IR 05000329/1980007
| ML19316A921 | |
| Person / Time | |
|---|---|
| Site: | Midland |
| Issue date: | 04/14/1980 |
| From: | Danielson D, Norelius C, Ward K NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML19316A919 | List: |
| References | |
| 50-329-80-07, 50-329-80-7, 50-330-80-07, 50-330-80-7, NUDOCS 8005280057 | |
| Download: ML19316A921 (12) | |
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U.S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT
REGION III
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Report No. 50-329/80-07; 50-330/80-07 Docket No. 50-329; 50-330 License No. CPPR-81; CPPR-82 Facility Name: Midland Nuclear Power Plant, Units 1 and 2 Investigation Co ducted: March 3-4 and 11, 1980 Investigation At: Midland, MI Investigator:
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C. H. Weil Date Inspector:
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K. D. Ward
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Ifate Reviewed By:
N. k.
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,//,, hg C. E. Norelius Date Assistant to the Director hwL~kk~
ddn D. H. Danielson, Chief
' Date Engineering Support Section Number Two Investigation Summary Investigation on March 3-4, 1980 (Report No. 50-329/80-07; 50-330/80-07 Areas Investigated: Special, unannounced itvestigation into allegations concerning the construction of the two borated water storage tanks by Graver Energy Systems, Inc., at the Midland Nuclear Power Plant Construc-tion Site, Units 1 and 2.
The investigation involved 30 investigative hours, both on and off-site, by two NRC personnel.
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l Results: The allegations were not substantiated, and no items of noncom-pliance with NRC requirements were identified during the course of the l
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l investigation.
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REASON FOR INVESTIGATION On March 3, 1980, Individual 'A' advised Nuclear Regulatory Commi,ssion Region III (RIII) personnel of three allegations concerning the construc-tion of the two borated water storage tanks by Graver Energy Syste.ms at the Midland Nuclear Power Plant construction site.
SUMMARY OF FACTS Individual
'A' advised RIII personnel of three allegations concerning the construction of the two borated water storage tanks by Graver Energy Systems, Inc., at the Midland Nuclear Power Plant construction site. The allegations e,
were:
(1) a separation had occurred in the lamination of r. vertical seam J'
in the east storage tank, and the separation was " padded-in" by welding over
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the lamination; (2) a crack in the floor of the east tank was discovered and
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repaired by grinding to a depth which did not meet the minimum thickness
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specifications for the tank floor; (3) the floor of the west tank did not extend the required 15 inches beyond the tank shell, and the floor was ex-terded by using weld metal to extend the floor plan the required distance.
Insd-tigation by RIII personnel disclosed the two borated water storage tanks were not completed (completion expected in May-June, 1980), and the problems described in allegations numbers one and two had been dis-covered by Graver personnel, recorded on Graver Nonconformance Reports Numbers 300 and 301, and had been marked for repair. The third allegation, concerning the use of weld metal to extend the floor plate was partially substantiated in that the floor plate did not extend the minimum distance.
However, the floor plate was repaired using Graver Energy System Specifi-cation Number WG-6, Procedure Specification for Plate Edge Build-Up. The investigation did not disclose any items of noncompliance with NRC require-ments.
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DETAILS 1.
Persons Contacted
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Consumers Power Company
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- T. C. Cooke, Project Superintendent D. B. Miller, Site Manager
- J. L. Corley, Section Head-IE&TY D. R. Keating, QA Group Supervisor
- D. K. Martin, QA Representative
- R. Ostrowsk., QA Engineer
- W. F. Szabo, Engineer Bechtel 'ower Company J. W. Lillywhite, Field Contracts Administrator
- M. A. Dietrich, QA Engineer
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- E. Smith, QA Representative
- D. A. Patee, Subcontracts Engineer
- W. L. Barclay, QC Engineer Graver Energy Systems, Inc.
- G. M. Ault, Program Manager
- Denotes attendance at exit meeting.
2.
Receipt of Allegation From Individual 'A'
Allegations On March 3, 1980, Individual
'A,' a boilermaker, formerly employed at the Midland Nuclear Power Plant Construction Site, provided to RIII personnel three allegations concerning the construction of the two
borated water storage tanks by Graver Energy Systems at the Midland l
Site. Individual 'A' provided the following information:
The design of the floor plate of the west storage tank required the plate to extend 1 inches beyond the exterior of the water tank shell.
This was discovered in late October, 1979, and the Graver Field Super-visor instructed the welders to use weld metal to extend the floor plate to the required length.
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,,, A separation occurred in the lamination of vertical sean number tLree,
- ring two, (south side) of the east storage tank. The Graver field supervisor instructed a welder to " pad in" the separation to " cover it up."
The separation in the laminated seas was found during October, 1979.
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During October, 1979, a crack in the floor plate inside of the east
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storage tank was discovered, and the crack was brought to the atten-tion of the Graver field supervisor. The Graver field supervisor instructed the Graver boilermakers to use a grinder to blend,out the crack in the floor.
Individual
'A'
was concerned that the grioding of the floor crack was too deep and the floor plate no longer. net the minimum density requirement.
Findings
The Midland Nuclear Power Plant was designed to have one borated water storage tank for each operating unit. The two tanks, designated IT60 (West) and 2T60 (East), were to support Unit I and Unit II, respec-tively. The design capacity of each tank was 500,000 gallons. The design and erection of the two water storage tanks were sub-contracted to Graver Energy Systems (formerly Graver Tank and Manufacturing Company), East Chicago, IN. Erection of the two tanks began on September 21, 1979, and proceeded until mid-January,1980. In January, 1980, the rate of construction had exceeded the capacity to conduct non-destructive examinations by the Graver Quality Assurance Section.
Construction was halted and the construction crews were laid-off until the Quality Assurance Section could complete the non-dest'ructive exam-inations. Completion of the two borated water storage tanks was expected for the May-June, 1980, time period.
On September 28, 1979, the bottom plate of the east (2T60) water storage tank was found to have been scratched and gouged during the materials
handling and installation processes. The scratched and gouged areas were marked for repair and Graver Nonconformance Report (NCR) Number 300 (Exhibit 1) was prepared. All scratched areas were repaired in accordance with Graver Energy System Procedure Number RP-3, " Repair Procedure Base Metal Defects." This procedure permits, "all material
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imperfection detected... chip marks, blemishes, or other surface irregularities may be removed by grinding... after the surface has been corrected it shall be blended smoothly into the adjacent area."
The procedure continues, " replace removed material as requested to meet minf.aum dimensions with shielded metal are process..
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surface shall be blended smoothly into the surrounding area." The repaired areas were measured by ultrasonic thickness gauge and found to be within the design requirements.
On November 2, 1979, the crack in the lamination of vertical seam number three on the east storage tank (2T60) was reported under Graver NCR Number 303 (Exhibit 2). The imperfection was found during the tank erection. The imperfection was marked for later repair in accordance with Graver Energy Systems Procedure Number RP-3, Repair Procedure, Base Metal Defects (described in the preceding paragraph.
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The cause of the imperfection was suspected of being a surface defect
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- caused during hot mill rolling. Graver NCR Number 303 directed the 4-I
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area of the vertical lamination to be reworked. Graver Erection
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Control Sheet Number WP-001 (Exhibit 3) was prepared to keep track of the progress of the repair, including final radiographing.
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During October, 1979, Graver personnel discovered the floor plate of i*.
the west, borated water storage tank (IT60) extended only one inch j
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beyond the exterior of the tank shell on the southwest side of the
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tank (approximately 31 feet clockwise from the Ring 1, Vertical Seam 3).
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The extension of the floor plate of only one inch beyond the tank shell
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did not meet the drawing requirements of 1 1/4 inches. The addition of 1/4 inch to the base plate was achie ved by buttering (weld build-up)
1/4 inch of weld metal to the base plate for a length of 1 1/2 feet.
Gary M. Ault, Graver Program Manager stated the buttering technique was done in accordance with Graver Energy Systems Specification Number WG-6, Procedure Specification for Plate Edge Build-up. This repair was not documented at the time of the completion of the repair, but was made a matter of record on March 4,1980 with the preparation of
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Graver Energy Systems Surveillance Report Number 3 (Exhibit 3).
j The buttering technique was used, rather than moving the tank shell plate, as a change in the position of the tank shell plate would have caused the tank shell to be out-of-round. Consumers Power Company
prepared a nonconformance report pertaining to the extension of
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the tank base plate.
D. K. Martin, Consumers Power Company Quality Assurance Representative stated the Consumers Power Company Quality
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Assurance Engineering Section was in the process of determining the
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welding techniques and procedures utilitzed, as well as the indentity of the welder, to extend the tank base plate. Martin advised that onca this information has been obtained the Quality Assurance Engi-neering Section will decide whether the welded extension of the tank base is within acceptable standards or if the welded extension should be removed by grinding and re-welded.
During the period September 1979 thru February 1980, the perform-
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ance of Graver Energy Systems in the erection of storage tanks, in-cluding the IT60 and 2T60 tanks, at the Midland Construction Site was
l audited three times. Graver Energy Systems was audited by Bechtel Power Corporation (the prime contractor at the Midland Construction
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Site), the Consumers Power Company corporate audit team from Jackson, MI, and the Quality Assurance Section of the Consumers Power Company at the Midland Construction Site. Additionally, the Graver Energy' Systems'
procedures in erecting the tanks was inspected by the American Society
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of Mechanical Engineers (ASME) during November, 1979. None of the audits or the ASME inspection disclosed any major findings or discre-l pancies in the procedures or practices used by Graver Energy Systems l
at the Midland Construction Site.
3.
Receipt of Additional Allegation
' -Allegation During the course of this investigation the appearance of linear indi-cations in radiographs of the welds of the two borated water storage tanks was brought to the attention of RIII personnel.
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Findings
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The Graver Energy Systems' Quality Assurance Section had radiographed the seams of the two, incomplete, borated water storage tanks. During the course of analyzing the radiographs the linear indications were found. Evaluation of the linear indications remains pending,*ty Craver Energy Systems, Bechtel Power Company (the prime contractor at the Midland Site), and the licensee. This matter has been brought to the attention of the RIII Reactor Construction and Engineering Support Branch for inclusion in future RIII inspections of the Midland Nuclear Power Plant Construction Site.
4.
Discussion with Midland Nuclear Power Plant Management On March 4, 1980, the allegations and the results of this investiga-
's tion were discussed with Mr. T. C. Cooke, Project Superintendent,
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e Midland Nuclear Power Plant Construction Site, and the members of
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the staff identified in paragraph one.
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i Attachments:
1.
Exhibit 1, Graver Nonconformance Report 300, Sept. 28, 1979.
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Exhibit 2, Graver Nonconformance Report 303, Nov. 2, 1979.
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Exhibit 3, Graver Erection Control Sheet Number WR-001.
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Exhibit 4, Graver Surveillance Report Number 3, March 4, 1980.
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Ordtr No.
61593-N
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.C.R. No.
M NORTHEAST
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Date 9-28-79
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NONCONFORMANCE REPORT
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NONCONFORMITY:
San)c NO. 2T-60 ELL Plate 3AS, Beat No. V-90774, MPO No. 9147'
DRN,iING 10: NIcl2051-2 ELL Plate has grind area wwc. 2" wide X 8" Iangth,
88" frczn straight Edge adjoiniDg A2 ELL Plate, and 454" frczn straigic. edge l
adjn%49 AS ELL Plate: 'Ihis area is appr=x.1/32" in dep*dl.
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, CAUSE: Excessive <p-4T5 A-im fab:-icatica l
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ACmON TO PREVENT RECURRENCE: All grind areas A-4_m Wr-ation W b
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w 2R. 1979 29-79 Corfective Action Date
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Sgn'ature & Dargf v
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INITIAL DISPOSITION:
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IJL-2h-79 P.A.
9-28-7c
Sgnat
& Date Sgnature Da O Replace.
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/7 u9-29_79 Q.C.S.%.t..b.te% 9-29-7c
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Egnardre & Date g Egnature & Date
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MATERIAL REVIEW BOARD:
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O Regi.ce E Use As is b Rework'
See Comments
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Customer Approval O Requiree Not Requireo
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Comments:
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The thickness of the area in question was measured y by ultrasonic +Mehess gauge and is within the h,
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assign 1.quir.ments.
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A N i WR.51klIt) 10 'l0 '77
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N,ORTHEAST EV. 2,1979 Data NONCONFORMANCE REPORT
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NONCONFORMITY:
FFlL PIATE NO: M2-016-000B2
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MPO-91274
NL-12046 Er. V-90758
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2T-60 CERI NO: 04497
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IAMI2RTICH AREA IN PIATE 4" IN II:NGIH Flui EIXE T PIATE.
SEE ATDGED SICIG.
Defect in CAUSE: Surface imperfection in slab or damage during hot rolling.
plate not seen by final inspector.
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We have cautioned our inspector to use greater ACTIC N TO PREVENT RECURRENCE:
care.'n inspecting for defects, se that defects may be detected and el4minated by corrective grinding before shipping.
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We'Ih 2-79 P.A.
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,Sgn{uretT^L ur3I 11-2-79 C.C.S. %.t A - 11-2-7!
O Replace P.S.
i Sigdeture & Date T Signature & Date I
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MATERIAL. REVIEW BOARD:
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O Replace Use As is b Rework M See Comments Customer Approval O nequireo O Not Requiree
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f Comments:
Rework in accordance with an approved araction control sheet utilizing procedure RP-3 and 47N.
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A N I 8M M MI dRequired O Not Requiree
Exhibit 2 - page 1 of 2
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N.C.R. NO: 303
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PIATE NO- _ BM24)16-000B2
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i Exhibit 2 - page 2 of 2
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Paseanzo sv:%A..%kAw ONECOPYSENT
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i, g" GRAVER ENERGY SYSTEMS lNC
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61593-N
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ASSEMBLY IDENTIFICATION & DESCRIPTION:
(RENDRK)
y ge, 2.- Vf*p7 3
[NE# 3 0 3)
P. NO. 1
'i i DRAWING USED IN PREP. OF ECS:
NIrl2046, Rev. 2
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STEP OPERATION DESCRIPTION SAT UNSAT DRAWING REY.
PROC.
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INITIAL DATE
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'l Iav out Area of Repair
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Mr Arc /or Grird Bepair Area h
(RP-3) & (47-N)
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N.D.E. Examine Cavity IPE-12
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LPE-12
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Weld Cavity of Repair (47eN)
47-N
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Grind Area Suitable for N.D.E, IPE-12
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Radiograph ocmpleted Repair (RE-12A, Rev.1 RE-12A
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DATE Q.A. APP VAL-DATE A. N. l. REVIEW FINAL Q. A. REVIEW DATE
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61593-N so m
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tecy sysrtus.ec ORDER SURVEILLANCE REPORT
SIR NO-
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3-4-80 DATg
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IKyrIU1 SKEn3I PIATE 3A7 Hr: V-90733, MPO 91284 l. TEM
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Plate edge was buttered for approxinately l' 6" X %" to extend b-/ " - stickout to meet drawing requirments of 1 " NL-12046. Work ms perfonned without proper Erectim Otratrol Sheets, but agrroved Procedures wre used.
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Signature REPLY:
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sonatwe ENGINEERING DISPOSITION:
signatwe
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QUAUTYCONTROL DISPOSITION:
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Exhibit 4 - page 1 of I agnatwe
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- r DO NOT DISCLOSE Contains identity of
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5, confidential source Investigation at Midland Nuclear Power Plant Construct. ton site on March 3-4,1980 (Report No. 50-329/80-07; 50-330/80-07).
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Individual Identifier Codes
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Individual Name Position A
Joseph Daniel Holmes Boilermaker, 9555 East Adams Founer employee of Route 1 Graver Energy Systems, Inc.
Wheeler, MI 486f?
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DO NOT DISCLOSE ity el g @l source
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