing procedure, it did not require POR. I disaaree with that determination by the_QRQC manager. . I, feel that '. this . is a special process. As such, measuring the curved surfaces of valves, I believe that requires special eaulpment, special -
Hudson /1-9-84 _19
techniques, and as such, you should have a procedure qualification test to demonstrate that you can actively measure -
the valve wall body thickness.
KIRSG : What's your level of f amiliarity with S TC.1A?
HUDSON : I am f amiliar with it as a basic 'ocument.
d I have-I worked wi th it on a . f ew cases.
KIRSG : Are you level 1, level 2, or level 2 .in ultrasonic... .
HUDSON : I have no ultrasonic certifications. I have limited experience participation in sc.me examinations but oniv as an observer.
MOREL (?) : But you were auditing the records here rather than auditing the actual testing itself?
]
HUDSON: That's right. The actual testing took. place between 1972 and 1976. What I performed was an audit of. the records Pullman had accumulated basically the valve data reports and subsecuent documentation. ' Pullman has a set of three volumes of information, three documentation packages, in a special-projects file. And that was the basis' for the unscheduled internal audit. I would like to point out that . the unscheduled internal audit was the result.of identification on internal audit l No. -1 that the ESD 236 did not. have . a. PQR. ' A t . that' ~ time, I -
accepted the QAQC -Manager's determination that it did not' reauire '
a POR but thought that there might 'be' aubsecuent deficiencies (and then performed an unscheduled internal audit of. the' procedures.
Now, since _ I have lef t the QAQC . department, Is have 'donesome more '
reflecting on ~ this issue and - have come to the ' conclusion that it -
H udson/1-9 2 0
i i
is a special process and as such reauires a procedure !
qualification record. What it boils down to is there appears to r-- l l
me to be sufficient evidence that puts the thickness .cif these valves in question. The AEC required that these valves be-determined to meet the minimum wall thickness requirements. It is my opinion that there is not enough evidence to indicate that l
this has been satisf actorily performed. l l
KIRS CH: H aroldt let me ask you a couple of thouchts here. l This audit'101, why was that one conducted?
HUDS ON: That was a regularly scheduled internal audit of the Pullman Power Products organization. That was part of my regular scheduled audit, my regular audit schedule, I should say.
KIRS CH : What were your responsibilities at the time that l J
was conducted? Or what was your role?
HUDS ON : My role, I was the internal auditor. I performed
)
the audit. I listed what I thought were suspected causes. I made recommendations concerning corrective action. It was then my responsibility once the OAOC manager approved the responsible I supervisor's corrective action to be taken, I would verify that corrective action had been taken and upon verification, I would close out the internal audit and then turn it over to the OAOC manager for his final approval.
MOREL (?) : The issue seems to be this procedure on the ultrasonic examination of these valves. Evidently, correct me if I'm wrong, but f rom what you' ve said, you found that this l
procedure had not been reviewed subject to' the normal cuality .l assurance control.
H uds on/1-9 21 i
4 6 .
i 1
HUDS ON : As being qualified, yes. l MOREL (?): When you identified that,. what happened 'from' that .;
point? What did the. organization do?. ,,
HUDS ON: The organization sat.on it for a . year and three' j months,.a year and two months. IL am .not prepared tonight to !
really go into internal audit 101. I have a number,of allegations to make ' concerning internal . audit .101.
MOREL (?) : But you did audit-1017 HUDS ON : I did the internal'auditLon 101.
MOREL (?): You completed it yourself?
HUDS ON : I completed it' and 'I' d like .to 'say at this . time with some reservations, there are in my opinion, a number of i
serious errors in Internal Audit 101 concerning these NBE and:UT '
j 1
measurement procedures, j MOREL (?) : And then the audit 34, unscheduled audit' 34. was 1 the follow up addressing this ESD 236?
HUDS ON : Right.
i MOREL (?) : And what was theidisposition.of this?
HUDS ON: I do not know what the disposition is.of l l
unscheduled internal audit no. 34. I terminated my employment.
i with the OhQC ' department prior to- them ? implementing ori ;
identifying the corrective ~ action to be taken. So I. do . not . know : g what their corrective action is onE unscheduled -internal audit no. 34. Unscheduled internal audit no. 34_does not address;the problem of ESD 236 not having a. procedurei gualification record. - '
That is only addressed-in internal audit no. 101. Unscheduled ..
~
internal audit no. 34 makes the statement that 0A00 manager H udson/1-9 2 2 1 i
determined that no POR was recuired and that's as f ar as that issue goes in unscheduled internal audit no. 34. The bulk of- _
unscheduled internal audit no. 34 deals with auditing.the valve wall data reports 254 identified reports for compliance with quality assurance records requirements.
INTE RVIEWER( ?) :. Run that by me once more, I guess I. . .
HUDS ON : Okay, unscheduled internal audit no. 34 was audited against the OA records requirements of contractors and contract specification requirements. What I did was I audited the valve data reports (Interviewer: these are the wall thickness reports?). These are the wall thickness reports. I measured those against the ESD 236 requirements for documentation against the reference documents in the procedure the ASTM recuirements, I think AST was the only that' had any actual record reauirements other than ESD 236 and of course my findings were that there was (someone moves chair, word unintelligible) traceability as far as the timing of the readings go, and the calibration eauipment.
What had happened was a lot of these UT tester eauiement had serial numbers for which there were no records of eauipment.
What I suspect happened is in their haste to fill out reports they probably transposed numbers or something like this. Again, this is speculation on my part. That would seem the most likely probable cause of not having records for the UT testing process. But that is speculation.
GONZ ALES : Excuse me, Harold, talk about these cerial numbers that are required. Is that part of the ESD _
~
specification, rather specified in ESD?
Hudson /1-9 23
l I
HUDS ON : The ESD I think makes a reference to serial l
number. Just let me do a quick shuffle here and I can answer tha r--!
question' The. pro'clem with the transducers: i'u ' that t.be ASTM 4
requires a certain series of information and that series of 1
information i.s not provided. The serial numbers are referenced l on the data reports but the ESD 2?6 documentation packages do not l l
list the transducers by any serial;mdeber P believe there is a ]
requirement to list by serial number ..^. (interruption: turns off 3
tape).
KIRS CH : Back on tispe, time 7i56 p.m.
)
l HUDS ON: All right, as f ar a,s Mr. Gonzales' auestion about 4 serial numbers .the data report valve wall thickness report which !
is Figure 2 to the ESD reauires that the test equipment have a serial number and the transducers have a serial number listed.
Now, as I stated there are no, in the documentation packages there is no list of transducers referenced to serial numbers as to type, manuf acturer's designation, whether that eculpment has i special shoes or ' adaptors. . .
KIRS CH : Frequency. J HUDS ON : F requency, that type of information.
KIRS CH : Size. l l
HUDSON: S ize , there's no information that I could find in the documentation packages that tied a transducer serial number to any other type of description. And why I feel it is important, the ASTM was included in the procedure, said the transducers would be identified by manuf acturer's description. .
They tied down the transducer by that type of information. What Hudnon/1-9 2 4
I l
I'm getting at is as f ar as the transducers used, there's no means to. trace them to adequate record of what was actually used -
to make the inspection, what transducers were used. .
INTERVIEWER: Let's go back. You made one statement,-you thought there. were a number of problems with internal audit 10l?
HUDS ON: Yes, INTE BVIENER: Okay, would you care to illuminate some of l l
those? .
j CLBWITT: I think if I can jump in for a second, as I think ;
1 you can probably tell from the level of detail that Harold tries to provide in bringing particular things to the attention of the NRC that he has pretty high standards about that. I think, 1
correct me if I'm wrong, but it's my impression that um, Harold I would like to, in the next several days, at some point, meet with you again to talk about the sorts of things that your question alludes to, about internal audit 101 in greater detail, but isn't really quite ready with all his documentation.
INTERVIEWER: Is that true, Mr. ...?
HUDS ON : That is correct. I am prepared to speak more on Internal Audit 101. I think there are some sianificant problems there. But I, when I make my presentation, I would like to be i able to provide you with adequate documentation and adecuate information. I have this all up here in my head right now. I-don' t want to miss anything. I am in the process right now of putting my notes together so that I can present a total picture of my point of view on Internal Audit 101. .
Hudson /1-9 2 5 -
9
., ., l INTE RVIEWER: Okay, when do you anticipate that you will be ready? -
HUDS ON : I could be ready toward the end of the . week, j Thursday. -
INTERVIEWER: Shall we consider Thursday evening, approximately 7 p.m. again to be a good time?
HUDS ON : That would be fine with me sir.
INTERVIEWER: Okay, let's make the appointment then for this coming Thursday evening, 7 p.m. , here at the same place. I will again try to reserve the conference room here again. And I will, since I have your telephone number, Harold, I'll get back to you and let you know whether or not I' ve got it reserved. Is that all right?
HUDS ON : Yes, sir.
INTE BVIEWER: Because I don' t have John's in the area. 3 INTERVIEWER: You mentioned the AEC letter as an attachment- )
i to the audit here. I was looking for it. I can' t find out where j that is.
HUDS ON : Okay, you have a quality audit checklist on unscheduled internal audit no. 34. That would be the last section of internal audit no. 34. It would be page one. You' ll find under program requirements that there is on the lef t ' hand side reproduced in miniature a copy of the AEC letter. I did this just as a means of expediting my audit so that all the !
pertinent documentmtion that I thought was relevant would be included in the audit. .
INTE BVIEWER: I see one from Westinghouse here.
Hudson /1-9 26
~
HUDS ON : Just back up a couple of pages.
INTERVIEWER: There you go, it's the last part of that. .i 1
INTE RVIEWER: So this is included as part 'of the.
documentation of unscheduled audit no. 347 -
1 HUDS ON : Correct. That is the basis, the documents that are included under this program requirement section were the basis for the internal audit. The main body of what I had audited against was the Pullman Power Products ESD 236 and of course the Westinghouse letter listed the valves to be audited or to be
)
examined.
INTE RVIEWER: Do you know the form that the licensee's response to the NRC in this issue took? Or have you ever read the licensee's response to the NRC7 1 i
HUDS ON: I do not know what the licensee's response is.
There is at the very end of this documentation a letter, an interoffice correspondence by Pullman Power Products, letter no. 50083. They indicated there and I'll read this' letter to you. It says "A recent AEC audit revealed a need for a more ;
comprehensive method for determining the individual boundary valves test results." Now, that letter was dated May 23, 1975.
I do not know what PG&E's response is. That is documentation .
l that I did not have access to. Again, based on my findinc,- that is why I am suggesting to the NRC that this is an area of concern and should be investigated.
INTERVIEWER: Sure. But what you do use, though, you.use the NRC letter as a base for your audit. .
Hudson /1-9 27
t F. .
HUDS ON : As a starting point, as a starting point. That was part of the documentation, part of the Pullman documentation, let r :'
me rephrase that. That was part of the documentation. associated with PG&E DR 103-1. Now that was the basis for starting the -
whole UT examination. PG&E initiated their DR.
INTERVIEWER: What's a DR?
HUDSON : Discrepancy Report.
INTERVIEWER: That's 103-17 HUDSON : 103-R1, I believe.
INTERVIEWER: And that started this valve wall thickness l measurement program or process. With ESD 236, then was a 1 l
I procedure for doing that program. j HUDS ON : Pullman then generated ESD 236 to implement the UT
\
examination as reauired by PG&E DR as required by the AEC letter. l t
INTE RVIEWER: Do you know what happened to the DR? I HUDS ON : The DR. was (was it finally dispositioned?) . No, there's a copy of the DR right af ter the AEC letter and there's a N note that says this DR is cancelled as of 6/21/74, reason all valves are tested to an approved procedure. Any valves that are rejected are processed on an individual discrepancy report, as 4
the Pullman discrepancy report (unintelligible) .
INTERVIEWER: Do you know what they were tested to? Is this ,
something in addition to ESD 236 or what? Do you know?
HUDS ON: I believe they are referring to ESD 236.
INTERVIEWER: Do you know who signed that? ,
HUDS ON: Mr. Tressler, I' believe, oh, vou mean the sionature .
~
on the note.
H udson/1-9 28
^
- j INTERVIEWER: Yes. I guess, I see Mr. Tressler's signature ~
there, too. On the DR. -
=-.
HUDS ON : I think that's a Petersen. 6/24 signature. I do 1
not know the-first name or initial but Petersen is a name that reoccurs in this ESD 236 documentation package.
INTE RVIEWER: When were you first on site here, Harold?
HUDS ON : I came on the Diablo Canyon site in September of 1978. .
INTE RVIEWER: What is the normal time f rame for Pullman to l
close out audit findings or disposition them? !
1 HUDSON: Pullman, per procedure ESD 236 has ten days af ter an audit finding is submitted to an individual for a response, they have ten days to provide a corrective action. be taken. Then ,,i supposedly, comes back to the internal auditor, I review .it and turn it - over to QAQC Manager, he approves Lit.: Then I would normally do a follow-up and make sure that 'that action had. t'aken place.
In reference to Internal Audit 101 an ;immediate ' response was generated but that response was requested thatfit be taken back so that they could provide a revised response.due to what they said were additional findings. Now, that revised response took approximately ten or eleven months before' it came back to ,
the internal auditor.
INTERVIEWER:
Do you have a copy of. the original response?
HUDS ON:
Uh, yes, well, the original response is . the fonly response there is.
A revised response,- there's a- single memo-I added to the AAR which acts as the revised response. .This is again, this is an area. where I would really l'ikef to golinto more.
detail on. j j
Huds on/1-9 2 9 i
- m. - .. ..
5, +..
INTERVIEER: So you' re saying that the response of the Pullman organization was basically to ask for more time and tihen ~-
subsequently, approximately a year later, the revised; response
~
i was a memo that was attached to the AAR, what .is that?
HUDSON : That is 'an Audit Action Recuest. . Gentlemen, there
]
is attached in this package the AAR No.1 to internal audit 101 which addresses that there are no formal procedure aualification records. - That is unaer internal audit no.101.
INTERVIEER: Is this it here?
HUDS ON: No, that's some additional documentation. I think i
the actual' AAR, okay, there's the revised response, here's- th'e j J
actual AAR and this is the AAR as hosed out. Needless to say, this ' internal' audit caused 'a lot of friction. between myself, the Pullman QAQC Manager, over a period of a year.
INTERVIEER: I' d like. to explore that .a little f urther. j l
You say, f riction between yourself and the Pullman OAQC - )
Manager. Were you threatened with any retaliatory action for the identification of these problems? ,
HUDSON: Not for the identification of the problems. Uh,-I was reprimanded on one occasion for addressing the problem to the-Director of Quality Assurance, Pullman Power Products Corporate Headquarters., Subsequently, at' a ' confrontation over another.
issue it got wrapped up into this issue,'I' was threatened with being gotten rid of.
INTERVIEER: By whom?
HUDS ON : By OAQC Manager Harold Connor. '
-l INTE RVIEER: . And . roughly. what time was this?.
Hudson /1-9-84 -i 30
s' ..
4 HUDS ON : This was in January 1983. That threat involves two issues, internal audit 101 and a subsequent issue. I t se ems ' l'ike '~75 they just got everything all wrapped up in one issue ,and went at'
'~
i t.
INTERVIEHER: Were there any other instances where you were threatened with retaliatory action?
HUDS ON : Yes, in the report no.1 that you have a cooy of.
I believe it is unscheduled audit no. 33, but I am not ouite sure.. You have in there a letter of reprimand from Mr. Connor, a handwritten letter.
INTE RVIEWER: Yes.
HUDSON: During that conf erence that was attended .by a Mr. Joe. Watson and Mr. Pat Watson, Mr. Connor again- threatened to get rid of me in that particular case over the issue = of performing an additional investigation to determine cause. of a problem identified in ' unscheduled internal audit' I'll u say 33, but I'm not quite sure if that's it.
INTE RVIEHER: Because he didn' t want you to conduct the f ull investigation?
HUDS ON : Well, the issue surrounded my use of the unscheduled internal audits. Mr. Connor thought. that I should be doing regularly scheduled audits. I attempted to explain.to him that these unscheduled. audits were the result of' identified 7
problems ~ and subsequent investigation I . just' called 'them unscheduled internal audits so that I. oould incorporate- them into my audit processing. I was required to do a certain number of o .
audits each . year. In order to maintain that . number, if I did an H udson/1-9 -84 : 31-1
w, i - !
. . l l
investigation, I would try to make it an internal audit. But he did not like that ... (end of side 1) ..
HUDS ON : Okay, Mr. Connor objected to my continued use of this format during sthis particular conference for which you have !
1 the letter of, reprimand with my response to this reprimand. At l the time, I did not know if the answer was to get another job or (unintelligible, too faint). )
i INTERVIEWER: Were there any ways other than the letter of
]
reprimand, you mentioned f riction (unclear, too f aint) .
HUDSON : Well we yelled and screamed a lot at each other. I j l
would raise issues . .. (Not clear) During the summer and f all of
]
I
'82, I did a lot of investigation to qualify, well not to l qualify, ... Pullman Power Products response was (unclear) my stand was (unclear ) . It was Pullman's responsibility to . . . And that issue was (can't hear this side of tape, too f aint) Me ;
i trying to convince him of my point of view and him trying to - !
l
... And neither one of us... Other than that, there was the normal of fice . . . _
He did not go out of his way. to antaconize me. ...
INTE RVIEWER: Anybody else have any guestions? Okay, let's call this time the end of the interview. The time is 8 :15 p.m. ,
January 9,1984. We will try to get together again on Thursday evening.
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%(,. .j Attachment No. 1
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c1 The attached sheet documents a telephone conversation (on December 20, 1983) j'b between an NRC Region III (Chicago, Illinois) Reactor Inspector (Mr. Isa Yin) i.: , l
[,y and the NRC Region V (Walnut Creek, California)' Director, Division of Reactor !
I'e!3 Safety and Projects (Mr. T. W. Bishop). In the attached sheet Mr. Bishop p '
jy summarizes the concerns o (the alleger) as relayed by M
tl{ Mr. Yin and as understood by Mr. Bishop.
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?[f' On December 22, 1983, Mr. D. F. Kirsch (at the direction of Mr. Bishop)
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telephone conversation is docceented and is enclose'd as Attachment No. 2. .
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4'lj Attachment No.2 !
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+:D p;:,+ The attached sheet documents a telephone conversation (on December 22, 1983)
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,,- If the problem st.atement is not clear as to who, what, where, when, or why j Q regarding the issue, the' commentary section will amplify the statement. The '
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- .4 . EXHIBIT A
$$$Y v%. , .;.' Nd 'f AFFIDAVIT'OF CHARLES STOKES , o M i 4.y. (11/83) 1 q y , i .' n t
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[U ' i% {!y'N' , c % :. in . ;wy+ean emm.u. t n :snmwnngwww. .usman :: .a ~ 1 ,_,_mmamwmmmummrmmer ~ f @., r" s 4 io both units. I had been attempting to convince various die superi. ors to~ write tise DR's in order to minimize my own risk of getting fired. Everyone I talked to supported me but D - refused'to stick their own necks out by signing a DR. They ~ ji;q b either. explained that they were u.p for review, or that they M did not want to jeopardize their positions in the company.. g@yl p et, As a result, I knew the only way to get anything done was 4
- n to write my own'DR's.
I searched out.and found the forms ome ~' - m night, made five copies and prepared rough drafts for three IT w *DR's. The first involved a subje'ct I had worked on since- ' ^ July on the inadequate design o.f g ecurate design drawings, for , F.4 Y% and improper installation and QC inspection of certain welds, [ particularly flare bevel, flare-V and other partial penetra-l f:,::j tion groove welds. This DR disclosed generic deficiencies g for pipe support welding throughout the two units: 9 1. y The design'gare bye,1,and flare-V groove welds [#4/ ,[ typically used on t'ube steel, specifies the maximum instead of t l 4_ 2 minimum radius, which is the relevant indicator of quality. R y Site investigations.re'vealed that the_ welds had up to 25F smaller 1 a,,j . radii.than American Welding Society minimums. Similarly, the , f 'p groove we'ds.did i not honor American Welding Society (AWS) Q . standards for support , steel work,.instead relying on Pullman h g weld proged g s g p ed for piping. .%s a result, welds were ' e made togangles which failed to meet minimum industry standards g and were not full penetration ' welds as ca.Lled for -by the design.~ .j 71nally, the procedures for fillet welds were gn g g with , the AWS requirements f'or contr'o1 of the weld'sgangle. The effect h . is that the design failed to safeguard against slag in the throat ",[d .s of the weld, which should have solid metal. y . -m . gtb (13 2. k drawings are inaccurate,because they didinot reflect c.)y e . _ . . . the design inadequacies for the welds. The effects. include . . ~ - $jj inaccurate use of AWS symbols. For example, the partial welds ~ x : * - W; y 9 - , (
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- described above war.e represented with AWS full penetration symbo .
- , Instt11ation and QC inspection were similarly deficient.'
.s . . j . 3 '. , Pullman's pipe weld procedures were not modified to pp reflect their use on support steel. The inaccurate procedures compromised QC inspections as well The inspectors did not look for the, effects of'using the wrong procedure, since they were N@. inspecting to it. ~
- q. ,,
(f 'The welding controversy was'due to, management's istence b;x, M that the American Welding Society requirements did not apply to Diablo Canyon. ' But management's explanation is selfMefeating ($ . Management's alternative standard is the American Institute of ( Steel Construction (AISC) handbook. Since the AISC section on M v.; A i ~: welded joints references to the AWS code, however, .the distinc-tion is. irrelevant. I have, learned that a transition is under-q, way on-sit ( to follow the AWS code for any new work. Unfortunate-J ly, the p' .t already has been built. This reform cimits correc-tive action for all the existing deficiencies. My Deficiency ~ p Report is enclosed as Exhibit 1. y,; ., - 3 The second'DR that I authored. concerned the angle members ' .e which are part of the piping cupport structures.. Angle members f aroughout the plant were too long for the allowable bending g stress standard used at the plant un g t AIgco The code Id requires on the angle. such angles to range from Jy to .y , depending To research the scope of this discrepancy I ' 't. walked through Unit 1 for an hour and w grp w y ll the angles b that exceeded the maximum code lengthg In that short time span, W I found around 200'to 300 violations on the angle members within n approximately 100 frames out of approximately 300 frames checked h... The violations were obvious. Angle members were 2 to 3 times . g~ . h longer than the maximum permissible lengths. In one case, a member was around nine feet long, when the AISC maximum length was 25.33". f , 7,- . dd Q-@ . l l ,4 , .,.. n ?" :a ' O. m *,. . ,, , '# % R5L.AR'M i *
- ST00:1 Q L w vT 6 F T I6 l' -
- is _ - There has been.some additional bracing, but it is erratic. l To illustrate, one oversized member had been repaired, while --- another next to it remained untouched. A more practical repair would be to cut out and replace the angle frames with tube steel. The effect of this violation is that the supports'canno*t reliably carry the loads. Theoretically, the angles could buckle under the pressure. The angles support loads up to 1000 potinds g or more, such as a bundle of small bore piping. The DR is h enclosed as Exhibit 2 60 The hird DR
- //LTE (d65) Y oncerned, Hith bolts, where the distance- - ,M E
between the center of the holes was not verified as the same (L length required and specified on the drawing. The DP. occurred as a result of a quick fix assignment where I could not determine the cause of the violations. I researched and learned that QC had skipped these inspections and instead measured the distance between the centers of the plates attached to the bolts. The problem is that the location of the bolts was supposed to be ?;N th , gk the control on the location of the plates. As a result, whole packages could be in the wrong location due to failure to measure the bolt holes themselves. f.-- 9 Further, I learned that the design group had made a mistake l on the initial calculations for the center to center bolt scacing. Duetothelackofcontrolleddcemegtsg pw had not received neces-sary data on the diameter of the 111th and Phillips shells that precede the bolt when installed. Since the shells are larger than the bolts themselves, ths shells determine the hole size. I The hole size is controlling for compliance with the M-9 design guide for supports. As a result of the missing data, we had based .our ca culations on the bolt size instead of the accurate, required data from the shell size.' 4 - A- T l f . [/* ' ~ _ 19 _ . g/t ^ The impact of this discrepancy ' skews the reliability of n anchor bolt calculations. In close cases, supports judged' ~' - acceptable should have failed. I cannot state with confidene how often this flaw would be decisive. Again, however,_the problem is generic throughout Units 1 and 2, at least for , small bore piping. The DR is enclosed as Exhibit 3. . 6 Filing the DRs was the kiss of death for-my career ~at Dia Canyon. Everyone o,n-site outside of management who talked wit .me said that'I would be gone shortly. Leo Mangoba said that 1 would'begefedtoreviewtheresolutionofthediscrepancies, but withaa few days a friend told me that he had seen my name on a list of five people in Mr. Leppke's office of those who , would be laid off. In the end, I l'asted nine days, which'is about how long it would take for my DRs to be channeled,through the Bechtel and utility chain-of-command and'for my lay-off to be processed. . On Friday, October 14 at exactly 11:30 AM, Mr. Mangoba . arinounced to me that upper management told him to . lay me off due due to decreasing manp.ower requj.rements.- 'He' assured me that the . layoff was not performance-related; he said.that-if'anything, my ' performance had been above and beyond their requirements. The layoff was effective the next work day, Monday, October 17. I never received written notice, and did not have my security passes removed. .. . There is no doubt in my mind that the layoff was pretextual. First, the nine-day time lag was suspicious. Secondi.I was sup-posed ' to stay' around to review the disposition. of my ' DR's. . Even if' manpower needs'were dimini'shed, someone else sh'ould have gone first until I..could follow through on.the'significant-issues I ( had raised. It was obvious to.me that.the layoff w.as designed -} ~ -}_ 4 V *' ' f .* . Prscedure 10,1, - l ,- ) Attachment 1 Pago 1 ef 1 .' PACIFIC CAS AND U.ECTRIC COMPANY ' - ENCINEERING DEPARIMENT -- )
- g. 9 '
DISCREPANCY REPORT Control Number G G G G G -. G 2lt0.TICT OR PLAhT(S): _ Diablo Canyon Unit No. 1 & 2 . CRCANIZATION AFTECIED: Pipe Support Design Engineering INDIVIDUAI,RESPONSISLE FOR RESOLUTION: __ C.V.Cranston Project Engheer SUBJECI (ITD1/ ACTIVITY): _ ****# * **"*** '****** #' " #
- g Hilti Catalog, and Phillips Catalog H-S & ESD 223-l l
} DISCREPANCYNanufactures roecid v the minimum center to center distance to he equal to 10D where I> the hole disater. Design has vead the bolt size en sMM ret en ai theMia role re:q'd for the shell for D. 'Ihis was caused due to missmJ ih ad =4,a . mu 'w =ka11 = " +=im PROPOSED, ACTION:- Rechech anchor bolt calc.' for shells. Reducing allevables per M-9 and rechecking interaction equations for these cases where 10D (shell hole size) exceeds that used on Dwg. SCEPDt: LED COMPLETION: Initiated by: te:_ /0! 83--- Approved by: Date: ACIIONS TAKIN: * . i l l = CLOSED Approved by: Date: i Concur
- l Date:' ,
Chief. Engineering Quality control i
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- caly reouired if initia5ed by EOC. .
' I' p y.I under the relevant professional code. In
f d, s t ~ ("DR") forms -- the engineering equivalent '(/ '{ , '//' of Nonconformance Reports -- necessary to # ir/ report major problems such as those Yf identified by Mr. Stokes (M. at 19-20); / (14) retaliation against those who %, N{ wrote Discrepancy Reports. In October Mr. Stokes took the initiative to obtain blank forms and submit the DR's. The DR's disclosed his unsuccessful efforts to raise these issues within the chain of command up to Bechtel headquarters in San, ^ Francisco. Within two weeks he was laid _ off. Although the official excuse was ., 9' 9TD4 MWsT O F-E h hangers, deleted hangers, deleted weld symbols from the drawings, and took similar actions.without the benefit of any calculations. 8f The Quick Fix program was a substitute for the formal design and construction QA reporting system throughout the program for hangers. At every step, from issuance of the, drawing through final QA review, "PSDTC" could replace the normal reporting system (Exhibit 1). This could mask the deficiencies from NRC review, either through routine disclosure j or audit, unless the NRC audits the Quick Fix sheets themselves
- 9. Quick Fix substituted an informal repair program for j I
controlled corrective action through the formal nonconformance ' system. Quick Nix engineers learned of significant deficiencies that are recorded on the Quick Fix sheets, instead l of being processed properly through the nonconformanc~e reporting system. To illustrate, I personally reviewed Quick Fix sheets that showed ' fixes to problems such as studs welded to plates on a hanger that fell off after the U-bolt war removed, concrete "shell" anchors that sere cut off, and similar defects., These ~ serious hardware deficiencies should have been. reported in the nonconformance system for trending and disclosure to,the'NRC. SEISMIC DESIGN REVIEW
- 10. The " final" calculations'in the seismic design review do not include'the assumptions sheets, which means'that-specific errors cannot be effectively tracked.- Thbomission.1s , _
odd, since the assumption sheets were the only things the-4 ( u
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(.l ) y '/ lj- f -- t . , engineers reviewing our work were supposed to have looked at. ;- .11. PG&E's December 28, 1983, letter to the NRC on small. - +- ] bore piping analysis does not contain enough information;to I support a conclusion. The data is missing or inaccurate for thermal anchor movements at relevant points: maximum desip and operating temperatures dimensions for the necessary length of l pipe to verify expansion, gaps at the. restraint location, and other examples. T will-gladly discuss with the NRC the specific significance that each of these analytical holes has . ] -for the'PG&E. conclusion that there aren't any problems. ') " j
- 12. Similarly, PG&E's January 27. 1984, response to-the- 1 NRC on expansion anchors relied on d'ata that was incomplete or
- \ of suspect accuracy.to support its conclusions.- For example, I never saw drawing 054162' referred to'on page 2, nor any calculations concerning.the NRC recommended design margins from 'I&E Bulletin 79-02. By contrast, the analysis'on page-two of; the reply does not me'ntion the more s.ign'ficant i NRC 'Bulletin 79-14, which should have been relied on to include the effects of flexibility. I never saw any' calculation accounting for plate flexibility. On page 9, the analysis covers Heating, Ventilating and Air Condition duct supports-and electrical raceway supports. However, it skips more.significant hardware such as small bore and large bore pipe supports. The'effect of the missing information could'be to rebut the conclusions-.that-are included.
- For example, in some linstances the factors of-safety'are described as approximately "1". However, according ,
to page 9.of the.PG&E reply, if the load case isLHosgri or- ('::,:2 mix M1Womii AWmM&M ';smntnKMMTSR?iTGXEM&MEdMW.:LdWh ' . . i ,, / h / . j Procedure 10.1 . Attachment A e: y Page 1 of 1
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e f. k', PACIFIC GAS AND ELECTRIC COMPAN"Y , M ENGINEERING DEPAT.TMENT ~ .m ,' DISCRIPA';CY REPORT . ? a-Control Nur.be:; k m-( 8) (,3) - (,0) (.;,) (j)-(,5,)
- h. Pyt0 JECT OR PLANT (S): Diablo Canyon Unit No. 1&2 Pipe Support Design Engineering lb :
ORGANIZATION AFFECTED: C.V.Cranston Proj ect Engineer INDIVIDUAL RESPONSISLE FOR RESOLUTION: o Center to center distance of Anchor Bolts 3j; SUBJECT (ITEM / ACTIVITY): c~'
- Hilti Catalog, and Phillips Catalog M-9 6 ESD 223
REFERENCES:
.s DISCRIPANCYNanufactures soecify the minimum center to center distance to be equal to 10D where D= the hole diem ter. Design has used the bolt size on shells
.-f,t not the hole reg'd for the shell for D. This was caused due to missing informatit;
.] as en hn1. c w vy'a e ne chol i e erm e emin. '
Rechech an'chor bolt cale, for shells, Reducing
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PROPOSED, ACTION:
allowables per M-9 and rechecking interaction equations f or these
- 7 cases where 10D (shell hole size) exceeds that used on Dw;
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033037
~, *1EROFFICE MEMORANDUM -
1 Jiablo CanyonProject o Q:.! '
l.k . PACIFIC GAS AND ELECTRIC COMPANY m ..:
. }- BECHTEL POWER CORPORATION September 28, 1983 to M.R. Tresler o.
2d t ro,,, J.K. McCall , ,, % . 52.3.6 j Wi ' j W ,",, Civil Engineering DR on Expansion Anchor ,
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Spacing, Shell Type Anchor {
1;p 45/23/B34 8-1414 1 Ai Eceas on (
1 f; 1. The attached DR initiated by ust 9, questioned
< ,.1 the use of spacing in accordance with DCM-M9 for .hsit anchors of 10 times
'M the normal size of the bolt while manufacturers specify 10 times hole size jy'[l as the minimum spacing.
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- 2. Discussion of the effect of this difference follows:
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- a. The anchor length for shell anchors (Phillips and Hilti) is in all cases less than 5d (d-nominal diameter). Appendix B of ACI 349 j specifies that the areas to be considered for reduction due to l overlapping are 45' sloping cones starting 'at the enter of the base of !
/' the anchor. Based on this criteria there would be no reduction I
.j.' required for a spacing of 10d (nominal). 1 o}
'j b. In 1962 Doberne and Eigenson, Counsulting Engineers of North Hollywood,
- r. YJ performed a series of tests on Phillips Red Head concrete anchors to
'i determine the effects of spacing on pullout capacities. The reported (1 results showed no decrease for 10d on h" diameter anchors and 9.14d
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DEF3C8ENT COND% TION NOTICE l 1
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Tuzminate ' Steve Lockert Number
- 1640 4
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W as og o , December 15, 1983 31 ,
5,
$8 m Failure to appear at assigned work area for approximately d 3 hours3.472222e-5 days <br />8.333333e-4 hours <br />4.960317e-6 weeks <br />1.1415e-6 months <br /> on 12-14-83
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Employee Contractor w , _ _ .2 "74 .
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8 On 12/14/83, at approximately 0700 hours0.0081 days <br />0.194 hours <br />0.00116 weeks <br />2.6635e-4 months <br />, I was contacted by Area 1 Lead. -
.W Pat Watson as to the whereabouts af Steve Lockert, the Inspector temporarily d4 assigned to cover Rup'ture Restraint work in Area 10 Fab Shop. I contacted
@ Mr. Lockert's Leadman, Jim Cunningham, who told me Mr. Lockert had indicated to him a that he (Mr. Lockert) had some paperwork to complete in Containment II and would ti hrad right on down to 'the Fab Shop.
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L% I tras contacted again at approximately 0740 by Pat Watson wondering *where the-M ~
Hell Lockert was?"
j
@dArea I again contacted Jim Cunningham'and told him to find Lockert and get him'dow 10 ASAP!
h I was-egain contacted by Pat Wat' son at approximately 0810 and told that Lockert still Nj'!! was not at the I again contacted Jim Cunningham regarding Mr. Lockert's '
and Fabwas Shop.
d whereabouts told by Mr. Cunningham that he could not locate Lockert, h I. was told by Supervisor, Jeff Charboneau to contact temponry Lead Jim Casper to"
% supply a man to the Fab Shop. Mr. Casper was contacted at approximately 0835 and 9 told to send a man down to the Fab Shop. - Mr. Casper said he would send Rich Ryan 1pdownassoon,aspossible. ,
At approximately 0920 Mr. Lockert apA:-ed in the QC Trafier and was confronted :
by Jeff Charbonesu as to where he had been. .
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- Russ Nol'e
,d QR Supervisor c.
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- s. Tennination Notice. to Payroll Department ff pg ,Page 2 of~2 R2ference: Steve Lockert Pr 4-Q;;23 .
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@"N I concur with the above chain of events. in which they took form. It is in my k2h~ ;ostimation that Mr. Lockert was not performing. his assigned tasks as required,
)
]!J inmore that he was merely out of his assigned work area on a wild goose chase'.I ver which they were to be performed.
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s: ' STEVEN LOCKERT - 1/16/84 v.
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KIRSH: The date is January 16, 1983, the time is 7:02 pm.
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This is an interview of Mr. Steve Lockert, a concerned citizen.
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Individuals present are Dennis Kirsh, NRC, John Clewett of Ef(ff Government Accountability Project, and Steven Lockert, the concerned citizen. In order to make it more readily apparent to W .. 1
[i the transcriber who is talking, my name is Dennis Kirsh and the
- other two individuals will identify themselves for your W.4 bM;h 1 information. -
} LOCKERT: My name is Steve Lockert.
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CLEWETT: And my name is John Clewett, f rom G.A.P. (
I 9;,9 KIRSH: Okay, with those formalities over with, let's begin i i
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with other additional information you have to give me, Mr.
((j Lockert. 4 2% !
,g CLEWETT: Okay, well I guess the main thing that we are 1 h;j hoping to do, or to start with at least, is to ao through ...
an
( KIRSH: This is Mr. Clewett speaking. I CLEWETT: Sorry, yeah, John Clewett . .. make corrections on n,
the copy of the letter to Mr. Padavan of the NRC that we'gave to Q 3 you, Dennis, on I guess it would have been wh'at, about a week ago'
- 1. or so, when we met with you, because at that point the dates'were h constructed from memory,.so that the first thing we hooe to do is ;
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w i
to be able-to correct'that by reference to the documents that you ;
got from the Pullman Company.
h:
@)l u KIRSH: Okay. Can we go.through this date correction very u -
M' ' '
guickly, or is going to take some time to go through the _'
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$s documents that I have copied from the Pullman Company in order to C'
gs establish what dates-they are and then we can go through.thos.e -
B dates very quickly after that, so i? Other words, what I'm Dj Q
er,a looking at is trying to conserve tape. ,
P CLEWETT: Okay, I'm not sure, maybe 1f we just start doing
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- j' it, and then if it looks like it's going to take' time we can go 5,ff off the tape and review.it and then hopefully.do it faster. I don't know actually how .
long it's going to take you to do this.
LOCKERT: Well, depending on what kinds'of paperwork you got :
fjjj there ... for instance,.this incident occurring on September 20th j m,
i hf] . would be addressed on a memo that I had. j m
j KIRSH: Okay, well let us do something. Let's agree 1to go hi off of~ tape for a time, allow Mr. Lockert the privilege of w::
C;j reviewing what I do have copied from his files at the Pullman 1
{
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j.g Company, and then perhaps we can come back on tape and,.with M
j Mr. Lockert having decided what dates are which, and nothing of
$.u#) .i
.Fj any substance would then be discussed off the tape. l LOCKERT: Fine. That sounds fine, so off we'go.
M R
te KIRSH: Very well..
N KIRSH: Time is 8:56 PM, January 16th,1984. Mr. Lockert .
US -
1 had previously provided the NRC with his statement,'and'the fj statement is dated January 2,1984 addressed . to Mr. : Mark Padeven, .
the resident NRC inspector, and Mr. 'Lockert had referenced a
' "j number of dates in his statement. For the record,'Mr. Lockert.
s has gone back over his copies of his, daily logsLand some of the. j i
g documents that Pullman had in their files that were. retained from? i k.] Mr. Lockert the day he was terminated, and hasLattempted to make. _.
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9.1 h.$ji . corrections to some of the dates that he provided us with 15 ta; previously. On page 1, the date September 20th, Mr. Lockert p ~
g-J} believes this date is exact. Mr. Lockert indicates that he had
'e" : t i . I s.j$ lost his copy and that Carner should have copies of a memo, J Q-Y!J however, he did indicate it also that he did not write this item J
I 1
[qf up on a DCN. 'Page 2, the date September 22nd in Mr. Lockert's j,]
.a statement. The actual date was September 1st, 1983 and the U
&; support referenced in Mr. Lockert's daily inspector's loc was j j
i d' 13/3RR.- Page 3, September'26, Mr. Lockert indicates this date is
[5[h rd 1
approximate. October 4th date on page 3 also, it was-actually !
a
, .m October 18th. The hangar referenced in Mr. Lockert's daily inspector's log is #412/55SL and.it belongs to the component fIi
,, 9 cooling water system. On page 3 also, the October 6 date, fj Mr. Lockert indicates that date is approximate, however, A- l Q Mr. Lockert couldn't find this in his daily inspector's log. J tQ ;
E Page 4 of Mr. Lockert's statement, October 10th, the date is
?:.Q i?l approximate. Mr. Lockert couldn' t find this in his daily Li ~
Jhi inspector's log. Page 5, October 12th, the actual date from sii ,
$$ . Mr. Lockert's papers that Pullman had retained was November 8th, 1983, and that was the date a Notegram memo was written and it is
.o
$9 document #70 in the copies of the log that I have. On page 5 N,4 also, October 17th date, Mr. Lockert didn't . find this in his Np daily inspector's log and indicated the date was approximate.
M Page 6 of Mr. Lockert's statement. The date October 20th was
@[:$
@ actually October 31st, 1983 and it is document #110, a 4:;
[f Y1 Notegram. October 24th date of Mr. Lockert's statement, page 6, kij was actually Novetaber 7th,1983. It's document #114, a l NI a
R Lockert/1-16-84'- 3 Q..
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Notegram. Page-7, no revision. Page 8, October 25th date. This
.. e e.$ was a personal Telecon between Mr. Dave Stupil and Mr. Lockert.
'~-
(}j The date is approximate as indicated by Mr. Lockert.
November 2nd date. Is that also an approximate date?- We - didn' t b
y C talk about.that one previously.
~'
LOCKERT :~ Ah, approximate.
J KIRSH: Okay. And the' November 2nd'date: appears.on l Ei!
,, '} page'8. On'page 8 also, November 8th, the support number.is
- h 3-10RRandIbelievditwasinMr.Lockert'sdailyinspector's j r .
1 log. ]
(( .
. LOCKERT : - Right. .
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y, KIRSH: 'Mr. Lockert also drew'this item up-where.the- j -
h defective welds ... either the welds he believes are defective
$, are located, and it's on rupture restraint 3-10RR. I have a copy .i 41 i j of that drawing provided by Mr. Lockert.- A new item,,page 9, Tt .
9 that I added at the top of page 9, the date~was 11/15/83.
k1 1 I "During a base metal repair of support 8-2RR, on November 15,
, r: i f 1983, Pullman was performing' plug welding of a-hole in the flance $
of.a beam. The concern that' Mr. Lockert has is that. Pullman did '
g,q not have a weld procedure qualified to performLthis plug weld,"-~ j q -
g, and this is referenced'in Mr. Lockert's ' daily 1insoector's logDof 11/15/83.- Another addition in-page 9-of Mr. Lockert's statement, under the' item mentioned on November 8. ' Last sentence that I,
[N1
$ added was, "Also Mr. Lockert rejected bolts'because'of. heat' treat.
M, '
}'j:4 cracks on A490 bolts." November 16th, we 'didn' t talk 1 about that'-
- J ; one. That was a date approximateotoo, also, Stave?
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Wp; LOCKERT: I'm checking my notes. Yeah,.let's make that an ih
[$,'j approximate date.
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00'. KIRSH: Okay, that's fine. Also, on page 9, December 8th -
,tN,;
m date, on page 9. Mr. Lockert believes this date is correct. - J
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Likewise, on page 10, the December 9th date, Mr. Lockert also
$.k believes this date is correct. Page 11, the December 12th date, pp j -Mr. Lockert also believes this date is correct. Page 12,
?9 .. .
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'E . ' December 13th date, Mr. Lockert also believes this date is j' d" .
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correct. Page 13, December 14th date, Mr.'Lockert also believes h this date is correct, and on page 13 also, the December 15th date. Mr. Lockert also . believes this date 2 is correct. In.
, addition, Mr. Lockert supplied f rom his copies'of lWi the documents that I obtained from Pullman', a number of DCNs p
f4 W.
wherein the field engineers would not sign and accept these-y DCNs. The DCN numbers are 1/1640-016','013, 015, 020,-021 and 7
022.
~
,i Okay, is that ... does that basically' summarize what-we had 3e talked about earlier while we were off tape and we were going q 1
through your files, Steve?-
y, i LOCKERT:. Yes it does.
di
- c. q CLEWETT: Steve, what do you think is the ef fect of the h; import of not being able to find some of these things its your - '
a.
dailies-that you referred to you in your-report?
LOCKERT: ; Oh, it's probably mostly my own ' . ..~ for not havina
%g'.
X;. a good enough record within my own notes that'I was_ unable-to. I find that. There are some pages missing here,.but....; -
y% CLEWETT: From your dailies or: from.your....
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LOCKERT: I think the dailies are all.here. It was just a M lack of good reporting on my own part. I (3 }
j;y CLEWETT: When you originally made the dailies?
, ~
-j
? i n LOCKERT: Yeah. You know,'the information in the dailies .l s
i has to do'with a lot of other ... the hangars and rupturf 1 restraints themselves, but don't necessarily document every
~Nh I N conversation.that had occurred on that date, therefore, some.of
. 1
)
7.. the documentation that I would have liked to have is missing due
]
- to my own fault.
]
j d.. KIRSH: Okay, do you.h, ave'any other cuestion, John?
44 Y CLEWETT: I don't think so at the moment. I'd like-to take kh j,j a few minutes maybe off tape, if you like, and just review these Oil -
3A other documents. I haven't had a chance to see.yet.
id jij KIRSH: Oh,,no problem. Going off tape.. The time is )
W j M 9:06 PM. J
- .in J Mj KIRSH: Back on tape. Time is 9:25 PM. Mr. Lockert just related to me a concern regarding. field ... Pullman Power g@[ Products in early December had been drilling exploratory' holes e
A into the Unit 2 reactor cavity concrete shield' wall outside
~
a ti surface. A Pullman Power Products field QC inspector, a Keith Of tenburg, noted that a Pullman Power Products ' layout -crew was -
h J[f doing the hole drilling without having an approved for-i h- construction drawing in their possession'during the time-of hole
] drilling. The QC-inspector wrote a DCN which was either not
]
l accepted or was lost by Pullman. The. holes were being drilled to' 3
.J see if base plates for hangars could be attached to the exterior 1
.j surface ... outside diameter surface of the Unit 2' reactor-cavity -:
gn '
l M shield wall. Okay,-going back'....
W\
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$f kg CLEWETT: Well, can I ask'a ... maybe I didn't pay enough -
~
M, attention.. Did you say this is also currently going on,.or wrote m
kI another DCN or....
g
!.] LOCKERT: The last time I talked to Keith, yeah., he's gonna w
}lj write another DCN because he noticed'they were continuing that
' practice, and resubmit it to Harold Carner or Jude Flederman, i
whoever.
- j. CLEWETT: And who is Jude Flederman, j LOCKERT: Jude Flederman.was an engineering lead or hP4
' fi- engineering supervisor for Pullman in year;2. He was'the one h
$3 that came up with the. exploratory. hole orilling' idea.
.sg s'y CLEWETT: And in. addition to not having an approved for R
Pq construction drawing,'was there an approved-procedure for this?. l l%
hd LOCKERT: Well, the memo or interoffice correspondence:from pn;
,i Jude Flederman tried to explain how the-QC inspectors would d
Ad handle that situation, but Keith referred'to the'auality-
{$s assurance manual and it says, "All work shall.be performed to-ad-Wd-hQ approved for construction drawing. No exceptions." lSo,'in ih Keith's mind the drilling of exploratory holes without the proper
@( . .
3 drawing was illegal and tried to write a.DCN:to get' attention b drawn to that-fact.
a?i - ~
.D CLEWETT And that was the.one that got lost..
ill .
LOCKERT: . I don't really remember exact disposition of it, l but Keith's words'to me were that'either it. was not accepted'or.
4 got lost. He was unable-to get-it into'the system.:
JM h 'CLEWETT: And Jude Flederman's memo authorized or attempted
!4] '
?.Q to authorize the proceeding without a. written, procedure. .
71 pe M4 h L'ockert/1-16 7-Gd.
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k'.g LOCKERT: That's right.
$D ,
l?;i.; CLEWETT Okay, I think I understand that. Shall we go back i off the tape then? .
~'
t 6
3 KIRSH: Yes. .Go back off tape. Time is 9:28 PM.
KIRSH: Back on tape. Time 9:33 PM. ~
k LOCKERT.: For whatever this may or may not be worth, this is n
an interoffice correspondence dated November.11, 1983 to Steven-
.h a _
Lockert, QC Inspector, from Frank Leoty, QA/QC' Assistant Manager,
?
.i
Subject:
AWS D1.1 Weld Rod Oven Storage Temperature
?
Requirements. And the text'of it reads:
] 1"AWS Dl.1', Paragraph 4.5.2 states: Low hydrogen electrode
- l' conforming to AWS A5.1 (7018). ' shall be stored in ovens held at a y,
g,<. minimum of at least 250 degrees F.
" Pullman KVP-12 and ESD-202 require a minimum of
%@ ~
225 degrees F temperature for low hydrogen electrode holding
$n [d ovens.
- 2 K.d " Pullman field QA inspectors monitor oven temperatures on'a-G daily basis and the temperature has been maintained above-
?
1 250 degrees F with-a few minor exceptions'because'of1 temperature fI, variations, i.e., due to opening door'of oven and fluctuations'of Wj
~4 the thermostatic controls.
{Qfij "ASME Section II, Part C, Table Al (pageT 26), recommends-Ms .. holding oven temperature of: 50 degrees ' to 250 : degrees: above Tb W) ambientLtemperature.
Recommended disposition:- '1) Maintain 1allt low hydrogen electrodes at 250-degree minimum'and revise KVP .
?$
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- ,....) . and ESD-202. "
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Signed by Frank Leoty, . Assistant QA/QC Manager. In the
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lower corner, FLajg, apparently referring to who signed it and fe sj;,7 , who typed. Here endeth the reading, that, and so we can go"off "-
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tape. .
j t
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.KIRSH: Time 9:35 PM. -
,i
- p$ _ KIRSH: Back on tape and time is 9:41 PM. This concludes' fj!O f a$4/
w; .the interview with Mr. Lockert and Mr. Clewett of Government-
,2 jff r..g Accountability Project. Thank you very much, Steve.
Qts KIRSH: Thank you, Dennis.
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INVENTORY OF DOCUMENTS LEFT BY STEVE LOCKERT WHEN TERMINATED 12-15-83
%':q h 1. DCN written on test shop - 1640-022
- ) .
I'
- 2. DCN written on welding on painted surface - 1640-020 .
l 3. DCN/ Hold Tag /DR Log Sheet N 4. DCN/ Hold Tag /DR Log Sheet
- d 5. Esalen Catalog (personal - to be returned). ~
$ 6. DCN #1640-016 written on shim rupture restraint 5-3RR
.d 7. DCN #1640-015 material imperfections
, ,4' M. 8. Remarks on PG&E 8711 NRC region V address.
- .p]
jy. 9. 2 copies of DCN 1640-022 (#1 above)
@, 10. Pipe support daily workshee,t 12-13-83.
h DCN #1640-012 hole in civil steel at hanger 2-19V.- [ Cp k V/S $TI6d d'6 64 N k #47/
i 12. Copy of DCN 1640-016 (#6 above).
I
- 13. Phone list.
'(;l 14. Plant maps.
4l 15. Hilti length identification system.
y 16.
Interoffice correspondence - vacation requests.
$g 17. Interoffice correspondence - included angles for partial penetration welds.
s ya 18. Interoffice correspondence - final as-built inspection. 1 m
f;,4 19. Interoffice correspondence - mainten nce of class I storage areas.
- 20. Memorandum - as-builts for pipe supports.
- 21. Interoffice correspondence - Foley grout slips.
j] 22. Interoffice correspondence - Current revision levels, August 24, 1983.
p 23. Interoffice correspondence - Inspection of pipe support welds.
! 24. Interoffice correspondence - Identification of pipe attachment.
%l 25. Remarks on ESD-223 and ESD-216.
p g 26. Remarks on ASTM requirements.
.e g 27. Remarks on training, ASTM requirements.
j,f 28. Remarks on ASTM.
pi 29. Remarks on ASTM.
e{
- 30. Remarks on ASTM Gd 31. Remarks on ESD-202.6, 215.5, 2.7.
n 4't 32. Remarks on QA Manual.
- 33. Remarks on QA Manual. I o AT ON Oy1 ,-i \/
gj 34. Remarks on QA Manual.
- e
- 35. Remarks on QA Manual, Q ,"
WJ 36. Definitions M
M"i Continued - Page 2
?
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t, f ' .J' 37. Definitions.
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- 38. Definitions.
- 39. Definitions. .
. 1
- 40. ESD-203.
{hi$$
- 41. Field Procedures for DCN.
s%
ly . 42. Field Procedures for NCR.
):
'43. W.P.P.S.S.' Inspection and Documentation.
@w 44. ' Inspection sequence,
- 45. ' Weld procedures.
hl-n p 46. QAI-144.
@ 47. .PG&E Code Classes.
5 p. 48. . Fatigue.
- 49. . Welding distortion.
b? 50. Monthly Maintenance Surveillance Report.
.] 51. DCN 1640-002. ;
r .
i .
- 52. DCN 1640-002.
.d 53.. DCN 1640-004.
M 54 DCN 1640-006.
8 ik)
- lm; 55. DCN 1640-007.
ig( 56. DCN 1640-013. ;
k!A-:
x 57. OCN.1640-013 sketch. !
ty.n i
- 58. 2216-188 Final As-Built Inspection.
8 59. Hanger As-8uilt Inspection, Hanger 898-6 !
- 60. DCN 1640-021.
!:lm 61. As-Built Drawing, Drawing 898.
$I$ 62. DCN 1640-020.
fl, ' 63. DCN 1640-021. U
- 64. Interoffice Correspondence - PG&E memos.
%9
% 65. Memo - A36 for shims.
.i 66. Memo - splices. j 4 67.-. Memo gaps RR. -
O N O N, d. ..
- 68. Memo - drilled. holes RR.
- 69. Memo - bolting RR.
O f,A S'
yfg - 70. Note-0-gram - washer, "3 '71. Interoffice correspondence - travel stops. _I gM)0 c.
g I$h Continued - Page 3~
- n
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qyf, ,..ory of Steve Lockert Documents Z .,d 3 Q;j .-
l
-J' )
&l '
- i.g[.
g, ' 72. Interoffice correspondence - signature traceability. _
N 73. Interoffice memorandum - confined spaces. l 7 74. Interoffice correspondence.
~
- j
- 75. Interoffice correspondence - ESD revision levels. -
.( 76. Interoffice correspondence - weekend work rules.
Mi #
- 77. Interoffice correspondence - vacation and holiday requests.
@f 78. Interoffice correspondence - ESD revision levels.
D 79. Memo - lunch breaks.
k Cn, 80. - Memo ' DR/DCN closure.
~
.1 i.gg 81 Interoffice correspondence'- NCR-STPR.
l Ty 82. Interoffice correspondence - training, l
$.tj 83. Interoffice correspo'ndence - monthly maintenance.
- 84. Interoffice correspondence - DCO-EC-5486.
- 85. -Interoffice correspondence - DR.DCN Hold Tags.
g}:: 86. Interoffice correspondence - monthly maintenance.
]
- 1<
- W
- 87. Interoffice correspondence - time off requests. j
- 88. Interoffice correspondence - work stoppage.
hl.{
l I pje.g 89. Interoffice correspondence - grout.
}{j 90. Interoffice correspondence - shift.
fid 91. Interoffice correspondence - DR/DCN closure.
g 92. Interoffice correspondence - Drawing control.
M w
- 93. DR 5249.
M; 94. DR 5249.
ris y,! 95. DR 5432.
k 96. DCN 1640-002.
i 97. DCN 1640-001 hupi.
L.
5 ~
- 98. DCN 1640-003.
d 99. DCN 1640-004.
h 100. DCN 1640-005.
101. DCN 1640-006.
- 102. DCN 1640-007.
f_ 103. DCN 1640-008.
- p 104. DCN 1640-010. er -J . > f 5P "N Oi\ii ',-
105. DCN 1640-011. [- ' n -. +et r 3
['i}[
E 31 Continued - Page 4
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dntory of Steve Lockert Documents 1 Ij age 4 (uil) i -
iss ,,y/
i 106. DCN 1640-013. .,j _
J fa.;o 107. Memo - thermal cutting defect.
sw m 108. Memo - DWHT. -
': 109. Memo - holiday request. -
pijp 110. Memo - oven temp 111. Interoffice memo - anti-sieze compound. j djj 112. Interoffice memo - anti-sieze compound.
D 113. Remarks on AWS D1.1-83.
g'f(4 l 114. Memo - joint detail AWS. ,
115. Interoffice correspondence - reply to memo referenced on P #110.
'] ]
pc 116. Support drawing 893-4 and accounting request and hanger Ps.
Nr)j Y" 117. Union notice . personal.
{l 118. Notice from UA local 403 - personal. ;
e.,,
) 119.- Time log. I 120. Memo - nut clamps.
f.( . 121. Memo - nut retainer clips.
' i'l 122. Time log.
~
.1-
-l gy 123. Daily inspection log. 1 J
124. Daily inspection log.
%1 , 125. Daily inspection log.
126. Daily inspection log.
[h
(!.-
127. Daily inspection. log. ;
128. thru 233: Daily inspection log.
3
( j fg 234. Termination notice.
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vNiT No. I p,TTAC.% " - DISCREPANCY REPOR_T. ,t j . CoDENO. 3 .y . routa: Pacide Cas & Electrie $PEC. No: 8711 CATE: September 2, 1983 ~ Diablo canyon (',.N pacacer: ;oe so.: 7177 INSPECTOR: Toon/Lockert s.,) 2 A490 BOLTS INSTALLED WITHOUT H.S. WASHERS ON EMBEDMENTS. UNIT I CONTAINMENT.
- 3
. orrestrawT Trut 1025-4RT.1031-4RT. 1024-f RT. dij rm4~4 wen en eisent,4~cv: During Engineering /QC inspection of rupture restraints 1024-4RT, ~ u..I 1025-4RT, and 1031-4RT, it was discovered that the A490 bolts installed did not sg.f have H.S. washers under the bolts that were installed with k" A516 G70 spacers. bl Per memo on 8-24-83, the k" A516 G70 blocks were acceptable with H.S. washers sc,3j between bolt head and spacer. The bolts have been installed and torqued, process yj sheets are complete. Embedment 1025-4RT-A has 3 blocks installed. Embedment N 1025-4RT-B has 4 blocks installed. Embedment 1031-4RT-A has 8 blocks installed, i not per memo pf 8-24-83 (memo stated 5 blocks on 1031-4RT-A and 4 blocks on ,] 1031-4RT-B) . Embedmont 1031-4RT-B has had Sk" A490 bolts substituted for the q 5 " A490 bolts in lieu of using the k" spacer block. Embedment 1024-4RT-A has ji 3 blocks installed (reference Engineering comments on tensioning process sheet .i forthisembedment). The material used for the " spacer blocks is A516 G70 with .l j charpy impact tests at +20* F. (Continued - Pace 2) /d M necouursoco oisecsmen: INDICATE APPROVAL BY CIRCLING THE APPROPRI ATE " RECOMMENDED DISPOSITION"- .o
- . 1) Accept installation and torquing as-is; -
}.s . . , E.M .Ji Remove and install H.S. washers, new A490 bolts requtwi, hi; ' ,1 l OR
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'PGandE to disposition.Pt9E M.d Ad-'l567- FGVIEMD E / h > JJ W . PATE ! b Aporsned By P.P.P. Fio4d QA. Mgr. D.te Customer - 0. t. . .n sr -\ priv As. OtSPCS!TICN ance With Above / C oth espion.fien and oppr. vel f.awit.4)) kM ;, .... c...i...a in.., ,- /g gp w rk c.. i...a in.,i o.... expusATion air NecessAnvi: g gp gg g gg7 g p p g g g g gf g - Mi& id91-4V419 /rcaffMcY terman wiry H+. w$itse. . ${ A. twMe-. frrk!NS ttfutsur. p fpp/n d 9-ni r.o. ,w a A. u.n.g., e .. . c .iom., o.i. s r.s ve e-event aeCuaacNer D N.e Applic.ble Craft Superintendent to advise Craft personnel of yj]
- p. responsibility to install structures per. design. -QC Supervisor to advise person- ~
93 nel of requirements for H.S. washers under the turning element in a bolted f:j ~ 9). connection. Document Steps to Prevent Recurrence on this OR, L/ 3, , p;..a c.A. M.nacer j aq it oevtics : Meir.r o.A. Fii. I Autn. inso. Z Engin.erme Cent. O Other 5 : cuivom.c O e.c. no Oy.gigst.ctog t. - ^ " ' ' l '[ .* AT"ACM $< ETCH IF NECESSARY "" (, , , , , , , %., . . . . . . . . 1 .+ .. ,.- D -@ , m. -- -~na .. ww.n. .w. ~ .. . ~. ..~ w . m- . . ~ , .,. .e .+ . a . . . _ . . -. . ~ ,~; .. n .....n. . ^ V. ^ , /(_ / ... . g.; .. . - , g . Z A) Pullman Power Proclucts .10 CR 'll f O.R. NO. 5249 Pano - 9 i . .1 DWG we.NO. 4'4R2 47 . (15) c[(IS NOTD ' DISCREPANCY REPORT UNIT NO. I J).; . ATTACHED , CODE NO. 3 tag - 'j'1 CUSTOMER: Pacifle Gas & Electric SPEC. NO: 8711 OATE: SeDtember 2.1983 Oleblo Canyon <' 7177 PROJECT: jog so,: INSPECTOR: TOon/Lockert I:,y EXPLANATION OF DISCREPANCY: (Continued from Page-1) ~ .E w' 7.n. 1031-4RT is located at elevation 130', 180' Unit I Containment. 1024-4RT and 1025-4RT "y., j. arb located at elevation 130', O' Unit I Containment. . Q .:. e}l '7 . 9.l !. ,;..p, . . . , .y
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{S,1 *~~ 1 . t4" s Y O ~.( g \ s m [% 1 . s, 'pA l' if 4 . t] . Q I q . . - ,_.w , ., - _n . , , , , . - . ~ , , . , . ~ ~ ) :, ~ r> yy _ ;w , s , . , .*ai.* ,.[?3 d V ;_h.;;-;;,ZL. ;[,'._?f ,3 ..s. Y _ ~._. , _ , , .Q? j. i .G.. .a .y , l 7N . A Pactfle Gas & Electric $PEC.NO: 8711 OATE: Io 9 !8'd s / - EjC ' CUSTOMER: PROJECT: Diablo Canyon JOB NO.: 7177 ' INSPECTOR: SEIVElf. / Z CV(([ {[.
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g7 wxs Z piscoveKro THAT Tuo Pieces wEKE ntshidC AMEKicAM 1RtDGE rtunt'S 3l N-tS-2 RR m E wk. tug we,ME SeiN 4 weeep@ ggggp t . THE ftECES WeRE Lt8xZb S H A re.5 Q nATaniAL. Not o AdteA fusioe. cou tauaneMT I. T is suses?Teo
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THAT we rwreenAL vA.s KEnweo ou Aiw c THe N,uusive etexu-o e E FPo &T 5 m f'Ro citG'55 Pci e. T. Inrt enewTATied oP secuctTT Loc.K*u'T . 4 tace rMeu 3 f'Ef% D.A.666, A nATCH14C3 PLECG lagan U46 T L l'o A. T H E LOM GeK EEAr\ wA5 j J.] sue,s rrto Te o , An o we ALE FAoKtCATH 4 A New 5*KT SEAR \ . is App tTio n 3 THE roo &. A,4 G'LE cue s ttt Au tReo Fo A. Set LCE t T-1. 6R-l wecE *Fou uo T6 Se ntS5444. TEC. P. A . 4.7 4 d &~I L WE ME sus 57tTwitM y b) C.L.tf 5 l Ct.i r'5 FKn n udtT Z. AMD PAE>f tcATtd 4 (7) sew y[ REcouu fNofo oisPosmoN: INDICATE APPROVAL BY CIRCLING THE APPROPRIATE " RECOMMENDED p';. DISPOSIUCN" 1 D. K . T6 soe.MTwoT us AuTt**RIEED itensvAs. 67' nA tu At At, ( i KEco KD -Tyre WoCtC EPAdiCED 15 BreH Cg cegouC Tep PE A P. CL , 44Lk 471 3 674 C oSE o. K . l AF'T1EA f. C. . tE . Arff,0 VAL OF THLS D.K. 1"II e Cert of: D. C . UMPUE So'TM . unt7 .T. ( UMtT T poCu ttesTA%,J fACKAdE5 ^ PGGE G.C. # #'I OUALITY NTROL ps uo.m. xo as co s crio s . noviews e .. ?- . m,
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e,,; holules g 44 m O,,,. /WIv//; ..... ,- aA. M.,.*E-~ (L ' o . , 5. a e ,_.m._oN,a. _ _ ..., C..e. .. i.... o .. a ..g .. ... .. . . . ..., .. .. i. , , . , C.e.,i. , ...., ...., 1 EXPT.ANATION ilF NECESSARYl: ', ' l}; s,, r> ,e ' ,,. s , .- g/ .'1 5 7 ,, - * 'gNk , dl * . . .... F. sed C.A. Meneger .Det. Customer - Oete ,[ s. $TEPS TO PR EVENT RECURRENCE knee Applicabl. , . % ., ' { gpI &p. 4- .~ s'i ** @ Q% y:d \% , Ed w .d i.* Fi.ed O.A. Meaager N/l/Jl8) - OtsTat BUTION: 3 Master Q.A. Fil. E Auth, ins E Engineerine D.ot. O Other ff . i ~.0 E Customer C Rec.aaae O ri d snoo.eter ( 4 f'3 ATTACH SKETCH IF NECESSARY h PRIORITY . /q e' , :1 .. O saavm e t .~. . ,y---- .-, ;; , ., . q, y~ .m.-, , .~.,.m.-- _ _ _ . , . . . ,. .v _ . , . . _ . . _ . ,. _ , , , , , . . _ .,.g - p., =m.,y ummm.auw:.ug.a.g a n %.a m w~ao m wzw m s.m w;;,cu - O.fe . F-12 9 . PULLMAN POWER PRODUCTS f IN . DEFICIENT CONDITION NOTICE - 6[ NM . t. bi lI! NIT f AREA ELEV COL /LINE DATE: i ,. / fpo&mf /2 $. ' AM W tdTI'CE NO. / '40 l- CO2 j y}
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%d4 h Lss2. c e C E Ps.w :h 37 DEFICIENT CONDITION: g g ( yf j' g y o g p ,, rig, g g y y , y , 4 pg _ yyy , 37Eid fi~ det J Ad / ' f A0 %'*'N A** NY. A'WWcW C/$udW g or.WEd1 ' ,M/ fuPfdtr ,&.s;&i:v//p.Jf. hy ,pic
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{?$,k Q n ./$#. wc .wro .oro a .reasre s, ' % t'oe4sco or.G e.,et<tr.cenuer [9[.y 5 N #re A d hcer,b e r <"4t iac w 1Co e mcp;;, p .c & -ORIGIN TO)#5 SIGNA _ RE, li[l, /025-fM'tP'Gc~ .4dk 4*'a ou & <44 ,Voc<29.47At K M/ l HOLD TAG APPLIED: %-g TAG # INITIAL DATE , 3d FIELD EliGINEER ' / /d l J.'$ RECOMMENDED DISPOSITION: ' h6NGr TO DiSIDSTUO4. f l/ [ g f j / g M />' MI ( E f t. 3 l 5 16*J./E fRocE55 @N E ' 412c STF1% (Grl2 SSO Z7/ . E ] Q.'T" 4 l'7' (To 250 Zil) MQ' JIM ' Nm ]$$ rda AN{ FIELD QA/QC MANAGER hM M ~ r[;j.j.{f FIELD QA/QC MANA'GERS EVALUATION: APPROVED AS RECOMMENDED OTHER C s NON-CONFORMANCE - D.R.# .( g. [ y ~, . f f w , REPAIR ORDER [ b] REWORK / REINSPECT he I) M Ad %i INTERNAL AUDIT pcW, E . .f OTHER JMQ [.,,$ DAT FIELD MANAGER . I NA 3 71.! CORRECTIVE ACTION REQUIRED BY: NOT LATER THAN: .; tt 1 th STEPS TO PREVENT RECURRENCE: 9 - NOT APPLI ABLE f wm .' gg l [ Vu n w' - r .,c. - ??,j m,a ; f !' q L i l '* "* ,' < rm C? ,y* i Rh ?d f RU q Q}gtJ L.4 .K{.f;,.l4 'i t u
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<c.,,. M is n h-a f / .s 2. h 3 W ~ 'j :EFICIENTC0I:DITION CLOSED:DATE SIGNAWRE. a) m ., w a- aM..> T. /or2 5jf.); - 6A sx;myw.r=~~ - ~ - ia. w . ., . + - .- g_. mm=- . x. m - If ' .- r u;;IT f ' AR$A ' ' ELEY. COL /gINE DATE: *// NOTICE NO. /"(SAHo Op yd P Hod. - 8/8/83 - " %:.b. ,.< i 9/* O - lb.,?: DEF4;IEN1 C0NDITIoN: K?t' ///P}t&/MRlnfp,* .&.y.rr'orfsfw,;q /%;ggf*mgo pg, lf. N /T47{ Bl.6~ 3. 475A'/A*(A w ,&Ma'A;dMr .9 9Rg .Sp. ,,att.Y;~~ spi,;r, -Mr.ctfI h A 3.ews fy' m 7,% fdc' W KM(//7A' Cy k d%MYo os 4. cts,oi,u r ' 3- eQ ([f a p '&& .;rk 7, no sr7Wt AM9;W e' KW //7P O I I" 5 ' m ir n s'29,Mq/g**??){"Aw? - fT W HOLD TAG APPLIED: g TAG # INITIALS DkTE g gy FIELD EN INEE REC 0t?. ENDED DISPOSITION: < N . Y;q @ E.YOC, M (55.06. P/5 FCA REPag FIELD y , '. u & :% gl , CHIE N .4EER Ui m'a . fy;; LEVEL LI Vt' _. j 2pj , FIELDiQ QC MANAGER M. - C < FIELD QA/QC MANAGERS EVALUATION: {,APPROVEDASRECOMMENDED OTHER ]. _ [ .'., (3 COMENTS . CAllSE CODE , j. : NON-CONFORMANCE - D.R.# / g 3 [ ] REPAIR ORDER @ ~ ~ -A .b g ) ' = - p, ,*
- REWORK / REINSPECT
, V 14 - l l INTERNAL AUDIT i v, R 1 . h0MR , ,pgA/ /_,3 DATE FIELD [ CORRECTIVE ACTIOf4 REQUIRED BY: e - /2_/ NOT LATER THAN: _ r . a,. , a - % . ,:n STE 5 TO PREVENT RECURRENCE: NOT APPLICABLE ,p . .: . kb MN [ . p P. I I - hi , ~~ ?
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%,y . v a e \ {. .v f v ". 9. -Q'a i S ( g { 's.i k 5 s I Ys ' / ) *ES:C:51 ELE 5U , IS DATE FIE GER 8M .) lEFI*IENT CONDITIO" CLOSED: DG fff g / SIGNATURE: .ffgf g, /ggf v 6, f / // . .- [f ;f g ., . ,, - .~ .. . . ,......*+s ..o. .: ;. t a p,.; , - +-.-< _ ?+ec- n~~ 7, . .zr . ~ - > c .. . . v . ; 7 - ,-a y, .-- . . <v,~,. , .~ ~. . u..~. =.u v=u :s.m..w a =.aumv.au.~a .a.= . =z c m g~,/ ..fx .) a.: DEFICIENT C.ONDITION NOTICE g l jj Un T f R ELE , C0' 'DATE: NOTICE NO. ,
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OEF'ICIENT C0NDITION: 6AA*'S{ 60ff /d .4 A!4 .5~7ska .rdig. AZ' A '.:V4y* M doof / /2, S4- /3 /. Spo&f Ar Me" O k/' M o f("JMg p ufo Q:t ?_ e /on s . 6 w n >V. CorSt' /r Aca6 op. x /hdeatic. mismerigy.ug' - '? A9% /17 /sB ' thnWA, .936 ',' Mo n f'on og$n * ' ' [g"g*
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{f.) HOLD TAG APPLIED: gg TAG f 4,,g INITIA DATk g RECOMMENDED DISPOSITION: YO f'[I Mc/M ~ /SSM haeccss nWee75 -/ 0 fM/A GMf' FIELD QC INSPECT 0k
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M 4l.7 i # LEVfL A gY l .;li FIELD QA/QC MANAGER ! M iN l FIELD QA/QC MANAGERS EVALUATION: ( APPROVED AS RECOMMENDED OTHER I. . h i.1 NON-CONFORMANCE - D.R.# COMMENTS.* CA,!JfSE CODE J .y , \ ,, l, REPAIR ORDER l J l N REWORK / REINSPECT t c; l ,3 INTERNAL AUDIT .. 4 . ,. CORRECTIVE ACTION REQUIRED BY: NOT LATER THAN: [Ji: d STEPS T0,,,PR VEN ,ECURRENCE: IQ Y NOT APPLICABLE ~ i I y if)frino o4e fo3 *b *- q* %,\.y s ! 'O -=, E. .. ! .-. , ., h ' ( { . b,( l - pOB u RESPONSIBLE SUPERVISOR DATE FIELD C MANAGER . SIGNAT DEFICIENTC0$iDITIONCLOSED:DATE ,-9p / .w .2 - ,f; . ; ? ..m m x ,m. _.x m m m:=.-MSmmvmmmig3mw;ga M .* ~0:'i e-12G PULLMAN POWER PRODUCTS t' I 9-DEFICIENT CO:;0! TION NOTICE .l'd /:Q.- S. Lry LA~2T cn ~ n , l l 0 U.*;!T # AREA ELEV. m DATE: g,e, .- . ./'.'::' ~:;- 140TICE i;0. ,. y ,4
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,7 OEFICIENT CONDITION: gg,,g,,;p y,,, g _j,gg. p , %,e,y r W , 4,'.e /,;, y ' /.v 6:s.G < /cW /#st Gc'c.Wb-fx.6.'~3a. .,f.<':' W '<' ' e . ' . 5.* D a N .:3'A~l
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/Vp< .s?2 /.2 ~,2 #'#<'< ,T;~'5".dd'?l . ORIGINATORf SIGNATUR F / fs.: r~ n nt;~ C L A S S % " /rY $~fD E4 S , g,.ggy HOLD TAG APPLIED: g TAGfg4 INITIA DATE ~ ' Mt ' FIELD ENGINEER I' 1:1i RECOMMENDED DISPOSIT10N:assur PRocs.ts sHsers rc Hud 'Alc~ ~~, u.< -m.- f*!**El Si PERroRM THE roll.oWW6I FIELD QC INSPECT 0if i ha .1. GRWD 7'o Rf.mov'E A wc .sreteeJ-P.7; sc u.*r. REQ,O *e, y ,- y ,.,,,, ', < 1 2. G,RlWO To 12Emove' cR A TCR. C RA C#;. P.T: l %{A , /. Reti,w'As. Art.cr,A . lT m = w =0 :;25 v w^7^2 CHI INEE !
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N 'y ' . A 7.a;wns,v ,,, rsw Keub c o *rin.u-ree weu. An w- ! - :.' :-- i a l':."'.^ u":' D. vt.funL. E,. LEtEL I11 - dN.i 4/w/O ..f.;;\ GC. t0 PsAfe% M D Cx9mm7/W GAWO *A-R -3 NLCAIo 70 $c78tfAto'*sT IF msw,c,w,*,4,w t,/ soc,+rp F1 ELD QAlQCy/ > "; FIELD QA/QC MANAGERS EVALUATION: ),( APPROVED AS RECOMMENDED OTHER h NON-CONFORMANCE - D.R.# COMMENTS.* , ,m. ., , . - _.~ --. e' .u a s ,n, , e s,,,.- CAUSE CODE' 3 l .4/zt' REPAIR ORDER o n . ., , , - "n y, ft* , REWORK / REINSPECT
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. INTERNAL AUDIT ;g. A g4 ?,b *i h r AA v' e /AR . wi f' M " $ N, { OTHER f p g gfy gg7f DATE FTELD OA7QC MANAGER . 7; CORRECTIVE ACTION REQUIRED BY: NOT LATER THAN: i C. w; l 0-T-': TC ""I"E"T R.~~URR- E r un ~ . m.,m. ..w , m,o n L e. . . c., t j % ! , D 1 n ., <y 0 , lfL ~, 5 ~ dA s.nU .. ~ t, - . - 4r; a ~ e ;c M b. " M s ,~w,. ,c Uf M 'e. o - 9 '7 ,,~[g .D_ e , {]'pg ~ N;a , in d,'3 w~ .} i Sr t ft# y f '7 2./ Om
- ESPO!;SIBLE SUPE:VIS00 DATE FIELD mat;AGER -
J DEF:CIENT C0t;DITION CLOSED: DATE SIGNATURE: '.Q n "s - ; / sr3 _) > h _ _ m _ _ ,,. 4 . ,_._.y__,,,. , ..<.we.q;gg.,yru:=== u::w1=;gl@n;,aMa&&FTWi=t.m X= v : <uu m = ' ,, , DEFICIENT CONDITION NOTICE {g g .) J,etNIT'# n 2 AREA /~ ELEV // / ,. CygI/p. nw DATE: f//4/~ 6.I ~ ' NOTI (E N0. M , g FD ,,9(;g gy a f<tr .//.bef2- 74 -234 - d g 95 ... DEFICIENT CONDITION: c.;j sep *?v% 7; s% @g). Ae' .rsien .J;!% akg.c .tcc4 . / c:w # c;v6cW Miter 72 sWxdda Am M,'Ir.r4 f%cesT& /S43 % # e. 6 he N a M A eo se W <tdeve< K'<'w 0** AM M *
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/ Q iso 2. 3 I 'he HOLD TAG APPLIED: /g TAG #[g,.g INITIA DATE y RECOMMENDED DISPOSITION: 15506 A2oc s svaerS '. p i v. T E Q. 'D. W 4 CHI N NEER li ' .:ld t L M III "gY'. FIELD QA/QC MANAGER vj , /b '; ; FIELD QA/QC MANAGERS EVALUATION: ~ ]i APPROVED AS RECOMMENDED OTHER h) NON-CONFORMANCE - D.R.# COMMENTS.' CAUSE CODE J l .n REPAIR ORDER c ,l, . ] REWORK / REINSPECT ] INTERNAL AUDIT , 3 $q
- 4 Q OTHER }(f/7/h DATE
/ 9/b v 63 FIELD QA/0C mat AGER /d ?3 CORRECTIVE ACTION REQUIRED BY: NOT LATEP m "- ;q ~ 1 / { j STEPS TO PREVENT RECURRENCE: h_ V NOT APPLICABLE
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- 1. Maintain all low hydrogen electrodes at 2500 minimum
? :..- and revise KFP-12 and ESD-202.
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