IR 05000461/1979009
| ML19260C227 | |
| Person / Time | |
|---|---|
| Site: | Clinton  |
| Issue date: | 11/08/1979 |
| From: | Knop R, Vandel T, Wescott H NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML19260C225 | List: |
| References | |
| 50-461-79-09, 50-461-79-9, NUDOCS 7912260091 | |
| Download: ML19260C227 (7) | |
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U.S. NUCLEAR REGULATORY COMMISSION
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OFFICE OF INSPECTION AND ENFORCEMENT
REGION III
Report No. 50-461/79-09 Docket No. 50-461 License No. CPPR-137 Licensee:
Illinois Power Company 500 South 27th Street Decatur, IL 62525 Facility Name:
Clinton Nuclear Power Station, Unit 1 Inspection At:
Clinton Site, Clinton, IL Inspection Conduc ed: September 24-28 and October 4-6, 1979 V f'
///f fpf Inspectors:
H. M. Wescott
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T. E. Vandel
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Observer:
M. J. Corcoran I,. < j '
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Approved By:
R. C. Knop, Chier
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Projects Section 1 Inspection Summary Inspection on September 24-28 and October 4-6, 1979 (Report No. 50-461/79-09)
Areas Inspected:
Routine unannounced inspection:
follow-up of previously identified noncompliances and unresolved items; review of ASME certification; review of reactor vessel installation implementing procedures; observation of reactor vessel lif t and installa*. ion work activities; record review of safety related structures installation. The inspection involved a total of 117 inspector-hours on site by two (2) NRC inspectors.
Results: Of the five areas inspected, no items of noncompliance were identified.
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DETAILS Persons Contacted Principal Licensee Employees E. P. Barganier, Supervisor C/S A. J. Budnick, Director of QA R. J. Canfield, Construction Department L. Dozier, Assistant Director of Construction J. F. Hampron, Supervisor of Construction QA D. E. Korneman, Supervisor of Mechanical Construction T. F. Plunkett, Plant Manager J. S. Spencer, Supervisor of Field Engineering Baldwin Associates B. J. Carson, Manager of Technical Services J. DeAngelo, Senior Civil Superintendent W. J. Harrington, Project Manager J. R. Hilding, Manager of QA J. Linehan, Manager of QC T. Selva, Manager of QA and Technical Services C. E. Winfrey, Senior QC and CS Engineering
W. G. Woolery, Welding Engineer General Electric Company J. L. Dempster, Site Manager S. G. Hall, Site QC Hartford Steam Boiler Insurance Company M. J. King, Authorized Nuclear Inspector State of Illinois D. R. Gallup, ASME Boiler and Pressure Vessel Code, Jurisdiction Authority Licensee Action on Previously Identified Items (0 pen) Unresolved Item (461/79-06-06): Records not available on site to enable verification that piping that had been through a hot bending process met the quality requirements of the ASME Code subarticle NB-4223.2.
The licensee stated that measurements would be taken and recorded upon receipt of the piping from Associated Piping where it is currently being re-worked.
(0 pen) Unresolved Item (461/79-16-07): Heat treatment furnace strip charts not available on site for the NRC inspector to verify the time at the required temperature for solution annealing of the reactor recirculating 1616 088-2-
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loop piping. The licensee stated that a typical strip chart would be
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retrieved. The NRC inspector stated that a " typical" strip was not accept-able and that only the strip charts that represent the time at temperature for the reactor recirculating loop piping that was originally purchased for this purpose would be acceptable. The NRC inspector has the understanding that the strip charts that represent the time at temperature for the reactor recirculating loop (original purchase) will be made available at the Clinton site to be reviewed at a subsequent inspection.
(Closed) Noncompliance (461/79-06-04):
Zack, Inc. welding procedure specifi-cation inadequately reviewed and approved.
Zack procedure specification C-B-QCP 22 has been revised twice (Revision 3 and 4) with the latest revision, dated August 20, 1979, reviewed and approved by the licensee on August 23, 1979.
Paragraph 13.1 was changed by Revision 3 to state that the welding procedure specification (WPS) qualified to AWS D1.1 Section 2.7 and Section 5 Part A (rather than Part B) which allows the WPS to be considered as pre qualified rather than the qualification by testing as required by Part B.
The correc-tive action for the citation was that Zack would review all of their procedures and revise as necessary and then submit for rereview by Baldwin Associates (BA) and Sargent & Lundy (S&L). Revision 4 of the above noted procedure was the result of this corrective action.
Comparing Revision 2 and Revision 4 established that changes were made to provide more specific criteria as well ac correcting errors. The inspector considered this item to have been satisfactorily resolved.
(Closed) Noncompliance (461/79-06-05):
Failure to provide objective evidence
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oi~ quality for purchased non-shrink grout material. A review of documentation made available to the inspector was undertaken. Documents reviewed included the following:
1.
A Master Builders Inc. letter of certification dated September 1, 1976 (placed in site records on August 8, 1979) certifying that Masterflow 713 Grout (as specified in S&L Specification K-2944) meets the require-ments and is the saine material as that covered by Herron Testing Laboratories, Inc. test report (file H84716).
2.
Herron Testing Laboratories, Inc. test report, file H8476 dated October, 1974, listing test results for Batch Code BE750V4 (supplied to Clinton).
3.
A Master Builders Quality Assurance Certification dated July 31, 1979 provided along with copies of the above listed test report, H8476, for the last two lots of grout delivered to the site (lot numbers BV0139 and DV129A).
4.
A licensee surveillance report, file Q24-PY-79 (08-20)-0, for the week of August 6, 1979 to August 10, 1979, rt,arding review of acceptable documentation for all grout received.
It. was learned that all grout received at the site had been established as meeting S&L Specification K-2944 including the Grout Mortor Testing of Table 5-1.
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The inspector also conducted a review of the on site testing facilities regarding user sampling testing of grouting material.
It was learned that for grout material used on the Reliance Truck gantry crane base plates, the required receipt material test (initial test) had been completed on April 21, 1979 and that the control test sample had been obtained from the material and the 2" x 2" cubes formed for compressive strength tests to be performed at the seven day and 28 day interval. No problem areas were identified and this item is considered resolved.
(0 pen) Unresolved Item (461/79-06-01): Spent fuel storage pool shop welds not in accordance with drawings. Nonconformance Report (NCR) No. 2436 was issued covering all material and an inspection was made of all welds with a disposition determined for all welds.
Completion of repairs is currently in progress.
(Open) Noncompliance Item (461/79-06-02):
Failure to identify and segregate nonconforming damaged structural steel. NCR 2365 was issued to control the specific structural members identified in the report.
Corrective action planned or in progress includes S&L defining defects and its repair require-ments with a new procedure to be prepared by B-A.
Functional or Program Areas Inspected 1.
Control Building Structural Steel Records Review The inspector selected several structural steel beams erected in the
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control building as samples for record review. The beams selected, located at elevation 749' as shown on Drawing ES 30-1408, Revision 2 are numbered IB3, IB4, 2B5 and 2B6. The records reviewed included the following:
Baldwin Associates Procedure BAP 3.1.3, Revision 1, Structural a.
Steel Erection b.
As-Built Drawings ES 30-1408, Revision 2 and ES 30-1409, Revision 2 c.
Form JV-560 Structural Steel Erection Checklist d.
Form JV-564 Structural / Miscellaneous Welding Surveillance Report Sargent & Lundy (S&L) Specification K-2948 e.
No items of noncompliance or deviations were identified as a result of this inspection.
2.
Review of ASME B&PV Code Certification The inspector reviewed the ASME Code Certificates to verify compliance with ASME Art.:cle NA-3000, as follows:
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Illinois Power Company, Owners Certificate, authorization to a.
complete form N-3 Number N-1425 for Clinton Unit No. I and for
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Unit No. 2 authorized on June 25, 1976 and expires on June 25, 1979. These certificates were extended on April 30, 1979 until June 25, 1980.
b.
Baldwin Associates Certificates of Authorization numbered N-2157 authorized NA work and N-2158 authorized NPT, authorized on August 4, 1978 and expires August 4, 1981.
Prior to issuance of the N Certificates, Baldwin Associates was authorized to perform NA and NPT work by letter of authorization dated June 7, 1976 and subsequent letter of extension until an ASME survey was held June 5-7, 1978.
c.
Reactor Controls Certificates of Authorization numbered N-1299 for NA work and N-1300 for NPT work was authorized on November 27, 1978 and expires on January 5, 1982.
d.
Chicago Bridge and Iron is no longer on site. The inspector obtained the certificate number from the ASME publication E-0061,
" Companies Holding Nuclear Certificates of Authorization." CB&I has Certificates of Authorization numbered N-1057-8, authorized on August 19, 1977 and expires on August 19, 1980, to build class 1, 2 and 3 vessels.
The NRC inspector reviewed the Hartford Steam Boiler Inspection and e.
Insurance Company's Authorized Nuclear Inspector's (ANI) Daily
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Inspection Records (Log) starting April 6, 1979 to present the ANI's Special Inspection Services Schedule (SIS) record of monitoring QA/QC programs of Baldwin Associates and review of the file of SIS Record for Monitoring QA/QC Programs. The ANI is assigned Baldwin Associates QA Manual No. 4.
f.
The NRC inspector reviewed Baldwin Associates Approved Suppliers List dated September 20, 1979 containing dates of last audits of supplier and further reviewed audits of three suppliers.
The above appeared to be in compliance with the 1974 issue of the ASME B&PV Code, NA-3000. Subarticles of the code are routinely inspected through the NRC's routine inspection program.
No items of noncompliance or deviations were identified in this area of the inspection.
3.
Reactor Vessel Installation - Review of QA Implementing Procedures The inspector reviewed QA plan, instructions and procedures for the reactor vessel installation activities to ascertain that these documents conform to the QA program as described in the facility PSAR.
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Review of reactor placement procedures as follows:
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a.
(1)
101 "Erectior. Procedure for the Gantry Crane at the Contain-ment Building Baldwin Associates Clinton Power Station Unit 1,"
Revision 2.
(2)
103 " Setting the Reactor Pressure Vessel in it's Final Position in the Containment Building," Revision 2, dated September 10, 1979.
(3)
104 " Transporting the Reactor Pressure Vessel from the Construction Pad to a Position Beneath the Containment Building Gantry Crane," Revision 2, dated September 10, 1979.
(4)
102 " Procedure for 762 Ton Load Test of Gantry Crane at the Containment Building," Revision 3, dated September 10, 1979.
(5)
106 " Hoist Prelift Checkout and Operational Procedure H-2 Bridge Crane," Revision 1, dated September 17, 1979.
b.
Review of Baldwin Associates Administrative Procedures, as follows.
(1)
No. 1, " Control of Instructions, Procedures and Drawings,"
Revision 2, dated September 1, 1979.
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(2)
No. 2, " Training Personnel Performing Activities Affecting Quality," Revision 2, dated September 10, 1979.
(3)
No. 3, " Document Control," Revision 0, dated April 4, 1979.
(4)
No. 4, " Inspection and Test Status," Revision 0, dated April 4, 1979.
(5)
No. 5, " Control of Nonconforming Materials, Parts or Components," Revision 2, dated September 10, 1979.
(6)
No. 6, " Corrective Action," Revision 1, dated August 14, 1979.
(7)
No. 7, "QA Records," Revision 0, dated April 4, 1979.
(8)
No. 8, "Audite," Revision 0, dated April 4, 1979.
c.
The inspector revin ed eight (8) prequalified welding procedure specifications titled, "Prequalified Joint Welding Procedures,"
all were Revision 0, dated March 23, 1979.
d.
Review of Baldwin Associates audits of Reliance Trucking Company, as follows:
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(1) Audit dated May 17, 1979, activity Jate May 14, 1979, con-
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sisting of observations made of steam generator lift made at Braidwood Station and a review of the QA program.
(2) Audit of Reliance Trucking, Pheonix, AZ, dated September 20, 1979.
Review of the checklists used to verify acceptability of the reactor e.
vessel moving and lifting equipment.
No items of noncompliance or deviations were identified in this area of the inspection.
4.
Reactor Vessel Installation - Observation of Work Activities The inspectors made observations of the reactor vessel move and instal-lation to ascertain that activities performed were in accordance with NRC requirements, as follows:
Observation of the gantry crane load test using concrete blocks a.
as loading of 762 tons.
The blocks were lifted and centered over the containment centerline. A minor problem occurred in that one wheel appeared to be frozen. The actual problem was corrected by replacing a quick disconnect fitting in a hydraulic line.
b.
Observation of the reactor vessel move from the construction pad to beneath the gantry crane.
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Observation of the reactor vessel lift and lowering into contain-c.
ment. Cleaning of the reactor vessel lower mounting skirt flange to remove loose scale and rust prior to mounting on the reactor vessel pedestal.
No items of noncompliance or deviations were identified in this area of the inspection.
Exit Interview The inspectors met with site staff representatives at the conclusion of the inspection on September 28, 1979. The inspectors discussed the scope and findings of the inspection which were acknowledged by the licensee.
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