ML20071D375

Forwards Info Requested by Congressman Udall .Info Includes Tabulation of Welders Qualified Under Special Program,Welding Procedure Excerpt,Qa Procedure,Ie Insp Rept 50-358/82-10 Excerpt & 10CFR50.55(e) Rept

ML20071D375
Person / Time
Site:	Zimmer
Issue date:	01/31/1983
From:	Gwynn T NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
To:	Hunter D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
Shared Package
ML20071D348	List: ML20071D375
References
NRC-83-06, NRC-83-6, NUDOCS 8303110143
Download: ML20071D375 (147)

See also: IR 05000358/1982010

Text

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NRC 83-06

January 31, 1983

Docket No. 50-358

MEMORANDUM TOR:

D. R. Hunter, Chief, Section 1, Of fice of

Special Cases , NRC Region III

,

THRU:

W. F.

ianson, Senior Residant Inspector,

Wm. H. Zimmer Nuclear Power Station

1

FROM:

T. P. Gwynn, Resident inspector, Wm. H. Zimmer

Nuclear Power Station

'

SUBJECT:

LETTER FROM M. K. UDALL TO N. J. PALLADINO DATED DECEMBER

20, 1982, REQUEST FOR INFORMATION

The enclosures to this memorandum provide the information requested in the

subject letter.

Each enclosure with referenced attachments responds to one

of the two requests.

The information provided van obtained from a number of sources including site

procedures, NRC inspection reports, internal ficensce and contractor documents,

1

and informal interviews of available personnel.

Infomation collection was

hampered by 1sek of availability of several key personnel,- including the

forr:ser !!. J. Kaiser Records Control Manager and the former H. .T. Kaiser

document review lead in the velder qualification review task force, and by

alternative assignments such as providing administrative coordination for

the NRC Evaluation Team.

The enclosed information was not readily available ; in particular, the re-

sponse to question 1 of the subject letter required as a prerequisite that

the licensco respond to an NRC concern documented in Draft Inspection Report

No. 50-358/82-12.

This licensee response (which required many engineering

and clerical man-hours) was then conbined in part (by the NRC resident staff)

vich informa tion previously provided by the NRC resident staff to the staff

j.

of the House Subcommittee on Energy and the Environnent (transmittals dated

November 23 and December 6,1982) .

The combination of this information

revealed several discrepancics, five of which were pursued by this inspector.

Of these five discrepancies, three were resolved as clerical errors, one

was due' to incomplete information, and one required further investigation

by the licensee's contractor which will probably result in a nonconfor::ance

l

report (see enclosure 1, attachment 1, page 43 of 103, welder symbol LVN).

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- - - - -

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.

.

D. R. Hunter

-2-

January 31, 1983

'

Further requests for specific docu=entation and/or clarification of the

information provided should be directed to T. P. Gwynn at (513) 553,-2052/

2053.

,

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.

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T. P. Gwynn

.

Resident Insp

or

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Enclosures: As stated

Attachments:

(1)

Tabulation of Zimmer velders qualified under the !!. J.

Kaiser "Special Welder Qualification Program".

(2) Excerpt from H.' J. Kaiser Welding Construction Procedure

(WCP) - 2. " Welding Performance Qualification Testing";

Exhibit E, " Welding Procedure Qualification Cross

Reference Matrix".

-

(3). CG&E Quality Assurance Procedure 19-QA-21, " Quality

Confirmation of Wclder Qualification Records".

(4)

Excerpt from H. J. Kaiser Procedure WCP-2 Appendix 3,

. " Welder Qualification / Review, Testing and Training

Procedure".

(5)

Excerpts from NRC Inspection Report 50-358/82-10 concerning

maintenance of welder qualification listing and trans-

mittal of qua3ity assurance records.

(6)

Excerpts from Draf t NRC Inspection Report 50-358/82-12

concerning transmittal of records and the special velder

qualification program.

(7)

Excerpt from the CG&E Quality confirmation Program Status

Report daced December 31, 1982 - Task 11

(8)

10 CFR 50.55(e) report M-73 dated January 14, 1983,

"Possibly Altered Welding Procedures".

.

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Enclosure 1 to

WHZ/NRC 83-06

Page 1

1.

A list of Zimmer welders who were requalified as a result of the welder

qualification review. The list should indicate for each welder the specific

procedures for which requalification was required, and the procedures for

which welders were decertified as a result of the review.

The list shculd

also include, for each welder and each procedure, the date on which quali-

fication tests were taken, and, where appropriate, the number of times a '

welder failed to pass the test, and was either decertified as a result of

that failure or was required to retake the test.

Response to item (1):

Attachment (1) to this memorandum presents a tabulation of 103 Zimmer welders

who were qualified under the H. J. Kaiser Special Welder Qualification Program

(SWQP).

This program resulted from the welder qualification review performed

by a task force under direction of the H. J. Kaiser Records Department Manager.

The purpose of the SWQP was to provide objective evidence (where objective

evidence was lacking) that ASME/AWS code requirements had been met prior to

a welder performing production welding in the field.

It was recognized at

the beginning of the program that the SWQP results could not be used to

disposition past performance since the welder may.have either improved his

performance through field experience or degraded his performance through

decreased manual dexterity due to age.

The code requirement states that

the welder must demonstrate his ability to produce a sound weld prior to

performance in production.

Thus a second program was instituted to disposi-

tion past performance related to the welder qualification review.

The folicwing definitions apply to the columns of the tabulation in Attachment

(1), and to the data contained in those columns:

l

This column denotes the specific procedures for which

Column 1

-

documentation was reviewed and the position (s) in which

requalification tests were taken, where applicable.

The

prefix "Special Process Procedure (SPP) 3.1. " applies to

each entry.

For example, on page 1 of Attachment (1), the

entry "7/6G" should be read as "SPP 3.1.7 in the 6G position".

I

An asterisk (*) after the procedure number denotes a sub-

stitution made by weld engineering.

A copy of the

,

H. J. Kaiser Weld Construction Procedure - 2, " Procedure

I

Qualification Cross Reference Matrix", is provided as

Attachment (2) for clarification.

For example, on page

6 of Attachment (1), welder symbol NFL was re. viewed under

Special Process Procedure (SSP) 3.1.6 and 3.1.21, but was

tested under procedures 3.1.7, 3.1.28, and 3.1.56 (sub-

t

l

stituted by weld engineering) in the 6G position.

Note

from Attachment (2) that qualification to SPP 3.1.28

qualifies a welder to perform the completion portion

'

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Enclosure 1 to

WHZ/NRC 83-06

Page 2

(shielded metal arc welding portion) of SPP 3.1.18 and

3.1.21, and all portions of SPP 3.1.51.

Column 2

This column denotes the document review group characteri-

-

zation of the documentation as acceptable (A), resolveable

(R), Indeterminate (I).

In the case of a weld engineering

,

substitution an (N) in this column denotes that documenta-

tion was not reviewed.

Column 3

This column denotes the weld engineering decision to either

-

decertify (D), requalify (R), or no apparent action (N).

Where no action was apparent, the condition identified by

the document review group may have been dispositioned

accept-as-is, or in some cases the man may have terminated

his employment, in which case he was no longer applicable

to the SWQP.

.

Column 4

This column denotes the dates of testing, from the date

'

-

the man arrived in the test shop until the date of final

acceptance (or rejection) of the test. Where multiple

-

tests were utilized, the dates extend over the entire

, period of testing.

Column 5

This column denotes the final test results, accept (A)

-

or; reject (R), and the method by which those results

were obtained, such as visual examination (V), bend test

(B), or radiography (R).

.

Column 6

This column denotes the number of attempts required to

-

achieve the final test results.

One test coupon corre-

sponds to one attempt.

This column denotes the status of this welder to the

Colu.n 7

-

listed procedurs from the H. J. Kaiser 10-18-82 Current

Welders List; active (A) or not listed (N).

Column 8

This column provides any clarifying remarks provided by

-

the H. J. Kaiser welding engineering department.

The data provided in Attachment (1) was derived from a number of sources,

as follows:

Columns 1, 2 - (a)

H. J. Kaiser document review welder status listing

(provided to the House Subcommittee on Energy and

the Environment on November 23,1982).

(b)

H. J. Kaiser memorandum from M. F. Albertin to

B. K. Culver dated January 14, 1983.

Subject:

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Enclosure 1 to

WHZ/NRC 83-06

Page 3

Evaluation of " Active Welder Requalification

Program" requested by H. R. Sager.

Columns 3, 8 - (a)

H. J. Kaiser memorandum from M. F. Albertin to

B. K. Culver dated January 14, 1983.

Subject:

,

Evaluation of " Active Welder Requalification

,

Program" requested by H. R. Sager.

(b) Weld Engineering Department memoranda (marked up

copies) from J. W. Flaherty to Discipline Super-

intendents (provided to the House Subcommittee on

EnergyandtheEnvironmentonDecember6,1982).

Columns 4, 5, 6 -

H. J. Kaiser memorandum from M. F. Albertin to

B. K. Culver dated January 14, 1983.

Subject:

Evaluation of " Active Welder Requalification Pro-

gram" requested by H. R. Sager.

-

Column 7

H. J. Kaiser Current Welders List dated October 18,

-

'

1982.

Where no action was indicated by the information source, that condition is

denoted in the tabulation.

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Enclosure 2 to

WHZ/NRC 83-06

Page 1

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2.

A description of the criteria used to determine, for each welder and

each procedure for which that welder had been certified as of July 9,1982,

whether the documentation was sufficient to demonstrate that the welder

was in fact qualified to perform the procedures indicated on his certifi-

'

cation card.

Response to item (2):

,

,

Welder qualification document review was performed by a joint task group

of individuals from H. J. Kaiser Quality Records Department and the CG&E

Quality Confirmation Program (Task II) under CG&E Quality Assurance Proce-

dure 19-QA-21 (Attachment (3)).

Deficiencies identified under this review

were documented on nonconformance reports (NRs) and corrective action

reports (CARS). These ccrrective action documents were processed in

accordance with applicable site procedures (i.e., H. J. Kaiser procedure

ZAP 0-5, "Nonconformance Reporting", and GQP-10, " Corrective Action Reports").

These procedures essentially depend on the good engineering judgement of

the dispositioning organization with independent overview by a material

review board or equivalent.

-

The Special Welder Qualification Program was conducted in accordance with

Appendix B to Weld Construction Procedure - 2 (refer to Attachment (4)).

This procedure includes a general description of the review process and the

criteria used by weld engineering to determine the need for retest of a welder.

In addition, an H. J. Kaiser Interoffice Memorandum from G. L. Fones

(H. J. Kaiser Quality Records Manager) to W. A. Hedzik (Site Quality Assurance

Manager) dated July 28, 1982 provides further clarification of site policy

concerning this matter.

This memorandum (Subject:

Basis for Welder Qualifi-

cations) stated in part that the criteria in question were set by welding /

engineering.

In particular, the following criteria were stated:

If a

"

current onsite welder has one of the below qualification deficiencies against

a particular welding procedure, welding / engineering has determined that they

need not be sent to the qualification booth as long as there are no other NRs

or CARS against that particular procedure:

CAR #147, 068, 085, NR #4144, 4495, and other NRs which address clerical

non-essential problems.and those which generated a closed CAR."

These specific documented criteria, in addition to the individual corrective

action statements and dispositions to CARS /NRs issued under 19-QA-21, formed

the basis for the determination as to whether the documentation was sufficient

to demonstrate that the welder was in fact qualified to perform.the procedures

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indicated on the H. J. Kaiser active welders list (the document which was used

by the Task II review group to determine where documentation was missing).

ihe corrective action documents involved (CARS /NRs) are too numerous to include

in this response, however, they are available for review onsite.

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Enclosure 2 to

WHZ/NRC 83-06

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Page 2

The NRC resident inspector has identified several deficiencies which did

and do impact the validity of the QCP Task II document review and the

documented results of the Special Welder Qualification Program (refer to

Attachments (5) and (6)).

The impact of these findings are reflected in the

QCP Task II Status Report (refer to Attachment (7)) and in a licensee regort

initiated under 10 CFR 50.55(e) (refer to Attachment (8)).

Of particular

,

importance are findings related to inadequate control of the active welders

list and the failure of H. J. Kaiser Welding Engineering to transmit all

applicable quality documents to the Records Management System.

The failure of H. J. Kaiser to adequately maintain an accurate listing of

qualified welders resulted in discrepancies between the active welders list

and the man's qualification card.

Since the active welders list was used

by the the Welder Qualification Review Group to determine where documenta-

tion was missing, there are potential errors on their current Welder Status

Listing (both conservative and nonconservative). When this problem was

identified by the NRC, the H. J. Kaiser Project Weld Engineer recalled all

qualification cards for verification purposes.

Some of these cards were

destroyed and the evidence was lost.

The failure of H. J. Kaiser Welding Engineering to transmit approximately

19,000 welding-related documents to the Quality Records Management System

(of which approximately 10,000 are related to welder qualification issues)

has a potential major impact on the validity of the initial QCP Task II

review.

Corrective actions taken by CG&E in response to H. J. Kaiser CAR

No. 84 (lack of objective evidence of the radiographic acceptability of

welder qualifications) resulted in obtaining a large number of previously

unavailable radiographic reader sheets from Peabody-Magnaflux Corporation

which also has a potential impact on the validity of the initial QCP Task

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II review.

,

The NRC resident staff is maintaining a continuing overview of QCP Task II

Welder Qualification Review activities.

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Attechment (3) to WHZ/NRC 83-06 , THE CINCIt;tiATI GAS & ELECTP.!C CC::FANY WM. H. ZIf0'ER ::UCLEAR FC;-lER STATIC:! . . . . . , . QUALITY ASSURAfiCE FF.0CEDUF.E - , i l ? .i i I . l . i 1 . . . . t 00ALITY CONFIR!uTI0ft OF .

- . , WELDER OUALIFICATION RECORDS

! . . . I i i. l PROCEDURE NUMBER': 19-CA-21 I REVISION: 2 . NM A */. I DATE: 4/f[t'l- FREPARED SY: , . . . , , APPROVED D DM h/[ CATE: 8- 2 C i ' I MAtiAGER-CUAL'jiY ASSURA.CE N i I

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- . . THE CINCINNATI GAS & ELECTRIC COMPANY AND SUBSIDIARY COMPANIES PROCEDURES Purpose 1.0 Purcose This precedure is to establish the method for review of the Welder Qualification Records (WQR) to confirm their ccnferm- with the applicable Welding Procedure Specifications ance (WPS)andCedes. Secpe 2.0 Scoce This procedure is applicable to the WOR's of all HJK welders e involved with the construction of the Wm. H. Zir: er fiuclear Power Station that qualified prior to 3/15/E2. Definitions 3.0 Definitions . 3.1 WPS - Welding Procedure Specification-A written welding procedure prepared to provide direction to the welder while making production welds. A WPS. lists the variables both essential and ncn-essential and the acceptable ranges of these variables when using the WPS. ' References 4.0 References 4.1 CG&E Prdcedure OPP-7.2 - Processing of Nonconformance Reports. 4.2 ASME Boiler and Pressure Vessel Ccde 1971 through - i . Winter 1973 Addendas. 4.3 American Welding Society D.I.1-7 2. ~ 4.4 ANSI 331.1 Pcwer Piping. 4.5 19K Procedure 2APO-5. Resconsibilities 5.0 Resconsioilities 5.1 CG&E Manacer - Ouality Assurance Decartment-is respon-

sible for tne overall Quaitty Confirmation Program. i 5.2 CG&E Director - Quality Ccnfir .ation Precram-is responsible for the administration and coordination of the l Ouality Ccnfir .ation Program 4ctivities.

5.3 OCP Task Ccordina:cr - is res;cnsible for tne feli:eing. I I 5.3.1 sucervision and cccrdinatten cf perscnnel wcrt- l ing to :nis erececure. . I M ** ? i CHAPTER l SU*.Jf07 ___t v : cN e u ANUAt s S I Cuality Ouality' Ouality Confir aticn of !_3.M". , ? Welder Qualificaticn , . , a .cs , e r . i . : : .n ...fceMc= Confir atien i -

. . - - _ _ . .- ..._ _ , _ . --._. _ _ __.--.. _ _ _ _ _ _. _ . _ . _ . _ _ . . . - _ . - _ . - _ = . - ! THE CINCINNATI GAS & ELECTRIC COMPANY AND SUeSIDIARY COMPANIES i ] -- - -- - PROCEDURES

, 5.3.2 Training personnel for reviewing the applicable ' [' documents. ' . t j i 5.4 OCP Occument Reviewers - are responsible for: 5.4.1 Reviewing the Welder Qualification Records and - documenting their findings including technical adequacy , l alterations, cross outs and white outs on Attachment 7.1. i

5.4.2 Reporting deficiencies wnen required in accordance with section 6.7. j , ~ Procedure 6.0 Procedure f l 6 ~.1 Prerequisites l 6.1.1 The following dccumentation shall be utilized

to perform the review of welder . qualification document -

! ation. - ,, .

! A) Welder Qualification Review Checklist Attachment Attachment 7.1 f, 7.1. , B) Welder Qualification Review log Attachment 7.2. Attachment 7.2 C) HJK Welder Qualification Records. . \\ l - 0) HJK SPP.Si 3.0 thrcugh 3.2., all revisions. l 6.1.2 All personnel reviewing welder qualification records shall be qualified to Level II Cocument Reviewer , . ! and receive training in the implementation of this pro- ' cedure and shall have a working knealedge of the j applicable qualifying code. i I 6.2 All Welder Qualificaticn records shallbe reviewed by I tha <.tider qualificatien review group. This group consists of members of the Quality Confirmation Program, Quality Assurance Records Verification Group, and the HJK - OA Occument Review Group. The Review checklist may be ccmp- leted by any mer.ber of the group, however, in all cases the

checklist must be reviewed by the assigned OCP representative. i 6.3 A Welder Qualification Review Checklist shall be ccm- ple:sd for each Welder Qualifict:i:n Test REO-!G Fec.). , When a KEO-1G Form is comple:ec fcr eacn incivicual : si icn }i ' of a test (i.e. 2G and 5G), enly cne (1) Weider Qualifica:icni I Review Checklist is needed. I i

5.a Weider Occlifica:ica Revie.: Che f :::. ! w ma i ewtea i sec.frer , arvmes t v u.uu , l M:;sii:v Cuality Ouality Canfirm::icn i mn nf Walder Qualificati:n L- h, .,,.. . - - 3 0 - -

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V THE CINCINNATI GAS & ELECTRIC COMPANh AP.O SUBSIDIARY COMPANICS PROCEDURES , . .. . _ _ _ 6.4.1 Title Sicek 6.4.1.1 Enter the welders name, stamp, social security and/or clock number, and the date the test was accepted. 6.4.1.2 Circle the applicable code (s). 6.4.1.3 Enter the WPS (SPPM No.) and revision ' in effect at testing. 6.4.2 Test Variable column and N/A Column (Section 1), . 6.4.2.1 Enter the information from the Welder Qualification Documentation in the spaces pro- vided where required or place a check (v') in the N/A column when not applicable. 6.4.3 Supporting Documentation Required (Section (E). . 6.4.3.1 Identify any supporting documents re- quired by other site HJK procedures or for verification of information. - 6.4.4 Per Evaluation Column (3) addressed in checklist Sections Q)and(3)ed or 6.4.4.1 Evaluate the information enter and . initial /date the Satisfactory Column if the information is acceptable. 6.4.4. If the infirmation in checklist Sectiers and 2/ is unacceptable er inde erminate, @dentify the specific c::urent violt:sd in ne i Decumentation Violation Column. 6.4.5 Remarks Column ({)and Ccmments Section(3) 6.4.6.1 The " Remarks". Column will be utilized to note any ' deficiencies noted in the reviiw of the adjacent checklist item or, if other doc- umentation is used to justify the acceptance of a checklist item, the type of cecumentatien shall be n:ted there witn a folicw-up explana- tien in the checklis: ":::::nts " se:-i:n. I 5.4.5 U:en cc:rletien of -he Welcer Cualifica:icn P.eview Checklist, the D: cure .t Reviewer snail sien ar.: :::e the c .eci.iis vcri' in; t'.2: : .e rtview is C:: lete and f crwarc :ne enc::,li: to the assiened OCD Recre==nin*iva 5-r revie,. I

• . U V C * 2

at vis:cN ' VANUAL I CHAPTER l $UR.jf CT f0uality Ouality Cuality C:nfirmatien

A-Il .- ? ' Assurance C:nfir.ation , :f Weider Cualifica:ic., x , , c t. ,, ., c , , , ,_, c - _. % m

. . THE C!NCINN AT! GAS & ELECTRIC COMPANY ANO SUBSIDIARY COMPANIES PROCEDURES - . .- . - - . . . _ 6.0 (cont'd) 6.4.7 The QCP Representative shall review the checklist to assure the review is complete and accurate, and appro- priate action has been taken if required by paragraph 6.7 - of this procedure. 6.5 Welder Qualification Review log 6.5.1 The Welder Qualification Review tog shall be util- ized to maintain control of the ccmpleted UOR Checklists Attachcent 7.2 (See attach =ent 7.2). 6.5.2 The OCP Task Coordinator shall maintain custody of the Welder Oualification Revica Log. The Task Ccord- inator shall verify accuracy ar.d cc pictence: cf individ- ual entries and the overall log by performing the following activities: 6.5.2.1 Sign and date each entry of the log in j the "QCP Signature and Date" section. - 6.5.2.2 At the end of each workday, enter each page number of all pages added to the log.that day. , ~ 6.5.'2.3 Secure log from inadvertent use. 6.6 All spaces on the checklist and log shall be completed or . markedil/A. . 6.7 Deficiencies 6.7.1 If in the review of the Welder Qualification Docu- mentation, it is detennined that a violation of the WPS, Code or other procedure has occurred, or there are alter- ations including cross-cuts, white outs, etc., unacceptable with para. 6.7.2, the QCP Personnel shall report the defi- ciency in accordance with one of the following procedures: 6.7.1.1 CG&E 15-QA-01 !;cnc:nformance Reports (fir) 15-QA-01 6.7.1.2 CG&E 16-QA-03, Corrective Ac-ion F.squests 16-QA-03 (CARS) 6.7.1 3 CG&E 15-QA-02 Stop Worx Orcer (54) 15-QA-02 6.7.1.4 16-hA-01ReportingofsDeficienciesunder 16-QA-01 10CFR50.55(e). 6.7.1.6 16-QA-02 Reporting of Defects and tioncon- 16-QA-02 formances under 10CFR Part 21. Consultants cerforming this activity follow their organi:aticns a:;r:ved : ::e:ures (i .e. :-:.'s ZAFO-5) I 6.7.2 Record Alterations , Cr:ts-cuts , vehite cu:s, etc. , without the identification of ::e incivicual ..ho ::ce the -:2ce. ;kali De

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chance and da:e 'n which tne :'2 rs .2: in -i.e ".e arks anc/:r Cc .w.r. * . :.'er :f . e :ns:r.-t l l and action taken as follows: l l i i . ' WM" l ' f '. *- M O * i CH APTER se r v! .~.e t >AANUAL ! . l u21ily lCuality Kusii y C W ir-::icn ! i~-02-21 i ' l 3 L;xuranz JC:nfir a: ion i:f '.. i dc r Qu:.i - i ca - cn 7 m:* P ,(t?PACI sp_ _

k . - . . THE CINCINNATI GAS & E'.ECTRIC COMPANY AND Sues 101ARY COMPANIES PROCEDURES __ _.. . . . . _ . . 6.0 6.7.2.1 Evaluate the alteration. If it is deter- (cont'J) mined to be clerical in nature, and does not advers- ly affect quality, the alteration shall be censid- ered acceptable. 6.7.2.2 If the re-entered infor=ation can be , verified as meeting the original cuality intended by other supporting documentation, the suoporting documentatien used for verification shall be noted , and the ALTERATION shall be censidered acceptable. 6.7.2.3 All ether alteraticas that can not te accepted by the above paragraohs shall be handled in accordance with pa'ragraph 6.7.1. 6.8 Clerical Errors (Welder Qualification Review Checklist and Log). 6.8.1 Correction of clerical errors shall satisfy the following conditions: . 6.8.1.1 The incorrect entry shall have one line only through it and the correct entry entered above or below as soace allcws, the initial of the individual who made'the change and the date on ' which the change was mace shall also be shewn. Attachments 7.0 Attachments 7.1 Welder Qualification Review Checklist (Form M-E903-53) 7.2 Welder Qualificatien Review Leg (Form M-8903-54) I. e ! I . a. u'.' r f " l Sur.lC O: I CH APTE R Eivir ON ! VAP.UAL ' I

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f~aclity f.Ouality e; Ouality Cerfirca: ice '

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At tech::nnt (4) To --- , , . _ ! WHZ/NRC 83-06 ititta l 7inJ i l . s !- w 11 [

HENRY J. KABE'En

C O M C:'A N Y - o- - 'C.6.C i O! !R t-b,. P# *ANL;.g g 'z., it .- hN " ' " ' ' ~ ~ P.O. SCX 201 MOSCCW.CHIO 45153

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WM. H. ZIMMER NUCt. EAR FOWER STAR!ON

--- f 4 0.' WCP-2 ReV. 1 FAGE 40 OF 4:_ ~ lW.CCEDURE EFFECTIVE MTE' S/19/S2 I ' WELDif,'G PE850E:'A?'CE GUALIFICATIO!! TEg7p;r. -. APPE!! DIX B . . . WELDER QUALIFICATIO!;/ REVIEW, ' - TESTIllG A! 0 Ti'.AI !I';G PROCECURE - - . . [ 1.0 PURPOSE / SCOPE L . ,

1.1 PURPOSE , ! ! The purpose of this appendix is to docucent the plan and policy for evaluating welder qualification documentation and the basis for a , i new welder qualification test to verify qualification of active The criteria and methods to De e= ployed in detennining the wel der s. welders to be tested, in testing a weider and qualifying a welder are contained in this appendix. '

. . . l'. 2 SCOPE , .This appendix is applicable to all welding to be performed for the ' purpose of testing and qualification of existing welders in accorda'nce with A!!SI standards, .the welding codes of the American ' Society of Mechanical Engineers ( ASME), the American Welding Scciety (AWS), and as supplemented by special project requirements which

-

exceed the minimum criteria established within any of the aforecentioned documents. ~ 2.0 GE! ERAL DESCRIPTI0ft' . 2.1 WELDER QUALIFICATI0tl REV'IEW

. . . The initial review of welder cualifications as performed by the HJK QA Records Group, shall be acc::plished in acccrdance vei:n the HJK Procedure QRM-1 (Review and Control of Quality Assurance Recor s) and CG5E Quality Confirmation Pacedure 19-0A21 (Quality - Confirmation of Welder Qualifica:icn Records). During :ne myiew cf the qualification records and all su:pcrtin; d: cur:nt;; ion special attention shall be focused cn the ac:cracy, com:10:cncts, iecibility and synchroni:ation of technical information cn all d:cuments involved. In the pro: css of the review if ar.y ceficiencies cr dis:r: pan:ics are dis:evercd th:v :r.all be no:cd and exn cc~1ctica turned ever to Weic Engin . -in; fcr evalu::icn. The C's .eccrds finsi Group cay make recc.=endations for a welcer ratest, but 2 deter .ination of such sntil rcs: upon the Project We1. ding En;iretr. - - - - - , . . ,

....-. . .. . . - , - . , . .,_. , . . . " ' '-' - H=.iVRY I. KAl=ER - . COMPANY ORD^=n,UR.::-.vC Wl .. . N U.AI iP M. . .: -

Jvw - P.O. BOX 201 MCSOOW CHlO 45153 SECTICtb III E

WM. H. ZIMMER NUCLEAR POWER STAf!ON

FECCECURE NO.

C?.2 Rey, 1

FAGE 41 OF 45 _ . EFFECTIVE CATE' 8/1g/22 WELDING PERFORMANCE 00ALIFICAT10N TESTINr, ! .- 2.2 BASIS FOR TESTING - ,e - , e i ,. The cvaluation and subsequent detemination t' hat a qualification l' test is necessarf shall be based upon the folicwing infor stion: , A. Clerical errors are not considered a cause for now . !j qualification of an existing welder. This type of deficiency - i may be acceptable on an " Exception Correction Notice". , i' , The following shall constitute the generation of an NR/ CAR and

. l B. possible testing of an existing welder. ! t 1) No evidence of a Level II accepting radiograph. i j - , i 2) Nissing qualification records and all supporting

. , documentation. . - i 3) Documentation deficiencies such as unauthorized - a . signatunts, essenti.a1 variable on back-up documentation conflicts with those on the qualification record and e , unsubstantiated change to essential variabics (i.e. j , , I white-outs, cross-outs without initials and dates). ,i e . ~ 2.3 WELDER QUALIFICATION .

.- Once the Project Welding Engineer has made the detemination that a welder is to perfom a qualificati n test he shall cualify (without practice) in accordance with Appendix A of this procedure unless . ~. otheraise noted in the folicwing special requirements. ! - Normal machine settings on a separate coupon shall be ' i NOTE:

pemitted. . . i 2.3.1 Retests . At the discretion of the Project Welding Engineer a welder , s ! ! who's coupon fails to meet the re:ui rc-en : f r : e or more of the test s;ecimen p rescri:cd fer .r.e ::.r.icular procedure the welder is being cualified : . .Ey be . retested under the folicwing : r.ditions: - NOTE: Unless :N:ial ci r:u .:.: :c .- :

.

..d

more than two (2) r?qualific:.i:n: Orc pcr-it.cu. .. M _. . - - - . _ - __

. . . - . . t 5 I rsE !\\ i1 ? ~~3 M' I=I O t i HENRY J. KA!.!E"2R . 1 Imr c kp M U [mL ,70V COMPANY AI t~L !- v InlE i IwI D-n o t-Mv v L.- '. P.O. BOX 201 MOSCCW, OHIO 45153 SECT'CN' !II E VO,f. H. ZIMMER NUCLEAR POWER STMION PACCEDURE t40. WCF-2 Rev. 1 FAGE 42 OF t5 j . E. FECTivE CATE' S/19/S2

'i?LDIf;G PEr:0EfCf:CE ^Mr.11Firi inn -? ct"c , A. Ir=ediate Retest ! ! When an ic ediate retest is made, the welder shall l ! make two (2) consecutive test coupons for cach j position which he hcs failed, all of which shall pass I the examinctinn requirements. B. Further Trainino - , When a welder has had further training or practice . l (not to exceed one scheduled shif t) one complete retest shall be ma'de for eadh position on which he The training coupon failed to meet the requirements. i and/or documentation shall be marked to denote the j coupon is for practice.for training purposes only.

/ - . C. Radiographic Examination ' When a qualification coupon has failed Radiographic , examination, the retest shall be examined by the ' ' . Radiographic method. . . , ' D. Bend Test - If a . bend test is going to be used to determine acceptability the convex surface of the Bend test specimen shall be visually examined for surfaceFor ac di scontinuities. contain no discontinuities exceeding the following . aimensions:. 1/8" measured in any direction on the surface. . 1. 3/S", sum of the greatest di.mensicas of all . 2. discontinuities exceeding 1/32" but less than or equal to 1/8". 1/4", =:ximum corner crack, c7.: cat ,chen th y 3. resulted f rc visible slag in:iusion or other type discer.tinuities, then the i/S" car.icum The s;eci en with ccener cracks shall a--ly. .i;c9:0 cf ring excccding 1/;" with n: - in:lusiens cr cther di:::nt n.ntics .y be tes; specimen frc= disregarded and a re;;1acc. en: . the original welc.9ent snail be tested. - .

.. --- -: - - - - - - - - - - - , ' - - _ _ . . . _ I O - . 1 L y\\ l M M, ,nrr ' --- HENRY.J. KA/EER - - i COMPANY F.o.ECuc, uCsCC&Cmo 43m PROCEDURES MANUAL ZPi. Yn.t. H. ZIMMER NUCLEAR PCWER STATION SECTICN: "Il E ' FRCCEDURE N O. h i. r'- 4 Kev. 1 FME 43 OF 45 EFFECTIVE ClTD 8/19/22

• ELDIt:G PERFCC'At:CE OUALIFICATION TESTING

- , .i , . I 3. (Continued) , If the second specitan fails to meet the above ' requirc ents the wel der shall then perfor a a i complete retest, in accordance with Paragraph i i 2.3. . ! i 3.0 PROCEDURE , I Paragraph 4.0 of this procedure and the following steps shall facilitate ' . the initiatio n, the perfor nance and subsequent qualificati'on of a i

' . welder's test. i

. . RESP 0:!SIBLE POSITION ACTION l , ' < ,' DISCIPLINE SUPERINTENDENT . ,'

.

l. While accomplishing Step 6, (Paragraph 4.0) -he shall also assure the - welder's identification (i.e. employee's brass, etc). f. ' . PROJECT WELDING ENGINEER (Test Shop) , i 2. In addition to Steps 7, 8, and 9 (Paragraph 4.0) the Project 'a'elding l. Engineer. shall assure the procedure is being implemented properly, (e.g. coupon is in proper and fixed position).

. QUALITY CONTROL INSPECTION ', ' , l 3. While . accomplishing Step 12 (Paragraph 4.0) the Ins'pector shall i assure the wel de r is ratesting and implementing the pr:per

p rocedure. This can be accc:plished by the 1:se of the "In-?rocess ' . Surveillance Sheet". . l Tne final visual insp cticn 5 cp 15 (Paragraph 4.0) cf all cc::leted l " l welds shall be acccepiished in the as weidec or gr:un: :cncitien as . l decided . by the CC Inspector. All other in-prc ess inspe::icn shall l be en a surveillance type basis only. All inspecti:n ;c rfcr ed (includinc surveillcn:c) thil 50 noted on t h :- in-Tre: css surveilia :e sheet v. hic a sh:li ai:e : .-in tr.ci r ti;n :ure and 5 I stamp denoting full CC acceptan:e cf the cc pleted wei d and benc f test (as applicable). - NOTE: For this appendix caly, the Quality Centrci curveillan:e , _ c r.: CG5E , and inspe:: ions shall be perior :-c by both : a j ' l Departments. ' ~ . _-. _ _

. ATTACHMENT 5 to WHZ/NRC 83-06 - PAGES 4, 5, 21-32 0F DRAFT IE' REPORT NO. 50-358/82-10 - Inspection Conducted: June 7 through August 18, 1982 _ , and others of the station and construction project staffs. ' _

• Designates those attending monthly exit interview.

+0esignates those attending July 9, 1982 meeting with the NRC. ._ Designate.s thos_e attending July 15, 1982 meeting with the NRC.

2. Licensee Action on Previously Identified Items a. (Closed) Unresolved Item (358/81-28-01): The issuance of weld' rod does not constitute objective evidence that the welder has satisfactorily performed to the qualified process. The AWS Code D1.1-1972, Section 5.30 states: "The welder's quali- fication as specified in this code shall be considered as remaining in effect indefinitely unless (1) the welder is not engaged in a given process of welding for which he-is qualified for a period exceeding six months or less (2) there is some specific reason to question the welder's ability. In case (1), the requalification test need be made only in the 3/8 in. (9.5 mm) thickness." The ASME Code, Section IX, Paragraphs Q/QN-26 require renewal of ' qualification (1) when a welder or welding operator has not used the specific process, i.e., metal arc, gas, submerged arc, etc., to weld either ferrous or non-ferrous materials for a period of three months or more, or (2) when there is specific reason to question his ability to make welds that meet the specification. Rene..J. of qualification under (1) need be made in only a single

test-plate thickness. This requirement indicates that a welder must perform satisfactorily to the qualified process at least once every three months in order to maintain his qualification to that process. The inspector observed the following transaction pertaining to the above requirements: On July 20, 1982, welder symbol MGG presented himself to the H. J. Kaiser Project Weld Engineer and stated that his cualification card would expire in two (2) days. The welder then supplied his card and a pink copy of a XE Weld-2 form (weld rod issue slip) to the Project Weld Engineer. The Project Weld Engineer, without any further investigation, prepared a new qualification card good for three months and returned it to the welder. The inspector questioned the credibility of the above trans- action with respect to providing objective evidence that the Code requirements had been met and requested that the H. J. Kaiser Welding Department Manager investigate the matter. The results of the Welding Department Managers' investigation revealed that welder HGG had not used the weld rod issued to -. him on July 20, 1982, and it was necessary that weld engineer- ! ing recall the card issued to that welder. 4 - . - _.

- -

- - . . . . . . .

. ATTACHMENT 5 to WHZ/NRC 83-06 - PAGES 4, 5, 21-32 0F DPAFT IE REPORT NO. 50-358/82-10 Inspection Conducted: June 7 through August 18, 1982 This is in noncompliance with 10 CFR 50, Appendix B, Criterion IX and the Wm. H. Zimmer QA Manual, Paragraph 9.3, which states in part that the CG&E QA Division audits HJK to assure that personnel performing special processes are quali- fied in accordance with applicable codes. (358/82-10-01(A)). b. (Closed) Unresolved item (358/82-05-02): H. J. Kaiser had no documentation of the results of evaluations for reportability under 10 CFR 21 and 10 CFR 50.55(e). CG&E Corrective Action Request No. 82-36 was written to identify and control this problem. As a result, H. J. Kaiser Procedure GQP-21, Revision 0, " Reporting of 10 CFR 21 or 10 CFR 50.55(e) Conditions" was prepared and approved. Subsequently, Revision 1 to GQP-21 provides the necessary administrative controls to pro- vide assurance that identification, control, and documentation of reportable or potentially reportable conditions is achieved and maintained. The failure of CG&E to impose the reporting requirements of- 10 CFR 21 and 10 CFR 50.55(e) on its contractors is in noncompli- ance with 10 CFR 50, Appendix B, Criterion V, 10 CFR 21.21(a), - and the Wm. H. Zimmer QA Manual, Paragraph 5.1, which states in part that activities which affect the quality of the facility are acccmplished in accordance with written instructions, procedures, or drawings which prescribe acceptable methods of carrying out . .those activities. (358/82-10-02(A)) 3. Followuo on Processing of H. J. Kaiser Requests for Information On July 20, 1982, a H. J. Kaiser employee brought to the attention of the NRC a potential problem related to the processing of H. J. Kaiser Request for Information/ Evaluation (RFI/E) forms. In accordance with H. J. Kaiser Procedure GQP-9, Revision 0, dated January 27, 1982, Para- graph 4.1.3, RFI/E's which were forwarded to the Welding Task Force were reouired to be orocessed as follows: , "The Welding Task Force Chairman will log receipt of the RFI/E by number and date and present the RFI/E to the welding task force membership for response." p The inspector was presented an information copy of an RFI/E initiated April 13,1982, requesting evaluation of a quality-related conditicn. This RFI/E was issued and responded to by the Welding Task Force (WTF) Chairman; hcwever, the RFI/E did not have a tracking log identifier as required by GQP-9. Discussion with the H. J. Kaiser Quality Engineering Manager and the H. J. Kaiser WTF Chairman revealed that the WTF Chairman did not fully understand the procedural controls of the RFI/E procedure or the scope of the RFI/E procedure. The WTF Chairman indicated that his under- . standing of the RFI/E was that the RFI/E was to be used for clarifica- tion of procedures, codes, and standards only; and he was not required to log RFI/E's which did not represent requests for clarification, s ._- _. _ .-

ATTACHMENT 5 to WHZ/NRC 83-06 - PAGES 4, 5, 21-32 0F DRAFT IE' REPORT NO. 50-358/82-10 Inspection Conducted: June 7 through August 18, 1982 (b) Assessment /Results I. 296 audits have been identified, of which 207 have been reviewed. II. Preliminary evaluation indicates that most audits were of limited scope, however collectively due to - the large number of audits performed, the applicable 18 criteria were covered for HJK, E0TD, NED, GCd, and NPD. There were areas not covered in audits of S&L and G.E. subsequent to April 8,1981, however, current audits of S&L and G.E. have covered the majority of applicable criteria. III. Procedure for interface with the QCP Tasks to verify adequacy of work is being developed. Draft of this procedure will be complete and ready for review the \\ week of June 28, 1982. IV. It is estimated that eighty-three (83) man days will be required for review and evaluation of the remaining audits, and for auditing missed criteria. (c) Status This task is 70% complete (d) Estimated Ccmoletion Date October 8,1952 No items of noncompliance or deviations were noted. 6. Welder Oualification Review and Verification - OCP Task II The OCP Task II recuires in part that the licensee (Cincinnati Gas and Electric Co.) verify the qualifications of welders qualified prior to April 8,1981. This task is presently being accomplished by a joint task group cceprised of personnel representing CG&E Quality Assurance De'partment, H. J. Kaiser Quality Assurance Department, and H. J. Kaiser Welding Department. Due to the relatively large number of nonconformance and corrective action reports being generated by this task group, the NRC requested that CG&E determine the impact of identified problems on the qualifi- cations of currently active welders and report the results of their determination in a meeting held onsite July 9, 1982 (attendees at this meeting are designated by a (+) in Paragraph 1 of this report section). In the July 9 meeting, the licensee reported that a meeting had been held on July 8, 1982, in which all concerned parties (CG&E and HJK QA _ and Construction) had agreed to the resolutien of a number of generic issues which could affect a large number of active welders. The resolution of these generic issues and the suspension of qualifications e

_ -= . - . . - . - , ._ ATTACHMENT 5 to WHZ/WRC 03-06 - PAGES 4, 5, 21-32 0F DRAFT IE REPORT NO. 50-358/82-10 Inspection Conducted: June 7 through August 18, 1982 (cards pulled) for a small number of welders (due to specific problems which would be handled on a case-by-case basis), resulted in the quali- fications of all active welders onsite being considered determinate by the licensee. This inspection was conducted in order 'o independently verify statements t made at that July 9,1982 meeting. l a. Documentation Reviewed (1) H. J. Kaiser Active Welders List dated July 9, 1982 (2) H. J. Kaiser QA Document Review Group Welder Status Log (3) H. J. Kaiser Corrective Action Reports: (a) No. 076 dated March 23, 1982 (b) No. 084 dated April 3, 1982 . (c) No. 114 dated May 20, 1982 (d) No. 117 dated May 19, 1982 - - (e) No. 123 dated June 3, 1982 . (f) No. 132 dated June 10, 1982 (g) No. 147 dated May 28, 1982 (4) H. J. Kaiser Nonconformance Reports: (a) No. E-4144 dated February 1,1982 (b) No. E-4495 dated March 18, 1982

• (c) No. E-4717 dated March 19, 1982

(d) No. E.-4842 dated April 12, 1982 , (e) No. E-4853 dated April 10, 1982

• (f) No. E-8095 dated April 14, 1982

. (g) No. E-8201 dated April 29, 1982 , (h) No. E-8418 dated April 25, 1982

• (i) No. E-8453 dated June 8, 1982
• (j) No. E-8519 dated May 14, 1982

(k) No. E'-8569 dated June 4, 1982 i ' 22 .. - - - - . . - . . ~.-- ..- . - - - . - - - . . . ..

ATTACHMENT 5 to WHZ/NRC 83-06 PAGES 4, 5, 21-32 0F DRAFT IE' REPORT NO. 50-358/82-10 Inspection Conducted: June 7 through August 18, 1982

• (1) No. E-8654 dated June 21, 1982

• (m) No. E-8657 dated June 22, 1982
• (n) No. E-8724 dated June 24, 1982

-

• (o) No. E-8719 dated July 6, 1982

(5) CG&E Condition Evaluation Request No. 82-015 dated April, f9,1982 (6) CG&E Field Audit Report (FAR) No. 126 dated July 8, 1977 (7) H. J. Kaiser response to FAR No.126, HJK letter KC-10362-Q dated August 2, 1977 (8) H. J. Kaiser Memorandum from M. Butterworth to M. Goedecke dated July 13,1982 (proposed corrective actions for HJK CARS No. 84, 85,117,123,132) (9) H. J. Kaiser Inter-Office Memorandum from M. Butterworth to M. Goedecke as follows: Date Subject (a) 6-30-82 Bend Test Acceptance (CAR 114) (b) 7-01-82 Signature Authority (CAR 117) (c) 7-01-82 Reader Sheets (CAR 84) (d) 7-01-82 Backup Documentation (CAR 85) - l

• See Paragraph 6.b(8) below.

b. Discussion /0bservations l (1) In order to verify the adequacy of licensee actions with regards to the qualifications of active welders onsite, a random sample l of 10 welders was chosen from the H. J. Kaiser list of active welders dated July 9,1982. These welders were then reviewed with respect to their status in the H. J. Kaiser document review welder status summary worksheet including outstanding (open) nonconformance and corrective action reports. Additional docu- , mentation was requested where necessary to verify or support l corrective action statements. Preliminary results were subsequently discussed with licensee and contractor personnel for clarification of the open issues. Significant questions remained after these discussions due to inadequate or incomplete answers for five of the welders reviewed, centering avcund two H. J. Kaiser Corrective Action ' - Reports (No. 84 and No. 114/123). ~ , i 23 , . - . - - - _. . - - . . - - - - . -- . _ . . ._

- ATTACHMENT 5 to WHZ/NRC 83-06 ' PAGES 4, 5, 21-32 0F DRAFT IE REPORT NO. 50-358/82-10 Inspection Conducted: June 7 through August 18, 1982 . (2) 10 CFR 50, Appendix B, Criterion IX and the ASME Code, Secticn III require in part that special processes (i.e., welding, heat treating, nondestructive examination) be con- trolled and accomplished by qualified personnel utilizing qualified procedures. The ASME Code, Section IX provides . explicit instructions for the qualification of procedures and personnel for welding activities, and requires that each manufacturer or contractor maintain a record of the test results obtained in welding procedure and welder performance qualifications, including suggested form. The results of the welder qualification testing may be deter- mined by either specimen bend testing or alternatively by radiographic examination. Where the bend test method is employed for welder qualification, ASME Section IX specifies the type and number of acceptable bend tests required for qualification. Where the alternate radiographic method of welder qualification is employed, the following requirements are stipulated: (a) ASME Section IX, Paragraph Q-24(d), requires that the results of the radiographic examination be recorded. - (b) ASME Section IX, Paragraph Q-1(c), requires that each manu- facturer or contractor maintain a certified record of the test results obtained in welder-performance qualifications. (c) ASME Code, Section VIII states the acceptance criteria for all examination of welded joints by radiography. (d) ASME Code, Section III, Paragraph NS-5510, requires that all non-destructive examinations required by that section of the code be performed and the results evaluated by SNT-TC-1A , l qualified personnel. (e) ASME Code, Section III, Paragraph NA-4930, states the requirements for the content of Quality Assurance Records, which include closely related data such as the qualifications of personnel. (f) ASME Code, Section III, Paraoraph NA-4932 (1971 edition, summer 1973 addenda), Item (h), requires the retention of non-destructive examination reports including the results of examinations. This report must also give the name and SNT-TC-1A rating of the NDE personnel interpreting the examination. H. J. Kaiser CAR No. 84 identified that some welder qualification records either emit or have SNT-TC-1A Level I personnel signatures whereas a Level II qualified person was required to perform radiographic interpretaticn/ evaluation. - - 24 - - .. . . - -

ATTACHMENT 5 to WHZ/NRC 83-06 - - PAGES 4, 5, 21-32 0F DRAFT IE' REPORT NO. 50-358/82-10 Inspection Conducted: June 7 through August 18, 1982 (3) CG&E Field Audit Report No. 126 dated July 6-8, 1977, made the following observation with respect to welder qualification records: "Although proper certification forms are provided in each welder file, there exists no forms for the alternate radiographic methed which was util'ized for qualifying the welder." " Discussions with Mr. A. Pallon and Mr. K. Bronder, reveafed that after the radiographs of the welder coupons are acceptable, and certifications granted, the radiographic documentation is then discarded." "Even though code and specifications allow the option of retain- ing or discarding the actual radiographs of welder qualification, it does not state the documentation of the radiographic tests reflecting the actual results be discarded." "Therefore, it is suggested that a copy of the acceptable radio- graphic report be attached to the welder certification. forms." In their response to this audit report, H. J. Kaiser Letter KC-10362-Q stated, " Quality Assurance is presently maintaining copies of interpretation reports for welder qualifications. In addition, Peabody Magnaflux has a complete file of these reports which will be transferred to CG&E at the completion of the job." (4) The inspectors noted that H. J. Kaiser procedures (SPPM 3.2) required that the H. J. Kaiser. certification on the Welder Qualification Record Form KE Q-1G be by signature of a H. J. Kaiser Weld /NDE Quality Assurance Engineer. . H. J. Kaiser CAR No.117 identified that this procedural requirement was repeatedly violated in that the KE Q-1G forms were signed by individuals who could not be verified as QA Engineers. Those individuals included H. J. Kaiser Assistant welding engineers, cuality control inspectors, and Project / l Senior weld engineers. The weld engineers were those directly responsible for the work performance. l (5) H. J. Kaiser CAR No. 85 identified that backup documentation substantiatina the welder qualification was missing frem several qualification record packages. These backup documents included KE-1 Weld forms and inprocess welder qualification surveillance data sheets. ! f (6) H. J. Kaiser CAR No. 114/123 identified that bend test informa- tion was added to the State of Ohio Q-1G form which conflicted ' l with information on the KE Q-1G form. Additionally, H. J. Kaiser l CAR No. 132 identified tiiat several KE Q-1G forms had essential I bend test information omitted. The accompanying State of Ohio ! Q-1G forms reflected the conditions stated on CAR No. 114 - (information had been added). 25 ,

, -- - ATTACHMENT 5 to WHZ/NRC 83-06 ' PAGES 4, 5, 21-32 0F DRAFT IE REPORT N0. 50-358/82-10 Inspection Conducted: June 7 through August 18, 1982 , (7) H. J. Kaiser CAR No. 147 identified that some of the KE Q-1G. - forms had qualification dates prior to the actual radiographic examination or radiographic acceptance date. This CAR indicated that in some instances, when the Level III Weld /NDE Quality Assurance Engineer certified the welder qualification, the actual results of the radiographic examination were not available for his review and verification. (8) Several nonconformance reports (i.e., H. J. Kaiser NRs designated by an asterisk in Paragraph 6.a(4) above) indicate that in some cases the radiographic acceptability of the welders qualification coupon was questionable but the KE Q-1G form was certified by H. J. Kaiser as being acceptable. (9) Two recent interpretations of ASME Code requirements related to the retention of records for welder qualifications (IX-79-01, question (1) and III-80-26, question (2)) appear to support the position of the CG&E field audit report No. 126 observation discussed in (3) above. These interpretations are for more recent versions of the ASME Code than that which the Wm. H. Zimmer Station was built to, however, the words of the 1971 code (through winter 1973 addenda) are not substantially different from the words of the later editions of the Code in the areas of interest (i.e., the intent of the Code does not appear to have changed in later editions). .(10) The H. J. Kaiser Weld Engineering Manager stated that a sub- committee of the ASME Code, Section IX, had recently provided (at H. J. Kaiser Company request) an interpretation of the 1971 Section IX requirements which stipulated that the radiographic examination reader sheets were not required for record retention as part of the welder qualification record. The inspectors stated that the requirements for retention of quality assurance records (including qualifications of personnel and test results) are established by the ASME Code, Section III, and 10 CFR 50, Accendix B, Criterion XVII. c. Findincs (1) Welder symbol LMF was reviewed with respect to his qualification status. The H. J. Kaiser list of active welders dated July 9, 1982, showed that welder LMF was qualified to SPPM 3.1.28H and 3.1.56. The H. J. Kaiser document review welder status listing i l indicated that welder LMF had current qualification to SPPM 3.1.21, l 3.1.28, and 3.1.56 (the documentation for qualification to 3.1.28 was identified as " missing"). A check of the welders qualifica- tion card revealed that he was currently active on SPPM 3.1.18, ' 3.1.21, and 3.1.56. The discrepancies between the list of active

welders, the H. J. Kaiser document review status listing, and the man's qualification card indicated a lack of management control in this area. The inspector noted that the H. J. Kaiser QA Manual, - Quality Assurance Procedure No.10, Paragraph 3.2.3.6, required that a computerized run out (printcut) of qualified welders be maintain'ed and updated at the end of each month. It also stated 26

-i . ' ATTACHMENT 5 to WHZ/NRC 83-06 - . PAGES 4, 5, 21-32 0F DRAFT IE' REPORT NO. 50-358/82-10 Inspection Conducted: June 7 through August 18, 1982 l that the Project Welding Engineer was responsible.for the accuracy and continual and timely updating of the Welder , ' Qualification Listing. The inspector requested a copy of this , listing to verify its accuracy with respect to welder LMF, but j was told that the subject listing was no longer controlled or .in use. The inspector further noted that the QAP-10 require- ments were reflected in WCP-2, Paragraph 3.2.1, which did not appear to be implemented. The failure of H. J. Kaiser Welding

Engineering to establish and accurately maintain a welder qualification listing commensurate with the requirements of . QAP-10 is in noncompliance with 10 CFR 50, Appendix B, Criterion V, and 10 CFR 50, Appendix B, Criterion IX, which ' require in part that activities affecting quality be performed in accordance with documented instructions, procedures, or drawings, and that special processes, including welding, be controlled and accomplished by qualified personnel. - (358/82-10-01(B)). 4 (2) Review of the qualification records for welders symbol KGZ, KUE, MBF, KGJ, and KFY indicated that there was a lack of objective evidence that the welders qualification coupon had been radio- graphically evaluated and found acceptable by a SNT-TC-1A Level II RT qualified individual. In each case, the H. J. Kaiser document review welder status sheet indicated that CAR No. 84 was open against the individual welder's qualification. Review of the complete log indicated that CAR No. 84 was open against . the qualification of approximately 89 welders, some of which ' had multiple procedure qualifications with CAR No. 84 out- standing (approximately 250 procedures). The proposed corrective action to CAR No. 84 stated, "If there is not a Level II signature on the welder qualification record and there is no radiograph reader sheet for that qualification record, based on the certification by the H. J. Kaiser Company these records shall be acceptable. No procedural requirements indicated the retention of the reader sheets prior to February 15, 1982, also no Level II signature was required on the welder qualifica- tion record by either procedure or ASME Section IX. All current and future welder qualification records shall be acccmpanied by a radiograph reader sheet with a Level II signature." This proposed corrective action, which was agreed to by "all parties" and which w&s part of the basis for the determination of acceptability cf current welders qualifications at the July 9, 1982 meeting with the NRC, was not acceptable to the inspectors based on the observation and discussion in Paragraphs 6.b(2), (3), (4), (7), (8), (9) and (10) above. The inspectors stated that there was no apparent reason why the radiographic reader sheets were not available today, in light

of the observations of Paragraph b(3) above. The licensee was ! ._ unable to provide a satisfactory explanation of the missing documentation. 27 - - _ - . . - - - - - .- - - - _. _-

6 ' ATTACHMENT 5 to WHZ/NRC 83-06 PAGES 4, 5, 21-32 0F DRAFT IE' REPORT NO. 50-358/82-10 Inspection Conducted: June 7 through Au,qust 18, 1982 Specifically, the inspectors questioned the acceptability of the statement in the affadavit, "In the case of welder qualification records where as the number of bends was recorded as (1) root and (1) face was in fact, (1) set of test specimens constituting (2) face and (2) root bends...," or in other words, one equals two. The inspectors observed that the individual who provided the affidavit was not the person responsible for perf'orming the bend tests in question, nor was there reasonable assur- ance that that individual had observed the bend tests .in question. Further questioning of H. J. Kaiser document review personnel indicated that attempts to establish a trend in this area (i.e., a certain individual (s) had made the correlation 1=2 over a specific time frame) had failed. These observations left questions concerning the adequacy of corrective action sprovided for CAR No. 123/132, however, time constraints precluded a determination of compliance / noncompliance in this matter. This item is unresolved pending further review at a subsequent inspection (358/82-10-04). (4) One welder (symbol KGJ) was listed on the H. J. Kaiser document review status worksheet as having a current qualification to weld procedure Specification 3.1.21, however, the H. J. Kaiser list of active welders dated July 9, 1982, showed current qualification to Specification 3.1.21 H (where the H designates a heavy wall thickness qualification). Review of the welders qualification records indicated that the KE Q-1G (record) form and the Ohio Q-1G form indicated the welder had qualified with a 6" schedule 40 (.432 inch thick) coupon. The Ohio Q-1G form only had subsequently been changed (by line through) to indicate qualification on a 5" schedule 160 (.750 inch thick) coupon. The change had not been made in accordance with the requirements of ANSI N45.2.9-1974, Paragraph 3.2.6. For clarification, the inspectors requested that the licensee determine (1) if other welders qualified to the same procedure in the same time frame had performed their qualification on a 5" schedule 160 coupon, and (2) if the 6" schedule 40 coupons were available in the 1 test shop at the time the qualification in question took place. i - The licensee's contractor representative reported that (1) review of welders qualifying to Specification 3.1.21 H in the same time frame revealed records that had been altered similar to the i records in question, and that (2) the 6" schedule 40 coupons were available in the test shop at the time the qualification in question took place. The inspectors stated that the objective evidence in this case indicated that a 6" s'chedule 40 coupon was used in the qualifica-

• icn, and that the alteration of the documentation outside the

requirements of ANSI N45.2.9-1974 placed the welders qualification to the heavy wall procedure in doubt. The evidenc,e of at least 29 i .-. . - . . _ -. . _ _ - - - - _-- . _ - _ - ._. _ _ - - - _ -

ATTACHMENT 5 to WHZ/NRC 83-06 PAGES 4, 5, 21-32 0F DRAFT IE REPORT NO. 50-358/82-10 Inspection Conducted: June 7 through August 18, 1982 2 other examples of this practice (based on statements by the licensee's contractor representative) indicates a potential generic problem which should be investigated by the licensee (358/82-10-05(A)). In addition to the above, subsequent interviews of licensee and contractor personnel prompted the resident inspectors to investigate an allegation that welder qualification records had been altered by personnel onsite as recently as March of 1982. Results of that investigation revealed that the H. J. Kaiser Project Weld Engineer and a H. J. Kaiser Mechanical / Piping Level III QA Engineer working in the Weld Engineering Department had rewritten approximately 32 welder qualification records which had been previously certified by the H. J. Kaiser Weld /NDE QA Engineer Level III. Review of a sample of the altered documentation (KE Q-16 forms for two welder symbols) revealed that several changes were apparent between the original record and the documentation transmitted to the QA Records Management system. (Theoriginal records were retained in the Weld Engineering Files). - There were no procedural controls which allowed such alteration , or supplementation of the record documents. There was no annota- tions on the supplemental records indicating the changes made or providing justification for the changes (358/82-10-05(B)). These items are in noncompliance with 10 CFR 50, Appendix B, Criterion XVII, which requires that quality assurance records provide evidence of activities affecting quality, and with 10 CFR 50, Appendix B, Criterion V, and ANSI N45.2.9-1974, Paragraph 3.2.6, which requires that " Quality assurance records may be corrected or supplemented in accordance with procedures which crovide for acoropriate review or approval by the originating organization. The correction or supplement shall include the date and the identification of the person authorized , to issue such corrections or supplements." (358/82-10-05) ' (5) The proposed corrective action to H. J. Kaiser CAR No.117 (see Paragraph 6.b(4) above) stated, " Certification of H. J. Kaiser

welder qualification records as required by site procedures l stated that a Weld NDE/QAE sign these records. In the cases where as the NDE/QAE delegated his authority to designees shall be by affidavit. (a) Affidavit frem Rex Baker for signature authority designated to: 1 Judy Reitzler - 2 . Jesse Ruiz 30 . _ _ -__ __ . . _ _

. ATTACHMENT 5 to WHZ/NRC 83-06 PAGES 4, 5, 21-32 0F DRAFT IE' REPORT NO. 50-358/82-10 Inspection Conducted: June 7 through August 18, 1982 (b) As attested to by W. O. Puckett, the following peuons shall be considered as acceptable. At the time of deltgation of signature authority W. O. Puckett held the position of Project Weld Engineer. 1 Mark Stacy (Assistant Engineer) 7 Mark Johnson (Assistant Engineer) Both persons were under direct supervision of W. O. puckett , at the time of certification." The inspectors observed that the person referenced in Para- graph 6.c(5)a above was the site Weld /NDE QA Engineer, a sworn statement attesting to his delegation of signature authority i ' (but not responsibility for review of the activities in question) may be acceptable. However, the inspectors further observed that the person referenced in Paragraph 6.c(5)b above was never employed in the position of site Weld /NDE QA Engineer. In fact, the person referenced in Paragraph 6.c(5)b above was the person directly responsible for the implementation.of site welding activities and did not posses the independence inherent in the position of Weld /NDE QA Engineer. As such, the accept- ability of this corrective action statement requires further - justification and remains unresolved pending the review and verification of corrective action by the licensee's QA organization. (358/82-10-06) d. Position Taken As a result of this review of welder qualification records, the following position was taken by the NRC during a licensee meeting held July 15, 1982 (personnel attending this meeting are designated with an (*) in Paragraph 1 of this report section): (l') Those KE Q-1G forms that are properly filled out in accordance with the requirements of the ASME Code, Section IX, and that include objective evidence that a SNT-TC-1A Level II RT qualified person evaluated the radiographic test results (when the alternata radiographic qualification method was employed) and found them acceptable, are acceptable to the NRC as objer,tive evidence of satisfactory qualification when the essential variables of the qualification (including the date of qualification) have not been altered, or when alterations have been made in accordance with ANSI N45.2.9-1974 requirements. (2) For those KE Q-1G forms which do not include the signature of a SNT-TC-1A Level II RT qualified person (when the alternate radiographic qualification method was employed) showing evidence of acceptable RT results, an appropriately signed backup document (i.e., RT reader sheet showing acceptable RT results) will be acceptable to the NRC as objective evidence 4 _ of satisfactory qualification, provided the other essential items referenced above are met. 31 - . . - - - . . _- - _ _ _ _ _ - - - -

ATTACHMENT 5 to WHZ/NRC 83-06 PAGES 4, 5, 21-32 0F DRAFT IE REPORT NO. 50-358/82-10 Inspection Conducted: June 7 through August 18, 1982 (3) Those KE Q-1G forms which are in conflict with backup docu- mentation with respect to an essential qualification variable (i.e., RT test results) are not acceptable. ~ 7. ' Site Activities of Interest a. Systematic Assessment of Licensee Performance (SALP) The inspectors participated in the NRC's annual assessment of licensee performance, which culminated in an open meeting held with licensee personnel on June 29, 1982. The results of this assessment are docu- mented in the 1982 SALP report, Inspection Report No. 50-358/82-08. b. Site Personnel Interviews The resident inspector participated in interviews of site QA/QC personnel performed by the NRC in order to determine if harrassment and/or intimidation problems existed, and if so, the extent of the problem. The results of these interviews will be documented in a separate investigation report. - c. In-Process Inspection Deficiency Reoorts (IIDRs) . The inspectors are conducting a comprehensive review of ZAP 0-5 and a walk-through of the handling of IIDRs frcm the originator to final review and record storage. . A sampling of the IIDRs is being performed in the piping, suppression pool, civil and structural, electrical, and hanger areas. HJK has now developed a system to facilitate the computerized entry of data and data retrieval for all finalized IIDRs. All IIDRs finalized after June 2,1982, will be entered into the computer after the normal quality engineering review is complete and the work package closed. All IIDRs finalized prior to June 2, 1982, are being coded and entered by the NR and Data Processing staff. An IIDR trend analysis for pipe supports and hangers has been per- formed in compliance with ZAP 0-5, Revision 1, Paragraph 3.3.6. During the period of January through June 2, 1982, hanger installation caused the greatest number of IIDRs, 41% of the total. The defects identified on hanger installations were as folicws: (1) 17% - Not installed per design drawings (resolved by DDC's orCAR's) (2) 14% - Improper Locking Devices (3) 10% - Incorrect dimensions - (4) 10% - Improperly tightened anchor bolt nuts 32

. - - -. - - - . - . _ . - - - - - _ . - - . , . - . . -

' ATTACHMENT 6 to WHZ/NRC 83-06 Page 1 of 5 FIVE PAGES FROM DRAFT IE REPORT NO. 50-358/82-12 Inspection Conducted: October 1 through December 4, 1982 . 2. Licensee Action on Previously Identified Items a. (0 pen) Noncompliance (358/82-10-05(B)): Records improperly supplemented with original records retained by H. J. Kaiser Weld Engineering. The inspector attempted to verify on two occasions that the original records had been transmitted to the H. J. Kaiser QA Records Department, however, the original records were not located with the supplemental records. (i) Documentation Reviewed (1) H. J. Kaiser Inter-Office Memorandum from John W. Flaherty to All Welding Dept. Personrel dated October 21, 1982. (2) H. J. Kaiser Welding Department Records Transmittals dated March 25, 1982 through November 17, 1982 inclusive. (3) H. J.' Kaiser Inter-Office Memorandum from E. H. (Woody) Wagner to N. A. Vitale dated August 12, - 1982 with attachments. (ii) Findings (1) The inspector found that original certified weld performance qualification records were retained in weld engineering files which were not available in the H. J. Kaiser records management system. These were the records which were the subject of noncompli- ance item 358/82-10-05(B). The licensee committed to expeditiously transmit any and all original welder performance qualification data sheets in the weld engineerino files to the OA records management system. This item cf noncompliance remains open pending licensee response and further corrective action followup. (2) The inspector found that surveillance activities related to this item of noncompliance, performed by the H. J. Kaiser Quality Engineering Manager and the H. J. Kaiser Welding Task Force Chairman (an H. J. Kaiser Quality Engineering Supervisor), had not been documented in accordance with H. J. Kaiser Procedure ASP-2, revision 1, " Surveillance Reports". Paragraph 3.2.2 of ASP-2 states, "It shall be the responsibility of H. J. Kaiser Quality Personnel performing surveillance to document observations on the surveillance report". Rather, the surveillance was documented on an H. J. Kaiser Inter-Office - Memorandum (see item 2.a(i)(3) above). Discussion of the above requirements with the former H. J. Kaiser . - .- .- . - - - . - . _ _ _ ,

.. . - ATTACHMENT 6 to UHZ/NRC 83-06 " , Page 2 of 5 FIVE PAGES FROM ORAFT IE REPORT NO. 50-358/82-12 Inspection Conducted: October 1 through December 4, 1982 Quality Engineering Manager resulted in a commitment to upgrade the Inter-0ffice Memorandum to a surveillance report. This appears to have been an isolated case. (3) During discussions of this matter in the office of the H. J. Kaiser Weld Engineering Manager on December 1 and 2,1982, the inspector observed other, - historical documents which provide objective evidence of quality-affecting activities. These documents, some of which were quality assurance records, places in question the adequacy of the licensee's actions in response to Immediate Action Letter (IA1.) 81-01, item 8, Records. This matter was discussed in a meeting with licensee personnel (designated with a + in paragraph 1 of this section) regarding the control and safekeeping of QA Records, and is a potential generic issue. This matter is unresolved pending further inspection and actions by the licensee (358/82-12- ). - 7. Scecial Welder Qualification Program a. Backcround > As a result of H. J. Kaiser document review findings and as a result of findings presented in IE Inspection Report 50-358/82-10, H. J. Kaiser Weld Engineering Department developed and implemented a Special Welder Qualification Program. Meetings were held onsite between licensee representatives and the.NRC Resident Inspectors to discuss special requirements, above and beyond standard site practice, to be applied to this Special Welder Qualification Program. These meetings were held on July 27, 1982 (personnel attending designated by a # in paragraph 1 -f this section) and on July 30, 1982 (H. R. Sager. M. L. GoQc/ , r. P. Gwynn, W. F. Christianson, and D. R. Hunter ' (telf-:' r 2nding). These meetings resulted in a verbal agre ms, r 3 was reflected as special requirements in Appendix B to m. J. t_ner procedure WCP-2, revision 1, dated August 19, 1982 (originally propulgated as Site Communique No. 20). The following special requirements were agreed to: " (i) Welders subject to this program would qualify without practice. Normal machiec settings on a separate coupon would be permitted prior td commencement of testing. (ii) When,a welder's coupon failed to meet the requirements for normal qualification, the welder would either be given an immediate retest per the ASME Ccde, Section 9, or be given additional training with a subsequent qualification attempt. ' - Additional training was not to exceed one full shift. . . - - , m .--,--y --. .,- ,-.---,,+,--,.,,,m. .-.w . - _ _. - . . , - - - , . .-m

. ~ ATTACHMEtlT 6 to WHZ/NRC 83-06 Page 3 of 5 FIVE PAGES FROM DRAFT IE REPORT N0. 50-358/82-12 Inspection Conducted: October 1 through December 4,1982 (iii)Unless special circumstances were documented (which were circumstances outside the control of the welder, i.e., welding machine problems, defective coupon) no more than two qualification attempts (test coupons) would be allowed per welder per position per process. , (iv) Final visual inspection of the coupon would be accomplished ' either in the as-welded or ground condition, at the discretion 4 of the quality control inspector. (v) CG&E Quality Control would provide full-time personnel in the weld test shop to perform surveillance and reinspection of H. J. Kaiser activities. (vi) This special program would provide the necessary objective evidence that ASME and/or AWS Code requirements had been met prior to the welder pe'rforming in the field, however, the program would not be used to judge past performance. This was because present performance could be different (either improved or degraded) from past performance based . on such things as on-the-job training gained through field experience or loss of manual dexterity through aging. A separate program was set up to~ determine past performance based on the objective evidence installed in the plant. ,

These special requirements were the bases for NRC acceptance of the Special Welder Qualification Program. b. Documentation Reviewed (i) H. J. Kaiser RFI/E 351 dated August 17, 1982 (ii) H. J. Kaiser Current Welders Lists dated November 3 and November 17, 1982 . (iii)H. J. Kaiser Weld Test Shop Logs (iv) CG&E flonccaformance Report C-QAD-82-3300-E dated August 13, 1982 (v) H. J. Kaiser Weld Construction Procedure No. 2, Appendix B, revision 1, " Welder Qualification / Review, Testing and Training Procedure" dated August 19, 1982 . c. Observatiens/ Discussions (i) The inspector reviewed item 7.b(i) above and found that the response to this request for information/ evaluation was contrary to the special requirements documented in 7.a above. In particular, the response indicated that a welder _ was not considered to be " retesting" until his coupon had been rejected by either a radiographic test or a bend test. 3 _ _ _ _ -~ __ . _ . _ . . - - . - - _ - . -

- .. _ -. . ATTACHMENT 6 to WHZ/NRC 83-06

-

Page 4 of 5 FIVE PAGES FROM DRAFT IE REPORT NO. 50-358/82-12 Inspection Conducted: October 1 through December 4, 1982 . 4 A visual reject did not constitute a qualification attempt. This response to RFI/E 351 appeared to allow a welder an indefinite number of test coupons, provided the coupon was not subjected to a radiographic examination or a bend test. . In view of the above, and the special requirements discuss in 7.a above concerning practice prior to testing and the,ed number of tests allowed, the inspector was concerned that the implementation of the H. J. Kaiser Special Welder Qualification program may not have been consistent with the special program requirements. (ii) The inspector interviewed construction and QA/QC personnel who were involved in the implementation of the special welder qualification program. The results of these interviews indicated that the program was implemented such that a welder was allowed three qualification attempts without special circumstances being documented. This condition existed because the words in QCP-2, Appendix B, paragraph 2.3.1 under the NOTE state "Unless special circumstances are documented no more than two (2) requalifications are permitted". These words were interpreted by the individuals responsible for implementation of the program to mean no more than two retests were permitted. The interviews indicated that at least one individual was < ' allowed four coupons-for qualification to a single process (single position). This matter was documented by CG&E QC on nonconformance report number C-QAD-82-3300-E dated August 13, 1982. The interviews further indicated that a potential existed for others to have received more than three coupons. (iii)The inspector reviewed construction and ouality logs related to the special welder qualification program in order to determine if the welders were provided more than two qualification tests and if "special circumstances" had been documented in those cases where more than two qualifi- cation attempts were made. The results of this review indicated that at least three (3) individuals (beyond the one documented on NR C-0AD-82-3300-E) were given four (4) - or more attempts to qualify to a specific process (in a single position) and at least four others were given three attempts to qualify. . d. Findinos (i) The inspector noted that the apparent failure of H. J. Kaiser Welding Engineering to cceply with the "special requirements" - of Appendix B to QCP-2 indicated a lack of adherence to pro- cedural requirements and/or a lack of effective management controls (i.e., specific training for those individuals . - _ _ . _ . . -. -- . - . . - . .

. ATTACHMENT 6 to WHZ/NRC 83-06 ' Page 5 of 5 FIVE PAGES FROM DRAFT IE REPORT NO. 50-358/82-12 Inspection Conducted: October 1 through December 4, 1982 responsible for implementing the program), since the respons- ible management authority was kncwledgeable of the intent of the "special requirements." The inspector requested, on December 1, 1982, that the licensee verify compliance with the intent of the special requirements of Appendix B to WCP-2, including the documentation of "special circumstances", and document any deviations from the intent of those special- requirements. The inspector further noted that the impact (on quality) of this apparent procedural violation was iiot easily determinable. It appeared that at least one individual was qualified via the special welders qualification program who had difficulty producing a sound weld (welder symbol LOW, process Gas Tungsten Arc Welding, position 6G: tested to SPPM 3.1.1, three attempts, did not qualify; tested to SPPM 3.1.6, one attempt, did not qualify; tested to SPPM 3.1.56, four attempts, qualified on the fourth attempt). This concern was discussed with licensee and contractor management personnel. This item remains unresolved pending licensee review. This review will determine if special circumstances were documented at the time of the qualification for welder symbol LOW, and if other examples similar to that described above exist (50-358/82-12- ). No items of noncompliance or deviations were noted. . l i ( . 6 , - _. , ,,,y . - , , _ . , , _ _ . , - _ _ < _ , , , _ _ _ _ _ _ , , _ , --w...---.-,

._. __ A. A A . m - Attachment (7) To QUALITY CONFIRMATION PROGRAM WHz/NRC 83-06 - , TASK II: WELD OUALITY ACTION SEING TAKEN PERFORM 1005 REVIEW 0F CODE PIPING KE-1 WELD DATA SHEETS TO D A. HEAT NUMBERS, INSPECTION STAMPS AND DATES, IDENTIFY MISSED HOLD POINTS, Af'O MISSING OR ALTERED DOCUMENTATION. REVIEW OF WELD PROCEDURE AND WELDER QUALIFICATION, PAST AND PRESENT. B. ' t - , SUMMARY OF TASK ] TOTAL # ITEMS ITEMS PERCENT PERCENT MANHOURS OF COMPLETED COMPLETED COMPLETED COMPLETED EXPENDED MANHOURS AREA ITEMS THIS MONTH TO DATE THIS MONTH TO DATE THIS MONTH REMAININC 1)STRUCT. 11,000 0 11,000 0 98 0 416 , - KE-1 REVIEW 2)SM SORE 32,000 0 25,841 0 79 0 818 PIPE (APPX) 3)LG BORE 9,400 0 0 0 0 0 1373 . PIPE (380 PSK'S) , 4) WELD FRO- 91 0 36 0 40 0 1309 ' i CEDURE (PROCEDURES) - ' REVIEW 121 REV'S 5) WELDER 4600 0 2574 0 55.9 0 1196 QUAL (DOCUMENTS) REVIEW 6) WELD ROD 0 0 0 0 0 416 ' CONTROL 7) FINAL SM 272S '229 229 8.4 8.4 244 2700 50RE REVIEW TOTAL 59,846 229 39,680 8.4 70 244 8228 CURRENT STATUS AND RESULTS AREA #1 - HJK TO PROVIDE CORRECTIVE ACTION TO CAR ON CONC 1. 2. AREA #2 - 19-QA-14 REVIEWED. THE FINAL REVIEW TO START JANUARY 1983. AREA #3 - TO BE COMPLETED, AFTER COORDINATION WITH HJK IN THEIR NPP-1 3. PROGRAMS.

REA #4 - WELD PROCEDURES WHICH HAVE EEEN CER'ED ARE ON HOLD UNT

J. FROM HJK WELD ENGINEERING DEPARTMENT HAVE EEEN REVIE PROCEDURE PACKAGES FOR REVIEW AND EVALUATION. . m --_._.,,.._..g,.,,wiw , , ,,,.-...me, - , , , _ e,,.,-i .-,,-v.#m--- - ,,.we, n4 -, _ ++ - - .--s _,qs._- _g

- . J QUALITY CONFIRMATION PROGRAM TASK II: (CONT'D). AREA #5 - WELDER QUALIFICATION REVIEW HAS STOPPED DUE TO THE NUMBE 5. QA DOCUMENTS BEING RECEIVED FROM HJK'S WELDING DEPARTMENT. STATUS SHALL SE DETERMINED AFTER ALL WELDER RECORDS HAVE SEEN TRANSFERRED, SORTED AND FILED IN THE APPROPRIATE WELDER PACKAGES. AREA #6 - WELD ROD CONTROL, NO RESULTS, DUE TO PERSONNEL BEING PLACED IN HJK'S 6. WELD ENGINEERING DEPARTMENT TO OVERSEE THE RETRIEVAL OF QA QUALIT AREA #7 - FINAL SMALL BORE REVIEW OF DOCUMENTS GENERATED BY OCP T 7. TO START. ESTIMATED MANHOURS 2700, T0 COMPLETE FINAL REVIEW. TO BE RESOLVED COORDINATION WITH HJK REVIEW FOR NPP-1 TO EFFECT A COORDINATED N- 1. INCLUDING ITEM (1) IN COMMENTS SECTION. 2. CONFIRM ACCEPTABLE HEAT NUMBERS ESTABLISHED BY TASK III. , MANPOWER SUMMARY ACTUAL . TASK C00RDINATGRS 1/2 INSPECTORS 0 DOCUMENT REVIEWERS 4 CLERKS 1/2 . TOTAL 5 i STATUS ,

• DUE TO.THE AMOUNT OF CRIGINAL QUALITY QA DOCUMENTATION RETRIEV

WELDING DEPARTMENT, IN THE AREA 0F WELD PROCEDURES AND WELDER QUALIFICATION RECORDS, AREA'S 4, 5 AND 6 UNDER SUMMARY OF TASK ARE INDETERMINATE, UNTIL ALL AREAS OF CONCERN IN HJK'S WELDING DEPARTMENT HAVE BEEN REVIEWE QA QUALITY DOCUMENTS, TRA';dMITTED TO HJK'S VAULT, REVIEWED AND SCRTED INTO THE APPROPRIATE PACKAGES. ESTIMATED COMPLETION DATE s CCFPLETION OF THE FINAL REVIEW TO 19-0A-14 IS JUNE 1933.

• COMPLETION OF WELDER PERFORMANCE QUALIFICATION TEST INDE

STATUS AE0VE.

• CCMPLETION OF WELD PROCEDURE INDETERMINATE DUE TO STATUS ABO

. % - (a) - - __ , - . __ _ - . - _ _ , . - - _ - - - -.

6 _ __ Attachment (8) To . " WHZ/NRC 83-06 -_ TIIE CINCINNATI GAS & ELECTRIC C O N11'.\\ N Y - - - ..s. . < . January 14, 1933 QA-2214 . ,, 1 - 1.~ - J . ea.seaowA~~ .- .- m.. . e e . . e $,.c - in .c i v. d i...C - , . . S' . U. S. Nuclear Regulatory Commission fg.' . Region Ill ' p"f 799 Roosevelt Road ~ Glen Ellyn, IL 60137 Attention: Mr. J. G. Keppler Regional Administrator . WM. H. ZI M R NUCLEAR POWER STATION UNIT 1 . RE: TOCEitSGTeEYTES M-73, POSSIBLY ALTERED [WELDIE72iEE6$RWDOCKET No. 50-358 _ 'CONSTRUCTIOh rr.JIIT NO. CPPR-88, Wo d57300 JOB E-5590 FILE NO. NRC-8, M-73 . Gentle =en: , . This letter constitutes an interim report concerning the subject o= mission on December 17, 1982 as c condition initially reported to the a potentially reportable deficiency under 10CFR50.55(e). During the review of H. J. Kaiser Company velding procedures by the _ CG6E Quality Confir=ation Program, certain of these velding procedures were found to have been altered or modified by =ethods which were poten- Three distinct methods tially in violation of regulatory requirements. were e= ployed which affected at least ten separate H. J. Kaiser welding procedures. The first method of alteration made use of liquid paper (" White-out") or erasure to change tha rreisien,nu=ber and the effective date of the The cover pages of these pro- cover page of five separate procedures. cedures contain the approval signatures signifying rr.-lew and concurrence In each of the five cases, a cover with the contents of the procedure. sheet fro = an earlier revision appears to have been =odified by changing the effective date and the revision level of the procedure, leaving the Although the available documentation indicates original signatures intact. that these latest revisions to these five procedures had been reviewed had revie.ed the errlier revi- and approved by the sa=e signatories that The originals of each siens, this in fact does not appear to be the case. of these five velding procedure revisions were found in their altered states This concern is while in the control of the H. J. Kaiser Uciding Department. (CAR) S2-157. described in greater detail in CCiE Corrective Action Request . m , - - - - , .7-- , - - - _ - , - q -_-----,-

. __ .

- , Mr. J. G. Keppler . Regional Administrator Region III January 14, 1983 QA-2214 Page 2 The second method of alteration involved changes to weld procedure - test results on which the welding procedures are based. Procedure quali- fication records for three separate procedures had all references to Post Weld Heat Treatment deleted from the original test report by the use of " white-out". This case is described in CGSE CAR 82-122. < The last method of alteration made use of supplemental change notices ' or temporary amendnent notices which changed essential variables without assurance that the appropriate review occurred. In at least five separate procedures, this method was used to delete the requirement for the use of backing material or backgouging in a groove weld originally qualified by the use of backing material. This change does not appear to have been approved by the organizations responsible for the review of tais type of change. Additional detail is provided in CC&E CAR 82-122. The potential impact the previously described modifications have on actual welding has not yet been assessed, nor has a complete review of the applicable docueentation been performed. The Zi==er Ouality Confirmation Program is atte=pting to have or,iginal documentation affecting quality transferred frc= the H. J. Kaiser Company Welding Department to H. J. Kaiser Co=pany Records Management. However'in a job site meeting held on January 13, 1983, Henry J. Kaiser and Cincinnati Gas & Electric agreed to an expeditious coordinated review in a controlled environment to evaluate the extent of alterations on all velding procedures. A formal review by QCP personnel will continue and appropriate deficiency documents will be issued to address all qualit,- concerns. At this time, a definite date for ccmpletion of this review cannot be determined due to the present unavailability of all required documentation necessary for this review. An interim report providing an updated status of this review will be submitted by April 1, 1983. ., We trust the above will be found acceptable as an interi= report under

10CFR50. 55 (e).. Very truly yours, ] THE CINCINNATI GAS & EI.ECTRIC COMPANY W" By E. A. BORCMANN SENIOR VICE PFESIDENT GMO:pic NRC Of fice of Inspection & Enforcement . cc: Washingten, D.C. NRC Senior Resident Inspector Attn: U. F. Christiansen Zis=er Project inspector Region III - - 9 % .,. - - - , , ,, - .--,-,---e,--.- - - - , , . , - , , - - --

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December 20, 1982 , U"1'O;Mo c . The Honorable Nunzio Palladino Chairman United States Nuclear Regulatory Commission Washington, D.C. 20555 Dear Mr. Chairman: Pursuant to the Committee's inquiry into the question of the Commission's ability to determine whether the reactor at the Zimmer Nuclear Power Station can be safely operated, I am seeking information pertaining to the Zimmer welder qualification review. The results of this review are described in documents obtained by NRC Region III staff on or about July 12, 1982. I would appreciat. your providing the following:

' 1. A list of Zimmer welders who were requalified as a result of the welder qualification review. The list should indicate for each welder the specific procedures for which requalification was required, and the procedures for which welders were decertified as a result of the review. The list should also include, for each welder and each procedure, the date on which requalification tests were taken, and, where appropriate, the number of times a welder failed to pass the test, and was either decertified as a result of that failure or was required to retake the test. 2. A description of the criteria used to determine, for each welder and each procedure for which that welder had been certified as of July 9, 1982, whether the documentation was sufficient to demonstrate that the welder was in fact qualified to perform the procedures indicated on his certification card. I assume this information is readily available. I would appreciate being informed by December 31 of any impediment to your fulfilling this request by January 7, 1983. This request, in part, has been the subject of discussion between our staffs. Sincerely 7 Up !)/kW MORRIS K. UDALIN Chairman . . . . .-- . _ . - - - . _ . }}