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1.0 PURPOSE
This procedure establishes requirements for safekeeping, processing and turnover of Quality Assurance Records.
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1 2.0 3 COPE:
This procedure is applicab e to H. P. Foley Quality Assurance Records associated with the fabrication, installation, erection, rsai n t enance, repair and testing of components, systems and structures at the Diablo Canyon Project.
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3.0 DEFINITIONS
3.1. Quality Assurance Redords - are those records which furnish documentary evidence of the quality of items and of activities affecting quality.
For purposes of this procedure a document is considered a Quality Assurancerjcordwhenthedocument has been completed.
3.2 Complete - e document is complete when it has been validated. "
3.3 Validate the application of a signature, initials or stamp, and the date signifying that a document i
has been accepted based on inspection for identi-l fication of the item and/or activity, accuracy, THE completeness, legibility and freedom from damage HOWARD P. FOLEY (such as wrinkles, tear, etc.) that could COMPANY adversely affect reproducibility.
3.4 Correction - the addition of missing information (such as signature, initials, date, inspection or test results, weld procedure number of revision symbol, welders identification, etc.) or change of incorrect information to a document.
3.5 ySplement - a document which provides information on items and/or activities beyond that which is available on another document previously generated. This includes, for example:
Ret.est or re-inspection data resulting from design changes I
or special investigation, such as void nonconformance reporte that contain inspection or inprocess document.
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3.6 Final Acceptance Review - a technical review of a-document or document package for a defined increment of the contract scope of work to assure that the documentation is complete and current.
4.0 REFERENCES
4.1 H.
P. Foley Quality Assurance drogram.
4.2 ANSI N45,2,9, Requirements for Collection, Storage and Maintenance of QA Records for Nuclear Power Plants.
5.0 GENERAL
5.1 Project Manager - is responsible to insure that all personnel are aware of an comply with the requirements contained herein.
l 5.2 Ouality Director - is responsible for receiving, processing, reviewing,. controlling, and submitting 5.2.1 Quality control Manager - or his designee is responsible for the technical review and acceptance of QA Records.
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5.2.2 Qua lit y Assurance Manager - or his designee j
is responsible for the final administrative review and ecceptance of QA Records.
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5.2.3 Records Manager - is responsible for M
receiving, controlling and submitting Quality Assurance Records.
i 5.3 Engineering Manager - is 1
responsible for:
THE l
HOWARD P. FOLEY
- reviewing project documents to establish l
i COMPANY adequate distribution
- performing a preliminary technical i
review of t
construction work packages and the associated documentation.
5.4 Retention Time - for all records generated prior to commercial operation the retention periods begins on the date of commercial operation.
i QA Records shall be retained until they are transferred to the Owner upon completion of I
construction and final acceptance of all or a i
portion of the facility.
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5.5 Storage Area otorage facilities shall be so constructed as to protect records from the g
q elements and shall provide one hour protection i
from fire in or around the facility.
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- n Orcer to pree'.aae deterioretton of records, the following requirements shall be I
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applied:
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Loose Records - Records shall not besetored loosely.
They shall be placed in folders or f
envelopes and stored in steel cabinets and/or files.
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b, special Process Records: Records such as radiograph, photographs, negatives and microfilm which are light-sensitive shall be packaged and stored as recommended by the manufacturer of the materials.
5.7 Vault Access - access to the QA Records area will be limited to only those persons identified on an access list approved by the Records Manager.
5.8 Index - record types and filing locations are identified on the Generic Index of QA Records,.
5.9 When QA Records are in the possession of organizations outside the records vault, a system shallt be established that will locate the record at ail times.
Records storage and a
protection pkior to submittal to the QA vault shall be the responsibility of the user.
6.0 PROCEDURE
6.1 Receipt of Records THE 6.1.1 QA Records shall be routed to the Records HChMARD P. FOLEY Depa r t roen t upon completion of the activity COMPANY f r which they are required.
6.1.2 Records will be accepted into the vault only when accompanied by a transmittal sheet.
The records will be inventoried according to the transmittal sheet. A copy of the transmittal sheet shall be retained by the Records Department.
i a) All documents, either single or package, will be completed and accepted prior to acceptance into the vault.
6.2 Maintenance and StoraRe of Records 6.2.1 Incomplete, illegible or unaccepted records will be returned for correction / completion.
6.2.2 Records shall be filed as indicated on the Generic Index of QA Records.
6.2.3 Volded and superceded documents may be I
retained in the original documentation package.
The document will be clearly marked " Void" or " Superceded" as applicable.
6.2.4 Anytime a record is removed from its file position for reproduction or study, an out card will be filled out specifying the' document I
i pulled, the recipient and the date. The card shall then be inserted in the removed record's place.
j 6.3 Revisions and Supplements to Records
'l 3.1 If it becomes necessary to change or correct any data on a QA Record, the following method shall be used:
a) Changes or corrections wi,'f be made by drawing a single line through the incorrect data and writing the correct data above or below the error.
The original data must remain l e g i bl e_.
The person making the change will place him initial and the date as near to the change as possible without obliterating i
otE' r data on the document.
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b) Changes or corrections that would alter thertechnical content or intent of the M
record shall be subject to the same review as the original record.
c) When supplemental documents are added to THE record / folder, the supplemental document HOWARD P. FOLEY shall be identified to the work to which COMPANY it applies.
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Release of Records 6.4.1 QA Records will be released from the vault only after a "0A Record Request" form (Attachment 2) has been properly filled out and signed.
6.4.2 Xerox copies of vaulted records may be released without a request form (paragraph 6.4.1).
6.4.3 In general, QA Records will be released from the vault only if the record is required by procedure to be outside the vault.
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s 6.5 lurnover of Recorcs 6.5.1 Records shall be turned over to the Owner's General Construction Group as follows:
6.5.1.1 Generally, work packages shall be turned over in a data package associated I
with a work request or specific activity.
(See attachment I) i 6.5.1.2 Generic records (PO's personnel certifications, etc.) shall be turned over individually, not with data packages.
6.5.2 Packages to be transferred to the owner shall be listed on a transmittal form.
The transmittal form shall accompany the QA Records package when it is forwarded to the owner.
6.5.2.1 Boxes shall have an index of its contents securely fastened to the outside of the box.
'2 6.3.25'2 Each folder shall contain a i
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file inventory delineating the contents of the folder.
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(Attachment 4) g 6.5.2.3 Each box in the shipment shall be i
numbered and the transmittal shall contain a list of the box numbers and a l
THE brief description of the contents of each.
I HOWARD P. FOLEY COMPANY 6.5.3 Each transmittal for records subjected to the review in Para. 3.6 shall contain the following statement:
"The records transmitted herewith have been reviewed to the i
requirements, the applicable Specification.
and to the best of our knowledge are complete and correct."
6.5.4 A copy of the transmittal, the box index and the file inventory for each shipment shall be maintained by records Management.
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ATTACHMENT :lr.
(
s OA RECORD RE00EST
. REQUESTED BY:
0 ATE:
DEPARTMENT / ORIGINATION:
PHONE:
e DESCRIPTION OF RECORDS REQUESTED: (Include doc nent title, description and number of pages) j.
REASON FOR REQUEST:
l e
PERSON FOR RESPONSIBLE FOR RECORD:
LOCATION OF RECORD WHEN OUTSIDE THE Q.A. RECORDS YAULT:
DATERECORDWIL(BERETURNED:
REQUESTED BY:
DATE:
(Signa;ure)
~l REQUESTING DEPARTMENT SUPERVISOR:
.DATE:
(Signature) l QA RECORDS SUPERVISOR:
DATE:
(Signature)
RECORD RETUP.NED:
DATE:
l (File Clerx)
Note: This form is needed only when original Q.A. records are requested l
for removal from the vault or vault area.
It is not required for removal of copies of Q.A. records, y., --
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NON PERMANENT RECORDS Employee Qualifications 1 year after Com. Ops.
,l Calibration Records (last calibration) 1 day after Com. Ops.
4 t
Special Process Procedures 3 mos. after Com. Ops.
Inspection and Work Instructions 3 mos. after Com. Ops.
Vendor Qualifications 6 mos. after Com. Ops.
Valve Maintenance Reports I day after Com. Ops.
i Equipment Maintenance Reports 1 day after Com. Ops.
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THE HOWARJ P. FOLEY COMPANY l
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_ LIFETIME RECORDS l-I Inspection Forms (completed)
Inspection Reports Discrepancy Reports Non Conformance Reports AS Built Drawings Determination / Determination Requests Circuit Installation Cards Splice Requests Jumper Termination Records Conduit Ir. s ta 11a t i on s l
Circuit Termination Cards Equipment'Itsta11ation Report NDE Reports Hydro and Pneumatic Test Reports Purchase Orders Equipment Technical specs Material Test Reports.
Engineering Disposition Requests l
{
Process Travelers which contain inspection information j
In all cases thelife$1me records the latest shall be'that which documents I
constructed configuration of the facility.
Documents which define [' previous iterations confir,uration are non permanent of facility records and may be discarded
{
one year after commercial operation.
THE HC6 YARD P. FOLEY CC4APANY i
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Attachnsnt 5 i
TliE HC'a'ARD P. FOLEY COM?.UY Ct'ALITY AS5'!?.A:: E ?.EC0P.35 FILE I:rv'D TCRY d.- (.,L e i O *)
D
. teork Iniciation Document Pachat,e I.D.
4 i
OISC?I?IION NO. SFEET3 As-Built Drawine D
p 4.,et R.sev 'i57 h
/.G ( Ad.
! Work Process Traveler / Connection chmge N e - 4 c.=
2
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M HPF/ MIS - Weld Inseection Sheet I
SDE Report k
Bolt.Fitup & Tightening HPF/ETT'- Inseection Reeort HPF/GIR - Rev.2 -Grout Instection~ Report Grout.Around Th=u. Bolts HPF/TEGIR
- Inspection Recort HPF/RSIR Reinforcing Steel Insrection Reeert HPF/RSWR - Reinforcing Stedl Weld Recort l
PG & E Authorization.to Drill i
HPF/C51 - or Chip Concrete-a HPT/ASIR - Anchor Bolt Inspection Recort
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l TOTAL Sd* EETS Thesa'I and Phase II raview of this p ckage is complete and acceptable.
' 6_M n
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' Review-Date
(/ Phaso Revicw
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I
.e ATTACHMENT 6 THE HOWARD P. FOLEY COMPANY l
TRANC 'ITIAL TO DATE JOB NO.
SPEC. NO.
. WE HEREBY TRANSMIT - FOR YOUR APPROVAL FOR YOUR INFORMATION FOR YOUR DISPOSITION OTHER f
DATE RECEIVZD RECEIVED.BY RETURN ORIGINAL SIGNED AND DATED TO i
FORM H.P.F./T.
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GvP-3Y i
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MA odd QA RECORJ)5
1.0 PURPOSE
This procedure e s t a bl i t.he s requirements for safekeeping, processing and turnover of Quality Assurance Recorcs.
J
2.0 scope
A This procedure is applicable to !!.
P.
Foley Quality Assurance Records associated with the fabrication, installation, erection, maintenance, repair and test:ng of cornponent s, systems and structures at the Droblo Canyon Project.
3.~
DEFINITIONS:
~1.1 cualttv Assurar e Records - are those records which farnis.1 documentary evidence of the quality of items and of activities a f f e.- t i ng q a r. i t t y.
For p u r rv --- t ~
t: :s procedure a. in e :. ::.e n t is considered a Quality Assurance record when the document hr s been com *.eted.
3.2 Complete -a document is complete when it has been validated.
3.3 Validate - the appliention of a signature, i n i t i. *. s or stamp, and the date sientfying that a doeuce t has been accepted based on inspection for ident;-
fication of the item and/or activity, accuracy, THE completeness, legibility and freedom from damap.r HOWARD P. FOLEY (such as wrinkles, teur, etc.) that could COMPANY
~*d * ** Y
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3.4 Correction - the add 2 tion of missing information (such as signature, initials, date, inspection or test results, weld procedure number of revision symbol, welders identification, etc.) or change of incorrect information to a document.
3.5 su,91ement -a document dich provides information on items and/or activities bevond that
.h i c 19 pYesIEDah, w[
J available o age ume s
generated 1 hQr lud f
ex r I h %etes es."rFEfitng{e s or re-inspectl(E[ data syfting
- at s pedi ait ih' es t i ga'((Ton,
such as void nonconformance reports that contain inspection or inprocess document.
._m_
____.______.m__._m._.
3.6 Final Acceptance Review - a technical review of a
(
document or document package for a defined increment of the contract scope of work to assure that the j
documentation is complete and current.
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4.0 REFERENCES
g,i '
4.1 H.
P.
Foley Quality Assurance Program.
4.2 ANSI Na5,2,9, Requirements for Collection, Storage and Maintenance of QA Records for Nuclear Power Piants.
5.0 G E NEn A*, ;
p%s i
5.1 Project Manap.er - is responsible to insure that l
a '.1 personnel are aware of an comply with the requirements contained heretn.
i '
I 5.2 Qua*itv Director - is respons2ble for receiving, processing, reviewing, controlling, and submitting l l L
5.2.1 oualitv Control Manager - or his designee l
1s responsible for the technica". reviev an; acceptance of OA Record..
5.2.2 Qualitv Assurance Mcnarer - or his designee is responsible for the final administrative review and acceptance of QA Records.
5.2.3 Records Manager -as respcasible for receiving, contro11:ng and submitting i
I Quality Assurance Records.
is responsible for:
5.3 Engineering Manager i
THE HOWARD P. FOLEY
- reviewing project documents to establish "d'9"*** di'
- iD"'*
i COMPANY
- performing a preliminary technical review of j
construction work packages and the associated documentation.
l for all records generated prior l
5.4 Retention Time to commercial operation the retention periodr.
begins on the date of commercial operation.
CA
.,1 Recorcs shall be retained until they are transferred to the Owner upon completion of construction and final acceptance of all or a portion of the facility.
?kt es\\s storage f i
all b so 5.5 Storare Area 1
constructed as to prote r
Y rg'p r;o$ h e m
y' elements a jndhgfT9{ov e(ho tect2on e o f r om f i rt. r.n.o...a r ot $. d t cility.
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}.6 Preservation: - In order to preclude deterioration of records, the following requirements shall he applied:
l a.
Loose Records: - Records shall not be stored loosely. They shall be placed in folders or envelopes and stored in steel cabinets and/or files.
E b.
Special Process Records: Records such as I radfograph, photographs, negatives and microffim which are light-senritive shall be packaged and stored as reco nmended, by the manufacturer of the materials.
3.7 Vault Ac c ra s s - access to the OA Records area will i
be limited to only those persons identified on an access list approved by the Records Manager.
l 5.8 Index record types and filing locations are identified on the Generic Index of QA Records, Attachment 1.
5.9 When OA Records are in the possession of j
organizations outsice the records vault, a system shall be established
- hat will locate the record at all times.
Recoros storage and protection prior to submittal to the QA vault shall be the responsibility of the user.
6.0 p R OC E Dt'R F :
6.! ' Receipt of Records THE 6.1.1 QA Recorde shall be routed to the Records HOWARD P. FOLEY Department upon completion of the activity l
COMPANY f r which.they are required.
6.1.2 Records will be accepted into the vault only when accompanied by a transmittal sheet.
The records will be inventoried according to the transmittal sheet. A copy of the transmittal sheet shall be retained by the Records Department.
a) All documents, either s2ngle or package, will be completad and accepted i
prior to acceptance into the vault.
t 6.2 Maintenance and Storage of Records i
6.2.1 Incomplete, illegible or u ed I'c o tl*
't i etion. g wi l l,,b e, r e prr u
d I W': 'd i
il ep 6.2.2 Records yhp)1 he Igjyg as ared on the Generic.Indbx of QA Records.
0 2
l 6.2.3 Voided and superceded documents may be
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retained in the original documentation package.
j The document will he clearly marked " Void" 1
or " Superceded" as applicable.
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6.2.4 Anytime a. record is removed from its file i
position for reproduction or stu'y, an out card
)
d will be filled out specifying the document i
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pulled, the recipient d the date. The card shall then be inse.cted in the removed
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record's place.
6,3 Revisions and Supplements to Records 3.1 If it becomes necessary to change or correct any data on a QA Record, the following method shall be used a) Changes or corrections will be made by j
drawing a single line through the incorrect data and writing the correct data above or below the error.
The i
original da.ta must remain l e p. i hl e.
The person making the change w i 1 *.
p* ace his initial and the date as near to the
'hange as possih*.e without obliterating other data on the document.
b) Changes or corrections that would alter the technical content or intent of tne j
M record sha11 be subject to tne same review as the original record.
c) When supplemental documents are added to THE record / folder, the supplemental document HOWARD P. FOLEY shall be identified to the work to which l
it applies.
l COMPANY 6.4 Release of Records 6.4.1 QA Records will be released from the vault i
only after a "QA Record Request" form (Attachment 2) has been properly filled out and signed.
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6.4.2 Xerox copies of vaulted records may be released wi',nout a request form (paragraph 6.4.1).
l 6.4.3 In general, OA Records will he released from the vault only if the record is required by procedure t gbe tsideg
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6.5 Turnover of Records
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6.5.1 Records shall be turned over to the Owner's General Construction Group as follows:
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6.5.1.1 Generally, work packages shall be turned over in a data package a r.s o :i a t ed with a work request or specific activity.
(See attachment 1)
- s 6.5.
.2 Generic r e c o rti s (PO's personnel certifications, etc.) shall be turned over individually, not wita data packag-w.
6.5.1 Packages to be transferred to the Owr.er shall be listei on a transm;ttal f o r:r.
Ti.e i
transmittal form shal'. :ccompany the Cs Records package when it is fo+ ward-d to the Owner.
6.'.
2.1 Bov vs shall have an index of ::s conten;s securely fastened to the outsice of the box.
l o.3.2.2 Eacn folder shall contain a flie inventory delineating tha i
.ontents or the folder.( M 4 6..
2.3 Each box in the shipment sac.; or I
numberec and the transmittal unali contain a list of the box numbers anc a brief description of the contents of eacn.
THE HOWARD P. FOLEY 6.5.3 Each transmittal for records sub ected to the review in Para. 3.6 shall contain the COMPANY following statement:
"The recorcs transmitte herewith have been reviewed to the requirements, the applicable Specification, and to the best of our knowledge are complete and correct."
6.5.4 A copy of the tranam::tal, the box index and the file inventory for each shipment shall be maintained by Records Management.
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OA RECORD REQUEST
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i DATE:
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DEPARTMENT / ORIGINATION:
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DESCRIPTION OF RECORDS REQUESTED: (Include doc nent title, description and number of pages) i
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i Note: This fonn is needed only when original Q.A. records'are requested L
for removal from the vault or vault area.
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removal of copies of Q.A. records { [f A
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NON PERMANENT RECORDS
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Employee Qualifications 1 year after Com.' Ops.
cal l:bration) t Calibration Records ( l a's t I day after Com. Ops.
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Special Process Proce tes AJ mos. after Com. Ops, i
Inspection'and Work Instructions 3 mos. after Com. Ops.
i Vendor Qualifications 6 mos, after Com. Ops.
Valve Ma2ntenance Reports i day after Com. Ops.
Equipment. Maintenance Reports d a :. after Com. Ops.
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THE HOWARD P. FOLEY COMPANY i
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Inspection Forms (completed)
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Inspection Reports Discrepancy Reports Non Conformance Reports l
AS Built Drawings Ds Determination / Determination Requests Circuit Installation Cards Spiice Requests Jumper Termination Records I
Conduit Instal *.ations Circuit Termination Cards Equipment Installation Report NDE. Reports Hydro and Pnaumatic Test Reports f
Purchase Orders Equipment Technical S p e.. s Material Test Reports Engineering T,isposition Requests s
Process Travelers which contain inspection information In al'. cases the lifetime records shall he that which documents the latest constructed conf:guration of the facility.
I Documents which define [' previous iterations of facility configuration are non permanent records and may be discarced one year after commercial operation.
THE HCh4ARD P. FOLEY COMPANY 1
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NDE Report
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- Inspection Recort I
HPF/RSIR - Reinforcing Steel Insrection Recort i
HPF/RSWR --Reinforcing Steel Weld Reco-'-
PG & E Authorization to Drill HPF/C51 -
or Chip Concrete HPF/ASIR - Anchor Bolt Inspection Recort
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direr-OFFICE LED i
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'ID:
Jim'Ihomosen/Q.A.."anager FROM:
Gary Boling/ Document Turnover Section l
l SURJECT: Qualification / Certification Questions l
A.
QU-l Rev. O Para. 4.1.3 requires that "All hold points indicated I
within package have been signed off by Q.C. Inspectors."
Is it within scope of Administrative Review to:
1.
Review documentation to detemine if inspector was classified in correct discipline to perfom inspection?
2.
Review documentation to detemine if inspector km certified /
qualified to appropriate level per signature list? If this is the case what criteria is to be utilized to dertermine which inspections can be performed and signed for by d at levels of inspectors?
~B.
(Exclusive Electrical Question) - Inspection classification THE defines-HOWARD P. FOLEY COMPANY
- 1. " Electrical Inspection" - As " Inspections relating to raceways, and associated supports...."
- r. o. sox 327, AVILA BEACH, CALIF.
93424 7B. " Visual Welding (Electrical)" - As " Inspections emm relating to electrical supports..."
Is it pe missible for an inspector classified as 7B to sign for a complete support installation or nust they also be classified
- m -
03 l7 ALLEMToWN PENNSYLVAN!A BALTiM3RE. MARYLAM) cM TExAj C.
Is there a time period where Inspectors were doing multi-discipline MARRiSOURG PENNSYLvAN.A inspections?
HOUSTON, TE XAS LOS ANGELES CALWO%tA 1.
I{ so gat time gramc?
wnT NE: CAU*OAN<a l
ui MPmis. TE NNE SSE E l NE w c*.tays LOuisi4Na 2.
Can ve obtain a listing of these multt-discipl1ne people.9 i
HiLADELA*' A DE NNSYLVANIA '
I i.
- HOeNii AshlONA f 8TTSBt.l A SH PE NNSYL V AN; A l
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TO:
Jim Thar.prson, Q.A. Man ucr
)
RickWil{.on,
.o b l
FEOM:
Qualit: birtetor t
i S t.'BJ ECT :
Velel Pcd Ce rt i f ic at icn3 I
I l
DATE:
September 20, 1983 There have been several questions concerning the usc of typiciil v.-
actual weld rod CMTk's.
I Please be advired that our prefect specification do not rciui v actual certifications.
The requirement for actual cher.icc1 c.ed physical ce rtifications is centnined in the ASME Codc Sectier. 11 :nc III.
Howard P. Foley does not pcrictm any work to the APli. Cc a.- tius that r e qu i r en.en t decs not apply.
FW:tt ersrv m; re car h)_
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THE liOWARD P. FOLE)
COMPANY i
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(_4 E M C_}
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October 17, 1983 s
[
INTER-OFFICE MEMO i
TO:
J. Thompson l)
FROM:
L.R. Wilson
SUBJECT:
Mechanical Signatures Section 1-201(39) of the Uniform Commercial Code defines (signed) to include "any symbol executed or adopted by party with present intention to authenticate a writing."
It is H.P. Foley's contention that any document bearing a manufacturer, vendor or supplier's name or symbol (logo) will be concfdered signed.
f-Sincerely, THE
.'t l' A L.R. Wilson HOWARD P. FOLEY Outlity Director COMPANY j
~A P, O UOX 327.
j p) s'
,,, q.1 AVIL A BEACH C Altf.
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oNes OLLE NT OWN. PE NNSYt v A46A -. - - - - -. - - - -. - - -
BotTiMORE. MARYLAND CHIC AGO. ILLINOIS DALLAS. T EXAS NCARISBJAG PENNSYLVANIA HOUSTON TEuS LOS ONGELES C ALIFOANia M ARTie.E Z.C ALIFOAN A MiupMIS TENNESSEE NE A OA E ANS Louisiana L
DMILADELPMa A. PE NNSYLv ANia PMOENit AR.;OPA PIT 158vAGM PE NNS4 L V AN. A i
RICHMOND VIRGINIA S ALT LAKE CITY. UT Aw i
T AMP A. FLOAID A
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TUCSON AACoN A W ASMINGTON. O C 4+.
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LiiMJNTON ALbLRT A 1
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{
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{
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TO:
Jie Thorpsor., Q. A.
Manager oh F 80.M :
Rick Wilso, Quality Director Sl'BJ ECT :
Purchase Order Peview (Approved Vendnri)
D AT E:
Sept erthe r 20, 1983 i
j There are several types of purchases which do not require that a i
vendor be surveyed and approved by Quality Assurance.
y l.
Items which are specified by brand nane in the desien docurr.ents may be purchased f rom any available sour:e.
The l
rnanuf acturer is considered approved.
l 2.
Cermercial grade itens (those which are com on}y stocked ar, shelf itens by cortnercial distribution and do net require certified test reports or other backup inspection data) do I
not require approval by Quality Assurance for purchase i
activity.
f I
The procedures base net properly incorporated this inforr.ation thus, rary procurement are ar this tin,e questionable.
In cases where item onc arm /or t wo appi:. Lie procurement is acceptat ic and reets the l
- <..p trer..:"tr of our centract.
' lace a copy of th re crardur i" the g
r i
.. '. :c:ter.
_ _ _ _ __j w
THE I
HOWAf D P. FOLEY I
C C t.i P /. N Y I
i f
t t
?
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1
1 1
,f C W 4/?ti owe I no mrsea cowseauw uses f rem Diviseon or ue :,-me-e QU/.1.1TY ASSURANCE FI' t NS 3Q3,2 R t L t-?t st er Off-the-Shelf Coccercial Grade Itecs
,xe.1..
and Certificates of Confor=ance To D.v seca or
)
to** ""i,
CI:: Ital. CO::STF.UCTION - DC P,:
Su Ars ER f wa March 31. 1983 GS. CR l.
c.<
c; E$
CO es.
2.
... r.. D. u. 2LE.:
CO r.
A::en:1ct. Mr. J.
F..
Eratten C@.E:-
This letter supersedes my letters of October 2, 19E'.' and De ce:ber lo. 1980 en eff-the-shelf ce:.ercial grade iters.
Several precure:en: docu:ents which have beer fervarded :c us by the P.aterials Depart:ent and recent cenversa:icns vi:h Materials and Diabic Canyen site persennel er crdering cff-the-sha.lf cc.ercial grade itees which cay require Certificates of Ccnforcance indica:e
- ha: further clarification is needed en this subjec.
Ve, therefore, offer the following clarification regarding off-the-shelf co==ercial grade ite=s and :he use of Certificates of Confor:ance:
A':51 N!.5.2.13, Section 10.3.2 gives the fo11ceing guidance for itets tha:
ccn be accepted solely by receiving inspection (a cualified supplier is nc:
required):
"Accep;ance scle'. b; recciving inspectier is sa:isia:tery when the iters er se: ices are -
I a.
rela:ively si ple and standard in design, canufacturc.
and test; and i'
RECEIVED adap:able:estandarderause:atedinspec:lensend/0DAUTY ASSURANCE t.
the'~nd produe: te verity qu.:.:y tests e:
e characteristics after deliverv; and l
JUL U b 1984 I
c.
sucn that rectiving inspec:1er does re: receira l
epera:iens which coule adverstly afie:: the ir:cgrHOWARD P. FOLEY CO.
l
- un:uen. :: ele:rness ef ths u.::."
Avila Beach, CA
".:str.eni d rect these rscuire:cn:s are : t e.s t h.: IC:.ndi censiders
- if-:.e.c hel f c c -c r e ial grade" 1:c s tha: r.a :. b purchased as nenssicty-l
.il.ttc
.d thcr qu-lifici cs safety-rclated threu;- :Se centro 11ed rc:civin; l
arepcc:ier precess by.a c,ualified inspcetor.
1: :s :he respensibili::. cf the sic:ifyir; sngineer te de:errine whether er net ar ite: neetr :hesc criteria
-d :t r c : d i- :hc ne: css ry rc civing inspec:ier rccu rcr.cn:s fer the 1:ct.
DCC 4,% S
- 0 n c'. C
.. c' v v u u
_______._..____._-.___________._m_
/
7
/
/
Mr. R. D. Etzler March 31,1982 f
ASSI S45.2.1), paragraph 10.3.3, allows a PORTION of the receiving inspec:icn prccess f or such "of f-the-shelf ce=nercial grade" ite=s te be based sclely cn a iupplier's Certificate of Confer ance that the specified require:er.:s hcve beef. net.
Because these ite:s are te be purchased as nensaf ety-t' lated, the e
recufrc ents for this type ef Certificate ef Ccnformance shculd be :ha: the itc delivered is the exact ite: erdered, or is equal to, er is be::er thar.
the exact ite ordered.
A request for this type cf Certificate of Ccnf or:ance can be requested on the f ace of the caterial reouisitien or EKM and dees not require the quality plan f orm or instructions to supplier icr, 'er any other f or=s te be attached te the requisition or EMM.
If the specifying engineer finds that an 1:ec requires a Certificate cf Cenfer:ance which states that a code, regulation, industrv standard (such as ASTM, IEEE, ASMI, etc.).. or PGandE specification, or soee specific quality.
pregra: has.been cet, then the iter nust,be purchased as safety-related and cus; be purchased fro: a qualified supplier.
In that case, the require:ents of Sectien 10.2 cf ANSI N45.2.13 on certificates cf Confor:ance vill apply.
These requirements are:
"'ihere cer:ificates of conf ormance are used, the f ollowing einizu: criteria shall be cet:
a.
The certificate shculd iden:ify the purchased caterial
_ enequipme.c. _ such as by. the purchase _erder. number.
b.
The cer:ificate shculd identify the specific procuremen:
recuire ents cet by the purchased caterial or equipment, such as codes, standards, and other specifications.
The precure ent require:ents identified sheuld includ appreved changes, valvers, or devia:icns applicabl ECEWED an.
c the subject caterial er ecyip er.:.
QUAUTY ASSURANCE c.
The cer:ifica:e should iden:ify any precure en:
JUI uo rec,uire:en:s tha: have not been cet.
d.
The.certifica:e sheuld be attested te by a perse 0)y?RD P. FOL6Y CD is responsible fer this quality assurance f unctica Ayl[a 88aCh, CA and whose function an positien are described in the Purchaser's er Supplier's cuality assurance prrgra:.
e.
The certification systen shculd be described ir the Turchaser's er Furplicr's c;cli:. assuranu rregrar.
': cans sheuld be previded :c verify :nc va. i d ::- cf Supplier certificates and the effec::vences ci the cer:ification systcc, sucP as curing :he perfert:nce ef audi:s ef thc Supp;ict or independcn: ins;cc:1en er teS: ef the its 5.
Such VL ifiC0! ions sh!U'.d he tenducted tv the Purenasc c: : :crv ;c c e r.: n e u r.: t t cucli. perier:..:c.'O C C 4 $ $.,' b vid the fupplier's past D r~(*
- ,3. ' (-)
us --
E
/
f*.
,e Mr.
P..
D. Etzler March 31,1902 l
In order to eceply vich paragraphs d, c, e.nd f cf the above, PCandI cus i
review the sup;.11er's qualf ty manual and audit the i=plecer.tation cf the supplier's' quality program.
i k'. A
.YMO.*D TGL*/DS Aa ron(2020) : r r t
'I
'T
_.._..._..._...._.L._.._...__.._..
- RECEIVED - -
~
OUAUTY ASSURANCE JUL U 0199-HOWARD P. FOLEY C0.
Avila Beach, CA DCC 4508 DCC 2969
THE HOh'ARD P. FCLEY CCP.Pld";
'i.
SUPPLIER APTROVAL REQUEST T. l ( ~'
TOR i
NON-CO.@lEFCI AL GRADE ~ T L.'.'s i
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QUALITY ASSURANCE j
JUL 0 6 OKd I
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j Dxtm.'nt Tunnver Swervisor/D'n Shaly I
,i SUMECT:
Policv LettUrr, fnn Rick Wilson I
l I: The attachd nariu, dated 09-20-83, wre received frx the Qaalit c
! Director / Rick Wilson on Septeier 20, 1983 to be.ced as policy d.cistens
! in your revic i of It chase Orders.
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I 2 SECUCE! CUE 6; THE V.ARD P.FOLEY Int.er-Of fice la:n, '..' eld
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7 9iablo CanyonProject \\
j PACIFIC GAS AND ELECTRIC COMPANY f BECHTEL POWER CORPORATION
.~
June 22, 1983 Mr. Paul J.
Bourque Project Director The Howard P. Foley Company P.
O.
Box 327 Avila Beach, CA.
93424
SUBJECT:
Procurement of Materials
Dear Mr. Bourque:
The Howard P.
Foley Company is hereby requested to submit all purchase orders for Class 1 material to the appropriate Project Team _
Residene 59ijleer f or Approval.
This does not include material that
_ _._.ii s..pu rcha s ed as.Of f -the-sne11-Commercia 1-Grade -items. --We - are awa re --
that the Howard P..Foley. Company is presently upgrading Quality Control-
-Procedure QCP-2, which will give more definitive guidance concerning this subject, but until the procedure is approved this interim action is required.
)
Material that is Class 1 and not considered Off-the-Shelf Commer-c:a1 Grade shall be purchased from qualified suppliers whose quality assurance program has been approved by the Pacific Gas and Electric
" Ccmpany.
The Howard P.
Foley Company shall submit to Pacific Gas and Electric Company the attached " Supplier Approval Request for Non-Com-merical Grade items" for each supplier of Class 1 item which must be manufactured per an approved quality assurance program.
Upon Pacific Gas and Electric Company's verification that the supplier can be quali-fied, the form will be approved and returned.
The attached internal Pacific Gas and Electric Company letter w:,ll give interim guidance on what is considered Off-the-Shelf Commercial Grade.
G SUN W 5 RECEIVED 3
fj ig OUAUTY ASSURANCE S
"N$LS X
4 JUL 0 61983 E
o ts
.. a: W e e e d %
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D C C,,
4508
@ 2.E go X
HOWA9D P. FOLEY C917,
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32 g Av;la Beach, CA P.
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Thank you in advance for your prompt attention to this matter.
f.
D.
A.
Rockwell
]
Assistant Project Superintend...
j DARock' sell /WEC:kdg Respon'se required:
No i
I cc:
J.
R.
Manning J.
W.
Shryock i
R.
D.
Etzler E.
J. Macias R.
R.
Lieber G.
T. Glascock W.
E.
Coley R.
L. Meredith' j
J. Arnold F.
M.
Russell D.
F.
Lent R.
G. McInerney RECEIVED QUALITY ASSURANCE JUL U 6 9*
HOWARD P. FOLEY CO.
i Avila Beach, CA i
DCC 4508
THE HOWARD P. FOLEY COMPANY l
RECEIVING DOCUMENTATION
/to C y 4t^1 W I
REVIEW i
File Number Date Reviewed i
r I.
PRELIMINARY REVIEW Ye's No N/A A.
Is a copy of the Purchase Order attached and complete?
B.
Is a copy of_the Material Requisition attached and complete (where applicable)?
C.
Is a copy-of the Receiving Inspection Report attached and complete?
j D.
Is a copy of the Letter of Compliance /
Conformance attached and complete?
i E.
Is a copy of the Certificate of Compliance attached and complete (where applicable)?
F.
Is a copy of the Certified Material Test Report attached and complete?
G.
Is a copy of the Packing Slip attached?
II.
INTERIM REVIEW A.
Does the' Letter of Compliance /Conformance reference the correct P.O.,
items, and/or Packing Slip?
B.
Does the Certificate of Conformance reference the correct P.O., items, manufacturer / code /
test requirements, and/or Packing Slip?
l C.
Does the Cert'ified Material Test Report reference the correct material (size),
type, heat number, and/or code requirement's?
i III. FINAL REVIEW
'A.
Have discrepancies noted on the Receiving Inspection Report been resolved?
a B.
Have discrepancies noted on this worksheet been resolved?
C.
Remarks:
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Reviewed By
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PACIPC CO AST CI'/15!CN r isen.;r s css w<r a c u r a. -o., rc.. va, t ma
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L.Q 3 A.NC E L.Es. C A VMi s.c 1.n.
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5IllL Dececber 13, 1H 9 l
Tell Stea.1 Inc.
2343 '.I. 17th St.
Lonj H2ach, CA 90313 Atta:
lir. Richard Campbell Subj ec t:
'Jign d Tc.it I'. a'j o c : :
i GentJemen:
' vie quota the following f rca cur legal departmenr.:
of tha Uniforn Commercial Ccdc defines ':ilgra
- o "Sce:lon 1-201(39) include 'any symbol e>:ecuted or adopted by party with prascut ' - '; e a t ica to authenticate a writir.3' (c=pha::.is added.)
The Officia! Ce n:n:.
a i to en :
by tha draf ters of the C;de provide further enli:;hteracat
'co=arcial docur;ent is ' signed,' to wit:
'T authenticatica in tba definitica of ':.i;"
'The inclu.on o to c:ake it. ele _ar t. hat as the tera is used in this Act a. a.c sis acurce is not nce.: s se n.
Authentica*: ion c.:V. he or : r: e..:
stacoed os_uritten.
So catalog of pasoible authm. tic..
? m ve '
be completrr an.1 the court nu3 t usa co=cn sense ant exoeri.eaie in pnnsing upo.' (the q'.estian vf what con:-:t.! te 71:
' signed docuccat').
The questic.n alwavs is chech:c *.h z s:. '. '?.
was execut:sd or adcotad _bv the c. arty with oresent inuat.ier te authentic'.re the writing.'
(Eaphasis added.)
"Our co cercial practice is to use extensively star ped and ty:' -! si.;;ra;u e-o in :hn preparatier, of cc :creial d.: ueents, e. g., c u r Ac kn m< 1 e
>;t m3 i
the ciechanical:.y cf fixed signat':re of
'J. 3. Doagherty, 'kneral %:m
'of Sales.'
"It i:s our opinion that Sectio: 1-201(39) of the Ccda supports ou: p as uun that cut ::111 tes t r3,'or:s are lez illy 'sigt..:d ' anf are en f o re,. -
d'-
The nr w c~
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nunca, notwitbc:.a:.!ir.g ~5e use. of a typed s17,nac:a e.
1 1
______________________j
Bath /uhem Stee/ Coq >orunon 1
i Tell 3:.cel Inc. December 13, 1979 l
Mr. P.ichard Cc.:pbc11 s
Chtef Metallurgist has been typed on each report with the orenent intec%cn Lo auth2nticata the recort.
Each report is submitted on 'Beth;1ehen Ste:1 Corporation' letterheads.
The fact that we use ' typed si;;na ttires ' cerc i.y
'as a labor and time saving practice does not permit disavowal by Sethlehen Es to the accuracy, valiJity, and legal caforceability of n111 test reports I
so ' signed'."
l If you.have any questions, please do not hesitate to contact us.
l I
Very truly yours,
/
BETHLEHD1 STEEL CO?202ATICS PACIFIC COAST DIVISION l
J. D. Gee, Manager of Sales C C /Nw i
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JCChildress/dv RECEIVED QC 1
DEC 2 01979 l
HOWARD P. F01.EY CO.
Avila Beach, Calif.
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THE HOWARD P. FOLEY COMPANY
[ fu C QUALITY ASSURANCE RECORDS FILE Ih7ENTORY Work Initiation Document Package f.D.
DESCRIPTION NO. SHEETS HPF/MR: Material Requisition HPF/CO: Change Order on Purchase Order HPF/RIR: Receiving Inspection Report IE: Letter of Ccxapliance/Confomance Cr/CMER: Certificate of Test PS: Packing Slip OIHER:
)
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TOTAL SHEETS Phase I and Phase II review of this package is complete and acceptable.
Phase I Review Date Phase II - Review Date
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __j
l THE HOWARD P. FOLEY COMPANY CIVIL DOCUMENTATION REVIEW C-blSI Package I.D.
~
Work Initiating Document YES NO N/A
~
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PRELIMINARY REVIEW 1
Are documents listed on the index A.
in the package?
l Has the index been signed for' Phase I B.
review?
Is the Work Initiating Document referenced o( attached and complete?
C.
'Is the latest Nork Process Traveler
-s Y D.
attached and complete?
Are supplements attached to the Traveler and complete (where applicable)?
E.
INTERIM REVIEW II.
Is the as-built or drawing included and A.
Phase I reviewed?
Were the required inspections complaced B.
and documented?
III. FINAL
' lave discrepancies noted on Inspection i
A.
Reports been resolved?
Have discrepancies noted on this worksheet B.
been resolved?
C.
Remarks:
~
Date Reviewed By
PACIFIC GAS AND ELECTRIC COMPANY G 7 (a b b (<-
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COPY E
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66 r
Nd P. O. Box 117 Avila Beach, California 93424
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October 12, 1976 The floward P. Foley Company s
P. O. Box 327 Avila Beach, California 93424 l
Attention: Mr.
L,, Addlenan, Proj ect ifanager Mr. V. Tennyson, Quality Manager Diablo Canyon Project i
Spec. 8802 Quality Assurance Documentation Gentlemen:
l Q
'fc have reviewed your September 20, 1976 letter enumerating the Q. A. documentation being prepared for turn over to satisfy the requirements of Specification 3302 and your Q. A. Manual, and find it satisfactory. llowever, please include the T115CI's in this list as a required document for turn over.
h' hen the docuraentation is, in your opinion, ready for release to P G and E, pienso nofify us so that we may audit the records.for content and organi:ction prior to acceptance. As has been verbally discussed in the past, we would expoet to receive the documenantion on a unit by unit basis beginning with Unit I.
Acceptabic docunents are to be rhipped to ftr. Don Day, P G and E Conpany, Diablo Canyon Proj ect..
Documents should be approximately 8=1/2" x 11", or folded to this size, and packed in cardboard containers with removabic tops of external diuensions as ne tr to but t
I not pxeceding the following:
10-1/2" high,13" wide' and 16" deep.
l Sincerely, RECEIVED QUALITY CONTROL I
,,,, y,,,,,,c,,3 lo 0CT 181976 Project Superintendent HOWARD P. FOLEY CO.
Avila Beach, Calif.
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September 20, 1976 pr.
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P. Friedrichs Proj ect Euroriscendant Pacific Cas and Clactri: Cerepany P.O. Box 117
- 4. fila 3each, 0.1 93424 ATT'!:
Con Day 95 :
cuality tocumentatien to be Turned Cver to P. G. 5 E.
Cen tle'.en :
It is our understa= ding tn:cuzh conversariens W th your cuality Ccuerol Deoart=ent that.che following Quality documents are required:
'*or's Sheats and Support 1.
Doct. ment's na.!aeded.
~
THE 2.
'Jork Sheets and Suptort OWARO P. FOLEY Cocuments as :.eeced.
COM?ANY 3.
P.avores.
16 JU'nVatr T*r"".ina Cion Racort s.
P. O. BOX 32 AVILA BEACH. CAus.
5.
3epor:s.
m 24 ti.
Uz.ta Scec. 1171.
sos.555 2222 7.
3ecords and Sucoort Occur ents.
ome..:
rts rstews =awssvisa 10.
Eculpment Documents and Suptor Docu=ents cevc=e..u.wtANo as ' reeded.
- - cos.wsois 11.
t'alibration Pocuttants.
msacesSr*N#*[v$$
12.
Dicerseancy 7eports and Lot (3207).
s
-:ssies trus 13.
Dicerseancy 'e:: orts and
- e t (3802).
$282,y $jy[j 14
- JP7 '* modification Beeorts and Ley..
wv"s swssses 1~.
'.Lider ar-111cacians.
rv:=.ms..cism 1..
"acars.al dar:1iica:1cus.
"",'.'. :*,5 7 5 T ^c*y'f 17.
Class I ?urcha.se crders.
y,
s:w.,4 eswsnvasiA 18.
3307 Insw etion 'eports and Log.
ac-voso viacima 19.
B302 Inspection P.ecorts and Lot.
"N',$$[,',^.,l
'23.
C.uality.uanu,tla Old and : lev F.evisions.
-.:ses A w esA 21.
Procedures Cid and New 7evisions.
'Sa'%cros. o c.
22.
Cuality.tssurance Audits.
A*JW AAGE. ALASO
- seaman hveteciary:
.. #r E:v0NioN AtagnTA i.
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We suggest the following secuence for turnover.
Unit I documents listad as itz=s (1-9) be turned ovet first. T.. e rt.cainin: Uni: I docu::ents listed as 1: r.s-(10-22) to be turned over with Unic II documents listad as items (1-20).
Sincer al r, ORIGINAL SIGNED BY.
l.
LAMOYNE E. ADDLEMAN LAMo rne E. Addl. an Proj ect Manager D
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UNIT I and II 1.
Raceway Inspection Work Sheets 2.
Support Inspection Work Sheets 3.
Termination Inspection Reports 4
Jumper Terminations 5.
Equipment Documents 6.
Wire Pull Inspection Reports 7.
Heat Trace Inspection. Data Spac.1171 8.
Circuit Installation. Records 9.
Circuit Terminatiorr' Records 10.
Box Inspection Reports 11.
Calibration Documents (Last Calibration only) 12.
Discrepancy Reports & Log (8807) 13.
Discrepancy Reports & Log (8802) 14.
HPF Modification Reports & Log 15.
Welder certifications 16.
Material Certifications 17.
Class I Purchase Orders
,g 18.
All Welding Documentation t
19.
8807 Inspection Reports & Log 20.
8802 Inspection Reports & Log 21.
Quality Manuals old & new revisions 22.
Procedures old and new revisions 23.
Q.A. Audits THE HOWARD P. FOLEY COMPANY I
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- July 29, 1983 Qh TO
Cary Boling/ Doc. Analyst FROM:
Jim Tnompson/Q. A. Manager I
j RE:
Your July 25, 1983 Memo Qualification / Certification The following is in response to your questions:
A.1 It is within the scope of your review to determine if inspectors were certified by discipline to perform inspections.
During the time period from 9-12-79 through 4-25-80, QP-5422-6, Rev.0 was effective for Civil Inspections (Spec. 5422) only.
There was a time period when ins;ector l
certification was not procedurally required prior to 9-12-79 and from 4-25-80 thru 3-2-81.
From 3-2-81 through 12-7-82, QCP-6, Rev.4 was applicable for certification requirements,by discipline for all inspection personnel.
Finally, on 12-7-82 QCP-6A, Rev.0 was implemented for certification of inspection personnel by levels.
Current practice is to certify inspection personnel by level l
and discipline.
An outline defining and classifying inspection discipline has been developed for clarification THE (attached),
l f
HOWARD P. FOLEY l
COMPANY A.2 Prior to 12-7-82, there was no procedural requirement for inspectors to be leveled.
For the time period from p, a ggx g, AVIL A BEACH, CALIF.
12-7-82 through 3-17-83, NCR 8802-824 was written 9924 identifying and dispositioning certification problems for 605 5M3m inspectors.
Therefore, it would be proper to review inspection docu=entation for level and discipline after the initiation of NCR 8802-824 (3-17-83).
0" m g
j.pg)p I aLLIN? oWN. PE NN5 YLV ANIA According tojguidelines T m
".C.!.
~ % a Level I Inspector j
l BALWoRE. MAAYLAND may sign certain inspections without a review or es Aj ijiN co-signature by a Level II Inspector (see attached).
g sconSevac PEN ~svevANiA For the purposes of this document review, look for a "ovstcw texas Level II signature en all inspections.
i l
LOS ONGELES CA IFoANIA l L
l MA4' int 2 CA'IronNIA -
B.I It is not permissible for an individual with only a visual l
VE upMis. T,ENNESSEE NE* CAEANS LoutSlaNA weld certification to sien for the final electrical support
"*"LGtJ'MA PENNSviVAYA
- HoENix An. oN, or raceway installation inspection.
DITISSUAGat PENN!YLVANIA 9:csuoNo viso:Na SQL T Lame Cm. UTAs l
TAVPA Flor:DA tuc50s ancoNA l
w ASW% TON O C
.-es-Lua,y I
E cvwc4 ancnia l
(Continued l
July 29, 1983 Qualification / Certification Memo Page 2 l
1 l
C.1 Some inspectors may have been doing multi ^ discipline l
inspections prior to 3-17-83.
Since NCl< 8802-52'. covers the time period from 12-7-82 through 3-17-83 it is only necessary to be concerned with 3-2-81 through 12-7-82 when QCP-6, Rev.4 was effective.
n C.2 A comprehensive listing of these people is not currently available. An attempt is being made to provide a listing of these personnel and will be made available upon completion.
9 J. Thompson j
- Q.A. Manager 4
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THE HOWARD P. FOLEY COMPANY h
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. r o t.1 t i ny. *% u l p r e r' t. Alad t"]ulpN nt -i n i! v,1ve FA i n t en.t nc e.
In st riiment at tr n Insrt c t ton:
Inspections relatin: (n tubing.
mall bore piping, pnematic te= ting, test witneosinv. braeing,
,w,! r ei s t +rel ftutruments.
' Civil Inspec t ion (St ructural):
Inspections relating to fabrication, Instal 1ation, knd betting of structural stec1. Incinding concrete arechor.*.
Civil Inspection (Concrete):
Ins pec t t on r. relatinZ to concrete. reinforcing s t eel, grout t rig, and plantering.
Receiving Inspeptlan:
Inspec t ions relatin. to rec e i v i i.: and stora'e of rvtcrjale.
t.... I W.1 <t i n g :
I n t p.ar t i c n.-
r.* l.i t I n g tc i o.t l. x...i na t t ons of.relds..nd w.*: de r 4 s il i f is 3 f it'lan.
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h EGsG ENERGYMEASUREMENTS GROUP San Ramon Operctieno 28o1 OLD CROW CANYON ROA CA + TEL(41M837-s381. MAIL Box 204. SAN RAMON. CA 94583 in reply piease refer to: WOW: 84-06 5 December 1983,
. Mr. Dennis.Kirsh U. S. Nuclear Regulatory Commission 1450 Maria Lane, Suite 210 Walnut Creek, California 94596 Subj ect:
INSPECTION STATUS REPORT
Reference:
Memo; D. Kirsh to W. Wade dated 30 November 1983 This report provides the information requested in the reference memo.
, tabulates the information by category with the exception of l
anchor bolt data which is not avail abl e.
Anchor concrete expansion bolts were inspected against the appropriate Foley or_ Pullman specifica-tions (QCP9, QCPE9, and ESD 223) when they were used for the installation.
Aside from population data, the information was derived from records main-tained for the inspections conducted under FIN B-8552.
The inspections were conducted between July and November 1983 'and some are incomplete.
As a consequence, a description of the discrepancy, and an assessment of the significance is provided only for completed inspections. illustrates the information stored in the data file for this project.
The computer was asked to list all completed inspection items having a discrepancy for which a quality assurance (QA) report and/or a citation has been initiated.
Incomplete inspection items for which QA reports have been initiated were also added since these reports provide the descriptive information needed to assess significance.
if further explanation or additional informati on is required please contact me at my office in San Ramon.
W. O. WADE MECHANICAL ENGINEERING DEPARTMENT WOW: cog Distribution:
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G. Cumings R. Pong
.M. Eli A. Debeling R. Bogdanowicz C. Morton M
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.c........, j I February 29, 1984 PGandE Letter No. DCL-84-083 Mr. John B. Martire, Regional Administrator T U. S. Nuclear Regulatory Comission, Region Y ? 1450 Maria Lane, Suite 210 Walnut Creek, CA 94596-5368 / Re: Docket No. 50-275, OL-DPR-76 ? Diablo Canyon Unit 1 j Weld Bevel Angles and Tube Steel Radius t
Dear Mr. Martin:
i 0 On February 8,1984, representatives of Region V identified some questions j related to weld bevel angles and tube steel radius. The questions and PGandE's responses are provided in the enclosure. j Xindly acknowledge receipt of this material on the enclosed copy of this letter and return it in the enclosed addressed envelope. incerely ,i Uf/ [ . Sch er 4 ? Enclosure cc: T. W. Bishop . ? D. G. Eisenhut H. E. Schierling a g Service List iy ) b S ff' iw gig gp M E
6 A PGandE Letter No. DCL-84-OS) ENCLOSURE 4 PGandE RESPONSE TO NRC QUESTIONS REGARDING VELD BEVEL ANGLE AND TUBE STEEL RADIUS BACKGROUND On February 8,1984, representatives of NRC Region V identified questions they had discussed with a concerned citizen on February 2,1984. These questions related to (1) the veld preparation bevel angle used for. partial and complete penetration velds on structural steel, (2) the effective throat of flare bevel groove welds on structural tubing, and (3) effective throat derating factors for skewed fillet welds. The specific concern is that field-installed conditions at Diablo Canyon may be less conservative than those assumed in the design. The NRC questions and PGandE responses follow. 1. QUESTION 1 -- 37.5 Bevel vs. 45 Bevel \\ Pullman Power Products (Pullman) allegedly used a 37.5* ASME weld preparation { on all AVS steel and structures instead of the 45* preparation angle required by AWS-D1.1. Reference was made to a June 23, 1983, memorandum on bevel { detail revision signed by Ruse Noble to H. Karner. This memorandum specifies that a 45* bevel angle is to be used in the future, without providing any assessment of or resolution for past practice. Thus, the implication is clearly that the field-installed condition does not provide adequate assurance that the design assumptions of the design engineer were complied with. In this case, the designer assumed a 45' bevel angle and, allegedly, the field j I used a 37.5* bevel angle. The AWS Code requires that load derating factors be used if the bevel angle is less than 45' and, since the designer didn't use the derating factors, it is alleged that the field installed ccadition is less conservative than the designer's intent. RESPONSE TO QUESTION 1 Most pipe supports at Diablo Canyon are fabricated from ASTM A-36 steel, a low carbon steel with excellent veldability properties. The veld process most commonly employed for pipe support welds is the shielded metal are process using E7018 electrodes. The weld procedures and welders used for the fabrication of pipe supports are qualified to the requirements of ASKE B&PVC, Section IX. This code provides extensive rules for the qualification of weld procedures and welders. The use of this code is not unusual; in fact, supports in recently designed nuclear lants are designed to the requirements of ASKE B&PVC, Section III, Subsection NF which requires welders and weld procedures to be qualified to the requirements of Section II. 0377d a t i j Section n does not recognize the use of welded joints without performing weld Pullman has performed these tests in accordance with Section procedure tests. Other welding codes do, however, make provisions for the,use of n. ] prequalified welds. One such code is AWS D1.1. i AVS Structural Welding Code Dl.1 provides details for prequalified complete d and partial penetration groove welded joints. These jointe may be used ] without performing joint welding procedure qualification testa prescribed in j Section 5 of AWS D1.1. i They are exempt from qualification tests because these { joint welding procedures for shielded metal arc, submerged arc, gas metal arc, and flux cored arc welding processes have had a long record of satisfactory j performance, i However, the AWS D1.1 Code does not restrict welding to the prequalified joint welding procedures; the code allows other welding procedures to be used provided they are qualified as prescribed. Regarding bevel angles on single bevel welds welded using the shielded metal are process, various bevel angles are specified as being prequalified. Depending on various factora such as the joint configuration, thickness of material being velded, root opening, and backing, the prequalified bevel angle can vary from 30* to 60* for complete penetration welds and is 45' for partial penetration. welds.. The AWS Code have a long record of satisfactory performance, they do not r procedure tests. Angles for partial penetration welds less than 45' are not prequalified, but are allowed provided tests are perfomed to demonstrate that the desired effective throat is being achieved and, therefore, the same strength is being developed as assumed by the designer. June 23, 1983, The reference to a question as described. memorandum by Russ Noble does not appear to be related to the The memorandum refers to stainless steel Veld Procedures Nos. 15/16 and 129 to be used for welding butt joints in the pressure boundary of piping. In a recent inspection, the NRC Staff questioned what bevel angle was used on carbon steel support members. Practice has been to use 45' bevels.The review showed that current and recent past This was based upon a June 28, 1983, memorandum to quality control, observations in the field, and interviews by the Staff with several QC inspectors. Notwithstanding the above, PGandE has expanded its review. of the Project indicate that the practice was to provide a Conversations with The Veld Procedure No. 7/8, which is applicable to this process, allows bevel angles of beth 45* and 37.5* and there are velas with bevel angles of 37.50 / The pipe support fabricator Pullman, has performed tests to determine the effective throat that would be obtained using their welding procedures in a tee-joint using a 3/4" plate with a 5/8" partial penetration veld beveled at 37.5* using the shielded metal are process. This joint configuration is considered to be worst case since it does not provide the accessibility of a butt joint. In this case, the designer would have assumed a 1/8" reduction in the 5/8" weld size which would give an effective throat of 1/2". The test 0377d..
results are summarized in Attachment A. Attachment B shows the coupons prepared for measurement. Note that in all cases in Attachment 1, the actual measured throat exceeds that assumed by the designer (1/2"). Other material thicknesses would provide equivalent results. In addition to the tests performed by Pullman, an existing 3f.50 partial penetration weld on a J/4" base plate was examined. The effective throat of the weld was measured in two places. The throat dimensions were 5/8" and 43/64", both meeting or exceeding the value assumed in design (5/8", which is 1/8" less than the depth of preparation). In summary, the designer epecified p~artial penetration welds that were compatible with single bevel weld preparati in angles used by construction. The designer derated these partial penetration welds by 1/8" to account for the lack of fusion at the root. Purther, sectioning and measurement of actual test coupons of typical joints demonstrate that the procedures used by Pullman on partial penetration welds with bevel angles of 37.5* produced effective throat dimensions that were compatible with designers' assumptions, s 2. QUESTION 2 -- TUBE STEEL #ADIUS It has been alleged that the Site and General Office design groups did not properly account for tube steel radius that actually existed in the field. Specifically, the following points were made: QUESTION 2a Some of the tube steel supplied by foreign manufacturers (Japan) had an outside radiua of 1.5T at the corners, where T is the steel section thickness. The American Tube Manufacturers Institute requires the radius to be between 2T and 3T. RESPONSE TO QUESTION 2a i Fullman purchase orders indicate that material shall be domestically manufactured, as required by the contract. PGandE has researched all structural steel mill certificates to determine origin and have confirmed I that no Japanese tube steel has been received. A single purchase of a l small amount (3000 ft.) of Canadian tube steel has been used; however, the manufacturing was in accordance with USA requirements. The American Tube Kanufacturere Institute requires a corner radius on tube steel equal J to 2T for tubes with a perimeter less than 14 inches and a radius of j 2-1/2T for tubes with a perimeter greater than 14 inches. Since all tube j steel supplied to Diablo Canyon is manufactured to USA requirements, the radii are 2T or greater. This is supported by en inspection of tube j steel as indicated in response to Questions 2b, 2e, and 2d. ) 0377d ___
i I I 4 QUESTIONS 2b, 2c, 2d b. The on-site design group assumed 2T in the'ir calculation of flare bevel weld effective throat. i c '. The San Francisco design group allegedly assumed 3T in their calculations of flare bevel weld effective throat. d. Therefore, it has' been alleged that the effective throats, existing in the field on the. steel with 1.5T radius, will not be sufficient.to satisfy the design requirements. 1 RESPONSE TO QUESTIONS 2b, 2c, and 2d AWS DI.1 Section 2.3.1.4 allows the use of an effective throat of 5/16R { (where R = outside corner radius of tube steel) for ningle flare groove welds without performing a weld procedure qualification.- It is accepted as being a conservative effective throat that can be increased if additional verifications are made in accordance with Section 2.3.1.4 (2) 3 of AWS Dl.1. A t The Diablo Canyon design groups use a corner radius (R) equal to 2T (where T is the thickness of the tube steel) for tube steel with a perimeter of less than 14 inches. A corner radius of 2-1/2T was used for pertneters greater than 14 inches (in no case was a corner radius of 3T used).' These are the radii required by American Tube Manufacturers Institute. Fifty pipe supports with tube steci members were chosen at random and the corner radii were measured. In all cases, the corner radii exceeded 2T. In some cases for tubing perimeters greater than 14 l inches, radii are less than 2-1/2T. The testing described below has shown that for these slightly smaller radii, an effective throat of 5/16R is obtained. Reviews have been made which substantiate the effective throat assumption of 5/16R as conservative. One review was done at Diablo Canyon by Pullman and a second review was conducted by Pullman and United Engineers and Constructors at Seabrook Station. The tests at the Seabrook Station were conducted using standard P-1 Pullman Welding Procedures for ASME P-1 materials. The technical report describing the review is attached as Attachment C. The purpose of this review was "To verify, as a minimum, that the effective throat thickness for a flare-bevel-groove weld when filled to the solid section of the bar will equal 5/16R, where R is equal to the radius of the bar." Four sizes of structural tube steel were welded using 3/32" and 1/8" dia=eter E7018 electrodes in the flat, vertical, and overhead welding positions. 0377d I' l c I i The results from the Seabrook Station review showed that the actual penetrations exceeded 5/16R (where R is assumed to be 2T for tubing with a perimeter less than 14 inches and 2-1/2T for perimeters greater than 14 inches) by as much as a factor of 1.0 to 1.92, with an av% rage factor of 1.4. The least amount of penetration occurred when 3I311/4 tube steel was welded using a 3/32" electrode in the flat position. In that case, the penetration equaled 5/16R. Tests at Diablo Canyon were conducted using Pullman Diablo welding procedures. A brief summary is attached as Attachment D. The tests were performed to verify that the actual penetrations met or exceeded the effective throat of 5/16R for the worst case identified by the review done at Seabrook Station. Six tests were conducted to determine the typical penetrations which would be achieved for flare bevel joints when velding 3X3X1/4 tube steel using 3/32" and 1/8" E7018 electrodes in the flat position. All tests indicated that the amount of penetration exceeds 5/16R by a factor of 1.4 to 1.7. In conclusion, field investigations have been performed which show that I there are no structural tubes with radii less than 2T, and tests at Seabrook and Diablo Canyon demonstrate that the design assumptions concerning effective throat are consistent'with as-built conditions. s QUESTION 2e A related concern is that AWS D1.1 requires, and assumes, " flush" welding on tube steel to obtain the AVS Dl.1 required effective throat of 5/16 R, where R is the outside radius of the tube steel corner, while ESD-223 apparently allows less than " flush" welding, contrary to AWS assumptions without having sufficient tests run to establish the acceptability of less than " flush" welding. REPONSE TO QUESTION 2e QC Inspectors randomly sample field conditions on flare bevel welds to determine if they are welded flush. A statistically significant sample of 233 velds were examined, all but five of which were flush. Four of these were 1/16 inch under flush and the fifth was 1/32 inch under flush over a part of its length. All of these "under flush" conditions resulted in an effective throat greater than that assumed in design and sufficient to satisfy stress criteria. QUESTION 2f In addition, ESD-223 allgedly allows a 150 dihedral angle with no corrections applied as required by the AWS Dl.1 Code 1983 Edition. The AWS D1.1 Code requires using effective throat derating factors of 1/4 inch for a dihedral angle between 30' and 45*, and a 1/8 inch deduction 0377d. 4
between 45' and 60*. A dihedral angle of less than 30' would require even more of a deduction from the effective throat dealgn. RESPONSE TO QUESTION Pf In the design or evaluation of a skewed fillet veld, pipe support ~ designers follow procedures that account for th6 possibility of non-fusion at the root of a skewed fillet veld with a dihedral angle less than 60*. This possibility has been recognized and addressed by either reducing the code allowable stress by half, or by reducing the throat thickness by 1/8 inch. Because of the uncertainty of the non-fusion associated with a dihedral f angle less than 30*, PGandE has set 30* as a minimum. Skewed fillet welds with dihedral angles less than 30* are very rare. Designers take no credit for such welds in as-built pipe support reviews. l Therefore. the inclusion of a dihedral angle less than 30' in the installation specification ESD 223 would not have caused any problems with meeting the design requirements. PGandE does not make a 1/4 inch reduction for a dihedral angle less than 450 for the following reasons: { The 1/4-inch reduction is a newly added requirement in AWS D1.1 Code, o l 1983' Edition. When the code was published, the majority of the pipe supports reviewed had been completed. Besides the inherent conservatism in the design and fabrication o process, PGandE uses a very low allowable weld stress. For normal load cases, 9.45 kai is used for welds within the B31.1 Code jurisdictional boundary, and 18.0 kai is used for supplemental steel within the AISC Code jurisdictional boundary. In fact, it can be 21.0 kai as permitted by the AISC Code. QUESTION 2g Thus, the skewed fillet weld table in ESD-223 is alleged to be wrong because it doesn't adjust the leg length to account for the designer's assumed effective throat and field installations are, therefore, less conservative than the designer's int ant. RESPONSE TO QUESTION 2g There is no table in ESD-223 that addresses skewed fillet welds. As mentioned in the response to Question 2f, possible non-fusion at the root of the veld is accounted for by the designer in the design or review process. It is not necessary for the welder to adjust the leg length to address the possible non-fusion which already has been accounted for. 'therefore, it is not possible to have final installation less conservative than the designer's intent. 0377d - _ _ - _ _ _ _ _ ~
4 a '~' ATTACHMENT A c, S c1) PARTIAL PENETRATION WELDED COUPONS (l) l'ca--*d e ACTUAL COUPON POSITION SECTION SIDE THROAT (2) 26 (Horizontal) 1 A B 0.518 2 A 0.51 8 8 0.594 3 A 0.594 8 0.550 4 A 0.534 B 26' (Horizontal ) 5 A B 0.657 6 A 0.633 B 0.633 7 A 0.633 B 0.61 0 8 A 0.610 B 36 (Vertical) 1 A B 0.550 2 A 0.550 B 0.641 3 A 0.641 B 0.550 4 A 0.550 B 46 (Overhead) 1 A B 0.692 2 A 0.692 B 0.704 3 A 0.704 8 0.595 4 A 0.595 B Average 14.548/24=0.606 Notes: (1) Welds performed using: a. 3/4" Plate l b. Root Gap = 0" l c. E7018 electrode (3/32") L d. Amperage = 75 (2) Includes natural reinforcement moea
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t = ,y ATTACHMENT C Sy.: 4579A Date: P.sy 20. 19E3 Tile No 11.E.1 'e e e UNITD D:31XIIP.5 & C0! 53UC70Rs INc. TECRKICA. P.ISOR7 Date: May 20. 1983 Purpose of Report t Qualification and veri.ficatier. of Tlare-Eevel Groove Welds - Square Tube i Distribsttion: M. P. McKenna UIC591 W. J. Duffy UIC589 I D. C. Turnquist UIC589 E. C. Leithead UEC294 }.
- 5. J. Pattisen DEC262 A. Randopadhyay UEC589
- 1. W. Gregory UIC58S M. B. Lasota UEC5E9
- 1. E. Berg UIC196 P. K. Jattavedaz CIC767
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- 5. C. Sethi UIC286 B. Easu UIC589 V. M. Alsan UIC196
- 5. C. Nadara UEC569
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- 5. N. Caruso VIC290 C. W. Mourar UEC392 J. P. Whoriskey UEC296
- 1. A. Mills UIC392 l
J. R. 51otterbach 11U0 B. J. Huselton UIC5E9 D. E. Rhoads 07U4
- 0. P. Kalani 09U4 l
E. M. Rayes UEpl43 J. M. Benenati 09U9 R. B. 3ryans UEC262
- 5. K. Cuha UECOE2 M. A. Edgar UICIS4 J. R. Julian UIC262 R. C. Sevoety UEC786 M. J. Kenopha 07US C. A. Callant UIC262 DCC Tield UIC185 P. A. Leone UIC591 DCC - PA 06U1 C. T.11gamnti 0704 S.M Tile UEC164
- 5. C. Levine UIC262 J. P. Cannon 14U'i E. J. Esplan 17U4 Report Prepared Ey: _d
/ e T. R. Trelo Report Approved By: \\ 'In 't-9 w
- 7. P. Tassa11o. Jr.
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E, h E5sG ENERGYMEASUREMENTS GROUP San Ramon Operations 2001 OLD CROW CANYON ROAD SAN RAMON, CA e TELl4151811-6301 'a MAIL DOX 204 SAN MAMON. CA 94583 In reply please refer to: WOW: 84-06 5 December 1983 - Mr. Dennis Kirsh V. S. Nuclear Regulatory Commission 1450 Maria Lane, Suite 210 Walnut Creek, California 94596
Subject:
INSPECTION STATUS REPORT
Reference:
Memo; D. Xirsh to W. Wade dated 30 ile/ ember 19d3 This report provides the information requested in tne roterence memo. ' Attachment 1 tabulates the information by category with the exception of concrete expansion - anchor' bolt data which is not available. Anchor bolts were inspected against the appropriate Foley or Pullman specifica-tions (QCP9, QCPE9, and ESD 223) when they were used for the installation. Aside from population data, the information was derived from records main-tajned for the inspections conducted under FIN 0-8552. The inspections were conducted between July and November 1983 and some are incomplete. As a consequence, a description of the discrepancy and an assessment of the significance is provided only for completed inspections, illustrates the information stored in the data file for this project. The computer was asked to list all completed inspection items having a discrepancy for which a quality assur ante (QA) report and/or a citation has been initiated. Incomplete inspection itms for which QA reports have been initiated were also added since these reports provide the descriptive information needed to assess significance, if further explanation or additional i n f ormu t'i on is required please contact me at my office in San Ramon. O W. O. WAut MECHANICAL EllGlflEERlHG DEPARTMEllT WOW: cog Distribution: LLill EG&G/SRO G. Cumnings R. Pony it. Eli A. Dobeling R. Bogdanowicz C. Morton flRC T. Bishop .A C P. Narhut "T P. Morrill
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'A11 AtilMLill 11 y N L O'> ' I FART STA81 00M'lETE STATUS-MAN
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. LOC-. T liEM. NUMBER DATE DATE CRil CONIACTS ATF STAidS ' DATE INSPHRS 0019 AUI BLD6 I RACEWAY SUFFORI 14/CSR-127-3480 7/13/83 10/19/83 000 3 QCr 5A DLr 9 GCP [9 MONILROLA EE CANTPILL F0 MORRISON TG FHYSICAL 9/23/83MWE 8.0 MVR-E2625 9/23/83 ACCEPTED 10/19/83 MWE
- 7. 0 ~
0020 AVI PLD'G 1 RACEWAY SUFFORT 10/CSR1274328 7/13/83 10/31/83 000 3 '000 56 DI f 9 OCP E9 N0tillf*tA TE .i CAMTPELL fu MORRIS 0N F6 RECORDS 9/23/83 MWE B.0 MVR-E2625 9/23/83 i ACC-W/0 CA 10/31/83 MWE 5.0 .1022AVIBLOG l RACEWAY SUTPORT 12/H-il5-6-105 7/13/83 F/29/83 GCr 3 DCr SA DCT 9 GCP E9 MONIER0LA PE CAMrPELL F0 i HEi,NANDEZ NR CliATION 8/20/83 MWE 2.0 MVR-E2618 8/20/83 ACCEPTED 8/29/83 MWE
- 5. 0. '
1026 AVI BLDG 1 RACEWAY SUFFORT K-154-1-il2 8/05/83 10/15/83 CCF 3 DCP 5A j DCP 9 j DCP E9 MONTER0LA PE I CAHffELL TO 4. MORRIS 0N P8 filYSICAL 9/15/83 MWE 5.0 MVR-E2653 9/15/83 !'027AUIBL90 1 RACEWAY SUFFORT 9/K-140-4-140 B/05/83 10/15/83 QCP 3 DCr 54 000 9 GCP E9 MONTER0LA PC CAMPBELL F0 MORRISON FG FHYSICAL 9/15/83 MWE 5.0 .MVR-E2653 9/15/03 l028 AU3 BLDG 1 RACEWAY SUFFORT 9/K-140-4-136 8/05/83 10/15/83 0CP 3 DCP 5A OCP 9 QCP E9 MONIER0LA PE o CAMTPELL F0 MORRISON F8 PHYSICAL 9/15/83MWE
- 5. 0 MVR-E2653 9/15/83 ACC-W/0-DA 10/15/83 MWE B.0 032 CONTAINMENT 1 RACEWAY SUFFORT 246-140-8-E3008 10/15/83 QCr 3 OCr 5A QCf 9 Oct E9 M0FRISON FG-J CANTPELL F0 fHYSICAL 10/20/83 MWE 5.0 1
MVR-E-2698 10/20/83 133 CONialNMEHi ! RACEWAY SUFPORI 10/F-140-5-965 10/15/83 QCP 3 i QCP So i' OCP 9 l DCP E9 MDERISON F8 l CAMfBELL F0 FHYSICAL 10/20/83 MWE 5.0 i)39PENEIRA7 BLDG 1 RACEWAY SUPPORT 146E8Wil51313 10/18/83 10/31/83 0CP 3 GCr SA QCf 9 l 00F E9 M0hRl50N TO l CA9ffELL F0 T3YSICAL 10/2U 83 MWE 3.0 MVR-E-2703 10/20/83 l ACC-W/0-DA 10/31/63 MWE
- 2. 0 J4311MBINE BLOG 1RACEWAYSUffGRTll/C-104-8-10 10/19/03 11/11/83 Orr :
GCr 'A QCf 9 DLP E9 MORRISDN 00 CAMfBELL f0 PHYSICAL 10/19/83 RMB 7.0 RECORDS 10/19/83 MWE 6.0 [ L
l 2 MVI. E 270510/31/83 -- .L aCC-is/04A !!/17/83 RMB 1.0 .~ 10/11/0311/15/03 CCf 3 E0044191il!NE BLD6-1 RACEWAY SUPPORT 15/A-119-3-44 r1 LA Pr9 + CLP E9 MDERISDN F6 C/ M ELL F0 DIMENSION 10/19/83 RMP
- 7. 0 RECORDS 10/19/83 MWE. 6.0 I
MVR E-2704 10/31/83 MVR E-2706 10/31/83 i ACC-W/0-GA 11/15/83 RMB 1.0 E0073 TURBINE PLD6 i RACEWAY SUFFORT 45/A-!!9 5-48 10/26/83 !!/01/03 DCP 3 OCT 9 FG CCP [9 MDPFilSON MELLD F0 RECORDS 10/26/83 RMB 1.0 FHYSICAL 10/26/03-MVR-E-2711 10/76/83 ACC-W/0-GA 11/01/83 RMB !.0 'E0077IURBINEBLDG 1 RACEWAY SUPPORT 50/A-107-7-88 10/27/83 11/02/83 000 3 000 5A OCP 9 GCP E9 f.3T<DISDN F6 NELLO F0 RE00RDS 10/27/83 RMB 1.0 FH)SICAL 10/27/83 MVR-E-2713 10/27/83 ACC-W/0-0A !!/02/83 RM8
- 1. 0 '
E007870RBINEl'LD6 1 RACEWAY SUPPORT 50/A-119-2-15 10/27/83 !!/02/83 OCP 3 GCF 5A Otf 9 0(r E9 MDRRISOls F6 NELLO F0' RECORDS 10/27/03 RMB 1.0 FHYSICAL 10/27/83 MVR-E-2714 10/27/83 ACC-W/0-DA !!/02/83 RM9 !.0 E1002 AU3 BLD6 1 RACEWAY SUPPORT CSR-127-4-56 11/08/8311/17/83 OCP E9 CAMritELL F0 MORRISON F6 MVR-E-272911/17/83 RP 3.0 1 1 RACEWAY SUPFORT H-85-1-42 !!/08/83 11/17/03 CCP E9 CAMFPELL F0 E1014CONielNMENT M0f;RISDN F6 MVR-E-2729 11/17/83 RP
- 3. 0.
M0023 CONTAINMENT 1P!r! HANGER 12-196SL 7/07/8310/12/93 ESD 223 TINKLE F6 6AUDIUSD f6 RECORD 5 - 9/02/83 MWE B.0 dmo 029 (see r.ut psge) y42 j{MWE / 6.0 j M0029 N/A ' 1 FIFE HANGER 46-9V 7/11/83 7/11/03 ESD 223 HOWELL P* !!!nLE F6 CliAl!0N. 7/11/83ABD 1.0 RP 1.0 N0047 N/A 1 FIFE HANBER 22-396SL -7/13/83 7/13/03 ESD 223 TilnLE FB HONELL h 2R-5184 7/13/83 A6D 2.0 i RP - 1.0 M0085 AU3 8LDE 1 FIFE HANGER W -172R 7/19/03 9/02/83 IS!: 223 IIHrLE F6 6fEOLD'll EE .FAUDIUSD F6 FHYSICAL 8/20/83 WELD 8/20/83 MWE 5.0 MVR-H4511 8/20/83 MWE 1.0 ACCEFIED 9/02/83-M0067 CONialNMENT l FIFE HAN6ER 57N-38R 7/20/83 9/02/83 ESD 223 6AUDIUS0 PG llurLE FG HOUELL I<E WELD 8/20/03 MWE 5.0 RECORDS 8/20/83 MVR-M4511 8/20/03 ACCEFIED 9/02/83HWE 1.0 M0068 CONTAINMENT 1 flFE HAN6ER 57N-28V 7/20/03 9/02/83 ESD E J.LLE FG GAC0LOH1 BE SAUDlUS0 F6 WELD 8/20/03 MWE 5.0 K Moi 38 '(see nut page) HVR-M4511 8/20/83 ACCLFIED 9/02/83 MWE 1.0 i G0160 t FIFE HAN6ER 73-39R 8/09/03 9/15/83 ESD 223 TlHFLE FG i EADICO FG 00LE FG MVR M-4533 9/15/83 RBS 1.0 CHM !.0 M0F 1 FIFE HANGER. 92 103R 8/17/03 9/15/83 ESD 223 IturLE FG St.DICO FG DrtE rG DR 5144 9/15/83 ENR 1.0 CHM-3.0 HONI N/A 1 FIFE HANGER 22-5475L 8/24/63 8/24/03 If!' 273 IlullE FC LDL1IE [ '. MVR 4542 8/24/03ASD 1.0 M0330 i HVAC SUFFORT SKC-HV570 B/II/83 9/20/03 0CP 40 PEfGSTEDT (0 0 'CFS F6 1h8927-71 9/20/83 RSS 1.0 CHM 3.0
A'.31 i HVI.C Surf 0R1 SrC HV368 8/11/83 9/29/83 OLI 49 PEll',tl Di 10 f.. ,V 0'00h0: fil IR3827 71.9/20/83R6S !.0 CHM 3.0 0?44 : 1 HVAC SUFFORT SKC HV!67 8/11/83 Otr 49 NOVACr f0 CARLEL'y FU BERESIEEI FC IRl;527 73 9/20/83 RSS 1.0 CHM 2.0 -0003 CONTAINMENT I ANN'JLUS. 6181-Cl-13-610 7/14/03 OC' 3 00F 5A CCP 07 DCr 9 r0fitfR PE K11CHEN PC BlR6 FD filVSICAL 9/15/83 QA 9/15/83 NCR542?272 9/15/33 MWE 5.0 0046 N/A 1 SW11CH 6 EAR 6422-it-13-8/l 8/25/83 8/31/03 DCP 3 PALARM0 PS NCR 8/31/83 AGD 1.0 5422-255 8/31/83 0049 N/A i SWliCH GEAR 6422-T1-13-874 8/25/83 8/31/03 Otr 3 PALAlm') r6 NCR 8/31/83 AGD 1,0 5422-246 8/31/83 0061 FUEL FfNDLING 1 FUEL.HANDL]N6 6tBO-fi-13-026-016 9/22/83 10/20/83 01.0 3 DCP 5A 0C0 C7 F0lfLER PE TINGLEY F0 Cati!NS F0 MUMD P! WELD 10/14/83 MWE 3.0 I NCR-8833 10/14/83 ACC-W/0-GA 10/20/83 MWE 2.0 0062 FUEL HANDLING ! FUIL HANDLINS 6180-F1-13-026-l!6 9/22/83 10/20/03 0Cr 3 000 5A 1 00F C7 t0llLER PE [ I!N3tEV F0 CANNING F0 MUNR0 PE WELD 10/14/83MWE 3.0 NCR-8833 ACC-W/0-QA 10/20/83 MWE 2.0 $063TUR8INEPLD6 i TUR8INE PLDG 6424-T1-13-794 11/01/83 CCr 3 GCr LA Gir C7 QCF 9 K0HLER EE IIARRIS0N PE i BERG FD MAR 11HSDK F0 KIRSCH NR WELD 11/01/03 MWE 16.0 NCR 11/03/83 RM8 5422-332 11/03/83 NCR 11/03/83 5422-333 !!/03/83 NCR 11/03/83 5422 341 11/03/83 NCR !!/10/83 HWE 10.0 5422-351 11/10/83 011A110N 11/18/83 MWE 10.0 ~ $025AUIBLO6 1 PlFE HANSER 855-66R 7/07/83 9/15/03 ISD 223 ilNrlr F6 SMllH BE EAUDIUSD FB FHYSICAL 9I02/83 gyA( 9/02/83 'ACClf@i[D 9/15/83 8/02/83 9/15/83 ESD 223 ilhKLE P6 A13B'1UR81NE BLDG ' 1. PlFE HANGER 384-393R' HOWELL BE FHYSICAL 9/02/83 ~ hNt> 9I /e Pd-l l Lv U
a_ n ny U JOS RECEIVED HJG JBH D:ABLO CANYON DN DLP PROJECT E Ns MAY 4 MB My acavto Jcs surtmH T.gNp0NT-R E /C' May 3,,1979 JN gg MN,. ['.I. ~ SAS GEu ,.o;.;.79 cTT s = ,,1. GMP arMimt ) r ilo ~~~~ G M__ Mr. R. H. Engelken, Director Office of Inspection and Enforcement d Region V U. S. Nuclear Regulatory Commission 1990 N. California Doulevard ~ Walnut Creek Plaza, Suite 202 Walnut Creek, California 94596 Re Docket No. 50-275-OL Docket No. 50-323-OL Diablo Canyon Site
Dear Mr. Engelken:
On April 4, 1979, the NRC Office of Inspection and Enforce-ment, Region V, was notified by telephone of a situation which was deemed reportable under Paragraph (e) of 10 CFR 50.55. The details cre as follows: During the progress of routine weld repairs on pipe rupture restraints, cracking was found in the immediate vicinity of the re-pairs. As a reault, Non-Conformance Report (NCR) DCl-78-RM-008 was initiated on October 3, 1978 to investigate the cracking. This in-vestigation identified significant cracking and resulted in NCR DCl-79-RM-006 inititted March 23, 1979. Thereafter an extensive investigation was initiated to determine the cause, extent, method of repair, and corrective actions necessary to prevent recurrence of these defects. The installation of the rupture restraints was pre-viously found acceptable after ultrasonic testing as required ay the specification. t The program of investigation in as follows: i' (1) Nondestructive Examination: A p' tan to nondestructively I l examine a significant sample of the pipe rupture restraint l weldments was implemented. The sampling plan calla fer examination of additional welds when defects are encountered in the original sample or the additional camples being tected. The nondestructive testing consicts primarily of magnetic particle testing, but also includes ultrasonic evaluation of eclected weldments. e l,1 *_n A rk y -~~ ~ ~ q A r. 1 1 mmm-
.;Mic G AS AND ELECT"'C COMPANY c...... f CC'PY ~ ,/ Mr. R. H. Engelken 2 May 3, 1979 ) 1 i/ (2) Welding Record Review: In parallel with the nondestructive testing,, the welding records for weldments to be tested are to be reviewed. The welding procedures used are to be-com-pared with the requirements of AWS Dl.0-69. This data is to i be compiled and-correlated with nondestructive testing re-suits. (3) Destructive Testing: Typicti defective welds are to be removed and metallographically examined. This evaluat: ion is also to include chemical verification of the materials found in the weldment. (4) Failure Mode Determination: The results of steps l'through 3 are to be correlated to determine the failure mechanism and to indicate the conditions and/or actions which caused K the defects. (5) Repair Method and Scope: A detailed repair plan is to be generated which will assure that all defective welds are identified and repaired without producing further defects. (6) Final Report: A report is to be issued which documents the final resolution of the repair program. The report will be issued upon completion of the repairs. .s The resultn of the investigation to date are as follows: (1) Nondestructive Examination: At this time, significant cracking has been found in two of the joint configurations. f i (2) Welding Records Review: Welding. records have been reviewed. Some questionable preheat requirements have been encountered, but these weldments are not in every case the defective weld-
- ments, More analysis is required to complete the correlation of the welding records with the NDE results.
(3) Destructive Testing: Samples of defective weldments have been removed. Initial evaluation of these samples shows cracks in heavy members. In addition to the metallographic evaluation of the defcets, several severely cracked stiffener plates have been removed and the cracks which were contained in the beams have been removed. (4) Failure Mode Determination: Work on this phase of the program is underway. l l
.lFIC GAS AND ELECTolC COMPANY CC'PY ',o ,/ Mr. R. H. Engelken 3 P.ny 3, 1979 l (5) Repair Method and Scope: This phano of work depends upon the progress of the failure modo determinations and there-fore has not yet beon initiated. ~ Since this report is preliminary n nature, a supplement will be submitted when sufficient information is available to deter-mine the scopo and method of repair. At that thno the report will addrcss the crack neverity and its impact on rupture rentraint per-formance and plant safety. Very truly yours, Philip A. Crane, Jr. JBHoch/ PAC:TC s CC: Director Office of Panagement Information and Program Control U. S. Nuclear Regulatory Commission Washington, D. C. 20555 bec: Elizabeth S. Bowers, Esc. James R. Tourtellotte, Esq. bbec: Diablo Distribution i i ~ { 1 a 1 I C 0 4 '. .}}