IR 05000329/1977008
| ML19326D371 | |
| Person / Time | |
|---|---|
| Site: | Midland |
| Issue date: | 08/24/1977 |
| From: | Hayes D, Vandel T NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML19326D370 | List: |
| References | |
| 50-329-77-08, 50-329-77-8, 50-330-77-11, NUDOCS 8006090787 | |
| Download: ML19326D371 (8) | |
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/~'N U.S. NUCLEAR REGUI.ATORY COMMISSION
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.V 0FFICE OF INSPECTIO:; AND ENFORCEMENT
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REC 10N III Report No. 50-329/77-08; 50-330/77-11 Docket No. 50-329; 50-330 License No. CPPR-81; CPPR-82
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Consumers Power Company
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1945 West Parnall Road
Jackson, MI 49201
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Facility Name: Midland Nuclear Power Plant, Units 1 and 2 i
Inspection At: Midicad Site, Midland, M1
Inspection Conducted: August 1-5 and 8-9, 1977
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l Inspector:
T.
E.~ Vundel
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Approved By:
D. W. Hayes, Chief V 'h7
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Projects Section
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Inspection Summary
Inspe tion on August 1-5 and 8-9, 1977 (Report No. 50-329/77-08 and
50-330/77-11)
Areas Inspected: Reviewed records and observed Unit 2 containment liner
repair work of the bulge area; reviewed corrective action records rela-tive to tec. don sheaths placement errors in Unit 1 containment wall; examined licensee activities concerning previously identified noncompliance and unresolved matters.
The inspection involved 53 inspector-hours onsite by one NRC inspector.
Results: No items of noncompliance or deviations were disclosed, i
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DETAILS
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Persons Contacted Principal Licensee Employees
.T. C. Cooke, Project Superintendent
- J. L. Coricy, Project Quality Superintendent D. E. Horner, Field Quality Assurance Engineer
- D. R. Keating, Field Quality Assurance Engineer B. W. Marguglio, Manager Quality Assurance R. E. Whitaker, Field Quality lssurance Engineer Other Personne]
- W. L. Barclay, Project Field Quality Control Engineer, Bechtel Power Corporation (Bechtel)
A. J. Boos, Project Field Engineer, Bechtel J. P. Connolly, Departing Project Field Quality Control Engineer, Bechtel Judy Davis, Assistant to Lead Document Control Supervisor, Bechtel
- H. D. Foster, Assistant Project Field Quality Control Engineer, Bechtel-J. G. Hook, Quality Assurance Engineer, Civil, Bechtel D. R. Johnson, Chief Field Quality Control Engineer, San Francisco office Bechtel Ih S. Kirker, Quality Control Engineer Civil, Bechtel
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T. Lieb, Quality Control Engineer Batch Plant, Bechtel J. Manno, Weldidg Engineer, Ecchtel L. Morris, Field Engineer, Containment, Bechtel
'*G. L. Richardson Lead Quality Assurance Engineer, Bechtel J. Savoie, Quality Control Engineer, Welding, Bechtel G. Smith, Welding Engineer, Bechtel
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S. Stornetta, Assistant Project Field Engineer, Bechtel S. Suggs, Construction Supervisor, Stri tural, Bechtel T. Thiruvengadam, Resident Engintcr, Be htel Associates R. J. Will, Field Engineer, Bechtel R. Yanekawa, Quality Control Engineer Welding,.Bechtel l
- Management exit meeting attendees-2-s'
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Licensee Action on Previous Inspection Findings
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(0 pen) Noncompliance Item (Report No. 50-329/77-05 and 50-330/77-08):
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Pipe support hanger bracket mounting cicarance failed to meet specific-ation requirements. The inspector conducted a review of Revision 1 of spc ification.7720-M-326Q, which was revised to include specification change notice, SCN3, dated June 1, 1977 among others. This change was i
made to clarify the design and acceptance criteria provided.
Also revised was the applicable quality control instruction (QCI, P-2.10).
Reinspection of the installed hangers, to the revised QCI resulted in (
issuance of two NCR's; (1) NCR U13 which included hanger 18-1HCB-2-H9 as peing nonconforming and (2) NCR 623 issued covering three different hangers installations.
Disposition has been provided for NCR 813 requiring rework to meet specification requirements. The inspector stated that review will be conducted of this hanger during future inspections to observe the completed installation.
(Closed) Noncompliance Item (Report No. 50-329/77-05 and 50-330/77-08):
Drawing changes in the field, contrary to established procedures.
The Bechtel memo of thy 26, 1977, is still in effect pending implementation of new procedural instructions. The following listed Field Instruction -
Piping (FIP) procedures have been newly developed, approved and issued relative to field modifications of piping hanger drawings.
(Approved and Issued August 7, 1977).
FIP-1.112, Field Markup Work Prints for Material Supports g-w FIP-1.113, Fielf Drawing Revisions-Erection Changes for Faterial gd Supports This completes the resolution of corrective action to prevent unauthorized changes to drawings in the field.
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(Closed) Noncompliance item (Report No. 50-329/77-05 and 50-330/77-08):
Failure to complete and issue reports of audits on a timely basis.
Four audits identified as follows: Aggregate Testing Audit, Report 76-52; Soil Testing Audit, Report 76-58; Testing of Concete, Report 77-01; and Concrete Placement Records, Report 77-04; were all issued on May 27, 1977.
Two quality findings were also issued in connection with these audits; QF-155 was issued at the time of the audit and was closed out on April 28, 1977, and QF-166 which was not issued until the report was
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issued.
QF-166 is presently open pending Bechtel Project Engineers j
response expected about mid-August 1977. Other corrective action l
i indicated in the licensee response letter was the staf fing of additional QA personnel at the site.
The QA Manager informed the inspector that
the following staffing at the site is expected to be completed in August 1977. The Quality Engineering section staff will total eight Engineers
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with the addition of six Engineers, while the Inspection, Examination and n-3-V e
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Test Verification section will total 12 Engineers with the addition of A)
. seven Engineers.
It was further indicated that an Audit Adminiatration (,
- Section staff, located at the Corporate officn, will have a total of five. Engineers hy the end of August 1977.
It was emphasized that these additions will relieve the short staffing condition that caused the identified noncompliance. The inspector indicated that he had no fur-ther questions regarding this concern.
(Closed) Noncompliance Item (Report No. 50-329/77-05 and 50-330/77-08):
Trend Analysis procedure was not being implemented. The following items of corrective action were reviewed by the inspector:
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The deficiency log (listing each QF issued) is current with the last entry QF-175 issued July 25, 1977.
Presently each deficicacy is
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entered as it is issued.
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The deficiency classification log is also current with each deficiency issued being classified into predetermined distinct classifications (a total of 78 classifications).
When three or more audit findings occur for a single classification within a year a trend analysis is
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identified and a report is issued, i.e., TAR-18.
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With the classification logs completion, a total of 19 TAR's were issued,.and of that total, all but six TAR's have been acted on
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and closed.
Six TAR's were issued and closed in June, and an additional seven have been closed as of August 3, 1977.
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- The inspector was informed that with the additional menpower (identified in the previous ncncompliance item) located at the site, the trend
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analysis activity should remain in a current condition. The inspector e
indicated that he had no further questions regarding this item.
(Closed) Noncompliance Item (Report No. 50-329/77-05 and 50-330/77-08):
As indicated in the letter of response, the defective ice batching scale was tagged immediately after it had been recognized that the tagging procedure had not been followed and was removed from the site. The inspector learned that additional corrective action included directive letters issued by Consumers Power and by Bechtel to applicable contractors and subcontractors. The letters emphasized the need for adherence to
approved procedures and programs. This item is considered to be resolved.
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(Closed) Unresolved Matter (Report No. 50-329/77-05 and 50-330/77-08):
Illegible. pipe support drawings.
The inspector was inforned that a new xerox machine has been installed onsite and is now in use.
In addition, as of August 1, 1977, first generation prints are being
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supplied to' the field for duplicating instead of brown line sepias.
The inspo. tor also was informed that prints of submittals produced with
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.the r.ew machine and with original drawings are being routinely issued.
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Also that previously issued prints are being replaced,on a request for
%s-a better print basis only. This natter is considered to be resolved.
(Closed) Unresolved Ma'tter (Report No. 50-329/77-05 and 50-330/77-08):
Field Instructions ~and Field Procedures review by Project Engineering.
In' discussions with the licensee representatives, the inspector learned-
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that currently established Bechtel procedures assure that not only the fieJd instructions and procedures but also the Engineering Department procedures are compatible with and responsive to the Quality Assurance Program. There-fore, review of such field instructions and procedures, by Project Engineer-ing is considered unnecessary.
The Bechtel governing occuments include:
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(1) Field Instruction General Procedure FIG-1,000, and (2) Nuclear Quality Assurance Manual in Section.IV-1. The inspector indicated that he had no further questions regarding this matter.
(Open) Noncompliance Item (Report No. 50-330/77-02):
Failure to report a 10 CFR Part 540, 50.55(e) item within the prescribed prompt reporting time (i.e., 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br />).
Corrective action provided in the licensee letter
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of response dated April 5,1977, include provision of a Consumers Power
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Company Quality Assurance Program Procedure No. 20-2 " Reporting Deficie>v:ies
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.to NRC".
In discussions with licensee personnel, it was agreed that
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further modification of paragraph 5.4.2, regarding prompt notification appeared appropriate.
Further review will be conducted at a later date.
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(0 pen) Four additional unresolved matters remain for further review dur-
[~'T ing future inspcetions (Repart No. 50-329/77-05 and 50-330/77-08):
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(1) Doaa liner Unit 1 coating repair, (2) Consumers Power Fbnuals revisions,
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(3) Further review of NATCO audit, and (4) Timely resolution and closing
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of NCR's.
Functional or Program Areas Identified
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1.
Unit 1 Tendon Sheath I
The present status of corrective action regarding the Unit 1 Tendon
i Sheath' placement ' errors was reviewed by the inspectcr. An interim report, dated June 20, 1977, providing the design disposition
for installing the two omitted tendon sheaths numbers 1132-037 and i
H13-037, was reviewed by the inspector prior to the onsite inspection.
The records of the tendon sheath installation were reviewed by the
' inspector on site. The results of the record review are as follows:
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a.
Bechtel NCR 778 issued on April 19, 1977, described the errors and requested project engineering to provide design dispaaltion
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for correction.
This NCR has now been closed with completion, C/
and reinspection signed off on July 22, 1977.
b.
Vendor drawings by Inland Ryerson had been revised to show the rerouting of the two identified tendon sheaths and also to show an altered routing of tendon sheath 1113-038. Drawings No. 7220-C2-348 and 7220-C2-357 were revised and subsequently utilized in the sheath installation.
c.
Special welding procedures were developed and qualified for use to weld rebar as follows:
(1) P1-Rebar, Revision 0, June 29, 1977, with qualification PQR No. 617, June 29, 1977, for rebar to rebar '.elding, and (2) PI-structural to Rebar, Revision 0, June 29, 1977, with qualification PQR No. 618, June 29, 1977, for structural steel plate to rebar welding.
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A survey was run establishing the correct elevations of the sheaths as prescribed on the drawings which was signed off by the surveyer and by the QC Engineer.
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QC inspections were performed of the tendon sheath installation with drawings and QCI records being marked and completed to establish as built conditions and acceptance of the repair and subsequent concrete pour.
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No problem areas were identified as a result of this review.
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The inspector was informed that the final 50.55(e) report is scheduled to be issued by August 15, 1977.
2.
Unit 2 Containmer t Liner Repair Bechtel NCR 717 issued February 28, 1977, requested Project Engineer-ing to provide disposition for the damage material removal, damage assessment, and eventual corrective repair.
A project Engineering letter was issued on July 11, 1977, prescribing the actual repairs to be made. The containment liner bulge deficiency repair was started on August 1, 1977.
The Project Engineering directive issued drawings 7220-C1101, -C1102, and -C1103 all Revision 0, to be followed for the replacement liner plate installation work.
In addition Attachment 1 to the letter is a procedure f or mixing, delivering, placing, finishing, curing, sampling, and testing of the grout to be used between the liner plate and con-tainment line plate building concrete.
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(g The inspector obsers ed the fit up and welding of the 1st four foot
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f,j lif t of repincement linerplatefastallegatelevation593'
i between column line azimuths 250 and 270.
Weld procedures used, welder qualifications, NDE procedures used, and NDE inspector quali-fication were reviewed and determined to be consistent with require-ments. The inspector observed NDE examination of welds including liquid penetrant, magnetic particle, and vacuum box leak test.
No
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A Lweld crack was detected near the azimuth 250 column line when the
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j arca behind the liner plate was filled with water (t soak the plate i
i and centrete subsequent to start of grouting operations).
Investigation of the crack revealed that the veld of the backing strip to tho i
support column had separated during veld out operations and the crack had propagated through to the 11ae plate surf,ce.
Corrective
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action included examining the 27d azimuth column liue weld (no defect found) and applying a modified weld out technique for the backing sttip welds.
Repair was completed, examined, and accepted without further problems.
The grouting operation utilized the established grouting procedure
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placement of grout, for the 1st four foot lift of liner plate. No problems were identified.
The inspector also reviewed records
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of qualification tests cf ingredients and observed current calibration
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stickers on the scales used. A total of 20.324 cu Ft of grout was
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placed. One mix of grout was rejected as b(tag out of temperature
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The inspector considered the 1st four foot lift of containment liner repair to have been satisfactorily placed with no problem areas i
being identified.
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Review of Training for Resident Engineers
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The inspector performed a review of Engineering Training for the
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-ass gned resident e,gineccs to determine responsiveness to commitment i
No. 21 of licensee _esponse letter dated June 18, 1976.
Bechtel
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- Engineering Departmenc Procedures FIED 5.34, EDP-5.34, Revision 1, and EDPI 5.34.1, Revision 0 were reviewed and it was learned that
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these precedures have been accepted by the licensee with procedure EDP15.34.1 having been accepted by letter, dated September 10,
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1976. Additionally EDP 2.14 " Duties of assigned Resident Inspector" was also reviased. The inspector considered the above listed pro-cedures to be r'esponsive to commitment 21 for Resident Engineers.
l The training records are being maintained at the Project Engineering 1l office in Ann Arbor, Michigan and thus were not available for review
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during the inspection, however, a phone check on one Resident (~"]
Engineers record file in Ann Arbor received a response that the
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j required records were on file. The inspector indicated that he had no further questions.
xit Interview The inspector meet with the licensee and contractor representatives (denoted with an asterisk under Persons Contacted) at the conclusion of the inspection on August 9,1977. The inspector discussed the results of the inspection and indicated that no noncompliance or unresolved natter had been identified during the inspection however, several previously identif f 'd unresolved matters will continue to be carried in an open status for further review duricq later inspections.
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