IR 05000546/1979010
| ML19208B353 | |
| Person / Time | |
|---|---|
| Site: | Marble Hill |
| Issue date: | 07/23/1979 |
| From: | Hayes D, Naidu K NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML19208B351 | List: |
| References | |
| 50-546-79-10, 50-547-79-10, NUDOCS 7909200066 | |
| Download: ML19208B353 (8) | |
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U.S. NUCLEAR REGULATORY COMMISSION
OFFICE OF INSPECTION AND ENFORCEMENT
REGION III
Report No. 50-546/79-10; 50-547/79-10 Docket No. 50-546; 50-547 License No. CPPR-170; CPPR-171 Licensee:
Public Service of Indiana 1000 East Main Street Plainfield, IN 46168 Facility Name: Marble Hill Generating Station, Units 1 and 2 Inspection At: Marble Hill Site, Jefferson County, Indiana Inspection Conducted:
July 10-13, 1979
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k'fjgc6 7/23/77 Inspectors:
K. R. Naidu
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Approved By:
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Ecgineering Support Section 1
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Inspection Summary
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Inspection on July 10-13, 1979 (Report No. 50-546/79-10; 50-547/79-10)
Areas Inspected:
Safety related structures - review of QA program and procedures, observation of work activities, review of quality records and audits. This inspection involved a total of 22 inspector-hours on site by one NRC inspectoq Results: No items of noncompliance were identified in the five areas inspected.
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DETAILS
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Persons Contacted Public Service of Indiana (PSI)
R. M. Brown, Construction Project Superintendent J. J. Cook, Senior Staff Construction Engineer J. Coughlin, Vice President, Nuclear L. A. Crews, Vice President, Construction S. K. Farlow, Construction Engineer
- T. J. Geymen, Quality Control Engineer F. R. Hodges, Manager QA J. H.
Hansker, Construction Project Engineer T. L. McLarty, QA Construction Supervisor W. A. Muensterman, Senior Construction Engineer Nuclear D. L. Schuter, QC Engineer R. E. Wooley, Construction Supervising Engineer American Bridge Company (AB)
- W. B. Zeeveld, Field Quality Assurance Officer Gust K. Newberg - Marble Hill (GKN)
- M. Cooper, Production Superintendent E. G. Guy, Quality Assurance Supervisor
- C. W. Mayer, Quality Assurance Administrator
- J. B. Moore, QC Inspector H. H. Robertson Company
- G. W. Brack, QA Inspector
- R. J. Goss, Field Superintendent
- W. D. Smith, Job Superintendent TRW-Nelson Division
- G. L. Luce, Sales Representative
- Denotes those who did not attend the exit meeting.
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Functieaai a Program Areas Inspected
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1.
Review cf American Bridge QA Program American Bridge (4B) is the cognizant contractor installing the safety related structural steel including the Seismic Category 1 auxiliary building framing.
Public Service Company af Indiana (PSI)
purchased the structural steel components and inspected them on arrival at site prior to installation. AB is a subcontractor to Gust K. Newburg (GKN). AB subcontracted the installation of metal decking to H. H. Robertson and Associates.
The inspector reviewed the AB QA manual dated October 17, 1977, a.
and the relavant procedures and determined the following acceptable:
(1) " Procedure Preparation" - QAPN-1, Rev. 1, dated October 11, 1978.
(2) " Training and Qualification of Personnel" - QAPN-2, Rev. O, dated October 11, 1978, reflects the requirements of ANSI 45.2.6.
(3) " Document Control" - QAPN-8, Rev. O, dated January 23, 1979.
(4) " Calibration of Instruments" - QAPN-8, Rev. O, dated January 5,1979.
(5) " Handling and Storage" - QAPN-9, Rev. 3A, dated April 25, 1979.
(6) "Nonconformances and Corrective Action" - QAPN-10, Rev. O, dated January 5, 1979.
b.
The following required clarification:
(1) " Identification and Control of Purchased Material Or Item" - QAPN-3, Rev. O, dated December 6, 1978. The scope of this procedure did not include the purchase of services.
';he inspectcr stated thtt since the services of J. J. Rober'. con, the decking installation contractor was purchased, this aspect should be addressed in the procedure.
(2) " Audit Procedure" - QAPN-11, Rev. O, dated February 5, 1979. The scope of this procedure did not include auditing subcontractors performing work on site.
The inspector discussed the above findings with representatives of GKN and AB.
AB in a letter dated July 13, 1979, to GKN stated that the AB Corporate QA office performed the procurement-3-
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and auditing functions. The AB Field Quality Assurance Officer
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(FQAO) informed the inspector that he will obtair. and make available copies of subcontractor audits.
Pending review of the audits, this item is unresolved.
(546/79-10-01; 5A7/79-10-01)
No items cf noncompliance were identified.
2.
Observation of Safety Related Structural Activities The inspector observed the Fuel Transfer Canal (FTC) being set a.
in place. The FTC was fabricated on site by Chicago Bridge and Iron (CBI) snd was transported to the intended location utilizing CBI approved instructions detailed in rigging drawings. The FTC was being installed in accordan" with the arrangement shown on CBI drawing 100, Rev. 1.
ubI procedure DCIN, Rev. O, dated May 8, 1978, titled " Dimensional theck Procedure for Field" for stainless steel free standing pool liners permits a 2" out of plumbness over the entire height of the structure.
Periodic surveys were taken to measure the plumbness; read. gs taken to-date indicate that the out of plumbness to be less than 2".
Shims were u:,ed to level the structure and the installation is in progress. Upon completion, final plumbness readings will be taken and recorded.
b.
The inspector observed the installation of beams identified as 6007B3, 6007B4 and 6013B4 at elevatiou 426'0"; the installation was in accordance with Inryco drawing sheet E 1293 Auxiliary Building. The inspector chserved beams being bolted in the auxiliary building area at elevation 463'5" between lines Q10 and Q13.
Bolting procedure QAPN-12 dated November 2, 1978, was being followed; " turn of the nut" method was being used to verify the tightness of the nut.
The inspector observed Nelson Studs being welded on the turbine c.
building decking by H. H. Robertson personnel. Even though this area was not safety related, the inspector elected to scrutinize the operations because the same personnel would be shooting Nelson Studs in the safety related areas.
Typical unacceptable conditions included the following:
(1) Shooting Nelson stuc's in wet areas; not wire brushing and cleaning the areas prior to stud welding.
(2)
Improper positioning of Nelson studs in the welding gun.
(3) Not adjusting the current setting when changing the location of welding from beam with no decking to beam with decking.
Nelson stud welding procedure No. 2 dated August 15, 1978.
in Paragraph 6.3.2 indicates the amperage and time for a 3/4" stud welded to a beam with decking to be 1700-1850 amps and 1.3 to 1.4 seconds.
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At the NRC inspectors request, an current / time analyser
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was inserted in the circuit to measure the current and time.
It was determined that the current and time was 1450 amperes and 1.3 seconds which are less than those specified in the procedure. The AB Field QA Officer issued a "Stop Work" order on their subcontractor H. H. Robertson. The AB FQA0 assured the NRC inspector that the "Stop Work" order would be rescinded only after satisfactory retraining and indoctrination of the H. H. Robertson's stud welding machine operators. The reason for the lower current from the power grid would also be investigated and corrected.
On July 13, 1v79, the RIII inspector accompanied by representatives of the H. H. Robertson, AB, GKN, "TRW" (the Nelson Stud Welding machine supplier) and PSI inspected the work performed the previous day. Suspected Nelson Studs were bend tested with a hammer. Typical failures indicated porosity and lack of fusion.
At the conclasion, the RIII inspector conferred with the represen-tative and obtained a committment to retrain the stud welding operators.
Pending review of the documented retraining session, this items is considered unresolved.
(546/79-10-02; 547/79-10-02)
3.
Review of Quality Assurance Records The inspector reviewed the Quality Assurance records relative to the safety related structural steel beams, components, bolts and inspection records.
The components fabricated by Inryco were subjected to shop inspections at the Inryco's manufacturing facilitiet.
a.
Beams (1)
Inryco manifest No. 59 dated March 12, 1979, document sequence number (DSN) No. 0502795019, indicates that 73 beams (identified with unique numbers) were received on site undamaged. A Quality Release Tag signed by the PSI representative indicates the following:
(a) All the documentation was complete.
(b) No outstanding items were attached.
(c) That the material described in the manifest is released for shipment.
(2) Receiving Inspection Checklist (RIC) dated April 30, 1979, indicates that the various attributes mentioned in the checklist were verified and determined to be satisfactory.
(3) Records indicate that dimensional checking was performed on a random sampling based on MIL-105D on various shipments of steel. Unacceptable indications were documented in-5-
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Field Nonconformance Reports (FNR).
Review of FNR 170
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(DSN 0611 79 5046) dated April 9, 1979, indicates that several beams supplied in various shipments had minor deficiencias; the deficiencies were repaired on site and the corrective action taken was documented in an Inryco site representative letter dated April 13, 1979. To preclude recurrences, PSI established a shop representative in Inryco.
b.
Structurel Components (1) DSN 0507795033 (manifest No. 49 dated May 5, 1979) indicates tbat 36 structural components were received on site with no shipping damage. Field Corrective Action Request (FCAR) No. 751 was initiated to clarify references identified in drawings 2129, 3073, 2024, 2049, 2098, 3027 and 3041.
The contents of the FCAR was satisfactorily resolved on May 7, 1979.
(2) A QRT signed by the PSI shop representative was attached.
(3) Material certificate from U. S. Steel Company furnished the physical and chemical composition and certifies that the material conforms to the requirements of ASTM A36-75.
(4) RIC dated March 12, 1979, ind' cates that the various attributes were verified and.ne unsatisfactory conditions are documented in FCAR 751 and FNR 139 (DSN 0514 79 5091).
As reported earlier, FCAR No. 751 was satisfactorily resolved on May 7, 1979, and documented the corrective action taken to repair the defeciencies on site.
c.
Bolts (1) DSN No. 022679504o dated February 23, 1979, indicates that
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s 7/8" diameter bolts of various lengths of ASTM A 325-76C type bolts and nuts were received with no shipping damage.
(2) Material certification from Russell, Burdsall and Ward (RB&W) dated February 9, 1979, furnish the heat number, the lot numbers from which the bolts and nuts were manufac-tured, the material properties, the results of the ultimate tensile strength and the Brinell or Rockwell-C hardness numbers. The material is certified to conform to ASTM A 325-76C requirements.
(3) DSN No. 060795031 dated June 6, 1979, indicates that 1 1/8" bolts of various sizes and nuts supplied by RB&W were received with no shipping damage.
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(4) Material Certification from RB&W dated March 7, 1979,
furnish the heat numbers, the lot numbers from which the bolts and nuts were manufactured, the material properties, the results of the ultimate strength and the Brinell or Rockwell-C hardness numbers. The material is certified to conform to ASTM A 490-76A requirements.
d.
Inspection Records Upon completic" of the installation of the beams and torquing of the bolts AB, the tightness of the bolts are verified by f
U. S. Testing Company (UST), the licensee's independent testing agency. Test reports identify the connection number, reference the drawing number and indicate the r esults of physical testing and visual inspections. UST procedure QCP-22, Rev. O, dated March 2, 1979, titled " Structural Steel Bolting Tension Testing" was used to perform the tests. According to this procedure, the licensee is required to te notified only if a rejection occurs. To date no rejections were reported.
No items of noncompliance were identified.
4.
Review of Quality Assurance Welding Records The inspector reviewed the Quality Assurance Records relative to the welding activities performed by AB and determined the following:
Typical Weld Electrode receiving report dated February 1, 1979, a.
indicates that AB received 5/32 E 7018 type electrode lot No.
03-2-G718B with no shipping damage. Liquid Air Incorporated, the manufacturer of the electrode certified that the weld rod with trade name LA 7018 ccnforms to AWS A5.1-69 and furnished the physical and chemical properties.
b.
AB surveillance reports indicate that the temperatures of the weldrod ovens were checked weekly; additionally, the oven temperature settings are calibrated every six months.
AB inspection personnel verified weld machine settings every c.
six months on all the welding machines to verify whether the machines deliver the current and voltage set on the dial indicator.
Surveillance report dated February 6,1979, indicates that the voltage and current settings on six welding machines were verified with an Amprobe with serial No. 4345.
d.
Weld Placement logs are used by AB to document welding activities.
Typical data on weld placement log indicates the date on which welding was performed, the location, the joint welded, the weldor, the inspector's identity and the date of inspection.
The AB FQA0 reviews the final status of the welding performed.
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e.
The followin8 AB Welding Procedure Specifications (WPS) were available:
(1)
F-1 (GGG) 5/32" 9 E-7018 rod for overhead.
(2)
F-1 (MMMM) 1/8" 9 E-7018 rod for overhead.
(3)
F-1 (FFF) 5/32" 9 E-7018 rod for upward progression.
(4)
F-1 (HHH) 1/8" 9 E-7018 rod for upward progiee: don.
(5)
F-1 (NNN) 3/16" 9 E-7018 for horizontal.
(6)
F-1 (PPPP) 5/32" 9 E-7018 for horizontal.
No items of noncompliance were identified.
5.
Review of Audits The inspector reviewed the audits performed by Gust K. Newburg (GKN)
on the activities of their subcontractor American Bridge (AB).
An audit performed by GKN on AB on May 31, 1979, vcrified the implementation of procedures QAPN-2, 4, 8,10,11 and Tssociated sections of the AB QA manual. GKN in a letter dated Jcae 1, 1979, requested AB to respond to the audit findings and to include the corrective actions taken to preclude repetition. AB in their letter dated June 11, 1979, addressed corrective action taken on findings.
The audits were legible and retrievable and were performed by qualified auditors.
In addition to audits, periodic surveillances were performed on AB by GXNA QA personnel.
Surveillance report dated May 22, 1979, indicates that NCR 368 was initiated to identify excessive coping on one of the beams. The NCR was processed properly; corrective action has not been completed. The inspector has no further questions on this matter.
No items of noncompliance were identified.
Unresolved Items Unresolved items are matters about which more information is required to escertain whether they are acceptable items, items of noncompliance, or deviations. Unresolved items disclosed during this inspection are discussed ir Paragraphs 1 and 2.c of this report.
Exit Meeting The inspector met with the site staff representatives (denoted in the Persons Contacted paragraph) at the conclusion of the inspection on July 13, 1979. The inspector summarized the scope and findings of the inspection.
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