ML20234F354

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Partially deleted,marked-up Affidavit Re Widespread QC & QA Deficiencies Existing at Pullman Power Products Co at Plant. Related Documents to FOIA Request Encl
ML20234F354
Person / Time
Site: Diablo Canyon  Pacific Gas & Electric icon.png
Issue date: 01/12/1984
From:
GOVERNMENT ACCOUNTABILITY PROJECT, PULLMAN POWER PRODUCTS CORP. (FORMERLY PULLMAN, INC.)
To:
Shared Package
ML20234F270 List:
References
FOIA-84-743 NUDOCS 8709230099
Download: ML20234F354 (160)


Text

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o AFFIDAVIT e

"y n.an e is I am giving this affidavit freely, without threats or inducements, to John Clewett, who has identified himself to me as a lawyer with the Government Accountability Project (CAP) of the Institute for Policy Studies (IPS) in Washington D.C. Iam%%ingthisstatementbecauseIbelievethereare widespread cuality control / quality assurance (QC/QA) deficiencies in the QC/QA the Diablo l Progran as it now exists at the Pu11 nan Power Products Company at Canyon ?Iuelear Power Plant, and because this raises serious questions about the overall level of quality required by the owner of the plant, ?acific 3as and Electri: (?GE) and by the 3echtel Company. I am concerned that this QA/QC brea%dewn may affect the public health and safety if the plant is allowed to go i

critical.

an currently enployed by the P211 nan ? wer Freducts Corporation. or.e of l 1

?31E's prinart subcontractors, as a QC Insrector, I.evel II .-

I have worked fcr ,

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l "y concerns about the quality control program at Diablo Canyon fall into several nain categories, including inadequate training, lack of supper of E inspectors by QC management, actual threats and intimidation of QC inspectcrs by construction persernel and by our own management, and reprisals agains these Q: inspectors who follow the code too 21csely.

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One of the biggest threats to effective QC work at Pullman Power Products is the fact that inspectors know that they can be fired for doing their ..

job too well. One of the most blatant examples of this happened recently, to a very knowledgeable, very competent, and very conscientious QC inspector named 8

Steve Lockert. Management claims that be was fired for being out of his work area, which is a completely ridiculous claim - no one is ever fired for being out of their area. Everybody in the QC Department knows the real reason Steve was i

fired: he had found a serious QC deficiency, and insisted on writing it up.

Steve was a graduate from Cal Poly in either Welding Technology or Welding l l

Engineering, and was consistently finding discrepancies in our welding procedures, weld rod material control, and other areas, where the American Welding Society (AWS) and American Society of Mechanical Engineering (ASMI) codes had been j l

violated.

The QC/QA management didn't like the fact that Steve was so interested in the l technical details of welding and was finding so many discrepancies. They would  !

prefer that you walk around with " blinders" on, so that if you're inspecting one l item you ignore an" thing that you discover wrong with another structure or piece of nachinery right next to it.

1 In any event, the thing that got Steve fired was an incident with the welding test booth.

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' In .early December of 1933, Steve approached me and discussed a situation he had noticed while workfng in the area 10 fabrication shop on a temporary basis.

Steve had been assigned to inspect welding of rupture restraint parts that were being fabricated prior to assen.J_y in the plant.

l Adjacent to the fab shop area is the welding test booth, where the welder qualifications take place. A QC inspector named had been assigned

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to monitor the welder qualification testing, but resigned on or about ,

December 7,1983 and for c period of three or four days no other inspector was assigned to take his place, the lead inspector responsible for the  ;

- l testing, did not have his desk in the test booth area and was present there only I on an occasional basis, to sign certifications and spot check the work. Steve q l

noticed that during that time welder qualification tests were being conducted without a QC inspector present, in violation of Pullman's regulations, their l

" Engineering Standards - Diablo" (ESDs).

Steve then asked the production foreman in charge of the testing who the responsible QC inspector was. He was told by the foreman that the inspector had quit and that another inspector had not yet been assigned to oversee the testing ,

but that was inspecting the tests on a randon basis. Thus, during this time, the necessary QC tests, such as bend tests, were being conducted by the production forenan rather than by a QC inspector. Steve mentioned this situation to me and we concluded that a deficient condition apparently existed. Without QC l presence during the testing, there is no way to tell if the test has been conduc-ted with the test weld in the proper position, or whether other irregularities have taken place.

Shortly thereafter, Steve told me he had wirtten a "DCN" (a Discrepant Condition Notice, A Pullman in-house QC report) of this deficiency. After submit-ting it. Steve told me that the DCN was not received well at all by his supervisors, in particular Harold Karner, the Pullman QA/QC Manager. Although they did assign a QC person to the test booth after that, there was a considerable reluctance to resolve the deficient testing that had been done in the three or four days when there was no effective QC coverage. To properly resolve the problem, the welders who were tested on those days (the daily number might vary from one or two welders to 12 to

4 15 welders) should have been retested under proper QC control. mm, 4.

j During the next several days, the facts of this situation became common  ;

knowledE 6 amont the other inspectors at Pullman and much discussion took place.

W All of the inspectors that I talked to agreed with Steve that a deficient conditien did occur and that he had justification for writing a DCN. There was also a con-I sensus of opinion that this particular DON would cause considerable embarrassment J l

to and to Harold Karner, the Pullman QA/QC Manager.

1 I spoke to several lead QC inspectors regarding the situation at that time and one of them, teld me that Steve was probably going to be fired.

I asked why and he had no answer.

Two days later, on December 15, 1933, I learned that Steve had been fired, supposedly because he was out of his work area. This seemed absurd to me because it had never happened before that an inspector had even been accused of being out of an assigned work area. As inspectors for Pullman, our work area can encompass the entire project, so it would be almost impossible to be out of one's work area. .

During the next week or so. I had many conversations with other inspectors and all of then indicated that they felt Steve had been terminated because of his DCN regardirig the test booth incident. I also have concluded that that is the only logical explanation for Steve's termination.

Interestingly, the Nuclear Regulatory Commission (NRC) recently held some  ;

interviews with five QC inspectors who they apparently randomly selected, and asked them if they had any prcblems with the way their DCN's were handled by QC management. All five of these pecple told me that these interviews were cenducted in the presence of A

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Frank Lyautey, Pullman's Assistant QA/QC Manager (Harold Karner's second in command). I was surprised that the NRC would want to conduct these ,1nterviews in 1

a fashion that would be likely to intimidate the witness, with his boss sitting

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there,nand bias the results toward saying nothing improper hai happened.

in One of the QC inspectors told me that his interview with the NRC and Frank Lyautey, Steve Lockert's name came up (the NBC had asked to see Steve's DCN log also). This inspector told me that Frank Lyautey told the NRC that Steve had quit. It amases me that Mr. Lyautey would say this, because he was involved in the incidents surrounding Steve's firing, and could not possibly have failed to know that Steve had been fired.

Steve's firing was not the first time this sort of thing occurred. In September of 1983, QC inspector was fired because he had insisted )

on pursuing a DCN on a particular condition, even after his lead man had said not to push it. The nominal reason for his firing was excessive absenteeism, but l

Pu11 nan did not follow their own warning procedures on this. The procedure is to get a warning letter after the first infraction, then to be suspended for three i i

days without pay after the second infraction, then to be fired after the third.

Roger had gotten a warning letter (like about half of the QC inspectors have -

after months of working 12 hours1.388889e-4 days <br />0.00333 hours <br />1.984127e-5 weeks <br />4.566e-6 months <br /> a day, six or seven days a week, people burn out, and occasionally call in sick), but had never been suspended f or three days without I pay. , Pullman skipped that and just fired him.

Sometimes QC inspectors have quit because of intimidation by the craft workers.

who I worked with in the spring of 1933, followed the book to the letter, and was very meticulous in his work. He generated a lot of resentment among the craft workers becuase of this, and one day he told me that he had been

6 physically threatened by a pipefitter and a welder. Later, the tires of his van ,j l

were slashed in the parking lot. He asked Harold Karner to do something to j i

protec.t him, and Karner said there was nothing he could do, so quit.

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I also have experienced attempted intimidation by the production workers whose work we inspect. In one incident, a production foreman, Rich Babineaux, told There are ways short of firing that the QA/QC management can influence the work of the QC inspector. One important way is that all reporting of non-conformances goes through Harold Karner, the QA/QC Manager for Fullman. All of our reporting of non-confermances is done via the " Discrepant Condition Notice" (DCN), a Pullman in-house report. In order to submit a DCN, it must be signed by a lead man, and ucually by an engineer as well (the engineers are part of the Production Department).

Then "r. Karner reviews it. He can void DCN's (this is also done by lead men some-times, per oral communication from Mr. Karner), or take some other action, such as directing that actual rework be done, or sending it to PG&E for their disposition.

If a DCN is forwarded to P3&E, it is called a " Discrepancy Report" (DR) . Then, if PG&E decides to forward the DR to the Nuclear Regulatory Commission, it beccmes a "Non-Conformance Report" (NCR).

The fact that this paperwork all flows through Mr. Karner gives him a lot of leverage to determine how effectively we enforce QC en the production workers.

Unfortunately, Mr. Karner seems to be more concerned with scheduling than he should be. He has often said that it is our duty to " support the craft." Mr.

Karner takes a lot of suggestions from Pullman's Project Manager (this position

7 was held by John Ryan until last summer, and is now held by Paul Steiger) in terms er l'

of deadlines by which QC must finish its work. ..

-6 Similarly, when Mr. Karner's assistant, Frank Lyautey, gave merit raises to almost everyone in the fall of 1983, he bypassed a few individuals. One of the e

ones who didn't get a merit raise was Craig Measher, our Union Steward, a very ecmpetent and thorough worker. Craig told me thet when he asked Mr. Lyautey why he hadn't gotten a merit raise, Mr. Lyautey said that it was because the production foremen had complained that he was holding them up in their work, and not being

" cooperative" enough with the craft workers. From incidents like this, it is c1)) ear that Pullman's QA/QC department wants us to give the production workers the benefit of all possible doubts, perhaps in the belief that if QC finds too many problems with production, it might affect Pullman's contract with PG&E.

ges\ 'This attitude toward quality is not limited to Pullman, though, and is shared 1

by PG&E . There has for a long time been a problem with welds in structures supplied l

by vendors. These " shop welds" are often very poorly done, in a fashion where no QC Inspector could possibly accept the work if done on site. In particular, some of the earlier work supplied by Bostrom/Bergmen Co. and by American Bridge Co. is truly aboninable. Some of the welds are so ragged that they will tear your clothing if you get too close.

In response to a series of questions about this situation, PG&E sent a meno-randum in 1982 saying that we were not supposed to inspect shop welds at all.

The memo said that since the plant was "over-designed", welds that looked defective were not a problem, and had in fact already been accepted, and so we should ignore them. PG&E said we are not supposed to grind, weld, inspect or othervice be con-cerned with shop welds, without specific P3&E approval.

f This situation has caused some friction with the craft workers, who resent 1 l

being told by QC that they have to meet standards that are much higher than those '

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l 8 of the shop welds on a structure immediately next to the work they are doing.  !

i And the QC Inspectors feel as though we're expected to put on our "QC blinders" I a.

when we go out to inspect work, so we don't notice a non-conforming condition that we're not supposed to.

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O , SI also question how "over-designed" the plant is, based on an incident involving an ultrasonic test that the Magnaflux Corporation did about a year ago on some welding in Unit 1. From discussions with Magnaflux employees while the testing was occurring, I learned that approximately 90% of the welds were failing.

In response to that, Bechtel employees directed Magnaflux to change the " acceptance criteria" on which the welds were to be accepted or rejected. That drepped the

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failure rate to 604, after which Bechtel changed the acceptance criteria again, lowering the rejected welds to 107!. When they got it down to 10%, they took those l'

welds and put them into production to be fixed.

In my opinion, for QC to improve at Pullman, the focus on schedule rather than quality must change, QC inspectors shouldn't be bullied and retaliated agains' by either the production workers or the QA/QC management, and the managers at Pu11 nan and at PGE must become much more willing to be told about the actual l QA/QCproblemswesee. In addition, other changes need to be made, in training and in document control.

[ The selection and training process for QC Inspectors is very poor. Most newly-  !

_ hired QC Inspectors (roughly 2/3 to 3/h of them) have no previous experience in welding inspection. A new QC inspector is given a crash ecurse that takes about j a week. This course doesn't even cover how to write a DON. There are, however, i

some written materials that say how to prepare a DCN. On the other hand, we have I never been told, orally or in writing, about how to fill out a Non-Conformance Report (NCE), nor would I have any idea where to get a blank form for an NCR.

Until the NEC came out to interview people last week, I didn't even know, after i

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9 being a Pullman QC Inspector for that QC Inspectors had the right to prepare an NCR. .,

When training M given on some subject, it is done by handing the individual

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some written materials, and then having him sign a statement that he has read them.

Unfortunately, very often the individuals will sign these statements without havir4 read the materials very thoroughly. ]

Another major problem is document control. The idea behind building a nuclear power plant is that you design it first, and then build it to those specifications, l usirg controlled documents. But at Diablo Canyon they seem to be making up the j

rules as they go along. With the pipe supports, for example, there are more than I

80 pages of ESD's with various acceptance criteria, but then there are a whole series of totally uncontrolled memoranda that we get through Mr. Karner that tell us to disregard certain portions of the ESD's and work to different standards. And in addition, because the ESL's and the design drawirgs sometimes conflict, Fullman's ESD's specify that the design drawing takes precedence over the ESD's. But the design drawings themselves have many hand-drawn changes that used to be called

" Quick Fixes" and now are called " Design Tolerance Clarifications". These Quick i l

4 Fixes are done by a Field Engineer if there is a problem doing the work as it was originally designed. The Quick Fixes are very poorly controlled, are often voided or removed from the work packages we get. The idea behind the quick fixes, which have not been analy::ed before they are implemented, is that subsequent re-analysis of the whole stnicture will catch any problems that exist. I feel that the situation with the quick fixes is one of the worst aspects of the whole system at Diablo Canyon.

Another problem that I am personally aware of that has impact on document control is the control of the various stamps that must be stamped ente drawings 4

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t to show approvals. These are not systematically controlled for access. I once i

saw an abandoned desk that had a whole set of stamps lying on top of it, where j 2.

anyone could have used them to make a drawing look more official than it really was.- l I want to clarify that I am not making these statements because I an in any way anti-nuclear. I believe that nuclear power can be a viable source of energy if nuclear plants are built with strict compliance to QA/QC principles, and with a desire to do the job well. But with Diablo Canyon, being built the wy it is, I seriously doubt that it will ever be safe to operate, at least in i

theabsenceofacompleteinvestigationintotheQA/QCbreakdownthatnowexists I

at Diablo Canyon.

I have read the above 10-page affidavit, and it is true and correct to the best of my knowledge and belief.

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l Subscribed and sworn before me )

on thisM day of January, 1934 _

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l Task: Allegation #25 l .

ATS. No. RV 83A33 Characterization: Deficiencies in the use of Phillips' Red Head anchors by a site contractor (HPFoley).

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Initial Assessment of Significance: The potatially extensive use of achors, l

and the number of more general concerns.

expressed regarding this contractor, warrents evaluation of this allegation prior to exceeding 5% power.

Source: Contractor Employee (Confidential)'8/83 Approach to Resolution: egion V:

1. Review use of Red Head Anchors at Diablo Canyon, s(

l g including) historical IEB 79-02 and actions licensing analyses.(i.e. Response toej-#a f

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Interview craft /QC personnel (20 individuals.$

Inspect sample of anchors (100-200 anchors).

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a) R view aga st NRC re uirement nd Ind str St dards. i b) Req st addi onal info tion o audit c Deve p staff osition a action equi d.

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Status: Region V review in progress including examination of the licensee's technical evaluation in this area. Additional information has been I requested of the licensee.

I Review Lead: Region V Support: NRR (Review of Licensee's technical analysis).  ;

NRR-DE-MEB Support:

Estimated Resources: Region V: 5 man days  ;

NRR: 5 man days Estimated Completion: 12/9/83 Evaluations 1/27/83 Final Evaluation f01b'ik'lf) ' I -

r Task: Allegation or Concern No. 189

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ATS No.: RV-84-A-0025 BN No.:

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Characterization Magnaflux weld verification program accepted bad welds. FcirA T l)

I Assessment of Safety Significance j 1

The staff's assessment of this issue is that the allegation is a known issue 4

which has been responsibly handled in the past. )

i Staff Position l

This allegation is an issue which appears to be a restatement of concerns l identified in allegations 123 and 192. The issue of concern here does not appear to represent a new significant management or quality performance issue which has not been previously addressed. l I

Action Required t t*1 PY l This issue till be turned over to PG&E for ; w L. - ... The licensee will be l required to provide a written response to their findings and corrective actions.

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Task: Allegation or Concern No. 190 m

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ATS No.: RV-84-A-0025 BN No.:

Characterization Pipe support base plate installation doesn't define bearing surfaces.

Assessment of Safety Significance A face value assessment of this allegation indicates it is not of major significance in terms of public health and safety or management breakdown.

The staff considers the placement of steel shims underneath base plates to be well within the purvue of the mechanics who install :.he base plates.

Staff Position The issue of concern here does not appear to represent a new significant management or quality performance issue. Therefore, it will not be pursued j further by the NRC staff. l l

Action Required None 1

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f Task: Allegation or Concern No. 191 *

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ATS No.: RV-84-A-0025 BN No.:

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Characterization:

1 PGhEhastheattitudethatQCfindstoomanyproblems. PG6E has directed l that shop welds are not to be inspected. % 4 0' " A y-u Staff Position L

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This allegation is an issue which appeers to be a restatement of concerns identified in the past. The issue of concern here does not appear to j represent a new significant management or technical situation which has not f been previously addressed.

Action Required  !

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This allegation will be turned over to PG&E for r -^1u:1Jir. The licensee /

will be required to provide a written response to their findings and [j/

corrective actions.

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i Task: Allegation or Concern No. 192 E ='N l

4 ATS No.: RV-84-A-0025 BN No.:

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Characterization I

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Acceptance criteria changed to decrease weld failure rate. .

1 Assessment of Safety Significance The staff's assessment of this issue is that the allegation is a known issue which is being responsibly handled.

Staff Position )

l This allegation is an issue which appears to be a restatement of concerns identified in allegations 123 and 189. The issue of concern here does not j appear to represent a new significant management or quality performance issue which has not been previously addressed.

l Action Required repMt- l This issue will be turned over to PG&E for retni e . The licensee will be req' tired to provide a written response to their findings and corrective Jl I actions.

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Task: Allegntica or Cencern No. 193 j lism

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1 ATS No.: RV-84-A-0025 BN No.:

Characterization k' Poor QC inspector selection and training Staff Position This allegation is an issue which appears to be a restatement of concerns l- identified in the past and also identified and extensively reviewed.in-allegations 57 and/or 58. The issue of concern here does not appear to 1

represent a new significant management or technical situation which has not-l been previously addressed.

Action Required f

ThisissuewillbeturnedovertoPG&Efore-gp-^in. re sf The licensee will be , .

required to provide a written response to their findings and corrective actions.

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Task: Allegation or Concern No. 194 ATS No.: RV-84-A-0025 BN No.:

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Characterization

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Document control is informal (rules made up as they go along).

Staff Position This allegation is an issue which appears to be a restatement of concerns' identified in the past and also identified and extensively reviewed in allegations 61 and 102. The issue of concern here does not appear to represent a new significant management or technical situation which has not been previously addressed.

Action Required V49 This issue will be turned over to PG&E for :::_fMit._uti:2. The licensee will be required to provide a written response to their findings and corrective actions.

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Characterization ,

bor.nmentcontrolstampsarenotcontrolled.

Staff Position This. allegation is an issue that is vague and is one of minor significance in terms of the health and safety of the public. It does not represent a new significant management or technical situation which has not been previously addressed.

1 Action Required r4% pMM This issue will be turned over the PG&E for ~ ^'"+ M . The licensee will be required to provide written response to their findings and corrective actions, &

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I Problem Statement Allegation #(s): . / 6C[- lC((

ATS No.(s): (l/-3 - A - 0025 .

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This document lists (or directly references) each allegation or concern brought to the attention of NRC personnel. The purpose of this statement sheet is to assure that all points raised by the alleger are covered. j If the problem statement is not clear as to who, what, where, when, or why regarding the issue, the commentary section will amplify the statement. The i l coamentary section will also be used if there is apparent conflicting information or if there is no or very little original information available which describes the concern (s). (This can occur if, for example, a line concern was received in an interview).

I Problem Statements (use extra sheets as necessary)  !

Allegation # Verbatum Statement or Reference i

i 189. Magnaflux Weld Verification Program Accepted Bad Welds l 190. Pipe Support Base Plate Installation Doesn't. Define Bearing Surfaces

'191. PG&E has the Attitude that "QC Finds too Many Problems" 192. Acceptance Criteria Changed to Decrease Weld Failure Rate 193. Epor QC Inspector Selection and Training ,

194. Document Control are Informal. Rules Made up as They go Along i 195. Document Control Stamps are not Controlled.

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2. Functional Areats) Involved: onsite health and safety (Crack opprop<ia's boiles)i _ operations ___

offsite health and safety

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h construction safeguards emergency preparedness other tspecity) 3.

Description:

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5. Date Allegation Received: O E O 7 g y
6. Name of Individual trirst two initi.is and I..t n.m.)

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11. Date Closed: 11.1 Document NOS.

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Tenk: J Allogstien er C carn Na. 188 ATS No.: RV-84-A-0024 BN No.:

characterization k-4reakdown at Pullman.

Assessment of Safety Significance The staff's assessment of this issue is that the alleger has identified issues  ;

which have been addressed and extensively examined in previous allegations 57, 68, and 103-119. ]

j Staff Position i

The issue of concern here does not appear to represent a new significant {

management or quality performance issue which has not been previously addressed.

Action Required rt@ N This issue will be turned over to PG&E for rg 21-uun. The licensee will be L ,

required to provide written response to their findings and corrective actions.

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A11egation f(s): . 13 5 . .

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BN(s): A) A T$tisdocument lists (or directly references) each allegation or concern , ,

brought te the attention of NRC personnel. The purpose of this statement .

sheet is to assure that all points raised by the alleger are covered.

If the problem statement is not clear as to who, what, where, when, or why regarding the issue, the commentary section will amplify the statement. The commentary section will also be used if there is apparent conflicting information or if there is no or very little original information available which describes the concern (s). (This can occur if, for example, a line concern was received in an interview).

Problem Statements (use extra sheets as necessary)

Allegation # Verbatum Statement or Reference fbb

'l 188.

QA Breakdown at Pullman (Hudson #4) e s

Commentary. .

o Date This Statement was Completed b Technical Reviewer Signature

"" ee we,. , , , ,

oW p 1 ,

- P "

L o . }-

Task: Allegation or Concern No. 133 - 6 a _

ATS No.: RV-84A-0010 BN No.-

Il

' Characterization:  ! ')

Foley did not properly accept / document reports (no specifics were provided).

~

f i

j l

l Staff Position This concern was received in a group conversation with certain plant-workers. No specifics were provided related to the concern and it appears to be a restatement of concerns identified in Allegation 24. The information does not represent any new significant management or technical situation which has not been previously reviewed by.the staff.

Action Required None - Allegation is a restatement of concerns addressed in Allegations 24, 26, 46, 66.

l I

l l

l

' u.s wem ersumes, couns.3 "5[th*# ALLEGATION D,ATA ketevet w on, o a. FORM

' CECEJVING OFFICE Docket Number (if appf;cebte)

. Tscllity(Is s) Involved:

N (Name)W b ym 1/1 o y o e c  ? , T_j

= rsc, or o o o 3 s 3

~

2. Functional Areals) Involved:

Iched apprope:.ie boitesil _ operations onsite health and safety b construction offsite health and safety

_ safe guards - - emergency preparedness other tspecity) 3.

Description:

lElolIlelvl ld]tlMl l dl elYI l8lclflflPlt! l IIII iumn io im ew.ci.,)

y 7;g g;,;,;g; ; p ,;,9; q yj gj g ; ; ; ; ; ; ; } ]

IIIIllIIIIIIliIIIIIIIIIIIl I/41lIloJol Ivlulmlhltlel lil3h,I I I I I I I I I I

4. Source of Allegation:

scN:n .pprop i.ie boil _ contractor employee security guard licensee employee news media

_ NRC employee private citizen

_ organization tspecify)

X other tspecityl N ( b ik f MM DD YY

5. Date Allegation Received: g g , , g
6. Name of Individual griest two initi.i no a.. n.m.) h Receiving Allegation:
7. Office: g y J

ACTION OFFICE

8. Action Of fice

Contact:

tries e . inii;.i .no i.., n.m.3 b.[d F

9. FTS Telephone Number: q g ,

q

~

10. Status:

schect on.)

/ Open, if followup actions are pending or in progress

_ Closed,if followup actions are completed l MM DD YY

11. Date Closed: 11.1 Document Nos.

l l C '

' "u'm*n f

  • to 50 cher ,eters) I I I I I l -l l IIIIIIIIIIIIIIIII1 IIIIIIIl l l l l l l l 1 I I I I I I I I l_]

ome. v.., Numb,

!a.'Alle t oWuWr:te i R V -

f 4 -A- O O t O 1

[<

. .\

o

. Problem Statement-s A11egation #(s):. ['/ d,'f ,$ ~ $^>lO l13' -

ATS No.(s): h g, A-ggg f.'

Bh(s):

This document lists (or directly references) each allegation or concern brought to the attention of NRC personnel. The purpose of this statement sheet is to-assure that all points raised by the-alleger are covered.

If the problem statement-is not clear as to who, what, where, when, or why i regarding the issue, the commentary section will amplify the statement. The commentary section will also be used if there is apparent conflicting information or if there is no or very little original information available which describes the concern (s). (This can occur if, for example, a line concern was received in an interview).

Problem Statements (use extra sheets as necessary)

Allegation # Verbatum Stateraent or Reference

3. Foley did not Properly Accept / Document Properly Reports s

Commentary t9 pv y, t, p 4,v b k % % ()M b%

dht,v vi% , h %ohes AhewN k k M1%

MEEGF '

I. pr ht % 3%t omowA.. .

Date This Statece.nt was Completed _

  • h Technical Reviewer Signature L

,A . pow . s te-a Task: Allegation or Concern No. 134 -

DW ATS No.: RV-84A-0011 BN No.:

Characterization Foley did not invoke Part 21 on vendor contracts.

Implied Significance to Plant Design, Construction, or Operation The procurement of basic components subject to the regulations of 10 CFR 21 i without referencing Part 21 on the purchase order may have resulted in  ;

l l products of inferior quality being supplied by a vendor.

l Assessment of Safety Significance 1

This issue had been identified previously to upper level Foley management.

The alleged discrepancy was based on PG&E direction provided to Foley.

The staff found that the allegation was true; however, the Foley p5ocurements l

involved predominantly commercial grade, off-the-shelf items which are exempt from the requirements of 10 CFR 21. The staff examined about 50 Foley purchase orders, selected at random, and observed that these procured  !

1

" parts" were exempt from the applicable 10 CFR 21 requirements.

Staff Position The staff considers that the licensee and Foley had acted responsibly in this area of procurement and finds that PG&E and Foley appeared to comply with I regulatory requirements.

i Action Required l l

l None i

L

+ , , -v A $l'  !

E , 1 Problem Statement i Allegation #(s): .ID

I  ;

ATS No.(s): ((\/TNb~ -

= ~

BN(s): i!

This document lists (or directly references) each allegation or concern- 'l brought to the attention of NRC personnel. The purpose of this statement . II sheet is to assure that all points raised by the alleger are covered.

I If the problem statement is not clear as to who, what, where, when, or why i regarding the issue, the con.:nentary section will amplify the statement. The l l

com:nentary section will also be used if there is apparent conflicting information or if there is no or very little original information available l which describes the concern (s). (This can occur if, for example, a line concern was received in an interview).

Problem Statements (use extra sheets as necessary)

A11ega tionl/ Verbatum Statement or Reference ,

0 1l Y

\hY fo A0 V e Y Q, coa nah.

" P Fo q he u+ 6 v44-cq tomm vya % ctm l 4A m 0 t+.1%tes IcHg um, n6m,#4s 9 ^^M*M hi9 puf tie g i

& A 6 N M N "b- m va k l v. a

&imb%.(Tr4" Corrmatarv i cd k hT"$ W %d A,,1 (

~

hi k, Fo l pv e. su et ushe ev*h/*~ vbt M 6- @g M eb Date Tbis Statement was Coc:pleted "h -TD3 _ _

Technical Reviewer Signature'

eevneem

' RECEIVING OFHCE D:ck:t Numb:r Of cpplic:t,let Yk 7 3, e, Ahfo bdA u m 8 b!1 O  !

g g c .neric. write GENMC) e

~

~

~~~"

onsite health and safety

2. Functional Area (s) Involved: _ operations sch.c4 appropriate bouwt i ,

offsite health and s'afety I construction emergency preparedness safeguards - as other (specity) _

14 o II I(191 Ivl(lt I d al alti lo l^l51 Ial d M

3. o:scription:

'* 'a '" "a' li13141141olIt13hlIIIIIIII'lIIIIId l

II I I l l I I I I I I I I I I I I I I I I I I Id l l l l l l 1IIIIIIIIIIIIIIIIIIJ F

Security guard

4. S urce of Allegation: Contractor employee

) ICheth app'optste bon) news media licensee employee _ _ _

private citizen NRC employee __

organization aspecifyi -

I other tspecityi M M b --

MM DD YY

5. Date Atlegation Received: g , , g tri,st two initials and tast namel
6. Name of Individual Receiving Allegation:
7. Of fice:

q g -_

AC110N OFFICE triest two initi is and test namel -

8. Action Office

Contact:

9. FTS Telephone Number: q 6 3 -

3 7' (

l

  • Open,it followup actions are pending or in progress

'e _

Closed,if f ollowup actions are complete d MM DD YY -

11.1 Document Nos.

11. Date Closed: l
9. Remarks: l l l l l . -l ll l l l l l l l l l l l l l l l l (Umst to 10 chaiseters!

Il l l l l ll l l ll l l l l l l l I I I I I Id 0"ica Ya' --

""*6 -

12.1 Man-h

13. AllegationgrgDate er:

,, 9'*A((CO,('I_o

~ _ - -

, 2/4/84 The attached information on welding performed on the CCW system is provided in response to a request by Mr. Gonzalo Hernandez of the NRC.

Although the material is believed to be securate, all facts and references may not have been verified and PG&E Management's review has not been completed.

The requested weld process sheets are attached.

MRTr sier }

l 1

i l

l l

l 0099t/2-4-84 t _=

(

s .

Concern: The NRC has requested: 1. A description of the basis for acceptance of welds made on the Component Cooling Water System;while the system is' filled with water.

l 2. Pullman Power Products Field l

Process Sheets associated with l

detail drawing No. HGR 18-SR dated 11-5-83.

Response: The review and acceptance of welding to water filled lines was perforr.ed by the cognizant engineer prior to any welding being performed. Welding to the CCW system, while filled, was a perferred method due to the cost and safety considerations associated with draining and disposal of the chromated water.

The weld procedure used was Pullman Weld Procedure 7/8 which is applicable to P1 materials. Both materials are PI (Per ASME Section IX). The pipe is A53 Grade _B and the attachment is A515 ICC 70 material. The veld procedure also requires a minimum of 50*F pre heat. The CCW system has a minimum temperature'well above 50*F, therefore preheat requirements are' met.

The main concern with welding to water filled lines is the possibility of cold cracking. The primary agent which can cause cold cracking to occur is hydrogen. The veld procedure dictates a low hydrogen weld rod (E 7018) which minimizes hydrogen and precludes the forming of cold cracks.

The sections welded were thin sections (0.375" wall pipe with 0.375" to 0.625" weld attachments) which assures a relative even temperature gradient during the welding process and eliminates the possibility of cracking occuring during the veld process.

Therefore, the welding to the CCW system while filled with water is a acceptable practice.

l 0099t/2-4-84

PAGE 1 0F 2

, s 58 5/82'(1000)

' PACIFIC GAS AND ELECTRIC COMPANY

- - DEPARTMENT OF NUCLEAR PLANT OPERATIONS

~~~ ,

DIABLO CANYON POWED. PLANT UNIT N05. 1 A'r ?

CLEARANCE RE00EST AND JOB ASSIGNMENT u '

iI r UNIT / SYSTEM // EQUIPt1ENT ddd 6//Mk MdEAS ,

REASON & DESCRIPTION OF WORK tv/SEgW /26Et 43 0 M24_.)

1 i

i WORK TO START DATE/ TIME 8-7-83 dM7dMORK EXTENDED T0: AA ODD a WORK TO BE COMPLETED DATE/ TIME 4-8-BJ (80tO CLEARANCE REQUESTED BY /M-r#t/g/s kSt/A>4 _ g4 PHONE NO. 273B 4 JOB LOCATION l NAMES OF CREW l

SWP CLEARANCE APPROVED m d DATE/ TIME % 23 de D m .

TECH SPEC TIME LIMIT [JA Y bb _ [] NO M l

l l

REDUNDANTEQUIPMENTbPERIBILITYCHECKED? YES [ ] N/A K A N OR 9PLICABLE PROCEDURES

[g inR ASSIGNMENT AS FOLLOWS:

CLEARANCE POINTS IN SEQUENCE q'INDEPINDEffT VERIFICATION REQ D) CftJ binA /"l 23MN 32 - Nf-)2 YES[] No {

h / J-2 l $8 ~ $b -l2 &>- gy gy O /-3 h Sa --M-/2 5b! 337tf71gg JCA 86 % DATE/ TIME E [DAT E/M ME REPORTED ON F ;7-f 3 / o.C / o TAGS ON BY 8 87 6 7-4 7 / c)(/ o [fM YO UA/6 REPORTED ON 7/7/f 3 / d/c2A TAGS ON BY M f 7-J7 /06 / o _.

DATE/ TIME DATE/ TIME REPORTED OFF T F3 / o'/vo TAGS OFF BY g 7-P M / M u d o

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REMARKS

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'A)L

~' YES [ ] NO [ ]

l INDEPENDENT VERIFICATION l

IRFORMED DATE TIME OFF BY SPECIAL INSTRUCTIONS /TAILBOARD BRIEFING:

DATE/ TIME /

l CLEARANCE REQUEST N0 14- w r3 l

l

PAGE 2-OF

, **5-9158-1

. 8/81 (100 )

DEPARTMENT OF NUCLEAR PLANT OPERATIONS DI AELO CA!4 YON POWER PLANT CLEARANCE REQUEST AND JOB ASSIGNMENT SHEET CLEARANCE POINTS CLEARANCE POINTS XM Cm tw>  %,

/rn Aso to t-t e ks " M

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l PACIFIC GAS AND ELECTRIC COMPANY r1 F (,

58 5/82 (1000) Ib i'  !

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DEPARTMENT OF NUCLEAR PLANT OPERATIONS DI ABLO CANVON POWER PLANT UNIT N05,1 AND 2 EE._

wiARAf CE REOUEST AND JGE ASSIGNMENT SHEET M _5fdIa >1 ,l UNIT / SYSTEM / / EQUIPMENT CCA./

REASON & DESCRIPTION OF WORK /doENA)6 //4 2's Oa CI'M 5 /.S.

L 31

,I DATE/ TIME 8//p'/gy 6bOCWORK EXTENDED T0: ,.

WORK TO START ^

WORK TO BE COMPLETED DATE/ TIME 66#O M/M/B.3 CLEARANCE REQUESTED BY Menzk/Mit) .

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PHONE NO. 872 B $N) P JOB LOCATION 3$ b al  ;

5I E k l NAMES OF CREW WE Il l CLEARANCE APPROVED [Wy/ Q TE/ TIME '

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TECH SPEC TIME LIMIT M A ,,

[] N0 $

REDUNDANT EQUIPMENT OPERABILITY CHECKED? YES [ ] # N/A N VALVE SEAL CHANGE FORM INITIATED?

OR

)'PLICABLE PROCEDURES YES[] N/A M

% B ASSIGNMENT AS FOLLOWS: INDEPENDENT VERIFICATION REQUIRED?

CLEARANCE POINTS IN SEQUENCE

~ D c'Cu) HiirrP /-/ 23Mk fB ~ UF-Ik YES [ ] NO Q kQ { J-A ( l ~ $87 ~ / ?-' ON BY

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l TAGS ON BY dI b 8 /9 .!'3 / C6 30 8/A D ON 2-/N-73/ 66 f TAGS ON BY d t' ./# C / O 3[ M% REPORTED ON F-N-93/ O>OS DATE/ TIME DATE/ TIME TAGS OFF BY /Alb8'/5 83/ F3 /8

( h REPORTED 0 - 93 / C 2-I REMARKS TAGS OFF BY D 8'/5' U/ 09/ 6 SF/1 REPORTED OFF 8 / {/#3 / O 2 9 POST MAINTENANCE TEST: VALVE SEAL CHANGE FORM COMPLETED?

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TIME INDEPENDENT VERIFICATION IRFORMED DATE 0FF BY SPECIAL INSTRUCTIONS /TAILBOARD BRIEFING: 7 h <_u AE R d TkJ D L/~ / CCL) MXJ DATE/ TIME /

l CLEARANCE REQUEST N0 jpg,y_,g3 i

, 5-9iW-1 8/81 (100 ) .PAGE MF k DEPARTMENT OF NUCLEAR PLANT OPERATIONS DIABLO CANYON POWEk PLANT CLEARANCE REQUEST AND JOB ASSIGNMENT SHEET CLEARANCE POINTS s.

l CLEARANCE POINTS

$dk r+t0L v

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, CLEARANCE REQUEST NO.

0%BtPn; sa sus unma uummm 60-4!58. 5/82 (1000) y , l DEPARTMENT OF NUCLEAR PLANT OPERATIONS DI ABLO , CANYON POWER PLANT Uf41T N05.1 AtlD 2 7 7, g.,J ' . (? [t y.! rg

[hh_-

CLEARANCE REQUEST AND JOB ASSIGNMENT SHEET 2 UNIT SYSTEM // EQUIPt1ENT /* C k ) #

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REASON & DESCRIPTION OF WORK /A_/o M#MF' cA /M- 73'34. W bar mr ,

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WORK TO BE COMPLETED DATE/ TIME k p /83 A6 M' CLEARANCE REQUESTED BY M7-[vhet) Q '

l PHONE NO. 272R JOB LOCATION NAMES OF CREW kll/d/Y CLEARANCE APPROVED /Fff/S (JA DATE/ TIME 7 - h lT SWP QUBED TECH SPEC TIME LIMITAf,A YES [ ] NO Q

, .tDUNDANT EQUIPMENT OPERABILITY CHEC ;g[ g/A R VALVE SEAL CHANGE FORM INITIATED?

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CLEARANCE POINTS tN SEQUENCE h.} --

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. [ I ON BY DATE/ TIME DAT / TIME DA E/ TIME N bO $h REPORTED ON 'CO 6()

TAGS ON BY h 7 TAGS ON BY @ M[WUD bMb/t/ REPORTED ON _ [tNf3/d420 DATE/ TIME DATE/ TIME TAGS OFF B k-37-N7/ ZZ65/

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RFORMED DATE 0FF BY SPECIAL INSTRUCTIONS /TAILB0ARD BRIEFING:

DATE/ TIME / )

' CLEARANCE REQUEST N0 p qfgy g _

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ - _ _ _ _ _ __ ________________________-____ - _ D

.= a .

PAGE 1 0F 1

.8-9158-1 8/81 (100 )

DEPARTMENT DIABLO CANYON POWER OF NUCLEAR ,

PLANTPOINTS EARAi4CE PLANT OPERA ~ ;e

~

_.' CLEARANCE REQUEST AND JOB ASSIGNMEN  !

p, ,

Qpff A

~

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CLEARANCE REQUEST p yf u t40.

ygj.

a, , ,. .

PULW M WJ7 (P9W8tN 9PdOL9Lujgy9 l P,D,17./.,5): h% 1:lELD . PROCESS SHEET .

Magt <e.cs465 %\nypD -

N/A- NOT APPLICABLE '.

OM(R tio.& SYSTEM ,

ISOMETRIC DWR. NO. REV. . I DETAll DWR. NO. REV. SHEET NO.

?uE l0-C.C.$. I ~ !4-5 NA h HGR I9-5R O 1 *' ~ 1 ~

PREPARED BY ' JOB NO. DAT E CODE CYDR INI RE V.

R. Ct.MP ,1,, V3g- 83 ss1., xxx cn c $-$,ylth5R O Held Mold PROO. NO. -

DATE PPP ant  ;

@PE R* for for O P E R.. IN S P. & lNsp &

N O. OPER ATION . ANI PPP RE V. D ATE COMP. DATE DATE Field Weld // X / 377 A  % l As, %

1. Ve-ity location 17/ S.S l3 .S.5 g3
  • ESD 220 sn1 7/27/ n ,e. g .2
2. Cze**f - 6-21-79 7/2 I/ur SM). i t h- A. EASE. 03ea.D
  • Esp 215 Fit-up Mt.E. C .5/g 40 sf rt/E's I B 83
3. 45,% .--

'-22-83

k. We1d C=:aleto ,

8 1_77 @% g3 h,,

5. =m w =

, wuM%

6. n m1 1mm.v.0:

43&?M-833 b1 96 */%

/8 Ubf, ESD 225 S&23 NJy)

7. Weld Sire __

114-74 l

ca. _ m. . . .e .

ITE7n i ~7 7'6 2/PE .

HVn20 WoT REQui,tEb u _

\

M prvr w y a c - >< fsa9 7/;y'n &

REKme/ WCAN M. .

2323 s/c/g3  %

e RN " * , _ _ _ # [2Q 2.M3 sp2fr-5  %

n e m e.n . n n u. n

u. v.t. i.a . - .--- -

i 1 --

FITE A"f2ACb.'E!TT - FILIST WELD ,_,

wsLD REconD SIZE THR l

MATERIAL _ _ ' f l PIPE m

.*.3...-.7.-.

7#I E * *3 8 O-g " UL '

(C.N h STt) WT .-- uOa7 7 nut ny ,

IATTACH- F1 3 ,,/B IM E.' l 3'/f n: sear HEAT NO. d4A f-INSERT N/A ,

BAE !4 IRE _7A M _ ,,, _ ,,

ECKING RING HEAT fiO. L LA -  ?

ELECTnODE EEAT No. 42c M G_ j LE m RODE _,F.201P . ,___ ~~~

LPEEAT Rajl,,2, _ W P Q[L,,__,,,_

.i.g AT CHAR 7 NO. pjA ,

L

' m'T E MM-U.O K~-- -

r , 1iLL.-..

25UEm .--

j

' "hLD '711G HRS . h]It t EAT RA NuF/FR. N/ e FINAL CHECK T/UL h/A

, CODL_ Q*"E

-.  : , _ O. A. O cM &- um DATE s r .p g'3 Ayi / DAT E *

' OTHER: I 't ) CU .-,L , a, _ , , . ,

eat f@% 7Ne L - n . , v.. _ . w ,w  ;

V VC)CPVvuNuv v vvvew -v w- _ _ - -

FIELD PROCESS SMEET l7-.137 N/A- NOT APPLICABLE

. Heart. 3455.Q[3/e - SHEET HD.

NO. & SYSTEM 1SOMETRIC DWR. NO. REV. DETAll DWR. NO. REV. i SMER 14-c.cs. I 5CODE W/A MR IB-sR o 1a 1  !

.at CLA.SS .. ... ARK ;NOr, e r rey.

.f 08 NO. DATE (EPAEED BY " y$ o k.(d4[h 7177 -3 0 - D 331.7 III hold

'e da R ' O' ' 6 R PPP ANI hold PROC. NO.

i

. DATE  ;

hER.

06 0 .

OPERATION ,

Ni pfp REV. D ATE E

COMR MA I$@E

'l Field Weld'# X / 377 3

  • 4,4

, H2) N'S 5 S 83 '

1. Te-1ty location

~

4g

-

  • ESD 220 6-21-7 9 gp g.

7A e

2. Cleaning itJ.AEA6E tucELC)6 2E t S/g, , ESD 215 6>

3-22-83 e a/63 1 3 Fit-no (C)t 6T r fBE rTMi7 Tid 3/S 8-31-77 .M 85 Yj3

4. Weld Corolete vi e Brush D3 W8'S +
5. L'l Ltg

, ISD 215 Bg83 l

6. ! 71'sual Insce tier 3-22-83 @3 ,

, ESD 225 D1 U/fy' nj Weld Size + 11-6-73 J2G.3 /83 @ 7A3

7. .

1

~l i

4 CCF_ENTS:

ITE7n /] 7'o PIPE HVD2o WAT REQui220 Rc '

4 penan:y umr.

M9 7blN $/b ,

d geuasupe ctao*

  1. Nfg2 3323 s/,3/ea g I '

? E C Tui 7. CC PT'_In v m N, V"..m u.v.u .m. _

WELD RECORD PITE L"".lsC9E!7 - FITRT VILD -

MATERIAL S!7.E THK. ~

373 D ELDERS SbSOL D'7 PIFr y 2 C " h Syg wT ROOT h% FINAL ty7 u

ArracL F1 3/g 7p/g 2 . 3 78 ,, - InsrRT Hr.AT NO. d~

N/A BAnr wing N/A EAcnIn: RINs_nrAT no. gjr%-

INSERT ;ELECTRODr ERAT MO. 426SWei.

ELEc; nods v7m A

  • - ERAT RANGE "F 50*P MIN.

ERAT CHART No. Q

. ER? ASS Tr9. "F50*F VTN.

l FWT Tm "r N/A i WOLD TI.ME HRS. N/A TAT RATE "P/MR. N/A FINAL CHECK I CODL RA"? "F/MR. N/A DAT E .il I Q.A. .

I

~ ~ ~~ ^^ ^ M / I run _ __gAvg

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b FIELD PROCESS SHEET FOR iMFORMATlbstE l .-

REV. DETAll DWR. N@NbT REV. SHEET NO.

1SOMETRIC DWR. NO.

7MER NO. & SYSTEM MR l B- S'R 0 1 a1 )

i4-C.C.S.DATE I 5CODE W/A whr ~

CLASS MARK NO. REV. i RPARED. EY JOB NO.

SV B-6R o I R. czA pp 7177 9-30-9.3 331.7 111 HDid hDid eco PROO. NO. DATE PPP ANg ER.

OPE R ATION M pyP REV. D ATE COMR ;hA Iy[fE i

So.

Field *Jeld'# I / 3 7 7 (e a,s

  • L'Z/- S.S.g3 ggp3 .
1. Vef fy Ircation

, ESD 220 n-21-79 3079 7Mh3 A.nb i 7/z

2. Cle* + g 8-% 7 ESD 215 3-22-83 fblM /4 3 Fit-::3

, 1-77 6-1363 l.i Veld CO tiete M74 g.ta d s

5. Viw3 :sb M rcd 21 1 Tisul respection 5~21-53 N 9-13-B5
6. rSD 225 d"~e'

, Iggg MSO 11-6-73

7. Weld Si::e CCE22CS:

ITE*m 1J T'o PIPE

~

Hyn2o WoT REGut2Eb u n.*p 3079 1h/n 1M3

+ zacrhy socarid>> ij l

l 1

E R hi .i . CUPTinhT.

...ar; . ~ ~ . . V..T.

. . _ WELD RECORD

_ ?.trr, AD.352*T - FIT 7 U ETJ '

SLIE THK. ~

MATE RI AL 374" ""F= "

PIPS ,, 2 o "y & s7D wv- ROOT u- rn:AL

  • 3 78 ,, n: SERT FEAT NO. M ATTACE. F1 3/B T//# M EACKING RUG hT.AT NO. 44- ~

n;stxr N/A BARE w!RE X/A 7701 R i ELECTRODE EAT NO. W70 i'/-6 35 ECTRODE ,

l 50"F 1037.

f ~9 EAT RA' I "r / IEAT CHART No._& _,

. EF? Ass "F Trv?. "r_FI N/A_

M I FCC N .

! MOLD TI}~Z MPJs ._ N/J, l EAT RA"'r *F/MR. N/A  ! FIN AL CHECK

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FIELD PROCESS SHEET .

FOMiGGRNMMuy b~MER NO.fi SYSTEM ISOMETRIC DWR. NO. REV. DETAll DWR. NO. C U'} SHEET NO.

.at i4-C.C.5. l 5 W/A Mc,R I B- 5R s0 1 ct 1

' JOB NO. DATE CODE CLASS 1.'. ARK NO. i NEPARED !rf SX.B-6R o REV.j

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PER.

N O. OT ER ATION /O'i pyP REV. D ATE

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1. Terity 1ccat1on 7079 3 Cle*9 % g 1 2.

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Fit-e 3-22-83 6ste 3

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'I#74 6 G>

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6. Ti'stEl Inseeetion 3-22-83 5- sy 3 433

, ESD 225 /Dg e-

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. 11-6-73 e tw @

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MATERIAL .

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'N FINAL IATTACE. F1 3/B "T//N M i.375 ' n: SERT HEAT NO. M i nasERT N/A BARE WIRE N/A BACKING Rn'G HEAT NO. /4 l ELECTRODE 77M R IELECTRODE II.AT _N_O. fe6V4-' F L -' EAT RANCE "P 50* F EDi. ~ ~~ ~ ~

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EEAT CHART NO. M .,___

l ?k '* *- N u "r N/A _

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E2FER 7D SHi r is A /S NO. OF ASSEMBLIES REQUIRED 1 N 0'. REQ'D MATERALS , PER ASSEM. SLY

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FIELD PROCESS SHEET ff

't-un-um . T;.:; ;; E BUSTOMER NO. & SYSTEM ISOMETRIC DWR. NO. '

-REY. DETAIL DWR, NO. I

'T NO.

R 6.1b s. t 4-Cc Lu * /-!M MfMA4%9WC2fi78

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PREPARED BY JOB N O. DATE CODE dfAS'S " ~ MARK NO. rey, BilETdsguAM 7177 8-/C-8 5 8 3/,7 W M' "

GsTi7i'84*tbt o -

I

@PER. Hold Hold PROC. NO. l DATE PPP ANI ~

OPERATION Mg N'O. pyP REY. D ATE

'.. COM P. %A 3% **

1. Verify location. 566 DC N
  • g UNE.AL WP ic. ATIONS , -

i

2. Grind to removehare strike and '

blend to base r.aterial and grind to blend route s.@ E.6*.I M.

~

k 8'll8%

~

. ESD 220 L 4M  !

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3. Clean renoval area.

+ 8-21-79 .g , ,gg  !

ESD 215 I

% Y IlI'E3454 6- w e,. 1 4-e,.- 4--

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c. ty_ - --..,1 ,..,* , e 4 a ..., * - bOI /

AT AfLC. 5706 6 (,L.(N E.A(2~ trtOtc ATION.

and record.

6. U.T. renoval area and crind area * > d / ,

j l and record.

  • l i

l CO.MSTS : Tf balev dad - --= 1 1 - -

ster verkt a D.P. v411 l b. ,_-.4-.,

l I

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l MATERIAL l S1ZE l THK. 3 l pin yl

. l Zo"d 570. tor l.3 W " ROOT RS 5" sol TINAL )$

  • l ATTAG- INSERT EEAT NO. ,/ I INSERT N /A BARE WIRE BACKING RING EEAT NO. /t i 4ELECTROSE N/A ELECTRODE HEAT NO. dA i l PFriEAT RANGE "T N/A BARE WIRE ET. NO. )

IINTERPASS TE9. *F u/a MEAT CHART NO. f P'M T '"e_ve. *F "/A ICLD TIME HRS. u/A IEAT T4TE 'T/MR . u/. 3 COOL RATE 'r /5*R . e/a ,

l

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.' e  ; a - tum u u r#f7 7 AREA LCLLCU. tr s/s/83 l~k W ocx, t w o' %9s/ussc is , - L A9D a us iePEW nntno !FICIENT CONDITION:h.bue. muot% a m e.53Ac pac.ent.1j V'G.Ar-wm t.ccAnoos Ltds.,

  • 15 1-K-lM (6-5R , r,ca, DMfT F m iM ( Asp N McKs A5 th3d F%E ~2.. 'fEC OdR01

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TAG i M k INITIALS NATE g>[8[6 ff OLD TAG APPLIED: g FlfLV.* N 9" % ' ; FIELD ENGI_NJIt f a g g_ WVd)3/[.% RECOMMENDED DISPOSITION: ;Xb CI SPEC y SN' SET TD D l1 }$502 f(LOC-65S I 6 t_ E.cd C G o u G G S h (/ 6 A o N' E - 4 8 0 572IR G S P5fL ES D 2 7). 8628 0 *T[} '-- ~ y,lE4 /2 [NDic A7 to d 05/N C. SAM2Ga' O 'Edyy~p {2 l %c.es,s 34 eer. P.T. 4 u. T. FIELD QA/QC MANAGER ' M;(_m. OTHER FIELD QA/QC MANAGERS EVALUATION: K APPROVED AS RECOMMENDED CAUSE CODE l COMMENTS ~* J NON-CONFORMANCE - D.R.! ~ M,9. ~ .~ ~ m' G-E% M p

  • REPAIR ORDER O . Gl'e - [

REWORK / REINSPECT 7 57/"'# 0../ ] INTERNAL AUDIT DATE FIELD QA/QC MANAGER [ OTHER p d,A/ h 5 e/b/e > 4L NOT LATER THAN: CORRECTIVE ACTION REQUIRED BY: b i NOT APPLICABLE STEPS TO PREVENT RECURRENCE: To oS E G it E A T E l i c d R. 6 w46N ' (dSTt2uc.T c2AeT c;,e tN Otra c oF F ATTA CIdA G N TS. ~ i ~ 7 FIELD GER DATE RES PDN31 PE m 1C a e m 0N u0 SED: opg/g; gggg g  ! - , , u ( hullMAN ?.CWEE PRODUCT- ~ mR iWFORMM10ii GNLY LIQUID PENETRANT EXAMINATION RECOR'Er w a ,~ -e-isn _ ?'_ /H/x3 i / ?./nnisC scaan TSn: HV-f* .G J No.14-c&li? #?= G-.. M/A 8: 50"522 DC.N II,0'l- 00f, o lHc-/oy.20 JG sO. 7177 m: st [g uv cs ??.oCunn ???-/*//z/d na 2 /0 n r. 7/z/g z. ??'a5 3 S*' O1las AM51 83'/7 6.iD ?LliE*? A5: ELD kRG/d FL uX 5707* c/Ecc , ivD ?zz2:2:r 23.23 su"** g3Onp) 7yoz./f, ~ gg ggpg C1.ELEE ?n . - GT n., , m.g j l SKC.-5 SKL , S ' a3 S C D - S' l } ACw m ~. r JECID _ A /4 52- u:2 C? T_G?EC:Oz , I ~ .. r o l MAf.:A:. C ?JJ.IIC~2 U.AMIHAIION ?200?.D p ) LA.3 W:.uaa 5D'E3: . r7r _=; EF" JG FO. 1 i !L . l l W!.'1C5 ??.Du.: )u:1 m* w. l 6 :. A53 ST.J.5D12D5 1 1 L. 2C ?>222C12 ?CDE 3?J.L D k.__C ?JJ.ZZCI2 ?CD E COLO3, -- 7 ( ? C2::OhIi? / ' [ . ,]NACLU o P2 2 C D ~ l ,. ca - .. -m . . .:. w. .a . v t.: ., s::;r7-. - . - . w.. - E.. . ol i -FOT.M F-69

  • PUIDAN POWEE PRODUCTS l- Pa '.,1' 2/2/82 THICDCSS PRORT
  • 1 ESD 244 P5.3~/ 7 22 '

PART/ ITEM NAME f50 # / -/'/'-[ wy1=mr M.o-Q ' E C LOCATION N68 /7-IN' M;O.DE5,0U:Ch?DCGfMGP. , ,. , . .. .... . m fC$Y... PART SERIAL NUMBER Cc N n' 0 V-006 ~ A\ < D.R. NUMBER = A REFERETCE BIDCE, IF OTHIR THAN ONE SU? PLIED "/4 MATEPlAL C 5 /e,ua #/-K-/O y ,20 SERIAL NUMBER M /0 85 TEICDIESS-STEP 11 .2 STEP 12 .3 STEP 13 .V COMMDITS: // .37S '~ nom- W Att-s' L o u)* LU A LL LIMIT ~ - .SQ$y */ [b ACTUAL lolu w ALL = .3[0 - l . W 1 l l 1 I U.T. CALI3 RATION' READING $EE ABCUE N/A {' r MIcoRMETER READING MICROMETER SERIAL f__ N/A ' DA':2 J////CJ f I '/ / DGPECTOR:k / ((D' _ h -c I NSTRU CT! 0 N ' HO . 12 j ' ATTACHMENT A - { SO. 'l-lc-l-b , PIPE 5'UPPORT DESIGN TOLERANCE C SEQU %h " EUS)ECT /8 .5~ f P.E V DC f CLASS __ f 1 ' LOCATION AREA: I --12 .ELEY: 9 /9 -l~ O " pye,- i n s p e c t O in-workE. S '(S /4 past workQ DRO! DESCRIPTION: I TE~M l'7 kJh tPAG E P/ c Cuca 1 ~ N' /GD (;,gp 'iR-T ' I Sowno J . . I SS VISE WELD oP ITFM 17 w ry pgg u _gna a CE400 b\ 7 l @N) MELD MELD O#:) L. ~ \a \ w. ,a e (E:D ><. Wl4 -A - H Y 0 ( . .- . i,- l l ' @ T s l l , i h., > y tt, ) - t\ '%7 7/= l l l FYXHIQA-3 H5 d Tff' > / FWm 414 E-H F5 A '/ * . ff ,. P.P.P. F.E. / 7/7_.y { . p _~ g* p p t .j - E P-90'll 2n' O , s_c, 7,5, g ijy;' } REFERENCE DRAWING v49 2 41 SH /" /p / 4. /6x , (/ , I ATTACHMENTS YES h 'PAGES (INC.THIS SHEET) / AREA ENGINEER: p/- , // /,W/J-i M"~ 'E, CONSTRUCTION MAY FROCEED DATE _~/-2 -@ $ . i CONSTRUCTION D.P. RE0'D l ' - DATE 7 I3 ' C-:'T R AC T OR R E C E 3 PT w - ._ j ~; , - s. - d .. Pa T cs 2_. . . . . m/ y , _- . . . . ._4-y ' . . . . F. . , - .1 . .FtI . . ?. . UG . j -. ._ .. . . . mers,,n , i- _1 . W hor

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  • 513- "

w.~ p6-d!12Sl. PULLMAN POWER PRODUCTS ' -- - ~ ~ 7 O $b FIELD PROCESS' SHEEi g [5 ~ dM hhhhsYg 4 i kBLE hUSTOMER NO. & SYSTEM ISOMETRIC DWR. NO. IED dETAll DWR. NO. REV. EET O. Par.z 14- C C LD 1-I'-l-5 A. M i$4V **O* ** FREPARED BY JOB NO. D AT E CODE CLASS MARK NO. REV. MGTHELWicr, '7177 '/-6-8 3 B31.7 III "c" f c_. /-Sf78 ,o y gg & & fo OPCRATION REV DATE PER? 7 FIIIDWEID#X/h/h y' . k

1. Verifv Iocation
  • 2323 efaiss9[gG NM gfg. 3- .3 l
2. Cleaninc f9 7.523 d'@ heS
3. Fit-Up kN N'M c/s3 07 sh2/s3 %,733
4. wela Pcot Pass s/$77 7
s. wela Cmpleta e/31/77 M Db kh
6. Wire Brush g3 NIh M[,
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  • 2 h7

-PO,12.25L 6 , y caers:47 TAC 4 ITGm . 17 TO PIPE. LuGw ovsa. . .. ERIS7/NG Fw>cB60 ( M96 / A S tLEo out ED Go (L GlooVE LuECD. M VOtto NlA o.4. - A R M RECTTm Yi GRDOVE WEIDS 'IO PIPE NELD RECORD MATERIAL SIZE THK. P1 M [ $ 70, Q){ ,37[" WELDERS SYMBOL B"'f PIPE ,, ROOT D"7 FINAL D7 l ATTACH. P1 YO 77/l4 d . 3 7 f,, INSERT SEAT No. u p. I INSERT N/A BARE WIRE N/A BACrlNG RING HEAT NO. M ELECTRODE E7018 ELECTRODE HEAT NO. 9%D546. ) PREHEAT RANCE "r 50"F Min. BARE WIRE HT. NO. MA TNTERPASS TEMP. "r 50*F Min. HEAT CHART NO. MA AM TEMP . "r N/A IOLD TIME HRS. N/A FHEAT RATE 'r/HR. N/A lCCOL RATE 'r/HR. N/A n . FIN AL CHECK I O. A. ( /d g _,. DATE f/4 $hG ) OTHER: All F J . ANI [ { DAT E - g - n lh I / /. _ ', / /) l , , g \ ,_,,,p ~ f) -f0 N PULLMAN POWER PRODUCTS RS2 Qg)ct d0346b .' (h3 FIELD PROCESS SHEET [ N/A- NOT APPLICABLE BSTOMER , NO. & SYSTEM ISOMETRIC DWR. NO.' R1 V JAly g REV. siittT. $ O. I" 'p{$iUIlB'@NO.({.(ATp d,fL PGts 14- 6 C (d l-/4-6 Nd H REPARED BY JOB N O. DATE CODE L_ CLASS M ARK NU.' * * M f k b ]Pgy, ' p B31 7 III "U i a : !: S C ~) # _ @GTilELWic4 '7177 ~1 .7-8 'S Hold Hold PROC.NO. ' - DATE PPP ant @ER. NO. OPER ATION , y, pyP REV. DATE P E R,- COMP. ME I$yE rmn wao # x /4143 verirv Iccation

  • 232.3 s/i2/s> g,m 1.
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  • p/ B[12% @Sil2653
4. We1d Poot Pass 8/31/77
5. Weld Complete 8/3 77 3 h t.
6. Wi.re Brush ,

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7. Visual Inspection
  • 2 3 8

~ oke:is: ATTACK ITEM 17

  • TO P(PE. Lu s u ? O V G it- -

EkiST(/VG FwkB(so t k% f _ As tr so out.eo. Go tL GlooVG Lv6C.D. 0.4. ~ ~ M Yo/2.o N(A . . . . -. - .... _- A.b...V Ld. MUT.u )\ x! WELD RECORD GRCOVE hEDS 'IO PIPE MATERIAL SIZE THK. ELDERS SWBOL D7 PIPE P1 7,0 "g .C jp. to 7 .3 7f" ROOT D~l FINAL b~7 ATTACH. P1 YO WC4 8 . 3 7E,, INSERT HEAT NO. /t// A BARE WIRE N/A BACKING RING HEAT NO. ///4, INSERT N/A ELECTRODE E7018 ELECTRODE HEAT NO. SWE - C 70#3 PREHEAT RANGE "F 50*F Min. BARE WIRE HT. NO.. // //A "NTERPASS TEMP. "F 50*F Min. HEAT CHART NO. /f//A "F N/A '.WHT 0LD TIME TES'P HRS. . N/A l HEAT RATE "F/HR. N/A n , FINAL CHECK I COOL RATE "F/HR. N/A V 4 % c ,= , s_ DATE / / W9-) (--- "" " O.A. oma / ggg . . 94 i 213- fD W- - ~~ ~ ~~ ' ^ - ,, ' W Tn g 5I. PULLMAN POWER PFDD0c15- . 6[G[jC) FIELD PROCESS SH USTOMER NO. & SYSTEM ISOMETRIC DWR. NOS w JN pgTAILllWn JO - - ,REV. _. ' SHEET NO. { vast IM- C C LU l-l4-5 Nh HGil IS-ClL o- 1 of 1 \ 3REPARED BY JOB NO. DATE CODE CLASS MARK NO. R EY. l M G T N E L u.H C M 7177 ~7 .6-8 3 'B31.7 III "C" 7c. /.g5 7g o ) @PER. Hold Hold PROC, NO. DATE PPP ANI OPERATION PER' l N O. A P REV. DATE COMP. MPg& E FIzw new s x 1m 4C l'. Verify Iccation

  • 2323 6/83/g8
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5. Weld Carplete 8/3 77 AD3 5 4I 3
6. Wire Brush $3 g tso 21s cr/ sp ag
7. Visual Inspection
  • 3/22/83 M323 com'rs:47 Tack ITGm /7 -

TO PIPE. Lu G W O V G it-EktS7ING FlokR60 t k9G / AS / Leo uut ED =o (L . GLO0VE LuEL Q. M VO(2.0 NlA 0."bl. -, - e. m m.n , , n .. ..: l z c 1.d. C. D% .L JU rv A l GRCOVE WEWS 'IO PIPE WELD RECORD i MATERIAL SIZE THK. l PIPE P1 7.0"g GC, u.17 ,37f" WELDERS S MBOL D'7 ROOT D7 FINAL D7 . 3 '2[,, ~ l ATTACH. P1 3[@ ,, ~/ 7](f /h. INSERT HEAT NO. A._% lINSERT N/A BARE WIRE N/A BACKING RING HEAT NO. M l ' ELECTRODE E7018 ELECTRODE HEAT NO. 92694E ! PREHEAT RANGE "F 50'F Min. BARE WIRE HT. NO. NA ~N_TERPASS TEMP. "F 50*F Min. HEAT CHART NO. MA 'WHT TD'P "P N/A .0LD TIME HRS. N/A HEAT RATE "F/HR. N/A COOL RATE "F/HR. N/A A FINAL CHECK O.A. M_ c,m DATE / # dG / 2 ANI / OTHER: All SMAW DATE . *. n_G_0_ A_______ _____x l_ __/9 . _ .? ./& of 11% 0,A ' _ /_ 74 70 213- .p sej M / PULLf4AN POWER PRODUCTS ) p a3456 Rh 2-gg FIELD PROCESS' SHEET m-- p r i NO. & SYSTEM , ISOMETRIC DWR, NO.' , R f 'DDAU$Y 5. O REV. SHEET (NO. ( .USTOMER p l. CC LO pc;g 1-l'l-5 d(L .%? 'T--~ u ~* PREPARED BY JOB NO. DATE CODE CLASS MARK NO. REY. DLIGTMELWtc4 '7177 7-6-83 331.7 m "c" rc,/ gy7g o 3 OPER. Hold Hold PROC. NO. PPP ANI N O. OPERATION y, pyP REV. DATE PER. DATE COMP. $hA l%E 'l rum wun # x /414 D ll

1. veriry tocation
  • 2525 8['3/83 M ']
2. cleanim
  • 7/]dll E3 Wa3 $
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4. vela poOt Pass
  • ef$77 M B5 g;g3
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6. Wire Emsh 23P> W83
7. visual Inspection ,

$21s ygg gg i l 1 Cums: ATTAC4 ITGm i2

  • H -

l TO PIPE. Cv G L D o y s it. ~ E>ctSTING Flok8bo { kSG f A G tt.Go uu7 ED r-o tL l Gd.ooVE LuEC.D. u M Yotto NlA O. 4 .' .- ,, . . - .... . . . .. u, bnWM.i .x i GOJVE hMDS 'IO Put ' W5(.D RECORD MATERIAL SIZE THK. PIPE P1 Z.C pd S70, uf f* .37[" ELDERS SYMBOL D7 ROOT D7 FINAL D~7 f ATTACH. P1 kg ,,'/7/(( k . 3 '?[,, INSERT HEAT NO. M INSERT N/A BARE WIRE N/A BACKING RING HEAT NO. MA ELECTRODE E7018 ELECTRODE HEAT NO. 42.05'4 E. PREHEAT RANGE "F 50'F Min. BARE WIRE HT. NO. M "F 50 F Min. HEAT CHART NO. M (TNTERPASSTEMP. *' "r N/A ( ..@.T._TE9 lOLD TIME HRS. . N/A [I } HEAT RATE "F/HR. COOL RATE "F/HR. N/A N/A A flNAL CHECK l O.A. $ ,s mm DATE II "J~~$ 3 l*l OTHER: All SMAW ANI / DAT E * *. J sin I . / l- o ' /6 /n se nn\ ..A PA 34.N213 ' PULLMAN POWER PRODUCTS, . %im =- R h 2. = . FIELD PROCESS SHEET - f g r= a en r ,s , .-.,.. - Wh.~.MO,T ,A,PPl.lQAB).g , @STOMER NO.& SYSTEM ISOMETRIC DWR. NO. R V. ( kETAlk}'DWA[NNN[I 6 : D.) J E.8IJ0. Par.z lM- C C LO J-/Q-5 d{th" %(L,IS-GR-. O at L CLXSSI'~ ~~ MARK NO. ~ REPARED BY JOB NO. D AT E . . CODE REV. l 4GT46LuJicK '7177 '/ .E-8 3 B31.7 III "C" rc , f.g 5 -)g o Hold H0ld PROC.NO. ' DATE PPP ANI !PER. N O. OPERATION [0[g pj,P RE V. D AT E PER" COMP. MA l%& rrrrn WEta # x /414E ~

1. Verify Iccation -
  • O e 4 z..g3, nen 220 Qeth
2. Cleaning /
  • Rn1n9 b 94Z,CA FSt>-215 842 O
3. Fit-Up 3/22/83 M3 A6 7/8 <:---
4. Weld Rcot Pass u-8/31/77 N d tF,,25
5. Weld Carp 3ete gf 77 hf hh h
6. Wire Brush 2h74 #!Uf8 -

ESD 215 ' 7' W

7. Visual' Inspection
  • 3/22/83 [J vlids>

omas: ATTAC V ITGm i2 Tb PIPE. LuGw o vstr. ~ EklSTING Foik850 t k% t AS tc E o ute E D  % (L - Gecovr= wECD. M Yoa.o NlA 0.4. n.b.M.E . SECT..QN XI nELD RECORD GM/E WELDS 'IO PIPE MATERIAL SIZE THK. ,3 75~ WELDERS SYMBOL 48 PIPE P1 Z.C"g)g70,uff" ROOT 6 /~ FINAL 6:> f* , ATTACH. l P1 3[g ,, */7]M /8 . 3 76,, INSERT HEAT NO. A.#p- ' INSERT N/A - BARE WIRE N/A BACKING RING HEAT NO.#4 E7018 ELECTRODE HEAT NO. *f.2,057-f l ELECTRODE PRIHEAT RANGE "F 50*F Min. BARE WIRE RT. NO. 4/4 TPERP ASS TEMP . "F 50*F Min. HEAT CHART NO.#4 'WHT TNP. "F N/A 40LD TIME HRS ~. N/A I HEAT RATE "F/HR. N/A lCOOL RATE "F/HR. N/A ll f FINAL CHECK DATE f/sf 83 l O.A. l OTHER: All SMNA ANI/ DAT E - *. AA A AA < / /////)) pf fi) A \ J b r,f) ; b70213- ~ PULLMAN POWER PRODUCTS / + ^ FIELD PROCESS. SHEET RS E 5:0R INFORMATIGLOMOG ESTOMER NO. & SYSTEM ISOMETRIC DWR. NOl RUV DETAll DWR. NO. REV. SijEE1 NO. 1 Pasz /t G C W 1-/4-5 NM. EL 15% o , -o QEPARED BY JOB NO. DATE CODE CLASS MARK NO. REV. B31.7 III "C" 77_, f . g y ~) g go (G74ELujicK '7177 7 f-33 Hold Hold PROC.NO. DATE PPP ANI $PER. NO. OPERATION M'; pyP REV. D ATE PER; COMP. hA I$E Fmn mn # x I4 /tl F l'. Verify Imation (% #d2 G Tm 220

2. Cleaninc R / 71/79 M PA v m -215 g
  • s)
3. Fit-Up 3/22/83 d8 8MI M 7/8 Q
4. Weld POOt Pass 8/31/77 fris 3 5
5. Weld Cm ple's 8/31 77
6. Wire Prush N Th 7 g ESD 215 y Dl;9 <53r-
7. Visual Inspection
  • 3/22/83 L681 ,fts b chtms: ATTAC C ITGtv1 12
  • TO PIPE. LUGLD O VG/z. . .

F.kts7ING FlokB(20 t k9G / AS lLEQuteED GofL Glo0VE Lv6CD. M V O ll o N lA O. & - . , . - - . . - - . - n m L1.t. btGT. TUN >t WELD RECORD GCOVE WEIDS 'IO PIPE THK. MATERIAL SIZE ,37f" WELDERS S WBOL V PIPE P1 7,0"g g j 0, u;7' ROOT G t'~ FINAL (3F ~ ATTACH. P1 3[$ 71)($ ' d , 3 7,f" INSERT HEAT NO. /49-INSERT- N/A BARE WIRE N/A BACKING RING HEAT NO. 4( ELECTRODE E7018 ELECTRODE HEAT NO. 12.8ff f I PREKEAT RANGE "F 50*F Min. BARE WIRE HT. NO. 4/4 TNTERPASS TEMP. "F 50'F Min. HEAT CHART NO. //4 ~ *WHT TEMP. "F N/A IOLD TIME HRS. N/A l HEAT RATE "F/HR. N/A N/A n glNAL CHECK COOL RATE "F/HR. l O.A. y h cg e. DATE /m f~ M~ ANI /* DATE - *c l OTFER: All SMAW _ ^ ^h I / L- '/.~ A,'? tr (M( ,,4 r/ lDo2& . o' . PULLMAN POWER PRODUCTS - . FIELD PROCESS SHEET >3 $Mk 'A P I BLE ISOMETRIC DWR. NO. R V. DSTAIL DWR. NO. REY. _EHE64=NO: OTOMER NO. & SYSTEM /-/N-$ h 6 8. M.T 1 *f 1 PG&E /N- d C Ld N JOB NO. D AT E CODE CLASS MARK NO. REV. t !EPARED CY 7177 /- 6 ,3 3 B31.7 III "C" 77_, / g 57g > SGTdEftdICV, Hold PPP ANI PEh* 'DATE Hold PROC,NO. FER. ZO. OPERATION A [I PNP REV. DATE COMP. [g A IQE FTTTn p rn # X /9 l h C l'. Verify Irv ation 6% @.C2. mo 220 g -

2. Cleaninc 9 /71 / 19 M 2-(2 05 i sT>-215 0-n 87
3. Fit-Up 3/22/83 d8 8l-U 1Q6 7/8 &
4. Weld PoOt Pass 8/31/77 @ S 15F3
5. Weld Ccoplete 8/3 77 I Ik#3 h 207 9 683
6. Wire p ssr; 215
7. Visual Inspection
  • 3/22/83 83 s3 owms: ATTAC-4 ITGP1 17
  • TO PIPE. Luew o vs/t.

Ek STING FwkBbo t kBG / AS (LeavutED Go (L Gd.00VE LuECD. 4 VO/Z.0 N [A O.d.~ m mv:mTm - ,e-e~

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,375~ " WELDERS SYMBOL (8 PIPE P1 "[,C "p6 gj'p,tv f'* ROOT 68- FINAL lo F ATTACH. P1 3[0 " W C4 /8. .3~16~" INSERT uEAT NO. x/te. N/A - BARE WIRE N/A BACKING RING HEAT NO.h#- INSERT ELECTRODE HEAT NO. 910 Sy of ELECTRODE E7018 PREHEAT RANGE "P 50'P Min. BARE WIRE HT. NO. ## UfTERPASS TEMP. "F 50'F Min. HEAT CHART NO. //4 *WHT TEW. F N/A 10LD TIME HRS'. N/A HEAT RATE "F/HR. N/A COOL RATE "F/HR. N/A A flNAL CHECK O.A. N - r DATE //-f43 'OTHER: All SM4W' , ANI/ - - DATE . - A mn // /. /.-  ?. n7 is k( a. ~/ f 5.;ro.213 7 , . PULLMAN POWER PRODUCTS FIELD PROCESS' SHEET  ; KB? s

b. -

run it'AnFFAMPXi < NSTOMER NO. & SYSTEM ISOMETRIC DWR. NO.' R V. { DETAIL

  • dwE O '.~ REV. SHEET NO.)

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1. verity tccation *

/658 giM Pm 220 5

2. Cleaning
  • g /71/79 M St E m-215 B-n.- 81
3. Fit-Up 3/22/83 @ @2 U jpg 7/8 < g
4. Weld PcOt Pass
  • 8/31/77 bI 6-l5Bb
5. Weld Carplete gj 77 N h kn
6. Wire Enish 20N 9h y l

Visual Inspection ESD 215 y 1 r P

7.
  • 3/22/83 INI MG R3 @3 73 b

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  • l TO PIPE. LuGLO ovse . -

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GFD'7E WELDS 'IO PIPE . WELD RECORD MATERIAL SIZE THK. PIPE P1 7,C"[ C TO, tu f ,37f" NERS SMBOI, (s8 l ROCft {> P FINAL (o P ATTACH. P1 3[g ,,71/$ /8. . 3 "?f,, INSERT HEAT NO. N4 INSERT N/A BARE WIRE N/A BACKING RING HEAT NO./V4 ELECTRODE E7018 ELECTRODE HEAT NO. 9 2.6G/-f PREHEAT RANGE "F 50*F Min. BARE WIRE HT. NO. h4 - INTERPASS TEMP. "F 50*F Min. HEAT CHART NO. A/4-DWHT TEMP. 'F N/A .10LD TIME HRS. N/A l HEAT RATE "F/HR. N/A L COOL RATE "F/HR. N/A A , FIN AL CHECK O.A. V M -,t c e DATE /I-[--83 OTHER: All SGM , ANI/ - DATE * *. L__-_-__-_-_- l l '" b^\ b Y g . ~ ~ INSTRuftieu n;, it , Iso H+r ~ 2 . adIB"d!MaciWM PIPE SUPPORT DESIGN TOLERANCE.CLgR I FI C ATI O'N F n D.M - . 6 . . , SEQUENCE NUMBER 7 c-/- M 78 SUBJECT / $ -- 8 M REV D C. CLASS  :/ j l LOCATION AREA: 1 -D- ELEY: 9 8 !- O " pre,-inspecta ' S yS /Af in-workGC. past workQ DRQ# DESCRIPTION: I-frH l'7 WARPACs& Pno Puccf L' * ' & VM/GD . (,,pf SownoJ . . . RS VIS6 WELD oP ITFM 17 70 ryg ..pyg nr ,gyow a Ge2cw 17 h poJ Neto Weu; ees g-  ! \ j - (8) ;<.1414 A -4 # (rb A- y ^ 1. pig) ) 6ho f 0 2- ) b % F W Pi - D hl M (fr)D 4' g > f pV # g FNxlH1'lA-DHs . Afwgww ' Fw k t HI4 E- H5s ' h T' .. gg () W W %oE}-ldb3 P.P.P. F.E. / 72"./h i DC-l-EP-904/ REV C2 , g,c, 7, g , gij,g ' REFERENCE DRAWING v49 2 41. SH /g / , /4, /(3x (/ ~ ATTACHMENTS YES h PAGES (INC.THIS SHEET) / , AREA ENGINEER: CONSTRUCTION MAY PROCEED _/ ,/,w gdb W I DATE 7-2-95 1 ' b CONSTRUCTION D.P. REQ'D . CONTRACTOR RECEIPT DATE ['T l ~60c-t- g.- PA %) ~.Q- o- _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ //o \' 2 "; . ,..... - HANGER SYMBOL h ~ ^""x / .O . -~ - une'/-#-/d4 # El >i' z a - \s ,- ( *ig . 98'O" .._ . C CW dd&#K //D H y g g g,g ~ ' ~ ~ p A ,Od*S/Gd/ CdA SS I MC %i CODd~ d*d4 66 C_. , QW & ry)) h{* U ~ ~  : W BSTwees\ / )^ Ed'

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i BN(s): N/A  ! This document lists (or directly references) each allegation or concern brought to the attention of NRC personnel. The purpose of this statement ] sheet is to assure that all points raised by the alleger are covered. If the problem statement is not clear as to who, what, where, when, or why regarding the issue, the commentary section will amplify the statement. The commentary section will also be used if there is apparent conflicting information or if there is no or very little original information available which describes the concern (s). (This can occur if, for example, a line concern was received in an interview). Problem Statements (use extra sheets as necessary) Allegation # Verbatum Statement or Reference l L0 edd liv) cd p\ ct tcO 47 p i P'"] b ' \ \ #4 dC" O. r. , t el e re c t ;c w c(ci ci(Sccm4 nu'k s e:- A' c A -t t u o cl4 4 , a n o L hecd- Lu A. A d tta. (.N 4 c} b 4tol hoick (.b . + \wc\ leen b y- po meck cdu.A lar) Alu c u layce d is 3; tc (cs c o u d m t + = m 1. ctbeve, i po_mmentary  ; bc o N ei 6-[u c( .shee.fr., i =_ Date This Statement was Completed 3/6/8V d M4 ro r lu,- TecgicalReviewerS{gnature I 3N v35# - a 9; + m - --- -------- y y - - ,.  : s . fgW% g-5944 i ,"~ Task: Allegation or Concern Eo. 132 L >--- g - d ' l . l4%a 5 l _AT.f. N o . kV-84 -A-009 BN No. . l .Ch. .arac t e riz.a ticn : x a We,1 ding was p( rformed era .at portion 'of the Component Cooling Water System with the pi i e full of witer. Additionally, the allegee evprer, sed concern.that'a Quality yontrol hcid pofut had been by passed during the subject welding. Irgli[d Sig,tl S if 3nce to Desigg',.Constructpfig or Operntionr: W2ter in the Ifnea could provide an additional head sink not accounted for by the 'welc procena thereby resulting in Peld discontinuities. l l Aenessment of gf,ety,Sjgg3,1ficengei The-allegacion is deperated ihto tdo topics: E l l ' l 1,. The' welding of plates to piping which is full of water, could cause veld l 4 discontinuities due to the Edditional heat p ink.. 1 .y--- / , _ .- Assessment: 1, t lo da: ermine the validity of this allegation, the inspector,eramined the-documents provided by.the alleger, the relaticd ifcensee documenta and the ( i f s = w F t welding in question. The inspector also met with the licensee to confirm the inspector's results. On February 1,1984, the inspector confirmed that attachment pads had been welded to the Component Cooling Water System when the pipe was full ~ of water. On February 4, 1984, the licensee provided a basis for the acceptance of welds made on the Component Cooling Water System mentioned above. The licensee contends that because the required minimum preheat temperature was maintained, for the veldability of the materials, welding with the lines full of water does not cause or promote weld cracking, for the specific case described. The only precaution the licensee took was to insure that the welding occurred with the lines full of stagnant water, that is, assuring that the Component Cooling Water Pumps were off during the welding process. p Examination of a document entitled a " Clearance Request and Job Assignment Sheet," for Unit 1 indicated that the Component Cooling Water Pump "B" was tagged off from July 28 through September 27, 1983. The I 1 welding in question was performed on August 13, 1983, on Train "B" of the 1 Component Cooling Water System.  ; i l Staff Position I Based on the review of the licensee's position by the inspector and four staff l metallurgists, no safety significance is attributed to this allegation. In " addition the welding in question did not violate any codes or the velding j procedure.  ! 7 4 ) Actions Required None

2. , A Quality Control hold point had been by-passed during the subject welding.

Assessment l To determine the validity of this allegation, the inspector reviewed relevant documents provided by the elleger and the licensee. The inspector's findings I are as follows. l l Examination of the process sheet for the welding performed on line No. 1-K-104-20, Hanger No. 18-5R indicated that on May 5, 1983, the , I preparation for the welding of two steel plates was started on the referenced line, but apparently because of fit-up problems, the plates were subsequently removed. In the process of removing the plates a number of grinding gouges were created. On August 8, 1983, a Pullman Quality Control Inspector (the l alleger) wrote a Deficient Condition Notice (DCN) DCN No. 1604-006 documenting that for Field Welds Nos. 1414 and 1377, grinding gouges, are strikes, and a possible linear indication had been observed in the area (where the plates had been removed). The DCN was dispositioned on August 9, 1983, with the recommended disposition, to issue a process sheet, blend the gouges, remove the arc strikes, to perform Liquid Penetrant Testing (P.T.) and Ultrasonic Examination (U.T.) (to check if minimum wall was violated). On August _11, t 1983 both the P.T. and the U.T. were performed and found that all areas l L __ _ ___ _ __ _ . _ _ _ _ _ _ _ _ _ - _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ . _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ a . examined were acceptable and that the minimum wall had not been violated.- On .j August 12, 1983, the location of the plates were re-verified and the plate i fit-up signed by the appropriate Pullman Quality Control Inspectors, including j -the fit-up for FW Nos. 1414 and 1377 which was verified by the alleger. The issue of concern to the alleger is that the original plates (which were subsequently removed) had been fully velded, rather than just tack welded, prior to being checked by Quality Control for fit-up. The alleger bases this upon the size of the grinding marks left when the plates were removed. The inspector could not determine from such circumstantial evidence whether the grinding marks were of full welds (which would have been a missed Quality Control point) or of tack welds (which would have been proper) . In summary, the inspector concludes that the work in question was redone and accomplished in proper order. The inspector could not find any conclusive evidence that l ) any codes or procedures were violated. Staff Position In conclusion, no violation of NRC regulations occurred, since the alleged l violation was found by Pullman's first line inspection force (the alleger), documented, and properly dispositioned in accordance with the approved quality program. Actions Required: l 4 None l 1 Iti!TRUCTIC?i.ti:. ;2 A T T AC :-:frE.'1T A P I P E . 5 U P P D F.T. D E S I 1.'t . ~ 0 L E R.nC E. C LA R j P I.O. A.T I 0 ri E n ?.y. SsEQUIfGS liUP.5 ER T c. - I - 13 4 3 c) SU3 JECT 2 ~ 43 R REY 3 ' CLASS ~ /- F._ " LC0 ATIO!! AREA: /- A t. LEY: /40' pre-inspectC in-workO past workg a P. 0 2 DESCRIPTION: RO BLEM: Q uganty 0F l ren Q 943 geCe Eamo neousty CALLED our As P. .. Ob CORRccr W G.LD CAccouT f0R ITEMS AUS w Is Guteo As T PY 2 "PL cs " , TC/'ld I ^3 0 0 'h f MO LD eG Ge B e to n G To HAu s si?. 2-43 2 - N8f N paw T OF R A a 6 ere, a - 4 5 R . Ti. icy Have Atzeaoy Bcca ADDev To 2-45R [o t vTsoa . O Cat.c. Qas o n ry w is As 4. Lb , b to CAttour fo rt 19 $nooLD ~2cgo . Ty 9 4 PLC .5 ". DecGrc I TEMS W , 2.0 ,d L] , f P.P.P. F.E. M oc.i.e-r soeo s 62, 6a A ,628 G.C. P.E.* REFERENCE ORAWIf(G 0 4 3 2.>4 su 6tc.6a x ATTA HMEsTS YES PAGI5 ( ! !ic . TH : 5 S W E E T '- 1 e ' a -. 1 ,l.Ja.st*.. 'C !is R U C T 10 tl MAY pt00EIO L h( * . . DATE IC$4l93 '3M i .~ *~IA ~$$ $5.*5 II( f p I r' ~ 5 < l / - + 1 j INSTRUCTION NO. 12 . 1 .. " ATTACHMENT A' PIPE SUPPORT DESIGN TOLERANCE CLARIFICATION FORM S Eh0ENCE NUMB ER , 7 C-/ #7dl 7 SUBJECT Z - i C) k

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CONTRA: TOE P.E:E!:7 e -d DATE 7- ;2 9 @ /m ._ _ _-__________ _ O fNSTRUCT10N Ngo 22 ATTACHMENT A PIPE SUPPORT DESIGN TOLERANCE CLARIFICATION FORM ) ~ { SEQUENCE NUMBER d-/-N88 SUBJECT ~2. - 49 k REV 3 CLASS 11 - E 1- A ' LOCATION AREA: ELEY: 14 0 -O " pre-inspectO i n-wo r kR 7m.s ptc7cp )$ supEACSD&D Zy 7c. /- 944 7 \ DESCRIPTION: Q j  %. Ir n fAJMATIOPPapgyr "

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2. Cla:p bolts hstned and tiv.c 8 1

3 Cle- spacer 1: stalled and tight A '. ....ad "'- ka'*s a.6 ad d-bo*k ' ' * ~,__ . k. _# ". a .*

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Solid coup-- d-*:alled ec:centricay vi"d- 1/S"

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10. Spherical bear:. gs free of pad : and c pushed out L's .

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11. Cc:ter pi:s fulls spread

~2. Spherical bea ."r.g vashes/ spacers installed where  ; rectired, reduchg te al side clearance te less tha I c:e washer thickness and g eater tha 0". ' 13 C_'a:p ears parallel

  • 1/8" at load pi side of cla:p l 1\)/f 4

*h. Oc=ents a:d/c: e=planariens FOR INFORnAATiON DEV l

  • Ite s 3 and 9 apply'to field-fabricated ct:.:ts, per :~?S 11-9 precedre l

s .~r i  :, w_ic:r. m.._C.h C _ _ c_v - e m. s e ...u. .' _a. . _r .. . . :. j i.c./ 3 to.( Q. 1, . - - . .- n_. - :- t,, - - . , . ~{b f '1. A) Stre: size: (CS, 14 20, te.) $[5 '\,l l ~  %=*

3) Cla:p size: (enter pipe dia.) 8_.,7 C) Coupling type * ' d u ocket veld ) -

CIICI MA?.I DTDICA*IS ACCIPTANCE i

2. Cla:p bolts installed and tight h/A
3. Cla=p spacer installed =~4 tigit n)8 I. cad ;in holes align =d '

'c:h c12:p halves /VA-5 7.cd sya "==4 ."_s1'cle -trced. sigh; he'.es . N 1

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l 7. Str : ** s #_ - : 60 cf opti== or vi-' ' special l requirements :::ed c: draP_:g/:eres / 3. 1/16" :"" bach 1: socke veld ve:c.fied c: ': recess shee: b iNW

9. Solid coup-- insta"ed concentrically vi+d- 1/8"
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10. Spherical bea-ings free of pad-t and sc: pushed on:
11. Cc:ter pins fully spread
12. Spherical bearing vashes/ spacers iss:111ed where required, reducing tocal side clearance Oc less than c e washer thi-t-ess and greater than 0".

l 13. Cla=: ea s parallel

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  • Ite:s 8 and 9 apply to field-fabricated struts, per 'TFS 11-9.precedure l

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Type Stud :sstalled ~l M [ C. 3:2 !C:. IMB. T?st: Milti/Millips l .- W l 1  : I l- , D. Anchors Torqued $=2 TA=E VII33 322*.1:. :rDMEZ1 .l lM ll l f. li

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3. Support Meoers:

d '. / I:25 SPE=AL .m.hw a .l ll l (1) Groove & Pull Pen Velds G . IC. *I 9 f a hto . '*to 4 t.*'#W Su./ W mT a w I , 6tfP_t"$ElbtM (v  % TO". i"~ #

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10. T.*.".Al. ;I= C:30:=3%.,c. a. 'GMRZ35 :

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3. Arc 3:::kee Removed /*-4-*+ed l Q f C. %14 Size ::ar:l' ee vita ersv".rM M 'i
11. It73't 13 CENZ2AL irmwaurs"9 AED CGEr:GRA=W: l rCPEHAN l 10.0. "A= !

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3. ?ipe "lesmace in Accordance with Draviar ,

d , 11.ser % 3 ears w Lug C. - _, ,,,, ,, d a 3 A h,5 % , I*arer'ta l4 ,e1 and F1:q ,, g g g 5,5 % Q 3f3 (@ i.( [> 'jl@ @j Q,j % 6 6

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4 i l y -- j l I. kg C*eart=:e . vita *.: Ic; erst.co . l Q. . f':. . I'""IIU.:: l' A. *2. stalled ter Se:arste ? cess: 2 hee: l  % l [' *--su r:s.:ssue p. n1 sue ~. :n. 2 =-= I l*1 .  :"'7?*?.: A: =?;= 1T ".:.  !*==lete 2s:41;sti:= $.ortevi .:. 3: =A""?2 ,' I . i )

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5. SI:33; Tack velds U ~4 - i
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10. WARPID 5ASE PI,1 23/L'.WBIES

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3.  ::22 6 $PEC: E ID5 m m u l 3

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3. Arc S:r2.s Reemd/w*-*-"ed l,((([!( h k C. v.a su. C =3u. vs= criv=A /59/ M ,M5s i
u. Ia e4 r0R CZKIRAL VCRIMAN5Z2 AC CONTI:;:RA=:N: [ T2IiAN c.0. !A!:

. . ._Au: A  : ... 1  ; A. Cc=penats saa 01menaicas Cosely W/ Dug. & P.at'i. lass y jg/g y 73g

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i. ,

, l l

3. GA?S; U-Bolts, Tee Shoes a:4 Luts  !

8 I 4 CLW PLATIS; Greut da= aged er Ecles in Plate - 8

5. srnes; Tack Vele,4 i 1
6. E7s NOT FULLY LT k"E
7. ARC S 3 :ZIS __

i.

8. nMm SIE 's
9. CTIESI::ID HCLZ3 D PLA3; Vashers
  • l
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} One h }-)(.$  ?) $ .[ h? d 1 b ':> - ' a ts .s - 1 TOAL CSPIC":CN CCtc :.;.w: CSPICTCR DATI kror wrco nua 7 rn RE 2 n.c.6_ (nce m Aut s acu2 men 7e uw o redes .,9; - ~ a 6 .&% fe. - WRM rA(s A,4orncwnsh / . -. .s_w . - , - 4,e r* . A6q_A smh CNMgg%&r-/M/e3 #N +:e i y { gee

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  • m i. e= = ae e av 7wPt f* \17  !"S t m*=

g g. ii ie r,-, , awww w . . A %./ ., 1",=9= . f",p . .q t *P . i i. ./" !-, A . L. u1 S f"' CD A ,S, .M- 6 MAM -. 4 iaa i a n-

  • A r= L n r- e2 _ s et y p r3 f.e. i e% s r,ms. iv sn . w . o ,.- - , , , -- , . . , .e e., . - - .an.i = *i- ,s e-vt s -.-'" sad

==m .- a ah 7 A ma A s.I. a #g J p g p ,a 4 M pm iE 1 u s; w e., nw6 ne s wg,wir w,,ws(o .- J.h e O. T 8- g es em @J 8# f *-*e A 1 c'%* * =n est M I-h's . i. - - , , , . . . -~ 1 u s n a m . wu v .r , _ - w . I ,,.,n.A W 4N h an-w n , nm2.i.-- . . . . . , _ p. ,. n ,3 Tu,A it,t ..a.~., i~ . ., . .s .we,1 mm u e ,t e .. ..... . w _ rg,p. py ) = < ~ ^ m e e r= -=- v=u- e e in e s, -es,e ,,,,,,r- 'c .V c , w t-  % f_r. e '- A V n ,, . ,r n a rtrar, sve , a. - . . , . . ~. - -- ~ --.,e } s  ? ?, & " $ <Y S - h k E 'T W ) t_ F. , l f -r e -p_ v i, o (L v , L / sj_ o ; ,e / t w m l i l .. - , f g, , - g w - , ( 9s'8: m .,,. r-,, ) l y .DSGN L o t t '. IDRAWING MO I L [< Dww A _- A g 9.q g t *:w c ' - f o,./ - *' ' g l , , 'h" . . HANGER &YMBOL [ AREA T I- A UN E - l -l # - 4404 '2 4 W M , f s X k 3 MAINT ' l o 5 gt l4e - o 3 U PG9EL EUM l '2. EX H AUF El$., .t ,, m . n ., r= . 3 . .i ' ., Sg, L . ON DWG 3 C' M 0 1. MU Q .[gy [fag ,4Q * *hg9 ,u,.tv ~'a u-lV} L.~.X #i: . .. ..a-- .. . a 04, 9a i,- Cf 4 * ' ^ ., s s'.- 64. r ,%.~N i . G > 15.- d/2; i4 - 8l

w. .- (~ w"op wraw ~x eo ePiirz cLieT ,

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,I \ . v ( \, .j - . . . . _ __ _ . . . _ . _ _ _ . g2_ _3 l_71  ! \ =J -__ . .LGT ,9 l #'& y 7 I l '\ , i\ l  % Tre.'t /g'& / \ $6D, ,/ './ < gh \ y- / , ..- / \ i ( / r ~. . . j - s - /. r .5 /z\ see es7 'i - ww so + ,' .3 Drag 9 y. \ - 7 C^ca # ? v,, / g,, 9,w s w._ c,sf 7 t_ A N viENv ='- . w-. ,,_,, ,,; NO OF ASSEMBLIES REQUIRED ~' NO REQO MATERIALS PER A,SSEMBLY , F '2 NPs GWAY' GTR$1" 4 Re, GI2.G '20 m bA ' I cr 4 Ft 3/4" x Idx ' l'-2"' ASD1 A 919 de 7e (ses' osv. 4) 7 , i 2.G " 9 F=. x 1 Lc," (watt, Twlca., = I') cut iW HA : AW Ws a f Y4 " )( ll X 0.Il0 {O Q ggg=cp gn, ,( A4, F,sp. MA:L. 4 j ~ ~d .' ~ 7. 3 7: 2. F l/2 " x 8 ' x t '- o " ' V 8

  • li: W u sh tj @ j UN IP 1 J Ft 15" x 6" x o'Llo" eMd4 V .1'w WFORMATM l E l e-F.' i 4 ." x 1

6". x L6 Fl: v :, cu[ ' h~ h r' ** M M 9/4 H X 5" X L. (o., ' * - . C I S Y ::"i!E.F Fics. [ i I l'7 I / I C W.4 " X '7 " X L. G BY DMN MKy N DR AWING NO , D w N R Je C fa,= 7- 9 3, m 3 , , CHKO.4 /j/7tv.4 * I t- ' . HANGER SYWSOL \' I- E N 4-2 M b. \' .'.i p, jp; I-A LlNE ,~U - HoralE 4.KrJanft.- " " ~ " - - -Y P;E.9iiL = @ l-lE4WAV6T et 140 - C ~ ru a,s c. LOC ON DWO FNCO 2-- ji . j B w f4 e a rs ust- or 13 7- ~ 12, """4 " W 1 s i 1 s - -== %== . ( .' g ( t . , %_#r [. +t1 _ .m \_+)  ? T.. i iIh +lu l _  ! ~ i[. f .\ l i >z , ~ \ &I . wmMo 3 . #,*4 N - N -: -3 */G 4 Pota 3 i [ .. S h ,/ . Ilif!NTA14., ~ 1 x' M'T W] c .~ "d 8 Q ;)'} f?,x ,f E# ' I h. J, s v.fjW*/ !/* f " -l' , \ - - - -.s. .cf g o , l F 1 q \ ' * \ I N l / / /K ~~ ' . 1/(' ~. , , :, , % .. / + y @ Y F*D 6 L y , T-rr) . . i S~ C TloN C'c . .J . .. .- . . q, . + m TA M I S ,(  ; - s . ., ' ~ ' 3 C7 sit 1" A I L. (t w de U

  • i a o. o e A <r e., o m s u s s - a n ut<2 s o -

@c> WLJ9. '~ MATEGtAt+r PIEIO 36cpErABL W . - I4 (/ ~Z/S. 6 A '24 s Sott var sdrU "

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-Loc ow owo 500002 - 1 lQ; y ,- ^ , y io - 'N a K, ~ d_p, - ) " 1 q .j- ,,_ LN* pC . J4'[ ii . i , i ., h, .- - Y,- r. -.7. ..r /E., w'!L, '2. i M Q Y ,,y ' Ll -- _ l  ! I l f I N, - W g .\A;'L .T+ . i_, _ ,#J  ; I ' 'f r s l em  ; .c::. , P }A.1L *F; ] [ }" h ): .'IJ / J2, 1Tgf Me @ d [ 3, / - h See try 8 * .gp;;;.WH, [cd: C"*"I / - kfj * ' No 9 ~.  ?=. m ) ~

a f. 1-  ;.n~s y- -y.

s y , .g yg yv <~>eE C T*) CP N h-A bi- - cj$&/'- c=caxe. un .e/ I +

  • P s:$1: cu & Elec.ric ge gd, we: sm d7g: Dece,by- -[ 1 , 1 ogg g 17pjg2 oloto canyon  ;;, ye,: m- ,us,se en: F. Lveute v/R, Li ew3 3 yn c im,,. UNACCEPTABLE WELD CONDITIONS ON EXISTING HANGER INSTALLATIONS tew escisenre w e : REWRITTEN PER PGaE RE00EST. ,7 which reinspection of hangers which are currently being released for modificationknthe 1 recaired by ESD E23, has shown thct there is a v. eld cuality/ size proble:
1. codified pr.rtions of installations, excludi'ng the weld of weld attachments to iping. The following conditions have beer ' entified: ,
l. Undersize d welds. gS
i. . Incompl e .e we4 0 s.

weld def ets. g30,-*p . _

me of these conditions afr quiG . epair to meet desien requirements',

These conditions a o exi t on hangers which are not bei:ng issuad for lDTE: l pacification. . OR will be r ared to documeng={afapdjkhYi=ks'g :::::fte35jie' n. ' , .cysien 1 i.s :::.:s i::egE".pI% h J kg D2ee eisvermen: INDICMIEMFNOVA'L"EY CIICLING T.-:E AP?ROPRIATE ," RECD..MDiDED ' D15?OSITION" , m j Undersized, eversized or . cam: tete welds shall be a s-bunt unless..the peg:{e, inspector determines th .,zytitichi welding en the undersized or inc mpie

e. i c s i s re quiru .

F:r veld defe::s ap. ud ersize,i or intempiete keids which recuire additional - weidine, jhe lo:a icn, deficien condition, and cisp:sitica shall be recorded anc veri Ted it wy;.,.t i n g bydC , En g # ns er i n g, a n d P G E EThis . information shall be re:orded (sees eqaple fo m attached) and wil.1 be retained as part of. the hangeh . ,,,. i document packaV. net recuire ad'ditienti welding shal~l be repbred by ' k Weld defe::s whic removal of the defect. No de:vmentation of individual defects is. necessarv 74if GC. b.- v-r.l.':CS M'[-/d , / ,  %,g ,g - -l , b-CONTINUED ON s ar.r.r.r. r.a em:. PAK2/- - on N ,"D 'e , , / .- 2. L /d 2 gy brecsmew: O in Ah::ne.= wie A% Oew(.r/./.;.n.ad.,em.1...;,a} Gk C..ap t. ,-d lasp . Dewt - ) my t ../ las p: _ Date i Srios or sectr.surs: . . t.evis ic: 1 to recise ?C&I cisposi: ice..  ! , b b I i 9.7 hs - l5\- e.

e. ~ .~, - =..

c_ . .=rvrc = revanscr_ Cw. An::ew. ESD 223 has been revi sed to more clearly detail  ! ,ir.staliation and inspection re:uirements. Acet,uate training has been pr vided for l I l... ..s e.e e+ - ins:e :crs, One:in training sessi:ns -en-are conducted concernino ~%+ =  :.r.  :-e,3-;.:,_, ns sen Mi,i '") !T . 2 Pulinian P.cser Products. . l' G y - m.a. no. 4678 .PAGE 2 & j ' 15 0.* o. ViU Otis um:: ras . i

5 NOT) .

. uusi no, t ," D!$CRE*t NCY ME? ORT C:or wo. 3/8 . Pa cif1: ca & Eln.etri: se se, wo. s7 1 _ e t7 g. December 11, *)532 4 1/6/53 f msrs: eg.5. Lyautey/P.. Ll ewellyn olabio canyon  ; s ke.: 7177

iCOM14D!DED D15?051T'ON CONTINUED

) ESD 223 will .be revised to reflect the ateve requirements, at which time, this - DTs may be closed. 4 . .si: r.. wc-lY.c, i urorg= TE wo 5, '& " Y A. ,g.&ps ,, 3, y ,,,$d by Q IMj L)o& 3 A' Y' " EWD ? ~' Cp 4 inp4" - \ 4 - f . . mm = u,,..u% 4y. e ... g y . 9 . g. e 9

  • e o e

~ .. FORgg70RMKIl00 l 9 e l e 9 .e p. aim - 6 e - - - - - - - - ~ - - . _ _ _ _ _ _ _ _ _ _ _ _ , _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ T. wU 55 R m " 0 tE oA oa 0L , "E $5 di Ei a a e m e E ;Eff E s es w e id * !. vW hl $ l e' = = =s E b -s ts en 'E k 3 JT "w e b ~. M > *"" r n \7 e w O 2 th 3 Ias ec ~p = 4:1 1'gO. 0 1 -= a g ,T2o g< 2 MD w e 5.3 E ;5 t G e 4,jl dI t. t.:$A wag E" E $ te b g@[z 8s s 5 Jia wa$g w 94 O 5 "{, brJ . iti s$ thp$z d 2 m 5 m a  ?.. E, - e ~ y yh g%(h r,Y s h,n h E ) b ]w. I c g s i13MO i f3d 20, r 3rk-e ig s< %y, qWwR 99 / e o o - ~ C 5S" N f s 3  ! ,s '3 = 3 P 2: a ws s i d s Te4 wf s s ss e s 3g- < e t.t = au g o '\lE \ J e"; 8 $ C W =a8 c W ,J 73d p{ l- _ ~ z e ., x v - e = R1 v v \e g  % w\ d , E b ( 4 y IiE e 4) 9" Nh g(W$ s. 9 1(k aac  ! m 4e 1 N( y 2"si gise G -s E Q; gg t-- d h f 3 v' .] w g; .t .e s t ka sy y yy le( +a w . c,  % )'s g == c . e = ,4 s w v e E 5 *  : y I 5 4t - @ t - ~ NU D, 9 - \ 3 u.s wuctran atoutatoaY couuission g ccc s xn ALLEGATIONe,.i, ci a .n DATA a. FORM limi RECEIVING OFFICE , Docket Number (if applienblel

o. FacIlitylles) Involved:

p = 'g g a ,c, twemet  %%Cwm i/L o g- o - o o s v s-o r a o e m t, ~ -

2. Functional Areals) Involved: onsite health and safety Ich.ek opp opei.te boat.sil _ operations _

offsite health and safety I construction _ safeguards - smorgency preparedness other isp.citrl 3.

Description:

1 Fl o I t I cl vl in I o It l I ,01 o f cl ul 46 lo l H t I4 la l l Mclel tuma io m es.r.ci.*' Iil & M MI I & I Kli lJ KI h 141<lolil eleld IIIIIll IIIIIIIIIIIIIIIIII1 IM ili l d glaltl i lo ln i 12161 I l l I I I I I I I i l

4. Source of Allegation:

sce c6 .ppropei.ie bo., b contractor employee security guard licensee employee _ news media _ NRC employee private citizen _ organization tspecifyl N other tspecityi  % R7 %4 00$h MM DD YY

5. Date Allegation Received: .

g g

6. Name of Individual trirst two initiet nd t..i n.m.) N b'ibOD '

ff1 Receiving Allegation:

7. Of fice: QY ACTION OFFICE B, Action Office

Contact:

tri,si ewo initi.e .no i. i n.m.) 3 N, bx

9. FTS Telephone Number: q g 3 _ g 7 g 3 fe ", " , , , , Open, if followup actions are pending or in progress Closed, if f ollowup actions are completed MM DD YY 11.1 DXUment NOS. b b b2 1 lc
11. Date Closed: ., l ), , j e, y
2. Rema,as:  ; ; i i ; ;;; ; ;;iii  ; i ;;;;;;;;

Rimn to 50 ches.ciers! l IIIIIIIIIIIIIIIIIIIIIIIIII 12.1 Man-h rs Date

13. Allegation um er:

9 sd [b8 ottic. R. V - v .., g y- -A- O wumb., o 2. f, .y

FlbE ' Task: Allegation or Concern No. 26 o[w-ATS No: RV-23-A-0033 i. Characterization Foley didn't document NCRs issued by Field Inspectors. ' i l Implied Significance to Plant Design, Construction, or Operation 1 See Task Allegation.or Concern No. 24 Assessment of Safety Significance See Task Allegation or Concern No. 24 l l Staff Position See Task Allegation or Concern No. 24 d 1 Action Required I I See Task Allegition or Concern No. 24 . i l I I _ _ _ - - - - - - - J

 . t 'i Task: Allegetica er C:ncarn No. 24, 26, 46, 66 ATS No. RV83A28, RV83A33, RV83A46 & RV83A52 i.

RN No. 83-164 (10/27/83) (for RV83A46) Characterization A site contractor (H. P. Foley (HPF)); (1) rejected nonconformance reports without justification, (2) was not documenting Nonconformance Reports (NCR) issued by field inspectors, (3) has incorrect procedures for voiding nonconformance reports and (4) incorrectly rejected defective weld reports. l Implied Significance to Plant Desian, Construction, or Operations Note: The resolution of these issues was complete in SSER No. 21, however the text has been reformatted to clarify the issues and add additional information to paragraph no. 4. The site cone.ractor in question (H. P. Foley) has been responsible for installation and modification of electrical, civil and mechanical Class 1 , l safety systems and structures which are necessary for the safe operation and j shutdown of the plant. Improper handling of nonconforming conditions could cause construction quality to be indeterminate. 1 Assessment of Safety Significance 1 l i ein

 ~

To casssa th2 conc 2rns, th2 st ff: (1) reviewed cpplic:b12 H. P. Falcy procedures, quality control (QC) inapection reports and specific NCRs; (2) 1 interviewed Quality Assurance and Quality Control inspectors; and, (3) l 1 conducted a field inspection of various welding activities in the+ structural cable tray support and Beating, Ventilating and Air Conditioning (HVAC) areas. A review of the Diablo Canyon Power Plant Final Safety Analysis Report and contract specifications issued to H. P. Foley established that the Quality Assurance Program was required to comply with 10 CFR Part 50, Appendix B. The staff reviewed the H. P. Foley quality control procedures for the specific disciplines (civil, mechanical and electrical) such as QCPC-7, QCPM-17, QCP-5A and QCPE-7 to assure reference to Nonconformance Procedure QCP-3. j The inspector's examination and evaluation of the allegations are as follows:

1. H. P. Foley rejected nonconformance reports without justification.

A review of the logs, of inspection reports (IR's) and nonconformance reports (NCR's) identified that over 1925 NCRs and 2156 irs had been issued against the 11 specifications issued to HPF. The staff selected a sample of 130 NCRs and 10 irs for an indepth review. These documents 1 spanned the time period from 1973 to the present and identified problems in the normal HPF inspection activities, as well as audit findings by PG&E and the NRC. The subjects of these documents ranged from the i identification of programmatic problems, such as qualification of personnel, to specific hardware problems, such as concrete voids at a particular location. All problems appeared to have been addressed and I

  . s cdiquately rass1vad. Bas d on this cxaminatien thz staff ecscludss that nonconformances were not being rejected without justification.

4

12. 'H. P. Foley was not documenting Nonconformance Reports issued.by field inspectors.

The staff's review of over three percent of all NCRs, irs, and other specific inspection documents found that nonconformances were documented, and properly administered. Although properly administered, the staff disagreed with the engineering resolution of one of the NCRs reviewed. The NCR concerned stud welding. The licensee's engineering disposition did not recognize that a material not allowed by the welding procedure was being welded. This staff finding is an apparent item of noncompliance which was discussed in SSER 21 (Nureg 0675 LD). Based on this examination, except for the ites described above, the staff concludes that nonconformances were being properly documented and administered by the contractor (HP Foley).

3. H. P. Foley has incorrect procedures for voiding Nonconformance Reports.

The staff determined in their review of the 130 IR's referenced in paragraph I that eight NCRs in the sample had been voided. The staff reviewed these NCRs, examined the rationale for voiding them, and discussed the voiding of NCRs with E.P. Foley's QA management. H.P. Foley Quality Control Procedure QCP-3 prcvides for the voiding of NCRs. Additionally, the inspector examined NCRs which were written before QCP-3 was revised to formally control the voiding process. These NCR's were

4 a fcund to be cyproprictaly vaidsd and legg2d in tha racords. There did

              .         not appear to be any evidence to indicate that H. P. Foley management' inappropriately voided Nonconformance Reports without justification. The
                      ' staff agreed with the reasons for voiding the NCRs and determined there
                      .was no safety impact. The staff, however, felt that H.P. Foley QA
                   , , management could be more responsive to the individuals concerns and communicate with the writers of the Nonconformance Reports, their rationale for voiding the Nonconformance Reports.

i Based on this examination the staff concludes the H. P. Foley Company has l correct procedures for voiding Nonconformance Reports and has been properly implementing their procedures. i i l

4. H. P. Foley incorrectly rejected defective weld reports.

This concern resulted from a report by a concerned citizen wherein a QC inspector's wife indicated her husband had identified defective weld i l reports and that these were being wrongfully rejected by MPF management. The QC inspector was interviewed by the staff and did not corroborate the allegation. The QC inspector stated that his concern had dealt with the efficiency of work practices rather than noncompliance with NRC regulations or with PG&E's or HPF's procedures. In December'1983, (after SSSR 21 was written), the Quality Control Inspector was again contacted and the staff was referred to eleven monconformance reports prepared by the QC Inspector. A review was performed of these documents and ten of these reports were determined to

. i hava be:2 cecept bly cddrass d ccd rassivad. Tha oisv: nth nrocenfermance report was found to be undergoing licensee review. The staff's review of the eleventh report determined that no significan; safety problem had

             ~

been identified. The staff examination and resolution :( this allegation

                            , (RV-83-A0052)isdocumentedinNRCInspectionReportsNos.5d275/83-36
                          . , and 83-41.

Staff Position Based on the foregoing information, the staff concludes that H. P. Foley procedures and policies for the control, voiding, dispositioning and administering of the Nonconformance Reporting system complies with the 1 requirements of the contractor's and the licensee's Quality Assurance Program. Action Required The licensee was informed that Notices of Violations will be issued by Region V in the areas of (1) engineering dispositioning of a nonconformance without realizing that the wrong welding procedure and material had been used, and (2) the discovery of untorqued structural bolts. Note: The untorqued structural bolt violation was discovered during the inspection of the stated allegations. 1 l i j i

0 I

___-_-- __- - ___-_ _ -_ A

U S. NUCLE EGU T Y COMW$pON "9[3* g

  • ALLEGATION DATA FORM D/)/8'i' instructions on extse sio.

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l. RECEIVING OFFICE Docket Number (if applicabt:) l I

1.' Facilitylles) Involved: INamel

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2. Functional Ares (s) Involved:

(Check appropriate boites)) _ operations _ onsite health and saf ety construction ._ offsite health and safety __ safeguards emergency preparedness l other tspecityl ] 3.

Description:

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                                            ._         licensee employee                                     news media                                                ]

NRC employee private citizen jO i

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organization (specify) I other tspecity) bt E, k [ ' ' M/* I i 7 N Mf A DD YY

5. Date Allegation Received: ,s -

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7. Of fice: .-

ACTION OFFICE ((l I' hi li

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Contact:

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9. FTS Telephone Number: q (,

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10. Status:

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12. Remarks: l l l gl l l l j.l l l l l l l l l (Limit to 50 characters!

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13. Allegation Number: _

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' &c len /J.Nr Flf E CO 7lMh( Task: Allegation or Concern Nos. 25, 58, 142, 154, 176 , ATS No: RV-83-A-33, RV-83-A-57, RV-84-A-0015, RV-84 A-0017, W% 7, pd RV-84-A-0007 BN No: N/A

  • M 3 *IY *SY
                                                                                    &Ts\ew
             ~                                                                         46 Characterization Alleged deficiencies in the installation of concrete expansion anchor bolts by site contractor H. P. Foley.

Implied Significance to Plant Design, Construction, or Operation Improper installation of anchor bolts could result in reduced load capacity of 1 the anchor bolts with attendant loss of design function during normal operation or design basis events, including seismic events. i l l l l Assessment of Safety Significance This issue was discussed in SSER21 (NUREG 0675), pages 2-44 through 2-54 allegation No. 25. The staff's subsequent reviews of the issues in SSER-21 and other related allegations are documented below. l The concerns raised by these allegations involve the installation and inspection of concrete expansion anchors by the H. P. Foley Company. A general and non specific concern with anchor bolts was supplied initially to the staff from an anonymous alleger. Subsequent interviews of onsite contractor personnel resulted in additional concerns with added detail in some 1

 '    r cases. -The. substance of the initial allegation and concerns obtained'from 1

interviews have been -characterized by the staff as follows: .i i 4

1. Phillips Red Head Stud Anchors have been forbidden for use in nuclear l
            ~

power plants. f

2. Phillips Red Head Anchors are not good because at other nuclear power J

plants they have been removed or not used. j

3. Many anchors _have been installed improperly.

l l 4. Anchors have not been torqued.

5. Phillips Red Head nuts are only tightened " finger tight".
                                                                                          -l l
6. Washers are not used on concrete anchors. l l

l

7. Quality Control does not inspect or inadequate'ly inspects anchor bolt holes prior to installation.

i

8. Quality Control inspection of 10% of anchors on instrument supports is inadequate.

i The staff approach to resolution of these issues was to: (1) review installation procedures, audits, nonconformance reports, discrepancy reports, l and licensee correspondence relating to concrete anchor bolts; (2) have an independent NRC contract team (Lawrence Livermore National Laboratory) inspect-i

                                                                  .h

1 l

   ,    -a sample of 124 electrical raceway supports modified in 1982 (involving                                                                         -

hundreds of anchors-bolts); and (3) request the licensee to perform torque i tests and ultrasonic examination on a sample of 40 installed anch,or' bolts to ) i verify the adequacy of installation. 1 The results of the staff investigation, as applied to the general concerns listed above are: I (1)&(2) The concern that Phillips Red Mead Stud Anchors are forbidden to use I in nuclear power plants or are not good is not supported by any NRC. criteria or industry standards. These anchor bolts are acceptable. (3) The concern that many anchors have been installed improperly was not confirmed by field torque tests.  ! I l (4) The concern that anchors have not been torqued was confirmed, however, there is no NRC criteria which require anchor bolts installed in electrical, heating, ventilation and air conditioning, and instrument' I tubing applications to be torqued to any specified value. The staff also-reviewed the licensee's electrical raceway qualification tests to determine if bolt torque was a significant parameter and concluded that anchor bolt torque would not impact the use of the qualification test results. (5) The concern that Phillips Red Head nuts are only. tightened " finger tight" was not confirmed. The " finger tight" check is a Quality Control inspection point. The anchor bolt installation procedures require nuts i

e to be tightened although a torque value is not specified. .The staff field sample verified that all anchors tested were tight. a.

           -(6) No specific requirement exists for washers to be installed on concrete anchors. This is not considered a problem by the staff.

(7) The concern that Quality Control does not inspect or inadequately l inspects anchor bolt holes prior to installation was not found to be a 1 problem. I l I (8) The concern that Quality Control inspection of 10% of anchors is , l inadequate was not confirmed. The staff consider that a 10% sample size is technically adequate and that it is consistent with that used at other i plants.  ; 1 Although the staff investigation failed to confirm the alleged significant l deficiencies in concrete anchor installations, the staff did come across some  ! l (PG&E was aware of issues i, ii, and iii and had taken concerns as follows. action prior to NRC involvement.) l l

i. Some Anchor bolts were too short to meet the licensee's minimum embedment I

criteria. ii. Field surveys performed after 1974 identified numerous cases where the spacing between anchor bolts did not meet PG&E requirements. u__. _ _ _ __.____.____._.________________a

 ~

iii. There existed a seemingly inappropriate disposition of several anchor bolt discrepancies involving angularity identified during PG&E's " Grid Program." (Note: The " Grid Program" was a 1978-1980 inspectfpn of all

                    ' Class IE raceway supports). The disposition in question was:with the
               ~

I corrective actions taken by PG&E.

                  .                                                                                                                         l iv. Numerous installation deficiencies have been dispositioned over the years without incorporating these dispositions in the current engineering 1

evaluations of raceway supports. l

v. The appropriate factor of safety may not exist in the "as-built" condition on electrical raceway supports.

vi. H. P. Foley anchor installation procedures did not contain PG&Es criteria for slippage which can occur as one tightens the bolts. In order to resolve the six issues listed above, the staff asked the licensee to perform various tests, evaluations and reviews. The staff then examined-the majority of these results and concluded that the concerns probably do not involve violations of any NRC criteria. The inspector still has to complete his review of the PG&E information. Staff Position The concerns raised by the various allegers regarding H.P. Foley anchor bolt practices were not confirmed by the staff.

    .                 Action Required The inspector still has to complete review of the PG&E material concerning the l                       items questioned by the inspector. Further followup action by the staff will                           J b6 performed as part of the routine inspection program.                                                  f O

I 1 t

             '[                        q                          t-7 @J kt DETAILS
1. Persons Contacted Q'M
                                              *R. C. Thornberry, Plant Manager
                                              *R. Patterson, Plant Superintendent                             "
                                              *J. M. Gisclon, Power Plant Engineer                              '
                                              *D. B. Miklush, Supervisor of Maintenance
                                              *J. A. Sexton, Supervisor of Operations
                                              *J. V. Boots, Supervisor of Chemistry and Radiation Protection
                                              *W. B. Kaefer, Technical Assistant to the Plant Manager
                                              *R. G. Todaro, Security Supervisor
                                              *R. T. Twiddy, Supervisor of Quality Assurance
                                              *R. M. Luckett, Regulatory Compliance Engineer J. W. Shryock, Assistant Project Completion Manager The inspectors also interviewed several other licensee employees including shif t supervisors,- reactor and auxiliary operators, maintenance personnel, plant technicians and engineers, quality assurance personnel and General Construction personnel.
  • Denotes those attending the exit interview on July 29, 1983.
2. Operational Safety Verification During the inspection period, the inspectors observed and examined activities to verify the operational safety of the licensee's facility.

The observations and examinations of those activities were conducted on a daily, weekly or monthly basis. On a daily basis, the inspectors observed control room activities to verify compliance with limiting conditions for operation as prescribed in the facility Technical Specifications. Logs, instrumentation,-recorder traces, and other operational records were examined to obtain information on plant con <litions, trends, and compliance with regulations. Shift turnovers were observed on a sample basis to verify that all pertinent information on plant status was relayed. During each week, the inspectors toured the accessible areas of the l facility to observe the following:

a. General Plant and Equipment Conditions.  !
b. l Maintenance activities and repairs (See paragraph 3).
c. Fire hazards and fire fighting equipment,
d. Ignition sources and flammable material control. .
e. Conduct of selected activities for compliance with the licensee's administrative controls and approved procedures.

l

f. Interiors of electrical and control panels.

l l 7 ' YW

   ,- .,                                         2
                                                                                         )

l

g. Implementation of selected portions of the licensee's physical security plan.
h. Plant housekeeping and cleanliness.

The inspectors talked with operators in the control room, atrd other plant { personnel. The discussions centered on pertinent topics of general plant I conditions, procedures, security, training, and other aspect's of the '

         '_   involved work activities.                                                   ;

1 No items of noncompliance or deviations were identified. I

3. Fo]Iow-up of a Local Citizen's Concern l

l At the Atomic Safety and Licensing Appeal Board hearing on July 19, 1983, j a concern on anchor bolt installation was brought up by a member of the { public to the resident inspectors. The concern was that in the 1976-77 l time frame a bolt was found connected to a nut that was welded to the l back of an embedded plate rather than anchored in the concrete wall. The NRC construction inspector, who was responsible for inspecting Diablo Canyon in 1976-77 at the time the alleged problem took place and ) appropriate PG&E construction personnel for Diablo Canyon were { interviewed. It was identified that during the 1976-1977 time frame j there was a significant investigation into the area of anchor bolts for 1 all design Class 1 pipe system anchors (PG&E Discrepancy Reports 282 for { Unit I and 284 for Unit 2). At that time cut Anchor sleeves, discovered j during a non-related repair of an anchor plate, were identified in ] Pullman Discrepancy Report (DR) No. 3160. Because of this report a l sampling program was initiated. The sampling program identified problems including the same problem as that expressed for the current concern. From these findings PG&E DRs 282 and 284 were initiated. The program related to PG&E DRs 282 and 284 required additional testing j to establish acceptance criteria for anchor bolt installation, and I examinations of 100 percent of Class 1 anchor work done prior to January ' 1977. After January 1977 additional (C inspection guidance and requireraents for anchor bolts were initiated. A large number of anchor bolt repairs (about 10,000) were performed and documented to disposition of 1)Rs 282 and 284. In addition, several inaccessible anchors were analyzed for acceptability. These corrective actions were examined by the NRC construction inspector at that time and were determined to be acceptable. 1 The individual who brought up the concern on July 19, 1983, was informed of the history and resolution of the problems, as identified above. He l expressed appreciation for the information. . 1 Currently, a licensee QA audit at Diablo Canyon has raised other questions related to electrical raceway and instrumentation anchors. This area is being followed up by the NRC inspectors (83--27-01). l No items of noncompliance or deviations were identified.

 ,                                                  y
                                                                                            ~ ~ - - - ~ ' ~ -]

e

4. Preoperational Data Review (Unit 2)

The inspectors reviewed the preoperational test data for Test Procedures listed below: 33.1 Containment Isolation and Spray Initiation 2, Integrated Safety Injection Preoperational Test 33.2 33.4 Emergency Core Cooling Systems (Portions required prior to Hot Functional Testing) The results appear to met the acceptance criteria. No items of noncompliance or deviations were identified.

5. Exit Interview The inspectors met with licensee representatives (denoted in paragraph 1) on July 29, 1983, and discussed the scope and findings of the inspection.

( l ' l I

m -- q , -.

 ,'                                                                                 h@M% Y            .

36% FALSE FLOOR IN CABLE SPREADING ROOMS IS NOT CLASS'l During a walkdown of cable tray and conduit supports on'Janugy 14, 1984, the NRC inspector identified two Class I Electrical Race'way

     ~

Supports attached to the Non-Class I steel supporting the diamond plate

                                                                                                        'j in the cable spreading room, elevation 127 ft.            These supports were CSR-127-3-634 and CSR-127-3-573. The inspector also noticed several l

I deficiencies in the installation of the concrete anchor bolts' securing the structural steel to the concrete. l

                                                                                                         )

The deficiencies in the anchorage of the structural steel had been i identified by a Foley inspector on October.7, 1983. The concern was based on the fact that this structural steel was being used to support Class lE electrical panels in the cable. spreading room. PG&E. initiated i a minor variatfor. report (MVR No. C-1338) on December 1, 1983 to l A feet et t s-address the deficient anchor bolts. This was evaluated by GPfg and a y disposition requiring corrective action was issued to construction on January 11, 1984. In addition, as a result of the NRC inspection MVR E-2773 was written y in assosrwa ePTML NRt., by PG&E on January 17, 1984 and sent to engineering for resolution.g*is MYg enas upgru bd To riousnfmna ne e scac~a.s eN s,npouiwy t9, tess/ trivp t.s y' 36urc, ReviE WED O D676EMNG NN57WER. TMA D VEsY ff A CoMSTRa d T7od 3 C Ftt'EMY (tocFtrooS55)) oL / eueurre*H AGPalAIA4- /HWA&Md; ef M J/tfW144. EVdV1~%sPJR1~, TP FSAR Section 3.2.1 addresses the classifications of structures. , Page 3.2-2 states " Plant features which correspond to Category I as

                                                                                                         )

identified in AEC Safety Guide 29 are designated as Design Class I." l In addition, the FSAR states that the Diablo Canyon Quality Assurance Program applies to Design Class I items. Design Class I items include

                                                                                    ]hg               s

l 4' those items whose failure could reduce the functioning of other Design Class I items (Item 17 page 3.2-5). l Contrary to the FSAR commitments PG&E has not designed and constructed

                       - the structural-steel supporting the diamond plate to Design Class'I requirements.

Tje. gus,u u , a

  • undo pare p u fo r m s set ly zuise injaenxy w em,pti, ,ee suur k rH FCPL Design Fasos
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  ,             NRC Walkdown of' Anchor Bolt Installations                          g '16          ,%%
                                                                                              '~ (f The NRC walkdown on Janauary 14, 1984, identified the following SWft'Af             4 deficiencies'in addition to the Class I supports. welded to Non1C lass I-structural steel.
                                                                             ..                          1
1. CSR 127-3-77 One bolt installed at approximately 19 One bolt with projection of 2 7/16 inch with two nuts on the stud.

One bolt that did not have a full thread projection. M6adr/AIV

2. Three BJH-17 junction boxes with one, bolty missing on the cable
  • q l

MNra ntAy ] spreading room floor. l l 3. CSR-127-5-11 Bracket pulled away from wall. { 4. Two loose nuts.. l GEfGW140-4-1071- X Support CSR 127-3-77 had been recently "as-built" and. transmitted to PG&E engineering on September 10, 1982. The "as-built" identified the j projection but did not identify the bolt angle. SupportsGEfGW-140-4-1071 and CSR-127-5-11 have been documented by PG&E x MUR E-2771 and MVR E-2772 for corrective' action. i Foley QC inspected these junction boxes on January 19, 1984, by removing the covers. The missing anchor bolts were inside the covers , y ;

f..- ^t,' 4 2 4 j ,';: ya,ya Man km dad!nett:6p!a'si and were installed in accordance with the detail reyairements. I se - s Foley QC will document the results of this reinspection. 5 e 4

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1 LIMITED DISTRIBUTl N ' John B. Martin ha HEMORANDUM T0: Regional Administrator Region V , I Harold R. Denton, Director FROM: Office of Nuclear Reactor Regulation DIABLO CANYON - ALLEGATIONS j i

SUBJECT:

j I (SubcommitteeonEnergy ' By telephone call November 7,1983 ities at Diablo Dr.Canyon. Henry Myersi y that he They are and Environment) outlined several areas of inqu r should evaluate regarding construction activWe have entered this is  ! summarized in the attached memo for files. ibution" because of Dr.Allegation Myers' T i anonymous and his concern That memo, and this one, are marked " Limited Distrf concern advice to us thatof the that the divulgence informant the specific items'o wishes to rema n that anonymity. i elated, and some of l Although I It appears to us that all of the itemsdare construct by Region V.osed on-r (my memo of No them may be areas that his have already particular i been allegation, I amnd evaluat any ac will look into the policy issues raised by tforwarding it appropriate. ~c < / Harold R. Denton, DirectorOffice of N

Enclosure:

As stated l l 1

' f y: . .g , m . _ _ _ _ __ WASHINGTON, D. C 20555

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Files (LIMITED DISTRIBUTION) ' HOTE FOR:- f FROM: Robert A. Purple, Deputy Director. Division of Licensing .- TELEPHONE CALL FROM DR. HENRY. MYERS, SUBCOMMITTEE

SUBJECT:

ON ENERGY AND ENVIRONMENT As a followup to our meeting last Friday, Dr. Myers called me today to further discuss the information that he had on Diablo Canyon deficiencies. He prefaced his conversation by stressing that he intended to give me this information only on the condition that by Friday of this week, I would. He call him to tell him what has been done to follow up on the information. expressed reluctance to convey the information to me since he was not confident that I would take the matter seriously and make a vigorous effort to get to the bottom of th'ings. He asked me to identify who the single person was who was in charge of resolving all of the Diablo Canyon _I told him that allegations and determining their significance. issues could involve construction deficiencies, design control deficiencies and perhaps even matters for investigation of wroiigdoing, the onlyHe single noted person in charge would be the Executive Director for Operations. that, since most of the items appear to be related to construction defi-ciencies, he planned to call Jack Martin of Region V later today. (I subsequently telephoned Mr. Martin's office, who was unavailable, and relayed a summary of the following information to Tom' Bishop of his staff.) Dr. Myers did not wish to provide copies of the documents to us-that we had seen last Friday in his office. He preferred instead to orally identify the areas that I believe that he felt that by he believed the NRC should look into. defining the areas in broad enough terms, the identity Heofwarned the alleger would me that by be more protected than if he gave us the documents. passing this information on to me that I now shared a personal responsibility for protecting the identify of the alleger and that if, as a result of our

       ; investigation of these issues, the identity of the allegerHe            is made  known the then outlined  that the responsibility for that compromise rested with me.

following nine areas of inquiry that he believes the NRC should investigate.

1. Review all new conformance reports concerning the purchase of material from non-approved vendors over the last 2 or 3 years. Check all purchase orders against approved vendor lists.

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f(o(e to Files .

1 1
2. Review'all NCR's vs DCH's and check the disposition thereof.. Look a. t l PG&E's DCN's vs the Foley and Pullman Companies' DCN's for discrepancies. m
3. Provide a description of deviations over the past 2 years in DCN's and.

revisions thereto regarding the control room pressure and venti)ation j system.

4. Request all documentation from PG&E, Foley and Pullman regarding the am upgrading of materials from non-essential to essential.
5. Check documentation to establish Foley and Pullman record on certification of inspectors.

Review NCR's against inspector control prior to 1983. Note those NCR's and their, disposition. yp 6. Are there any NCR's on Redhead stud. anchors?

7. Review inspection reports and NCR's by Foley and Pullman on testing 'of concrete and grout and the use of samples.
8. Ask PG&E and Foley for all NCR's regarding wire traceability. Check work packages to determine if they clearly indicate the. source of all wires.
9. Ask for documentation establishing wire cable termination and pull test and inspections performed per Appendix B. .

Mr. Myers reiterated that he expected to hear from me within a few days with respect to the Agency's actions on these allegations. l Robert A. Purple, Deputy Director . Division of Licensing i i e e S e 4

7

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TIME DATE CONVERSATION RECORD f o , ,s. ,. ,,, . .eAfAy 0 visir g CONFERENCE g TELEPHONE . / i NAME/smso - g INQQMING J Location of Visit / Conference: O ouTcOING TELEPHONE NO'. h

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! 't PROBLEf1 STATEMENT Allegation No(s): 25 ATS  !!o(s): RV-83A-33 a. l Bf!(s): ,

                                            "Jhis    document lists (or directly references) each allegation er concern brought to the attention of fiRC personnel.                         The purpose of   this     statement   sheet is  to assure        that ALL  points          raised ~ by the alleger are covered.

If the problem statement is not clear as to who, what, where, when, of why regarding the issue, the commentary section will cmplify the statement. The commentary section uil2 also be used if there is apparent conflicting information or if there is FO l or very little orir,inal information available which describes the concern (s). ( This can occur if, for example, a one line concern was received in an interview). i i PROBLEM STATEMENTS (use extra sheets as necessary) 1 l ALLEG ATICI: # VEREATIM STATEMENT OR REF ERE!!C E 25 Red Heads are unsatisfactory anchors for safety related raceway supports. This allegation is similar to allegation fl o . l 56, transmitted to che NRC by Dr. Henry Myers. See also allegation Nos. 142, 154, and 176. i COMME!!T A R Y l Date This Statement was Completed 3/16/B4 D. Haist Technical Reviewer Signature I l 1 i 9 1

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2. Functional Areats) Involved: -

operations offsite health and saf ety scheck eporoprisie boite.11 _._ construction _ emergency preparedness safeguards _ i other (specify) _ 10 ll lL lf-l/ b-l/ -l l lTlh li li-l )l l'illclie ll>l lill / t 'l/ Id f q q, p p lqQ lg l, p l lq g( j,] 3.

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5. Date Allegation Received: [ IM L n'I. Il L
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Open if followup actions are pending or n l d (Check one! L t Closed, if f ollowup actions are comp ete DD YY MM ' 11.1 Document Nos. _ o

11. Date Closed:

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11. Date Closed: _
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