IR 05000341/1980006
| ML19321A244 | |
| Person / Time | |
|---|---|
| Site: | Fermi  |
| Issue date: | 06/16/1980 |
| From: | Barrett P, Knop R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML19321A242 | List: |
| References | |
| 50-341-80-06, 50-341-80-6, NUDOCS 8007230066 | |
| Download: ML19321A244 (6) | |
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U.S. NUCLEAR REGULATORY COMMISSION
OFFICE OF INSPECTION Ahd ENFORCEMEhT
REGION III
Report No. 50-341/80-06 License No. CPPR-87 Docket No. 50-341 Licensee: Detroit Edison Company 2000 Second Avenue D.:iroit, MI 48266 Facility Name: Enrico Fermi Nuclear Station, Unit 2 Inspection At: Fermi Site, Monroe, MI Inspection Conducted: April 30, May 1, 2, 28-30, 1980
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'j Inspector:
P. A. Barrett Accompanying Inspector:
R. C. Knop (May 28-30, 1980)
4 /o90 Approved By:
R. C. Kn
, Chi Projects Section 1 Insp-ction Summary Inspection on April 30, May 1, 2, and 28-30, 1980 (Report No. 50-341/80-06)
Areas Inspected: Follow-up of previously identified items including review of construction organization and design change control; plant tour; and discussion of the status of piping and hangers. The inspection involved 40 inspector-hours onsite by one NRC inspector.
Results: No items of noncompliance were identified.
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DETAILS o
Persons Contacted Detroit Edison Company
+*E. Hines, Assistant Vice President - Quality Assurance
+*W. J. Fahrner, Manager Fermi 2
+*T. A. Alessi, Quality Assurance Director
+*W. M. Everett, Project Superintendent
- H. A. Walker, Site Project Quality Assurance Engineer
+ S. H. Noetzel, Director Field Engineering
+*L. Jones, Director, Project Records Management
- W. W. White, Plant Superintendent Operations
- B. F. Kauppila, Project Quality Assurance
+*E. H. Newton, Plant Quality Assurance Engineer
+ C. R. Bacon, Field Project Engineer
+ T. H. Dickson, Director, Project Design
+ R. A. Vance, General Director, Project Engineering
+ C. A. Kus, Assistant to the Manager
+ G. Carter, Quality Assurance Engineer Daniel International Corporation
+ M. Albertin, Construction Manager
+ J. G. Bolt, Assistant Quality Assurance Director
+ G. Curtis, Quality Assurance Engineer
- Denotes those attending the exit interview on May 2, 1980.
+ Denotes those attending the exit interview of May 30, 1980.
Licensee Action on Previous Inspection Findings (0 pen) Followup Item (341/80-04-01): New site QA organization. During this inspection, the RIII inspectar individually discussed the implementa-tion of the new Project Quality Assurance organization with thirteen members. The members consisted of both supervision and staff. The dis-cussions indicated that duties, responsibilities and authorities were understood by each member and that the new organization would be effec-tively implemented.
The documented QA program and procedures were in an interim status. Many of the job functions had not actually changed. Therefore, the procedures from the previous organization were being used until superficial changes, such as titles, could be made. Where new job functions had been estab-lished, written and verbal directives and instructions were being provided to define duties, responsibilities and authorities.
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The licensee stated that the QA program and procedures will be completely formalized and implemented by June 15, 1980. The formalized program and procedures will be reviewed during a subsequent inspection.
(0 pen) 10 CFR 50.55(e) (79-xx-04): Misclassified ASTM A-36 steel plate.
Reference followup action on IE unresolved item 79-14-07, addressed in this IE Report 80-06. The corrective actions taken by the licensee are defined in the Detroit Edison Minutes of Meeting (F2S80-370) dated March 17, 1980. Essentially, 114 tensile tests and 58 chemical analyses indicate that only heat number 801B22820 does not meet the requirements of ASTM A-36 steel. All safety related supports fabricated from heat 801B22820 are being removed.
To preclude additional problems, the licensee has removed all A-36 plate material from stock. ASTM A-516 Grade 70 steel will be used for future raceway supports.
The licensee also identified problems with extreme carbon segregation.
The corrective action defined in the Minutes F2S80-370 will be reviewed during a subsequent inspection.
(Closed) Unresolved Item (341/79-14-07): Laminations in cable tray support base plates. The laminations, located on supports in the Residual Heat Removal Building, were originally identified by the licensee'and dpcm ented on Deviation Disposition Request (nonconformance) reports.
The licensee has subsequently identifie'd and documented on DDR's the source of the affected material, and all of th> locations (including the Reactor Building) where the affected material could have been installed and stored. The licensee's investigation revealed that part of the material used for the supports was misclassified as ASTM A-36 steel. The NRC was notified pursuant to 10 CFR 50.55(e) on July 23, 1979 concerning the misclassification.
The dispositions of the above DDR's require that the materials suspected of containing laminations be removed. The remaining stock of A-36 steel has been scrapped. The future supports will be made with ASTM A-516 Grade 70 steel.
Reference corrective actions identified in this IE Report 80-06 relative to the 10 CFR 50.55(e) report addressing the misclassified A-36 steel.
(Closed) Followup Item (361/80-01-03): Verification of level and align-ment of switchgear in the Residual Heat Removal complex. On January 24, 1980, the licensee audited the QC documentation for 26 pieces of elect-rical equipment located in the RHR building. The documentation was found to be incomplete (including verification of level and alignment on some equipment). The licensee stated that the Audit Finding #80-01-22D would remain open until the records are complete (i.e., installation criteria is verified).
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(Closed) Unresolved Item (341/78-09-15): Measures not established to o
control reinspection activities necessitated by design changes and per-formed by L. K. Comstock.
L. K. Comstock Procedure 4.8.3 for equipment setting has been modified to require verification of all applicable design changes to be documented on the inspection records. This require-ment is a generic practice for all LKC safety-related activities.
(Open) Unresolved Item (341/79-17-02): Design documents which have had numerous unincorporated design changes listed. Reference IE Reports 80-01 and 80-04.
The RIII inspectors met with the cognizant DE staff on May 29, 1980 and discussed at length the problems identified concerning the con-trol of design changes. The licensee formally addressed the problems by describing the reorganizations made to control the problems and by dis-cussing the programs implemented to identify the scope and resolutions for the problems.
The licensee stated that significant increases have been made in staff personnel in all engineering disciplines (including electrical, mechan-ical, and instruments and controls). An Engineering Assurance group has been developed. The input controls to the Automatic Records Management System have been centralized within a Project Records Management group.
The activities of each of the orgarizations are being reviewed by DE management.
A statistical summary of the specific problems and the initial effects of the corrective actions was provided. The problems essentially effect all types of design documents (i.e., drawings, specifications, changes, etc.).
The cause of the problems was inadequate control and input into the Auto-matic Records Management System and Report 4 (a monthly printed extension of ARMS).
In addition to the problems addressed in IE Report 80-04, a DE audit of drawings revealed numerous problems with (1) the identification of the open/ closed (unincorporated / incorporated) status of changes, (2) the data entries into ARMS and (3) the accuracy of original documents (1450 errors).
l The licensee indicated that the first two of these problems have been resolved.
The licensee has also identified the drawings with five or more unincor-porated design changes. An initial trend review indicates that this problem is increasing in that the number of drawings with five or more unincorporated changes is increasing.
l The licensee stated that all of the design changes applicable to specifi-cation 3071-31 have been incorporated and that specification 3071-128 i
currently had 76 changes unincorporated. Of those 76 changes, approxi-mately 2/3 were Design Change Requests, DCR's.
DCR's are originated in the field and therefore has a high probability of actually being incor-porated into the plant.
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A review of design changes generated during two separate months, a year d
apart, was made by the licensee. The review indicated, that based on engineering judgment, approximately 8-12 percent of those changes had some potential for not being incorporated into the plant.
The licensee stated that the following activities will be performed to expedite, define, and assure the resolution of the problems and effec-tiveness of the actions being taken:
By June 6, 1980 a directive will be issued requiring a 100 percent purge, of all documents at all distribution locations, to be made to assure that accurate and current documents per the updated ARMS, are being used.
A review will be made of all open design changes to identify those changes which could have an irrecoverable impact (e.g., welding, core boring, etc.) on the plant. A report to IE/RIII will be made by July 1, 1980 of such open changes and the planned preventive actions.
A detailed program will be provided to assure that all safetyrelated design changes are accomplished and verified in the field.
Additional audits will be performed to followup the Phase 1 and Phase 2 audits addressed in IE Report 80-01 and to assure effectiveness of the new programs and organizations controlling design changes.
The 1450 errors in the original drawings, as addressed above, will be corrected by September 1, 1980.
IE RIII will be notified by June 23, 1980 as to whether the 8-12 percent of the potentially unincorporated design changes, addressed above, are significant problems or not.
A complete review will be made by August 1, 1980 with established criteria to identify all of the design changes which potentially could have not been incorporated into the plant.
As of September 1, 1980, if any documents have five or more changes unin-corporated, the activities relative to those changes will be stopped until the documents are revised to five or less unincorporated changes. Current-ly, there are 411 documents with five or more unincorporated changes.
Program Areas Inspected Plant Tour and Status The RIII inspectors took a tour of Residual Heat Removal building, the Reactor building, and the Auxiliary building. The genera 7 plant condi-tions were observed. The plant status, including curret'. and scheduled activities (e.g., large and small bore piping, hangers, hydrostatic test-ing, flushing, and control room panel pin connector problems) were dis-cussed.
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No items of noncompliance or deviations were identified.
- Exit Interviews The inspector met with the licensee representatives on May 2, 1980, and May 30, 1980. The inspector summarized the scope, findings, and commit-ments of the inspection. The licensee acknowledged the findings as re-ported.
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