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i DIABLO CANYON NUCLEAR POWER PLANT QUALITY CONTROL PROCEDURE FOR INTERNAL AUDITS
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e APPROVED FOR CONSTRUCTION i
QUALITY DIRECTOR APPROVED ) [
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// 12 THE DATE r
HOWARD P. FOLEY COMPANY PROJECT MANAGER l
P. O. BOX 327, APPROVE Y'
AVILA BEACH, CAUF, o
y 93424 DATE 805 595 7377 Officos:
l Al LENTOWN. PENNSYLVANM
$7M 1
THE HOWARD P.
FOLEY COMPANY OALLAS TEXAS WASM PEMWVM aPPeovateas er3ttD)
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E0MONTON. ALSERTA 8708190357 870014 PDR FOIA DEVINE84-743 PDR l
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QUALITY PROCEDURE CHANGE NOTICE Procedure Number OCP-32 PCN Number i
Revision Number Rev.0 Effective Date 12-83 PAGE PARAGRAPH PAGE PARAGRAPH 2
4.4 Revised 2
4.4.1 Revised 2
4.4.2 Revised l
O APPRovAt:
CustosER APPRovAt>
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QUALITY
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PACIHC G81 & (LE C T 4tc CO.
Ossoro Conven Instruction 1)
A file of this change notice shall be maintained in the Q.C.
File:
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PG&E G.C.
QUALITY CONTROL O
aev>eweomat QCP-0
/d//d/TJ HPF/PCN 6-8-83 ons-
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SCOPE 1.1 This procedure establishes the system for the QCP-32 REV. 0 scheduling and conducting of Quality Assurance Audits to determine the adequacy and effectiveness of I
The Howard P. Foley Company on-site Quality Program.
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2.
REFERENCES 2.1 American National Standard ANSI /ASME N45.2.12 - 1977.
2.2 The Pacific Gas and Electric Company Specifications as assigned to The Howard P. Foley Company.
2.3 The Howard P. Foley Company Quality Assurance Manual.
3.
RESPONSIBILITIES l
3.1 The Quality Director shall be responsible i
for employing all measures necessary to assure I
audits are conducted in accordance with the contract documents and this procedure.- The Quality Director shall also be responsible for i
assuring those performing Internal Quality THE Assurance Program Audits are not directly HOWARD P. FOLEY responsible for the performance of the activities j
COMPANY they will audit.
i 3.2 The Quality Assurance Manager shall be i
responsible for providing systematic audits which objectively evaluate the adequacy and effectiveness of the on-site Quality Program.
In addition, he shall be responsible to provide direction and training for Quality Assurance personnel involved in auditing.
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4.
PREPARATION l
7-4.1 Audits shall be scheduled for each calendar i
quarter on the Quality Assurance Activity Plan, (HPF/QAAP, Exhibit 1).
1 4.1.1 The Activity Plan shall'.be signed by j
th: individual who prepared it and approved by the Quality Assurance Manager.
l 4.1.2 The plan may be changed during the I
active quarter as deemed necessary by the Quality Assurance Manager.
4.2 The subject matter and frequency of scheduled audits will be based on the status and significance of current activities.
4.3 Unscheduled audits may be conducted whenever deemed necessary by the Quality Director.
PCN-1 4.4 Audits shall be prepared by development of a written audit plan and checklist.
PCN-1 4.4.1 The audit plan (Exhibit 4) shall include I
as a minimum:
a)
Audit Number i
b)
Audit Subject
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c)
Scope of ALdit d)
Documents Researched e)
Tentative Audit Points iHE ' PCN-1 4.' 4. 2 The' audit checklist shall consist of HOWARD P. FOLEY spscific questions derived from the tentative audit points.
COMPANY 4.5 Auditor selection shall be mede by;the Quality
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Assurance Manager.
When an audit team is" to be utilized, a qualified auditor shall be chosen as Audit Team Leader.
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'i 4.5.1 The Audit Team Letder's responsibilities include orientation of the team, coordinating I
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the audit process, establishing the pace of the i
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audit, assuringt' communications within the team and with the department being audited,4 3
participation in the audit performance.and
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coordinating the preparation and issuance g
qq. reports.
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) /4.5.2 Audit' Team Member 3 can be auditors-in-ticining or those individuals having special-iz ad knoviledge in the area (al o being audited.
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- s 4.6 Managing personnel of departments to be involved in the audit, as well as the Senior Site
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Representative shall be notified prior to the start i
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of audit activities.
5.
PERFORMANCE 5.1 A Pre-Audit Conference may be held after notification and before the commencement of QCP-32 a Quality Assurance Program Audit.
REV. 0 5.1.1 During the Pre-Audit Conference the Audit Team Leader should present the audit 1
plan, confirm the audit scope, distribute checklists, introduce auditors, meet counterparts, verify the audit schedule and establish lines of communication.
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5.2 Audits shall be performed as delineated in the audit checklist.
The checklist does not limit the investigation when evidence indicates further i
examination is warranted.
i 5.3 Audits shall give special attention to discrepancies identified during previous audits.
I 5.4 All conditions requiring prompt corrective i
actions will be reported to management immediately.
5.5 At the conclusion of an audit a Post-Audit Conference shall be held with management of the audited areas to present audit results and clarify misunderstandings.
i THE 6.
REPORTING HOWARD P. FOLEY l
COMPANY 6.1 The Audit Team Leader shall sign the audit report which should include the following:
a)
The audit scope.
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b)
Identification of the Audit Team Members.
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Names and titles of personnel contacted I
during the course of the audit.
d)
A summary of audit results, including conclusive statements concerning the adequacy and effectiveness of the areas audited.
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A detailed description of the audit results and/or open audit findings in sufficient detail to assure that corrective actions I
/'T can be effectively implemented.
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Rscommandations for correcting open cudit
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findings.
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Reference to controlling documents.
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Signature (s) of auditor (s) and Audit Team Leader.
6.1.1 The audit report shall be issued within 30 days of the conclusion of the ' audit.
QCP-32 REV. 0 6.1.2 The audit report shall be documented in business letter format, addressed to the Senior Site Representative and contain all the pertinent information required by this procedure.
6.1.3 Concerns and unresolved items shall be identified within the audit report and require l
written response by the audited department.
6.1.4 Generic discrepancies and program implementation discrepancies shall be documented on a HPF/ Audit Finding Report, (HPF/AFR, Exhibit 2) and intergrated into the audit report.
Open Audit Finding Reports will be issued to the responsible department with a noted Completion Due Date for Corrective i
Action required.
6.1.5 An audit report normally consists of l
M individual audit findings and will not be I
c'osed until findings are closed.
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6.2 Each calendar quarter, a report of audit l
THE status shall be prepared.
Copies shall be i
HOWARD P. FOLEY submitted to the Senior Site Representative, l
COMPANY Regional Vice-president, Pacific Gas and Electric f
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company and the Quality Diiector for their review.
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7.
AUDIT REPLIES j
7.1 The completion due date for audit replies is l
thirty (30) days following the issuance of the audit. :
Request for delay may be submitted to the Quality I
Assurance Department.
The acceptance or rejection of requests for extension shall be subject to the approval of the Quality Director.
7.1.1 Open audits that have not been replied to within the thirty day issuance period shall be
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brought to the attention of the Quality Director.
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7.2 Those, responsible for answering audits shall:
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a)
Define the action taken to correct the
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individual discrepancies identified in the audit.
b)
Define the research taken to: expose similar deficiencies and c)
Define the measures taken to prevent QCP-32 recurrence.
REV. 0 7.3 When an Inspection Report and/or a Nonconformance Report is generated as a result of an open audit finding, the finding may be documented as closed upon approval of the Proposed Disposition of the report.
7.4 Audit replies shall be made on The Howard P.
i Foley Audit Reply, (HPF/AR, Exhibit 3) and submitted to the Quality Assurance Deparment.
7.4.1 Acceptable audit replies shall be summarized and/or referenced, by the auditor, in the corrective action space on the Audit Finding Report.
The Audit Reply shall be included in the completed audit package.
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FOLLOW-UP t
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Action to correct audit discrepancies shall be verified as complete and properly implemented prior to closure of the audit findings.
THE 9.
DOCUMENTATION HOWARD P. FOLEY COMPANY 9.1 Records generated as a result of this procedure'which are intergrated into the Audit Report (i. e., HPF/QAAP, HPF/AFR, and HPF/AR) shall be maintained with the Quality Assurance Department in a readily retrievable manner.
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QUALITY ASSURANCE ACTIVITY PLAN
~00ARTERLY REPORT.FOR 4
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APPROVED DATE HPF/QAAP 5-12-83 r
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l The Howard P. Foley Company Audit Finding Report EXHIBIT 2 Audit Number Page of l
l Audit Date:
From To Completion Due l
Audit Subj ect l
Controlling Documents Auditor (s) l Quotation (s) from Controlling Documents l
Audit Finding (s)
Q.A. Recommendation (s)
(optional)
Corrective Action (s) 4 Prepared By Closed By Review / App.By 0
Date Date Date HPF/AFR-1 1-3-83 s
EXHIBIT 2 (cont.)
AUDIT NUMBER PAGE OF i
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J AUDIT REPLY EXHIBIT 3 THE HO*JARD P. FOLEY COMPANY QUALITY PROGRAM
'Q AUDIT NUMBER DATE OF AUDIT PAGE OF SUBJECT OF AUDIT SUBMITTED BY:
DATE AUDIT ITEM (S) l l
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REPLY TO AUDIT NUMBER PAGE OF AUDIT ITEM (S) 4 8
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-FORM HPF/AR-2 10-10-75
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ALLEGATION DATA FORM
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laettvet one on meres ese CECEIVIN3 CFFICE Decket Numb::t (if applicable)
I 1, Fccilitylles) Involved:
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onsite health and safety operations (check appropriate boitent s offsite health and safety construction a
emergency preparedness safeguards j
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Description:
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- 4. Source of Allegation:
contractor employee security guard (Cheen approprete box news media licensee employee private citizen NRC employee organization tspecityt O
M Il other tspecity)
MM DD YY
- 5. Date A(legation Received:
g W L* (aster
- 6. Name of Individual (First two initiele and test name)
Receiving Allegation:
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- 8. Action Office
Contact:
trirsi swo initisi, and insi namet _
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- 9. FTO Telephone Number:
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- 10. Status:
Open,if followup actions are pending or in progress i
tcheck one)
Closed, if f ollowup actions are completed f
MM DD YY 11,1 Document Nos._
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- 11. Date Closed:
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Number _
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- 13. Allegation NurkfDate 12.1 Man-hour er:
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.,. Feellity(l;s) Involved:
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- 2. Functional Ares (s) Involved:
onsite health erid safety scheek asorepriate bonfeel l operatione M construction offsite health and safety safeguards-emergency preparedness other (spec 6ty)
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Description:
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- 4. Source of Allegation:
contractor employee security guard tchect.pp ca,ste box) licenses employee news media NRC employee private citizen organization tspecifyl
_I other especifyl
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- 5. Date Allegation Received; g
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- 6. Name of Individual trir.st two initiets eng test narnet Receiving Allegation:
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I 8 Action Office
Contact:
triest,w oinit:.i..ng i. t n.m.i S. FTS Telephone Number:
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[ Open,if followup actions are pending or in progress
- 10. Status:
Icheck one)
Closed, if f ollowup actions are completed MM DD YY j
n.ost. Cio..d:
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11.1 Document Nos.
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December 13, 1983
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INTER-OFFICE MEMO TO:
Ted Canning /Q.C. Manager FROM: Bob Walcheski/Q.A. Auditor RE:
H.P. Foley Audit PA-135, Item 12.
Your response to Item 12 of Internal Audit PA-135, which was received by our department on 12-1-83 is not sufficient in itself to close the item. By re-establishing the required daily and weekly Storage Oven Inspections, the problem is partially resolved.
However, for the period of time when these inspections were not perforced, there exists a documentation deficiency which renders the quality of welding electrodes indeterminate.
Para. 4.7 of QCP-4A states, " Nonconforming items that are not possible to " Correct In-Process" shall be documented in accordance with QCP-3."
According THE to QCP-3, Para. 4.4, a Nonconformance is defined in HOWARD P. FOLEY part as, "a deficiency in characteristic, documentation, COMPANY or procedure which renders the Quality of an item unacceptable or indeterminate. Examples of AVILA BEACH, CAL.'
nonconformance include:.... incorrect or inadequate j
93 3 documentation, or deviation from.....
inspection....."
sos.595 7377 The method for documenting the nonconforming condition is as prescribed in QCP-3, Para. 5.1.
Whichever way you choose to document this condition, it should be noted ornces:
that the goal is to achieve a "Use As-Is" disposition.
I ALLENToWN. PENNSYLVANIA s gg ay M aCdW Ms dhposith WM be M BALTIMORE. MARYLANo review Weld Electrode Requisitions (HPF/WER) for j
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CHIC AGo. lLUNOIS applicable storage oven locations for the time in which 1
HAARISBURG. EN S LVA 8
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8 houston. TEXAS WER documents storage oven temperatures.
If no LoS ONGELE S. CALIFo ANIA discrepancies are noted in this review, then significant
- T[gEZ[ TEN ES$Ej basic for a "Use At-Is" disposition is established.
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ygy NEW oALEANS LOUISIAN A PHtLADELPMIA. PENNSYLV ANI A PHOENIX, ARI2oNA PITTS8UAGH. PENNSYLVANIA RICHMcNO VIAGINtA SALT LAKE CITY. UTAH i
TAMPA, FLoA:DA TUCSON AACN A WASmNGTCN O O ECYON'!*. ALC5:*A
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T. Canning Page 2 December 13, 1983 Audit Tinding #12 for PA-135 will remain outstanding until such documentation is generated to iden'tify, j
and satisfactorily resolve the problem. Your response to this Item, only provides a Means for Preventing Recurrence but does not offer any Corrective Action for the resulting documentation / inspection deficiency.
Please provide Q.A. with a response for corrective action to this outstanding problem as soon as possible.
I Sincerely, R.J. Walcheski Q.A. Auditor RJW:cw cc:
L.R. Wilson Q.A. File THE HOWARD P. FOLEY COMPANY j
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The Howard P. Foley Company Audit Finding Report l
Audit Number P A - ! v.
Page 13 of 13 Audit Date:
From 9-27-83 To 10-4-83 Completion Due l
Audit Subject Welding Ele, g ede Control Contro11ing Documents HPF'QC{4A Auditor (s)
S. Ryan, R. W..lchaski wr Quotation (s) from Controlling Document:
QCP-4A, Para. 4.6, " Quality Control shall perform a daily and weekly inspection to assure that this procedure is being followed."
Audit Finding (s)
ITEM 12 - Contrary to the above requirement, daily and weekly inspections are not being performed by Q.C. for Unit I storage ovens. Quality Control is unable to gain access to Unit I due to Security Lockdown.
(See Exhibits 10&ll attached).
Q.A. Recommendation (s)
(optional) bb W
O 4z a5allBR Corrective Action (s) l l
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R.J.Walcheskif.[@#g/
Prepared By Closed By Revie'.7/ App.By l
r 1n-1-83 Date Date Date rurms;x====:nmer.me:=r-ze:.
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7 REPLY TO' AUDIT NUMBER P A-13 5 P AGE _jt_O F 2
.1 AUDIT ITEM (S)
FISTING XII:
Access has been established to Unit u via ke: carded inspectors or escorted inspectors. With this required inspc.tions-will. be r e-e s t ab11.shed.
GkLksh W RECEIVE 9 QUAL.P'.SR' 5 24 ^6 DEC 011983 H0nanu v.cu a..,J.
Avila Beach CA
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The Howard P. Foley Company O
s Audit Finding Report i
Audit Number PA-125 page 11 of 17 Audit Date:
From 1-17-83 To 1-26-83 Completion Due 3 ' 93 I
Audit Subj ect Work on Containment I A.nulus steel Modif'ications Controlling Documents P.G.6 E. W/R '!C-6!E.. HPF/ Travelers & Procedures Auditor (s)
P.F. Ratterman/P.W. Fre1ch Quotation (s) from Controlling Documents HPF/QCP-17, Rev.1 4.6.1
....When Quality Inspection Hold Points tre identified by the Work Process Traveler, work shall not proceed until the Quality Department has been notified and such inspections h.ve been completed and Production has been notified of the results of the inspection.
Audit Finding (s)
During the course of this audit it was noted there are Hold Points established for P.G.6 E. Final Acceptance of welds. These appear on approximately 40% of the Work Process Travelers generated as a result of Work Request #C-6181. The P.G.& E. Hold Points are in place as the result of a verbal agreement between P.G.6 E. and The H.P. Foley Company to have Constructor approval of each weld on the Annulus Steel Modification Work.
In each case where welds are completed and accept-ed by H.P. Foley personnel, there has been no P.G.6 E. concurrence; thus, the loss of double coverage.
Although this is not considered to be an Onen Item. it is a situation requiring clarification.(Continued)
Q.A. Recommendation (s)
(optional)
Item X-1,2 & 3 Research the Quality Control and Work files to identify all cases where work has progressed beyond Hold Points without the requir-ed sign-offs.
A Nonconformance Report should then be initiated for dispositioning of this discrepancy.
Included in the "Means to to inform th'se involved, Prevent Recurrence", should be a commitment o
with work and inspection, of the importance of not progressing past un-signed Quality Hold Points.
(Continued on Page 12)
Corrective Action (s)
Item X-1,2 & 3 - See attached Audit Reply to Item X, submitted by R. Wilson on 8-15-83.
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P.F.Rattermani..
P.N.
French f(/d D
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Prepared By Closed By Review / App.3; j
1-27-33 8-16-83 j
Date Date Ds. t 2 m._.r n=
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i AUDIT NlD!BER PA-125 FAGE
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AUDIT FISDING(s)
(Continued from Page 11)
Item X - Generally, HPF/Qualit:. Hold Points are being signed-eff in accordance with the above quotation; however, there were several Work packets examined where work had progressed without:the required Hold Point sign-offs.
1)
On Connections G-7, G-8, V, X-1 and more, bolts were installed and tensioned (not yet checked with a calibrated wrench) where the Hold Points established for the bolts, i.e.,
Material, Dimensions and Edge Frep., had not been signed.
2)
Weld No.14 on Connection CG and weld No's. 14 and 15 on Connection HH have been completed and accepted on the appropriate Weld Inspection Sheets.
The Quality Hold Points for these welds have not been signed-off.
3)
Hold Points for piece No. EL C41.1 on Connection 41 have not been signed-off. The plate has been installed and the welds which attach the plate have all been completed and. accepted with Hold Points signed-off.
Q.A. RECOMMENDATION (s) (Continued from Page 12)
It was observed that earlier revisions of Travelers are not always kept with the current copy in the work packages. Quality Hold Point sign-offs are not generally transferred to new Traveler revisions.
It is a recommendation of this department that all revisions of individual Travelers be maintained in the current work packet.
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- AFR-2 10 19 75
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CCF-3 REV.7
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SCOPE i
This aroceoure estaolisnes tne m e...od s der reporting, docun en t ing, and processing materials; parts; compcnents; or services wnlen are not in conformance I
with design or procedural requirements.
2.
REFERINCES 2.1 Title 10, U.S.
Code of Federal Regulations, Part 21 (10CFR21) 2.2 American National Standards Institute (ANSI)
N45.2.10-1973 " Quality Assurance Terms and Definitions" 2.3 Pacific Gas and Electric Company Specifications as asssigned to The Howard P.
Foley Company 2.4 The Howard P.
Foley Company Quality Assurance Manual Sections XV, Control of Nonconformances, and XVI, Corrective Action 2.5 The Howard P.
Foley Company " Quality Control Procedure for Receiving, Handling, and Storage", QCP-4 2.6 The Howard P.
Foley Company " Quality Control Procedure for Corrective Action", QCP-33 3.
RESPONSIBILITIES THE HOWARD P. FOLEY 3.1 The Project Manager shall be responsible for COMPANY employing all measures necessary to accomplisn ene work in accordance with the requirements of tne contract documents and this procedura.
3.2 The Engineering Manager shall be responsible for recommending dispositions on NCR's and dispositioning IR's.
3.3 The Production Superintendent snail ce responsible for accomplishing all work in accorcance with tne specifications, design drawings, and procedures.
He is also responsible for immediately notifying Quality Control wnen nonconforming conditiens exist.
I 3.3.1 It shall be ene responsibility of tne l
individual Production Superintendent to ensure tnat l
Procuction forces under his supervision are trainec anc working in accer=ance wits current revisions of quality procedures.
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Et:ler P'oject Superintendent Pacific Cas and Electric Connany Post Office Box 117 I'
Avila Beach, CA 93424 l
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Audits RE: Internal The Howard P.
Foley
Dear Mr. Etzler:
i Due to an intensive internal training and certification effort, the restructuring of several key procedures and revision of The i
Howard P. Foley Company Quality Assurance manual; The Howard i
P. Foley Company is foregoinst its formal activity audit per-formance for a period of approximately ninety days.
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This action will not adversely affect our Quality Assurance Program; will allow us to ef fectively utllize all of our personnel in the execution of theie tasl.s. and will provide necessary time to implement the new procedures effectively.
At the end of this period The Howard P. Foley Company will THE perfortn a program audit to assure that the effort is success-HOWARD P. FOLEY fully completed.
COMPANY P. O 80x 327 I
Sincerely.
AVIL A BE ACH. C AttF.
f 805 595 l'
Rick 'Jilson Quality Director o,,
Au.ENtom PENNSYLVANIA gej; g g l
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det.ory slutual Research
!15) Boston Providence Turnpike Norwood. Massachusetts 02062 OctobeE 28, 1975 26543.
(4610)
FIRE ENDURANCE TEST on PENETRATION SEAL SYSTEMS IN PRECAST CONCRETE FLOOR UTILIZING SILICONE ELASTOMERS (CHEMTROL DESIGN FC 225) for DOW CORNING CORPORATION MIDLAND, MICHIGAN 48640 and CHEMTROL CORPORATION 10600 HEMPSTEAD RD.
HOUSTON, TEXAS 77018 GENERAL This report describes the construction, the test procedure and lists the results of a fire test conducted on twelve penetration seal systems installed in a 17 ft - 10 in. by 14 ft - 2 in. nominal 8 in, thick precast concrete floor assembly.
The penetration seals included silicene elastomeric foam, silicone bonded lead radiation shields, flexible silicone impregnated fiber-glass boots, silicone adhesive / sealant, and alumina silica damming material.
The penetrations consisted of rectangular openings containing cable trays with conductors and various combinations of steel pipe sleeves containing electrical conductors and steel pipe conduits.
The test assembly was constructed as shown on Illustration 1.
Chemtrol's specifications of the products employed in the construction of the penetration seal systems are attached as appendix sheets to this report.
The' raw materials or the in-place products of the seal systems are not manu-factured or produced under Factory Mutual quality assurance follow-up in-plant inspection program.
The object of this test program was to investigate the fire endurance characteristics of the penetration seal systems as described herein.
The test was-performed following the procedures for evaluating floor-ceiling assemblies s W _naA = A ar the Standard for Fire Tests of Building Construction and Materials ASTM E119-7 (NFPA 251).
The The penetration seals were subjected to fire exposure for 3 hours3.472222e-5 days <br />8.333333e-4 hours <br />4.960317e-6 weeks <br />1.1415e-6 months <br />.
pe:formance of the twelve seal systems during fire exposure is detailed in this report.
j e e_t A?
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FACICAf MUTUAL 815E ARCH CORPOR A TION Page.2 26543 DESCRIPTION MATERIALS The materials used in the construction of the floor assembly.and the desig-nated penetration seal components are described below:
Concrete Floor - Nominal 8 in, thick precast, prestressed hollow-core concrete
'. planks manufactured by Spancrete Northeast Inc.
Deck units were 40 in, wide by 13 ft-9 in. long.
Concrete - Laboratory mixed concrete consisting by volume of 1 part Portland c em en t, 2 perts sand and 2 parts pea gravel mixed with 6.0 gallons of water per 94 lb. bag of cement.
Foamed-In-Place Silicone Elastomer System - Dow Corning 03-6548 Silicone RTV Foam /Chemtrol Part No. CT-18 designed as a medium density penetration seal for liquids, gases and fire confinement.
Dow Corning supplied certificate of compliance that the material furnished was within all applic~able specification requirements.
The average open-cup density of the silicone foam was 18.3 lbs.
per cu ft.
See Appendix E for cup specifications.
Specification No. 3300 covering the foam is included in this report as Appendix A.
Foamed-In-Place Silicone Lead System - Chemerol CT-300L gamma radiation shield-ing penetration sealing material.
Material formulated utilizes a matrix including Dow Corning's Sylgard 170 silicone elastomer and' powdered lead.
Certificate of compliance for the Sylgard 170 was supplied by Dow Corning certifying the material as complying with applicable specifications.
The-
' nominal 150 and 250 lb. per cu ft density lead foam were 156.5 lb. per cu ft and 246.8 lb. per cu ft respectively Chestrol Specification No. 3400 for the radiation shielding foamed-in-place silicone lead is included in this report as Appendix B.
j Penetration Boot Seal System - Chemtrol CT-15B silicone rubber fabric.
Boot seal intended for use as a seal for pipe and duct penetrations where movement or vibration is present.
The boot seal was installed with a fire stop.
The boot fabric was fastened with Dow Corning 96-081 RTV Adhesive / Sealant or Chemtrol Part No.. CT-4C.
Certificate of Compliance for the adhesive was supplied by Dow Corning certifying the 96-081 RTV Adhesive / Sealant as comply-ing with applicable specifications. Chemtrol Specification. No. 3410 for the boot seal and specifications for the adhesive are included in this report as Appendix C.
Damming Materials - The following materials were used to contain the liquid silicone in a specific area while it reacts and expands into a solid mass.
The damming materials were left in place and are an essential component of the
- seal, a)
Chemtrol Part No. CT-23F - Loose alumina-silica fiber for service temperatures of 2300*F.
FACTORY MUTUAL ttSEARCH CORPORATION
~
Page 3 26543 b)
Chemtrol Part No. CT-23B - Nominal 1 in. thick alumina-silica fiber blanket for service temperatures of 2300*F..
Specifications for the damming materials are given in Appendix D.
Cable Trays - 5 ft long solid bottom and ladder back ventilated'c'able trays The sides of the open ladder trays were chan-were used in the construction.-
nel shaped, 4 in. deep with outward extending flanges - 7/8 in. vide and a 3/8 in, wide return flange on the cable side, fabricated from 12 gage (0.107 in.
thiek) galvanized steel.
The rungs were 1 in, diameter tubes of galvanized semel and located 12 in. 0.C.
The inside dimensions of the trays were nomi-
'l nally 3 in, deep by 18 in vide.
The solid bottom cable trays were constructed with channel. shaped sides 4 in, The deep and fabricated from 17 gage (0.060 in, thick) galvanized steel.
The
. cable side flange was formed into a 3/8 in, square closed box shape.
solid bottom was 23 gage (0.030 in. thick) corrugated galvanized steel with a pitch of 1 1/2 in, and S/16 in, deep._
The trays were nominally 3 5/8 in. deep by 18 in wide.
The 34 in, wide cable trays were f abricated at the laboratory by joining two ladder back trays with the adjoining sides removed. The rungs were joined The 34 in, wide solid with pipe sleeves and welded to form a single unit.
thick) back trays were f abricated in the same manner with a 18 gage (0.052 in.
galvanized steel back welded to the ladder backed trays.
Electrical Conductors - The copper electrical wires used to fill the cable trays and conduits were as follows:
a)
Anaconda W Type TW No. 14AWG.
600 volt oil resistant single I
conductors and having a thermoplastic coating.
b)
Anaconda W Type THW 300MCM.
600 volt oil resistant single i
conductors and having a thermoplastic coating.
Anaconda M power and control tray cable, Type THHN or THWN c)
CDRS, 7 conductor No. 12AWG 600 volt cable for installation i
in continuous rigid cable supports and having a thermo plastic coating.
Cable trays in one penetration were filled with the following copper con-ductors:
i a)
Raychem Flamtrol No. 4/0 AWG.
1000 volt, 90 C Type XLPE h
b)
Raychem Flamtrol, 7 conductor No. 32 AWG.
2000 volt,
(.
90 C Type XLPE.
c)
Raychem Flamtrol, No. 12 AWG single conductor.
600 volt, Type XLPE.
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FACTORY MUTUAL RE SE ARCH CORPO R ATION Page 4 26543 Conduits and Sleeves - Standard weight steel pipe of nominal 6 in, dia. (6-5/8 in. 0.D.) with a 0.280 in, wall thickness and nominal 10 in, dia. (10-3/4 in.
0.D.) with a 0.365 in, wall thickness.
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Appendix Sheet Al Specification 33300
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i PE TETRATIO 1 SE ALS Foamed-in-Place - Silicone Rubber Chemtrol CT-18/Dow Corning Q3-6548 Silicona. RTV Foan (Medium Density)
PRODUCT DESCPlPTION CT-18 is a two component silicone foam. When mixed in a one one ratio by weight, or volume, the Silicone RTV Foam exhibits excellent fire resistant properties (as a penetration seal).
.DVANTAGES j
i Chentrol CT-18/Dow Corning Q3-6548 Silicone RTV Foam offers superior properties in:
l Fire Retardance
. Cell Structure
. Lack of deterioration
. Non-chaulking characteristics
. Resiliency
. Rate of expansion during cure process
. Time of cure
. Methods of handling Safety factors while material is in its liquid state and other proprietors chemical matrixes of cr-18 as listed in the following specifications.
l
'JSAGE Chemtrol CT-18/Dow Corning Q3-6548 Silicone RTV Foam when installed with Chemtrol's proprietors installation procedure, offers excellent properties as a penetration seal to resist fluids passage, smoke passage, air passage, and fire penetration.
CT-18 flexible, expanding Silicone Foam can be foamed-in-place to seal electrical cables, conduit, pipe, cable trays and pull box penetrations through wall, floors, and cabinets.
,-Appendix Shast A2 Specific =.t ton 5 3 300' (cont ie,3_
t TYPICAL PHYSICAL PROPERTIES CURE 0 FOAM-(Mixed one Part A - One Part 8 a'nd cu' red at 720F for a minimum of 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br />)
DESCRIPTI0tl TEST METHOD
^[
RESULTS i
Appearance CTM 0176 Dark Cray-Black Density CTM 0812 Power mixed Hot less than for 30 seconds and 15 lbs/f t3 cured in non-confined Chemtrol centainer #1516 I
Closed Cell Content-CTM 0826' 95%
Breathability Method Thermal Conductivity CTM 0224 1.8x10-4 Cenco Fitch Method i
i Cream Tice CTM 092A 1.5 min.
Limi ting CTM 0780 35 0xygen Index L.O.I. Rating ELECTRICAL PROPERTIES (Cured Foam 125 mils. thickness)
DESCRIPTI0tl TEST lETH00 RESULTS Dielectric Streng th ASTM 0877 165 Volts / mil 01 electric Constant ASTM 0150 (100 Hz) 1.95 Dissipation Factor ASTri 0150 (100 Hz) 0.00505 Volume Resistivity ASTM D257 2.24x1015 OHit-CH R ADIATI0tl RESISTANCE PROPERTIES
~ DESCRIPTI0I1
. TEST METHOD RESULTS flegarads Exposure CTH 0525 Modulus at 10%
Compression,. psi 0
CTM 0525 0.62S 6
CTM 0525.
0.672
'22 CTM 0525 0.92 i
49 CTM.0525 2.00 124 CTH 0525 2.32 still resiliant I
- - - - - - - - - - - - - - - - 1
7-Appendix Sheet A3 Specifice* inn 23300 (cent'd)
TYP:CA1 PROPERTIES. (The following properties are for general information.
Physical data on properties not herein listed can be obtained by testing according to direction of the customer.)
PA?.T.3 DESCRIPTION TEST METHOD R ESULTS Appearance CTM 0176 Black Liquid Specific Cravity ASTM D-70 1.05 V is co sit y ASTM D-1084 50 Poise Brookfield Model Haf Spindle No.3 at 10 RPMS Shelf Life
( E s t ima t e)
' 6 Menths Flash' Point ASTM D-92 470 F Fire Point ASTM D-92
> 6 50 F Sulphur content CTM 0787 None Detected Less than 2 PPM Chlori a Content CTM 0787 None Detected Less than 4 PPM Bec-ine Content CTM 0787 None Detected Less than 5 PPM Iodinc Ocntent CTM 0787 None Detected Less than 6 PPM FLECTRICAL PROPERTIES ( 50 mils liquid)
Diclectric Strength ASTM D877 680 Volts / mil Dielectric Constant hSTM D924 (100 Hz) 3.08 Dissipation Factor ASTM D924 (100 Hz) 0.00103 12 Y'lu o Resistivity ASTM D169 ( 500 Volts)D.C.
3.23x10 OHM-CM
Appendix Sheet A4 Specification #3300 (con t 'd,p P ART B l
DESCRIPTION TEST METHOD RESULTS Appearance CTM 0176 off White Liquid Specific Gravity ASTM D70 1.05 Viscosity ASTM D1084 60 Poise Brookfield Model Haf Spindle #3 at 10 RPMS Shelf Life
( Es tima t e) 6 Months Flash Point ASTM D92 2700F Fire Point ASTM D92
> 3 90 F Sulphur Content CTM 0787 None Detected Less than 2 PPM Chlorine Content CTM 0787 None Detected Less than 4 PPM Bromine Content CTM 0 787 None Detected Less than 5 PPM Iodine Content CTM 0 787 None Detected -
Less than 6 PPM ELECTRICM. PROPERTIES (50 mils liquid)
Dielectric Strength ASTM D877 900 Volts / mil Dielectric Constant ASTM D924 (100 Hz) 3.29 Dissipation Factor ASTM D924 (100 Hz) 0.0034 Volume Resistivity ASTM D 169 ( 500 Volts)D.C.
3.38x10 12 OKM-CH l
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Appendix Sheet.A5
<e It, TRUCTIOMS FOR MS
- APPLICATION, DISPENSING, A!!D MONITORING OF SILICONC FOAM b
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1.0:
SCOPE l
Electrical cable, conduit, pipe, cable tray, and pull box penetrations
- l
'through walls and floors, as indicated on the attached drawings, shall 5
be sealed with CHEMTROL CT-18/Dow Corning Q3-6548 Silicone RTV Foam.
pf These seals are to resist passace of fluids, smoke, air, and fire through said penetration openings.-
(
- i
' 2.0 SUBSTRATE PREPARATION j
2.1 Chemtrol dams shall be provided and installed for those penetrations scheduled for sealing prior to foaming operations.
2.2 Electric cables through the penetration opening are ' o be spread c
where possible to facilitate the flow of silicone between cables.
j 2.3 'If cables.are too congested to allow spreading through penetration openings,. the customer' can. request boxing outside the opening to spread the cables and such boxing then filled with silicone fean, i
3.0 DEPTH OF FILL 3.1 Pipe, cable, conduit, etc., penetrations with surface areas i
of 80 in.2 o less shall be sealed with 1" of CT-23 series
, damming and;7" of CT-19 silicone foam.
- i i
Pipe, cable, condul etc.,. penetrations with surface areas 3.2 greaterthan,80in.g,shallbesealedwith1"ofCT-23 series s
damming and (Ll]'j of CT-18 silicone foam.
3.3 Where seals are provided in fire rated walls or floors that have
- thickness of less than' that specified in 3.'. and 3.2, then boxing shall be provided exterior to the openings to accomplish foam depths as specified in 3.1 and 3.2.
j 3.4 Should clearances in openings to be sealed (between cables and tray l
or between pipe and opening) be less than " then an approved sili-cone elastomeric caulking material can be used in lieu of silicone foam.
3.5 Boxing, spacing and. dan naterials are to be non-combustible where
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same are scheduled to be lef t in olace following application of the foan.
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in [eith'er drun or bulkc vessels'..two'part liquid ndtdikllsspa!
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4.2( The material as received shoulo bdjhept at about 7:J T.
If the-f
) Niterial-should h subjec'ted to temperatures beWp 320T, it d
[dould be hought to not -les/ than 50 F and' reaiJtated to insure W
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J 4.3 h'"bg mateziaT}bould be maintp.ned at room' temeprature q.
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Vi Afgossibl% prior to its becging ' feed-stock material' for dis. l
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jzingIhr gh Chemtrol dispdnsing' equipment.
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5.0 MATERI AL' STORAGE
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tion.
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'6.O CHEMTROL.DISPENSINM EOUYPMENT
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3' 6.1 Chemtrol' dispensing machines hav'e the primary function to receive j 9
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two Spnper/ent material as feed 4tiock, individually mainthin prop !
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temp'eraturi/'and dispense the paterial to precise pre-adjysted
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</ },d' r.3,tio through a' variable speed shear mixer head.
1 K.2 *?he foping nachines to be cupplied by Chentrol are especially 1*
.t 4ngineered machines'. They are designed to maintain the' required l t'atios. Pressure cau? s and !.ndependent temperature centrols are
/
,Ycovided.for bcNh ' con %;nentd j i,
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opera ting time' of the Q.iipment.
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i 7.O APPLICATICM PROCEDURE T>
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7.1 The calibration of the dispensing unit nust be checked each day l
prior to dispenning.
The naterial nust be brought to a pre-determined temperature by the individual comoonent temperature-a dj us tnent, so as to create the proper cure rate-reauired after the dispensing.
An equally timed shot of a predetermined duration of the individual unnixed components, is extracted into containers of equal sine.
Both containers are to be weighed and the ratio calibrated accordingly.
7.2 After calibration, a snall test pour is to be shot into a contain j permitting free rise c.f the foan for density check.
If the obtai density'is within the required specifications, the sample is to b l j
I 1
l Appendix Sheet A7 e
properly identified and retained for Quality Control records.
1 If the obtained density provcs out of specification, a recalibra-tion and examination of the material is required before the test pour procedure is repeated.
7.3 Machine mixing of the two components is to be accomplished in a i
mixing chamber and not mixed at a time more than 15 seconds prior to the nixed neterial being poured in place.
7.4 The foaming systen shall not be set at a delivery range of more than 12 pounds per ninute.
7.5 If foaning.is required to be done in stages, the heights of each stage is to be determined by the onsite Quality Control Inspector.
"I 7.6 Maintain component ratios with + or - 5%.
7.7 The above procedures are.to be supervised by the Chentrol Quality Control Inspector, and performed to his satisfaction prior to any infield production of the Chentrol system.
7.8 All instrument calibration, naterial history tracing records, in-1 field calibration, field test pour records, ambient condition re-ports, etc., should become permanent records kept on file by the assigned Quality Control Inspector and also distributed to the Home Office Docunent Control Clerk and the customer as required under the approved Quality Assurance Progran.
7.9 Those technicians assigned to the foaning equipment shall have had at least two years experience in dispensing foan, or be abic to demonstrate proficiency to satisfaction of the onsite Quality Con-trol Inspector.
In cases where a technician is assigned temporar-ily to operate the foaming equipment, who 'ts had less than two years foaning experience, an additional technician must be assigned to be within 25 feet of the operating equipment at all times while foaning is in process.
The second technician must have had at least two years experience in the operation of foaming equipment.
S.O MO"ITORIMG REQUIPIMENTS 8.1 Continuous visual inspections by an onsite technician shall be j
maintained on the flow indication control and flow rate of the h
dispensing unit.
I 8.2 continual visual inspection shall be maintained of the temperature of the chenicals.
8.3 Toam reaction tine shall be taken at least every 4 hours4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br /> during actual production time and reported as follows:
8.3.1 Gel time minutes.
- a. 3. 2 Tack free tine minutes.
1
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App 2ndix Shcat A8 1
8.4 Liquid and foamed sanples will be taken and retained as required.
8.5 Total through-put will be determined and recorded daily, a.
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/A ALLEGATION DATA FORM u.s wuctun nicutAtony couuissios
/A insirwetens on revers ee.
RECENING OFFICE Docket Number (if applicablel feiernel h/
47 [wp i
6 [ O C C 1 7 [
of eners th n 3..a a perwtc. writs GENERIC) 0 o g o c o 3 u s
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- 2. Functional Area (s) Involved:
(ch ca appropri.te bosteelI operations onsite health and safety coc.;truction offsite health and safety safeguards i emergency preparedness other (specity) 3.
Description:
lfl/MIPIVlol0l<lVl lI lnl5 l-Hel/ I IIalvti It !al I c144 1 I Fll lfld l'5l11e lpl lainldl Iglelal /lainlTl l III I I I I I -l l I Al' I l. l ol Irl, lelakl I / l#lvi-l /l@ F/
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- 4. Source of Allegation:
scNck.ppiopewte box) contractor employee security guard licensee employee news media NRC employee private citizen organization tspecifyl other tspecity)
MM 00 yy S. Date Allegation Received:
O 2.- O I
8' 1 M'
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- 6. Name of Individual irirst two initi.i. nd i : n.m.i M
Receiving Allegation:
R tsa-
- 7. Of fice:
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ACTION OFFICE
<D K/IS &
- 8. Action Office
Contact:
triest two inii;.is.nd i.it n.m.)
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- 9. FTS Telephone Number:
9 3 g 3
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- 10. Status:
I f
Open, if followup actions are pending or in progress (check onel Closed, if followup actions are completed MM DD YY
- 11. Date Closed:
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11.1 Document Nos.
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2: Remarks:
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flimt to 50 cw.eterst
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i INTEROFFICE MEMORANDUM i
Diablo CanyonProject i
PACIFIC GAS AND ELECTRIC COMPANY BECHTEL POWER CORPORATION To
~
De D. A. ROCKWELL February 2, 1984
'd'*
R. G. McInerney O'
Purchasing suoi c' Bisco - Pipe Penetrations Ai Diablo CanyonEntension 3113 I
On Fe brua ry 2,
1984, Clay Brown of Bisco phone number (312) 298-1200 called in regards to pipe penetrations and explained the following:
Mentioned that Ken Dukes of Bechtel asked their Mr. Sims to leave the jobsite on 02-01-84 and if not he would ask security to escort Mr. Sims from the site.
l l
Mentioned that Bechtel was not co-operative and that some of the pipe penetrations existing were not put in properly.
Mentioned that his Q.A. supervisors were told not to report any problems even if they dealt with 10CFR21 requirements and_ to consider the fact that it was reported to Bechtel enough.
Mentioned that the PG&E Fire Marshall requested information on pipe penetrations and that Mr. Sims was told not to furnish the information.
Mentioned that the Silicone Foam installed by Plant Thorpe was incorrect and discussions with the Flant Thorpe Foam Installer revealed that he had no previous training with installing this material.
Mentioned that the Silicone Foam used has to be mixed properly or it cill give off excess hydrogen while curing.
Therefore, trained people should install this material.
Mentioned that Bechtel was trying to convince Bisco employees to go to work for them.
Bisco employees wrote reports to the Home j
Office about such instances.
9 Hentioned that Frank Germano was notified of the above and that Bisco would write a report to him.
//l N nerney s.
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Senior Buyer N
L-aut r sNE SILICONE FOAM TEST RE? ORT m;
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Part A Lot No.
8 f / 2.3 P'/ 6~ '
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Scale No.
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oensity 4.3.2 Color d.3.3 jcp7 4eg7 l
Cell Structure 4.3.4 i
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2/C SILICONE FOAM TEST REPORT Part A Lot No. E4bs/78c/
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Part B Lot No.
2402/0//
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Scale No.
/ 006 Y Cal Oue Date 6- 0 9-B 2 REQUIREMENTS
'ACPT/REJ REQUIREMENTS ACPT/REdi Snap Time 4.3.1 gg.
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Density 4.3.2 g
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Color 4.3.3 g'g Cell Structure 4.3.4 1
AC T
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m p p ca - y o Part A Let NO. FG O f/8C E/Gf Part B Let ;o. E /-f O 2. / ? O 7 Scale No.
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Cal Due Date 6 -/W-G V L. E....Di'E1T5
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'[ t C h DATE 8M2<7[.?
i CA-8 (10/50)
Ref. DCP-2 e
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