View source for DCL-84-029, Forwards Info Re Testing of Carboline Protective Coatings Used in Containment Bldgs,In Response to NRC 831205 Request at Meeting Concerning QC Program for Painting (Sser 21,Allegation 100)

{{Adams
| number = ML20210E933
| issue date = 01/24/1984
| title = Forwards Info Re Testing of Carboline Protective Coatings Used in Containment Bldgs,In Response to NRC 831205 Request at Meeting Concerning QC Program for Painting (Sser 21,Allegation 100)
| author name = Schuyler J
| author affiliation = PACIFIC GAS &amp; ELECTRIC CO.
| addressee name = Martin J
| addressee affiliation = NRC OFFICE OF INSPECTION &amp; ENFORCEMENT (IE REGION V)
| docket = 05000275, 05000323
| license number = 
| contact person = 
| case reference number = FOIA-84-744
| document report number = DCL-84-029, DCL-84-29, TAC-54434, NUDOCS 8603310027
| package number = ML16341D666
| document type = CORRESPONDENCE-LETTERS, INCOMING CORRESPONDENCE, UTILITY TO NRC
| page count = 2
| project = TAC:54434
| stage = Meeting
}}

=Text=
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                                                         - . ; ,. ,9_.
PACIFIC GAS AND E LE C T RIC C O M PANY r3,;y                  g   -
3@W3                           77 BEALC STREET . SAN FR ANCISCO, C AUFORNI A 94106
* G15) 7914;11 . tas 9:0 372 6587
: s. o se-u-                                     REGIO.
v.Ct Pat L"E.f
        .a u..     .E . m.....
January 24, 1984                      -
PGandE Letter No.: DCL-84-029 Mr. John B. Martin, Regional Administrator U. S. Nuclear Regulatory Commission, Region V 1450 Maria Lane, Suite 210 Walnut Creek, CA 94596-5368 Re: Docket No. 50-275, OL-DPR-76 Docket No. 50-323 Diablo Canyon Units 1 and 2 -
SSER 21 - Allegation 100

==Dear Mr. Martin:==

The, enclosure to this letter provides with information regarding testing of Carboline protective coatings used in the Diablo Canyon containment buildings. This information was requested by the NRC Region V Staff during a December 5,1983 meeting with PGandE at the plant site to discuss the quality control program for painting (SSER 21, Allegation 100).
Kindly acknowledge receipt of this material on the enclosed copy of this letter and return it in the enclosed addressed envelope.
Sincerely,
:                                                                    .         ./Jo Enclosure cc:         G. W. Knighton l
Service List 8603310027 860123 PDR    FDIA          PDR                                                             , , , f f, DEVINE84-744
[

 .. 3 DCL-83-029 PGandE Letterces     No.:ec.
coo co m a ENCLOSURE-e cao6 tCARBoCos*6evs
                                                                                                               =
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car boline .                   '
riat P=ov ecT eou e  acon ~o~
COATIN eGSat w   tae=oori~c e 13, 1983 PR OTECTIVEron commosion December               nrsisvauct                               .
Mr. Walter J. PratherPccific Gas & ElectricRoom 305 Mission St.,Srn Francisco, CA 94106 Diablo Canyon.
R3forence:                                                                           with in  accordance307* and 340*
DeOr Mr. Prather:               ted,    has been testedof ANSI N101.2 for both ts Carbo Zinc 11, untopcoaand meets the requiremen curves.                            sted in accordance 7* curve with and meets thewhen Ph;noline 305 has been teof ANSI N101.2 for a 30 with and meets the rcquirementsused as primer.                         accordancewhen              Carbo Zine 11 ic                                  tested in ' curve Carboline rcquirements 191 HB has beenof ANSI                 with N101.2 and meets        onethe forofa 340 10 used as primer.                            accordance       when    used in ted ina 320* curve Phenoline requirements 302 has been tesof ANSI N101.2                        300 Finish         for the following systems:                Phenoline 302                            i ish Phenoline 300 Orange /2c    Phenoline 302/Phenolineline          If you have Phenoline 300 Orange                        /2cPhenoline i n you   require. contact 300 Orange /
this is the informat ol ase do*not hesitate to We trust thatany further questions,          ,
pe Sincerely, Carboline Company.                        ,
CARBOLINE COMPANY r
                                                            /
Duncan M. Stewart QA/QC Manager jag /l/803/
Diablo/121283 s utssovai est44
                                                -- '~ousin>4L count . sr . Loui
                                                                                        ' ~ ~ ~ '      .m.

7 QUALITY    CONTROL b.isco O,                   PROCEDURE COVER SHEET s
                                                                       #256            .3 Procedure No.             Dated      Revision No.
QCP-507                Dec. 10, 1979                      TITLE: BISCO FLEXIBLE BOOT INSPECTION

==SUBJECT:==
METHOD FOR INSPECTING BISCO FLEXIBLE PENETRATION SEALS SCOPE OF CURRENT                  REVISION:
This document contains information proprietary to Brand Industrial Services, Inc.,
and shall be surrendered upon request from Brand Industrial Services, Inc. The contents are not to be used for other than the expressed purpose for which '
loaned without written permission of Brand Industrial Services, Inc.
BISCO        APPROVAL SIGN ATUR E S OriginalAue Rev.I Rev. 2 Rev. 3 Rev. 4 Rev. 5 Rev. 6
: v. I A UMOr         . J. Barta O. C. Approval z
: r. J. Barta
('~       Management      CM8-g.
Approval       C. W. Brown                                       fo3
                    ~8kd3'280167                                                     Page I of 6    ,

g bisco                              QUALITY CONTROL PROCEDURE TITLE:            BISCO FLEXIBLE-BOOT INSPECTION                  QCP-      507 1.0       PURPOSE 1.1      To establish the criteria and methods for the inspec-tion of BISCO Flexible Penetration Seals.
2.0       SCOPE 2.1      To establish.the acceptance criteria and inspection documentation methods fer all types and configurations of BISCO Flexible Penetration Seals (Boots).
3.0        APPLICABLE DOCtDfENTS 3.1      10CFR50, Appendix B, " Quality Assurance Criteria for Nuclear Power Plants and Fuel Reprocessing".
3.2      ANSI-N45.2, " Quality Assur,ance Program Requirements
                            ,            for Nuclear Power Plants".
3.3      BISCO Quality Assurance >!anual
                                                                                      /
3.4      BISCO Production Procedures 4.0         BOOT TYPE DESIGNATION 4.1      The type of installation is determined from customer approved documentation and specification.
V.                                                                       .
Date 12-10-79                           2 og    6 Rev. O  Page

bisco                       QUALITY CONTROL PROCEDURE c                          Ot TITLE:     BISCO FLEXIBLE. BOOT INSPECTION                     QCPe    507
: 4. 2'  The BISCO Quality Control Department shall record the installation type according to the following schedule:
Configuration Coding     ,
Description I                   Boot Seal between a pipe and sleeve extended f, rom concrete,   ,
g                                 II                   Boot Seal between an insulated pipe and sleeve extended from Concrete.
III                      Boot Seal between a pipe and sleeve flush'with concrete.
IV                       Boot Seal between a pipe and Bolted-on-Flange..
V                     Boot Seal between an insulated pipe and sleeve flush with con-crete.
VI                      Boot Seal between an insulated pipe and Bolted-on-Flange.
(;                            S                       Single Penetration M                       Multiple Penetration Date    12-10 73        Rev. O      Page 3  of 6

                                               ~
T.            .
: o.           .
                              ]
bisco                              QUALITY CONTROL PROCEDURE O                            O' TITLE
* _ BISCO FLEXIBLE BOOT INSPECTICN                  QCP      507 Coding                         Description F                         Fire Barrier R                         Radiation Barrier P                         Pressure Seal A                         Air Seal
    '             ~'
{"                     Example:       Boot Type IS-P ,
A Boot Sea'. between a pipe and sleeve ex-
                                ,                tended from the concrete, a single penetrating item, and intended as a pressure seal.
5.0     PROCEDURE 5.1      Pre-installation 5.1.1       All inspections shall be documented    on Form FB-6 and in conjunction with the internal work release '(IWR) and latest approved re-vision.of the penetration drawing.
5.1.2     The Quality Control Department shall inspect and accept the pre-installation requirements as dictated by customer specifications and BISCO standard procedures prior to production progressing with the application of the BISCO Flexible Boot.
Doia      12-10 79     Rev.0    Page 4   of 6

       .?
BISCO                     QUALITY CONTROL PROCEDURE q                         D                                                            .
TITLE:     BISCO FLEXIBLE'B00T INSPECTION                 Q CP   3o7 5.1.3    All boot mounting surfaces shall be fr'ee of sharp edges or protruding surfaces which could damage the boot fabric.
5.1.4   Surface mounted flanges shall be verified as having an adequate seal between the flange and mounting surface.
5.1.5    All internal barriers / seals shall be inspected in accordance with the applicable customer
("}                                   specifications and BISCO standard procedures.
v 5.2    Final Inspection 5.2.1    All inspection shall be documented on Forn FB-6 in conjunction with the internal work release (IWR) and latest approved revision of the penetration drawing.
5.2.2    The finti inspection and acceptance of a BISCO Boot Seal shall be in accordance with the applicable customer specification and BISCO standard procedures.
5.2.3    The areas of adhesive bonding shall be in-spected for adequate adhesion and workmanship.
For exampic, there should be no discontinuities such as "fishmouths'' existing along all bonded
(}                                   edges and seams.
Date     12-10-79   Rev. O      Page 5 of 6

bisco                    QUALITY CONTROL PROCEDURE l
({-
I TITLE:  BISCO FLEXIBLE BOOT INSPECTION                 Q CP             507 5.2.4    Each Boot Seal incorporating an internal barrier within the boot fabric area and in-stalled after the installation of the BISCO boot, shall be verified in accordance with the appropriate' BISCO installation procedure and/or customer specification.
Eh3 0F TEXT       <
i
       \.                                      .
6 Date 12-10-79         Rev. O    Page           6 of L_

  '                                                                                           FB-6 Rav. O FLEXIBLE BOOT PENETRATION SEALS 0l Project Nome                                           Bisco Job No.
Trace   iWR    Boot      Pre - Install                   Final     .
Date                 insp. Date                  Insp.
No. No. Type       inspection                   inspection 9
CODING:                            See OCP-507 for inspection details.
l
                                  /. Acceptable o Not Acceptable l       .
l

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6
                       ,                                                      PRODUCTION DISCO                                      '
gi               PROCEDURE COVER                   SHEET
  ' x(r                                       ,
                                                         ~
                                                                                  #256-3 Procedure No.                 Dated      Revision No.
SP-805-1        ,
DEC. 20, 1982                .
TITLE:                INSTALLATION OF A BISCO PENETRATION SLEEVE EXTENSION UTILIZING BISCOSEAL (POURABLE OR TROWELABLE)

==SUBJECT:==
INSTALLING A PENETRATION SLEEVE EXTENSION UTILIZING BISCoSEAL SCOPE OF CURRENT REVISION:
s                           .
    . , .                                  REWRITTEN FOR CLARIFICATION i1                                                                                       -
L)                                                                         .
This document contains informatico proprietory to Brand' Industrial Services, Inc.,
and shall be surrendered upon request from Brand Industrial Services, Inc. The contents are not to be used for other than the expressed purpose for which loaned without written permission of Brand Industrial Services, Inc.
BISCO APPROVAL SIGN ATUR ES Original issue . Rev. I Rev. 2 Rev. 3 Rev. 4 Rev. 5 Rev. 6 Author            J. EtD I
                                                        ~
: 0. C. Approval A vs i        h             jg/
(.                      ppr va
                  ~D 3 R Fo.yy4 ..                                                              Page I of 4

bisco                                 Production ' PROCEDURE c.
D      J e
R                                                            .
j INSTALLATION OF A BISCO PENETRATION SLEEVE TITLE: EXTENSION UTILIZING BISCOSEAL (POURABLE OR                      SP-805-1        4 TROWELABLE).                                                             l a
1.0 PURPOSE 1.1 This procedure describes the design and construction' cri-teria for installation of a BISCO penetration sleeve exten-sion utilizing BISCOSEAL (pourable or trowelable).
2.0 SCOPE 2.1    To provide the general method of installation of a BISCO sleeve extension utilizing BISCOSEAL (pourable or trowelable).
3.0 RESPONSIBILITY 3.1 The BISCO Project Manager is responsible for identifying and scheduling the work.
The BISCO Supervisor or other             ndividuals designated by the 3.2 BISCO Project Manager is responsible for the orderly pro-(3..
[.V''                        gression and proper construction of the work.
3.3    TheBISCOdesignatedTechniciaN. (s) are responsible for the installation of the BISCO sleeve extension and BISCOSEAL materials.
3.4    The BISCO Quality Control Inspector (s) are renponsible for performing the various inspections'of the work,.in accor-dance with applicable Quality Control procedures.
l                   4.0 GENERAL REQUIREMENTS                          .
4.1    The BISCO sleeve extension shall be constructed from 18 t
l gauge galvanized stgel sheet rolled to a tubular        -
i                                 configuration.
4.2    The dimensions of the sleeve extension shall be determined by the size of the opening to receive the sleeve in each construction situation.
4.3    The BISCO sleeve extension shall be equipped with a set of slotted holes.             The sleeve shall be pop-riveted to a.
rigid diameter determined by the size of the' opening.
l
        ..,                4.4    BISCOSEAL     material should NOT be stored in areas where
(,                         temperatures are likely to exceed 100 degrees fahrenheit.
l DO t e _     12/20/82      Rev 3     POge 2   Of 4 4

PROCEDURE f
     *                                -        PRODUCTION OISCO NETRATION SLEEVE SP-805-1 E-                                                                   URABLE OR TITLE.     .
INSTALLATIONrequires TROWELABLE)        _
OF temperatures A BISCO PEExT l
m of BISCOSEAL         ideal curing conditions.
4.5     The installationabove 55 degrees fahrenheithours                              for roximately i    t  ly 24 hours at 4.6    The pot life of BISCOSEAL is appand curing is a room temperature (72cF) .      ~
5.0   PRE-INSTALLATION                                  h      opening to receive the The over-lapping surfaces of t e tension                       shall be a positive bond between 5.1 sleeve extension and the sleeve exroughened the aforementioned surfaces antension and the sleeve The opening to receive the sleeve          t     petroleum ex products 5.2    extension shall be free of rus , d up, dust and dirt.with solvent and (greases, oils, etc.), weld buil -
Sealing surfaces must be wiped            l            clean p                             prior to installation.          .
A 6.0    INSTALLATION                                           opening'and/or the BISCO L d with sufficient BISCOSEA 6.1    The overlapping surfaces of thesleeve extens (pourable- or     trowelable) be positioned tlo the               1 se al . .
f sleeve is             I 6.2   The proper   BISCO depth,  sleeve        extsnsion
                                                             'so .that        approximatelyshall          3" ofrom th
                              ,. inserted and exposed-                               tension      shall be fixed The diameter of the BISCO sleeve                            exone ofSome  several met 6.3    to its proper dimension by any application.
depending on each individual                    :   design typical installation methods are shall be pop -riveted to stainless   steel ve in opening.
6.3.1   The BISCO sleeve extension                   i l
J a rigid configuration, utiliz ngrivets, pri L
Pag e _3_ Of _4_
          '.                                                                             R e v._ 3 -
Dole _ 12/20/82_

bisco                              PRODUCTION               PROCEDURE l
INSTALLATION OF A BISCO PENETRATION SLEEVE TITLE: EXTENSION UTILIZING BISCOSEAL (POURABLE OR SP-805-1 TROWELABLE) 6.3.2    The back hole in the sleeve shall be riveted, the sleeve inserted in the opening, and the front rivet then put into place.
6.4   The excess BISCOSEAL      material is spread around the open-ing - sleeve extension interfaces to form a smooth bead of t-material.                           ;
     '~
6.5   Additional excess BISCOSEAL           aterial is then removed.
                                                                   +                        .
6.6   The completed BISCO sleeve extension should be allowed to' cure in-place for a period of time consistent with operating temperature and humidity conditions.
s 7.0      HOUSE CLEANING                           .
7.1 All excess BISCOSEAL        material, spills'and scrap, shall be
                        -       removed from the production area.
7.2   Scrap materials, rags, etc., shall be disposed of utilizing proper containers.    ,
7.3   All equipment used,.shall be properly cleaned'and stored for future use.
i END OF TEXT t,
       ,                                           Dote   12/20/82         Rev 3      PO g e.L_. Of       ,
l                                           .

s
                                                                                   ., L u m. 4 eo o
g Ai0-Sy Ade#'
                                                                                          % M Mr. Dossey (12/83)
        . 99.                                              Falsification of Vendor inspection            Open    RV83A0068        OI/RV records related to structural steel products.
(Bostrom-Bergen/Meddco)                                       BB1       BB2 OC        0C
                  /'-                                     a. A former B-B inspector alleges to have                      O         C documented inspections he never performed (2.1.1)*                                                .
g                                     b. B-B qualified welders are alleged to                        O         C have questionable quals in that welders didn't maintain their quals by continuous welding for six month           . (2.2.1)*
1,                            c. Parts are alleged to have been assembled                   0         0 by' a manufacturer other than B-B. (2.2.2)*
l                           '/ d.                             The adequacy of some inspections performed                 30%       60%
by B-B inspectors are alleged to be ques-                           (c) tionable due to poor conditions for inspections such as inaccessibility and poor lighting. (2.2.3)*
i
(                              e. B-B personnel performing quality-related                    0         C activities are alleged to have received no QA program training. (2.2.4)*
I                   o                                     f,  B-B fabricated components found to be discrepant           30%       90%
and/or damaged were shipped.     (2.2.5)*
                                                                                                      ,                            (c)        :
                     -)                                  g. B-B quality practices are suspct due to management          0         0 pressure to meet schedules. (2.2.6)*                            '
                      ]                                  h. B-B/Meddco Metals CMTR's were appanently altered.    (2.3.1)*
24%       70%
(c)
                    ,                                    1. Material heat cert, numbers are alleged to                  O         C have been ground off and new numbers stamped in their place.    (2.3.2)*
: j. Material piece mark 10 numbers are alleged to                30%       75%
have been ground off and new' numbers stamped in their place.    (2.3.3)*
I         /                                              k. Red " Reject Tags" were taken from materials                O         C i
and replaced with " Accept Tags" and the materials placed back in the system. (2.3.4)*
: 1. Foreign steel purchased by Meddco was used as                 O       C domestic steel.    (2.3.5) f See PG and E reports on Bostrom-Bergen dated January 26, 1984 and February 2, 1984 10 7  g*

                 - Mr. Dossey 12/83 '                                                                                                                Page 2
: m. A~ shop worker scraped paint off an 0b              bob.           -
e'
                                    '                                                                                                              .0              0 accepted item and found the word " bad" 2
on it.   (2.3.6)*
                                 /-       n. Painted over cracks to disguise flaws.                                                              NA            NA
                                 .'       o. Weld rod not controlled.                                                                            NA           ,0
                                     ,    p._ No QA/QC program prior to 1979.                                                                       NA           -0
;                                        q.      Pre and post heat treatment on " nuclear quality"                                                  NA           *O material not proceduralized.
[ r.      Covered up laminations on plate and welded "non-QA" steel to "QA"          plater Twelding performed NA             0 0
on wet steel;*tsed 30, rather than 45. weld bevels; nused uncalibrated welding equipment; andl8 prior to late 1980,.no heat numbers were transferred small pieces of steel cut from larger "QA" pieces, t
a l
1 It y                                          .
 't i
i I
e 3
i
               *See PG&E reports on Bostrom-Bergen dated January 26, 1984 and February 10, 1984.
i
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O #
* ALLFGATInP (Al         '
Cot 1CEPPI (Cl              LFAD B. 2-8-83 Pemo Bishop to Shackleton
: 1. Anonymous - In early '82, several truck loads of                                  p                  OI pipe hangers were shipped to Diablo Canyon without             -c.g , \
tual OC inspection performed.           .
9 <,iold.
5.W      s h b4M w tw h Jw@+ + )4o So.dhTe wL C. 12-13-83 Statement (Dossey)
: 1. Falsified inspection QC documents on steel destined               F                b        '
for Diablo Canyon.                                             2ti
: 2. Steel bought from all over the world, but switched                   _           k
* heat numbers to make it look domestic.                       O'      D
: 3. Falsified welder certifications for work done on                 y                 A Bostrom-Bergen steel.                                  % 1,(
: 4. R d hn W ibs (brM <h *.1) m d                     ic    !       l W 4                           oI g f.     "a.uteu over tracksxo aisguiw Tis .;.             '
                                                                      }                                         _
D.
: 1. f'o negative aments about work, o,ing on at Diable g
per se. He c.sd confirm that             numbers may have
(                  g been altered on steel being shipped from Bostrom-Bercen, and that the quality of steel was suspect, **
g*           .
gg because.it      could not always be checked. A W H 'l F       d b,
                     . . ~           & . % .y t hotM Q ,
E.
: 1. Falsified welder certs.                                         /                    A                C (1o70-10P0)                  1. 2. . l                                  t:.
: 2. Bostron-Bergen hired " seedy" characters, whose work
             -was of poor quality.                                                                 C                M
: 3.    ?!o QA/0C program prior to 1070                            I       9     }                            RN-4     Pre and Post heat treatment on " nuclear cuality"                                    Pr weld material not proceduralized.                         _
c ]
Nspections performed in a rush, ad hoc nature.
OT
: 5.                                                                    /
: 6. Many cuestionable work practices existed on "0A"                                                     RE materialatshop,includingcoveringupalamination{-                       c            j 4 on steel plate,possibly destined for Diablo Canyon.
Questionable practices included:
: a. Welding non "QA" steel to "0A" steel plate.              Ii        d
: b. fio control af weld rod.                                  1        43
: c.                                                                                                          gI fioheatnumbersweretransferredtosmallpieces.I of  steel. cut from larger "0A" pieces, prior to                                   l[
late 1090
: d. Unodibrated welding equipment used.
e.
f.
Welding done on wet steel.
0 L [f q Used 30     w instead of 450,. weld bevels.               jw    c             (
to6            -

4 ALLEGATION (A)
CONCEPN (C)     LEAN F.
i                               1. Improper weld techniques used.
w             a
                                ?. NRC investigative techniques not thorough or complete.                                            C            0+
f
* C            #E
:                               3. Government's inter-agency corrunications are faulty.                                      '                 -
l 4
i I
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1
     .                                    Leade_for Bostrom-Bergen Investigation Per Discussion with Don DRISKILL QA Manual: Review for adequacy with emphasis on upgrading material A. Approved Vendors List
: 1. Survey / audit reports
: 2. Qualifted auditors-list
: 3. Review survey / audit reports of Bostrom-Bergen vendors                             ,
: 4. Internal audits of QA program by. management                                  i   -
                                                                                                       .t' -
g5 T
: a. Done by whom                                       ,, j' '
v' F<s
: b. Time interval Q'**a                             g/v
                                                                                                          ~ h *'
f~\         fl' r' *s
: c. Requirements _                                                      g3
                                                                                    .3 '      . o^ I
                    ' B. Contracts (P0s) for NUC orders                            ,-
(.
                                                                                'Q o-          ',-
i,
: 1. Review ASME or ASTM requirements on PO                          y i
: 2. Review CMTRs sent w/for each order l                          3. Break requirements down (Heat No. - NDE traceability) - CMIR will generally include statement identifying heat codes, mech.
;-                              properties, and control no. log
: 4. Heat logs (often shows what original heat was assigned that
(                               material) l
     , y hJw h 2.1.p. 7..r '2. 3 4 [d /GC M o'4< 9 D,N 8Af-!r'^ %
s i
0 J. vo#(t) Q zA.i,2.3,s, a Wsc tbM                                                                             go L

g C. Show and Tell
: 1. Requirements - Look at:
: a. HT records
: b. NDE records
: c. MTR from supplier
: d. B.B. P0s to suppliers D. Nuclear Contracts
                            'I. Have B.B. prepare matrix that includes:
: a. every PO number sold nuclear and to whom
: b. control no. for materials
: c. ids for material supplier t
i ~
: d. ids for supplier's heat code and B.B. heat code E. Determination by RIV Vendor and/or RV Technical Staff-
{                            1. Are there technical problems
: 2. Are they safety-related
: a. Not safety-related - no Part 21 violations O
L'

3
: b. Ask for'any legal opinion of any other violation if not safety-related F. Interview involved individuals as approg,riate depending on E and lead sheets e
e 4
e S
e e e la     - -
ii - -
e

F' Summary of Allegations / Concerns for the
                 ,                                                   Bostrom-Pergen Issue Allegation 99 P383A00c8 ALLEGATI0?l(A)            y St.'?'t'ARY C0t'CEPf! (C)        LEAD A.       1-?f-84 PG&E Letter Schuyler to f*artin 2.1.1 A former Bostrom-Bergen inspector alleges to have                A documented inspections which he never performed.
7.P.1   Bostrom-Bergen qualified welders are alleged to                6                4 have questionable qualifications in that welders-
* did not maintain their qualification by' continuous welding during six-month periods.
p'      -
Dr
                           ?.2.?    Parts are alleged-to have been assembled by a manufacturer other than Bostrom-Cergen.
2.2.3 The adequacy of some inspections performed by                  4p                   @T Bostrom-Bergen inspectors are alleged to be questionable due to poor conditions for inspections such as inaccessibility and poor lighting.
2.?.4 Postrom-Bergen personnel performing quality-related activities are alleged to have received no Quality k
                                   /ssurance Program training.
                           ?.7.E   Postrom-Bergen fabricated components found to he                b discrepant and/or damaged are alleged to have been shipped.
                           ?.?.F   Ecstrom-Eergen quality practices are allegedly                                     "E
    ,                              suspect due to management pressure to meet schedules.
A 2.3.1   Postrom-Bergen/?'eddco l'etals Certified l'aterial Test a
M to'r Reports are alleged to have been altered.
2.3.? t'aterial heat certification numbers are alleged to                A                  M have been ground off and new numbers stamped in their place.
2.3.3 !'aterial piece marl identification numbers are alleaed           14                 C
,                                 to have been grount' off and new numbers stamped in their place.
2.3.a
                                                                                                                     /
Ped " Reject Tags" were takert from materials, replaced with " Accept Tags," and the materiais placed back into         4                 ET t..e system.                                    '
2.3.5 Foreign-produced material pu'rchased by l'eddco !'etals            h                #5 is alleged to have been inapproppiately used as dumestically produced.
2.3.6 A shop worker scraped raint off of an accepted item              6                 Gr and found the word " BAD" on it.
4bNW k                       9 td to b v 4<v wad d.oM g p9 M ')
         +p RT ew,*md ~ 31 S wop e ri or A A! + Jm ad at Sputs,                                                 01 c5 or, ' wNp+q ,
f-L                                                            -

      ..                             E PRODUCTION JiSCO PROCEDURE COVER                          SHEET U  O' C-
                                                       .               .                      #256-3                .
Procedure N O.              Dated                   Revision NO.
SP-505            May 13, 1983                                                                                                                                                      ,
TITLE:                 sISCo rLExIaLE BOOTS.
SU B J ECT:            INSTILLATION OF BISCO FLEXIBLE PRESSURE, FIRE AND RADIATION SEALS                                                               ;
SCOPE OF' CURRENT                      REVISION:                                       .
COMPLETE REVISION.
:i                                    . ,
This document contains information proprietary to Bron'd Industrial Services, Inc.,
l                  cnd shall be surrendered upon request from Brand Industrial Services, line. The contents are not to be u' sed for other than the expressed purpose for which loaned without written permissior, of Brand Industrio! Services, Inc.
BISCO      APPROVAL SIGN ATUR ES Original Issue Rev.I Rev. 2 Rev. 3 Rev. 4 Rev. 5 Rev. 6                      -
                                                                                                                                 ~!
                             ^"    '
: c.    . FEDOR l
\                                                         %
l                    0. C. Approvdl           .          *~t'*
        ,                              .          'J. BARTA l..                                                                                                            lof
!                     Managernent               g yg ~               -                                       .
                          .A p p roval         C.W. BROh'N
          ~
7 fo d 3 W 6 7 Q ~ --
Pnno I nf   11

bisco                           '
PRODUCTION          PROCEDURE 3                                  0     '
TlTLE:-        . BISCO FLEXIBLE boots                          S P - 50s
: 1. CF PURPOSE
                                 .To establish installation methods for BISCO Flexible Boot Penetration ~ Seals where the criteria of p'ressure (Hydrostatic
                                  / Air), fire, radiation or any combination thereof exists.
2.0    SCOPE To provide the standard installation method for BISCO flexible boot seals capable of withstanding the design criteria.
3.0    GENERAL 3.1   Flexible boots designNd to provide a specified criteria "p[y(                            may be installed directly to penetrants o        having a maximum
(/                               operating temperature of 400 F.
3.2  Penetrants equipped with insdlation and requiring a flexible boot should be sealed for-air infiltration through the insulation prior to boot installation.
3.3 Insulation seals on Stainless Steel piping shall be
 '                                     provided by a Biscoseal replacement ring or by Booting           '
directly to the pipe.
          ^
!                                3.4   Where a fire criteria \is indicated, the flexible boot F
'                                      should be installed on the non-hazardous side of'the barrier. In the event a potential fire hazard exists for both sides, or the hazard side cannot be determined, a flexible boot should be installed on both sides.
!                                3.5   Fire configurations with stainless steel pipe penetrants I
must be sealed with Ceramic Fiber (Blanket Strips /
Bulk) which is certified for compliance with NRC f                                      Reg. Guide 1.36.
!                                3.6   A flexible boot designed for use as a pressure seal (hydrostatic / air) should be installed on the negative side of the barrier for maximum resistance.                    -
       ./
Date    s/13/83      Rev. 2      Pageu 2 of ll

bisco                            PRODUCTION            PROCEDURE D
v'                                                                    .
TITL El       BISCO FLEXIBLE boots                              S P - 505 t
4.0    RESPONSIBILITY                                                -
4.1   The BISCO Project Manager is responsible for identifying and scheduling the work.
4.2 - The BISCO Supervisor, or other individual designated by the Project Manager, is responsible for the orderly progression and proper construction of the work.
4.3   The BISCO Technician (s) or other designated craft personnel are responsible for the installation of the work.
4.4   The Quality Control Inspectors are responsible for performing the various inspections of the work, in
                    ~
- ' . ,y                           accordance with applicable Quality Control Procedures.
Ag 5.0    ASSEMBLY MATERIALS 5.1   Product Name ................. Supplier - Product Descriptior.
BISCO SGR-600................ Keene Corp. (56493F031) -
A Flame retardant class fabric
                  ,                                               coated with silicone rubber on both sides.
5.2   Boot Clamps...................Murray Corp. - A reinforcing
:ompression strap (hose-clamp), of stainless steel, ',
                                                     .            used to secure,each end of boot.
5.3   Bolt-on-Flange................As supplied by BISCO / client-An angle ring intended to provide a sealing surface where sleeve extensions do not exist or cannot be installed.     .
(
Date   5/13/83       R e v. Page     3 of 11

0                                -
JISCO                             PRODUCTION                      PROCEDURE
(
TITLE:     BISCO FLEXIBLE boots                                        SP-      505
                                       ~
5.4   Sheet Metal Sleeves ..........As supplied by BISCO / client-(Sleeve Extension)                         An 18 ga.or heavier calvanizec steel sleeve, intended to provide additional sealing surface for existing sleeves or a form in reducing the      *
                                                       .                   annular gap for radiation seals.
5.5   Hi-Temp Cement ...............Thermon T A high tempera-ture cement used to restrict air through insulation for low pressure and non-hydro-static insulation seals.
5.5   BISCOSEAL .................... BISCO - A trowelable or pourable material used as
         ,'                                                                an insulation replacement y                         .                                         for a high pressure insulatio: t
                                                                       ; seal (air / hydrostatic) or as
                     ,                                                     an adhesive for the install-ation of galvanized sleeve extensions.
5.7   732 Silicone Sealant .........Dow Corning 732 - A RTV l              .
silicone sealant used to bond longitudinal boot ~ seams and boot fabric to all metal except copper.
l                      5.8   790 Silicone Sealant . . . . . . . . . Dow Corning 79 0 - A RTV silicone sealant used to bond concrete to metal and Boot Fabric to metal, includim i                                                                          copper.
l                      5.9   Ceramic Fiber . . . ,. . . . . . . . . . . . B&W Kaowool Bulk Fiber /
l                                                                         Blanket, J. M. Cerafiber/
l                                                                          Cerablanket - A refractory l                                                                         material intended to provide a fire barrier.
Date         s/13/83            Rev. 2     Page 4   of 11 l
L

0      .
aiSCO                            PRODUCTION               PROCEDURE TITLE:      BISc0 FLEXIBLE BOOTS                  ,          S P . 50s 5.10 BISCO    SF-lS0NH................ BISCO - A high' density elas-tomeric material used as a radiation barrier for annular gap,between inner and outer
  ,                                                              . sleeve.
5.11 BISCO Split
* Shielding Collars ............ BISCO - A high density elastomeric or metallic material used as a radiation seal to compensate for the gap between the inner sleeve and the penetrating item.
5.12 Solvent ......................Ashland WS6962 - Cleaner used to wipe down.the boot fabric, sleeve and pipe.
6.0 BOOT PRE-INSTALLATION                  i 6.1  Boot can be mounted on existing sleeves or flanges to existing penetrant, providing:
6.1.1    Sharp edges of metal , sleeve or flange are sanded, filed, or ground smooth.                        l 6.1.2    All sealing surfaces (approximately 2-3 inches
                                      .on pipe and. sleeve) are clean and free of dust and dirt. Sealing surfaces must be wiped with solvent and dried prior to installation.
6.2  Where a sleeve does not exist or does not provide sufficient sealing surface, one must be provided.
I i                            6.2.1     A bolt-on-flange may be utilized to provide an
!                                      adequate sealing surface in accordance with BISCO Production Procedure SP-505-A.
6.2.2     A sheet metal sleeve may be installed in order
!                                      to provide adequate sealing surface pursuant l
to BISCO Production Procedure SP-805-1.
i Date     s/13/83         Rev. 2   Page 5 of              11 t

bisco PRODUCTION            PROCEDURE f'.
   \. -
1 TITLE: _ sISCo FLExIsLE soots                            SP     sos 6.3   Insulated pipes shall be sealed to limit air infiltration through the insulation, prior to the installation of the flexible boot.
6.3.1  Where the insulation seal is designed for high pregsure, hydrostatic conditions, and a maximum 350 F operating temperature, BISCOSEAL (pourable /
trowelable) shall be provided as a replacement in the clamping area.
6.3.1.1    Jacket insulated pipes shall have the shortest practical length of jacketing removed over the clamping area.
6.3.1.2    A minimum of three inches of insulation Rn W' '
shall be removed in the clamping area (as close to sleeve end as possible) and replaced withjBISCOSEAL to the equivalent diameter of the insulated pipe with jacketing. (NOTE: See Paragraph 6.1.2) 6.3.1.3    The BISCOSEAL in liquid / paste form shall be allowed to cure for approximately 24 hours before proceeding.
6.3.1.4    Jacketing shall be re-installed up to, but not covering the BISCOSEAL.
6.3.2  Where an insulation seal is designed for low gpressure, non-hydrostagic condition and a maximum 1250 F operating temperature, hi-temp cement must be applied
                       ~        to the existing insulation in the clamping area.
(NOTE: See Paragrpah 3. 3) 6.3.2.1    Jacket insulated pipes shall have the shortest practical length of jacketing removed over the clamping area.
Date    5/13/83            2           6      11 Rev. Page        of

                                  ]
JISCO                                           PRODUCTION                PROCEDURE Qi h                                                                                                                        .
TITLE:                        sIsco FLsxra'st soors                            S P -sos 6.3.2.2 A minimum of three inches of insul'ation shall be removed (intact) . The removed sections shall be re-applied after a coating of Hi-Temp cement is applied to the exposed pipe surface and all insulation surfaces.
6.3.2.3 Jacketing having a flat surface shall be                              -
re-installed utilizing 732 sill:ene sealant between the jacketing and the coated pipe insulation.
9 6.4        Penetrations designed as a fire barrier shall have ceramic                                 '
fiber (bulk or blanket strips.) installed in the gap
                        ,               between the penetrant and sideve, to a minimum depth of "nine inches.
4 6.4.1         For annular gaps of one-half inch or more, ceramic blanket strips shall be utilized. The blanket strips shall be wrapped around the penetrant in a continuous circular fashion and slid into the                           .
opening, flush with the barrier surface.
6.4.1.1 Ceramic Blanket strips shall be installed in three segmented raps. Each segment shall consist of .one wrap of one inch blanket for each inch of annular space, Plus additional wrap (s) or portion s thereof to ' provide approximately twenty-five percent pre,-load compression.                                              .
6.4.2          Where.the annular gap is less than one-half inch, ceramic bulk fiber shall be installed flush with the barrier surface.
Date    s/13/83          Rev. 2   Page 7 of                 11

O                           '                   .
JISCO                             PRODUCTION          PROCEDURE
  ..                     Ql                                                              .
TITLE:      BISCO-FLEXIBLE BOOTS                           S P - 505 6.5   Penetrations designed as a radiation barrier-shall be equipped with an internal ring of BISCO SF-150NH high density elastomer installed within the annularfgap, with BISCO split shielding collars flanking the penetration opening.
6.5.1   Installation of the inner sleeve.
6.5.1.1      The inner sleeve shall be of a sufficient length to acccmmodate the specified depth of BISCO SF-150NH or equal to the barrier.
6.5.1.2      The annular gap between the penetrating object (s) and the inner sleeve shall be
       .                                   as specified on the approved Penetration Seal Design Document.
6.5.1.3      The annular gap shall be maintained by (F'\'
sf/                                     installing temporary blunt non-metallic shims, such as wooden wedges, dowels, or Ethafoam, secured in place.
6.5.2    Installation of the damming media for BISCO SF-150NH shall be in accordance with established BISCO Procedure SP-103.
6.5.3    Formulation of BISCO SF-150NH shall be in accordance with established BISCO Procedure SP-304NH.
: 6. 5. 4 - Installation of BISCO SF-150NH shall be in accordance with established BISCO Procedure SP-205.
6.5.5   When pipe insulation is necessary within the penetrating opening and does not exist, the installation'shall be in accordance with client procedures, utilizing client. approved materials.
6.5.6    The BISCO Split Shielding Collars shall be to sizes as required.
6.5.6.1     The BISCO Split Shielding Collars shall be mounted on the pipe using the
   ,                                       appropriate fastener method, based on weight and size.
((
Dote 5/13/83             2           8    11 Rev.      POge     of

DISCO              ,
PRODUCTION          PROCEDURE l
l TITLE:             bisco PuxIB u boots                                     S' P     505 6.5.5.2      The split collars shall be positioned as close to the end of.the boot as allowed by the clamping area location or other existing obstructions.
6.5.5.3       If a collar cannot be positioned on both side,s of a penetration due to elbows, hangers, or other obstructions on the penetrating object, then both collars shall be mounted end to end on the other side.
7.0       BOOT      INSTALLATION 7.1     All intended sealing surfaces of the boot material (the overlapping axial seam calculated from Production Procedure-fh                          SP-504 and clamping area of Pipe and Sleeve) shall be                        .
45                         roughened with sandpaper a mimumum of three inches from the edge and wiped clean with solvent.
7.2 "The pre-cut BISCO Boot shall be positioned on the sleeve and/or pipe to allow the sealing of the overlap seam.
7.2.1          The sealing area and overlap seam of the boot seal should be free of wrinkling.
l'                                 7.2.2          A bead of bisco 732 RTV Sealant is applied to the
                                              . overlap seam and spread to an approximate width,
!                                                 calculated from Production Procedure SP-504. The            /
seam is then closed, with all excess sealant being L
l forced out ,and removed.
[
7.2.3          Duct tape may be used to hold the seam together l
until cured, at which time it shall be removed.
1                                                                                                                .-
7.2.4          The sealant shall be allowed to cure a minimum of sixteen hours before disturbing the boot for l
further processing.
7.3     Position the boot on the pipe and sleeve for final proces-sing until the required length of boot is obtained.
Date   s/13/81      Rev. 2     page    9 of 11

C J I S'C O
                                        '             h PRODUCTION                    PROCEDURE ~
g                                  V([))
TITLE:               bisco FLEXIBLE Boors                                            SP      50s
           ,                   7.4         Require'd boot clamps for the pipe and sleeve shall be
                                          ' determined utilizing Boot Clamp Chart, FB-2 (attached).
                                                       .Using Flexible Boot Worksheet Form FB-1, found in 7.4.1 Production Procedure SP-504, determine the circum-ference of. the pipe and sleeve to be clamped.
7.4.2 Find the corr'esponding closest circumference on
                                                 - Boot Clamp Chart FB-2, then determine required clamp part number in the far left column and the quantity in the top column. Where the pipe / sleeve
* circumference does not appear on Form FB-2, pick the next larger value on the chart. In addition, whenever possible use the lessor multiple of clamps needed to band' pipe / sleeve.
'     '.ts'
      /
        ?
EXAMPLE:    (1)         Pipe Diameter = 6"                                   .
Pipe Circumference = 20.81" Closest, Chart Circumference = 21.5" Clamps to be used #104 (1) i EXAMPLE: (2)      Pipe Diameter 22.77" Pipe Circumference 71.5" Closest Chart Circumference 72"
;                                                                        Clamps to be used 73" - #88 (4) 7.4.3       Before being installed, clamp (s) must be opened l
and the end of the band at the clamp head should be bent up.
7.4.4      When attaching any series of clamps together, they should be threaded thru approximately<one-half inch into the adioining clamp.
l                            7.5 _ Apply 732 silicone, sealant on both the pipe and sleeve                                          .
for sealing surface (l" minimum width). Fold the boot                                -
l ends over the sealant and position the clamp (s) on the boot fabric, and tighten.
l                                         7.5.1       Where multiple clamps are utilized,'the position l                                                     of the clamp heads should be approximately equally
    ,                                                 spaced around the pipe / sleeve.
    '(%. .
l l        -
Date     5/13/83                   2 Rev.            Page in of 11

bisco                            PaooucTioN PROCEDURE
(<'                       D1 TITLE:       BISCO FLEXIBLE BOOTS                           SP sos 7.s.2   When installing a Boot on a insulated penetrant, the clamp (s) position shall be centered on the insulation. seal.                                   '
7.6  Where necessary, trim off excess material and remove excess sealant.         .
8.0       HOUSECLEANING 8.1  All excess and scrap material shall be removed and properly stored, relocated, or disposed of, into proper scrap
                                                    ~
containers.
               ~
f"            *** Attachment - Boot Clamp Chart Form FB-2 ***         ,
:i END OF PROCEDURE.
* i t                                               .
e (I
t Date       s/13/83  Rev.2        POge 11 Of 11

f? -
BOOT CLAMP CIIARj' REQUIRED CLAMP (s) FOR PIPE CIRCUMFERENCE CLAMP NO.              2 1                  3       4          5        6      7        8        9           10
                                                  ~
6
                                               ~
2.5 8        3.5 12         3.75                                                                    .
16         4.5
* 24         6 28         7 36         8.25 40        9        18 44        9.75     19.5   29.25                                    .
48      10.25      20.5   30.75  41 52      11.25      22.5   33.75  45         56.25 56       12         24     36     48         6'O    " 72 60       13         26     39     52         65       78      91 64       13.5       27     40.5   54         67.5     81      94.5     108 72       15.25     30.5    45.75  61         76.25    91.5   106.75-   102   137.25 80       16.75     33.5    50.25  67         83.75  100.5    117.05   '134   150.75       167.5
      '88       18.25     36.5    54.75  73        91.75   109.5    127.75    146   164.25       182.5 96       19.75-    39.5    59.25  79        98.75   118.5    138.25    158   177.75-      197.5 104        21.5      43      64.5. 86      107.5     129      150.5     172   193.5        215               .
116        23.75     47.5    71.25  92.5    116.25    140      166.25    190   213.75       237.5 L-}}