ML20215H012

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Followup of Alleged Deficiencies in QA Program at Diablo Canyon Nuclear Plant
ML20215H012
Person / Time
Site: Diablo Canyon  Pacific Gas & Electric icon.png
Issue date: 02/29/1984
From:
PARAMETER, INC.
To:
Shared Package
ML20215G377 List:
References
FOIA-84-744, FOIA-87-744 PAR(DCNP)-NDE-3, NUDOCS 8706230482
Download: ML20215H012 (125)
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dp Report No. PAR (DCNP)-NDE-3 h;

February 29, 1984 Page 1 of 12

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Followup of Alleged Deficiencies in the Quality Assurance

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Program at Diablo Canyon Nuclear Plant References Contract No. NRC-05-82-249

'[t:f Task Order No. 58 n

PAR: NRC/IE-82/83 Writer of Followup Report

@d Kenneth A.

Ristau, PARAMETER, Inc., NDT Level III, MT, PT, RT, b

and UT s ci-Refer to Exhibit 1 for Qualification Certification M,1 Subject Reports p$

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1. Report #2 of 1/2/84, Allegation #121, referencing Pullman g.&j N

Power Products Internal Audit #34

fj In Allegation Items Al through A4 of this report, g.1_

measurements of valve wall thickness are challenged Mi.

because they were made per unqualified procedures.

isp In Allegation Items B1 through B15 of this report.

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%py]j documentation of the measurements of valve wall thick-ness mentioned above is challenged because it is in-

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complete.

In other words, information required by the procedures was not provided.

Q 4.11 In Allegation Items C1 and C2 of this report, lack of a W

weld repair procedure for valves is claimed and identi-f^f cation of repaired valves is challenged.

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,Q In Allegation Items D1 through D5 of this report, code

$J conformance of valves is questioned.

Although these 49 five items are identified in the text of Report #2, they i,, )

are not numbered 1 through 5 specifically.

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5 In order to identify these allegation items positively, Fyl Allegation #121 is entered in parentheses following the Tl Allegation Item Number.

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Example: A1(121) d!)

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N Report No. PAR (DCNP)-NDE-3 C February 29, 1984 l Q Page 2 of l'2 ] 1 'l g .2. Report #3 of.1/12/84, Allegation #122, referencikg Pullaan Power Products Internal Audit #101 uh 5 t l jYg In Allegation Items Al through A5 of this report, qualification of five NDE procedures applied to L various components is questioned.

  1. {;.U;i '
  • q; Allegation Items B1 and B2 of this report are repeti-tions of Allegations Al through A4 of Report #2.

t ,p In Allegation Ites C1 of this report, after-the-fact ';3 qualification of three NDE procedures is questioned, g and lack of acceptable approval signatures is claimed. e p?.Cs Allegation Items C2 and C3 of this report are repeti-f.$j tiops of Allegations A5 and A2, respectively, of the same report. l-ld The remainder of this report is general; in effect, the P ' Allegation Items described above are repeated. 5$ Record of Activities of Writer at Site "!,j;t fl February 6,

7. 8, 9 and 10. Report #2 (121) and Report #3 (122) were examined.for substance and compliance to applicable codes and specifications.

Prior to leaving the site on the 10th, at /d his request, copies of the writer's findings in rough form were i f;4 conveyed to Dennis Kirsch, Chief of the Reactor Safety Branch of p NRC Region V. d$

ntroduction eth J.n compliance with Task Order No. 58, Reports #2 and #3 (later Q;

identified as Allegations No. 121 and 122, respectively) are to be examined for substance and compliance of procedures with v M regulations, codes, standards and contract specifications. t:5 Procedure use with respect to 10 CFR 50 Appendix B; ASNT-TC-1A; Si ANSI B31.1 and B31.7; ASME Section V 1968/71; contract j specifications; and others is to be checked for compliance. h aq To simplify comparison of this report with Report #2 on $g; Allegation #121 and Report #3 on Allegation #122, Allegation , Items used in this report are numbered like paragraphs in f

Reports #2 and #3.

g tij Example: Allegation Ites A1(121) satches M Paragraph Al of Allegation #121. f.d{ .3 st q l ~D T:s 1n.\\ >4....,. - - = - - -

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Report No. PAR (DCNP)-NDE-3

  • j February 29, 1984 N

Page 3 of 12 a,,

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iN$ Pertinent Excerpts.from Atomic Energy Commission Let~ter of kjp

6/20/72 to Pacific Gas & Electric Applying to Reports #2 and LJ
  1. 3 (Allegations #121 and #122. Respective 1v)

.,,e 1 I .g You are requested to verify through manufacturing records or 4 other suitable means, that valves important to nuclear safety, 3 installed or to be installed at your facility (ies) meet the @%q minimum wall thickness requirements of the specified codes or standard. if] The valves which require demonstration of acceptable wall thickness are the followings g4 Each valve within the reactor coolant pressure boundary, as p3 defined in Subsection 50.55(e) (Codes and Standards) of 10 CFR Qj 50 where the valve is: A. Over 1" nominal pipe size for pressurized water reactors. H.y B. Over 1-1/4" nominal pipe size in waterlines for boiling ,]N C. Over 2-1/2" nominal pipe size in steamlines for boiling water reactors. water reactors. [g The following techniques are considered to be a sufficient b.6 demonstration of acceptable wall thickness. Alternate gd techniques may be offered but there is no assurance that they ~ 9:,1 will be found acceptable. oc gg Documented direct physical measurement of wall thickness 4;j with comparison to specified minimum wall thickness. 1 4 j.f Documented results of ultrasonic measurement of wall thick-1 T) ness with comparison to specified minimum wall thickness, )[;j j and documentation that the ultrasonic measurement technique is demonstrated to have a maximum error in repeatability and q accuracy of not more than 2% of the wall thicknees. {.%p 10 CFR 50 II Control of Special Processes i.0 XVII Quality Assurance Records 4 i 'd Allegation A (121). (Items 1 through 4) {plj

  • Ultrasonic thickness measurement of reactor coolant pressure l boundary valves had not been controlled and accomplished

, -1, using a qualified procedure. ld M Notes Refer to preceding excerpts ~j iM from AEC letter of 6/20/72. p t .i1 O .1* 8 y ,q l]

hiFfdfg(WP@ $ @ M M l $ $ $ I M ); M $ $ $ M [ ; M g R a O T 08 i'f&Q*- h Report No. PAR (DCNP)-NDE-3 7.$ February 29, 1984 Q Page 4 of 12 { -l Q. M A1(121) There is no evidence of a procedure qualification record T documenting that the ultrasonic measurement p'rocedures ESD236 and ESD244 are qualified by a proven demonstra-J tion as required.. J 4H A2(121) A procedure qualification was not performed as required g by above.

M A3(121) Procedure was not performed to determine transducer re-cr quirements.

Mj A4(121) Similar in content to A1, 2 and 3 above. %4y Writer's Findina: A1, 2, 3 and 4 are potential violations of the procedure qualification requirement of 10 CFR 50 Ap-Y{ pendix B II and XVII. These potential violations may or may ) U) not have adverse influence on quality of product. The Pull-J JJ man response is inadequate. See Audit No. 34, A.A.R.P. No. 1, h Page 1. , Normal calibration of instrument by comparison of 4 L:q mechanical and UT measurement does not constitute documented H assurance of repeatability as required. A suggestion would ) y$j be to inspecc a quantity of the valves, using a qualified procedure, to verify authenticity of measurements reported. qu O A11enation B(121). (Items 1 through 15) Pullman Power Products Unscheduled Internal Audit No. 34 of hqg 254 Valve Wall Thickness Data Reports, etc. a j.3 B1(121) None of the 254 reports listed size, shape, and type of { (,9 transducer. 1 kg B2(121) Most data reports list a transducer serial number. W ESP 236 documentation packages do not provide any d information or description for transducers by serial ni number. J B3(121) Seven data reports do not list serial number of j d ultrasonic testing instrument. q B4(121) Nineteen data reports did not list testing frequency N'il or nominal frequency of the transducers used, l B5(121) Nineteen data reports list both Nortec NDT-120 Serial l kj

  1. 12224 and Branson Sonoray Model 303B Serial #18060 as g

tester used, but only one set of readings. Actual UT

y equipment used cannot be determined.
  • j B6(121) 207 data reports referenced serial numbers for ultra-

$9 sonic thickness tester equipment that could not be '3 traced to documentation for certification of equipment E:a$, calibration. 2[h Writer's Findi. pas Pullman Power Products' response to B1, 2, 3, K((J a 4, 5 and b is considered adequate. Lack of data is due to omissions by recording personnel. See 6/4/83 reply to Audit M No. 34, A.A.P. #1 and #2, Pages 2 and 3. -l a 9 a I ygy --. ~ .~

/$s N N Ut d $ddNI N b bhIh d bbENN.!T$EENN N '. 4 f[C Y.? I 7:7Q* Report No. PAR (DCNP)-NDE-3 A lt February 29, 1984 Q, Page 5 of 12 .s ' 1-% 9

Bl. Use of unrelated equipment would be immediately: obvious ed to qualified technicians.

~ pi? i B2. Several ultrasonic tester units were considered capable of rd producing same end result. f;h B3. Ultrasonic equipment was calibrated pre and post in-spection. j cM B1, 2, 3, 4, 5 and 6 are potential violations which would not 9 seriously influence or have an adverse effect on quality or .h) safety of product. L1h B7(121) Fourteen (14) data reports do not list serial numbers p;n for micrometers used to check the calibration accuracy @);j of the valves by a mechanical means. B8(121) Eighty-four (84) data reports referenced serial numbers { jy for micrometers that could not be traced to document-3 ation for certification of equipment calibration. m1 Writer's Findinn: Pullman Power Products' response to B7 and B8 9 is considered adequate. See Unscheduled Audit No. 34, A.A.R. %l f3, observation 3-1(B7) and 3-2(B8), response dated 6/20/83. Experienced technicians would merely zero a 1" micrometer and .M a damaged micrometer would be obvious. Readings out of the j EM ordinary would trigger a warning also. B7 and B8 are poten-2 3 tial violations which would not seriously influence or have E d, an adverse effect on the quality or safety of product. hl B9(121) Six (6) data reports do not list any information d concerning the stepwedge blocks used for calibrating 4 ultrasonic test equipment. q.; M Writer's Findinn: Pullman Power Products' response to B9 is

  • G adequate. See 8/3/83 response to Unscheduled Audit No. 34, if A.A.R. f4, Pages 1 throu8h 3.

This information indicates j f1 that all step blocks used for ESD-236 were acoustically simi-J, lar. B9 is a potential violation which would not seriously D influence or have an adverse effect on quality or safety of Q product. g.,M B10(121) Eleven (11) data reports do not list pre or post

g wj operation calibration information.

{ i fj Writer's Findina: Pullman Power Products response to B10 is fi adequate. One valve was already installed, one was returned ti to. Westinghouse and the balance were not documented cor-W rectly due to operator omission. Their explanation indicates -} that an accoustically similar step block was used.

Further, g

due to operator nad dates tests were made and sequence in 1 t :..] 3 ~ 'l 9

YN$$$$$ibbYb $Y$0 YY bb A L eg II$ p- ,o y EU Report No. PAR (DCNP)-NDE-3 hj,9 February 29, 1984 n Page 6 of 12

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0.0 p.) P ip which valves were inspected, it is believed that lick of ps recorded calibration information is due in most part to oper-i 4d stor omission. See 8/3/83 response to Unscheduled Audit No. 34, A.A.R. #4, Pages 4 and S. B10 is a potential violation 4g !y which would not seriously influence or have an adverse effect p g,1 on quality or safety of product. h' d% B11(121) Forty-two (42) data reports indicated the valves as E6 below the minimum allowed wall thickr.ess but data gd reports were signed in the Item 7 space that indicated (<:d the valves were physically marked as acceptable. Q)) y, Writer's Findinn: Pullman Power Products response to B11 is l yd adequate. The fact that Item 7 space was signed off re- .si gardless of valves acceptability, was due to operators con-j hT] fusion as.to the intent of Item 7; indicated by the 42 sign-E offs. Further documentation indicates valves were all on DR's or other memoranda, and not installed. See 8/3/83 re-sponse to Unscheduled Audit No. 34, A.A.R. f6, Pages 1 h through 3, including the list of 42 data reports which show c.- disposition of each valve. Bil is not a potential violation. ,d B12(121) Many data reports were found to have original inform-1 Pj ation " whited out" and new information inserted with e 3Q no explanation for changes.

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1 Writer's Findinn Pullman Power Products response to B12 is y;] adequate. Information indicates that for a period of time

4 this method of " whiteout" was used to make corrections.

This 44 method is no longer acceptable. A single line is drawn i Ep,'j through and the correction m.3de. See 8/3/83 response to Un-g scheduled Audit No. 34 A.A.R. #6, Page 4. B12 is not a v potential violation. /. i-B13(121) Eleven (11) data reports did not have a complete i h}) measurement inspection of all areas of the valves as l 9 required by the procedure. There is no documentation %j, i authorizing the incomplete measurements. 2 Writer's Findinn: Pullman Power Products response to B13 is I Q)] adequate. Eleven valves were returned to Westinghouse and were replaced by ultrasonically tested (QAP-UT-3) and ap-(I]j gj proved valves. See 8/3/83 response to Unscheduled Audit No. f 34 A.A.R.

  1. 7.3, Page 2 and 3.

Also, 9/17/83 Westinghouse letter to Pacific Gas & Electric Company summarizing the i gg status of the valves in question. No potential violation by {j Pullman activity. 1 4 'l j i I

dk$$$$$5E$[2dMNUFMN3NNs$$$$NONI$3G!dS$NNDn N$:INM ..W {R: di t.p b up g; Report No. PAR (DCNP)-NDE-3 ij.;.i February 29, 1984 y Page 7.of 12 g_., B14(121) Fourteen (14)valvelocationslistedbyWesti5ghouse 1etter #PG&E-2080 to be seasured, have no document'ed $h evidence of being examined. gij h-Writer's Findina Pu11aan Power Products response t'o B14 is-adequate. Records exist which indicate these 14 valves were %h removed from the list of valves to be sensured. See 8/3/83 response to Unscheduled Audit No. 34 A.A.R. #7.4, Page 2 and 3. B14 is not a potential violation. 3 f(g B15(121) Two (2) of the 20 valves physically checked had serial numbers that did not match the data report. serial rli. - numbers. N pd Writer's Findinn: Pullaan Power Products response to B15 is F adequate. Records indicate inversion of heat number was. N recorded as serial number. Correct serial number was located Ka on the valve; also, vibrated markings of correct-serial lQ number were located on second valve along with the infora- %,J ation recorded as serial number. See 8/3/83 response to Un- ,fg scheduled Audit No. 34 A.A.R. #8.1A and 8.18. B15 is not a y potential violation. d A11enatio'n C(121). (Items 1 and 2) Refer to AEC Letter of 6/20/72, Page 3,' Paragraph 6. q;d Status c6] In certain instances, you may wish to repair valves found to have wall thickness below minimum specification. In such $j instances you are requested to provide to this office for our k.: review the proposed repair procedure, including a' description of 3j techniques to be used to verify the acceptability of the y repaired components. I qy Allegation N There is no documented evidence in the ESD-236 documentation packages indicating compliance with the above requirement. $a C1(121) There are 47 data reports that indicate valves were su below minimum wall requirement, UIA #34 AAR #8 identi-33 fled 2 valves #2 PCV-455A and 2 PCV-455B that were weld Qi repaired to meet minimum wall. ESD236 package does not T specify which of the valves were repaired. 6 ?ft Writer's Finding: Pullaan Power Products' response to C1 is in-1 W; adequate. It cannot be determined from the information available if repairs were performed, which organization made 6-the repairs and how many were made. A complete evaluation of ^' this allegation ites cannot be made. [.,

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' Y4W= -_d MG 1 *" F F "m=*'dWiteCW $4 4 ' *T 8 ' @*Dr a. Y sR M."R'. OO1 Gr4 60egwegemmeL y .1-Am nya g g +o r sq pna m Ww _

f.N D :22{k M M W W G M W W NN! h b M 6 W ^ $ 5 $ W X R$ s ?]b M yl;' Report No. PAR (DCNP)-NDE-3 k February 29, 1984 1. Page 8 of 12 +.__ Sp T D. m lQ C2(121)ThereisnodocumentedassuranceofapprovedwUldpro-k procedures or description of techniques used to verify p[/!j acceptability of repaired valves, There is no evidence available that would substantiate y a weld repair procedure qualification or a qualified procedure for verifying acceptability of repairs. f1 Writer's Findina Pullman Power Products' response to C2 is in-adequate. C2 is a, potential violation of the AEC 6/20/72 n.d. letter, Page 3. Paragraph 6, 10 CFR 50 Appendix B. Section .3 "}d V of ASME Boiler and Pressure Vessel Code. ANSI B31.1 and USAS B31.7 only if substantiated that Pullman Power Product.s /lk, repaired the valves. This condition may or may not have an [. adverse influence on the quality or safety of the part. <.q lml?]' D1(121) Question: What is the relevant code or standard " Reactor Coolant Pressure Boundary Valves" should con-lI form to for specified minimum wall thickness? e

  • i1 3

Writer's Findina The writer has not investigated which code or M standard is relevant for specification of minimum wall thick- /a ness. Typically, an NDE inspector would co. pare measured thickness with thickness specified by means.of a drawing or a di specification. He would be justified in assuming that the y thickness so specified was correct. v: ; D2(121) Page 1 of Westinghouse letter see via #34 QA checklist, y Page 5, Westinghouse supplied reactor coolant pressure k boundary valves Unit I and 2 Diablo Canyon were designed to meet requirements of Article II of ASME Boiler & (i Pressure Vessel Code, Section III, 1968 edition. Valves were not designed to meet minimum wall thickness re-r f@ quirements of ANSI B16.5 (USAS B16.5) which is refer-enced in AEC letter as one of the relevant codes. I n3 Ed This raises question whether Diablo Canyon reactor cool-N ant pressure boundary (pressurized safety valves) meet d the AEC (NRC) Code requirements. (;.) Writer's Findina: The writer has not investigated which code or ob standard is relevant for specification of minimum wall thick-p# Typically, an NDE inspector would compare measured ness. 3 thickness with thickness specified by means of a drawing or a M specification. He would be justified in assuming that the thickness so specified was correct. hj D3(121) The Westinghouse supplied " pressurized safety valves"

  • /,

(reactor coolant pressure boundary valves) do not comply Q]1 with PG&E C.S. #8711 Section 2.2.1 Code requirements to be designed, manufactured and fabricated to ANSI B31.1. l j, I, e .q _,_,,,m_..-._ ~ m,,,m.

,MFSMMFMiER94* WGM923dDEEP%AEMiM * ~ * "% a J \\ k,;V. \\ i .,. t . ?, @q] Report No. PAR (DCNP)-NDE-3 February 29, 1984 l p. Page 9 of 12-y i.';[ Writer's Finding: This allegation item has not been eva15ated by the writer. ,j)! D4(121) PG&E C.S. #8711.2.2.1 states the reactor coolant piping l c and pressurizer surge lines of reactor coolant systems i @W have been designed, manufactured and fabricated to ANSI l B31.1 with apglicable nuclear code cases and will be furnished by Westinghouce" C.S. #8711 Section 2.1 and leD 2.16 states reactor coolant system except that main 3, coolant loops a6d pressurizer surge line are to be de-g signed, fabricated and erecte'd per ASME Boiler Code, h Section I. The Westinghouse supplied " pressurizer pj safety valves" (reactor coolant pressure boundary val-l >lly ves) as referenced in the Westinghouse letter PG&E 2080 i c "J. do not comply with the PG&E Code requirement to be de-I m signed,* manufactured and fabricated to ANSI B31.1. This W; is a non-conformance to PG&E C.S. #8711 Section 2.2.1. l ^ @j The Westinghouse supplied valves were designed to meet 7 Article 9 of ASME Boiler and Pressure Vessel Code, Sec-y tion III, 1968 Edition. ~. d Writer's Findinn: This allegation item has not been evaluated by 4 the writer. hj D5(121) The apparent non-conformance of Westinghouse supplied ,] " pressurizer safety valves" (reactor coolant pressure j^, boundary valves) to PG&E C.S. #8711 Code requirements indicates non-compliances to 10 CFR 50 Appendix B, Sec-g tion III Design Control, Section IV Procurement Docu-b,.; ment Control, Section VII Control of Purchased Material, @d Equipment or Service, and Section IV Non-Conforming ,.a Materials, Parts and Components. Writer's Ptndine This allegation item has not been evaluated by ,r.j the writer. .:n g A11enation A(122). (Items 1 through 5) <W Refer to Report #3 (122) Quality Assurance Discrepancies di Associated with Pullman Power Products Internal Audit #101 at lyf the Diablo Canyon Nuclear Plant, 1/12/84. It is alleged that IM Audit Action Request #1 findings have not had adequate l@4 corrective action implemented. !.id A11enation A(122). General Five NDE procedures wu c identified on Internal Audit #101 as si; not having evidence that special processes were controlled and y accomplished using qualified procedures or that qualifica- ,1 tion records were maintained to document and assure quality d of material and work. There are no procedure qualification l,1 tests for these five NDE procedures. The five NDE procedures j are ESD-234-241-246-247 and 270. _Y ..__.-__-.l.-.~_n-..$ Y - Y '_ A~ _ _~

';$EC$$E M WWF@ Mif1'{f9@#M M M.e @ $8Mi@M MynWMgE.[5 IGE E Q(0 s s. ' 7. i !);Q f$,, Report No. PAR (DCNP)-NDE-3 X February 29, 1984 Q Page 10 of 12 t.e i . - V. pg;; Hs Writer's Findinn: Procedure qualification' records of each of the pf five procedures is required, according to the quality assur-y.) ' ance requirements for special processes of 10 CFR 50 Appendix-y'; ,B, II and IVII and PG&E C.S. #8711 Section 4.3.23 and 4.3.29. r5 NOTE: For purpose of simplifying this finding, each of g[4 procedures will be indicated separately as follows.

8...

,%q A1(122) ESD234 - UT inspection of groove welds. AWS-D1.069, ASME Section VIII and Section V were used to examine gi,J full penetration groove welds on pipe rupture restraints Hg prior to July 1979.

b If,I Writer's Findina: Pullman response to Al is adequate.

"rocedure qualification was performed 10/1/82 after inspectiora were [;N) p made. See 1/13/83 response to Internal Audit No. 101, A.A.R. K,y

  1. 1 and E8D 234 procedure qualification record.

ESD234 is b'Pi proven to be a reliable procedure. There is no potential violation. d M A2(122) ESD241 UT examination of safety yoke rods on 3707 RAI (4 6.21 safety valves. . 9: .c rp.j Writer's Findinn: Pullman Power Products' response to A2 is in-adequate. This is a potential violation of 10 CFR 50, Appen-d@d dix B. Section V of ASME Boiler and Pressure Vessel Code, ANSI B31.1 and USAS B31.7. This may or any not have adverse ?M roduct. Records indicate influence on quality and safety of p/73 and 12/20/73, h inspections were made between 12/17 prior to ]a ESD 241 date of issue which was 12/26/73. Reinspection using f3 a qualified procedure would seem to be one possible correc-p tive action. @'j A3(122) ESD246 - Magnetic Particle Procedure / Dry / Continuous Coil M B31.7. W Ci Writer's Findina Pu11aan Power Products' response to A3 is 35 adequate. Procedure qualification was performed (HT-3) 11/9/8'2 after inspections were performed. See 11/9/82 re- -d sponse to Internal Audit No. 101, A.A.R. fl. There is no 4.1 potential violation. Subsequent qualification of procedure indicates the procedure's ability to detect specified dis- %j - crepancies. V-A4(122) ESD247 - Magnetic Particle Procedure Dry / Continuous Coil fd B31.1 was used to examine repaxc welds in feedwater Q nozzles on Unit 1 generators. y ,j ~l i! fb 1 a 1 _,,y.

y~.-Qw-.:n=@pp.yM.~i4:ta alq%..:f6W?$.iT@a%'R$<_ggg'QQya;%Dk m, y; x., g4 4. w.9u.&~~T NW y y w.w m a. w -a w-I g e-l.~3 i ft.:. j !e i \\ wR Report No. PAR (DCNP)-NDE-3 GR February 29, 1984 S Page 11 of 12 ' 4 ~-- .:9 $;j Wr3ter's Findings laullman Power Products' response to~:A4 is M adequate. Procedure qualification was performed (MT-3)- d 11/9/82, after inspections were performed. See 11/9/82 re- ..d sponse to Internal Audit No.-101 A.A.R. fl.. There is no j P potential violation. Subsequent. qualification of procedure i 3 indicates the procedure's ability to detect specified dis-

.y crepancies.

xi

W A5(122) ESD270 - Liquid Penetrant Procedure (use unknown).

j l e j h, Writer's Findinn: Pullman Power Products' response is adequate. ( Wq There is a similarity of materials and raethods to existing h procedure ESD210 which is a qualified liquid penetrant pro-cd cedure. It appears there is no potential violation unless it ?l)J can be proven that ESD270 has been used. Even then, there is M)i reason to believe ESD270 would demonstrate ability-to detect 1 G; specified discrepencies. See Page 3 of Internal Audit No. 101 .l.] for recommended corrective action. ) 3 Writer's Findinn on A11enation Items B(122) and Cl(122): m 1 B(122) Is a repeat of Allegation Al-2-3-4 of Report No. 2 '4 (121) dated 1/2/84 and finding is stated there con-C cerning ESD236 and ESD244. Refer to Pages 3 and 4 ,.i of this report. A! Cl(122) The "after the fact" qualification of procedures A'; ESD234, ESD246 and ESD247 is approached on in-dividual bases in A1, A3 and A4 Refer to Page 10 1 Of of this report. j @d The second part of C1 deals with alleged absence of 9 proper signatures approving qualification pro-y cedures. J t*' ,pj A11enation Ites Cl(122). Second Fart u j i Tj ESD234 ESD246 and ESD247 qualification procedures performed I q'd, 10/1/82 and 11/9/82 have not been approved by appropriate MI management authorities. .m ~4 { [ Writer's Findinn: Pullman Power Products' respone.e is adequate. Q Procedure Qualification reports were signed by a Pullman J Power technician qualified and certified to ASNT-TC-1A NDE g Level III. There is no potential violation. An NDE Leve.1 III individual should be capable of establishing techniques a ,) and procedures, interpreting Codes, Standards, specifications El and procedures and designating the particular test methods, 1 h t .j dN U

reTg'WF. _F%u._1Mi?3fE.F_W_pM. _M.E:Jp,6iM_ M,,, W_f!N.M_Pdf2.WWESR2.MG.Mr. _?>rs.hu@.__r.,,,c.p r 'gW it. 42 .y m ..c l'N, c;t. r,., g'd Report No. PAR (DCNP)-NDE-3 ? February 29, 1984 E.E 4 Page 12 of 12 / i.vl { c Y:pht. M,4 (gj techniques and procedures to be used. That procedures demon-qg strate the ability to detect specified discontinuities,..is Qt;,; the prime factor. Records indicate PG&E quality controls MA . acceptance of all examinations by ESD247 procedure 2/9/83. y ac 3 l?N Writer's Findinns on Remainder of Report #3:~ ll!:) ?; C2(122) ESD270 is reviewed in A5(122), Page 11. f-U, yl C3(122) ESD241 is. reviewed in A2(122), Page 10. h.h< y. The balance of Report No. 3 is primarily repetition of condi-p.l7.j tions already reviewed. ' f t: ['d List of Exhibits , ?,

1. Qualifica. tion Certification of Kenneth A. Ristau..

.;q 1 .O n,a 1: - [.' O Prepared by: p'd, lKennethA.xe2l// L /tv tj Ristnu, Level III 2 .d M Reviewed by: ph] R p @i Walter J. Fole'y, $s. Q/A Engineer

    • I

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  • 9

,i,ni l74 KENNETH A. HISTAU is hereby designated a Lovel III -] di Non-Destructive tout examiner, in the ro11owan6 disci- ' yj plines M e.', a A. Hadiography B. Liquid Penetrant , a. C. Ms6netic Ferticle /W D. Ultrasonic 9 Documents covering examination and compliance >) scoordii2g to the guidelines published by the Americun ~. a Society for Non-Destructive Testing for Level 111 j Certification, including testing and grading of General, ~j Specific, and Pratical examination by an outside agency b.] are in the Corporate file. Also included is evidence j, of past experience and proficiency in the four disci-f.n plines involved. L r M These documents are available for examination i /4 11900 receipt of a le61tiaste inquiry requesting the ..l 21 professional services of Mr. histau. i, $Y!11 .? w

r. 4 Na sus 11 L. Yoho

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[25.5df2 dss @MNO3I3DfNd.MM1 f % $ [, h p W < f S. 4 " 561 M.* Exhibit-1 to 't Report No. PAR (DCNP)-NDE-3 7/d ehd.Ristau bl araas#lar a c, r s Staff Consultant d c o u s ettsm s suesweses a sta saove, wiscoussw Ml.J ~ :~~ u4 Level III Examiner 7f RT, UT, Kr, PT T IHI Nondestructive Examination p Ijn s.., ?. Mr. Ristau provides PARAMETER, Inc. with expertise and practical S.][ experience in all areas of nondestructive testing. Ile has con-k tributed in this capacity on numerous field assignments for NRC during the past four years. !$.] 4 (g For twenty-six years, Mr. Ristau was employed by the Allis-Chalmers l fi Corporation West Allis Manufacturing Operations as a Supervisor (h in the Nondestructive Test Department. He has examined a wide Ig variety of their usual products, such as pressure vessels, pumps, compressors, steen turbines, steam turbine piping, transformers, penstocks," minf.ng equipment and large rotating machinery. Many of }d.? the foregoing products were manufactured in accordance with the i AS W Boiler and Pressure Vessel Code, Sections III and VIII. His k experience includes examination of equipment hatches for nuclear power plant containments, nuclear pumps and vessels. ...) At Allis-Chalmers, Mr. Ristau served as Supervisor of the Nondes- ,Uj tructive Test Department. He had charge of a two-shift operation i' with twenty four people total. Because of his responsibility for Quality Acceptance of Allis-Chalmers products, he worked with Quality Assurance Engineers to make sure that specific NDB requirements were I @/: met and that PCB operations were coordinated with the Product De-partment. He was responsible for development of methods and pro-cedures for testing personnel qualifications in accordance with the M ASW Code for Nuclear Powisr Plant Components. He worked directly .j} with Customer Quality Control personnel on documentation to satisfy requirements of the casting ungrading program. N From 1965 to 1969, Mr. Ristau served'as Inspection Supervisor, re-(, sponsible for work assignments of MDB personnel on three shifts, p)y for documentation of compliance with NDE requirements and for p, liaison niith customers' inspectors as required. O 7$ From 1963 to 1965, Mr. Ristau was an Inspection Foreman. Except N for the additional supervisory duties, he had essentially the same l b]1 responsibilities noted above for the 1965-1969 period. From 1953 to 1963, Mr. Ristau served as Lead Nondestructive Test Inspector. In addition ~to the usual products already mentioned, c.4 he examined primary coolant pumps, a reactor vessel test head and other' components ?or the nuclear power industry. Mr. Ristau is a member.of the Advisory Board of the Milwaukee Chapter of the American Society for Nondestructive Testing. 3,: ,[ ... _,. - ~........, _..... _....,. _ _...

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j KIRSCH :' The date is January 12, 1984.

The time 7:05 p.m.

h Present for the Nuclear Regulatory Commission are Gonzilo t

..( Hernandez, Reactor Inspector out of Region 5, Lou Schoenberger, N the Regional Attorney in Region 5, Bill Waoner, Reactor Insoector ^ e,. 5 out of Region'5, and myself, Dennis Kirsch, out of Region 5. ?. I; Also present for the Government Accountability Project is John i Ef "[]I Clewett, representing Mr. Harold Hudson. Harold Hudson has some l .p ' e;';. additional concerns that he would like to cresent to the E !, l,lj Commission during this meeting and, in order that the transcriber .,q'fj - may recognize various voices, I would like each individual to. 9!. state his name for the tape recorder so that the transcriber can associate a sound with a name. [ CLEWETT: My name is John Clewet'., I'm the person from GAP. HUDSON: My name is Harold Hudson. y?,, WAGNER: My name is Bill Wagner. I'm a reactor inspector

  • i from Region 5.

90 KIRSCH: My name is Dennis Kirsch. t.. aa [." 3 SCHOENBERGER: I'm Lou Schoenberger. 'e,1 HERNANDEZ: I'm Gonzalo Hernandez. ,.i j KIRSCH: Okay, with that all completed, Mr. Hudson, this !q' hj) meeting is at your disposal. p ,1 ; HUDSON: I have prepared another report and have attached ed 9 documents relating to Pullman Power Products Internal Audit 3 E.,j No. 101. The report is number three addressed to Mr. Galinski, 4.. ~ but again, being discussed with this meeting prior to being l , a NJ 4 Hudson /1-12 1 A rd Q , t _ _ _._, m . ~..

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.f ~ -. % % mWY ' M submitted to Mr. Galinski. The report deals with auality t ^ assurance discrepancies associated with Pullman Power Products s

jf Internal Audit No. 101, the Diablo Canyon Nuclear Plant.

Pullman ~ r "1 Power Products Internal Audit No.101 performed on 1/1~8/82

q

~. R..u identified significant conditions adverse to cuality which were M

jd not promptly corrected and resulted in corrective action which W

was not adeauate. Pullman Power Products Internal Audit No. 101 Audit Action Request No.1 finding did not have adequate corrective action implemented. Five non-destructive examination .3-ik[ procedures were identified on Internal Audit No.101 as not ' y1 j having evidence that special processes were controlled and a ji accomplished using qualified procedures or that qualification "i records were maintained to document and assure material 3'i and work. There are no procedure qualification records i J, documenting the procedure qualification test for these five NDE a. procedures. The five NDE procedures were ESD 234, ultrasonic i- 'j inspection groove wells AWSDlO69, ASME Section A, and Section 5. This procedure was used to examine full penetration J ,,n groove wells on pipe structure restraints prior to July 1979. O H ESD 241 ultrasonic examination of safety yoke rods on 3707 RAX 4.c/l 6-21 safety valves. ESD 246 magnetic particle procedure dry 7 {

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continuous coil, E317 use unknown, EST247 magnetic particle 1 "c v] procedure, dry continuous coil, B31.1 used to examine craft ( 3? 42 f.g repair wells on P water nozzles to unit 1 steam generators. DSD ,4 ll'% 270 ligid penetrant examination procedure, use unknown. Two n f @y ultrasonic material thickness measuring procedures were ll dgj identified as not having evidence that the special processes were l1' n,'i j H f. Hudson /1-12 2 q] a

'[ 3 5rd:; d !L d s/2$N8','CM$d$bd@ YdblI$b($b;d!$Id3 M b M v ,O controlled and accomplished using aualified procedures. Or that, ly qualifiation records were maintained to document and ensure quality of material and work. No procedure qualification records

g documenting the procedure qualification test.

These procedures r.m 'g are ESD 236, ultrasonic thickness measurement of bbb, two, b 3] ultrasonic material thickness procedures did not have procedure N qualification records or ESD 236 ultrasonic material thickness %M measurement of bbb. This item has already been addressed in Pullman Unscheduled Internal Audit No. 34 and my report number 2 .aN to Mr. Galinski. Also ESD 244 ultrasonic thickness gauae pij procedure. Pullman Power Products OAQC Manager Harold Connor .y.l determined that since these two procedures were not non-8 destructive testing procedures, they did not recuire PQRs. My q 'h op4nion is that this is not a valid determination. All soecial .y processes not done, heat treating, welding and non-destructive tenting are to be controlled and accomplished usino cualified d procedures. It is alleged that OAOC Manager Connor's id (!j determination that ESD 236 and 244 did not recuire procedure _[ qualification records covers up a serious breach in the cuality ] assurance requirement for special processes as recuired by 10. CFR N 50 Appendix B, Section 9, and Section 11. No corrective action sq has been implemented on these two procedures. ESD 234, 246, and Es 247, indeed deep procedures, did have procedure cualification mE records as corrective action to Internal Audit No.101, AAR 1.- M 91 These PQRs are after the fact qualifications of these $b to procednres. The actual use of these procedures was not

p; controlled and accomplished using a qualified procedure.

A j Mj i t,. 3

  • i oj Hudson /1-12 3 e,1

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]d@?O'E N~Sf[jd3/2[hdyi d sy,$'d855N6 M N NEOj33$1 5 $$$ d !$N Q special note about these three procedures are that PORs that were r ", ' (J performed af ter the f act do not have approval signatures of l ~#~'! / either PPP or PG&E management authorities. The only signatures on PQR's are those of the individuals performing the tests. It I9 is alleged that these PQR's do not have, or have not been W $O approved by the appropriate management authorities. ESD 270 did s,9 y.. not have a procedure qualification test performed as part of the y d[ corrective action. OAQC Manager Connor determined that ESD 270

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.l used'similar penetrant materials and examination methods as an $k ESD 210 which was a liquid penetrant procedure and CB 317. An W h.,d ESD 210 had a procedure qualification record which demonstrated .( []} the ability to detect specified discontinuity. Mr. Connor y]d j.l directed that ESD 270 be revised to incorporate the PORs of ,;.l ESD 210. The use of ESD 210 POR does hot provide the proven .' ]. ! demonstration to identify discontinuities. ESD 210 and ESD 270 must have some differences or there would be no need for two Dj different procedures. It is alleged that OAOC Manager Connor's n k' j directive to use ESD 210 POR's for ESD 270 did not provide p, h,3 adecue corrective action to the. audit finding that the ,e i ESD 270's lack of proper PQR's to a condition adverse to quality. No investigation was performed to determine where k.i fj ESD 270 was used. ESD 241 did not have a crocedure cualification bg !h record, procedure qualification test performed as corrective 'n f4 action to the audit finding. It was proposed that the corrective d t action taken that a POR would be established but AAR-1 was closed ?N" f,$ out by the OAOC Manager "onnor without a POR being generated. m $) The basis for this action was a memo prepared by Internal Auditor 4 dj i Uj Hudson /1-12 4

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..i u w John Guiler dated 1/13/83. This memo stated that a pending DR 7, involving ESD 241. He went on to state that this is a soecial

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~ ] procedure created to supplement PG&E and manuf acturer ,1 IEj examinations. PPP had accomplished this per instruction of

9 PG&E.

He goes on to state that it is evident that a ~ l.('l nonconformance does not exist and a DR is not necessary. A ),..' written response indicated this would be considered basis for [! closing this portion of the AAR. Mr. Connor, the OAOC Manager n,,

.}}

indicated on AAR No.1 that this memo by internal auditor John q ,;.j a Guiler would be used to close out that portion of the AAR No.1. y, l It is my contention that Internal Auditor Guiler's statement that a. it is evident that a nonconformance does not exist and a DR is .'1 ' lj not necessary is not a valid statement. It is alleged that Mr. Guiler and Mr. Connor have covered up serious breaches in the quality assurance program and are in nonconformance 10 CFR 50 sd j Appendix B, 16 and PG&E Contract Specification 8711 Section 41328

  • 3 requirement that all conditions adverse to quality are promotly Q

identified and reported and corrected. In a conference to 1l: formulate a response to revised response to AAR No. 1091482, it g was agreed that a Discrepancy Report would be sent to PG&E 4 f., identifying that there was no POR procedure and that the UT 9 examination of the yoke rods was performed prior to the ESD 241 V.h >l being issued by M. W. Kellogg and approved for implementation by wp f)3 PG&E. QAQC Manager Connor later reneged on this acreement when Ni he approved Internal Auditor John Guiler's memo and aporoved the 3 h.t closing of AAR No. 1. Mr. Connor has cover 4 up significant OA ai discrepancies in the use of ESD 241 by refusino to forward the .3 Wkj ] Hudson /1-12 5 j y k _ -._,.._. _

QQu. M >. L,W S:?M@uM QWgS[.yfjf&QQXf( ~nG4.QW 22: 0%l,5 g Tjj proposed DR to PG&E. The proposed DR, dated 11/3/82, preoared by y d, H. Hudson, identified the following discrepancies: a) ESD 241 73 ~- (;' did not have a PQR as required by contract specifications 711~. The UT examinations of the yoke rods were performed orior to ni (c.f ESD 241 being issued by M.W. Kellogg and approved by PG&Ei The kidl examinations.were performed between 12/17/73 and 12/20/73. q QP ESD 241 was issued on 12/26/73 and approved for construction by J +j ir;j PG&E on 2/12/74. The build change order directing M.W. Kellogg f.iM y[ to perform the work required inspection for and PG&E A d;, memo by J. Sahl. The Sahl memo specified the part of the Dreiser [8I) structure used was paragraph 12 " bolt and studs greater than v. Ih? 2 inch diameter and up to 4 inch diamer." The Dreiser procedure /j states "All bolts and studs shall be examined prior to q ',1 threading. The yoke rod UT examined by M.W. Kellogg were Tj threaded. The examination of each threaded yoke rod was in q, gj nonconformance with the Dreiser instruction. The report of '.M ultrasonic examination used to document the description of 1 1 +,M jyj equipment and procedures used and the results of the examination .9 l)I was not a formed reference to ESD 24118. It was not certain @j p required information. This information included surfaces to be 9I tested, description of calibration, calibration method, l1 . j calibration frequencies. Of particular import here is the fact fig' that ESD 241 and the Dreiser structure procedure reauirements for 3 calibration frecuency were oroduction runs were not for Sh individual rod examinations. Two procedures did not meet the q ],D needs of the type of examination being performed. The ESD 241 m k was used to examine individual rods. Both ESD 241 and the " d) n.s.i, l Hudson /1-12 6 f.y.; y g , 'J,j

yij g ig M M f 6 i% n'<4 %.ib5 K 2: 4 2 i; M G R his B 5 R R % M s. M 5 2 dstE 9liS A ihn y 4 ' u;, { J Dreiser procedure stat,ed that they were going to.be used for n C production type situation. The ultrasonic examination for. j j g,, Appendix B form F66 ESD 241 was not used to record the reauir'ed M]

'
?

) M .information. There were differences between ESD 24L and Dreiser d{" instruction concernir}g information used to determine the ~ %j !? reference point of precipit sensitivity and criteria used-to

  1. f i

. i1 record questionable items. The PG&E memo by J.. Sahl stated that .I .w in addition to the UT inspection, a backup inspection was t.)j performed with the ' guide finishing technique to check the voke l e rod ends for indications of cracking of through the Q I 3 threaded area'of the yoke rods ends. The UT reports indicate .g F that no instructions were performed. ESD 241 did not j m. r.':;l gl stipulate the same reauirements as the PG&E memo as far as using the liquid penetrant, dyed penetrant method. No corrective Mj' i ,.;1 ' action was taken on the audit finding for ESD 241. The orooosed j .g-J h DR concerning E$D 241 QA discrepancy was not approved by the OAOC y i Manager and was not forwarded to PG&E with his permission. This %j j d is in nonconformance with 10 CFR 50 Appendix B, Section 16 and q i.t 1 i Y;) PG&E Contract Specification 8711, Section 4B, Corrective sy '.hy Action. Only 2 of 7 procedures identified in Internal Audit ,.yg No. 101 were identified for PG&E on Discrepancy Reports for their J g'u disposition. 8711 and 8833 XR reauire contractor to n% assure that all conditions adverse to cuality are promptly 3(j identified, reported and corrected. PPP did not report all the fj@ m conditions adverse to quality identified in Internal Audit No.101 to PG&E. This is in nonconformance to Contract l .q - Specification ESD 246 and ESD 247 were identified to .d y ? .s Hudson /1-12 7 hDy

VYff;fi ffkMMWQff%3QMV%@2QQ-)fffe%%QQ}Q.iiWSQNW r.x ,., s gif PG&E on 4662"as'having no procedure aualification records. m. DR 4662 identified ESD 247 had been used to M examine the inside fk diameter of P water nozzle wells between generators 11'and l'4-

ipd, d'uring repair of cracked walls.. PG&E accepted all' work examined

[& !;) by ESD 247. DR 4662 did not identify any location mk where ESD first was used. No reference was made except in iQ. $Y anywhere but formal ESD 246. I was ordered during the investi l &y ... ESD 247 is identified as being used on a feed water nozzle. LM Mr. Carner ordered me'to' discontinue the investigation of ESD Prj - 246. T'herefore, no-reference on DR 4662 could be made. for the l a; 6 ).; location for ESD 246. There are two questionable quality NgD assurance issues related to the use of ESD 247. ESD 247 E,q ji specifies that it is a magnetic cartridge feature, dry continuous . ;.}lj coil for P311 code. Contract 8711 specifies that portions of the un ,$a feed water piping, steam generator to the isolation valves are to be designed, f abricated and erected for ASME Section 1. An MT

;u Q

examination referenced task GR4662 indicatino the acceptance m.g standards for the ASME Section 1. This raises the question, can N a D311 code MT procedure be used to examine ASME Section 1 pipinc .g- <- g. and obtain results which are reliable? The M examination ${. records attached to DR 4662 are dated 10/19/77 and 10/20/77, and q, the Ms were performed by P.R. Jessin. The MW cataloa personnel a-M testing records with indicating he was certified as 1 77!] .i ' a welder PMT on 8/23/76 with a deposit rate of 98%. The testing C 9 record under examination grading percent did not record any L;i scores for general, specific, or practical examinations. It is JAQ not-understood how... I don' t understand why has a toxic reading (d g,1 nt {('} Hudson /1-12 8 ag ?i

f Mi@WE6dsh@MN00.hd}[f%1M$h531II263092;S$$dNNd$$0EIII23E'$5NNk y c p r y1 r., of 98% butane. There are no 40th percentile scores for the j ~- general, specific and practical examinations., ' Pullman's' ESD 235 procedure qualification and certification ~and SNT f. y PClA require general, specific and practical examina,tions.to - 8 3.1 qualify for MT level 2. The personnel testing records for f does not provide the necessary information to verify the ESD wa's properly qualified for level 2 It is-w 4 M. my contention that NRC should investicate these issues to assure. ~ that there are no quality assurance discrepancies associated with 9! O the ESD 247 and examination of ESD 246 and 247 had ~ M'j qualification testing on 11/9/82. The corrective M -action responses by Dan McCray states ESD 246 and iQ ESD 247 have been withdrawn from use and equipment listed in both w.1 procedures is no longer available for use. The eauipment used S, W-[ for these will be personnel with P90 h' The procedure qualification test was performed in 'd p-the.different work as specified in md procedures. Response does indicate that the P90 puts out less

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amperes than the equipment listed in ESD 246 and ESD 247 and that r.,wld !:

  • f f,

acceptable results were obtained. The question is raised, would .m[ the acceptable qualify MT procedures af ter the fact using

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,{

different equipment in the procedures. concern that Yj the NRC should investigate. The most important issue raised by W. JE this report findings is to hand DB procedures to hgh qualify after they have been used. Appendix B9 of w the contract specification date 7/11 883PSR require special I.d fa processes to be controlled and accomplished using oualified Gi - u: e - N Hudson /1-12 9 gj ,t

  • k q -_-

(f$13EGijP@M ' *WGdaFN2M!#.SiEn5?2Elsst.?itWE n!E16N 3?y, g.: UE 4/5/82 and was received and approved. Before the followup audit. b Q through corrective action by OA/QC manager H. Carner b

M,

requested NAR1 back so that a revised response was prepared and d. F,i additional findings would be identified. The additional finding

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~ pj was that ESD 241 had been used and decided under the original dig response to procedure has never been 7%) NAR1 could not be repaired and my suggestions were a followup t,-:*? 't audit It's not a Then in 1983... G Wfg that is almost a year later... Strong corrective l l .q, Nj action was not to the project of NAR1 and reauires Mli J[] , Appendix D, Section verification l Of This is the gist of this report. An UMg audit was performed on 1/18/82. Corrective action from 4/5/82. l OA/0C manager requested audit back for revise his gj N corrective action response. That response has not come back to t.q

b;t.

the internal auditor until a year later on 7d 8/22/83. I would spend the next year trying to f -ad provide a revised corrective action response for the NAR1 L.C. i gn1 findings to be closed out. Following the action a and revise corrective action What '..h follows internal correspondence OA/0C c: fd on 5/18/82 asking for a manager b) \\ gi revised response. On numerous occasions a verbal reauest for j ".4 ' 4;N) e.y response. At 6/14/82 I sent an interoffice correspondence to Al M corporate director of quality assurance, statino an [ NAR directed to his district manager which response ti.Jf response. On 7/6/82, a full 3 months af ter a @w "M Hudson /1-12 11 l en 2> L, t .,~_..:__ m m m m.,

p p y g ~; P er) Q :GWNWQ]g'j.l?iWb. jf[Q$%gQiPRM.QQggiQM3(f5 MG%i 4 m] F0 rf) I n M j.vf ) Mi . response and a form 31, p.. 1 (y Mr. Beck, for the director of OA, the unscheduled audit form to {q identify to management and personnel the deficiency of { g: l [N implementation of corrective action reo5rts. The i M. { j audit finding OA/OC manager did not properly l Mp,a implement findings. Mr. Beck 4 q s Idd interoffice on 7/18/82 but he did not address this issue of W}3 corrective action time and manner. { 8 i y:a with incorrect application of 263, unscheduled i 1 internal audit number 31 was not responded to by the director of m i C OA It appeared to me that improper ) . ).1 bp application internal audit procedure of cetting the N $e corrective action interim audit findino Dq ,,j proceedings A special notice of i. s.: p] reprimand directed me to sign resolution of the NAR in response ,4 M'l.1 - to supervisor, On 7/22/82, yd M: conducted a meeting time to blY gj was discussed and Mr. We noted that s!l i j no mention was made as to when a revised corrective action On 7/,__/82, another interoffice response h,N correspondence asking what corrective action j j!! take to resolve audit findings of NARs .y.t NI I asked Mr. Carner this time if he wanted me to M ff readdress NAR1 supervisors Mr. Carner G verbally responded that, no, he would provide a resolution resolution to NAR1 At this time I recommended that f4 NAR1 findings be identi.fied with EE on discrepancy report. In Wj y Hudson /1-12 12 J1 ?!

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??)};g{fp&%if,6fyp$lf@H'[fffj!MWFGjQjMQ[j@y @iW/[iMQM:MM;@jg!N#i@ N:) W pe s-jf., M. addition, I stated that subsequent investigations fh 236 required QR. On 9/15/82 g g.y interoffice correspondence to OA/QC managers documentina ,4 y]- revised response of NARl. What had hap 6ened is I pi! finally supervisor and myself to meet /hs formulate a revised corrective action to NARl. That meeting we kg7 agreed on. the following courses of action to resolve NAR1 '%j findings. ESD 234 would have a procedure cualification test performed.. ESD 241 would be to PG&E on a DR Identifying 2R and that be performed prior to ESD 241 ESD 246 and 247 would have [.W additional investigation to perform before'a (.3g corrective action proceeding was made. ESD 270 would have m 'l incorporat.ed into the procedure ESD 210. ESD 236 <a kl,) will be stated reouired. On 10/13/82 ..jW another interoffice correspondence was reauestina [$ et the revised response to NAR1, and this interof fice Wil Q correspondence stated that PG&E's contract 871188 ) by required all conditions be 81, with the record. On 11/3/82 I prepared a discrepancy report p SJ., concerning ESD 241 compliance The proposed DR hsh comment the DR. Whether the DR was h3 f5 reviewed by Mr. Mike McCray and he wrote comments concerning the DR. On 11/22/82, he sent an interoffice corresoondence to the d QA/QC manager responding to both Carner's and McCray's comments iwj [te, on the prop m d'DR. He noted that subsecuently the OA/QC manager ,4 ^ I;'j DR procedure to identify and On 'N bW M W-l! Hudson /1-12 13 Q-

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revise a revised corrective action message, I (:f9 fj-informed nonconformance procedure on r.n {.$I 871188,. requirements for the corrective Kction. On v. N! D.:.j 1/21/83, an interoffice correspondence theOk/OC l h@d; manager indicating that corporate audit #7177-l-83 had identified r a required number of would not be closed out to the k.aiij revised corrective action _ response _ That was the b$$j last on __f /83 correspondence by that %i $h) time I response and I did close'it out i 40 I tq at that time. f,Tl .gj CLEWETT?: You said you closed out... gq . (.] HUDSON: Right. I don't is one of my ti c

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finpf ] M M M M9{@ M M 9 9 % d % 2; M 3 @jfM @ $$s d g @ @$fM N b y;i 'j,f h lNTEROFFICE CORRESPONDENCE .i M-pats July 28, 1982 idM To QA/QC Manager, H. Karner m h FROM Internal Auditor, H. Hudson N 3, susJECT Corrective Action to Audit #101, AARf1 - NDE Procedures without Procedure Qualification Records $@9 ) What Corrective Action is being taken to resolve the audit finding of' i h AARf1 which identifi'ed five NDE procedures as not having femal procedure Jg qualification records? Do you want ne to readdress the AAR to NDE Supervisor (Leadman) Paul "g Dawson for him to resolve per the directions of A. Eck in his Interoffice l Correspondence of 7-16-827 ) W I h. I recommend that the Corrective Action include identifying the NDE ?% procedures listed on AARf1 on a' Discrepancy Report for submissio'n to PG&E Ey for review. 1 gh In addition, subsequent investigation of ESD 236 - UT Thickness Measure-Stj ment of Boundry Valves, determined on Audit #101 not to require a procedure qualification record, may be required to have a qualification record. m .h ESD 236 indicates the Specification Number is 8711. Attachment #1, PG&E g Memorandum of 2-4-74 concerning Valve Wall Thickness Measuring, indicates it g is work performed under PG&E Contract Specification 8711. Specification 8711, p Section 4.3.23 and 3.29 indicate NDE procedures must be qualified and records Ql maintained of qualification of procedures. $ 2, Westinghouse Electric Corp letter concerning Diablo Canyon hA Site Valve Wall Thickness Measurement of Reactor Coolant Boundry 10" Swing ) 9 Check Valves, indicates the work performed is being evaluated based on the gj requirements of ASME Boiler and Pressure Vessel Code Section III, 1971. ASE j y1 III - NB 5112 states all NDE shall be executed in accordance with detailed j vritten procedures which have been proved by actual demonstration to the satis-faction of the inspector. It also states that written procedures and records of demonstration of procedure capability shall be made available to the inspector y upon request. ASE V,1971; Article 1-T-150 states all NDE performed under this ht Code section, except as vaived by subsequent articles or modified by the referenc-Q ing Code section, shall be done to a detailed written procedure proved, by actual demonstration to the satisfaction of the inspector, as capable of detecting and M 1 coating discontinuties of types described in the applicable Subdivisions of T Articles of this and the referencing Code section as unacceatable or as required Q to be reported. S ~ 4: p Ul &[ s_ t2b. s.u..

W M. W % R a..? "W Q S; W M G R $' W O S $. W ?E N $? ? b 5 $ 5 ?l b b 5 b ? ? Y iv w,. n.. e, ..~v e .. e ((re}1? a I. s* .,,~ 5-h mM (,(~.} t ,4' t., W il w a ig, ', ro, QA/QC Manager, H. Karner oavt July 28, 1982 ,e pa- ~ 0" sue;ccTi ~ j'k Corrective Action to Audit 1101, AARf1 - NDE Procedures without Procedure l [.,d, Qnalification Records s. g ract wo. 2 i };;: ,I bl0. KP 2 ASMEV, Article 5-T310' cludes thickness determination in the scope of requirements. { f'yi-k4' 3, PG&E Memorandum of 9-28-72, concerning Diablo Canyon M Valve Wall Thickness, states " licensing is involved". I would like to f' yD suggest that since licensing is involved it would be a good practice to p:9 have a procedure qualification record for ESD 236. f jy"]A This information is presented to the QA/QC Manager for his review and reconsideration. I recommend that ESD 236 be included on AARf1 as a finding not having a procedure qualification record and include on the fjy-proposed Corrective Action Discrepancy Report to PG&E. pd { W ^ LW Ny) O Harold Hudson y[. Internal Auditor -)1 Diablo Canyon Nuclear Plant %;s.; HH/dd s C;. Att. M lb5 'M;

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V MS Problem Statement I [$y: r c. rg.c. Allegation Number: 122 G .ATS Number: RV-83-074 w[0j ? BN Number: None' W ~ j.'}h M' Problem Statement Allegation 122 stems from Pullman Power Products Internal Audit number 101 M and can be summarized as follows: Some NDE procedures used by Pullman were @y' not properly qualified. One procedure was issued after inspections were 'M performed. Pullman failed to report difficult problems to PG&E, this ) h constituting a coverup of serious breaches in the QA program. The QA system 3 1-did not implement adequate or timely corrective actions for audit discrepancies. hhi,j Each of the statements made in this allegation are listed'below,'along with any necessary references or clarifying commentary. Underlining was not Vj. included in the original text, but is added to emphasize the major points of the allegation. 71 pI-l b '- Opening Statement ai - ..a [').q " Pullman Power Products' Internal Audit #101, performed on 1-18-82, L ? identified significant conditions adverse to quality which were not promptly X corrected and resulted in corrective action which was not adequate." ?v ,m ' il - Allegation Items , t.j [] Items 1 through 9 are technical or quality procedural issues. O.M 1. "Five NDE Procedures were identified on I.A. #101 as not having '.M evidence that the special processes were controlled and accomplished 9?j using qualified procedures or that qualification records were maintained 51 to document and assure quality of material and work. There are no /q Procedure Qualification Records documenting Procedure Qualification %g Tests for these five NDE procedures. The five NDE procedures are: [ESD 234, 241, 246, 247 and 270]". j q C,; "hto Ultrasonic Material Thickness Measuring Procedures were identified gh as not having evidence that the special processes were controlled and 1,:7.4 accomplished using qualified procedures or that qualification records M were maintained to document and assure quality of material and work. g There are no Procedure Qualification Records documenting Procedure j 49 Qualification Tests. These procedures are: [ESD 236 & 244]". 3;) 1' {l. Ed dlf_ 1 O x.1 l ( G a, m~ .--.mn ~ _ +~---"-r----e---mem ~ n ~

hMNf N!8NNN $NbNb5dl $b.bbd NNbb %g b, h 7 M "ESD 270 did not-have a Procedure Qualification Test performed as part M of the corrective action to I.A. #101, A.A.R. #1. QA/QC. Manager k@[ H. Karner determined that ESD 270 used similar penetrant materials and - examination methods as ESD 210 - Liquid Penetrant Procedure h (ANSI - B31.7) and that ESD 210 had Procedure Qualification Records which demonstrated the ability to detect the specified discontinuities. g QA/QC Manager H. Karner directed that ESD 270 be revised to* incorporate M,; the PQR's of ESD 210 as the corrective action to be taken. (see - h I.A. #101, A.A.R. #1 Corrective Action Taken). The use of ESD 210 PQR's h, does not provide a proven-demonstration of ESD 270's ability to identify g discontinuities. ESD 210 and ESD 270 must have some differencies or p. there would be no need for two procedures. It is alleged that QA/QC h. Manager H. Karner's directive to use ESD 210 PQR's for ESD 270 does $,j not provide proper or adequate corrective action to the Audit finding (ifj; and that ESD 270's lack of proper PQR is still a condition adverse to 9 quality." s;; @jj "No investination was performed to determine where ESD 270 was used."

M 2.

a. "ESD 241 did not have a PQR as required by C.S. #8711 Section 4.3.23 and 4.3.29." m jy b. "The UT examinations of the Yoke Rods were performed prior to ESD 241 being issued by M.W. Kellogg and approved by PG&E. The j{j examinations were performed between 12-17 12-20-73. ESD 241 was rip issued on 12-26-73 and approved for construction by PG&E on d 2-12-14." ed L,j "The PG&E Field Change Order directing M.W. Kellogg to perform the i c. l work required inspection per the Dresser Instruction and a PG&E /j-} Memo by J. Sale. The Sale Memo specified the part of the Dresser Instruction to be used was paragraph 12, " Bolts and Studs (Greater hj; than 2 inch Diameter Up to 4 inch Diameter)". Dress #SP-52-166, [g paragraph 12.1 states "all bolts and studs shall be examined prior

-N to threading". The yoke rods UT examined by M.W. Kellogg were threaded. The examination of these threaded yoke rods is a M]!

fy nonconformance to to requirements of the Dresser Instruction." d. "PG&E Memo by J. Sale stated that "in addition to the UT h. inspection, a back up inspection should be performed with the dye M.. penetrant technique to check the yoke rod ends for indications of cracking that might extend into the threaded area of the yoke ends". j 1

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M The Ultrasonic Status Reports indicate that no dye penetrant inspections were performed."

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"There were differencies between ESD 241 and the Dresser e.f Instruction concerning information used to determine the reference pi. point for sensitivity and criteria used to report questionable ?.d items".~ , J';

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SY hYbN L.: YY.$ $. ^ .l q$ e (/W .t f. "The " Report of Ultrasonic Examination" used to document the 9 description of equipment, procedure used, and the results of the .h exainination was not a form referenced in ESD 241.18. It did not ,L.]u include certain required information." s. 1 M 3 I'M "It did not include the surface or surfaaces from which the' test f.] shall be performed as required by ESD 241 and the Dresser m.; Instruction." f. j M8 "It'did not include a description of the calibration block (size, 2 (:,h material and basic calibration reflectors) and calibration method _,p as required by ESD 241 and the Dresser Instruction." S. M "The equipment calibration frequencies reference on the " Report of sj Ultrasonic Examination" were not as required by ESD 241 and the f Dresser Instru6 tion. It should have been noted that ESD 241 and M the Dresser Instruction procedure requirements for equipment for calibration frequency were for production runs and not for L@ individual rod examination. The two procedures did not meet the needs of the type examination being performed." M g. The " Ultrasonic Examination Report", Appendix A, Form F-66, g referenced in ESD 241 was not used to record the required '1 information of ESD 241.15.3." vM.. 1 h. "ESD 241 did not have a Procedure Qualification Test performed as 7 .s corrective action to the Audit finding. A Procedure Qualification ,;4 Record was suppose to be prepared per A.A.R. #1 Corrective Action j Taken but this corrective action was never implemented and 9 A.A.R. #1 was closed out and approved by the QA/QC Manager without d the PQR being generated." 'ij "The bases for this action was a memo prepared by Internal Auditor Q-J. Guyler, dated 1-13-83 (see attachment to A.A.R. #1) that g stated: "There is a pending DR involving ESD 241. This is a Qi special procedure created to supplement PG&E and manufacturers y examinations. PPP has accomplished this per instructions from h PG&E. It is evident that a nonconformance does not exist and a DR is not necessary. A written response indicating this will be E.] considered basis for closing this portion of AAR". QA/QC Manager lfa H. Karner indicated on AAR #1. QA/QC Manager H. Karner indicated fj on AAR #1 that this memo by I.A. J. Guyler would be uses to close p out that portion of AAR #1." 6,' " Internal Auditor J. Guyler's statement that "it is evident that Q( a nonconformance does not exist and a DR is not necessary" is not X,} a valid statement. It is alleged that I.A. J. Guyler and QA/QC j,'E Manager H. Karner have covered up serious breaches in the Quality N Assurance Program and are in noncomformance to 10 CFR 50 App. B XVI k and PG&E C.S. #8711 Section 4.3.28 requirements that all conditions Mj adverse to quality are to promptly identified, reported and p corrected." 9 J 'i ' fi .Si L I.

,.,,._,7:.;?M W WWM M M.--@ t % f:_a. n. ~. ~My .y.- ~ a m,s -.. W-. # D W U Q 1 ) mm x .n 1;9 a \\ Y 3. "Only two of the seven procedures identified on I.A. #101 not to have d PQR's were identified to PG&E on Discrepancy Reports for their g disposition. C.S. # 8711.Section 4.3.28 and C.S. # 8833XR -I %q Section 3.4.1210 require Contractor to assure that all conditions adverse to quality are promptly identified, reported, and corrected. j ?$ P.P.P. did not report all the conditions adverse to quality.. identified y in I.A. #101 to PG&E. This is a nonconformance to the C.S.' requirements." aJ 4. "ESD 246 and ESD 247 were identified to PG&E on DR #4662 (see attached) 61 as having no Procedure Qualification Records. DR #4662 identified that W ESD 247 had been used to MT examine the inside diameter of Feedwater M Nozzle welds to Steam Generators 1-land 1-4 during the repair of cracked i welds. PG&E accepted as is all work examined by ESD 247. Because d DR 4662 did not identify any locations were ESD 2146 had be used ] no reference was made to accepting any work performed by ESD 246." i. 5. "ESD 234, ESD 246 and ESD 247 NDE Procedures had Procedure Qualification M Tests performed as corrective action to I.A. #101, A.A.R. #1 (see @U attached PQR's). These PQR's are after the fact qualifications of these l procedures. The actual use of these procedures were not controlled and accomplished using qualified procedures." Edd "ESD 234, ESD 246 and ESD 247 NDE Procedures had Procedure Qualification J} Tests performed as corrective action to I.A. #101, A.A.R. #1 (see y attached PQR's). These PQR's are after the fact qualifications of these 'l procedures. The actual use of these procedures were not controlled M, and accomplished using qualified procedures." $] "It should be noted that the PQR's for these procedures do not have approval signatures of either P.P.P or PG&E Management authorities. The 'O only signatures on the PQR's is that of the individuals conducting the 'q qualification tests. It is alleged that these PQR's have not been y approved by the appropriate management authorities." h 6. "ESD 247 specifies that it is a Magnetic Particle Procedure / Dry / c) Continuous Coil for B31.1 Code. C.3 #8711 Section 2.2.1 specifies that fj portions of the feedwater piping from the steam gen'erators to the isolation valves are to be designed, fabricated, and erected per ASME a% Section I. The MT Examination Records attached to DR #4662 (see .)) attached) indicate the Acceptance Standards to be ASME Section I. This I i,q raises the question can a B31.1 Code MT procedure be used to examine .d ASME Section I piping and obtain results which are reliable." M fj 7. "The MT Examination Records attached to DR# 4662 are dated 10-19-77 and Q*p 10-20-77 and the MT's were performed by D.R. Geske. The M.W. Kellogg (Pullman) Personnel Testing Record for D.R. Geske (see attached) indicated he was certified a Level II MT on 8-23-76 with a composite M grade of 98%. But the Testing Record under Examination Grades in Percent does not record any scores for the General, Specific, Practical .. Q Examinations. It is not understood by this writer how a composit grade of 98% could be obtained when there are no recorded percental scores for + d

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- -l 4 qualify for Level II MT. The Personnel Testing Record for D.R. Geske does not provide the necessary information to verify that Geske was properly qualified as a Level II MT Technican." 6 Summary statement covering issues 3, 4, 5, 6 and 7: N$ "The NRC should investigate these issues to assure that there are no QA 't discrepancies associated with the use of ESD 247 and the examinations of $? the Feedwater Nozzles to Steam Generators." Md 8. "ESD 246 and ESD 247 had Procedure Qualification Tests performed on ? 11-9-82. The Corrective Action Response to I.A. #101, AAR#L, by [ M. MacCrae (see attached) states "AS both ESD 246 and ESD 247 have been g withdrawn from use and the equipment listed in both procedures is no j v longer available for use, the equipment used for these PQR's was'the i E Magnaflux Mode] P-90 for the coil technique only". The Procedure i i Qualification 'lest was performed using different equipment than specified in the original procedures. The Response does indicate that f,4 P-90 puts out less asperage than the equipment listed in ESD 246 and ESD 247 and that acceptable results were obtained. But a question is p raised. Is it acceptable to qualify Mt procedures after the fact using q different equipment than listed in the procedures? This is an item of i concern that the NRC should investigate." 9 d 9. "The most important issue to raised by this report and ARR#1 findings is , l,^ can NDE procedures be qualified after they have been used? 10 CFR 50 App. B IX and PG&E C.S. # 8711.4.23 and C.S. #8833XR.3.4.128 require W special processes to be controlled and accomplished using qualified 7 procedures. The seven procedures identified in I.A. #101 were used l p.; without being qualified by Procedure Qualification test and are nonconformances to the above requirements." %g i "This is a major breakdown in the PPP Quality Assurance Program. In my S] opinion, the use of unqualified procedures puts the work examined into l a questionable status. The NRC should investigate this issue to assure l if that there are no conditions existing which would adversely affect M. quality and tend to cause failures or malfunctions in the work examined h by these procedures." hIh Item 10 alleges deliberate procrastination by QA/QC Manager in reporting l audit findings because he could not formulate proper corrective action. ]q ' A] It is further claimined that Corporate QA Director failed to expedite corrective action. 10. "The Internal Audit #101, AAR#1 findings were not promptly corrected as FJ required by 10 CFR 50 App. B XVI and PG&E C.S. #8711.4.3.28 and C.S. M

  1. 8833XR.3.4.1210 requirements.

It is alleged that QA/QC Manager j& J. Karner deliberately procastinated on these findings to avoid S Q Q.)

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identifying these discrepancies to' PG&E and pullman Corporate Management M and because he was unable to formulate a proper corrective action. It W is alleged that Pullman Corporate Director of Quality Assurance, 3 A. Eck, failed to expedite corrective action once he was made aware ~ y% that the on site QA/QC Manager was not providing a prompt response to h AAR#1 finding." ]{y " Internal Audit #101 was performed on 1-18-82. AAR#1 findings were not c.5 formalized until 3-22-82 due to additional investigation requested by 5 the QA/QC Manager. AAR#1 findings were acknowledged by QA/QC Manager. @h AAR#1 findings were teknowledged by QA/QC Manager H. Karner on 3-23-82. Corrective Action Taken response was due on 4-5-82 and was received and N approved. Before the follow up audit to assure activities complied with Tf, approved corrective action, QA/QC Manager H. Karner requested AAR#1 back i ( 10 so that a revised response could be prepared due to addition finding being identified. The additional finding was that ESD 241 had been i{ used. It had been decided under the original response that this procedure had never been used. AAR#L would not be returned to my Q possession for a follow up audit until 3-22-83. Prompt corrective j.y action was not implemented for the findings of AAR#1 as required by >P 10 CFR 50 App. B XVI and PG&E C.S. #8711 and #8833XR." e 3 "It appeared that the Director of QA was more concerned with the so 9 called inproper application of ESD 263 (Internal Audit Procedure) than Jj with getting corrective action implemented to an Internal Audit finding that NDE procedures did not have Procedure Qualification Records. It ']q should be noted that A. Eck's reprimand directed me to assign resol Eion of no formal PQR's for NDE procedures to the responsible NDE Supervisor." I "It is alleged that Pullma'n Corporate Director of Quality Assurance, py A. Eck, failed to expedite corrective action once he was made aware O'! that the onsite QA/QC Manager was not providing a prompt response to l AAR#1 findings." Q! 3(&y .1 Items 11 and 12 are intimidation issues that are being investigated by I&E as a separate allegation.' Refer to allegation or concern iM #3D. .j 11. "On 1-28-83 QA/QC Manager H. Karner and myself had a violent verbal confrontation concerning AAR#1 and another issue. ]+ "During review of Rupture Restraint Document for investigation of tj Unscheduled Internal Audit # 35 I identified three full penetration y,j welds that had NDE by MT instead of the C.S. required UT process. While g preparing to report these discrepancies, Mr. Karner confronted me at my a desk and wanted to know what I was doing. I informed him that I had identified Rupture Restraint NDE discrepancies. Mr. Karner then asked y me if I had been directed by him to identify these problems. Mr. Karner at this point began to scream and shout at me that I was no M longer the Internal Auditor (I had been replaced but given permission to kQ) conclude two audits in progress, one of which was U.I.A. #35) and that I f]% was only to do what he told me. In effect, Karner was telling me that I as a QA/QC Inspector could no longer identify discrepant conditions .j unless specifically order to do so by him. Mr. Karner screamed at me 4 that if I did this again he would get rid of me." %] .olk l J

((4?NMMETM2,k,I@kNMkMN[$$N$dbNN[b!Nfbb.'< A NN$b m i i i i y y d "Karner then accused me of going to unscheduled audits to get around his l approval of the audit checklist. He accused me being adverse to quality. p/f; At this point I screamed at his that,he had been sitting on AAR#1 of,, r @ji I.A. #101 for a year and that he wcs violating 10 CFR 50 App. B XVI and ~ -4 %@3 two PG&E Contract requirements by not preeptly correcting problems I adverse to quality. QA/QC Manger Karner at this point stated that it was OK for him to violate the Code and Contracts. He repeated this-statement twice. Mr. Karner also stated that one of the reasons why I g didn't have all the required 1982 audits done was because I investigated 5.5 items not on a checklist or irrelvant. I responded to this by saying %.3 one reason was that he had been sitting on an audit (AAR#1, I.A. #101) for a year." W pc N "I should point out that this time we were toe to toe, face to face, yj screaming at each other." W, 9) "Mr. Karner again repeated that I was only to do what he told me to do. j (E which I interpreted to mean that I could not identify Quality Assurance discrepancies unless specifically ordered to do so." i %h "This confrontation was witnessed by numerous persons in the QA/QC k office." "This confrontation prodcced two significant conditions adverse to quality." i !.. [ a. As a QA/QC Inspectc.r I was ordered by the QA/QC Manager not to K identify QA discrepancies unless specifically order to do so by the Q; QA/QC Manager. If I did I would be gotten rid of. This was an Liz attempt to intimidate me from identifying discrepant conditions. D,A This violates 10 CFR 50 App. B I requirement that persons j performing quality assurance functions shall have sufficient g authority and organization freedom to identify quality problems." Y 9;j b. The QA/QC Hanager stated he did not have to comply with 10 CFR 50 d App. B and C.S. requiremente to promptly correct conditions adverse y]y to quality. This is a base violation of Quality Assurante requirements. QA/QC Manager H. Karner has demonstrated this dieregard for this QA requirement in his lack of corrective action y,j for I.A. #101, AAR#1 audit findings, in a timely manner." 7,0 12. "During the Internal Audit investigation into the use of ESD 246 and s) ESD 247 I was ordered by QA/QC Manager H. Karner to crease the d)i investigation once it was known where ESD 247 had been used. I was not @j allowed to continue the Audit investigation to determine where ESD 246 l,, was used. This resulted in DR #4662 having limited information )M concerning the discrepancies being reported. This statement was i.apleted March 7, 1984 /,. ) ;'l 4 rank 4. Casella ", Technical Reviewer ,7 h !Q 'Q y Q.; u=._e_ 1.=_ u _= _= _ . _ = = - _ = - - - - -- - ~ -

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SUMMARY

P2 PORT ~ V: ~ l AUDIT DATE:1-18 82 _ Q !$j FILS NO.

  • T N.s DISTRIBUTION

{f,WO. : 101 N A"E y flVITY AUDITED j ~ TIYLI E.F. Gerwin i I VICE PRESIDENT OA A.A. Eck M.Canization DIRECTOR OF OA J. Ryan $FLICA3LE DocUENTSJ PG&E 8833XR, 8711 RESIDT'NT CONSTR. MGR.; H. Earner. R. Eine f.$ SUPER. AREA AUDITED ShCFR50BT. KTP 1. KFP 16. KT'P-2 R. Sanderson OF ACDIT_j A.N.I. H. Karner $7D.P OSE ~ FIELD OA/00 MANAGER P. L. Evnn s if V.P, VECH. CONSTR. .T. f=mnn Mhiduled PG&E l jf~ fRERJ V;) c:

SUMMARY

j I y 7-A..\\. Re I W DZ ORGANIZATION __I s were qu'alified jI d This audit was condheted to detemine if NDE Proce ured t I o i. I ,. I and if the Field Organization Chart reflecte Eleven NDE Pro yy. )f Three NDE Twenty-one NDE Procedures were audited. Master Job File. " Procedure Qualification Records" located in the alification records wa t.', Procedures were provided to Pullman.by PG&E and the qu Two NDE Procedures are used t 'D f5 are maintained by PG&E. ccomplished using quali-thickness and do not require procedure qualifica %p l do not have evidence that the special proce

      • MLW intained to document M1 1

A. Km. and assure quality of material and work. functions listed on Q &y The Field QA/QC Organization Chart listed all job The Field Chart does not have a Eey ex f The Field Chart does not the EFP-1 Organization Chart. the reporting relationships between job functions.QA Manag t.S 2 h accurately show the reporting relationship of d2 t Assurance. $J listed all job d (f The Field Production / Engineering Organization Char The functions except one that was listed on the KFP-1 the Field Chart. 3 job function of " Material Cont." was not listed onmuerting functions $1 i Chart had a key explaining the (Rup-but the Key is different from the EFP-1 Chart Key an k The reporting relationships of Field Eng 2 3 p same type information.ture Restraint, Piping, Hangers and Snu W g, C

the KFP-1 Chart.

PP2PAF2D BY: B. HUDS'ONDATE: 1-1o-61 l gi TITLE : TvrdNAL AUDITOR TJ E. EARNER FISPOJ513LS CONTACT: t TITLE: QA/QC MANAGER y, - ~ ~. - + -..,,,

E0E'.?'%,,.,3, ~..' -. ; y. s. 7 ~_ ,.p' 4 n,...:. 4 7,,3 af.a..g.ti,,, y,, ;'C,@ y 4 ,..z.;y 3 ""~ " ' + - -'I^ - hi

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  • tf 35 rev. 77b/ J 9"~

g 9..! / rev. 3/30/79 DIABLO CANYON P.E 1 Or 3_ yJ; NUCIZAR POWER PLANT R .Qy AUDIT ACTION REQUEST 5.D i Q c, A.A.R. 70.: 1 g)y AUDIT No.: 101 I 772,3 to. : S ACTIVITY AUDIT":D: NDE Procedures 1 03SEnVATION CcDE: ,N. 1-18-82 e% AUDIT DATE: 1091 9 14 v.gn ph4 v.qn phy PG&E 8711. PG&E 881975 .Q] RSTERENCE DOCUMENTS: h:.,W FINDING: There are no femal procedure qualification records for the following NDE pro N .J 3N Continued on Page 2. 1[9v _ DATE : 9-22 82 ACT D 3*l: Nu-v D A"'E : FItoIT,BY: H. Hudson Finding fl - Per the QA/QC Manager the requirements of ESD 234. SUSP2CTID CAUSE: b'] j the qualification of this procedure. Configuration to represent the veld u $1 Continued on Page 3 reference. Firure 1. 2 and 9. $j

  • CCo*rC:1DED CORICCTIVE ACTION:1. -NDE procedures be qualified a G.l

( delete those NDE' procedures which managem 'cj a 1, wid,w). W u ib R. Had Lua. k (..A 1 i M 74,M,e eJ.,o 44. mehNUEATE :D MKa, g, 'g.jQa -%ad - a - u.sl 1 jobsite. w JL u.T. r.. 1 Continued on Page 3.;; p 1 N Ec VE ACTIO'1 T."CN: **/*WG/Cs gn' WkG- /W,##"*'9. 0 0Mf& s'r'M .u wsJ 4S..t.4xecnu u s M S P 4. H + 2 f / 44d Hof Mw G-et ss*P. h CCR2E9T}9la, ld pa tacwc! of rM M fMneusty 4d rMG. < ssco, 7xoc?putsM 70 ds' W4cfMD.fyk t Af hf/ d) Moes* psee,y s N cc.s D re Ra' s wit.tJows,nvoisr // c's ><.sMrtaco re wcastpeteste l'gpe t ga.p m. fa* 6 g 4 pra f 's groud5 M FAoM oso _16w APPROVED BY: d o d g. (,.0,- .1.2 f,stmritrdy Wds D 2 7o J'e m s TAlu..i BY: C' "/ '$rd J dy f/r%1 s-M* ST::PS TO P*CV::MT T*CURRE fC::: C ist ic t ag' C& o se,.y 4.!',r p, y,r,,o gg z A/DG joi onc c>cr A;c'-J ffa,,7 ye tat s E3j 1o A s>a te e f/d-fGM$ AM ' N e c. u o c' O - APPROVED BY: NOL1 4-44L L ACTIVITY COMPLIES WI':3 APP?.CVED CORP.1CTIt15 AC ...j i TAKEN BY: V""' 10' /4 i TOLLOW UP:

  • !li l

IF !1 - PLE ASE EEPLAIN :

18. LA %+ A M dAa w 9% ahm p;]

% SN CSD '#M sw3 M'N. M.!l LuegK Mew.J p 9.t.tC C DATE: 'Y TL-M 7d 3*' s d. tkh% DATE : 3,27. 93, A. A. R. CLOSED BY : 6. d - Ah 2 g py DATE :., APPROVED BY .M s .d. 3 i-a,.n g yn p - m.% .Aa ,.e, , ul , y,, I' I'# p t wye. y_

    • 'em.t m.

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n ~. w,, y * ' " ;~ ::a e rA:.: \\ n,, m-n. .,9,,.* ...*., 'g.4,;.. . # ', C ~ E MSE DD%,.7 m .E M . "'"';"' * *"'. ~ _vu 9 ;h rc'v, 7/f> / 7 0. !5Y V I ro v. 3/30/70 P.s. DIADLO CANYON PACE 2 OF 3-r NUCLEAR POWER PLANT ce %.:.s ?.

  1. ,y AUDIT ACTION REQUEST _

5 f..y AUDIT NO.: 101 A. A. R. N O. : 1 I 5,3 PILE NO.,: L2 ogsERVATION CODE: ACTIVITY AUDIT::D: NDE Precedure'5 1 m 1-18-82 M., 'AU,DIT.DATE: ..~ %f PGEE 8711, PG&E 8833XR, EFP-1,2,16, ESD 246 ESD 247 qh ECTURCNCE DOCUFENTS: l Mi 4ip COnLuww FROM PAGE 1 FINDING: hj ESD 234 - Ultrasonic Inspection Groove Welds AWS-D1.069, ASME Section VIII and Section ffd 1. (Noncompliance to PG&E 8833XR Section 3.4.128 and 4.1211). y , V. eraMnation of Safety Yoke Rods on 3707 RAI6-21 Safety Valves: h ESD 241 - Ultrasonic (Noncompliance PGEE 8711 Section 4.3.23 and 3 29 or PGLE 8833XR Section 3.4.128 a 2. $;1 4.1211, EFP-1.14.5, KFP-2.3 and 2.4, IFP-16.5.T.) ll'Q (Noncompliance to PGEE ESD 246 - Magnetic Particle Procedure / Dry / Continuous Coil B31 h,# 3 (Ncncemoliance to PG&E );q ESD 247 - Magnetic Particle Procedure / Dry / Continuous Coil B31.1, Yj 4 8711 Section 4.3 23 and 3 29, ESD 247 13 2.) ation Procedure (Nencompliance to PG&E 8833XR Section 3.4.128 ard 3 23 LiquidPenetranth*=1"g ,U 5. 4.1211.) ES P - 2 /o ,f Finding fl - ESD 234 and Finding 12 - ESD 241, have established in their procedures a means to demonstrate the qualification of the procedures each time the procedure is used (see [E.. Suspected Cause) but there is no formal documentation of the qualification. Finding #5 - ESD 270 uses similar penetrant materials and = = 4 nation methods as EsD 210 - I' 1 ESD 210 has procedure qualifications records

.7 Liquid Penetrant Procedure (ANSI B31.7).

f.M which demonstrate the ability ts detect the specified discontinuities. pj faj bl:, l\\ w

i. : !

4 = ACTIVITY CO!TLIES WITH APPROVED CORRECTIVE ACTION V YES NO f,d FOLLON UP: p) IF NO - PLEASE E : PLAIN: O Ej DATE: 3 BY DATE: A.A.R. CLOSED DY: y. ~ DATE: <,n h. APPROVED DY:

y. ; '

.Q - - - - ~ - _.'E*"L??_*_JL._.____ =.

p.. W W 44 ~ ;e.g, 6; [7 ', f ' DIADLO CANYON rav. 3/30/79 l'. 3' ' NUCLEAR POWER PLANT P A G E,,_ 3 _,,, O F 3 .. A ~ >.y ,n) W AUDIT ACTION RCQUEST_ - ^ ' ?,, AUDIT NO.: 101 A. A. R. NO. :. 1 N PILE NO. T ,4; l. OBSCRVATION CODE: 1 ACTIVITY AUDITED: NDE Procedufe .n N.s G AU.DIT DATE: 1-18-82 9 'N REFER NCE DOCUMENTS: PG&E 8711, PG&E 8833XR, IFP-1,2,16, ESD 246 and ESD 257

a WJ

$j SUSPECTED CAUSE Con.muw: , f r. Finding 11 continued - A radioirraph of each star.dard shall be on file for proof of defects". T.]$ Paragraph 9.2 states "the operator vill check his test unit to this standard and show bovn 31 dsfect". 5p l.d Finding 12 - Per the QA/QC Manager the requirements of ESD 241.11.4 establishes the qualifi-cation of the procedure. Paragraph 11.4 states "the mmination.shall be conducted with a N) frequency that is capable of producing a mini" rum of 50 to a maximum of 75% of full scale ?$ I9 raflection from the provided drilled hole in the reference speciment (MWK 001 Sketch #1). Ed Paragraph 131 states " reference specimen shall be of same nominal diameter, thickness and co= position and heat treated condition as the product being enmined. The separation betvoen standard defects placed 6 the same reference specimen shall not be less than twice ther r J,0 "1 lingthof'thesenspgunitof,theinspectionequipment". .T Finding 13 & 4 - ESD 246 and.ESD 247 - Unknown. M F ading 75 - ESD 270 - Unknown. se i H l 4J'jj RECOMMENDED CORRECTIVE ACTION: Request Williamsport office to check if they have P.Q.R.'s for ESD 246 and ESD 247, if 2. f they do, to forward copies to the job site. Per the QA/QC Manager a copy of ESD 210 Procedure Qualification Recor'd be filed with ~ d 3 ESD 270 based on the similarities of the procedures. /' R.4 .n N.,

d. ;.1

.s ,. M .m M N FOLLOW UP: ACTIVITY COMPLIES WIT 11 APPROVED CORRECTIVE ACTION IF NO . PLEASE E;; PLAIN: .YES NO s.g.i i DATE: ed BY: A.A.R. CLOSED DY: DATE: 'l .: t U'd "] APPROVCD DY: DATE: 'l, 'd ..ej m...

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sie av wMswx .o k (( .I y%wa-3 asad sedsm na-n 6M sysrs Jy Gd/Ge.xfx - j dj,Drkok G'f/d6 )RfA (1, g //' Jtt W$ i 54fs kdV$ 4 2 C W f lt f k I fSft adit swd'.ds ebrse /$ n a [^[i ','q i, 0] ) a

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j g g 9 be d W 'a p yrj f W <!E G M T P rpj$ p.4lf %.fj M Q M Q f..g M L. F N $. 4 Puuman Power Products tp FORM. F-12 5 - rav. 7/6/78 h.i /- rav. 3/30/79 g f,~5,0 ./ DIABLO CANYON. i 4'.; NUCLEAR POWER PLANT. PAGS 1 OF 2 vs @ 'f; AUDIT-ACTION REQUEST ?m C $I-FILE *10. : I AUDIT NO.: 101 A. A. R. N O. 2 h j OBSERVATION CODE : 1&2 ACTIVITY AUDITED: ONOCFielddrranizationChart [f.9, AUDIT DATE: 1-18-82 ylj Mg REFERENCE DOCUMENTS: EFP-1 w h-FINDING: QA/QC Field Organization Chart g@%y 1. The Field Chart does not have a Iey explaining the reporting relationships between job functions. This is an item of concern requiring supervisory attention. E 2. The Field QA/QC Chart does not correctly show the reporting relationship of the QA Q)- Manager. Continued on page 2. / FI'4DIMG BY: H. Hudson DATE: 1-19-82 ACM'D 3Y:M _ m DATE:Jd1M u I MI SUSPECT 3D CAUSE: y,,f 1 A 2. Unknown fa, .L;d "CCO.'rCNDED CORRECTIVE ACTION: $~ Revise the QA/QC Organization Chart to incorporate the EFP-1 Key for explaining the i ly reporting relationship between job functions and show the correct relationships.of the QA Manager. ? 3 n.8t DuS DATE, c.);3 c=""c=7=.ac=1 3 "= alt L L w t m ~ \\ " Q~ =^^^*~ y^ = ~j=.. gict 4 9 l ]- = TAKEN B'Y: L APPROVED BY: b b 'M'b ..y l my T.a d STEPG TO P'CVENT ".RCURE?1CS : .-&7 a m j.) 0 f f %_mA AA/.dr )k J,i.] d -A h /[dP L,. - APPROVbD BY: b bb TAKE. Y: 03 FOLLOW UP: ACTIVITY COMPLIf S WITH APP'.OVED CORP.SCTIV ACTI Mj IF NO - PLEASE EXPLAIN: S NO fiig } M~b 3Y: k N DATE: k A. A. R. CLOSED BY: {1. I b M A DATE: 3 "L3r-D N1 yq APPROVED BY: DATE: } a,. i-Av 3 4 1 3 ..] y m..._,,._,m_.-_._.,._ r...__..

W W, 5 & y $ 9.' N.% M !in f;3%RM F-125 rev. 7/6/78;NAa$iW*TWW *WW$g%5l'%: .vi rv...n.< a e @n.r r a vuum - >fjjf&w.,.::.'.' Mv.Wi'WEilcM% 1 i e gy. 'l' rev. _ 3/30/79 f M@% ~. ./ DIADLO CANYON- _ PACE 2 OF 2 NUCLEAR POWER PLANT Sm u y; Is AUDIT ACTIO'N REQUEST _ L 3 v - 1, M PILE NO. : I AUDIT NO. ici-A.A.R. NO. 2 k.' h OBSERVATION CODE: _ 1- & 2 ACTIVITY AUDITED:: QA/QC Field Organization Chart p, S.

  • AU,DIT DATE:

1-16-82 ~ g., sta REFERCNCS DOCUMENTS: HP-1 $. (. f' gl FINDING: Continued. W h-

2.. Continued.

$ff Tha chart shows the QA Manager under the " Administrative" control (as defined by the FP-1 '.C Chart Key)of the Director of Quality Assurance, Williamsport, PA., and in a " Communication" role with the Resident Construction Manager. This does not comply with the UP-1 Chart and - EP-1.11.2 which calls for the QA/QC Manager to be under the "Mministrative" control of the .? :; h 6 !y Essident ' Construction Manager and reporting to the Director of Quality Assurance on all pp "T2chnical and Functional" matters relating to Quality Assurance. Q c" *' 1 I:.~%

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&i /> :, y ?,.,. i p;.3 l n 1 i @4 [:.[ m,n - 'M 7. ) Y, '3 ..nW d FdLLO[UP: ACTIVITY CO!TLIES WIT 11 APPROVED CORRECTIVE ACTIONYES NO y IF NO - PLEASE E : PLAIN: ~ eg (.T jd DY DATE: j( 2i A.A.R. CLOSED BY: DATE: ~ Q 'g V: APPROVED BY: DATE: bi d . v. 7l e4 w,m,-.m._,...-_...-

WQ.yjjfljQ@WcidSN{15AQ@>y,Pupman Power)Phl[{9}fjQQQQ.Q:;J@$Q[ \\ %9lV*fy W, c;} b;L . ' FORM F-125 rev.

  • 7/6/.78
  • t;i re v.

3/ 30/ 79 s. DIABLO CANYON I ~ ./ PAGS 1 OF 1 f - NUCLEAR PCHER PLANT V.- 4 h 1 k'f AUDIT ACTION REQUEST n$: .,l' 4 FILE 10. I AUDIT NO.: 101 A.A.R. 30.: " 3 C ) OBSERVATION CODE: 'l & 2 ACTIVITY AUDITED: Production /EdrineerineOtraniza- ) h-- tion Chart ~ [p" AUDIT DATE :. 1-18 ' PM T/ REFERENCE DOCUMENTS: KPP-1 b $d FINDING: Production / Engineering Organization Chart hy 1. The Field Organization Chart has a Key explaining the reporting relationships between ,y job functions but the Key is different from the IFP-1 Chart Key and does not include the same type of information. The Field Chart Key shows reporting relationships of " Direct g$p Control" and " Engineering Reporting Function". i I F Continued on page 2. M FI'4DIMG BY: H. Hudson DATE : 1-19-82 ACH' D 3Y : 61/2 - DATE :.3-/B 87,. h SUSP::CTED CAUSE: kyl-1,2,3,4 Unknown ru,m b h'

  • ECOtrCNDED CORRECTIVE ACTION:

I

h.,j The Field Organization Chart be revised to reflect the KFP.1 Organization Chart.

ly) b' b~ 25'b ) DUE DATE: l .I CORPICTIVE ACTIO'1 TAKEM: I, 1, 3, / 4-7 p+ i iws.o oIzandtes md--cangr H4 B as,EJ RwfMO 70 Wi 7" YMa= K FP- / OMAN/**I "* 7 N f( L 8 ',22 - 8 ~2-APP ROVED BY : w $// i TAKEN BY: (2 r ob f g ST::PS TO PREV':NT "ZCURREMCE : Wif ' 61 Ih TAKEN BY: APP ROVI:D BY: $d FOLLOW UP: ACTIVITY COMPLIES WITH APPD.OVED CORP.3CTIVE ACTI h IF NO - PICASE EXPLAIN: YOS NO p g.w* 3Y: .k b(/vs. ' DATE: h* I1*N d, A.A.R. CLOSED BY: Q. tM A DATE : "I - l l. 4'l-f APPROVED BY: DATE : ?k m. dk

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8 '"N"~~~~~ k.FOR'"F-l'25x rev. 7/G/70 - di -~ kM' ', rev. 3/30/70 f k i DIADLO CANYON PACE 2 OF 2 f@ NUCLEAR POWdR PLANT AUDIT ACTION RF. QUEST u;. l @Yl' ~ lk PILE NO., l I AUDIT NO.: 101 A. A. R. NO. : 3 ( ;'! OBSERVATION CODE: 1&2 ACTIVITY AUDITED: Production / Engineering Organiza-

c. p$

tion Chart k ' AUDIT DATE: 1-18-82 g REFERCNCC - DOCUMENTS : UP-1 INDING: Continued. 1 This does not comply with the EFP-1 Chart Key which shows "Adminiatrativa", " Technical and $Q Functional" and " Communication" reporting relationships. This is an item of concern requiring supervisory attention. j f /, p M 2. The Field Organization Chart shows Field Engineers Restraints, Piping, Hangers, and Snubbers) as being under the "DJrect Control" of The Assistant Construction Superinten-M ' dents and having a " Engineering Reporting Functfion" to the Chief Field Engineer. This does' M not comply with the F P-1 Organization Chart which shows Field Engineers reporting "Admini-p.d stratively" to the Chief Field Engineer and having a " Communications" role with the Construc M tion Superintendent. This is a noncompliance to EP-1 Organization Chart and H P-1.14.7 %( 3 The Field Organization Chart shows the $erPurchasing) as being under the " Direct Control" of the Office Manager. This does not comply with the FF-1 Organization Chart which shows the Buyer reporting " Administrative 1y" to the_ Resident Construction Manager and 4I having a "Comnunications"~ role with the Chief Field Engineer. This is a noncompliance to tha /. /4, /t h,+ FP-1 Organization Chart. ,M / 4. The Field Organization Chart does not show a job function of6 tarini Con 2 " The Field jf'. , Chart does not comply with the EFP-1 Organization Chart which shows a job function of ~ " Material Cont." reporting " Administrative 1 " to the Chief Field Engineer. This is a non-7 07, comn11ance to EP-1 Organization Chrt. >CA M ppn w <sr. p3h,. "fdat,fFvNeTMMb f Comm uN I CA7t* O S'.b ,,k M FOLLOW UP: ACTIVITY CO!TLIES WITl! APPROV :D CORRECTIVE ACTION d,% IF NO - PLEASE E : PLAIN: YES NO w m BY3 DATE: y,hj M A. A.R. CLOSED DY: DATE: .d O ?.),9 APPROVED DY: DATE: m y .4 Ut' I +~+v,_7 _m

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enm u 'F ATTACHED OlSCREPANCY REPORT UNIT NO. I i '8r CQoE No. O [] SToMEm; Pacific Gas & Electric SPEC.NO: 8711 0 5 11"b-b2 OJEcT: DiaMe canyon yy) Joe No.: 7177 iNspecTom: R. Hudson /MacCrae ~ j .s.] ESD-246 and ESD-247 - Magnetic Particle Procedure / Dg/Gontiauous co u Metnoa

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n.4 NATION or oisCREPANCY j bh Internal Audit #101, A.A.R. #1, identified that there was no Procedure Qualification Record ESD-246 and ESD-247. $J Subsequent investigation has revealed that ESD-247 was used to MT examine the inside i-l;q ceter of FW #197, Iso #500146, Steam Generator 1-1, DR #3484, on two occasions (see attached 3 mination records) ESD-247 is listed on DR #3453 as well, under Reconnended Disposition and W suspected to have been used (there is no: examination record with the D.R.) to MT examine inside diameter of FW #244, Iso'#500146, Steam Generator 1 4 The velds in questien are on ) les K16-554-16 IV and K16-556-16 IV, both Seismic Class 1 code. /I The use of ESD-247 on Seismic Class 1 pipe without a Procedure Qualification, Record is a LM 1conformance to Contract Specification 8711 Section 3 Table I and Notes to Table I, Section (' 'aragraph 3 23, Section 5 Paragraph 1.2, Section 2 Paragranh 2.1 and Section 3 Paragrach 1.h. h --CONTINUED ON PAGE 2 0F DISCREPANCY REPORT--

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INDICATE APPROVAL BY CIRCLING THE APPROPRIATE " RECOMMENDED .d DISPOSITION" q 1. Accept-as-is all work examined by ESD-247 " I m:

2) File a copy of this D.R. in the following locations:

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r.. A. Document package for Iso #500146 FW 197 and original DR 3484 'q ) B. Document package for Iso #500146 FW 244 and original D.R. 3P .T]J PG&E G.C. C. Originals of ESD 246 and 247 OUALITY,0NTROL 0J on FLEVIEWED p$ zs n e.o.&E. to disposition 79,/m c,, 2 -,,......,, n. s 4 - ~ d.h,_g_ M e.ua/WD j e. .'.n g] At otsecsmcN: p8n A "/ +

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,oeneswie A7A O o m., (..p.o. .nw.,,,...I c.wi, ) > ' i ~ 'o.... , c...i. m i.... ..,,c...,.,,, in.., o.. 4j UNATioN HP NEcEssAMYit ij v i b M ,Q 7 m o c.A. u. o.t. c-cet. t.; .( @l To PREVENT REcVARENCE @ Nee Ap,li.ebl. i ~~ l J Manager shall assure that N.D.E. procedures have the necessary Procedure Qualification 'i .: rds perfer :ed and included as part of the procedure prior to submitting to P.G.&E. for Pt..a c.A. u.n , M[m 9 t/ 3 raisu?icN: 2 van.,c.A. Fa. 2 Aum. inia. 2 Empa nn, o.ot C oin., 4 T"^- ~~ ' ~ - ' ~ ' ' ..-.- 3

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w.n. -n) Pullman Power Products ',lf] 10 CFR 21 lP 4662 + o n, no, E[9[. ATTACHED DISCREPANCY REPORT UNIT No. I 115) or (15 NOT) iso. No. 500wo cede No. O p^.. CUSTOMER: Pacific Gas & Electric 1~ 2 SPEC.NO: 8711 cATE: [,$l Paosser: 08868* W H.~ Hudson /MacCrae Joe Noa 7177 NsencTon: 1 zw, ..+ t;p ?.. l < a _' 50.. --CONTINUED TROM PAGE 1 EXPLANATION OF DISCREPANCY- ' M4 ,W ,ji A PQR for ESD-246 and 247 has been performed (see attached copy of Procedure Qualification 2'3 No. MT-3) and is currently on file. It demonstrates the ability of the procedure to detect .;d known discontinuities on the I.D. and O.D. !.7) 4 ,l's

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.s !#U MACNETTC PARTTCLE y.'; f PROCEDURE OUALITICATION RECORD 9 g;r>; [jj 1 i Procedure Qualification No, MT-3* Au M'f Method Dry Powder Continuous; Half Wave D.C., Coil fy Equipment Manufacture ' Maenaflur Enen. W Brand -Name Ma ena flur f.,.5 Model Number P-90 4 Magnetic Particles: Brand Ma gna flux Type Dry Color 8A-Red I g Hagnetization Current Hal f Wave Rectified D.C. M, Out Put Amperes 1000 Amos. %p. Tes t: Piece Position . Vertical Test Es.carial Carbon Steel ?; Type Test Piece 3"x2" Reducer with cut fillet weld at socket end 3h Surface Condition Bare Metal W* Pre-Cleaning Method None Weather 70o Ory F Base Metal Color Dark Brown and Shiny Metal q Contrast of Particles to Base Metal Good 01 Hethod of Particla Application Powder Bulb '['- Method of Remo'ving Excess Particles Blowine

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.Demagnetiza tion None i ] Prod. Spacing and Amperage: 3 Coil Loops of 5 x Pipe Diameter with 1000 Amps. .U E [Msaker. -] 1 co a p\\va.3. A k b Wj l.). Leface. tad. d \\ t.t. %hso,.t.c. h f""'" ; { g m h\\f-wave. hch A'e.) I {y] c.D. sA e, &g e DC C.arred. (tic vct+') lA \\'d4, Jg ,\\ Q 4 3"x2' M ocar @J I h.uca.hons are. Educe.cA %,ac,g 3.g,cq moge, g L W Ii"** y a W v.wau cut oC a U dh 4 som % co u.9 .h Coil We. Arv wah cut ws back-l@14 s. welcw.A +o Nvce.un sveke. ^ M;ca.%a ' Evaluation of Procedure Good-Indicator and defect showed well. .g fd gj Procedure: C""? Approved O Not Approved Test Conducted By M. MacCrae n/4/ G gj vw..S O wo-:.C % __ Si t4 T"' \\. Ave.\\ 'IE. ,3 jj PREPARED BY M. MacCrae DATE OF ISSUE 11/ 0 /*

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DATE OF REY. - APPROYED BY c C W. ,3

Gygp M 2;W??h M W U W N S #' ? n; ,1 11 1 ~~ ~m x P ENGINEERING $PECIFICATION ' SPEC.NO. e] I 8711 M,- 'ENGlHEERING DEPARTMENT ES 0-247 g., ' :, D-t

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f,!) MACNETTC PARTTCt.E Q PROCEDURE OUALITICATION RECORD 5 s 4.% Procedure Qualification No. MT-3' l, 33 M.f; Method Dry Powder Continuous; Half Wave D.C., Coil Gj Equipment Manufacture Maena flux cnro. af] 3 rand Name Ma ena fl u x N Model Number P-90 5. ' Magnetic Particles: Brand Magna flux Type Dry Color 8A-Red ?] Magnetization Current _ Ral f Wave Rectified D.C. y Out Put Amperes 1000 Amos. 1 Test Piece Position . Vertical k$ Test Material Carbon Steel .;' /' Type Test Piece 3"x2" Reducer with cut fillet weld at socket end y$ Surface Condition Bare Metal

d Pre-Cleaning Method None

)Lj Weather 7 00 Dry 1.. Base Metal Color Dark Brown and Shiny Metal r,! Contrast of Particles to Base Metal Good Method of Particle Application Powder Bul b Method of Removing' Excess Particles Binwine i Demagnetization None j Prod. Spacing and Amperage: 3 Coil Lo, ops of 5 x Pipe Diameter with 1000 Amps.* E.f.l / n4c +o<- i i.). Lek.a. k,t, ,q C; ] 1 Cod P 9-3*d O ~ I "" 'r ' - "J l b WAc ,1 6 4.4 h. A Noftu s M c M P--lo p9 H..tf-wave. he % 9.e.J uw.. ) o.D. s b c. g 9 DC C.ocred. (ino v W) c

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l 1 h&cc.%oss are. m6oce.d I.];) m%'sca\\ deCec.4s mm.de. by i Test Piece, r.+ o, Weu-watt est oS a bad 1 crs $} w % cm, eeessed. Eev c9 'd;.[ Coit# . Ws hev watt cet was bac.k - A ' ^ " q{q u w e W eta +o W oc e w w s ur-4 c.c. Mica.% e ' Evaluation of Procedure Good-Indicator and defect showed well. 4 a V ;$ Procedure: C"] Approved O Not Approved Test Conducted By M. MacCrae tim /C. i r N..5 D%h [h,,, 5 9g gg g l - l PREPARED BY M. MacCrae DATE OF ISSUE 11/C/*? DAGE OF-1 DATE OF REY. 3 APPROVED BY pi l,, t.. y.. ...,c - ~ - - * - -, - - + - - ~ r ~- '~

7838 M 25558383E FE2 D W 13.565E$Il$T'W M$$$$5hN'W N MENId ' s.,.- t.. .o ,9 fy J; Response to Internal Audit #101, A.A.R. #1 k '.e.g /4 g A procedure qualification was performed'in order to qualify ESD-247 as YI] well as ESD-246 (ref. Internal Audit #101, A.A.R. #1). .A< As both ESD-246 and 247 have been withdrawn from use and the equipment h listed in both procedures is no longer available for use, the equipment used for these h PQR's was the Magnaflux Model P-90 for the coil technique only. All other factors k are the same as specified in the procedures. As the Magnaflux (icdel P-90 putsfless amperage than the equipment listed j h in ESD-246 and ESD-247, and acceptable results were obtained (i.e; I.D. and 0.D. surface ) pig and I.D. subsurface indications were located), the demonstration of this technique is deemed adequate to approve this method employed by the equipment listed in the above $$q-procedures. e A record of the procedure qualification demonstration is hereby submitted woQ along with this response. The originals will be filed with the applicable procedures. T,} In the event that either or both procedures are re-activated in the future, et e [c;j they will be revised to incorporate the Magnaflux Model P-90 into the list of equipment. j As both procedures are currently withdrawn from use, no revision is deemed necessary f.'s at this ""e. @.j h i rd n nu A h* ?..:,; !!j Michael S. MacCrae e i. MT Level III y;; 11-9-82 ?.9I4 $M

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mL* '.W~@. _Mus.WJW~SOM.u.-~FM~ W~M<: mU9d5FMM-@I@SM.M D 8dNO M MEGNY! N W 1. x- - ~ ~ ~ ~ ~ - L.'.. j ggy M ENGINEERlHG $PECIFICATION - spge,go, Pv: 3711 p-W orm F-23 . ENGINEERlHG DEPARTALENT ES 0-247 70. i .5 r;;; > j a r r. u.n q., MACNETIC PARTICLE 4 PROCEDURE OUALITICATION RECOg 7 dr 2.. s ',f E Proceddre Qualification No. MT-3' W ([$Y Hechod Dry Powder Continuous; Half Wave D.C., Coil Equipment Hanufacture Maenaflur Core. y Brand Name Maena flur 4:'" Model Number P-90 ff)

  • Hagnetic Particles: Brand Magnaflux Type Dry Color 8A-Red Magnetization Current ' Hal f Wave Rectified 0.C.

qw out Put Amperes 1000 Amos. f;l Test Piece Position . Vertical M Test Material Carbon Steel ) ypd Type Test Piece 3"x2" Reducer with cut fillet weld at socket end f*g Surface condition Bare Metal ,cj Pre-Cleaning Method None 'f t'h Weather 700 Ory , P] Base Metal Color Dark Brown and Shiny Metal M; Contrast of Particles to Base Metal Good ,S Hethod of " article Application powder Bulb , ;j '- Method of mo'ving Excess Particles Blowino jj Demagnetf' .on-None 4,.yl. Prod. Spas 3 and Amperage: 3 Coil Lo. ops of 5 x Pipe Diameter with 1000 Amps. J!S h.:. n.n. s,ek.a. s.,s. /ga:cao,.

9 in.

3 y z P W-33eg @ \\ o "d g','.3* -u u.., t 9 -l N%fiox Medal P b ladica %. r i + pg = -w%. / W.\\f wave. Rtch %.e.) fi1 ,o. n. sAme, 4 ' ^ t>c. cserent. (Lc v lf) s,> e j .e. i.sa:c.6 a hp g 3 ~* 2 ~ M * " "' l i Ld'ica%s ace. mckvce.d ,,,%',ca\\ deCr.c.h de. by w hk M Ii"' a heu-wu cut oC a bad h c4 bc., j w4% co,eesssel. %eY c9 j .M,,., Coit Ws Arv weah cet ws back-

  • j weWc.\\ % Noce wb sve-%ce.

Qn n.- Mubar 8 p.d W aluation of Procedure Good-Indicator and defect showed well, u+ Procedure: O Approved C Not Approved Test Conducted By M. Ma c Cre e ti A1 M1 m ,..cvmc_ Q+J ). 1. MY Leve\\ TE li ~ Qd . PREPARED BY M. MacCrae DATE OF ISSUE 11/ ? DAGE OF %7 DATE OF REY. APPROYED BY

  • J Leir-i mm.

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g' 1-ENGINEERING SPECIFICATION '

SPEC.HO. g:. 8711 1 crm F-23 9f: . ENGINEERING DEPARTMENT ES 0-246 m O. L;;.i MACNETTC PARTICLE 'j; PROCEDURE OUALITICATION RECORD W [,; . Procedure Qualification No. MT-3* t ;-s [d Method Dry Powder Continuous; Half Wave D.C'., Coil 0M Equipment Manufacture Maenafinx cnre. ff Brand Name Ma ena f1uy k: Model Number P-90 %e)j,

  • Magnetic Particles: Brand Ma gna flux Type Dry Color 8 A-Red Magnetization Current. Hal f Wave Rectified 0.C.

)'[ij Out Put Amperes 1000 Amos. l*/] Test Piece Position . Vertical %@3 Test Material Carbon Steel Type Test Piece 3"x2" Reducer with cut fillet weld at socket end 3 7 Surface Condition Bare Metal 'h Pre-Cleaning Method None

I.l Weather _.

700 Ory Base Metal color Dark Brown and Shiny Metal Contrast of Particles to Base Metal Method of Particle Application Good Powder Bulb ] '- Method of Removing Excess Particles R1nwine ^ Demagnetization None Prod. Spacing and Amperage: 3 Coil Lo, ops of 5 x Pipe Diameter with 1000 Amps, yd' / n4c4&ov-i l.'n. Lefsta. k4 M q % ] k. V %eGmes. p "-33

  • d b*C g,,g g

t~i,.c.6 Ja, m p% .g'y.j tc carred'. (tc v t#) H:.tf-w. ave. Re.ck %.e.J

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{I e N l h 4 3~*I '*"gi l Leca.%s a,ce. idduce.cl w $? M fi- e4ca\\ deCec.4s Qe. by W a Weo-wau cut o9 a bad f,,'"i c/S wh% c.o eeessed. %.c V c9 [fh. Coit Ws bew wo.h c.ot us tm.k - Eb wakwa+n m e wssch.e. $g ~ sa me 4

  • Evaluation of Procedure Good-Indicator and defect showed well.

f5A h; Procedure: Q Approved O Not Approved Test Conducted By M. MacCrae n/4/ W 2,.s

n. c s ~.o -

v pig MY Leve.',.nt u Qi., Nd PREPARED BY M. MacCrae DATE OF ISSUE l'fo/'? DAGE OF ",1 DATE OF REY.

' 2

^, APPROVED BY Ffg -) ,- w u us m-

QpGQ, WifW.F.F.W>.~W.WEw@@YOTsn> M.n.u.w'@. W.u~KW 5%wE #424,@w W~E. nf:6 4.~6 .a.m a WM W d ~ m -~. W y aL .== =. ,,y. ~ .A q;a c.?, v.,, ".. ^ n. i V7 .f T!! E !!. W.1; E L L O C C CUuPANY 0; i

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.. ' ' J'.".. .[ . '. ' '.J-L I OU I D P E!!ET R AllT EILE ll! A T I Cf1 R E co n 0 . ; *....e. ...' c,l...W . ~ q w .t. a.t ..s. e. h i ' DATE + ) . s.. ' e

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r fSo/DWUMBER. "F" S H E'E T UA I e 1 s. n N-7;yy 1 )h JOINT NUMBER _ JOB NO. ,pi t' I s a PjhtMATERIAL y;; ' 9.'. t '-

~

8711 ESD 5 Q ..EXA.tlNATION PROCEDURE KPT-M.. ' L : ;.',,. a. &qa.z.. - Aggq.. (,. . ACCEPTANCE STANDARDS s-grM e .u. W . tiAGNAFLt.!X DYE CllECK., i'

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  • t.lOUID PENETRANT BRAND L. y.

M, LIQUID P. ENETRAN.T BATCH. NUMBER PENETRA""T DEVE' Opr p' % d CLEAHER ~ t < ,,t

1. ;n.w.. s ).;".', %

>d. l. e s.; ,...:.+, n.... ..n s. s.. .,.r...-;.... g. ;. p. r. 9 .~ j. g. ,5,,'Y, h., .. v. L.. h...ACCEP.TED 3 ~ f:i. 4tEJECTED-c; S 8 G N A 1 U R t; 0F 1NSPECTOR ..p.....- ,...s.... f. o..' y, .t.*.. ... pas + w b . r..;..,. w, i.,. . 'r. w.. .~ M

  • '. ". M.

1 l.,*,'. i;n!IGHETIC P1RTICLE EIf.ClH ATI0li REC 0!!D.., -. ..%v o-

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hQ. .... '. Q. L... C. :.. b ~. do.. } f,.. ' %.,,.. ~ oA,E shfk?* # g .? ' '~ n ~.. . :.. i.. g o/DLc Nuuo Eg' 5NW A ' M W.... o :..;NV ' 8M ' "F" SHE ET WA. v4 s.. JOINT NUMDEl O* l 7 bio "$6

  1. M-

'.Mf772 ? . JOB NO. 7I77-l %.1.. '.. w n't D-owT).4.3**

  • 4.-

p. g.g C/JDON STEEL M..e, MATER,1 AL .$. EXAMINATION IROCEDURE KMT-.871) ESD-W $ d/f'I* Yd YB -/7 l

  • n,.

M d i ~ ?A.CCEPTANCE STANDARDS n Lq ' g.gg ygpy g.S" MAGNET lC PARTlCLE POWDER BRAND +L ngo-(8h) fd.t ." MAGNETIC PARTICLE POV.' DER COLOR w ' COLOR OF COMPONENT ' METALLIC .L I s f:1u0.1ChTlonS EDE S: .'*>i.., 3 *. . :.r. d. p0T'E:

  • Con. #trru 00' QF. M:

01 ~; inicer c ANg.Vt-1. 2 '.... N.'., ^. ' ~' und e;c, c A11 gr.cd .s s l p. 1 '.u 4., y 7. '. h REJECTED .. h A CEPTED 1 SIGNATuftE OF INSPCC10ft 1 n 7 _, _.- _ m _ m .,. m.... _.. _

'Y'MSI$1@lE 5$ @ AQ:liEpig.g 'gjp], g,[ j+gg er; a $.+ .~ ~ THE II.T. Kell 0 0 5 C 6M P A N Y ' 2v N s. .seiessi..etettuaw escearesatte $11,. ,w.. . A;.:n, 24 %,....."'A. @.. j; 4 - _ LIQUID PEllETR AllT EI AlllM Atl0li ftECORD - v.----- w , y... ;.. DATE a u.. e '.s .N/A 1 .g.:1 a, .c .w,. a. + .s.

  • F" SHEE r 4ht

%,0/r'3G NUMBER. .h0D 110. 7177 k Jo[NT NLNBER e. m pp . MATERIAL nd Q'h fd EXAMil/ATION PROCEDURE KPT 8711 ESD-y ASME 1 k, ACCEPTANCE STANDARDS '... \\- T'**

M l 10UID PENETRANT BRAND

.MACNAFLUX DYE CHECK H. CLEANER PENETRANT DEVELOPER l d ih'[. LIQUID PENETRANT BATCH NUMBER i t y.. ,.1 +r

^ ;

i-e i ~ c. . p, ...araccTEo SIGNATURE OF. INSPECTOR j O ACCEPTED L';. i .i h I r.., %;s ':e j .:.W

  • i

.V MACllETIC P ARTICtt EX AMill ATI0li RECORD W,x.

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l0 AO~YT f DATE l N/A ] 8DNM UU "F" S H E ET .~: ISO /DWG NUMBER i 7177 ^ . Jd!NT NUMBEn FW-W L NDE N AFM2.

  • dt.

JOB NO. i . :. v.. gMM.MATERI AL _ CARBON STEEL ~ 4 47 / 8711. ESD-2 4 "/ 'hEXAMINAT10NPROCEDUREKMT. E Med 7 tj ~ 2 n.'* ACCEP.TANCE STANDARDS .b..s. MAGNETIC PARTICLE POWDER BRAND MAC W LUX m, m-RED (SA) w e% ;..... MAGNETIC PARTICLE POWDER COLOR m. 4 8 METALLIC M@. ' .'. COLOR 01" COMPONENT INDICATIONS l/ + .S. i 3 Linear. .a. 5.. . gnynf '.,. =., *%, s ~ ,' f ..< y 3,, - . Aligned REJECTED @ ACCEPTED S I Gil AT U N E of lHSPECTCH K

  • * ~,so -

............,.8 .e +.. '""8**5*'8"' 7*W. 3e t y*%]"**t*****M. * * %Q'""% g - . ]-W f *1

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M522AM9XEES$$f3*M&MMiffdE:IMMM5sEm$2&EEMsWeW$n. f-kA, -. o 4y3,. - , v.. k THE M.W. KELLOGG COMPANY Page i of 3 h A OlVisioN or Put.LMAN INeoRPQRATED D.M. NO. %E3 Rev. I fiY 2 C Wj iso. No. cnn1h6 (M - L rd 5 9 DISCREPANCY REPORT Unit No.1 C00E NO. N/A c n

s..

$;3 gf; cusT0MERr Pacific Gas & Electric SPEC. No: 8711 DATE: 0-26-77 @d.,9, ~~ - PROJECT: Diablo canyon Jos No.: 7177 iNspEcTon: Runyan/Scannell/ Guest a. 7 oisCREPANTrTnM: Line K16-556-16"! Snool Piece 500: El. 1548-44": Area G: Sect. I )r g. ' ? EXPLANATION or oiscREPANev: Reference P.G.&E, Orawing 500146, Rev. 9e b i N Per P.G.&E.'s request, an Internal inspection of F.W. 244 on Steam Generator 1-4 d Feedwater Nozzle will be performed. The line entry will be made in the following 1.g. manner, see Reconssended Disposition. m.1 t y **. ? ?. :$ . $ h.,a 0 \\ ..,, ~~4 ,lY 'c,V, f Q @ Nb '* laf !. % 2;y Y.1 i :.,

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    • ~

g M ~.a r$t e.: i I M.f a RECOMMENDED oisPosmoN: fh I. Measure 2" from F.W. 244 center upstream on pipe (Spool Piece 500) circumscribe gf the pipe using a wrap around, then prick punch the scribe line, / Q" 2. Using air-arc, cut the pipe all around maintaining less than a 400 total bevel to v.. h* within approximately 1/8" from the 1.D. (See Sketch '#1). 3. Using a thin blade grinder, cut through the center of the bevel, then dress up h)l both bevels (See Sketch #1). 4 4 Jeck pipe away from cut on upstream side per Superintendent's Instruction, install 5'egl2 a dam,in nozzle beyond F.W. 244 to prevent air from entering Steam Generator. @f 2, Clean and Inspect F.W. 244 Internally ad directed by P.G.5E. (Con't jo gage 2) 5. 4:j 2 Y!77 Approved sy: M.W.K. Fie4d Q.A. Mgr., Date S I Customer A De [ I reewired ' r** E Other (esplenetion b oMto 7,M FIN AL DisPosmoN: $in ordence Mth Above ine, # MA os..,//-r.7 7 N,,,c,,,,,,,,,,,,g "4 // 2-n os,e, a.ru ca....,e, /t $=- R 8/g' EXPLANATION tlF NECEssARYh w$ Revisfori 1 - Delete Step 6 In its entirety (access was achieved). Refer to Attach-U1 ment #1 for results of initial inspection and recommended disposition. Q Revision 2 - See Page 3 of 3 and Attachmentf3. !bEWM*A/ M, a Roe Az de4L ~ 9 /7/ 77 e ea

  • g < o.'2c.7y h.y u.w.K.,we o$N ) #0b+---

ooie Th'M conome, [ /M N NJTefeiS//7'? I I A I >p STEPS To PREVENT RECURRENCE Appliesble M.. ] r uA u-o{J y Fie4d O.A. Manager DesTRisuTloN: 3 Master Q.A. Fi6e E Auth. Insp. E Engenserin0 Dept. O Other a co.t,ner a M - nB o, w i, se,., i i 1j; ATTACH SKETCH IF NECEssARY F \\ J s ve***7 w 4 as*;* -+N - gp q - _ q e. es ---..m---.,,

  • m%,

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3,q4fiWiNETFffiEERWMfiWMgi'7MU.Egig[WMNS@gggMsgyJ;graps.My g. wl.. '. g: s

.i

,.. s...i. cu b$(.9 THE M.W.- KELLOGG CO.TIPANY Page 2 of 3 A nivisioN oF Put.LMAN INeoRPoRATED D.R. No. 3453 Rev. I R_fV2 iso. No. 500:46 sht. 4 of 5 ig g .C DISCREPANCY REPORT UNIT NO. I COD NO. N/A d,*b; ,R b*2b"77 h ?j customer: Pacific Gas & Electric gegC. NO: 8711 DATE: mable canyon Joe No.: 7177 iNsescTon. Runven/Scanne11/Cuese t.M PROJECT: n e. ~ ~ oisemerawriteM: ' t.Ine K16-556-16": Spool Piece 500: El. 154'-44": Area c; sect. t* 4 1 .i h RECOMMENDED DISPOSITION: (CONtT) Mk 6. If access to'F.W. 244 1.0, cannot be achieved, proceed with alternate instructions (See Sketch #2). 9A 7. Upon completion of inspection, remove dam, grind bevel to facilitate fit-up as fp needed, clean and fit to ESD-215 and ESD-220. a.yh 8. Weld out using F.W. 549 and procedure 4/5. M'k Inspect and NDE to ESD-215 and ESD-206. 9 ?!

y>
10. Add all,Information to process sheet and.isemetries.

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O V4 I ki ~ ~ h4 . w'y ** Y 3 4 [ c..m t < 9 7.. g Ar y '? ",'.'.,.9... C..,.n.. ;', r'*5.. Q. $. . Q.$ 2 J. t L,q ....t I ,9 ' *,. i, $y.,m....... ' 3.[ .85 'G 'E. U [id.f 7,. a w.. 4.I 1.' %- "4$ S..w 's! Z8 $. p 3 p

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... '. ', g.p., ! 4 A ,.r. ,,, '4 j A .n 5 i rei lW r.u'N .1 ..v,q. b' ?g $Q .$3,, otsTRisUTiok' E Meetse O.A. Fi6e E Auth.esuso. . E Eng.neering oeot. O other q 4 E Customer D Recemag D Fi.6s insosctor ( 3.. '. 3t ATTACM sMETCN IF NECEssARY p". 4. ]w.',,..m.:. .,,,,,,....r.,.m,,.,,__..,,.,,,.

g12histd:!han2ndliMGMS2MWMMitNM9%%,y%%gBL3@v+;wMW &w, _... - f ,,s b,y THE M.W. KELLOGG COMPANY Page 3 of 3 0.R. NO. 3453 W 7. A OtVistoN oF PULLMAN INCoAPoRATED' iso. No. Cnnihn ut. L af 5 - DISCREPANCY REPORT UNIT No. t g. I CODE NO. M /A .. I, M, R ?A b ouEn: Peeltic Gas & Electric sPac.wo: 8711 oATE: Oleble Canyon JoS No.: 7177 INSPECTOR: Runyan/Scannell/ Guest PROJECTS W" ossem e' ANT 'Tf* t.ine K16-556-16": Spool Piece 500: E1. 154'-44": Area G: Sect, f j ~ D.R. 3453. Revision 2 A

w EXPT.ANATION OF DISCREPANCY; W

During the performance of ' grinding per D.R. 3453, Revision 1,' Step #5, four- (4) Indica-kp J tions'of heavy drop thr:ough with roll over were removed along w.ith all of the existing .i root penetration. Re-inspection revealed a linear indication.11tilong on the fusion line to the Feedwater Nozzle. Further ' grinding, to a maximum:de th of.110", removed T@j the linear indication (see Attachment #3)~., j g yds

  • (.;,, a a, l

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  • y QW w-i i

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9..

COMMENDEDDISPOSITION: ((;/h Add the following to Step #5 and delete original Steps #7, 8, 9 and 10. Perform the l

  • following repair:

g(; ph yd A. Grind the bevels en farf t itate Fit-on of F.W. 549. [ s. M.T. l.D. 'of F.W. 2% using ESD-247 coil method,' and clean grooved root pass at skfd A# $b F.W. 244 per ESD-215. 2Vh[! Remove the dant f rom the nozzle at F.W. 244 L" 1 % i C. PreheatF.W.2Mtoaminimumof2500F*Interpassnottoexceed5500Fmaximum.gTh#,8;p l y D. 8o31 g$j Maintain this preheat until stress relief begins,. l E. Wald to procedure 200 (F.W. 2M RI), using E7052 wire with the GTAW process, to gM w~ conform to blended configuration of the balance of the weld. T.,0. omilV N F. Grind and polish the added weld metal to blend with base metal surfaces. l } G.' Inspect and NDE to ESD-215 and Ps4 E.bEA., -ro neFeM 8.8 A T tWWAT-TM i f Fo,eso.w nw Ac su 7W f*Py

  • A"

! cree eace y, NOTE: Proceed with D.R. 3456, and X-ray weld, hot for information only. 9 j j 7'. Upon completion of inspection, remove dams from F.W. 549 pipe side, clean and fit F.V. 549 to ESD-215 and ESD-220. j 8. Weld out using F.W. 549 with procedure 4/5 A,0. e 9. Grind F.W. 549 for X-ray. ^- ~ ~ Ins N * "' - W

pect and NDE F.W. 549 to ESD-215 / u"'r"a-

~gfQ,tf'&1 ~# 1 10. f ~,,,, - .w - x -n a l NOTE: X-ray weld hot for information only. hi 'i

11. Stress relieve at F.W. 2% R1 and F.W. 5491100 F to ll500F per ESD-218.

~[ M (,,12. NDE F.W. 244 R1 and F.W. 549 to 50-207.l77 A

  • sa n eco.tu $

9p. $i l3, n a. n (%)' r d. ad o ao rm mw to e.ms warr.s. hh costarsuvioin E Manor 0.A.Fue E A.sm. sano. E Eacasereas osos. O omer E c ae, o a-o = in -- e a._ Ng w suaTcN ip NEcEssARY ..n..=. w,=. ~n.n,w.. ..,_.n.:.n,.,.

s aay#.3. 4. 99gggggg!,@yOSM%f&fFYLW.WQd?.M.u !kpiW6hM..R.&aa.Q. MMqw.:l:CMd4Mr.e. ks E

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a, fy hi i euiP... "e "e f =.:, m [53 U / 7 = ~ 't $$I f.$i v ,r e- { W 1 v. o?' <t-p- S k . k v k y@S) s i? '/ fp t. $p$ // k au /, ) I 1 i ~ '.n..', = ?? / if / n d a tu w ~ l M i 3 4. L, ~ l 3 y

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n '. macs, a w.ce mana.3+me.a c wa.em sme w r-u'ae ve men =+ - w++..=e 9*N**-*.u.ee- -- a s--e am. " F- - ~ * -

ffi223ID[52NN2 3 8 M N N E U M.$ $ $ $ 5h d d[ N N 5 /h s d 6 S $ b i d $ 3 ' N b 5ii' '

4...-

A.- y; y gfj ALTERNATE INSTRUCTIONS N m !.M (' l. Cut out F.W. 509 using air-are and taking necessary steps to mainta.In the ability [ to bevel the 450 oli side of the weld to 2002210 and a 3/32"! 1/16" land. Also, cut out F.W. 339 shown on iso. 3-2k6.

q. ;d a

gg P 856+ ling or soc-o-let A105. ] 2. Requisition: of 16" Pipe, Schedule 80 A106 Gr 8 and a 3/4" 3000# S.W. Half coup 3. Install the 3/4" half coupling or soc-o-let four (4) inches from the end of the 16" pipe. 4 Clean and Fit to ESD-215 and ESD-220 j j f4 5 5. Weld out with procedure 92'/93 (F.W. 831). ) 6 Inspect and NDE to ESD-215 and ESD-211 ) 1l 7. Upon completion of F.W. 244 1.D. Inspection and P.G.&E.'s direction, fit-up 16", f Schedule 80 pipe and proceed with Step 7 of attached D.R. using F.W. 549 and F.W. A. 509.

y.. :.

8. Reweld F.W. 339, as shown on Iso. 3-246, mgintain original line configuration. M w) M 9. Clean and Fit-up to ESD-215 and ESD-220. 9 i p 0 Weld out with procedure 92/93. ,'; c

  • 3 1.

Inspect and NDE to ESD-215 and ESD-211. M1 h "s3 .4, 4 g 4 d) qk gb M... i 4 e neew p gy s.o %q /;\\ u,! 5%

  1. 1 6y

$3 d< ,,m b 4in STEAMGEM l-4 .si li >j 3 'l 2f f*, .+mY . N .s 3 . rj SKETCH #2 DR 3453 y .,.,,_..-,.nm,.,_.-.--,...,.._m ._..._.....,w,,, ...m_mm_,..m.

@, @ h M NTN*lMdf$E71$$$d M'IIN'NN5M2fIhSi$.NN'E.'D b) SG) f.)!;^' ~ ~ J... ~ 4,g ylhd(r.csfai F.W. 244 i ik.. .Aj; .<v,R

9; A

g4 1 .W $pj I ./ Nozzle %, W;' Punch M r b '- pj Pipe on 0.D. ~

6 1

j 4 m; i j 4 b \\ 11" Grooved Root Pass i to eliminate linear. 1/16" % es A $ I' f n WA d.Rb A;.{ ^y*n VbWM&VMh 3/16' pt 1 'a'-4 i qr f $g!O I ] . I 10" --> ?;c;:i lD**P (7). Groovn ( Nozz1e 1IH w'J:: ?< 1

  • pq l

( 5t 7 riginal Root Pass O 4, fi !ly Ground e,mooth and 4 Blended to Parent ?} mzw)awa "*c='- -3k 41 Section A-A dj m d .h NOTE: Average Wall Thickness =.580" to.600" e Remaining Wall At Groove =.450" ~'0 Punch Marks on The 0.0. =.047" Deep Y;$ (Punch Marks are directly on the fusion line of F.W. 244 to 1/8" inside the f.;:i fusion line.047" deep.) wt .e W$ [df] a dj j h v 4A js ATTACHMENT #3 ..9 DR 3453, Rev. 2 A

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{ ' n ~.,,,.., -.,.w, ,~,.,ne~n.~.'- - - ~ ~ - - - - - ~. - - =x =- a

5T@9p*p, nenwgps, EM_@. xWtF%ifeigWcvMg65!K%7d..N..;.w4%!stf5:.1. , m c .n W a wa.: .r n.....,. w. ' ~ '. . ~. .. w...z--. ......,.....;....n .. ~ -... ...f ; ' ' %:y f.s ................-.......-.....:.:...... =. -... ...... -......:~..... J.g ld e O, t^T IH*lEnONICS CORCESPONDENCs N ATTACHMENT.#1 (NY. '. - 9 DR-3453 Rev. 1 M jf TO J. P. RUNYAN, Q.A./Q.C. MANAGER DATE ' AUGUST 31, 1977 p:

  1. i FROM D. R. GESKE, NDE SUPERVISOR j

p ) kd suancT kRUJ.D.MEIME...EMM[ MUON,,,,,E,L,,244 ,,,1,NS,10,E,_ D1AMEJg,, l a frih I M On August 31,1977, F.W. 244, Line K16-556, Isometric l-03-500146 Feedwater 24 . piping to Steam Generator 1-4 Nozzle, was liquid penetrant examined on the inside L.9 diameter. 1 lgi. p.- @j The following Indications were noted:

s..u Jyp 1.

2" from top center of nozzle, a small faint transverse linear-nonrele-g vant due to weld geometry.

4.,

Z 2. 7" from top center of nozzle, heavy 1" drop through with roll over.

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Enn. '.a.u.#RQgWEWNECMe@%%MMPM%%9RMMMMMM@WWF ? [; INTEROFFICE CORRESPONDENCE f. [,Q oAre July 16, 1982 ~ ~ 70 fi% rnou A. A. Eck beh SUBJECT AAR's #1 and #2 of Audit Report #31 jf3

Reference:

Your Memo Dated July 8, 1982 hf

f..Z Gentlemen:

y,j. fh The organizational level addressed for. unscheduled Audit #31, con-l:0 ducted 7/6/82, is incorrect due to incorrect application of ESD ^3 9[S 263.10.1. The Supervisor that is referenced in ESD 263.10.1 is the 'I same Supervisor that is included in ESD 263.8.1. It was never in-tended that the Director of Quality Assurance attend Post Audit l') conference at Diablo Canyon for review of Internal Audit Findings. l-W.0 The original Audit Action Requests, from Internal Audit #101 and lJj the unscheduled Internal Audit #29, were assigned for review of } Audit Findings, determination of Corrective Action, and implemen- @i tation of steps to preclude recurrence to the Field QA/QA Manager ,e. and should have been assigned to the appropriate Supervisor of the' aj Audited Department. See NOTE of ESD 263.8.1 QUOTE, Recomended "] corrective action by QA is not mandatory. The supervisor is respon-

,4 sible for determining and initiating all corrective action. Correc-

"f.< tive action will be subject to Field QA/QC Manager approval, end ,j

Quote,

%j d A. Therefore resolution of no fonnal Procadure Qualification Records 4; for NDE Procedures should be assigned to the responsible NDE 9 Supervisor, f[j. B. Resolution of improperly accepted Rupture Restraint Groove q.g Welds should be assigned to the QC Supervisor, ]n It appears that the Administration of the Internal Audit Program has s p not complied with ESD 263.8.1 in that there is no evidence to sug-

.jj gest that a Post Audit Conference was held with the responsible y

Supervisor of the Audited Department. By eliminating the Super-4j visors from the administration of corrective action, the audit re-gi sults have forced the QA/QC Manager to address all problems, major T and minor, thus constituting a violation to ESD-263 as written and h approved by PG&E for implementation on the Diablo Canyon Project. K.*,. i f: ? y., Ph .) = y [ ~ - - = -

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p Harold Hudson ro,

,o 1 9!$ suex er, AAR's #1 and #2 of Audit Report'#31 ?.n g [) ' l PAGE NO. R e-h..u..; RECOMMENDATION -s fl6 A review of all outstanding Audit Action Requests be conducted by g; the Internal Auditor with assignment of responsibilities adjusted to be in complete compliance with ESD 263.8.1 and begin the cycle SA of response and review. The QA/0C Manager shall review and approve b6, the Corrective Action upon satisfactory and timely implementation. It is further recommended the Internal Auditor review ESD-263 in 1 its entirety concerning administration to assure a realistic, viable (d program of Audit implementation within the scope of the procedure ] meeting the procedure objectives. M , /,1 k. $$$kL jj A. A. Eck ..3 'l AAE/ lam s.H T] cc: H. W. Karner q J. W. Ryan ,7.'n File s:o ..q M ,m ti

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V f INTEROFFICE CORRESPONDENCE DATE July.16,.1982 TO FROM A. A. Eck suanct AAR's #1 and #2 of Audit Report #31 )

Reference:

Your Memo Dated July 8, 1982 ) Gentlemen: The organizational level addressed for. unscheduled Audit #31, con- 'l ducted 7/6/82, is incorrect due to incorrect application of ESD I 263.10.1. The Supervisor that is referenced in ESD 263.10.1 is the same Supervisor that is included in ESD 263.8.1. It was never in-- j tended that the Director of Quality Assurance attend Post Audit conference at Diablo Canyon for review of Internal Audit Findings. l The original Audit Action Requests, from Internal Audit #101 and the unscheduled Internal Audit #29, were assigned for review of Audit Findings, detennination of Corrective Action, and implemen-tation of steps to preclude recurrence to the Field QA/QA Manager j and should have been assigned to the appropriate Supervisor of the-Audited Department. See NOTE of ESD 263.8.1 QUOTE, Recommended 1 corrective action by QA.is not mandatory. The supervisor is respon-sible for determining and initiating all corrective action. Correc-tive action will be subject to Field QA/QC Manager approval, end Quote. i A. Therefore resolution of no formal Procedure Qualification Records for NDE Procedures should be assigned to the responsible NDE Supervisor. ') B. Resolution of improperly accepted Rupture Restraint Groove Welds should be assigned to the QC Supervisor. It appears that the Administration of the Internal Audit Program has not complied with ESD 263.8.1 in that there is no evidence to sug-gest that a Post Audit Conference was held with the responsible l l-Supervisor of the Audited Department. By eliminating the Super-q visors from the administration of corrective action, the audit re-sults have forced the QA/QC Manager to address all problems, major and minor, thus constituting a violation to ESD-263 as written and approved by PG&E for implementation on the Diablo Canyon Project. ) \\ e

gp q 7 ~ ~ ' :jf ~ oarc July 16,'1982 l l d Harold Hudson l -sue;ter, AAR's #1 and #2 of Audit Report #31 1 PAGC NO. l l I REC 0ffiENDATION I I A review of all outstanding Audit Action Requests be conducted by the Internal Auditor with assignment of responsibilities adjusted to be in complete compliance with ESD 263.8.1 and begin the cycle of response and review. The QA/QC Manager shall review and approve the Corrective Action upon satisfactory and timely implementation. i 1 It is-further recommended the Internal Auditor review ESD-263 in. its entirety concerning administration to assure a realistic, viable l program of Audit implementation within the scope of' the procedure meeting the procedure objectives. S6$k. A. A. Eck AAE/ lam cc: H. W. Karner J. W. Ryan File

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pmemammsweswamagssemupg g x s m._ j u,_._ m .bg-y g r. d x s. q. +. w .~. ..w. 4[IlcStID3h233C E Cg!: harpcra!!Uf! PCW2TSySt0!n3 FwRsysnmachten,

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] a.:. :f. an::s l-4_ sne.m,a w n..c. e . e. m.. w. ..1. a :. n s .~.: .v. n a-,2m. m 5.0. PGE/ PEG-220 4 5.4 Hr. D. Y. Kelly - j I y chief Hechcnical Engineer' ..Ref: AEC Letter 2 g Tacific Gac cnd T1cetric Company Docket ?!o. 50-275 & 77 Beale Streat Docket t{o. 50-323 p& San Francisco, California 94105 F N ... n' W. p? PACIFIC GA$ AND ELECTRIC COMPAllY .:.i.y j :p:' i J..' [9, pd: NUCLEAR PLAllT. 01ABLO CAUYOH SITE

  • j

@d VALYE Wd.L THICKNESS IEASUEEIENT ON j . w :. 1 r$. REACTOR C00LMit' BOUf!DnY 10" SWING CHECK VALVES.10-C48I ' s. P '.2. - % l k:p 6.r - 1 D1-~ This is in response to your request for evaluation of the reactor coolant-i j 'lm boundry check valves for which U.T. measurements tic revealed some Doirits ~ J. l Sj. J. is based on the requircaents of ASi1E Boiler and Pressure Yessel Code,

,,,@/.,

$,j of thickness less than the recuired mirrimum uall. The following evaluation ... ' ' / 'J r Section 111.19/.I ana trie.rmtaranceo AEC letter.. 1 b.l

  • The pressure wall thickness of the 10" swirig check valve body have been 3[..g t

.g ' .'[ j Q reported as having local regions below the minimum required AS!!E Botier e.',gi j 4 and Pressure Vessel Code, Section III, paragraph HB-3511, pemits local J:m t variation in wall thickness and the referenc.cd AECJetter limits the ..$' ".M' i t' W variation.t.cr 90% of minicum wall required provided sufficient strength can s f be demonstrated with. actual mechanical properties.- 573 ';T.., b .ch324.. L 3 ii The AS'4E Boiler and Pressure Yessel Code - Section Ill, paragraph 3213.10 '" S:. -l.h i '!CR.' E 'T'{y N stipulates that a stressed region may be c6nsWred local if the distance of the discentinuity does not extend in the meridional direction more than O'JU.. Os,.'Tt and if it is not closer in the meridional direction than 2.59Ti 7:1-5\\ M t's another' region. It has been calculated that the local. region may extend t' 7.Cl b g,p.. 2.175 inches in the otridiensi diiettion, honaver, no tm local regions E 9 ..,,2.;.' jl may be closerg n the meridional direction than 10.875 fnches. J i ,,3 ,,4 m [ Valve Location No. 24355-3 {10-C48Z - Darling Valve S/N 94-12892-55)I "7. h l M1 I.' ' .. Ai> f M. The valve is reported to have a local region extending 1.22 inches in'the

' {i 19--

meridional direction and under minimum wall by 8.76%. The actual mechanical areuv, O 59*..lgL13.1% while tp .)- p u properties shot that the te ny X <tn Q - A TTk.umEvr 45 2;.

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[ ~ c i [ .q y .l l yield strength is gr. enter by 18.0% than the required minicum mochinical 'I Since the region is less than allor:cd by [ . properties of A571i A-351-CFD. .L Code and the actual rt.sterial propertics are sufficient to compensatt for. .j T.$j i* the wall variation the valve is considerpd acceptable. i- /.O 2 y;q Valve location !!o'. 2-8955A (10-Ct,8Z - Darling Valve S/il 94-128g2 55); f ~ I i i sU ~ The valve is reported to have e local region extending 1.0 inches in the meridional direction and under minimum wall by '2.29:. The local regi.on b d located between two points which have been reported to creeed minimum warl A by 7.63% and 14.5%. The actual mechanical properties hsve been reviewed l .d

.which shows the tensile strength to be greater by 2.85% while the yield 2

W% . strength is. greater by 16.0; than that required by A5171 A351-CFa. The valve is therefore considered acceptable. M j up Yalve Location !!o. 2 8943-A (10-CCSZ - Darling Yalve 94-12892-57) t,i l a

  • )

5 The valve is reported to have a local region extending 1.5 inches in the eridional direction and under minimum wall by 4.555. The actual tensile $h strength is reported as 76200. psi which is B.35 greater than the minimum l W m .M. of 70,000 psi as required by ASTil A351-CF8. The actual yield strength is r i p?[ reported as 33,600 psi which is 11.20% greater' than the minimum of 30,000 psi as required by the AS111 A351-CFB. Therefore, since the local region I m.; - is less than pemitted by code, the minimum Vall thickness is greater than "Fc. - 90: of the required minimum wall and sufficient strensth is avaticeie j O' as demonstra'ted by'the actual mechanical preparties the valve is considered-g q ,1 i pp acceptable. t [ 4 U'- If there are any questions, please do not hesitate to contact us at your - (} . ff - D', convenience. Qi . Very tru17 yours, u ' i.. ' [ n.

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f WESTIllGHOUSE E'.ECTRIC CORPORATIO!! ^ M _ w L,)s, .( ~ *

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v.. sm fa Engineer F. K. a .i Hydraulic Equipment

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g! ~* y9,j !.~: - p., g c-v Approved: ?q J. W. Dorrycott. Project llanager .t jQ - g t y D. V. Kelly 6L 5A d R. L. Hellers 1L jj-V,, San Francisco .t I

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,j ?.[ :l l [i., 79., \\ ,,, g 5.c. 7 y y es.@... .a ^ q M 4j INTEROFFICE CORRESPONDENCE c.A M,m. ,3 3 DATE September 15, 1982 6.a F, 37 to Internal Audit #101, AARf1 FILE Mfl in FROM Internal Auditor, Harold Hudson .4 [Y SUBJECT Conference to Formulate a Revised Response to AAR#1 (NDE Procedures without $j Procedure Qualification Records) s hN'. A conference was held on 9-14-82 to formulate a revised response for M Corrective Action to AARf1 finding that six NDE Procedures did not have y procedure qualification records. Conference was attended by H. Karner, d QA/QC Manager; P. Dawson, NDE Leadman; and H. Hudson, Internal Auditor. D g.d The following action was agreed on to implement Corrective Action to the audit findings: 'di 1. ESD 234./ t-A. The NDE Leadman would perform a qualification test by the end of the week (9-17-82) and upon satisfactory u' completion of the test a procedure qualification record would be initiated. st / 2. ESD 241 t2 V,hj A. A Discrepancy Report would be sent to PG&E identifying J that there is no PQR for the procedure and that the UT examination of the yoke rods was performed prior to LSD CJ 241 being issued by Pullman (M.W. Kellogg) and approved T.d for implementation by PG&E.

a t,

M B. It was identified to the QA/QC Manager during the conference [c that the UT examination of the yoke rods was performed prior ] to ESD 241 being issued by M.W. Kellogg and approved by PG&E. There is a PG&E Field Change Order, dated.11-14-73, directing N;i M.W. Kellogg to furnish labor and equipment to Ultrasonic i 3 inspect the Unit #1 yoke rods per the Dresser Instruction N

  1. SP-52-166 and a PG&E memo signed by J. Sale dated 3-27-73.

Q The work was performed between 12-17-73 and 12-20-73 per the kd Ultrasonic Status Reports. ESD 241 - Ultrasonic Examination ..i{ of Safety Valve Yoke Rods was issued bv M.W. Kellogg on 12-26-73 ,ej and approved for construction by PG&E on 2-12-74. The Report .y of Ultrasonic Examination used to describe the equipment and procedure used references both Dresser Procedure #SP-52-166 and ESD 241. I s

& a gj f M M M M M M ; F 5 9 R Y M f $ ${y M 5 M $ 2 5i 33 M Q M M M y; d L M M

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- ~ - - .~ n ~-. ~ i ~ 4.'..fC i: h @ $ f..Y*. ,4 g . E.L. #pr-qfg erc. ) y a N S 2:'.&_ S d d Inte,rnal Audit #101, AARf1 FILE o,1c September 15, 1982 l '3 to: g Vi suencTi Conference to Formulate a Revised Response to AAR#1 (NDE Procedures without ,j Procedure Qualification Records) m PAGE NO. 2 Ab. f, ; Y C. There are some differences between ESD 241, Dresser Procedure 'j

  1. SP-52-166, PG&E memo by S. Sale and the documentation of test results.

A

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1) The " Report of Ultrasonic Examination" used to document the l

description of equipment and procedure used cnd the results h>/g 3., of the examination is not a form referenced in ESD 241.18. It does no,t include the following required information. rjo M a) It does not include the surface or surfaces from f.lj which the test shall be performed as required by d ESD 241.15.3.g and Dresser #SP-52-166, paragraph

pg 21.3.g.

h b) It does not include a description of calibration H block (size, material, basic calibration reflectors) N and calibration method as required by ESD 241.15.3.1 j and Dresser #SP-52-166, paragraph 21.3.1. 10

2) The Examination Report, Appendix A, F-66, referenced in ESD

,;) 241.15.3 and 18.1 is not used to record required information. hrd

3) PG&E memo by J. Sale states that the parts of the Dresse;r

'4 Procedure to be used are those parts'that refer to " Bolts and Studs (Greater than 2 inch diameter up to 4 inch diameter)." i i a) The Dresser Instruction #SP-52-166, paragraph 12.4 J used to determine the reference point for sensitivity l h is not the same as ESD 241.11.4. i b) The Dresser Instruction #SP-52-166, paragraph 17.1 l which established the acceptance criteria is different m W from the criteria of ESD 241.11.6 and 11.7 used to report questionable items to PG&E. l '1 l

4) PG&E memo by. Sale indicates that "in addition to the UT l

MC inspection, a ack up inspection should be performed with the i, d dye penetrant technique to check the yoke rod ends for indica-N.h tions of cracking that might extend into the threaded area of @9 the yoke rods." The Ultrasonic Status Reports indicate that no dye penetrant inspections were performed. ESD 241.17.1 does A not agree with the requirements of the PG&E memo. ESD 241.17.1 3 states " Liquid Penetrant or Magnetic Particle will be used on I k::a rods which are suspected of containing discontinuities which D may extend into threaded areas or to support areas where UT 01 tests indicate discontinuities with lengths in excess of 1" j long". ..n

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. an.W.ij M,tuliw @ pg % ;a.Q..g,.a... M.31 a.. ~ m..s.u w.b, Q Min M
tTQ.M..a!?. M...y.Qyis@u.sW K

ik Q , n..< u. w.s. t ... a ., m.a . u~ y*,. : 5w,,.e,,,. - " :": ~ ~ - ;'n t... -;~~:U. K. c -1 rmm r.w y :., 9.. ..a .........fg.g q . :) vo, Internal A0dit #101, AARf1 FILE em September 15, 1982

~

suesteti Conference to Formulate a Revised Response to AAR#1 (NDE Procedures without ..j Procedure Qualification Records) p y.k ~'. ('; j PAG [ NO. 3 };,* : ~ 'ni V' f 3. ESD 246 and ESD 247 f51 . !.fTS i A. NDE Leadman would perform following'-investigations:

1) Check with Williamsport and Paramount to see if they have p/y
g. t,N a PQR for these type MT procedures.

wa.j

2) Check records of Steam Generator Nozzle work to determine t@

2d if these procedures were used. @d l

3) Check MT Daily Reports to determine if these procedures were used.

,,;,1a B. I.g; Internal Auditor checked B31.7 code and found PQR's are required for NDE procedures. 9y C. After investigation is completed, a decision as to Corrective 1 Action would be made. . 1 4. ESD 270 '/ [N] A. ESD 270 would have incorporated into its procedure the procedure qualifications records of ESD 210. The NDE Leadman has stated '.e;. the two procedures are similar and can share the same PQR. d B. This Corrective Action has already been implemented.

9

~ j 5. ESD 236 (Reference Interoffice Correspondence of 7-28-82) ($q i A. The procedure shall be withdrawn from use. . y, i '.tj B. The QA/QC Manager stated that within the procedure there is a pij means to demonstrate the qualification of the procedure and i.: again stated he felt no PQR required. .x, j uh bcLAcN M w -a [40 6 Harold Hudson Internal Auditor si q;d Diablo Canyon Nuclear Plant ,ogj HH/dd A I lj.1 .,n

q i

79 i f:l e. 4 2 I*'

V ": NWBWNQ@r;W6M#AMMMM,BFR.We% M d@iMyr@MMW,k ,' ?: /(. H. GET~.$. ~ fj&dhtol 'l m mpm_ N FORP F-126 rev. 7/6/79 i ~ ~ ~ ^ ~~ /e/f1 5' re v., 1/ 3/ 79 DIA3LO CA'iYOM ;1CCCt.R rit / rev. 3/29/79 f(e., PO'7ER PIKTT ,k,, 4 ' /,. ' ;, PAGZ l OF 1 .. : w... .c ,. g m.., M.= d [.'.b.l. di C g,] QUALITY AUDIT SMmRY REPOP.T J W 4 $:n AUDIT '70.: 101 FIC NO.* I \\t' SIT SATE 1-18-82 'M I ACTIVITY AUDITED l 9'i DISTRISLTIO.4 ? Organization-TI TLr., 4.rI Sii 1 APPLICA3LI DOCUv5NT3-I PG&E 8833XR, 8711 VICE PRESID M QA E.F. Gervin N JTRECTOR OF QA A.A. Eck KM 10CFR50BT. M -1. M 16. M -2 TEST 3ENT CONSTR. MGR.

7. Ryan i

$p l ?UPPosr.; OF AUDIT l $UPEL ARRA AUDIT 1PD L Karner. R. me Pd L:T.I. L Sanderson ] $g Scheduled rrtin oA/QC MANAr.n H. 1ramer l 'u:1.T.R l 7.?. MECH. CONSTR. P.L. Evana PGAR .T. Annnnn d M d).j A. A. R. / \\ t.' CODE a SUylmRY ./.:t N !*f. / f? f lf) / {),7 ',I / ORGANIZATION I ? (,,, / N This audit was condheted to detemine if NDE. Procedures were qualified. ] s ffj and if the Field Organization Chart reflected,the.1FP 4 Organization Chart. i g ' V w Twenty-one NDE Procedures were audited Eleven NDE Procedures had M " Procedure Qualification Records" located in the Master Job File. Three NDE h Procedures were provided to Pullman.by PG&E and'the qualification records C are maintained by PG&E. Two NDE Procedures are used to measure material 6] 1 1 thickness and do not require procedure qualification? Five NDE Procedures do not have evidence that the special processes are accomplished using quali y fled procedures or that qualification records were maintained to document Q and assure quality of material and work. .g Pa.QA/0L Ma 9 e K m - {gj

  • NM The Field QA/QC Organization Chart listed all job functions listed on 2

2 the KFP-1 Organization Chart. The Field Chart does not have a Key explainin 4~ the reporting relationships between job functions. The Field Chart does not L'.h; accurately show the reporting relationship of the QA Manager to the Resident 1 Construction Manager and to the Director of 4.tality Assurance. l v i i 1 3 The Field Production / Engineering Organization Chart listed all job p{ functions except one that was listed on the KFP-1 Organization Chart. The job function of " Material Cont." was noc listed on the Field Chart. The Fie i 2 3 Chart had a key explaining the reporting relationships between job functions $, }1 but the Key is different from the KFP-1 Chart Key and does not include the - l same type information. The reporting relationships of Field.tgineers (Rup-M C ture Restraint, Piping, Hangers and Snubbers) and the Buyer do not agree vit y the KFP-1 Chart. '3 EE5?OJ5I3LI CONTACT: H. KARNER P. EPA?2.D BY: H. HUDSON i TITLI: QA/QC MANAGER TITU : INmNAL AUDTTOR O '.'"' : 1-19-8' l Et

f W Q jf 4/8 Ef $ Q { f M L, b rj { t M @ y.j {:fj pj'.% b. T P M Q j g,? ? ^ < % ; ,,, t a : q {.; *** M Q Q. ,. FORM F-125 rsv. 7/6/7@ }) re v. 3/30/79 l DIABLO CANYON PAG': 1 OF 3 ,/ NUCI. EAR POWER PLANT w ,:b AUDIT ACTION REQUEST +-- ~ / l. FILE *10 : I AUDIT NO.: 101 A.A.R. J0.f." 1 l OBSERVATION CODE: 1 ACTIVITY AUDITED: NDE Procedures b.6 [,h AUDIT DATE: 1-18-82 }f REFERENCE DOCUME:TTS: P0&E 8711. PG&E 88'4't75 rFD 1 9 14 - mn PM mn %7 j I 9.. i. 7.y FINDING: f There are no formal procedure qualification records for the following NDE pro edures:

y,y Continued on Page 2.

FI'qDI:Tf, BY: H. Hudson DATE: ~4-22-82 ACT D 3Y: 7$ I/fv .) SUSPECT':D CAUSE : <f $ ' / N Finding fl - Per the QA/QC Manager the requirements of ESD 234.9. a4F 9.2.A..sfablish the qualification of this procedure. Paragraph 9.1 states tha piliogg%tandardsof .d Configuration to represent t,he weld under test with known def cts Vill *bp'used as [,"i reference. Firure 1. 2 and ~4._ Continued on Pare 3i

CCO!!CMDED CORICCTIVE ACTZON:

\\/ Lj.0 "2 1. NDE procedures be qualified acid these qualification records be Inaintained; or, ( d.elete those NDE procedures which ranagement decides are not anplicable to the !.) $& h M % %R &gpg,,.%*dj( *e4 - (((.j Continued on Page 3%.Lt, gbsite. W W JD.. a c a.A tu.a.A g L A i4 6, d E pw c hf,9doA. E v/9AW'UE DATE: =_.I., ue $j CORRE97)TVE ACTIO'1 YA2 N: **/*WG/G Hd' /dMG- /%*Mc*'#= 0 Mf & d!"N 'I N y--~0 ' Y f 0 l' *

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RSnveyWWFinw:n%%2@fww;M94%W6@.?G2%tM%fMM%U% M w g W ~ m,J' Pullman Power Productss W FORM Fw125 re'v. 7/.G/70. .c- ? '*.* ro v. 3/30/ 79 f 7] i DIADLO CANYON Eh HUCLEAR POWER PLANT PACE 2 OF-3 b<,: p ' fyhh AUDIT ACTION Pr.OUEST . g, .x ,,v FILE NO., I AUDIT NO.: 101 A.A.R. NO. ; i J L' 1 ODSERVATION CODE: 1 ACTIVITY AUDITED: NDE Procednves k. d " AUDIT,DATE: 1-18-82 p k 'REFERCNCE DOCUMENTS: PU&E 8711, PG&E 8833IR, IFP-1,2,16. ESD 246. ESD 247 n, "M

  1. g.

FINDING: CONTINUED FROM PAGE 1 ' pi 1. ESD 234 - Ultrasonic Inspection Groove Welds AWS-Dl.069, ASME Section VIII and Section i J V. (Noncompliance to PG&E 8833XR Section 3.4.128 and 4.1211). p].K. p 2. ESD 241 - Ultrasonic hamination of Safety Yoke Rods on 3707 RAI6-21 Safety Valves (Noncompliance PG&E 8711 Section 4.3.23 and 3.29 or PG&E 8833XR Section 3.4.128 and g 4.1211, IFP-1.14.5, IFP-2.3 and 2.4, IFP-16.5.T.) 3 ESD 246 - Magnetic Particle Procedure / Dry / Continuous Coil B31.7. (Noncompliance to PG&E hq 8711 Section 4.3.23 and 3.29, IFP-1.14.5, IFP-2.3 and 2.4, KFP-16.5.T, ESD 246.13.2). @,';j] 4. ESD 247 - Magnetic Particle Procedure / Dry / Continuous' Coil B31.1, (Noncomoliance to PG&E g;. 8711 Section 4.3 23 and 3.29, ESD 247.13.2.) W 5. Liquid Penetrant hamination Procedure (Noncompliance to PG&E 8833XR Section 3.4.128 and g q!j 4.1211.) S5S - 2 /o " ]f Finding 11 - ESD 234 and Finding 12 - ESD 241, have establishe.' in their procedures a means to demonstrate the qualification of.the" procedures each time the procedure is used (see Q Suspected Cause) but there is no formal documentation of the qualification. Finding #5 - ESD 270 uses similar penetrant materials and armaination methods as ESD 210 - A Liquid Penetrant Procedure (ANSI B31 7).. ESD 210 has procedure qualifications records p,j, which demorstrate the ability to detect the specified discontinuities, p. UP b i \\ 3. f/ \\ 3 e.: .i @) / A/ f h"l S'f' M $.d j Mi / FOLLCf.f UP: ACTIVITY CO!TLIES WIT 11 APPROVED CORRECTIVE ACTION $1 IF NO - PLEASE Em> LAIN: YES NO .J. Z) y, .g DY: DATE: ..d A.A.R. CLOSED DY: ~ DATE: it.1 1 $l APPROVCD BY: DATE: q L. 8:d .a.- - - - - -, = c== ==== =

=====---= - -==== - -

g; iEWyP%Mf; 49.@943'gsfgeNfkiWWh96M@-d@@.QiQilyNMM@GQg& e. Pullmari Power Products .?pnM h155 revo 7/G/70 c-rov. 3/30/79 f, %'a P DIADLO CANYON PACE 3 OF 3 NUCLEAR POL 1ER PLANT rw y iC.D AUDIT ACTION REQUEST . x,.. l %,] it AQ PILS NO. r AUDIT NO.: 101 A. A. R. NO. i' 1 .o S 9,.} OBSERVATIOM CODE: 1 ACTIVITY AUDITED: NDE Procedure @e 'AU.DIT DATE: 1-18-82 REFERCNCE DOCUMENTS: PG&E 8711, PG&E 8833XR, IFP-1,2,16, ESD 246 and ESD 257 .ll$ d5 SUSPECTED CAUSE CONTDfUED: fn Finding #1 continued - A radiograph of each standard shall be on file for proof of defects". 9/ M Paragraph 9.2 states "the operator will check his test unit to this standard and show known

7 defect".

yJ vfj Finding #2 - Per the QA/QC Manager the requirements of ESD 241.11.4 establishes the qualifi- , cation of the procedure. Paragraph 11.4 states "the awa= 4ation.shall be conducted with a g;* d frequency that is capable of producing a minimum of 50 to a maxista of 75% of full scale reflection from the provided drilled hole in the reference speciment (MWK 001_ Sketch #1). ', d Paragraph 13.1 states " reference specimen 4 hall be of same nominal diameter, thickness and composition and heat treated condition as the product being examined. The separation between standard defects placed in the same reference specimen shall not be less than twice the length of the sensing unit of the inspection equipment". 3gj Finding #3 & 4 - ESD 246 and.ESD 247 - Unknown. 7.hd Finding #5 - ESD 270 - Unknown. MN %'i l i qt kdd RECOMMENDED CORRECTIVE ACTION: 2. Request Williamsport office to check if they have P.Q.R.'s for ESD 246 and ESD 247, if @A jl they do, to forward copies to the job site. d 3 Per the QA/QC Manager a copy of ESD 210 Procedure Qualification Record b iled'q1th i ESD 270 based on the similarities of tho' procedures. d?- N sg y i 4* y,f 4: : ,A C

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= __. $'l DIABLO CANYON 3 ) NUCLEAR POWER PLANT PA73 L O? 2 g 4 M.. AUDIT ACTION REQUEST

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l )b. _ _( / m.. l r r4 FILE '10. I AUDIT NO.: 101 A. A. P. 3 0. t 2 phj k0 OBSERVATION CODE: 1&2 ACTIVITY AUDITCD: QA/QC Field Orranization Chart 9,3 AUDIT DATE: 1-18-82 s."7] F REFEENCE DOCUMENTS: KFP-1 &., )l FINDING: QA/QC Field Organisation Chart M 1. The Field Chart does not have a Key explaining the reporting relationships between job functions. This is an itsa of concern requiring supervisory attention. N 2. The Field QA/QC Chart does not correctly show the repcrting relationship of the QA T Manager. Continued on page 2. ).% FINDIMG BY: H. Hudson DATO: 1-19-82 AC*UD 3Y:,[J b w Dr."'T :J/bd 4.,- I dt' SUSPECT 3D CAUSE: 'd MI 1 & 2. Unknown j IUR lilIORWJiGH W.{ ed ) y ICCO rC: DED CORICCTIVE ACTION: ~~~ Q1 Revise the QA/QC Organization Chart to incorporate the KFP-1 Key for explaining the Wj p reporting relationship between job functions and show.the correct relationships of the M..; % QA Manager. h) CUE DAT3: 3'M 8h N. C "5f ^ ^CTIy':"'jMM A Mr JJ A a_. V ^ ^~ n(- ey m& g=.. J-m r o . hj hL-APPROVED h b 'M'bb TAKEN BY: my N2 3TOPG TO P'C1.CNT "?'CURIC'tC3 : N W1--1l .h 0- ^ fy'1 d. _ _ _ 93a ~, ar 1 r-- //g t, APPROVE BY: b e5 TAKE Ye w s -i N FOLLOW UP: ACTIVITY COMPLIfS WITH APPS.OVED CORP.'!CTItC ACTI k IF NO - PLEASE EITLAIN:

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OF 2 W NUCLEAR POWER PLANT ) hk AUDIT ACTION RCOUEST Q ~ !;]. 1'ILE NO. : I AUDIT NO. 101 A.A.R. NO. ! 2 .[j OBSERVATION CODE s 1&2 ACTIVITY AUDITED: QA/QC Field Organization Chart i j Auu1T DATE: 1-18-82 qj RcFeRcNc= DOConenTS: UP 5 N i1 FINDING: Continued. {.! 2. Continued. I The chart shows the QA Manager under the " Administrative" control (as defined by the IFP-1 Chart Key)of the Director of Quality Assurance, Williamsport, PA., and in a " Communication" J.f role with the Resident Construction Manager. This does not comply with the EP-1 Chart and 4 KFP-1.14.2 which calls for the QA/QC Manager to be under the "AMMstrative" control of the Resident Construction Manager and reporting to the Director of Quality Assurance on all } " Technical and Functional" matters relating to Quality Assurance. 9 FOR IU." Tl '.f.! n. w. n.-- a u Qij .o .G

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  • g FILE-10.:

I AUDIT NO.: 101 A.A.P. 30.t 3 ?h /.? OBSERVATION CODE: 1&2 ACTIVITY AUDIT::D: Production /Enrin[erine Orraqi.gg.. tion Chart Wi AUDIT DATE: 1-18-82 3. GF' REFERENCE DOCUMENTS: 'KFP-1 ed !;y Qj FINDING: Production / Engineering Organization Chart N 1. The Field Organization Chart has a Key explaining the reporting relationships between job functions but the Key is different from the EFP-1 Chart Key and does not include the gj same type of information. The Field Chart Key shows reporting relationships of " Direct ...M Control" and " Engineering Reporting Function". 71 Continued on page 2. N?d FI1DI:1G BY: H. Hudson DATE: 1-19-82 AC:P D 3Y: #& DA"'E : 3-4 82.; e ;) s p.-g SUSPECT 3D CAUSE: ?y 1,2,3,4. Unknown . l;j f0R ""' 4

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RECO?rc:NDED CORRECTIVE ACTION: r;j The Field Organization Chart be revised to reflect the KFP-1 Organization Chart. W C j 2b'b k ~ .a DUE DATE: e COR.*ECTIVE ACTIO*! T.*.KEM: 5;f i, '2., Q f4-The t ~/ at.a o RGAd/M md CMAM 7" N4 9ttW f A Riw$dO 70 R.& A&c 7" 7" M k F"A / 0/C6.AA/ at^'/70d [NU C1 (/I/-I-_ TAKEN BY: I2 N R' \\ 8

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DIADLO CANYON A PACE 2 OF 2 Y! NUCLEAR POWER PLANT V .g_ ? 'C.'). AUDIT ACTION RT:OtIEST a .y n.g Nl PILE NO.* I AUDIT NO.: 101 A. A. R. N O. :., 3 af M,5 ODSERVATION CODE: 1&2 ACTIVITY AUDITED: Production / Engineering Organiza-v Z tion Chart H,.; ^AU.DIT DATE: 1-18-82 q s. 6.b REFERCNCE DOCU)ENTS,a EFP-1 Yk FINDING: Continued. h This does not comply with the EFP-1 Chart Key which shows "Administe=*4va", " Technical and T Functional" and " Communication" reporting relationships. p.g Inis is an item of concern requiring supervisory attention. l, / 4, f k')l l 2. The Field Organisation Chart shows Field Engineers e Restraints, Piping, Hangers, 4 :. and Snubbers) as being under the " Direct Control" of e Assistant Construction Superinten-- f dents and having a " Engineering Reporting Funcnon" to the Chief Field Engineer. This does'

4. -

not comply with the EFP-1 Organization Chart which shows Field Engineers reporting "Maini-A stratively" to the Chief Field Engineer and having a " Communications" mle with the Construc ]l tion Superintendent. This is a noncompliance to IFP-1 Organization Chart, and EFP-1.14.7 U'j-3 The Field Organization Chart shows the er Purchasing) as being under the " Direct f. Control" of the Office Manager. This does no comply with the EFP-1 Organization Chart g; which shows the Buyer reporting " Ad=4n4 =tratiiely" to theJtesident Construction Manager and i.J having a " Communications" 'mle with the Chief Field Engineer. This is a noncompliance to the /, / 4, / T. [.jj IFP-1 Organization Chart. / 4. The Field Organisation Chart does not show a job function ofn+avini &n2" - The Field %j Chart does not comply with the IFP-1 Organisation Chart which shows a job function of I I.. g) " Material Cont." reporting " Administratively" to the Chief Field Engineer. This is a non-sg comoliance to IFP-1 Organization Chart. N m.4 &] pu. f' rm<re4 fpys t rJ !$7 Y. I. ) 19? }M Comm uN ICA7/* N 2Y 21), F0il INFGRMnilon fr' Did.Y @8 H f:0 FOLLON UP: ACTIVITY COMPLIES WITH APPRO' ::D CORRECTIVE ACTION IF NO - PLEASE EXPLAIN: YES NO q n h. HYt DATE: A. A.R. CLO.9ED DY: DATE: b APPROVED BY: DATE : 9 .? 1 f:p'l y [_t=-- -===== . - =, - - - _. = - _ - =. _ _ _ _ -

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