ML20138K397
| ML20138K397 | |
| Person / Time | |
|---|---|
| Site: | Wolf Creek  |
| Issue date: | 08/25/1983 |
| From: | DANIEL INTERNATIONAL CORP. (SUBS. OF FLUOR CORP.) |
| To: | |
| Shared Package | |
| ML20138G131 | List:
|
| References | |
| FOIA-84-291 NUDOCS 8512180427 | |
| Download: ML20138K397 (36) | |
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weld was a pipe to elbow fit. The actual condition of field weld FW512 was a pipe-to-pipe fit, which indicated to me that the radiograph for field i I weld FW512 was in fact a radiograph of a different w Id. GC @l' I made a request to the Supervisor F Engm.. ens; for D!, Gary JONES, that a new radiograph be taken of the weld. Gary JONES denied my request. I then made the same request to my senior supervisor, Ed SHEVLIN. This request was also denied. Mr. SHEVLIN told me that I had fulfilled my duty by reporting the condition and preparing an NCR. I later learned that the i ' NCR No. ISN14769PW that I had I prepared on field weld no. FW512 had been dispositioned "use as is," with a Bechtel concurrence. I feel the reason l
- that this weld was not repaired was that DI was on a tight time schedule to I complete the piping system, and rather than repair the weld or perform another radiograph, a decision was made to cover up this problem in order to meet production schedules. Even though I know of no witnesses. 3 meeting l was supposed to have occurred between Keith HOLLINGSWORTH, DI Project Weld Engineer, Jack MAY, DI Engineer, Ron McCRANNEY, DI Project Quality Inspection Manager, and Ed SHEVLIN, DI Senior Quality Supervisor, that '
resulted in a decision to cover up the discrepancies of field weld no. 512.
#* M fy concern about the problem of field weld no. FW512 I lo//IdAd 7md -
pliotographs of the weld to be taken by the site photographer, doch STEELE. I had made arrangements for these photographs to be made available upon development to the NRC. My second concern involving Wolf Creek stems from an instance where I felt I was intimidated by DI's Senior Quality Supervisor, Ed SHEVLIN. On November 30, 1983, Ed SHEVLIN called me and my DI Lead, Howard SIGREST, into his office. Ed SHEVLIN told me that I would cooperate with construction and that he would not have anyone work with him who would not cooperate. At.this time, I felt I was intimidated by Ed SHEVLIN. His insistence upon my cooperation was a determining factor for my resignation l on December 23, 1983. ! I felt after this intimidating conversation by such I a high-ranking DI official that I could not effectively inspect or perform - my inspection duties knowing that I was supposed to cooperate with construction. I felt that this intimidation would keep me from properly p performing my duties as a quality control inspector, and it is for this Lead H r SR c H a l SIGREST agreed wit' m at tW M w 7--4 t ocu t, in some type of ' l } written fom, that this meeting had occurred. . IQ My third concern involvir.g Wolf Creek deals with the technical issue of the
% quenching of stainless steel welds with the use of water. I at aware of l
three welds of which I knew that water was used to cool the stainless steel welds. h These welds are (1) IM03-BB0700ZECR-17RW308,
\ (2) IM03-BG23QECR-27RW315, and (3) IM03-BG210ECR-16WO12A. I am attaching three documents Attachment to this statenent which supports and clarifies my concerns.
is an inter-office memorandum dated May 26, 1983, Attachment is an inter-office memorandum dated June 9,1983, and Attachment is a memorandum dated July 21, 1983. All three of these documents concern the quenching of stainless steel welds. This was a standard practice and does not violate code or procedure criteria, however, no action was.ever taken af ter a request was made for procedural changes.
g'- ' Tne request for a procedural change was done by a DI Quality Engineer, David MAULDEN who expressed concerns over the use of using water to quench stainless steel welds. David MAULDEN requested that additional justification be put into the procedures for the continuing use of water as a method of quenching stainless steel welds. My concern is that David MAULDEN's request for procedural changes has .never been properly addressed. My fourth concern involving Wolf Creek involves potential quality problems that should have been directed to quality engineering for a response, but - were short circuited by DI Supervisor, Richard BOOTH. Richard BOOTH decided that as supervisor he was qualified as a quality engineer to answer potential quality control problems. As a result of Richard BOOTH's decision tc short circuit these written requests, potential quality control i problems were never addressed by a qualified quality engineer. I am ' attaching six three-part memorandums. Attachment Nos. (4-9), which will clarify my concern. My fifth concern involving Wolf Creek concerns DI Supervisor, Richard - BOOTH. During the course of my duties as quality control inspector, I wrote a surveillance report as required by APVI14 that was closed-out by , Richard BOOTH,-with a message "See attached memo." This type of answer violates surveillance procedure. IamenclosingAttachment(10),whichis ! a memorandum from myself to Quality Engineering, and Attachment (11), which pp is a Quality Surveillance Report dated 5/83. I am also enclosing ' Attachment (12, which is a Quality Surveillance Report dated 8/8/83. These documents should help clarify my concerns of this issue. My sixth concern involving Wolf Creek relates to an incident in which vendor spools were cut in half prior to inspections by Quality Control. The traceability of metals was lost because these spools were cut in half prior to inspection. I am enclosing Attachment (13), which is a Quality . Surveillance Report dated November 11, 1983, to help clarify this technical issue. My seventh concern involving Wolf Creek is in the way that changes to the hDE tags on site were processed. I feel that the way it is currently
@ handled violates AP-VI-05, which is a procedure which involves NDE .
N subcontractors. I am enclosing Attachment (14), which is a report entitle
? Processing of NDE Reports. This attachment should clarify my technical concerns of this issue.
- My eighth concern involving Wolf Creek is a problem with generic NCR reports.
I feel that the current procedure AP-VI-02 does not contain any ; requirements that would properly document generic NCR's I am enclosing Attachment (IS), which is a six-page document titled _ Generic References, which should help clarify this technical issue. My ninth concern involving Wolf Creek relates to the inproper documentation involving the heat number on a piece of traceable metal to be welded to a ! valve. I do not feel that Supervisor Richard BOOTH adequately handled this documentation. I am enclosin , more detail to this concern. g Attachment (16), my notes, which will give r I
My tenth concern involving Wolf Creek involves the use of small hanger parts (load pins and conical washers). I feel that these parts were not tagged in accordance with procedural requirements. I am enclosing Attachment (17),aQualitySurveillanceReportNo.SR-601-N,and Attachment (18), which are my notes concerning the issue, as documentation that should clarify this technical issue. My eleventh concern involving Wolf Creek deals with Nonconformance Report ho ISN12865P. This NCR was voided because it was felt that this - inspection was beyond the normal scope of a quality inspector activities. I am enclosing Attachment (19), which is Nonconfonr.ance Report No. ISN12865P. The details reported in the NCR should clarify my concern on
' the improper voiding of nonconforr.ance reports. I am also enclosing Attachment (21), which is an inter-office memorandun dated August 20, 1983.
My twelfth concern involving Wolf Creek deals with the problem of using correcting ribbon on a typewriter to make corrections of Noncomformance Reports. I feel this does not meet procedure, and I am enclosing
- i i Attachment (22), a memorandum dated 7-14-83, to address these concerns.
My thirteenth concern involving Wolf Creek deals with the improper use of Surveillance Reports. I am enclosing Attachment (23), which are my notes
- on this generic problem. These notes should help verify my concerns i
' involving improper use of Surveillance Reports. I am also enclosing Attachment (24), which is a Quality Surveillance Report dated 12/15/83, which has not been properly handled. I am also enclosing Attachment (25), which is a Quality Surveillance Report that has not been properly handled. All these documents should help clarify y technical concerns on the improper use of Quality Surveillance Reports. I have read the foregoing statement consisting of $ typed pages. I have made and initialed any necessary corrections and have signed my name in ink , in the margin of each page. I swear that the foregoing statement is true and correct. Signed on k .. m /c /9F V at N/come ! ) # M 8/Med # l SIGNATURE: _ Paul B. HALE i Subscribed and sworn to before me this /O day of , 193,at W 00, , y h. 1H, - IliVESTIGATOR:
.endel W E. FROST WITNESS: htd
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%-k/,Yh,h li. T E R O F F i C E CO M M U NIC A TlON e .- . .. . m in. Distribution DATE- Atrpast 20, 1983 Fnov. J.J. Grabusky PAN: 575
$UBJE CT CAR-25 '
'In response to stop work action no FA:-001, we will cease to accept bolting material under Corrective Action Feport 1-G-0025 for all large bore pipe supports, and for all snall bore veriable springs, -
oonstant springs, rigid struts, and nechanical shock arrestors. All other small bore MS-25 items and all "U" bolts can be inspected and accepted to Revision 5 of the CAR under the following restricticn. ,
'Ihe QIC Supplemental Sheet shall be used for both previously accepted insh11ations, and insu11ations mde not Quality accepted or currently being made.
The potential of replacing sterial of insufficient or incorrect material specification and the possibility of accepting an erroneous material does not exist since all MS-25 bolting material (as quantified with exceptions abcree) is specifici as SA307GrB (or A307GrA as allowed by Code case 1644). In consideration of the above, these items are deerned acceptable and are execpt frcun the stop work, all previous inspections to the date of the stop work concerning these MS-25 items are acceptable, and no reinspectio'n will be required.
'Ihe CAR will be rewritten specifically a:kiressing the concerns of the stop work and will provide the raterial reqairements as well as the allowable identification markings. In addition, the scope will be **
expar&d to incitdo all available inforation for both catalogue ittr.s and subcogenents not specifically identified as a vendor part
. . _ nt:ter. -
'Ihis revision to the CAR (Rev. 6) will be inplemented as a retrofit ruinspection for all supports (other than the MS-25 ite z c>. cept fran the stop work as stated herein) previously accepted to Favision 1 -
throtrih 4. Favision 5 will not b3 affected in so far as the secpe is li:.ited by this respo.sa. y, l s N
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* ,J.J. Grabusky ,
FipingN21 ding P.ar.ager JJG/ID/IC/Is cc J. Cbok D. Pauldin J. Flet.cher L. Eastar#.od J. W rren A. Early C. MKonald L. Coricy J. Grill hgNtBIYk
l CFi% SSc". LI) A stau rican sxnew,Jis.s<'v s.r:nns er rin. nn,9 s ,, .,ew ez,. p c 4A m gratuero in Aco u x:E nie rx mc Lo e, c,um a- m. g ,, ,, 4:
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'~r.e fol'.ov'n; is a list cf the questi:nr ssked by Qus'.ity Inspection du-in; I
the '* raining classes fer Q F-Y11-20s, Eev. S and their respective ans.ers frc: Quality Engineering
- 1. Q: Seetton 1 Ite= 5B.1 What are the marking requirements for the second strut of a two strut support, if the support was received i
with culy one Code Data Tag on one of the items? A: } The second Mark numberstrut must have identifying either the ite=. a serial ftTHER nu=ber OfJ STAMPLA or hanter THL ITCIE OR OtJ B T/7C liTTECHED ' il, THE ITEfn. l 2. Q: Section 1 Item 7 states: Surfaces that shall not be painted-verify to note B. Note B states: No paint shall be on any threaded surface, bushing, Code Data Tag or sliding surface. j . a. Does this note (paint on sliding surfaces) apply to t j PG1hS, PG15S, P016S, PG20S and pipe saddles? ,
- b. Can we accept a rod hanger if the rod is 6' long and *
! it has sone ye. int on the threads 3' from the connection? l At a. Ne--this note does not apply to the items stated above, it ** applies to supports which utilize Teflon plates, Lutrite j plates or an alterr.ste desitned to minimiee-. friction between the slidir.E surfaces. ' N. ,
- b. Yer- you can accept a su;;srt if e paint an the,ted vill '
i not bind the nut en the ,hresda per RCI 1-0$0',P (150 00ff OPM 7ry 3. Nn HM SUCh* A5 LLt2L Ri it]r ' RCrxt% t. SUS aII 6 - U.*tJE. Q: Se:tien 1 Ite 10 k* hen veri ^/ing a :!al instru:::cr. sheets, : 2at ' an NOF. te eleset tefere ve est. :i;n eff thi: s e: . :n 2 : gnifyi::t all instru::!cr.'.' cr. the ll0F. h:.vs :e=n fen:.ed ir:: Jit.g ihe "acticn : ;rever.: re:rren:t** ! A: You sy sig the C:0 ;.rt:r :: the :;r tetr.; e : e: a: ;f e e s i gnat.2, in the tic:P. is ' have beer. scherei'to. *.o veri.^/ thst the it.ztru:ti:r.: in ths it : Tr
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1;TLCEEE.NT ll f, J_ - d" Q,k/,Dh IN T E R.O F FIC E C O M M U N I C A T 10 N To-29t@- Ron M:Craney/Lacnard Jchnson DATE: October 05, 1953 F R O t/ Doug Barone/ Tor. Dobbins - suBncT: Shi==ing/SGN-1 This corresRt3ence is being generated in order to provide clarification Js as to the intent' of MS-25, SGN-1, Note 7. The subject note addresses
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( the utili:ation of cepper or brass shi= caterial when copper piping . syGis'are encountered du-ing SGN-1 installation applications. This criteria was established in order to cocpensate for excessive clearance
' inherent to SGN-1/ copper pipe installations as a result of sunller .
..fi outside disseters when co= pared to standard nominal pipe diameters.
-Mk .' ; ,, , It is not the intention of this requirement to ' provide for a means of *
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preventing possible contamination resulting from bi-metallic cross con-
","' tact. An approved alternate to this method of clearance resolution is delineated in Revision 11 of WP-VII-208 which states in Appendix XI:
4 "Smil SGN-1 asse=blies may be used on copper tube as long as proper fit-up and insulation thickness can be maintained. . . ." One of the purposes of this provision is to . allow for substitutions of smaller
- size SGN-1 supports, specifically, for alleviation of shim installation
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to compensate for excessive clearnace. This prescribed alternative has k been approved by Bechtel Engineering via RCI #1-0516-P and is considered * , t- acceptable for site utilization. , . f/ *.e -
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/ SUBJE CT : Oversized Fillet Kelds The most_ critical fa:ter when determining acceptability of weld size is to verifyZthat the minimum specified si:e is met or exceeded.
There are no Project requirements existing which define maximum allowable weld size. As long as design requirements are met and no visible distortion of either member is present, the weld should be considered acceptable when verifing size. , _ As an accepted industry standard, use two (2) times the design size. Anything greater than this should key the Inspector tc pay closer atter.tior. to evidence of ciistortion. If excessive distortion is suspected, contact the responsibl'e Engineer to perform an evaluation. Two (2) ti:.es the design size is not accept / reject criteria, only a guideline as described above.
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. TO Ron McCraney DATE June 19, 1982 FROM: David Mauldin PRE - 135 SU B JE CT :
Documentation of Special Scope Systems Weld Buttering . This memo is written to clarify the documentation requirements for weld buttering on Category II/I, D' Augmented. Fire Protection, and non-seismic Category I applications. Since the redefinition of Special Scope requirements in early June, 1982, Traveler documentation has be revised to use the Special Scope Weld Record rather than the Weld Control Record (F101). Welding inspection by Quality is required only for final visual on welds, , therefore, no requirement exists for Construction to document weld buttering, [- ~u or for Quality to verify the buttering process. hw , w D'av bu n
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CDM;rek . xc Bill Friedrich - Erbie Flynt *
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g41;WJ% aEE M iun a.o r r ic s co u u u nic u ig -f W TO I. B. James DATt October 21, 1980 rROM: B. A. Seabury PME #345 SJBJECT: HVAC Hanger to Square Embed Sleeves Drawing C-0017 and C-0019 show two (2) details of square embed sleeves. One Detail (Detail 3 on C-0017) is Non-0, the other (Detail 3 on C-0019) is "Q". The way the details are fabric ^ted are in such a way that, when an HVAC Hanger welds to the outside edge of the sleeve, a crack exists where the angles meet; thus producing a leak during operation. Bechtel states that Spec. H-618.3, Para. 5.2.1, and M-635.3, Para. 5.2.2 allows us to make a seal weld at the point of the leak; i.e. , the cracks. Engineering requests thaJ on "Q" embed sleeves, QC check the gap, fitup, preheat, and do a final inspection of the seal welds on the sleeve. All work will be documented on a Hiscellaneous Structural Steel Card. Weld Procedure will be N-1-1-A-8, and weld size will be in an "as-is" condition after grinding flush. Your cooperation is greatly appreciated in this matter. k w. Irian A. Seabury Project Hechanical Engine BAS /dir~ cc: TT Annas _ blBi1'
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, , . _ 1 INTER. OFFICE COMMU NIC A TION r -36,ses..sni I
TO: To:n Ecynolds D AT E : February 23, 1982 F R O L' : Oavid Mauldin PQE - 065
SUBJECT:
Separation between cembers of NT Supports and the subsequent additional fillet veld size requirement. Eecently we encountered a situation whereby the integrity of a previously accepted NT support fillet weld was in question because of a . separation between two wide flange members. -
, Governing drawings require a i inch fillet weld on the web and inside flanges of the vertical member to the outside flange of the horizontal member. (See attachment). Upon reinspection of this veld, a gap was noted at point A of 1/8 inch, which according to the assigned weld pro-cedure (N-1-1-A-6A), should have increased the fillet size to 3/8 inch.
The weld as applied is i inch. , Obviously, additional fillet size is required, but as previously stated, this veld was visually inspected and accepted in 1980, and per ~~ the definition of CWP-504, falls into the ' category of a completed weld. - However, Ch7-504 allows the. addition of filler retal to a cceplete:1 weld only af ter the elimination of a subsurface defect. The above situation 4 does not f all into this or any defined weld category of CWP-504. In an atter.pt to settle this matter as expeditiously as pessible and with the least a:.ount of pa;erwork, Bill Friedrich, Jim Madri; ar.d I reached the agreement that this and future situations of this nature could 1e handle.' u fe!!cws:
- 1. Le eu .cn: tuc d: sac;2:.c; c n .:, s=*.e2112 . c : vpert.
- 2. Cer.erate a supple: ental held Contrbl Eccord in accordance
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- 3. Additional welding te be performed, inspected and docu.ented per requirements of the original and supplemental WOR.
This will identify the discrepancy and will take pcsitive and documented steps to correct the discrepancy, and will avoid the use of a deficiency report. . I would recommend that CWP-504 be revised as soon as is practical to identify this type occurrance and the above solution.to the proble=.
, - Your assistance in this c.atter is greatly appreciated.
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DATE: 1-10-84 r I, Paul B. HALE, hereby make the 9110 wing voluntary statement to Wendel E. FROST and Brooks H. GRIFFIN, wlr hive identified themselves to me as Investigators with the U.S. Nur. Mar Regulatory Commission. I make this statement f reely with no tnrear , or promises of reward having been made to me. I was previously_ employed by Dar f el Internation Corporation (DI) as a Quality Cor. trol Inspector at the Wolf Creek Nuclear Power Station, Burlingtcr, Kansas. I held that ;.osition for approximately 20 months and left DJ's employment on December 23, 1983. My first concern involving Wolf Creek stems from an incident that occurred to me in December 1983. I was called to do a cleanliness inspection, both internal and external, in the Pressurizer Room. Upon looking inside a horizontal run of pipe, a visual defect was noted. The piping in question is ID loop piping that comes out of the top of the pressurizer and is safety-related pipe. The weld with the defect that I am referring to is Field Weld No. FW512, reference Drawing No. IM13-BB040. The visual defect that was noted in the weld was excessive penetration of unconsumed filler, this is commonly referred to as a melt-through or a burn-through. This defect can be observed visually as unmelted portions of filler wire extrude from the weld and can be seen visually. Upon viewing this discrepancy, I asked the pipe fitter to call the DI Foreman, Robert ATKINSON, and the DI Welding Superintendent, Bruce HARDEN, to the Pressurizer Room. Bruce HARDEN related to me that a meeting had transpired earlier that day between himself and DI Project Welding Engineer, Kieth HOLLINGSWORTH. The results of this meeting were that even though both men knew that the weld did not meet acceptable standards and approved procedures on the site, no repair j would Jualitybe done on the weld because an acceptable radiograph was on file with., Control. I then asked for the DI Weld Engineer, Jack MAY, and his % v assistant, Gerald DOLNEY, to be present. Both men were sumoned to the Pressurizer Room at this time. All the above mentioned personnel then looked inside the pipe and agreed that the weld was not acceptable. I then
%. asked Jack MAY to issue weld repair instructions. ' Again Mr. MAY said that ,; he couldn't because the weld had an acceptable radiograph on file with the in A Quality Control Department. He told me that he believed we had a possible 5055E reportable violation "on our hands." I told Jact MAY not to be using' those words so loosely at the time. Gerald DOLNEY (supra) expressed his concern that he wanted to talk to upper management about the problem; however, I suggested to Jack MAY that the proper thing to do was to write an NCR.
I then requested verbally from Jack MAY a reshot of the radiograph of field weld no. FW512. Jack MAY again refused the request, basing his decision on the fact that an acceptable radiograph was on file. At a later time, I was unable to take a look at the radiograph that was supposed to have been for field weld 512. The Radiograph Report Number was PBTRT6813. This radiograph indicated that the joint configuration of the bkO5T
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