IR 05000461/1981022

IE Safety Insp Rept 50-461/81-22 on 810801-31.Noncompliance Noted:Contractor Was Performing Stainless Steel Welding Operations Using Oversize Electrode & Unmarked Wire Brushes, Discs,Chisel & Chipping Hammers

ML20011A020
Person / Time
Site:	Clinton
Issue date:	09/15/1981
From:	Livermore H, Reimann F NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
To:
Shared Package
ML20011A008	List: IR 05000461/1981022 ML20011A007
References
50-461-81-22, NUDOCS 8110060364
Download: ML20011A020 (5)

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U.S. NUCLEAR REGULATORY COMMISSION

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OFFICE OF INSPECTION AND HiFORCH4H1T

REGION III

Report No. 50-461/81-22 Docket No. 50-461 License No. CPPR-137 Licensee: Illinois Power Company 500 South 27th Street Decatur, IL 62525 Faciliti Name: Clinton Power Station, Unit 1 Inspection At: Clinton Site, Clinton, IL Inspection Conducted: August 1 - 31, 1981

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cl - 10 - $1 Inspector:

H. H. Livermore fC -h ?

Approved Rr:

F. Reimann, Acting Chief

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Projects dection 1 C Inspection Summary Inspection on August 1 through 31.1981. (Report No. 50-461/81-22)

Areas Inspected: Routine, Resident Inspector's inspection of construction activities including material laydown and storage areas, welding activities, quality control inspection activities, nondestructive testing, and electrical cable pull activities. The inspection involved a total of 64 inspector hours onsite by one NRC inspector, including O inspector hours d"Mne off-shifts.

Resul ts: Of the areas inspected, one item of noncompliance was i.;tified.

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DETAILS 1.

Persons Contacted Principal Ilcensee Dnployees W. C. Gerstner, Executive Vice President

• J. O. McHood, Vice President, Project Manager, Clinton

• G. M. Brashear, Site Manager, Clinton

• R. J. Canfield, Director-Construction

• A. J. Budnick, Director-QA

• E. E. Connon, Assistant Directon-Construction

• L. W. Dozier, Assistant Director-Construction

• D. E. Korneman, Construction R. W. Folck, QA Specialist

• J. S. Spencer, Director-Engineering R. We M r, QA Engineer J. Geit., Manager-General Engineering W. L. Calhoun, Electrical Construction B. Spicer, QA Consultant

• M. C. Hollon, Supervisor-QA

• F. G. Schwarz, Supervisor c/s Construction

• G. N. Motsegood, Engineering

• R. Morgenstern, QA Specialist Baldwin Associates

• J. W. Smart, QA Manager

• T. Selva, Manager, Quality and Tecluncal Services

• W. H. Harrington, Project Manager

• J. E. Findley, Project Engineer

• H. R. Swift, Assistant Project Engineer

• L. A. Gelbert, QC Manager G. B. Browne, Manager, Subcontracts B. Curby, Asst. Project Manager

• G. Chapman, Manager, Technical Services General Electric J. L. Dempster, Site Manager S. G. Hall, Quality Control Other staff and personnel were contacted during the reporting period.

• Denotes those attending at least one of the exit meetings.

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2.

Functional or Prorram Areas Inspectod a.

Site Tours At periodic intervals during the report period, tours of areas of the site were performed. These tours were intended to assess the cleanliness of the site; storage conditions of equipment and material being used in site construction; the potential for fire or other hazards which might have a deleterious effect on personnel and equipment, and to witness construction activities in progress.

No items of noncomp1._ance o deviation were identified.

b.

Inspection Support An NRC investigation of Quality Control related activities was performed for the period of Jura ?-19, and July 31, 1981. The Resident Inspector has continued to provide staff technical support and follow-up for these activities. All relatad items of noncom-plience or deviation will be included in the I ton III report.

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Inspection of Material and Component Storage Areas During the span of the reporting period, the Resident Inspector toured the yani and powerblock storage areas several times.

Safety-related material was segregated, off the ground, protected, and, in general, adequately stored. Minor problems were corrected by local supervision.

No items of noncompliance or deviation were identified.

d.

Fabrication of Safety-Related Systems During the reporting period, the inspector observed work incicding handling, protection, inspection, and welding of the following eefety-related systems: Electrical Hanger Traveler E26-1003-03A-H51, SMAW, Welder V318; Main Steam Quencher to Suppression Poc1 floor, welds 1MS25012A 2 and 1MS26011A-2; and Containment Pep tion, RH System, joint 1RH-8-35, traveler RH-8A.

For each of welds one or more of the following fabrication activities was observed. Handling and protection of piping or structure and partially completed welda were satisfactory. Purge and shielding gas was correctly used wn.n applicable. The weld area was free of contaminants. The joint fit-up t lmensions were within requirements i

and the welders were certified as qualified for the thickness and the process specified to be used for welding the-joint. Technique and weld results appeared to be satisfactory.

No items of noncompliance or deviation were identified.

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Installt. tion of Main Steam Quoncher Support The inspector perfomed a surveillance of the installation and-3-

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welding operation of the stainless steel Main Steam Quencher Support to the Containment Suppresion Pool floor per traveler H-1B21-IE00H-A(16 location). Weld number 1MS22017A-2 was in progress per the requirements of weld procedure NP-8-8-BA-L/2.

Figure II of the weld procedure specifies 1/8" or 3/32" size E XXX electrode only. Welder F167 was performing Shielded Metal Arc Welding (SMAW) with oversize 5/(32" E308L electrode.BTSF 030) in the All electrode field requisition forms area were incorrectly filled out by craft supervision - calling for5/32" electrode.

The inspector also noted that welding tools such as wire brushes, discs, chisel, chipping hammers, were not marked for use on stainless steel. Baldwin Procedure BAP 1 9, paragraph 4 3 requires that tools be clearly identified as to the surface material on which they are to be used, i.e., marked with purple paint or tape for stainless steel. The inspector also noted that the welding tools were scattered around the floor amidst dirt and debris.

This item is considered to be in noncompliance with the require-ments of Criterion IX of D CFR 50, Appendix B, (50-461/81-22-01).

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Piping System N#estructive Testing During the reporting period the inspector observed nondestructive testing (liquid Penetrant) of the main steam quencher assemblies to the containment suppression pool floor.

Surveillance of NDE was performed on welds 1MS21018A-2, 1MS22017A-2, 1MS36013A-2, and 1MS24012A-2. Surface preparation, application and technique were satisfactory.

No items of noncompliance or deviation were identified.

g.

Electrical Cable Installation During the reporting period, the inspector observed work including installation, handling, and protection of electrical cables.

Specifically, work associated with the electrical cables listed as follows was observed: Cables 1 DC03 F, 1 DC03 E, and 1 DC03 D, and 1 DC01 F.

The cable was hand pulled through conduit and tray in the Auxiliary Building and Control Building 781 level.

It was observed that: Pull cards were in use; cables were identified; Quality Control inspechions were performed and Quality Control personnel witnessed the pull.

No items of noncompliance or deviation were identified.

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Authority for 2 top.-Work Action Baldwin Project Procedare BAP 1.6, Initiation of Stop-Work Action, paragraph 5.1, states, in part, "The Project Manager and Manager of Quality and Technical Services, or their delegated representative, chall be notified when significant nonconformances are recognized-4-

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at the Construction Site, and the authorized Baldwin Associates personnel deem such nonconformances serious enough to warrant stoppage of work involved." The inspector notes that actual stop-work authority rests only with a few top management personnel.

The 6uthority of a Quality Control inspector to stop work is not delineated or detailed in a procedure. The inspector notes that

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when a specific safety concern arises during a aingular on-the-job operation (such as a concrete pour, etc.) Quality Control must have the capability to stop the work immediately if necessary.

The quality or safety concern must be addressed immediately by a qualified responsible inspector, not delayed or dispositioned after the fact. This is.Open Item 50-461/81-2202.

Noteworthy Events Mr. George Brashear, Site Manager for Clinton Nuclear Power Station, has left the employ of Illinois Power Company. His duties havo been absorbed by Mr. Jartes McHood, Vice President for Construction.

Exit Meetings The Resident Inspector attended exit meetings conducted by Reglon III inspectors R. Ganiner, R. love, R. Douglas, and C. Oberg on August 14, and 25, 1981. The Resident Inspector met with' licensee representatives (denoted under Persons Contacted) on August 14 and 28,1981. The inspector summarized the scope and findings of the. inspections performed.

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