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Forwards marked-up Affidavit of WR Mcafee Re Concerns Over Quality of Const at Facility & Ability to Operate Safely & W/O Harm to Public Health
	ML20205E643
Person / Time
Site:	Catawba
Issue date:	01/03/1984
From:	Garde B; GOVERNMENT ACCOUNTABILITY PROJECT
To:	Sinclair J, Uryc B; NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II), NRC OFFICE OF INVESTIGATIONS (OI)
Shared Package
ML20205E641	List: IA-84-722, Provides Addl Info Re 831025 Interview.B Garde,B Jones & B Guild Attended Interview.Signed Sworn Statement Not Taken Due to Late Hour of Termination of Interview.Info Partially Withheld; ML20205E638; ML20205E643; ML20205E646; ML20205E651;
References
	FOIA-84-722 NUDOCS 8510170349
	Download: ML20205E643 (49)
	v • d • e

{{#Wiki_filter:, u.vm v1 v rav GOVERNMENT ACCOUNTABILITY PROJECT t IAstitute for Pokey Studies 1901 Que Street. N.W., Washington. D.C. 20009 (202)234 9382 Tiu.62 4-09.$ January 3,1984 fM Mr. Bruno Uryc Investigation / Allegation Coordinator U.S. Nuclear Regulatory Comission . Suite 3000 101 Marietta Street, Northwest Atlanta, Georgia 30303 . Mr. John Sinclair Office of Investigation U.S. Nuclear Regulatory Comission Washington, D.C. 20555 Gentlemen: Enclosed is a notarized copy of the Affidavit of Mr. William Ronald McAfee, a foriner worker at the Catawba Nuclear Power Plant. We believe that issues raised in the McAfee Affidavit are relevant to both the Region II inspection of the as-built condition of the Plant, as well as to the OI investigation into the deliberate undermining of the quality assurance program by Duke Power Comany management ,of ficials. Very truly yours, UL b Billie Pirner Garde Citizens Clinic Director BPG:me

Enclosure:

a/s cc: Mr. Thomas Rehm, EDO 8510170349 851000 PDR FOIA b-h

                                                                                / , u wj'.

DELL 84-722 PDR

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i* AFFIDAVIT My name is William Ronald McAfee. I am making this state-ment of my own free will to Emily Ansell, who has identified herself as an investigator for the Government Accountability l Project. I am speaking without threat or promise of material

benefit. My reason for making this statement is to express my i

continuing deep concerns over the quality of construction at the Catawba Nuclear Power Station being built in Clover, South 4 Carolina and its ability to operate safely and without harm to

public health.

I was employed by Duke Power Company (DPC or Duke) at the

Catawba plant from March 1977 to March 1979. I quit my job there i

1 as Electrical Quality Control (QC) Inspector in mid-March,1979 l because I got fed up with DPC's deliberate efforts to force me to i j do my job improperly. 1 Prior to working for Duke I was a substitute teacher for the York School District Number One in York, S.C., teaching grades y nine through twelve. Before that, I was a graduate student at 4 l Vanderbilt University, from 1975 to December 1976. Prior to that, in 1975 I received a BA degree in Biblical Literature and Language l from Gardner-Webb College in Boiling Springs, North Carolina. j I held several jobs with Duke at the Catawba plant. From j March 1977 to approximately December 1977 I was a concrete pourert from December 1977 to about March 1978 I was a concrete prepour , runner, helping to coordinate the pouring of concrete by dealing ' f with the paperwork; from March 1978 to about May or June 1978 I t was secretary of the Utility Department office. Finally, about i 1 Zo[/7

i . j , May or June 1978 I was promoted to Electrical Quality Control

Inspector, where I remained for nine months until I quit in mid-q March 1979. { The reason I wanted to be a Quality Control Inspector was i that in the approximately fif teen months that I had been working in the Utility Department I gpseenthatmanythingswerenot i done the right way. esausst, during the course of my QC Inspector i fach%;tAA job I found out that this wa knot the case. I observed severe i 1 deficiencies in the way the QC program operated. That is, I ob- ! served problems regarding Design Control, conflicting policies ; regarding Non-conforming Itam Reports (NCI's), and a general QC/QA breakdown, as illustrated below.

,                                Before I was actually certified to inspect work on my own I had about four or four and a half months of on-the-job training,

from about July 1978 to about November 1978.

Mk* I received three or j four half days of classroom instruction in which we went through j inspection procedures and were instructed as to the specific points we had to verify in order to approve the particular item we were inspecting. We were given a list of different procedures for ! different it9s we inspected and we were told that that list was i % Dlt* # to be our "94bse" for performing inspections. Also, I learned i i what I was supposed to do by accompanying various inspectors and l watching them do their jobs. , ; j Electrical QC Inspectors were responsible for inspecting , l cable tray hangers, cable tray supports, cable trays, and cable l : I i S of /1

i . i pulls in certain areas of the plant, notably the Reactor Building i l I One Pipechase and several areas of the Auxiliary Building. I l During my training time we had to verify work so that the

  !                                                                                                                               l l                     work could proceed, for example be painted, but we did not have                                            l
 !                     to sign off on anything -- nothing had to be documented.                         If we I                     found that some item of work, for example anchor bolts on a uni-strut in the Auxiliary Building, was not done right -- if it was not done according to blueprint -- we went to the craft supervisor and told him about it, that the bolts were not right or they were in the wrong place, and told him to fix it.                       Generally, craf t would fix its sometimes we had to go back a second time and tell them again.      But these errors were not documented.                                                          [
                                                                                                           ~

During my QC training period, from about July 1978 to about Or.br M p====har 1978, I did not see anyone documenting inspections of i unistrut installations, in the sense that no one hung inspection l tags on them or signed off on them. It was my understanding that 1 l this was just the way the system was set up. Although we had. , t specific procedures to follow for each inspection we did, to my knowledge those procedures did not have a form for documenting the results of the inspections. If there were forms, we were not using them a't the time. The aa-awcan+!rntethiewe;f;rzpM c:51e r 11ing veilfic:tica; : did ;i;- aff on thn== 4 r ::;ica;. i If we found a construction deficiency during our initial inspection, there were several ways available to document it. , O Y b/ l'l '

                                                                               =. _.__ _ -               _ - - - -

M We could write 6 , an M40-C (a minor defic-iency report), or a Q-1A Non-conforming Item Report (NCI). However, the decision as to which of these we would use -- or if we would - document a d'eficiency at all -- depended upon the then prevailing policy of any of our supervisors in QC - whomever had the "last : 1 word" at the time. Those supervisors were: Larry Davison, head of QC; Tc--_-j h ;;; n, M M r W i:;l ^^ ;.. gin;;r; Dick Hannay, my im-1 mediate supervisor Jim Allgood, QC Electrical Engineer. To my understanding, based on my experiences in QC, there really was no clear policy as to which form, if any, we were to use in any given instance. It seemed like the supervisors were always changing their minds as far as how they wanted to document deficiencies or if they wanted to document them at all. k/INI At one point, f - -- - % m le, i . -- -i r -- Jen - % is H, 1 (on the day of Tommy Barron's lecture, discussed below), I thought I had a real clear understanding of when we were supposed to use the NCI form and when we were to use the M40-C, although I never was given a clear understanding of when to use the Variation Notice. But since Duke's policies on documentation arbitrarily changed from day to day, the clear understanding I thought I had one day did not hol ue for the next day. For example, on one occasion p

               --;r--             r- -
                                         - _ -e we - my partner Johnny Byers and I -

were called to inspect twenty-seven cable tray hangers. We found that seven of them were not installed according to print; the ' most common error being seismic bracing running in the wrong direc-f.. ' 5of/7

tion or missing entirol . The very day before, Tommy Barron lectured us ;;;; M Le ;c _a _:::rs) on how to use the NCI report e I j and told us to use that form to report deficiencies. So, in this instanc'e we told our supervisor, Dick Hannay, about the seven errors and told him we intended to document the problems on NCI's as we . had been instructed. However, we were told in no uncertain terms ! by either Jim Allgood or Dick Hannay or both.not to use the NCI's; in other words, now we were being told not to do the job in the way l that Tommy Barron had told us to the day before. Instead, Dick Hannay talked to Cecil'Cox, the steelrigging foreman,and the next day Cox or his crew corrected erro,rs on the spot. Dick Mannay l was alarmed that there were seven hangers that we could NCI but he did not want us to write that many NCI's because it would not look i goodforgjmorthesteelpeople. He was concerned because Larry Davisons disapproved of writing a lot of NCI's. 1

All of us knew from experience that Davison's attitude re-garding NCI's was that he was generally against writing them.

1 e l My understanding from Tommy Barron's lecture as to why we were given this lecture was that Duke's attitude or the attitude of QC i was that we had not been documenting deficiencies well enough in the past and that the documentation was not as good as it should be. Barron stre,ssed better documentation. However, it was made clear to i us that the main reason, if not the only reason, for document,ation l

was for the benefit of the NRC, not for Duke.

We were told, though, that the only time we could use an NCI was 1 when we found a deficiency during a preplanned inspection. In other words, we could not red-tag a deficient item unless we were called 1 by craft to inspect. ;

i l

l - - - -- - -. . - - - - - - . .

                                                                                                                            & cf17l

          .  .                                                                                              i Instead, he encouraged us to get the deficiency resolved without                                    ;

documentation. Davison reserved writing MCI's usually for very seriour deficiencies; i.e., only if the deficiency could not be - remedied quickly, quietly, and easily would he not usually override the NCI documenting it, if written. So far as I know, no documen-tation of the seven cable hanger errors exists to show they were initially installed improperly because neither my partner, Johnny Byers, nor I wrote them up and I feel sure that no one else did because that was our area of responsibility. To my knowledge, the prevailing attitude was that if the NRC did not require it, we would not have to document deficiencies. It was our feeling that, Duke's attitude was that if Duke could get away with it they would just as soon not document the problems. Either Jim Allgood or Dick Hannay told us, the QC Inspectors, that every time we wrote an NCI that meant at least $700.03 in expense for Duke -- in paperwork shuffling and people's time. The policy of preplanned inspections was very clear. We had to have permission from craft supervision to inspect their work before we had a right to non-conform something. In fact, craft ; got rather " bent out of shape" because some of us were inspecting before they called for us and we were finding things wrong. Our QC supervisors came down on us and told us not to inspect anything i until we were called by craft to do so. This, of course, presented problems when on a few occasions

we were just walking through the plant and spotted construction deficiencies. For example, in Unit 2 Auxiliary Building 560 eleva-tion we found cable tray hangers which were not seismically braced

l l

i 0 !

_7_ . J according to the blueprint. They already had an inspection tag hanging on them from another inspector (Bill Reffner) who had inspected and approved them as being done according to print. We just happened to notice that they were wrong; there were two hangers and one was physically in the way of where a cable tray was sup-posed.to run. We told the approving inspector about it and he promptly removed the approval tag. As I recollect, he told the l I . foreman it would have to be put in the proper place. To my knowledge, this deficiency was not documented, although I believe an NCI could have been written up. Because of the contradictory policy on j writing NCI's, I believe that if I had tried to write an NCI

;                            chances were good that I would have been stopped.                                           This problem of                ,

j having to fight for NCI's was very discouraging; after a while we 4 i just stopped writing them. l There is yet another example of this situation. This one took j 4 place in the cable room directly below the control room for Units I and 2. We were inspecting the grid system that supports the cable tray under the cable room and we were finding a lot of deficient work -- work that was nowhere near being right; basically unistrut and cable tray hangers put in the wrong places. Bobby Land, electricians' foreman, had called us to inspect, j meaning that the work should have been completed properly. Land told us to mark whatever we found that was wrong (we tied yellow l ribbon to those items). We found literally dozens of problems; , 1 i 2q:/?l

d the cable tray room was filled with yellow ribbons and when Land I and one of his ;r: hr-r s5e5 (M '-

                                                                          ^r, Mrr 0;;i , came in and saw r--4       ^

3 1 l it they both got very upset. All their mistakes were marked by

                                                                                                                                            .           1 i

yellow ribbons for everyone to see. They promptly fixed the errors l and removed the ribbons. No documentation of these mistakes or the corrections was made. As far as OA documentation is concerned i ! it would appear that the work was done right initially, sometimes, the work was not done right the second time either, still it i would not be documented as a problem. i In general, we were encouraged by our supervisors not to f write NCI's; we were told to tell the craft supervisor about the l , problem and see if we could get him to fix it -- without documenting

4

! it. To my knowledge, most of the Electrical QC Inspectors handled i , i discrepancies in this way. This was exactly the opposite of what i b% j was written in our procedures %Dtbts." i There were also problems with Design Control. That is,

blueprints were changed to reflect construction errors. The

! result of this is that the prints reflect the "as-built" condition I

l 4

of the plant instead of the plant "as-built" reflecting the blue-I

print. In other words, construction errors that were not physically corrected were " corrected" by revising the prints. Construction l errors were reflected in revised blueprints to appear as approved

               " design changes" made prior to construction, not after the fact                                                                         !

to covei up the errors - the nonconforming items.

1 Yo{/9._.

   .                                                                                                                     \
                  ,      ,                                  . .                                                                                                                       \

l l To my understanding, the correct and most efficient procedure to follow when we found a nonconforming item that could not be ! fixed easily by craft was to write an NCI to document the problem I and let Design Engineering and Technical Support handle the decision. But, the common practice was that NCI's would not be written. l DesignEngineeringwouldwriteupaDesignChangeandrevisethg,,g_ f print.without an NCI documenting the mistake. So, there 6d be no evidence that a mistake had been made at all. It would appear that the mistake was, in fact, not a mistake but proper according f to the revised print. In some instances Variation Notices (R-2's) were written and were reflected in the print, but this would not necessarily indicate a construction error -- just a variation. I In other instances, the deficiency was merely noted but not docu-I mented in any formal way and the print was revised to accommodate the error. l The most typical exr.mple, in my experience, of prints being l changed without NCI documentation happened in the Reactor Building l Number One Pipechase. The prints called for all cable tray hangers I i .; in this area to be seismically braced according to a specific con-l figuration and a specific direction according to degrees. What I found, during my inspections, was that in a lot of cases (involving Cecil Cox's crew) the seismic bracing was incon.sistent with the

!                         blueprints -- it was installed in the opposite direction or perhaps I

ninety degrees off from the direction called for by the prints. We i told Technical Support about the problem (and were told later that l l As sf/?

i l they contacted Design Engineering). In most of these cases, t Design Engineering changed the prints to reflect the bracing as eftew # installed; abthough no NCI's were written documenting the errors Since our inspections were done by comparing the work to the print, when we were given this new print -- the one revised to , reflect the construction foul-up -- we had no choice but to

                , inspect by this                       print. Therefore, we were now approving undocu-i                   mented construction errors that had been legitimized by a revised j                  print.

4 Another example of this situation occurred in the Auxiliary i Building. Again, the seismic bracing on hangers I inspected was

;                  run in the wrong direction from what the print called for.                                     Here, i

too, the print was revised to reflect that as-built condition i without NCI's being written up. While we thought it was a very serious matter, the QC Inspectors

had a running joke that Duke will build the plant and then draw j . r

;                   the blueprints to reflect how it was built.

I' There were numerous incidents in the Cable Room also where, although we found construction errors -- items installed in the wrong place, crir-i: ir:ria; ag=in in=ta11.a in th. wren- ' ire;;ier

!                   -- no NCI's were written, there was no official documentation and yet the prints were revised to " correct" the construction foul-ups.

All in all, I would say that prints were revised in this way

                    -- with'out writing NCI's -- in approximately 25% of the cases

where I found construction errors.

In addition to these problems, there were others that I

                                                                                                                          //oll7

d

                                      - 11      .

encountered before I became a QC Inspector -- ones that add to the contention of an overall QA breakdown. For instance, in early 1978 when I was a prepour runner, I witnessed concrete for the

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4ttacnrent Ni to NCI 9092 4 w/ Previous resolutions have proven to be very difficult to implement without damagint' the containment plate. The following procedure shall be followed to determine which defects are acceptable and which require repair. Details concerning the development of these criteria are contained in calculation file CNC-ll44.09-01-000:
~~1. Surface flaws with a depth of 1/8" or greater shall be weld repaired according , ;~~
~~to ASME procedures.~~
2. Surface flaws with depth less than or equal to 1/32" are acceptable if they do not interfere with other flaws as outlined below. ,

3. The remaining flaws shall be inspected'to detemine their acceptability using
- the attached' Figure 9092.1. The acceptability of a given flaw will be determii by the size of the surface which it covers, the depth of the flaw, and the proximity of.the flaw to other flaws. Surface defects failing this criteria a shall be wald repaired according to ASME procedures.
N q 4. The following definitionsThe apply to the variables used ia Figure 9092.1: dimension of the surface flaw in the direction of y* === a. d (flaw diameter): the next adjacent flaw. For circular pits surrounded by a circular patter of smaller pits, d_ shall be taken as the distance across the circular O y b. pattern. 0 (spacing between flaws): The minimum clear distance of unflawed surface - between adjacent flaws. If D_ is greater than 1 3/8", D. is to be taken to
~~, be equal to 1 3/8".~~
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~~c. t f (flaw depth): The maximum penetration of the flaw measured from the unflawed surface.~~
~~'T W " In applying Figure 9032.1, the two surface measurements 0 and d should.be 5.~~
N made first. With these two measurements, one point on tiie figure is determine This point will lie between two flaw depth lines. The flay depth indicated by the line imediately below the , Joint given by D and d is acceptable, while
~~--)~~
the flaw depth given by the line inmediately above the point is unacceptable. For points lying on a given flaw depth line, the flaw depth given by that line O y is acceptable. For example, a flaw with 0=1/2" and d=5/8" is acceptable for N a flaw depth of 5/64" and is unacceptable for a flaw depth of 3/32". The actual flaw depth should be compared to the acceptable value to determine whether repair is required. Repairs may be made either to the flaw in questio or to an adjacent flaw to arrive at a combf'nnation meeting this criteria.
6. Figure 9092.1 assumes an identical flaw on the opposite face of the dome plate If it can be verified that in the area of a given flaw no surface flaws are present on the opposite face, the allowable depth given by Figure 9092.1 may be multiplied by two.

7. Surface flaws with a maximum dimension d_ greater than 13/8" shall be weld repaired according to ASME procedures except as noted in 2. above.

8. Surface flaws with a maximum dimension d less than 1/8" are not required to be repaired except as noted in 1. above'~
_- 9. Repairs are to be done in accordance with Section 111, Subsection NE, of the ASME Code. , By: Technical Approval: QA Approval: 2,-
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