ML20023C053
| ML20023C053 | |
| Person / Time | |
|---|---|
| Site: | Zimmer |
| Issue date: | 09/17/1982 |
| From: | AFFILIATION NOT ASSIGNED |
| To: | |
| Shared Package | |
| ML20023C048 | List: |
| References | |
| FOIA-83-74 NUDOCS 8305090555 | |
| Download: ML20023C053 (14) | |
Text
{{#Wiki_filter:- - - . . . . .. _ Elic National Boato of Boiler anb IJressurc dessel 3nspectors s . s F. H ARRISON. t aecuts.e Ditector to.S Capt a avta n ut a BOARD or TRusTtts J J Dus ty COLUw9uS Cmo e3229 u 5 A . s.. ., o, w.,e .... J T CactSv. C*seaa Pfsono tia8888370 teii<e Roca. A rn a-.a. Totes te%25 ' A MIL L E R WE ST B L wmTLiv.1st v.re C%m Pro.. ace of Pe*ce f e.are es and f Pa op, Peonh Ca o'eaa M. CH LT[R$ R st is',*,5CH 2fid bc e C%m tatt La.e Cetr. uran
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August 6, 1982 PRil:C IPAL ST/.FF -
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Mr. Donald M. Milan, Division Chief iV:M i h.L-e:: ' IfT(7 Departcent of Industrial Relations Division of Boiler Inspection U.ypjs{l'7E,";ip' p{ {-* ~ ;g,g 2323 West Fifth Avenue 95,Tp'~[' l P.O. Box 825 I t ; Columbus, Ohio 43216 6L l [flLE l /
SUBJECT:
National Board Audit as Requested by the State of Ohio, Division of Boiler Inspection, of the ASME Code Related Construction of the William H. Zir:mer Nucicar Power Plant, Moscow, Ohio INTERIM REPORT t No. 2
,(SUPPLEMENT 1)
Dear Mr. Milan:
In accordance with the agreement of January 6, 1982 between the State of Ohio Division of Boiler Inspection and Cincinnati Cas and Electric Company, the National Board Audit Team has continued its audit activities at the 4 William H. Zimmer Nuclear Power Plant. . This report is a Supplement to Interim Report No. 2 (dated July 1, 1982 and covering activities from May 13 to June 18, 1982), and covers the National Board Audit Team's activities at the Zimmer Nuclear Power Plant from June 18 . through July 30, 1982a ' Interim Report No. 1, dated Fby 12, 1982, covers the National Board's activities from March 1 to April 23, 1982.
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1.0 INTRODUCTION
1.1 Charles W. Allison, Michael F. Sullivan and Robert P. Holt were the National Board Audit Team member participants on various dates during this period. The findings, comments and proposed resolutions are as follows. 2.0 CINCINNATI GAS AND ELECTRIC COMPANY (CC&E). - 2.1 At the request of Cincinnati Cas and Electric Company a i meeting was held at the National Board of Boiler and Pressure Vessel Inspectors' office, Columbus, Ohio, June 30, 1982 to
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(' ~ Page 2- Mr. Donald M. Milan August 6, 1982 i- discuss . Interim Report No.1 (dated Ma" 12, 1982). Representa-tives of Cincinnati Cas and Electric Company, Henry J. Kaiser Company, the National Boa'rd, and members of the National Board Audit Team were present; and, each item in the report was dis-cussed, wherein CG&E committed to a written response to the report and the proposed resolution to comply with enforcement and regulatory requirements. 2.2 As of July 30, 1982, neither the State of Ohio Division of 3 Boiler Inspection nor the National Board of Boiler and Pressure Vessel Inspectors has received a written response to the National Board Audit Team's Interim Report No. 1 dated ' l May 12, 1982. ATTACHMENT "A" 3.0 HENRY J. KAISER PROCEDURES MANUAL REVIEW. 9 NA-4320 3.1 During a review of the HJK Procedures Manual it was noted that NA-4400 Henry J. Kaiser does not in all cases document review of con-NA-4430 struction procedures which are quality affecting. The HJK Q.A. Manual Q. A.P. #8, Rev. 9, Para. 3.5 states....."Zimmer project procedures affecting quality shall be reviewed by the Q.A. Department to assure that the Quality Assurance Program is _... I properly implemented." The HJK Q.A. Manual (Glossary) further .
- defines review as....."The process of appraisal of documentation 4
to determine its adequacy with respect to specific requirements by signing and dating." , 3.1.1 The National Board Audit Team is of the opinion that HJK Q.A. should review all Quality affecting procedures, and that such a review should be documented on a controlled document. The HJK Procedures Manual ZAPM-2, Rev. 1 , (dated June 3,1982) provides a matrix showing the approvals and reviews required on all procedures. This ' matrix is blank. HJK has submitted to the National Board Audit Team a completed matrix dated June 16, 1982; how-ever, ZAPM-2 has not been revised to include the revision. I 3.1.2 The National Board Audit Team is of the opinion that Q.A. review of all procedures affecting Quality is required by NA 4320, NA 4400, NA 4430 (ASME Section III,1971 l Edition, Summer 1973 Addenda). The National Board Audit l Team is of the further opinion that should HJK desire to , use the procedure review log maintained by the procedure coordinators as the document to provide evidence of Q.A. t , review, then this log should be referenced in the Q.A. ! Manual and in ZAPM-2 -- and this log should also be a controlled document. l l t I l i
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4 Page 3 Mr. Donald M. Milan August 6, 1982 3 3.2 The HJK Procedure for Con; rolling NCR's ZAPO-5, Rev. 1 (6/2/82), i ; . NA-4550 3.2.1 As part of this' procedure Section 3.2 deals with in-process inspection deficiency records (IIDR). This document appears to be a vehicle which allows non-: conforming conditions to be dispositioned and resolved 4 without the proper or required review which would'be 4 mandated if the NR were to be used. One NR reviewer who is not in the cycle of review for the llDR is the ANI._ Also, there is no required review by the Architect Engineer (AE) for repairs. 4 3.2.2 The major concern of the National Board Review Team is
. the possible misuse and abuse of the IIDR and the -
definition of when " final inspection" takes place.; 4 l 3.3 HJK Q.A. Review of Procedures Affecting Quality. t NA-4400 3.3.1 The National Board Audit Team also discussed with HJK NA-4430 Q.A. personnel the concern that some special process l procedure methods (SPPM) which are required to be re-viewed and approved by the HJK Q.A. Manager (Para. 2.10, i QAP 10, Rev. 10, 3/24/82) are being superseded by weld control procedures (WCP) which do not have Q.A. approval' . These procedures (WCP) are prepared by the welding ! manager and approved by the project engineer. 3.3.2 HJK has taken the position that the WCP's are adminis- , trative procedures and not SPPM's, and therefore do not require the approvals required by QAP 10. 3.3.3 It is the opinion of the National Board Audit Team that WCP's which include activities such as weld procedure , preparation and qualification, welder performance qualifi-cation, weld filler metal control, etc. are in fact quality procedures and should be approved by Q.A. i l ATTACEMENT "B" 3.4 Temporary Change Notices (TCN). i 3.4.1 HJK Procedure ZAPM-2, Rev.1, 6/2/82, allows non QA/QC ' procedures to be revised without issuing a new revision through the use of a TCN. This system is not described in the HJK Q.A. Manual (QAP-2, ! Rev. 10, 3/24/82). 1 i - l 3.4.2 This system was in use prior to the recent ASME survey of March 22-24, 1982. HJK indicated that during this
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Page 4 Mr. Donald M. Milan August 6, 1982 survey concern was raised,by the Survey Team that if TCN's were used th8y woula have to be referenced on inspection documents to as'sure adequate paper trace-ability. (See Attachment *"B", Concern #1). 3.4.3 This system was deleted from the Q.A. Manual. However, TCN's are still being utilized for QA/QC procedures in the Zicmer Procedure Instructions Manual (ZPM). NA 4430 3.4.4 The National Board Audit Team is of the opinion that NA 4452 when TCN's are used either on QA/QC Procedures or Construction Procedures, they must be identified by the TCN number on the inspection record. This is not
.being dsne.
ATTACHMENT "C" 3.5 Non-Destructive Examination by the Henry J. Kaiser Company's [ (the Installer's) Sub-Contractors'. NA-3451(a) 3.5.1 Nuclear Energy Services Inc. (NES) is currently the NA-4900 non-destructive examination'(NDE) sub-contractor to NX-5500 Henry J. Kaiser (HJK) for' radiographic (RT), magnetic " particle (MT), non-destructive examination. 3.5.2 The National Board Audit Team is reviewing and.will continue to review NDE procedures, personnel qualifi-cation and certification records of NED performed for the Installer, Henry J. Kaiser, under their ASFE "NA" ' and "NPI" Certificates. 3.5.3 NES apparently was placed on the HJK pproved Vendor List (AVL) on May 14, 1982 as a result of a March 9 - 1982 audit conducted by HJK. However, a review of -
, HJK's historical and current vendor documentation does not confirm that their NED sub-contractor (s) had been surveyed and qualified by HJK prior to this date (3/9/82) as required by ASME Section III, 1971 Edition, Summer 1973 Addenda. ASME Section III, 1971 Edition, Summer 1973 Addenda requires the Inst.-13er (HJK) to survey and qualify the Q.A. programs of suppliers of sub-contracted services, including their NDE sub-contractors.
3.5.4 A review of NES records indicates that NES began in-voicing HJK for NDO services on approximately March 10, 1980. Prior to that time, Peabody Magnaflux Testing Laboratory was the NDE sub-contractor to MJK for non-destructive examination. Peabody Magnaflux Testing
Page 5 Mr. Donald H. Hilan August 6, 1982 Laboratory appears on HJK's Approved Vendor List from August 2,1976 to 1980; however, no records of audits or surveys have been presented to the National Board , Audit Team by HJK or CC&E that show Peabody Magnaflux Testing Laboratory was ever surveyed or audited by HJK as required by the ASME Code. 3.5.5 The National Board Audit Team, during the week of July 12,1982, requested from both CG&E and HJK records of Peabody Magnaflux Testing Laboratory's NDE personnel qualification and certification records, NDE procedures used during the period on the Zimmer site, and a list of all personnel indicating time periods on site involved in NDE activities. To date
,these records have not been made available to the National Board Audit Team.
3.5.6 In the opinion of the National Board Audit Team, ASME Section III, 1971 Edition, Summer 1973 Addenda requires survey and audit of NDE sub-contractors for qualification and retention of those records during the period of con-struction, and these records should be available for audit.
* ~ '~
3.6 Radiographic k' eld Identification. 3.6.1 The National Board Audit Team requested HJK's Quality Engineering to identify procedures that address the responsibility for flagging or marking to verify the correct identity of field welds to be radiographed.
- i Quality Engineering indicated to the Audit Team that no procedures exist. .
NA-4420 3.6.2 An "NDE Request Instruction" was reviewed by the National-NA-4430 Board Audit Team. The instruction vaguely addresses the - topic; however, it is an uncontrolled document which is not approved and distributed in accordance with HJK's QAP 8, Rev. 9. In the opinion of the National Board Audit Team, this does not meet the requirenents of ASME Section III, 1971 Edition, Summer 1973 Addenda. 3.6.3 Since HJK Quality Engineering has stated that no pro-cedure exists, the National Board Audit Team is concerned with the possibility that personnel who are not properly trained and qualified may have been identifying and ' marking welds, causing a potential loss of integrity of the radiographic weld identification. HJK should provide to the National Board Audit Team evidence that proper radiographic weld identification integrity has been maintained during the period of construction. l ATTACHMENT "D"
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Page 6 Mr. Donald M. Milan August 6, 1982
SUMMARY
r ' This St.pplement is a progress report of the National Board Audit Team's activities since the issuance of Interim Report No. 2 dated July 1, 1982. The National Board Audit Team will continue its audit and surveillance of prograes, their impicmentation, and the ASME construction at the Zincrer
. Nuclear Power Plant to assure conformance with the State of Ohio and ASME Code requirecents.
In addition, the National Board Audit Team will review all proposed resolu-tions of previously identified findings and the re-verification and confirmation programs to assure that proper corrective action is completed in accordance ! with the State of Ohio and ASME Code requirements. By a ccpy of this Supplement dated August 6, 1982 (to Interim Report No. 2), Cincinnati Cas and Electric Company is advised to respond in writing to each item contained herein within fifteen (15) working days from the date of the meeting scheduled for August 10, 1982 at the National Board of Boiler and Pressure Vessel Inspectors' office, Columbus, Ohio, or no later than August 31, 1982. A copy of the CG6E response should be sent to the National Board of Boiler and Pressure Vessel Inspectors. Respectfully submitted. - -
- h h mh Donald J. Mcdonald Director of Inspections , ,
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sv Charles W. Alliso Te3m Lea e f .
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Michael F. Sullivan Team Member , , obert P.
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t Team Member DJM/ CWA /MFS/RPH:jsb Attachments - cc: E. A. Borgmann, CG&E cc: Victor Stello, NRC W. A. Hedzik, HJK Janes C. Keppler, NRC J. W. Watkins, HJK J. Stretter, NRC William Dircks, NRC
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, THE NATIONAL BOARD OF BOILER AND PRESSURE VESSEL INSPECTOPS ATTENDANCE, SHEET EV1 V O INVESTIGATION b AUDIT O OTHER O COMPANY: _ .J. * -
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THE NATIONAL BOARD OF BOILER AND PRESSURE VESSEL INSP ATTENDANCE SHEET s REVIEW D INVESTIGATION O AUDIT O OTHER O COMPANY: (. h 8 ADDRESS: DATE: C PRINT PRINT NAME TITLE SIGNATURE ORGANIZATION o.1 s..L:r n.. on x.;
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INTER OFFl.CE MEMORANDUM -
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To V. A. Hed ik - c,y AT Moscow
- DATE July 14, 1982 J
, enou B. D. Varchol coms to J. a .s. :
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suanct FIVlEU AND APPROVA1. OF ZI."MER SITE PROCEDUP2S . Mr.follovs: as Sullivan ha,s recently expressed concerns in three areas of ..
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TCN's to quality 'proceddres were issued 4-2S-82 af ter the ASME S r.5..,... . d urvey ... ... . . gj. ,.2.
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-Rf signing the cever sheetThere is not docu=entary evidence .
that'QA .. has re ,-
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J - to the procedure. on procedures b 3. Special Process Procedures ~are not getting the appropriate qualit y review and approval and many verc being transferred to velding constructi without approval of the Quality Organination. , - on procedures In respense to the above concerns, I am offering the following sy current QA Program require =ents to the best of =y knowledge , - nopsis which outlines the In respense to concern #1: ! During the ASME Survey a concern was expressed by the Survey Te inspection procedures vould have to be referenced on inspam that TCN's issued 1 insure adequate paper traceability. ection docu=ents in order te decisien was made and agreed to by the Survey Team thatIn order to avoid confu TCN's would be removed from our manual and that TCN's to the Qualitthe g y Assurance Procedures r.anual vas, or to the Inspection Procedures vould no longer be used b y HJK. The
=ade th'at therefore, revised to remove all references to TCN's and a state =ent and specific i=ple enting procedure require =ents.imple=enting pro -
After the ASME survey, an administrative decision was =ade th issued to QAP-8. erenced.in Section IV or Section V procedures of the Zi=meratPro no TCS's vould be cedure Manual ref-allowed the use of TCN's to 21==er Project Procedures.This was don any TCN's which were approved by HJK prior to the It was ASME alsoSurvey decidedand thatw for final approval vould be issued after CC&E approval was re ere with CG&E TCN's thatapproval were inwas thisreceived. catagory at the time of the ASME S ceived. r There were five
. after CC&E u vey and they were issued This was done in accordance with 2.APM-2, Rev. O.
In order to procedurally change the TCN program issued with an effective date of 6-2-82 which, ZAPO-2, clearly Kev. I was prepared and their use on Section IV and Section V procedures restricted TCN's and prohibited TCN's have been issued to Section IV and Section Vbest To the of =y knowledge, no except procedu were being processed atfor those five TCN's which were issued after CC&E appro the tire of the survey. s received and ne 3 e issuance of these five TCN's did
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not violate the QA pr.ogram or the'i=plenenting procedures rince ZAPM-2 was not i changed natil .6-2-82 and all TCN's to SectYos IV and V vere published prior to 6-2-S2. Our QA Manual does not prohibit the use of TCN's with the exception of QA Manual Procedures, which require procedtfral changes.to the QA Manual to be re-issued as a revised QA Procedure per paragraph 3.2.5 of QAP-2. , In response to Concern'i2: - The current QA progran, as spelled out in QdP-2, QAP-8, and ZAPM-2, does not require QA to approve construction procedures"by signing the cover sheet of the procedure. The only require =ent th,at currently exists.i's that the QA Depa'rt=ent review all quality af fecting procedures 'as established on the review and approval matrix, described in ZAPM-2 (attached). This = atrix require.s all Zi=mer Project Manual Procedures.to be either appr,oved, concurr'ed, or reviewed by the Quality Assurance 4 l-
-,a organi:ation. Those proc,edures that do not require QA approval are reviewed by one or more cognirant QA individuals and a log of. this review is maintained by both
,. J!JK's QA Procedure Coordinator and the Construc'tiori Procedure Coor'd inator. *
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The HJK QA Depart =ent is therefora co= plying with the requirements of the QA Manual _ and of the implementing procedures.
- In respense ts Concern 03: *
- The prepau tion and control of Special Process Proced'ures is outlined in'the BJK QA Minual, QAP-10, Rev.10. - In accordance with QAP-10, Rev.10, a Special Process -
._ Procedure Manual is used for the issuance of Special Process Procedures and requires the approval of the Site QA Manager, the Project Manager, Welding Manager, Site Disciplf nc Quality Engineer, the Quality Engineering and Services Branch of the Corporate QA Division, and S&L prior to issue. Welding Inspection Procedures a'nd Velding Construction Procedures which are issued in Section V-E and III-E of the . . 21=cer Procedure Manual are approved, reviewed, and distributed in accordance with 2.APM-2.
To the best of =y knowledge, HJK is co=plyisg with the re' view and approval require-cents established by our current QA Manual. Since their appears to be some con . fusion in this area, I have prepared a PCRM to QAP-10 which clarifies the review and appreval process. If you concur with this PCRM, please sign the for= and I will have it processed in accordance with our procedure revision program.
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's ut n newono ncenin onTASnEET (SEE REVERSE SIOL F OH INSTRUCTION & RESPONSIBILITIES)
,N cErmiR NO. n ___
SYSTEM OR / ISO LINE COMPON ENT ._ hfl.h 4 %"TW'M4 DWG. NOWY ~ lMS-1'I A NO INS *915 A 1~2_ MK # 5f'L. N l AM To MK #M__G_) f-E*~I"8B W4 r' fR p FILLER MAT'L. REQUIREMENTS: ELECTRODE - B ARE SIZE 85 8:- HTW / LOT # J 157.'5 SIZE EB HT# / LOT # WELD PROCEDURE NO.$ rpm 1Agy.; PURGE REO.: 1.D. PU R G E' CFH. TORCH PURGE CFH MIN. PRE HEAT M *I' MAX. INTERPASS DT
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REWORK INSTRUCTIONS N OA Al @ WELD REPAIR SKETCH: R E O. STAMP DATE Hold Pts R EM AR KS IF ITEM IS A BASE MAT *L. REPAIR- ECO,RD LOCATION & EXTENT.
' SEQUENCE OF OPE R ATION C
kwl elded ean-surf per WCP-5 R. 0 ) ace-to-bu_ . MAmRO MINOR sKEiCaay
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)( i TPirea cleaned pec' HIP-27 R.1 y; m J
[ft J- g 4
- Check velders-QUA!:S O and filler material 5g N L[4p h'
Add reinfon.ei.n iii. fillet if required pc( '
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fSPPP. 3.1.28 R. 2 N 4 - g uler.d1rtnd reinforce- 1 A \ P a ncnt fillet if req. for / tU \ G , bearing per WCP-5 R. O [\ [ -
\ @Ecrea of reinforce ~
cent per WIP-27 R . 1%. o T
@ HT area of reinforce-tient per WIP-25 R. 0 .
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@ NOTEff Step ,4 or 5 are not req. H/A Block '
andJoye_.to_.n95t_ste 3. HECORD WELDER SYMBOL g e GAGS 3 "
@ REFERENCE ORIGINAL ME.8 FORM No. @
- NISO SGA/[RIC A.s. R E inw .r.
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g l APPROVALS ' _ AS q-ra-n ; f9 Fb e - -' <a* . CONS WEL/q Cass 412-0 A N G E N G R. ry . - ,- . WEL NDE 04 ENGR.
PATE 4-23-82
. ccats to J. Nolting FnOM ,R.
All Inspectors ). Davis Ar
- -- 9 Moscow. Ohio .-
sv0JEc7 . JoS NO. 7070 Please find attached Radiography R equest Instructions to be used in prepar a ti comply with the instructions as noted on of NDE Requests for NES. est- Instruc directed to your imediate supervi . sor. Any further questions should be Please RAD / nam cc: C. Hill l-
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W. Smith
- C. Melton ,
P. Norman R. LaFontaine t l r
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. .. S NDE REQUEST INSTRUCTIONS g
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, Block 1 List NDE number taken from Control Log.
List the time NDE was reequested of N.E.S. They would Block 2 , like this infor=ation to nonitor their response time. Block 3 List the location with the following minimum information. a) Building - Ex. Reactor Suppression Pool, SWPS Ironworker Fab Shop b) Approximate elevation c) Column reference or degree azimuth if in Primary Contain-ment - Ex. 10' s of R4, 8' w of R4 or Drywell azimuth 142*. Block 4 List the governing drawing and/or details. This may be a structural, mechanical, support, or piping isometric drawing. For piping weld maps (PSK or ISK), list current revision level. Block 5 List the component or item number being requested. This may
- be a beam number, a field weld number, or a base metal repair.
If base metal repair, list component number being repaired. Block 6 - Indicate which NDE method is being requested. Normally this will be either MT or UT on this form. Only one method per
.' request. 'T . Block 7 - List any pertinent remarks.
a) For base metal repairs, give specific location from fixed point to the area to be inspected. This will enable tech-nicians to limit. inspection to area requested. In addition, mark on the component with certified marker the area to be inspected. b) List the weld stage Ex. Repair excavation before welding, repair finsi, root, first intermediate. c) List the code required Ex. AWS, ASME,
. ANSI B31.1 (For Class D Piping only). -
d) List material thickness. Depending on the thickness, the NDE techniques and acceptance criteria may vary. e) If UT is being requested, list material type. This will affect which calibration block will be used. f) For UT for minimum wall verification, list nominal thickness and minimum thickness, if known. - g) For MT of are strike removals from piping, specify Yoke method. h) Structural only, list work package number. Block 8 Print or sign your name as neatly and distinctly as possible. List department name and phone number you can be reached at.
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. . 'E 1 r0s4*.*HD.CO.196 _
NCENO. O NDE REQUEST e TIME NDE RE QUIRED _ LOCATION OF NDE ARE A _ _ OWG. N O. - - SYSTEM OR CCMPONE NT ( TYPE OF NDE REQUIRED: PT MT RT UT OTHER REMARKS CIGNATURE DATE 6
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. . k RADIOGRAPHY REOUEST INSTRUCTIONS e
Block 1 Date requested. B1'ck o 2 NDE request number - to'be supplied by NDE group. ' Block 3- Weld or item number. . For structural lis; uork package and weld number.
~
Block 4 Repair Nedber - List number shown on upper right hand corner. of KEl-A if weld is not a repair weld, N/A. . Block 5 List veld stage - Ex. root, repair excavation, final. Block 6 List line numbey.4r,b g--aumber -
~, s.
as recorded on KE1 or KEl-A. Block 7 List PSK and current revisj'on for piping. For structural, list structur 1 drawingeumber. Block 8 List pipe / component size. Block 9 List material thickness. If root or repair excavation, list approximate thickness of area of interest. Block 10 . List veld procedure shown on KE1 or KEl-A. This vill help the
- NDE technician evaluate indications and complete inspection -----
reports properly. Block 11 List welder /s symbols. Block 12 List location using building reference and column or azimuth marking reference - Ex. Reactor Drywell Azi 142* or Reactor Building 10' s of R4, 8' w of R4. Block 13 List elevation of weld. If 'ocation l and elevation of weld at-time of request is different from. location and elevation at - time of installation (pre-fab component), then list location of installation in Remarks column. This will help technician locate weld if it has to be moved before X-ray is performed. Block 14 List any pertinent remarks. This would include but not be ' limited to code requirement (ASME, AWS, ANSI B31.1), location variation (see note for block 13), name of requesting inspector, i and department ncme. List phone number you can be reached at. In addition, you are responsible to properly mark with blue flagging and/or certified marker the veld or area to be x-rayed. This should be done prior , to requesting R.T. All appropriate documents shall be* completed and submitted with R.T. request. You are remided that welds you want to have x! rayed that day should be submitted by 2:30 that day. S
- e:ti::t;
- _ . RAJIOGRAPHY REQUEST
.s OJ.~ NDE , e
- f 9
e6 D # __ REPAIR E#_ WELD STAGE
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S,ze @ LOCATION TH IC K N E SS._ _ WELD PRO ELEVATION WE LD E R/S __ 3SITION REMARKS e
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/$ 5 7
o INSPECTION CGgE/ CATALYTIC, INC. (CI)
~
AUGUST 10 - SEPTEMBER 17, 1982 r . ABEAS OF CONCERN' i DA PROGRAM
, QA/ TRAINING
. DESIGN CONTROL
. PROCEDURES
. DOCUMENT CONTROL
, , INSPECTIONS
. NONCONFORMING CONDITIONS
. CORRECTIVE ACTI.0N 7 RECORDS
- 1. .
. AUDITS i u O t.; % cG { b - pct 5
. QA PROGRAM / TRAINING
~
FINDINGS
' LACK 0F ADEQUATE WRITTEN POLICIES, PROCEDURES, INSTRUCTIONS WITH MAJOR ORGANIZATIONS / FUNCTIONS DEFINED INCLUDING
. RESPONSIBILITIES AND AUTHORITIES ORGANIZATIONAL CHARTS AND FUNCTIONAL DESCRIPTIONS
, INTERFACES DEFINED LACK OF ADEQUATE TRAINING
. GENERAL INDOCTRINATION TRAINING 0A/0C PROCEDURAL AND TECHNICAL TRAINING
~
PREVIOUS FINDINGS BY NRC (INSPECTION REPORTS 1
. 80-16 QA/0C ORGANIZATION CHANGES WITHOUT UPDATE OF FSAR, QAM, AND PROCEDURES.
. _80-25 REACTOR CONTROLS, INC., QA MANUAL
.- 81-13 CG&E QA PROGRAM BREAKDOWN
.'- 82-01 CG&E QAD PERSONNEL RESPONSIBILITIES, AUTHORITIES, AND PERSONNEL CERTIFICATIONS i
. 82-06 HJK ENGINEERING ASSISTANTS PERFORMING WELDING ENGINEER FUNCTIONS c.
2
DES 1GN CORLRD,L ,
~
FINDINGS CORPORATE DESIGN CONTROLS
. INSUFFICIENT DESIGN REQUIREMENTS SPECIFIED
. LACK OF DESIGN CONSIDERATIONS
, FIELD PROCEDURES OUTSIDE S&L DESIGN CRITERIA SITE DESIGN CONTROLS
. ALTERATION OF GENERIC DESIGN REQUIREMENTS BY SITE RESIDENT ENGINEER
, CHANGES TO BOLT SPACING AND STRUCTURAL BOLTING BY SITE RESIDENT ENGINEER ,
PREVIOUS FINDINGS BY NRC (INSPECTION REPORTS) j . 80-05 DESIGN CONTROL ASSOCIATED WITH SMALL BORE PIPING SUSPENSION SYSTEM 7 80-19 DRAWINGS NOT REFLECTED IN THE FIELD
. 80-22 DDC AND SPECIFICATION CONTROLS
. 80-25 S&L SPECIFICATION INADEQUACIES i
. 81-07 INADEQUATE DESIGN REVIEW BY S&L AND CG8E GED
. 81-13 OVERALL DESIGN CONTROL
. 81-15 CG8E NPD DESIGN CH.dGE CONTROL PROGRAM 3
r PROCEDURES ' F'INDINGS - PROCEDURE ADEQUACY v! UNCLEAR PROCEDURES CONTROLLING RCCs AND DDCs
./f INADEQUATE CONTROL OF WORK ASSIGNMENT y v' INADEQUATE CONTROL OF WORK CLASSIFICATIONS t PROCEDURE IMPLEMENTATION FAILURE TO ISSUE A DDC WHEN REQUIRED FAILURE TO ISSUE A WORK REQUEST (WR)
PREVIOUS FINDINGS BY NRC (INSPECTION REPORTS)
. 80-16 HANGER QC INSPECTION PROCEDURE DEFICIENT
, 80-25 INCOMPLETE PROCEDURES FOR CRD SUSPENSION SYSTEM, VOIDING OF NRs BY QAM
, 81-13 VOIDING OF NRs
, 81-17 INADEQUATE PROCEDURE REVIEW (11 MONTHS)
; 82-01 INADEQUATE PROCEDURES -
~
. 82-06 FAILURE TO FULLY IMPLEMENT CALIBRATIOK PROCEDURE 4
1
DOCUMENT CONTROL
- FINDINGS v/ FAILURE TO ENSURE LATEST DRAWINGS AND DDCs IN CWPs
.v FAILURE ALLURE TO CONTROLTO CONTROL DDCs AND REVISIONS ISSUANCE
'h "'#l
/[""
. FAILURE TO ESTABLISH MEASURES TO EVALUATE CHANGES RELATED 10 0NG0 LNG AND COMPLETED WORK 1
PREVIOUS FINDINGS BY NRC (INSPECTION REPORTS)
, 80-05 CONTROL AND APPROVAL OF DDCs
. 81-13 CONTROL OF DDCs AND INSPECTIONS-4 W
L - 5
l.
.lRSPECTION ,
pINDINGS -
. -lNADEQUATE QC INSPECTION PROGRAM
. -LACK OF INPROCESS INSPECTION PROGRAM PREVIOUS FINDINGS BY NRC (INSPECTION REPORTS)
. 80-15 INADEQUATE INSPECTION OF STRUCTURAL DESIGN CHANGES
. 80-25 FAILURE TO INSPECT CONCRETE ANCHOR BOLTS AND SUSPENSION SYSTEM
. 81-13 LACK OF INPROCESS INSPECTIONS 19
- I
~
6
RQRCONFORMING CONDITIONS
~
FINDINGS -
. INADEQUATE NCR AND DDC NOT ISSUED
, MAPPING OF CORE DRILL H0LES - NO NR ISSUED
, USE OF~DDC IN LIEU OF NCR PREVIOUS FINDINGS BY NRC (INSPECTION REPORTS) 1
. 80-05 FAILURE TO ISSUE NRs
. 80-09 INADEQUATE HANDLING OF NONCONFORMING ITEMS
. 80-25 DDCs IN LIEU OF NRs
. 81-13 PROCESSING OF NRs
. 81-17 DDCs ISSUED IN LIEU OF NRs
. 81-18 FAILURE TO IDENTIFY NONCONFORMANCES 1
l l
~
l L - l 7
CORRECTIVE ACTIONS . FINDINGS INADEQUATE CORRECTIVE ACTIONS REPETITIVE ITEMS IN ALL AREAS INCLUDING CORRECTIVE ACTIONS
. PROCEDURES REVIEWED BY UNQUALIFIED PERSON UNTIMELY CORRECTIVE ACTION FAILURE TO ENSURE AUDIT FINDING PROMPTLY CORRECTED
. FAILURE TO CORRECT THE DEFICIENCY REGARDING WORK-CLASSIFICATION PREVIOUS FINDINGS BY NRC (INSPECTION REPORTS)
. 80-14 INADEQUATE RESPONSE TO AUDIT FINDINGS AND INADEQUATE '
CORRECTIVE ACTION REGARDING WELD R0D CONTROL
. 80-19 INADEQUATE CORRECTIVE ACTIONS - WELD ROD CONTROL (11 CASES IN 5 YEARS)
. .80-25 INEFFECTIVE CORRECTIVE ACTIONS
; 80-26 INADEQUATE CORRECTIVE ACTIONS ASSOCIATED WITH AN AUDIT FINDING l
. 81-13 INADEQUATE CORRECTIVE ACTION i
. 81-18 REPEATED FAILURE TO TAKE CORRECTIVE ACTIONS
. 82-05 INADEQUATE CORRECTIVE ACTION TIMELINESS, PROCEDURE ADHERENCE, UNDERSTANDING, AND OBJECTIVE EVIDENCE 8
~
RECORDS , FINDINGS -
. LACK OF SURVEILLANCE ACTIVITY DOCUMENTATION
. FAILURE TO PROVIDE / RECORD INSPECTION PROCEDURE / ACCEPTANCE CRITERIA PREVIOUS FINDINGS BY NRC (INSPECTION REPORTS)
. 81-13 INADEQUATE RECORDS e
M Sua e 9
- a -
J _aL. 4. w. w . - .._sy A,.- __ . 4_ l. _d__.L Y e AUDITS ~
~
=~
FINDINGS Y
.'iUDITS
. . FAILURE TO ADEQUATELY AUDIT ACTIVITIES AUDIT FOLLOWUP
. FAILURE TO REQUIRE-FOLLOWUPS OF AUDIT CONCERNS AUDIT EFFECTIVENESS
. PROVISION OF DETAILED AUDIT CHECKLISTS TO AUDITED GROUP i PRIOR TO THE AUDIT i -
PREVIOUS FINDINGS BY NRC (INSPECTION REPORTS)
. 80-25 INADEQUATE AUDIT OF REACTOR CONTROLS, INC.
l
; 81-13 INADEQUATE AUDITS L -
i :
- 10
SPECIFIC REPETITIVE PROGRAM DEFICIENCIES DA PROGRAM 80-25, PARAGRAPH 1.s - SIMILAR FINDINGS DISCUSSED IN THE REPORT SITE DESIGN 80-05, PARAGRAPHS 4.s(1) AND 4.B(2) - SAME CONTROL FINDING DISCUSSED IN THE REPORT PROCEDURES 80-16, PARAGRAPHS 3 AND 5; 80-22, PARAGRAPH 2; 80-25, PARAGRAPHS 1.C AND 3.D; AND 81-17, PARAGRAPHS 1 AND 3E .SIMILAR FINDINGS DISCUSSED IN THE REPOR INSPECTION 80-25, PARAGRAPH 1.D - SIMILAR FINDINGS DISCUSSED IN THE REPORT AUDIT 80-25, PARAGRAPH 2 - SAME FINDINGS WERE DISCUSSED IN THE REPORT NONCONFORMANCES 80-05, PARAGRAPH 4.A (2); 80-25, PARAGRAPH 4.s; AND 81-17, PARAGRAPH 2.c .SAME FINDINGS WERE DISCUSSE IN THE REPORTS. USE OF DDC IN LIEU OF NRs IS A VIOLATION OF THE CG8E SWO-80-12 ll
SPECIFlf MANAGEMENT AND STAFF MEETINGS PIPING SUSPENSION SYSTEM PROBLEMS
. 03/07/80 REGION III, REPORT 80-05, PARAGRAPH 6, CONCERNING HANGERS AND RESTRAINTS, QC INSPECTIONS, AND OTHER NEEDED IMPROVEMENTS.
. 08/15/80 EXIT INTERVIEW, REPORT 80-16, REGARDING THE PIPE SUPPORT SYSTEM PROBLEMS.
. 11/20/80 SALP, REPORT 80-27, PARAGRAPH 3C, REGARDING PlPE SUSPENSION SYSTEM PROBLEMS.
. 01/28/81 REGION Ill ENFORCEMENT CONFERENCE, REPORT 81-04, RELATED TO INSPECTION FINDINGS ASSOCIATED TO REACTOR CONTROLS, INC. DESIGN AND INSTALLATION OF -
THE CRD SYSTEM INCLUDING THE UPGRADE OF THE CG8E QA PROGRAMS.
. 03/31/81 SITE STAFF DISCUSSION, REPORT 81-17, PARAGRAPH 3, REGARDING VOIDING OF NRs: LACK OF CG8E AUDITS OF REACTOR CONTROLS, INC: 100% INSIALLATION INSPECTIONOFHANGERWELDING,ANDINADIQUATE PROCEDURE REVIEW.
12
DTHER RELATED MANAGEMENT AND STAFF MEETINGS
> 08/19/81 REGION III, REPORT 81-23, REGARDING THE
- PLANS TO UTILIZE CATALYTIC, INC., TO PERFORM WORK AT ZIMMER
. 02/12 8 19/82 SITE AND TELEPHONE DISCUSSIONS, REPORT 82-03, PARAGRAPH 3,.REGARDING PERSONNEL QUAllFICATIONS AND PROCEDURE ADEQUACY I
i 9 I. i 13
. EAILURE TO MEET-PREVIOUS COMMITMENTS kRC-Rll! DECEMBER 24, 1980 IAL -
. ITEM 3 "NOT ALLOW ANY FURTHER WORK BY RCI UNTIL NRC HAS RECEIVED YOUR~ CORRECTIVE ACTIONS AND DETERMINED THAT SUCH ACTIONS ARE SATISFACTORILY COMPLETED."
CG&E SWD 80-14, REVISION 1, DATED DECEMBER 31, 1980
. " EFFECTIVE IMMEDIATELY, ALL WORK ON MATERIALS, EQUIPMENT OR SUPPORTS FURNISHED OR INSTALLED BY RCI...SHALL BE DISCONTINUED.
THIS SWO WILL BE RESCINDED FOLLOWING ACCEPTANCE OF RCI QA . PROGRAM AND PROCEDURES, AND SUCCESSFUL COMPLETION OF AN AUDIT TO EVALUATE DA PROGRAM IMPLEMENTATION." CG&E/CI PROGRAM INADEQUACIES -
. NUMEROUS AREAS OF CONCERN
. FAILURE TO ADEQUATELY AUDIT CI
. INEFFECTIVENESS OF CORRECTIVE ACTION i
14
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