IR 05000329/1979019
| ML19260A424 | |
| Person / Time | |
|---|---|
| Site: | Midland |
| Issue date: | 09/25/1979 |
| From: | Gallagher E, Haynes D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML19260A412 | List: |
| References | |
| 50-329-79-19, 50-330-79-19, NUDOCS 7911210088 | |
| Download: ML19260A424 (11) | |
Text
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U.S. NUCLEAR REGULATORY COMMISSION
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OFFICE OF INSPECTION AND ENFORCEMENT
REGION III
Report No. 50-329/79-19; 50-330/79-19 Docket No. 50-329; 50-330 License No. CPPR-81; CPPR-82 Licensee: Comsumer Power Company 1945 West Parnall Road Jackson, MI 49201 Facility Name: ilidland Nuclear Power Plant, Units 1 and 2 Inspection At: Midland Site, Midland, Michigan Inspection Conducted: September 11-14, 1979 b
Inspector:
I Gallaghe
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Approved By:
D.
. Hayes, Ch f/A.fb9 Engineering Support Section 1 V
Inspection Summary Inspection on September 11-14, 1979 (Report No. 50-329/79-19; 50-330/79-19)
Areas Inspected: Containment prestressing system work procedures, work activities and quality records (units 1 and 2); QC inspector qualifications; status of soils work activities and 50.55(e) reports relative to contain-mer? prestres;ir.s ayatc= and concrete expansion anchors. The inspection involved a total of 27 inspector-hours by one NRC inspector.
Results: Three areas were inspected. Two items of noncompliance were identified in the areas inspected. (Infraction - inadequate design control -
Paragraph 2.a; Infraction - inadequate QC personnel qualifications - Para-graph 1.c).
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DETAILS,
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Persons Contacted
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Principal Licensee Employees (t/CO)
- B. W. Marguglio, Director Quality Assurance
- D. H. Miller, Site Manager
- T. C. Cooke, Project Superintendent
- G. T. Black, Quality Assurance Engineer
- R. Wheeler, Staff Engineer
- J.
L. Corley, Section Head - IE & TV
- D. Horn, Civil QA Supervisor Bechtel Power Company
- J. A. Rutgers, Project Manager
- W. L. Barclay, Project Quality Control Engineer
- A.
J. Boos, Project Field Engineer
- W. J. Creel, Quality Assurance Engineer
- L. A. Breisback, Project Quality Assurance Engineer
- Denotes those in attendance at exit meeting.
Licensee Action on Previously Identified Items (Closed) Noncompliance (329/79-10-01; 330/79-10-01):
Inadequate control.
of design interfaces; (a) Specification C-2 specified material for pre-stressing system sheathing to conform to ASTM A-366-66 or 68 while FSAR Section 3.8.1.6.3 required ASTM A-513, type 1, Grade 1010-1020 or A-53 type E or S, Grade B.
FSAR Section 3.8.1.6.3 has been revised via amend-ment 22 to be compatible with specification C-2 requirements.
(b) Speci-fication C-49, Section 6.2.2 specified the chemical limitations for prestressing system corrosion protective grease to be a maximum of 5 ppm chlorides, nitrates and sulphides while FSAR table 3.8-25 required 2 ppm (chloride), 4 ppm (nitrates) and 2 ppm (sulphide).
Specification C-49 has been revised via change notice 9004 to meet the commitments in the FSAR.
(0 pen) Unresolved (329/79-10-02; 330/79-10-02): Unavailable quality records relative to performance tests on prestressing system; items 1 and 2 of the unresolved items remains unresolved since the quality records are being researched.
Item 3 relative to buttonhead rupture tests quality records were made available and reviewed for tendon V-79, V-77, V-82, V-83 and found acceptable.
Items 1 and 2 will be pursued during subsequent inspections.
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Functional or Program Areas Inspected During this inspection the containment prestressing system procedures, work activities, suality records, and inspection and testing personnel qualifications were inspected.
In addition, significant construction deficiencies reportable in accordance with 10 CFR 50.55(e) relative to centainment prestressing system, concrete expansion anchots for component supports and site soils and settlement were reviewed.
Containment Prestressing System (Unit 2)
a.
Procedures The inspector reviewed the following procedures for containment prestressing work activit es:
(1)
C-2, Revision 12 (Mas 10, 1979) including FCR C-1986 (revised stressing.squence), FCR C-2046 (calibration of stressing jacks and gauge).
INRYC0 had approved the changes.
(2)
C-2-146-9, Field Installation Manual, including FCR Nos.
2062, 2049, 2048, 2047, 2041, 2042, and 2020.
(3) PQCI-9.10, Inspection of Post-Tensioning System (4)
C-49, Revision 2, Tendon Sheathing Filler Material and FCR 2069 SCN 9003, and SCN 9004.
The inspector indicated to the licensee at the exit meeting that PQCI-9.10 had not been revised to the revised requirements of C-2-146-9.
The licensee informed the inspector that the changes would be incorporated and that the QC inspectors are aware of the field changes in effect.
b.
Reportable 10 CFR 50.55(e) on Prestressing Tendons Notification in accordance with 10 CFR 50.55(e) was made by licensee on July 26, 1979 that a number of containment pre-stressing tendons were fabricated and shipped to the site with indeterminant wire lengths and in violation of the 1/8 inch maximum wire differential. MCAR 33 was issued on July 27, 1979 documenting the deficiency. NCR 2373 was also issued placing the 7 vertical tendons already installed in the Unit 2 contain-ment and 10 horizontals received in storage at the site on hold.
Inspections by the licensee at INRYCO's Melrose Park, Illinois facility and Wiremill facility in Florida were performed to 1381 207
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investigate the cause and which facility is responsible for the
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fabrication of the deficient tendons.
It was determined that the tendons fabricated at the Wiremill facility produced the tendon with differentiated wire due to the following reasons:
(1) back tension device was switched off and not opera. ting resulting in varying wire lengths, (2) catcher clamp was found to be damaged due to weld fatigue, and (3) limit switch had excessive travel. These three mechanical deficiencies contrib-uted to the production of differential wires in the tendons fabricated.
A total of 38 tendcas have been fabricated at the newly opened Wiremill facility. Tendons traced were as follows:
Seven vericals installed (on-hold)
Ten borizontals on-site. in storage (rejected and shipped back to INRYCO)
Seven verticals (on-hold at Wiremill)
Ten horizontals (on-hold at Wiremill)
INRYC0 has :,ubmit.ed a salvage procedure for the seven verticals installed in Unit 2.
Procedure F-365-9.0 Rnvision 1, was currently under review and comment which proposes a method to field cut and modify to satisfy requirements.
Bechtel has performed two quality program verification surveys of the INRYC0 facilities. Results are documented in QPVS No. 9Q and 10Q. In addition, a Bechtel inspector is stationed at the Wiremill facility to perform continued inspection of the tendon fabrication.
The NRC regional office will review the final 50.55(e) report upon receipt.
c.
Qualifications of QC Inspectors for Prestressing Work Activity During a May 14 17, 1979 inspection (report No. 329/79-10; 330/79-10; page 4) the NRC inspector had indicated to the licensee that none of the Bechtel QC inspectors to be assigned the inspection and testing of the containment prestressing system has any prior related work experience on prestressing systems nor construction of power facilities. At this time no work had 'oegtn on the installation of the prestressing system.
The inspector, indicated that this matter would be reviewed during followup inspections.
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During this inspection the matter of qualification of quality control inspection and testing personnel was once again reviewed.
The personnel qualification and training records of eleven quality control persornel were reviewed and compared to the requirements of Regulatory Guide 1.58 and ANSI N45.2.6.
It was concluded that five of the individuals certified as level I inspectors were not qualified in accordance with the above standards as well as Bechtel program requirements contained in PSP-G-8.1, Qualification, Evaluation, Examination, Training and Certification of Construction Quality Control Personnel.
Section 5.2 (Education and Experience Requirements) of G-8.1 requires that one of the following requirements be satisfied in order for an individual to be considered for certification as a level I inspector:
(1) Two years related experience in equivalent testing, exami-nation or inspection activities associated with power plants, heavy industrial facilities or other similar facilities.
(2) High school graduate and one year of related experience in equivalent testing, examination or inspection activities associated with power planta.
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(3) Completion of college level work leading to an Associate Degree in a related discipline plus six months of related experience in equivalent testing, examination or inspection activities associated with power plants...
It is important to note that the above requirements are also included in Regulatory Guide 1.58 and ANSI N45.2.6 and requires education in a related discipline (i.e. technical, engineering, etc.) and prior work experience in a related field of testing, examination or inspection activities (i.e.
concrete, soils, prestressing, etc.)
The personnel qualifications of five of the QC inspectors certified as level I indicated no prior related education nor prior related work experience nor prior related construction experience. A summary of the individuals qualifications are contained in Appendix I.
These individuals have performed various QC inspections on the Unit 2 containment prestressing system.
It is important to note that the remaining six QC inspectors have not had any prior experience with prestressing systems, however, they have had prior construction experience.
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Discussions with the licensee's contractor Project Quality Control Engineer (PQCE) indicated that an attempt was made to secure fully qualified personnel through the corporate office.
However, that office was unable to supply the requested per-sonnel based on comments by the PQCE.
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The licensee's contractor (Bechtel) informed the NRC inspector that Section 5.1.2 of progra G-8.1 states, "The education.and experience requirements spet.fied below shall not be treated as absolute. These requirements ray be altered when other factors provided reasonable assurances to the supervisor responsible for certifying a lower level candidate that t'le person can competently perform a particular task."
The license indicated relaxation of the education and experience requirements was exercised based on the above provisions.
The inspector informed the licensee that while it was fully recognized that the requirements for education and experience are not absolute, the intent of the Regulatory Guide 1.58 and ANSI N45.2.6 was that the individual has prior related education and related experience while perhaps not the exact length of time.
The inspector indicated to the licensee that the liberal inter-pretation of the requirements were unacceptable and considered to be an item of rioncompliance with 10 CFR 50, Appendix B, Criterion II.
(329/79-19-01; 330/79-19-01)
d.
Observation of Prestressing System Work Activities (Unit 2)
The inspector observed selected work activities relative to the Unit 2 prestressing system. The following specific items were observed:
(1) Tendon D124 stressing using calibrated Jack No. I and Gauge No. 191; Bushing ID MW-303, Peaning Plate GM-257; lock off load and tendon elongation were within predicated range.
(2) Grease tank temperature 152 F; required temperature is 140 to 210 F.
(3) Tendon D-112 stressing; Field Anchor ID MQ-120; Bearing Plate GS-136.
(4) Completed Tendon D-124 and D-312 The above work was observed to be performed according to the prescribed work procedures.
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e.
Quality Records for Prestressing System (Unit 2)
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The folloving prestressing system gyality records were reviewed:
(1) Nonconformance Reports
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NCR-2205 (Open) Lack of acceptance / rejection criteria for rust and bent wires on tendons H13-252 and H13-24.
NCR-2505 (0 pen) Tendon D-301-2 had 5 wires broken during stressing.
NCR-2372 (0 pen) Issued 50.55(e) on differential wire lengths.
NCR-2382 (Closed) One wire on shop-end buttonheaded but sent to site - wire repaired.
NCR-2383 (0 pen) Tendon H21-234 and H21-236 inspected with
"E" rust statua - unacceptable rust - wires pulled for testing.
The above NCR's will be reviewed when fully dispositioned by the licensee.
(2) Buttonhead Repair Log This log tracks the buttonheads inspected and indicates the number defective and repaired in order to meet speci-fication requirements on permissible number of buttonheads defective. Tendon V-90 indicated six buttonheads were defective after repairs made. Specification C-2 permits only four. The licensee indicated V-90 is being reviewed and repairs to be recommended by engineering.
(3) Stressing Gauge Dial Comparison The stressing gauges are compared,to a master gauge once daily.
If the gauge is determined to be out of calibration the last tendon stressed is completely restressed with a calibrated gauge. The new stressing valves are then compared to the work performed with the uncalibrated gauges and raluated to determine if other tendons require work.
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Tendon D-321. V-28 and D-121 were restressed due to gauges being out-of-calibration.
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(4) Field Buttonhead Records - Tendons V2-2, V3-2, V13-2,
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V14-2 and V54-2 were reviewed and found acceptable.
The inspector indicated to the licensee that the quality for the tendons completed to date have not been completely as;embled in order to perform a complete review of each tendon. Various inspection and e ality documentation is located in various files without a complete review of an individual package as required by the Field Inspection report.
The licensee indicated the completed tendon package would be assembled and reviewed prior to final acceptance of the work.
2.
Review of Site Soils and SettJament a.
Backfilling Procedure Specification C-211(Q), Revision 7, Structural Backfill, Section 8.1.2 and 8.2.4 permits the use of lean concrete in lieu of structural backfill and sand backfill material. This specifi-cation is used for placement of safety-related soils. The above sections state, " Lean concrete shall be made of non-Q (non-safety related) material and workmanship."
The inspector observed lean concrete material placed adjacent to the borated water storage tanks in the tank farm area which is designated as a safety-related "Q" area. The licensee informed the inspector that previously placed lean concrete material in safety-related areas were also designated and placed as non-safety related material.
10 CFR 50, Appendix B, Criteria III requires that appropriate quality standards are specified and that deviations from such standards are controlled. Contrary to the above, materials being used in safety-related structures were specified and permitted to be of non-safety related material and workmanship.
The quality assurance prcgram has not provided control over this safety-related work activity.
This is considered an item of noncompliance with 10 CFR 50, Appendix B, Criterion III (329/79-19-02; 330/79-19-02)
b.
Placement of Soils Specification C-211, Section 8.5.1 requires that equipment being used to compact soils be qualified prior to use. Quality control initiated NCR 2492 on August 30, 1979 due to Bechtel 17o1 11 7 IJC1 Jli-8-
construction use of an unqualified type of handheld compaction
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equipment ("po-go stick") in safety-related "Q" areas. The Bechtel project field engineer dispositioned the NCR as not being valid while being aware of the specification requirement.
The "po go stick" was again later used in safety-related areas.
Bechtel QA department subsequently issued Stop work report No.
6 for use of such equipment until such time that the nonconfor-mance was resolved.
The licensee has indicated that Bechtel Geotech has directed the field to qualify the equipment as required prior to any further use.
The NRC inspector questioned the licensee why the project field engineer was permitted to disposition the NCR as invalid and again permit the use of the equipment in violation of the requirements. The licensee indicated that the quality management personnel would take appropriate action to preclude such events and that QA acted promptly in issuing the stop work report.
c.
Status of Site Settlement The surcharge load in and around the diesel generator building has been removed as of the end of August, 1979.
Soil response to the removal of the surcharge is being monitored. Discussion with the licensee, bechtel Geotech and DR.
Dunnicliff indicated that the soil has rebound approximately 3/16 of an inch; expected rebound is predicted to be on the order of 1/2 inch or less.
Temporary dewatering system in the vicinity of the Unit I and 2 valve pits have been installed, however no pumping or drawdown of the ground water had begun at the time of this inspection.
Pile tests are being planned in the vicinity of the service water pumphouse structure. Tests are to begin in early October by Bechtel Consultants.
Excavation of soft-material in the borated water storage tank farm was in progress with placenent of sand material inside ind around the tank foundations. Sand was being placed using qualified handheld compaction equipment to 85% relative density for support of structures and 80% relative density for areas other than under structures.
3.
Review of 50.55(e) on Concrete Expansion Anchors _
Specification C-305, Revision 9, Section 6.2.2 requires shell type expansion anchors to be tension tested to the specified loads.
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addition, in-process inspection is reouired. Because in process
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inspection had not always been performed it was requested to randomly select 60 anchors to verify adequacy of past installations.
After testing 32 of the anchors, the results indicated nine failures where the anchor slipped prior to achitving the test load.
At this time MCAR 34 was issued on August 21, 2979. Results are documented on NCR-2461 and NCR-2481.
Engineering requested another 100 anchors to be inspected ( IVX-5383 dated August 24, 1979) for proper setting and tension tests. The results of the additional tests are documented on QCFM-6560/AI-667 dated September 6, 1979. Visual resalts indicate 20 acceptable and 82 unaccept 61e (i.e.
not fully set). Twenty-three (23) could be reset.
Sixty (60) 3/8 inch anchors were tension tested of which two failed while 37 1/2 inch and five 5/8 inch were tensioned and found acceptable.
The licenst.e indicated that approximately 900 of the shell type anchors have been installed prior to identifying the deficiency.
Because of the above information the licensee reported the defi-ciency in accordance with the requirements of 10 CFR 50.55(e).
The licensee is continuing to evaluate the results of the testing and what corrective action is required to resolve the deficiency.
The final 50.55(e) report will be reviewed upon receipt by the NRC.
Exit Interview The inspector met with the licensee representatives (denoted under Persons Contacted) on September 14, 1979. The inspector summarized the scope and findings of the inspection. The findings were also discussed via telephone with Mr. B. Marguglio and management of RIII NRC on September 17, 1979.
The licensee acknowledged the. findings as reported.
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Attachment: Appendi:: I 1381 114
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APPENDIX I PRESTRESSING SYSTEM QC PERSONNEL QUALIFICATIONS Bechtel Certified Related Related On-Site Areas of Individual Employee Level 1 Education Experience Training Inspection A
7-12-79 8-6-79 none-none-janitor, 25 hours2.893519e-4 days <br />0.00694 hours <br />4.133598e-5 weeks <br />9.5125e-6 months <br /> Tendon insertion, high school cook, IGA buttonheading, stressing, gressing (1st shif t)
B 7-12-79 8-6-79 none-none-23 hours Tendon insertion, high school Ramada Inn, buttonheading, printer stressing, greasing (1st shift)
C 7-12-79 8-6-79 none-
.sne-26 hours Tendon insertion, 3 year student buttonheading, college last strearfng, greasing (2nd shif t)
D 7-16-79 8-6-79 none-none-26 hours Tendon insertion, B. A.
student buttonheading, Business last stressing, greasing (1st shift)
'E 7-12-79 8-6-79 none-none-28 hours Terminated on 8-10-79
[
high school bar tender Co
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