IR 05000546/1979011
| ML19260A442 | |
| Person / Time | |
|---|---|
| Site: | Marble Hill |
| Issue date: | 10/03/1979 |
| From: | Fiorelli G, Hayes D, Williams C NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML19260A437 | List: |
| References | |
| 50-546-79-11-01, 50-546-79-11-1, 50-547-79-11, NUDOCS 7911210127 | |
| Download: ML19260A442 (74) | |
Text
{{#Wiki_filter:( v . ' U.S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT
REGION III
Report No. 50-54o/70-11; 50-547/79-11 Docket No. 50-546; 50-547 License No. CPPR-170; CPPR-171 Licensee: 2blic Servir of Indiana 1000 East. Matt zet " %ciMield, I'. 46168 Facility Name: Marble Hill Nuclear Generating Station, Units 1 and 2 Inspection At: Marble Hill Site, Jefferson County, Indiana Inspection Conducted: July 26, 27, 31 and August 1-3, 1979 /$ C. C. ffg6&sm /8-8-7f Nilliams, Chief Inspectors: Projects Section 2 W hi /d E 7f , Engin ering Sup o. t Section 1 /O~3-7f F
. K. R. ~ a /O'3'7 , /e f'29 Approved By: . Florelli, C ief h - Reactor Construction and / Engineering Support Branch Inspection Summary Inspection on July 26, 27, 31 and August 1-3, 1979 (Report No. 50-546/79-11 50-547/79-11) Areas Inspected: Special, unannounced inspection involving determination of adequacy of site management, QA/QC and engineering organizations. The investigation involved 240 inspector hours onsite by four NRC inspectors.
Resalts: In the areas inspected it was determined that the pubject organizations were inadequate in staffing, technical qualification and experience to an extent that precludes continued construction of safety-relatei items. Four items of noncompliance were identified and are outlined in Paragraphs 4, 5 and 6 of this report.
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f = Introduction - The Marble Hill Nuclear Power Plant, Units 1 and 2, licensed to Public Service of Ir ^laa, is under construction at a site approximately 10 miles south of Madison, Indiana. Sargent & Lundy is the architect engineering agent for the plant. The facility will utilize two 1150 megawatt pressurized water reactors supplied by Westinghouse. Unit 1 is approximately 20% complete and Unit 2 is approximately 6% complete.
Reason for Special Inspection As is detailed in Region III Marble Hill Report Numbers 50-546/79-07; 50-546/79-08 and 50-546/79-09 and the July 10, 1979, report from "The National Board of Boiler and Pressure Vessel Inspectors," serious and extensive noncompliance to construction and fabrication requirements have occurred at the Marble Hill plant site. As a result of these findings, civil car.struction activities were stopped several times. The objective of this inspection was to identify tne underlying causes of the nonconforming conditions outlined in the reports referenced above.
During the conduct of the above referenced inspections, symptomatic deficiencies were noted in the number, qualifications and nuclear construc-tion experience of personnel in the site organizations for management, quality assurance / control, and engineering. This effort focused on an assessment of the practical capability of these organizations and their methods of operation and interfacing for controlling the construction activity.
Summary of Findings NRC has concluded that effective implementation of the documented Marble Hill Quality Assurance program for all safety-related construction has not occurred. PSI has not sufficiently complied with its fundamental commitment to conduct all of these construction activities in accordance with the requirements of 10 CFR 50, Appendix B, and other required codes and standards.
The principal causes of these adverse conditions and noncompliances were: (1) insufficient management and management support, (2) insufficient number of personnel, (3) insufficient technical qualification of personnel, and (4) insufficiently experienced personnel.
The secondary but significant contributing causes were: (1) failure to adequatey identify PSI's task or mission regarding the verification of the adequacy of work done by contractors, (2) failure to devise a system to comprehensively account for and evaluate all identified nonconformances occurring on the site, (3) failure to recognize the generic implications of recurring deficiencies, (4) failure to recognize that fixed, price construction contracts, while not inherently defective, are likely to place heavier demands on the licensee verification of construction adequacy, 1382 039-2_
, (5) failure to delegate sufficient authority to QC inspectors and their managers regarding stop-work authority, (6) failure to institute employment (manning) and compensation practices which would attract adequately qualified and experienced job applicants, (7) failure of corporate management to recognize the need to be more responsive to site QA/QC manning request, (8) failure to be responsive to and recognize the importance and authority of construction code enforcement bodies, and (9) failure to recognize that the use and attempted upgrading of laborers to supplement unavailable journeyman craftsmen requires more comprehensive training and oversite.
The above findings by their nature involve all safety-related construction activity at the site. Without extensive corrective actions, there is little likelyhood that continued construction can be accomplished with adequate assurance that quality requirements will be met.
Based on the above, NRC participated in the licensee's decision to stop all safety-related work at the site until comprehensive corrective actions were established and demcastrated to be effective. This conclusion was further reinforced by the issuance of a confirmatory order by the NRC on August 15, 1979.
I382 040-3- .
e , DETAILS 1.
Principal Persons Contacted Public Service of Indiana
- S. W. Shields, V. P. Electric Systems
- L.
A. Crews, V. P. Construction
- T. R. Burns, Supervising Engineer Nuclear
- G. Hofmockel, V.P. Engineering
- F. R. Hodges, QA Manager
- M. L. Morris, /ssistant Project Manager R. M. Brown, Construction Pr.3 ject Superintendent
- T. L. McLarty, QA Construction Supervisor
- W. T. Smith, Construction Field Supervisor
- S. K. Farlow, Site Design Control Supervisor D. L. Shuter, Lead QC Engineer J. Roberts, Supervisor QA Design and Procurement V. Berlin, QC Engineer T. L. Sheet, Supervisor QA Records Reviewer F. Wilkins, Records Reviewer W. Minic, QC Inspector J. Span, QC Inspector R. E. Wooley, Construction Supervising Engineer J. Bott, Engineer R. E. Coughlin, V. P. Nuclear W. A. Muensterman, Sr. Construction Projecc Engineer R. A. Latronica, Sr. Construction Project Engineer C. J. Korba, Personnel Manager D. A. Dedrick, Senior QA Engineer L. Davis, QA Engineer D. Barker, QA Engineer N. Nocodemus, QA Engineer J. Payton, QA Engineer R. A. Mustafa, Engineer Construction Code Representatives W. F. Johnson, Superviuor Quality Systems, National Board of Boiler and Pressure Vessel Inspectors Robert F. Johnson, Chief Inspector Indiana Boiler and Pressure Vessel Board C. W. Allison, Field Representative National Board of Boiler and Pressure Vessel Inspectors.
Charles Merkel, Nuclear Inspection Specialist, Indiana Boiler and Pressure Vessel Board W. Braden, Authorized Nuclear Inspector (Site Contractor), H. Moran, Authorized Nuclear Inspector (Site Contractor) i382 041-4-
r i e Nutech Corporation - R. F. Reedy, Consultant (ASME Code) J. Crowe, Consultant (ASME Code) Newburg-Marble Hill M. P. Cooper, General Superintendent J. Ball, Lead QC Engineer E. P. Guy, Quality Assurance Supervisor Chicago Bridge and Iron Company L. Bauer, Project Foreman Cherne Contracting Corporation C. Jergens, QC Manager Stewart Mechanical Incorporated D. A. Hignite, QC Supervisor B. Cash, QC Inspector
- Denotes those present at the exit meeting.
2.
Scope of Inspection This inspection included review and examination of the PSI organizations for corporate management, site construction management, site QC, Corporate QA, site engineering, and corporate engineering.
It also included evaluation of PSI's resolution of nonconformances to the ASME Boiler and Pressure Vesm.] Code Section III, Division 1, as documented by " National Board" letter dated July 10, 1979, and the construction performance of site civil, mechanical and piping contractors to the extent that PSI's capability to control the quality of the plant construction activity was demonstrated.
3.
Corporate and Site Management a.
Interviews were held with supervisors and managers of Public Service of Indiana QA/QC, Construction Project and Personnel organizations. The purpose of these interviews was to determine underlying causes of the concrete and other problems experienced at Marble Hill. This was accomplished by review and evaluation of: ' (1) Organization and staffing.
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, , (2) Knowledge and experience of project management personnel in nuclear power and major construction projects.
(3) Understanding and commitments to quality assurance.
(4) Establishment of goals and objectives.
(5) Responsibilities and delegation of authorit y.
(6) Action on field identified problems and the timeliness and adequacy of this action.
(7) Interface provisions and communications between organizations.
b.
Based on these discussions with both site and corporate management personnel and review of records and internal reports, the apparent major contributors to the Marble Hill problems are summarized below: (1) Lack of full understanding and appreciation of the complexity of managing a project of the magnitude of Marble Hill.
The Tendency was to treat managment of the Marble Hill project much the same as past management of fossil power plant construction. There was not a recognition of the need for perst'nel having nuclear coastruction experience to man key site positions nor of the number of site personnel needed to exercise adequate control of site work.
(2) The role and responsil>ili+.y of the QA/QC organization and its impact on other company organizations had not been adequately defined and this has led to apparent misunder-standing and lack of full acceptance of the QA/QC organization.
(3) Adequate authority had not been delegated to site management personnel.
c.
Other contributing factors include: (1) Over reliance on contractors.
(2) Emphasis on costs.
(3) Pay policies.
4.
Review of QA/QC Organization a.
Objective The objective of this part of the inspection was to' determine the effectiveness of PSI QA/QC organization during the construction of Marble Hill Units 1 and 2.
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F t b.
Method of Accomplishment The preceeding objectives were accomplished by an examination of: (1) PSI QA/QC organization; staffing and qualifications.
(2) Responsibilities and authorities of QA/QC personnel.
(3) Interfac.rs between QA/QC - project management - engineering - contractors and craftsmen.
(4) Determination of possible constraints relative to the effective implementation of these responsibilities.
(5) Communications within the project management group both upward and downward.
(6) Effectiveness of dealing with unsatisfactory conditions which have been identified.
(7) Attitudes toward quality.
The methods used in accomplishing the objectives required interviewing PSI QA/QC and project management personnel, reviewirg PSI QA/QC management and technical records including documented requests for additional inspection personnel, Fielu Nonconformance Reports, PSI Field Corrective Action Requests, and correspondence involving ASME Section III materials.
Interviews were also conducted with representatives of the National roard of Eciler and Pressure Vessel Inspectors, and the Authorized Inspectors representing site contractors.
c.
Findings (1) Liberal interpretation by PSI, for PSI QA/QC personnel, of the ANSI N45.2.6-1973 standard (concerning qualification of inspection examination and testing personnel) has resulted in the following: (a) Neither PSI procedure QAP 6.8 nor CMP 3.10 requires extensive previous inspection experience prior to assigning personnel as PSI Inspectors (Level I, II, or III), QC Engineers or QA Construction Supervisor.
(b) Of the twenty-nine (29) PSI site QA/QC personnel, who are currently involved in inspection / surveillance or overview of site activities, only four (4) have had g nuclear power plant construction inspection experience 1382 044-7-
, . prior to being assigned by PSI to the QA/QC organization.
There is less than 15 man years of experience distributed between these 4 people.
This condition is contrary to 10 CFP 50, Appendix B, Criterion II; the Marble Hill PSAR Chapter 17.1.2 and therefore ANSI N45.2.6 (1973). This item is an infraction.
(546/79-11-01; 547/79-11-01) (2) PSI has failed to provide comprehensive documented instructions or procedures to assure that repetative nonconforming conditions are identified, tracked and corrected to prevent their recurrence. Consequently, the following adverse conditions were noted.
(a) Over a twelve month period Newberg-Marble Hill issued ninety-one (91) Field Nonconformance Reports identifying areas of defective concrete (i.e. honeycomb).
It was not until April,1979 af ter NRC intervention that PSI viewed this condition as an unsatisfactory trend.
(b) Over a fifteen month period Newberg-Harble Hill issued twenty-five (25) Field Nonconformance Reports identifying "out of slump" concrete as being placed.
The applicable specification (Y-2850 paragraph
411.A.e addendum 1) has not required that the placement of concrete be slowed to minimize the amount of nonconforming concrete placed, should the in process concrete test results prove unsatisfactory.
It was not until July, 1979 'nat PSI seriously viewed this condition as an unsatisfactory trend, requiring a specification change.
(c) A total of two hundred and thirty-five (235) Field Corrective Action Requests, identifying unsatisfactory documentation or nonconforming piping spool pieces, were issued by PSI to/against ITT Grimmell (an off site vendor supplying piping spool pieces). One hundred and ninety-six (196) of these beinF documenta-tion defficiencies, the remaining thirty-nine being related to improper fabrication. The corrective action for these unsatisfactory conditions failed to prevent recurrence.
This condition is contrary to 10 CFR 50, Appendix B, Criterion XVI and the Marble Hill PSAR Chapter 17, Section 17.1.16.
This is an infraction.
(546/79-11-02; 547/79-11-02) , I382 045-8- .
, . (d) As a result of interviews with QC inspectors and review of nonconformance documentation, it was deter-mined that there have been numerous unsatisfactory conditions which have occured during the in process installation of concrete. However, immediate stepping of the nonconforming activity apparently did not occur. These conditions may have been prevented or reduced to a minimum; if the PSI QC inspector (s) who observed the occurrence (s) could have required that the activity was immediately stopped. The present system employed by PSI for issuing a stop-work order requires inordinate processing through the QA/QC organization, and project and engineering organizations.
Consequently, the effectiveness of QC inspection is seriously compromised. That is, the inspector has no practical authority to stop in process nonconforming activities. NRC inspectors determined that there has been only one quality related stop-work issued by PSI at the Marble Hill site. This condition is contrary to 10 CFR 50, Appendix B, Criterion II and the Marble Hill PSAR Chapter 17, Section 17.1.1.1.
This is an infraction and is cited as an element of Appendix A, Item 1.
(546/79-11-01; 547/79-11-01) (e) It was determined through indepth discussion that PSI's practical understanding and assesment of their QC inspection task or mission, is not comprehensive.
Historically, the QC organization conducts survell-lances of construction activities. However, these surveillances have been mostly topical without enough depth or frequency to adequately assure that the contractor's craftsmen and QC organizations were performing as required. Perfunctory QC surveillance appears to have been the basis of PSI management and implimenting decisions regarding the site QC organization. As can be seen in the sites noncon-formance history, and the multitude of adverse issues identified by NRC and others, this QC philosophy is inadequate and has led to conditions as identified in this report, that constitutes nonconformance to 10 CFR 50, Appendix B, Criterion II.
(546/79-11-01; 547/79-11-01) (f) As is indicated by attachments A and B (PSI QC Group Manpower Summary) the PSI site QC organization is and has been seriously understaffed.
By site QC managements estimation, there is current;y a need for additional members of the QC organization.
It is ind_icated that 31 QC inspectors are needed, whereas only eight are currently available. Moreover, the eight who are-9-
, , currently available are in some cases, seriously inexperienced as cited above and in Appendix A of this report.
(546/79-11-01; 547/79-11-01) (g) As is shown by Attachment A of this report (graphic comparison of PSI total site QC organization to total site manning), the number of inspectors as compared to construction forces has remained virtually the came from December 1978 to July 1979, although site construction activity during the spring and summer has increased tremendously. Approximately 300 additional people were added to the work force.
(Note: only eight of the 29 members of the site QC organization are QC inspectors.) NRC inspectors determined that in November 1977, PSI QC forces represented 41% of the total QC forces at the site In December 1978, PSI QC represented 36% of total QC staffing at the site. at the time of this inspection PSI QC represented 31% of the total QC forces at the site. The foregoing shows fundamentally, that while construction activity was increasing tremendously, PSI capability to monitor it was steadily decreasing.
At the time of this inspection it had decreased to the extent that PSI's quality assurance commitments were not being effectively implemented. Moreover, this finding confirmed in part, that all safety-related work was involved.
NOTE: Stating that PSI's yC forces represented 41, 36, and 31 percent of total site QC staffing does not indicate that there is some ideal percentage.
Its use here indicates only that reliance on contractors QC forces was increasing, and PSI's QC staff's surveil-
lance capability was decreasing as the construction activities increased.
(h) In regard to the Newburg-Marble Hill organization NRC inspectors have determined that their performance was less than satisfactory (reference NRC Reports 546/79-07, 08, and 09).
It is noted here that the causes for these unsatisfactory performances were in part, inadequate experience, numbers of personnel and apparently inadequate independence of QC personnel from the Newburg production organization. See Attachment C.
NRC inspectors concluded from observation and discussion that Newburg production managers have appa.rently an undue impact on the quality decisions of QC inspectors.
These observations and judgements by the NRC inspectors led them to the conclusion that the nature of the contractural relation (fixed price) betwten PSI and-2 1382 047 -
. . Newburg production has had an adverse effect on Newburg QC. The many unidentified problems and their acceptance by Newburg production and QC contributed to perceived " undue influence" that Newburg production has on Newburg QC. This conclusion is more judgemental than clearly demonstrable.
It is not believed that fixed price contracts inherently compromise quality, but rather, in circumstances where a contractor is experiencing serious difficulties acquiring qualified manpower and adequate production, extremely heavy demands are placed on the licensee's quality verifying organizations if all construction quality requirements are to be met.
It is to this extent that NRC inspectors believe that the nature of the contract has affected the quality of construction at this plant site.
(i) As is indicated above, NRC independently determined and site records confirmed that the PSI QC organization is seriously understaffed.
(See Attachments A and B).
It is apparent that site managment of the QC organization although not adequately aware of the need for fully qualified and experienced QC personnel, were aware of the need for 44 additional personnel at the time of this inspection.
(j) As stated above in subparagraph (f) the PSI site QC organization management, recognized that it was seriously understaffed and in part under qualified.
NRC inspectors questioned the apparent delay in hiring the necessary personnel for these positions.
NRC inspectors reviewed and examined the PSI management records associated with request for additional personnel for the QA/QC department and the PSI administrative procedures for processing personnel or " manning request."
It was determined that the PSI administrative practices for processing QA/QC manning request involved the highest level of management in the utility and required many levels of approval between the initiator and those providing final approval. This process is graphically represented by Attachment D.
This system imposed an incredible amount of tedious justification on the initiator of the increased staffing request (QC Manager). The system routinely took months to complete, and frequently approved only a fraction of the requested staffing. This process was applied to every position within the site QC department from file clerks to principal engineers.
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. . Review of PSI " Manning - General Headquarters - Nuclear Services Department Quality Assurance Section" documents dated from 1976 to present, show consistent failure of corporate management to be sufficiently responsive and timely in acting on the staffing requirements of the site QC orgsnizations. These records document a litany of lack of knowledge and appreciation of the site QC role; reluctance to accept the judgements of the requestor; bureaucratic minutiae and simple ignorance of the construction and quality implementing process. The specific documents reviewed included meeting minutes and notes of the various participants as outlined on Attachment D of this report. Examples are QC staffing manning records dated, April 18, 1978, July 26, 1977, June 1, 1979, February 17, 1978, July 12, 1978, June 24, 1975, November 12, 1976, March 30, 1978, June 29, 1976, and June 22, 1976.
It is apparent that this extraordinarily rigorous administrative practice applied by corporate management to QC staffing request was prompted by a need for fiscal responsibility. This pract. ice existed since 1947. However, its effect has been to seriously undermind the capability of the QC organization to accomplish its mission and it is viewed as the single largest contributor to the many deficiencies, noncom-pliances, and omissions noted to date at the site.
It is considered that the job descriptions and related salary ranges involved clearly indicate that the likelyhood of attracting and employing fully qualified persons for these tasks was small. Based on the issues identified above, subparagraphs (e)-(i) it is concluded that PSI has not sufficiently established and implimented its quality assurance program. This is contrary to 10 CFR 50, Appendix B, Criterion II.
This item is an infraction.
(546/79-11-01; 547/79-11-01) 5.
Examination of Site Engineering Organization As a result of record review and indepth discussions with site construction engineering personnel of various disciplines, the RIII inspector has established the following conclusions.
a.
Relative to site Construction Engineers it is concluded that the documented job description is inadequate, and the task instructions and directives are unclear.
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, . Review of personnel files of the construction engineers indicates basically, that they a-e to review and evaluate construction procedures and supervise construction. Though the concept appears to be adequate, discussions with personnel indicate that they were not appropriately familiar with the work in progress to enable them to adequately evaluate the work performed.
In other words, training and indoctrination of the staff was apparently inadequate.
Moreover, the overall job related experience of the construction engineering staff appears inadequate to successfully accomplish their aission. Less than 4% of the total (24) construction engineers at the site excluding S&L engineers have had previous nuclear related construction experience. For many, their current employment at the site provides the first field construc-tion experience in their careers. Also, these circumstances prevail to some extent in the site based S&L engineering organi-zation. These circumstances as supported below are considered an element of noncompliance as identified in item 1 of Appendix A of this report.
(546/79-11-01; 547/79-1101) (1) Training Program Inadequate A documented program outlining the various subjects in which indoctrination and training should be imparted, was not established.
Examples of this finding are as follows: (a) It was determined that mechanical construction engineers were not sufficiently familiar with the ASME code requirements which not only led to the precipitation of the National Board of Pressure Vessel Inspector's findings but also resulted in the inability of the engineers to assess the significance of the findings for the work in progress.
(See noncompliance item No. 546/79-11-04.)
(b) The electrical construction engineering group has not documented an acceptable program to train and indoctrinate personnel in the requirements of IEEE and ANSI standards and the Safety Analysis Report.
b.
It was determined that the staff demonstrated an inability to adequately assess problems in construction which resulted in their inability to initiate timely corrective action.
Examples of this finding are as follows: , (1) Unfamiliarity with acceptable Nelson Stud welding resulted in J. J. Robertson construction personnel continuing - - 13 - 1382 050
. . . nonconforming welding of Nelson studs in the turbine building deck (Category II) unchallenged by PSI constructing engineering staff or others.
(2) Lack of knowledge c f the construction sequence for in-stalling safety related structural beams resulted in torquing the bolts if structural beam connections prior to acceptance of welding attachments to the beams.
(3) Failure to recognize the significance of an apparent honeycomb condition associated with observable vcids on the curved wall of Unit 2 containment building resulted in failure to identify and tag this nonconformance pending further investigation. They were tagged at the NRC inspector's request on July 31, 1979.
(4) Being apparently unfamiliar with the requirements of the ASME code, mechanical construction engineers failed to realize that a serious co-ordination problem relative to quality records, etc. existed between Cherne and Stewart Mechanical which resulted in the documentation of numerous nonconformance reports.
(5) Failure to properly assess the significance of fabrication defects and failure to relate them to other similar com-ponents was disclosed. This is exemplified by Nonconformance Report No. 6.28 which identified multiple linear indications which were discovered after Cherne welded a pipe to an embedded Category 1 pipe penetration identified as 2AB-3, (located in the auxiliary building). No action was taken to verify the adequacy of other piping common to this material heat and manufacturer. The NRC inspector identified this concern and action was initiated on August 2, 1979, to perform NDE tests on penetrations of the same heat (No.
73457) such as IAB-3, 1AB-50, 1AB-140, 1AB-141, 2AB-113, 2AB-114 and/or review the CMTRs to determine whether they met the prescribed tests prior to installation.
(6) The demonstrated lack of familiarity with welding procedure specification (WPS) requirements and failure to scrutinize work in progress, contributed to their failure to recogize that the CBI welding procedure E7018/7303 Revision 1 dated June 20, 1977, did not specify weld technique for some positions.
c.
The inspector reviewed CBI Weld Procedure Specification (WPS) E7018/7303 Revision 1 dated June 30, 1977. This WPS was being - used by CBI to field fabricate Diesel Fuel Oil Storage Tanks on site.
In Revision 0 of the WPS the weld technique was initially specified as " Stringer Bead" with an asterisk and later - 14 - 1382 OS1
. . . obliterated with 'x's; the asterisk indicated at the bottom of the page " Weave bead technique for vertical up and overhead passes"; this obliteration left the WPS without any technique for all passes other than vertical up and overhead. With this error, the WPS went through the review cycle which included Sargent & Lundy, the Architect Engineer, and was approved without detection and correction. The WPS was later revised and Revision 1 dated June 30, 1977 was issued with the error undetected and corrected during the subsequent review cycle.
The inspector informed the licensee that reviews performed to evaluate and approve the WPS was insufficient and that this was an item of noncompliance (infraction) contrary to 10 CFR 50, Appendix B, Criterion IX.
(546/79-11-03; 547/79-11-03) d.
Motivation / Initiative / Leadership Appears Inadequate (1) It was determined that Construction Mechanical engineers made no attempt to digest the National Board and Boiler Pressure Vessel Inspector's findings (report dated July 10, 1979), examine the issues themselves and/or respond to correct the findings and issues.
(See noncompliance item No. (546/79-11-02, Paragraph 6.e of this report.)
(2) Neither Construction engineers nor QA/QC engineers were successful in their examination of Unit 2 containment building and auxiliary building to determine that all possible honeycomb conditions and nonconforming patches have been identified and tagged.
(See RIII Reports 546/79-07, 08 and 09.)
(3) It was apparent that neither construction engineers nor QA/QC engineers have determined or examined the acceptance / rejection criteria for receipt and construction documenta-tion packages.
Incomplete checklists were provided to the document reviekar: en site. The Lhecklist orginators (engineers) should be provided additional training; efficient channels of communications should be established with requirements to periodically verify the adequacy of documenta-tion packages and associated instructions. The identified ommissions contribute to quality problems as is evidenced by the finding that minimum wall thickness of Borg Warner Valves were not measured and recorded by the vendor.
(4) It was determined that to the extent of their participation, construction engineers did not establish an adequate system to tag or otherwise identify equipment with incomplete quality records.
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. . . e.
Inadequate decimination of information that is, use of NRC - Bulletins / Circulars to make personnel aware of potential problem areas: (1) It was established that receipt inspection personnel were not on the distribution list for such information and other mechanisms were not apparent.
(2) It was determined that there was no formal or routine method for informing construction engineers to be on the alert for material or products known to be unacceptable for use or otherwise questionable.
6.
The National Board of Boiler and Pressure Ves.sel Inspectors Report /ASME Boil'r and Pressure Vessel Code Issues a.
On July 10, 1979 the National Board of Boiler and Pressure Vessel Inspectors issued a report (provided here as attachment E) which documented extensive items of apparent nonconformance to ASME Code requirements. The inspection on which this report was based was conducted at the request of the Secretary and Chief Inspector of the State of Indiana Boiler and Pressure Vessel Board. This request came as a result of long term issues of apparent nonconformance to ASME Code requirements, on the part of PSI, which had not for reasons yet undetermined, acted to comprehensively and forthrightly resolve these issues.
b.
Fundamentally, PSI without benefit of proper ASME qualifications and documented authority, was perceived by the national board, based on PSI activities and site records, to be acting as a material supplier and/or an ASME Code N-stamp holder. Moreover, two site contractors who were properly qualified and authorized by the ASME Code, were experiencing difficulties meeting their code commitments as a direct result of (1) PSI not being duly authorized and/or qualified to perform as either an "ASME N-stamp holder or applicant" or a " material supplier", and (2) PSI's inability and/or refusal to make adequate and complete quality documentation available for the site contractor's Authorized Inspectors review.
c.
Discussion with PSI's site and corporate management regarding these issues after the issuance of the " National Boards ." .. report, demonstrated a serious lack of understanding and appre-ciation on their part, for the seriousness of these apparent nonconformances. This is further demonstrated by the fact that PSI did not notify NRC of the board's findings.
d.
During this inspection, NRC inspectors conducted int'erviews with piping contractors (" Stewart Mechanical" and "Cherne 1382 053 - 16 -
. .
Contracting Corporation") authorized nuclear inspectors. Based on these discussions and review of nonconforming material records identified by the Cherne ANI, NRC has concluded that the problems in material records identified by the " National Board..." Inspection prevails.
Among other identified nonconformances there is currently no documented applicant for N-stamp certification for the construction of the Marble Hill plant. NRC recognized that the " Board's" findings were based on conditions which prevailed at the time of their inspection and that some of these findings may be imraediately resolvable by records currently available at the site.
e.
During examination of site records NRC inspectors identified a multitude of records (nonconformance reports, letters and other documents) which demonstrate that the licensee was fully aware of these circumstances as early as July 14, 1977 and has failed to date, to provide comprehensive and responsible corrective action. This conclusion is based on the following letters from site contractors regarding these issues provided as attachments to this report: (1) Attachment "F", Stewart Mechanical letter dated July 14, 1977, J. L. Butt, QA Manager to Frank Hodges, PSI.
(2) Attachment "G", Stewart Mechanical letter dated June 2, 1978, J. L. Butt, QA Manager to Frank Hodges, PSI.
(3) Attachment "H", Stewart Mechanical letter dated July 13, 1978, J. L. Butts, QA Manager to J. Roberts, PSI.
(4) Attachment "I", Cherne Contracting Corpcration letter dated May 14, 1979, C. Jergens, QC Manager to T. McLarty, PSI.
(5) Attachment "J", Cherne Contracting Corporation letter dated March 7, 1979 M. Anderson to Frank Hodges, PSI.
(6) Attachment "K" Cherne Contracting Corporation letter dated June 6, 1979, C. Jergens to T. McLarty, PSI.
. (7) Attachment "L", Cherne Contracting Corporation letter dated June 6, 1979, C. Jergens to T. McLarty.
(Second letter to this date.)
(8) Attachment "M", Cherne Contracting Corporation letter dated July 27, 1979, C. Jergens to T. McLarty, PSI.
The above is contrary to PSI commitment to 10 CFR 50., Appendix B, Criterion XVI in that these nonconformances and other discrepant issues were not promptly corrected and the measures . L' 1382 054 - 17 -
. . . ' taken did not assure that the cause of the condition was corrected to an extent to preclude repetition. This item is an element of Appendix "A" item number 4.
(546/79-11-02; 547/79-11-02) f.
During examination of the PSI documents (nonconformance reports associated with the PSI /Cherne quality records issues) the inspector questioned Cherne NCR No. 6.94.
Nonconformance report No. 6.94 dated June 11, 1979, identified as a problem that PSI was not an N-stamp holder. However, it was subsequently voided. The controling procedures do not describe the " voided" status of a nonconformance report. The " voided" NCR No. 6.94 reference Cherne NCR No. 0.1427, however, the PSI records system does not account for NCRS by the given designation (0.1427).
It was subsequently reported that the referenced NCR 0.1427 was never written. Therefore, it appears that there was no basis to void or close NCR 6.94. Subsequently, it was reported that a Cherne letter was the basis for the voiding of this NCR, but it did not relate to NCR 6.94.
The unresolved status of this documentation, and the defective records system, does not constitute an adequate basis for closing or voiding NCR No. 6.94.
This matter is considered to be in noncompliance to Pi! commit-ments 10 CFR 50, Appendix B, Criterion XV, in that control measures did not provide appropriate procedures for identifica-tion, documentation, disposition and notification to affected organizations.
(546/79-11-04; 547/79-11-04) g.
PSI has subsequently applied to ASME for an N-stamp for Class 1, 2 and 3 piping systems; requested " Hartford Steam Boiler" to furnish full time inspection of the project and initiated other corrective actions as outlined in PSI letter dated July 28, 1979, attached here as item "N".
This matter is considered unresolved.
(546/79-11-05; 547/79-11-05) Attachments: Attachments A - N 1 3 8 2, U S b.
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' APPROVAL CH IN REQUIRES FOR ADDITIONAL MANNING ' ' ' IN PV8LIC SERVICE OF lNDIANA GA/GC., DEPARTMENT ATTACHMENT D I ,b' GENERAL To s ' EXE C.UTIVE - GE NE RAL EXEC UTIVE ' OFFICER o pp,g,g g G.
H.
. b . ' V a) VIC E PRES I del 4T - "' PRESIDENT
< b) SENIOR VICE PRESIDENT y
VICE PREslorur - E.
OF PERSONNEL. E
, - ' h - 3 r M A NNING COMMITTEE b, Mar,gger requeg+s pe rrniss ion to here sQ TREASVRER b') DIR F.CToR DF OPERA 738NS l C rnP ayee 's. CW . c) PERSONNEL MANAGE R 0A PProt e S Or dss ~ OPProves,, s0 DI RE CTO R op POWL R PRODUCTIoM D.
C Approves or dis - appro vec..M 1his point D. Approves or otus - approves.
u . additional. very detailed .juslific ation is require d fo r-additional mannu n3 ' T E. Once. approve d by 4he mannung co mrn t tte e.
+he re q ue.c4 is then forwarded ' VICE to the Preside n+ who, aided by 4he PRESIDENT OF 6 Vice Presideont of Funance, wee Pressdent NULLEAR. SERVICES of fe rro tmel, a nd 41,e Se nior %ct C.
Preside ni, can 00- approve or DPPMC or ask Jor incre .) utlification for lhe h a ddi fiona I ' rnanniny 6. P. S. I.
Gene ral Es e c v ive.
officer 4 hen , recie ves the reeguesi, If it has been 1 f - appro ve d to +his 70ini.
He oIso duhLITY can * aPPro ve, dis-o ppro ve.
or as k for ASSURANCE addsilone l psillic o fion for NANAGER rnanns ng - a.
H. Ass,s +s a c ne. cal exe eviivc officcr ' its glec as ton rnakIn3 g , v . h382 159 ~ GUALITY - ASSURANCE SUPER VI S O R A.
.
. . . i ,
ATTRCHMENT E ', \\ - Elp National Baarh of Eoiler and firessure liesse! Ensperiors s. F. H ARRISoN. Enecutnre Director 1055 CRUPPER AVENUE EXECUTIVE ConstBITTEE . COLun8905 oM#O 432M m wmeng C amme - Pnone 6ta esa 8320 g,,,,, % % . 0 R CALLUP.1stv. cec * Tewa f as 425 . n etcassom se~ve.
, '" **"*"" .- aT cRosiv.em u.C = ' ' **'J,,'[,,,,,,, c- .' ' " ' * * " July 10, 1979 C W A.L.ise.os. Eas#Chanmen .. n,i.~..w.
Mr. Lloyd A. Crews Vice-President of Construction Public Service Company of Indiana D,, D [} . 1000 E. Main Street Plainfield, Indiana 46168 ,, y _ _ SUBJECT: National Board of Boiler and Pressure Vessel Inspectors Unannounced Visit of June 12-14, 1979 to Public Service Company of Indiana, Inc., Marble Hill Nuclear Generating Station, Units #1 and #2, New Washington, Indiana.
' @ par Mr. Crews: In compliance with a r'equest from Mr. Robert R. Johnson, Secretary and Chief Inspector, Seate of 4ndiana Boiler and Pressure Vessel Board in his letter of May 29, 1979 to Mr. D. J. Mcdonald Director of Inspections, National Board of Boiler and Pressure Vessel Inspectors, requesting that a visit be made by National Board Representatives to the subject site to determine if compliance with the requirements of the ASME Boiler and Pressure Vessel Code Section III. Division,1, Nuclear Power Plant Componenta arers being maintained. National Board Representative's Royal Beckwith, Michael Boule and Charles Allison visited the Harble Hill Nuclear Plant site on June 12-14, 1979.
Upon arrival at the Ramada Inn, Scottsburg, Indiana on June 11, 1979 Mr. Charles E. Merkel, Nuclear Inspection Specialist, NBf4111-N, Indiana Boiler and Pressure Vessel Board was contacted by telephone. Mr. Merkel joined the National Board Representatives at the Harble Hill plant site the morning of June 12, 1979 and remained with them during the remainder of their visit through June 14, 1979.
~ Onthemorningofkune 12, 1979 the Mational Board team visited the site officos of Public Service Company of Indiana Inc. and met with Mr. T. L. McLarty, Q. A. Construction Manager, and on June 13, 1979, the ' Team again visited the Public Service Company of Indiana, Inc. site offices where they met with Mr. Prank Hodges, Public Service Company of Indiana Q. A. Manager, Mr. Jeff Roberts, Supervisor of Q. A. Design and Procurement . and Mr. McLarty. The National Board Teams exit meeting was held at the mud of Lhlw June 13, 1979 meeting. Those attending that mesuting were: ' Prank Bodges, Manager QA, PSI Chas. E. Merkel State of Indiana Royal Beckwith, National Board Charles W. Allison, National Board g Michael J. Roule, National Board [J , Jeff Roberts, Supervisor, Q. A. Design & Procurement 'r.
T.. Mcf.nrry. PRT. Q. A. Construction Supervisor . 1382 060 ~
-
- -.:w ; w,w.
- ...; .w - . , D{] Ok Cre s July 10, 1979 i s Following are the findings of the National Board Team during the - .
~ ' June 12-14, 1979, visit.
1.0 Public Service Company of Indiana. Inc.
Public Service Company of Indiana, Inc., (P.S.I.) is the owner 1.1 of Marble Bill Nuclear Generating Station.
They are in the possession of ASME owner's Certificate of Authoriza-tions #N-2022 issued February 27, 1978, expires February 27, 1981 for Unit #1 and #N-2023 issued Pebruary 27, 1978, expires February 27, 1981 for the h rble Hill Nuclear Generating Station New Washington, Indiana.
The Docket date for these two 1130 MWE units was September 1975.
1.2. The construction permit was issued on April 4,1978.
The A. E. and subpontractor's for Public Service Company of 1.2.1 Indiana at this site are; 1.2.1.1 A.
E., Sargent & Lundy Engineers, Chicago, Illinois Ceneral Contractor; Gust K. Newberg Construction Company, 1.2.1.2 2040 N. Ashland, Chicago, Illinois 60614.
Interim letters 20, 1979 and June 9, 1979, expires b y 20, 1980 renewed May and June 9,1980; N-class CC Concrete Containment at various field sites-no site audit at Harble Hill; NA, Class 1, 2, 3 Components, Parts. Appurtenances, Piping Subassemblies and Component Supports at various field sites; Class 1-2-3 Piping Subassemblies and Component Supports at various field sites; ~ ,' no site audit at Marble Hill; NPT-Class 1, 2, 3 Piping Sub. assemblies and Component Supports at various field sites, no site audit at Harble Hill, A. I. A., Lumbermans Mutual Casualty.
Cherne contracting Corporation 7777 Washington Avenue, South 1.2.1.3 Minneapolis, Minnesota 55440. NPTf1375 issued May 18, 1979 - 14, 1982. Class 1-2-3 Piping Subassemblies and expires May Component Supports and Class MC Penetration Assemblies at NAf1374 issued various field sites, no audit at Marble Hill.
expires May 14, 1982, installation of Class 1-2-3 May 18, 1979 Components, Parts, Appurtenances, Piping Subassemblies and Coe-ponent Supports and Class CS Core Support Structures at various field sites; no audit at Harble Bill site; A. I. A., Hartford Steam Boiler.. p . - . i i 1382 061 . g a
.
' ' . .... - ' v%)$ ...
- - um - . - . Page (3) . , r Mr. Crews D ,D ,q.
b e ]Ju LS.
- July 10, 1979 e .m s 1.2.1.4 Stewart Hechanical Enterprises Inc., 757 Cradylane, Louisville - Kentucky 40213. NPT-f2274-10 issued January 19, 1979 expires January 19, 1982. Class 1-2-3 & MC Component Parts and Appurtenances and Class 1-2-3 Piping Subassemblies and Component Supports at Harble Bill only. Units il and #2; NA-f2273-10 issued January 19. 1979 expires January 19, 1982; Installation of class 1-2-3 . Components, Parts, Appurtenances, Piping Subassemblies and Component Supports at Harble Hill only. Units il and #2.
A. I.
A., Lumbermans Hutual Casualty.
1.2.1.5 Chicago Bridge & Iron Company, 800 Jorie Blvd; Chicago, Illinois - 60521. N-f2134-80 issued May 1,1979, expires May 1,1982, Class ~ .- 3 Storage Tanks at Harble Hill only. Units #1 and #2.
A. I. A., Eartford Steam Boiler.
1.2.1.6 Whalen-Chilstrom Company, Louisville, Kentucky; no Certificate of Authorization. Perfoming re-bar work on containment not under
Section III.
- 1.3 The Owners Designee, Sargent & Lundy Company prepared and certi-fled the Design Gpecification. The Design Specification was certified on December 16, 1977 with revisions on February 9, 1978 and August 25, 1978.
1.3.1 The Design Specification for the Nuclear Power Systems was to the 1974 Edition of ASME Boiler and Pressure Vessel Code Section III, Division 1 and Winter 1976 addenda. The containment vessel was designed to the 1974 edition of Section III Division 1 and Winter 1974 addenda. The Concrete portion of the containment (and othez concrete work) preceded the mandatory date of Section III, Division,' - 2 and therefore was not designed to ASME Code requirements.
1.3.2 Stewart Hechanical Enterprises, Inc. a sub-contractor of Gust T.
Newberg Construction Company, the General Contractor, could not on June 13, 1979 determine the Code Edition and addenda the pipe.
material they were receiving from Public Service or the pipe material they were purchasing was required to be purchased too.On June 14, 1979 they were advised by Public Service Company of Indiana, Inc. by telephone in the teams presence that the Design Specification Code dates were the 1974 Code Edition of Section III, Div. I and Winter of 1975 addenda. Their Code work is being performed to the 1977 Edition of Section III, Division 1. no addenda according to Mr.
Barry Cash. Welding Supervisor and Q. A. Inspectot;. Cherne Contracting Corporation is a piping contractor for this job.
1.3.3 The Sargent & Lundy Design Specification Y-2739-CA, 08-25-78 Cherne is required to work to states in paragraph 123, "All work, material, and equipment shall conform to the following Codes , where applicable; 123.1, ASME Boiler and Pressure Vassel Code Section III,1977, with addenda and Code cases in effect (see subarticle 113.1)".
(See . ettschment II).
1382 062 ~ ~~ '
. _ _ _ . . _. _. _ _ _........ _ _. . _... _.. _ _ _ _ _ _ , , - ..... - - ,. $I& ~ ' D
- D " 3, L l
~
s Page (4) E6
~" Mr. Crews July 10, 1979 . Public Service Company of Indiana purchases and supplies Cherne.
with all Code pipe mateial over 2h" NPS. The majority of ths - material supplied by Public Service Company of Indiana was purchased to Code editions prior to 1977, including material purchased to the 1971 Edition of Section I.
That material was aise supplied to Cherne by Public Service Company of Indiana for nucivat code fabrication and installation.
NCA-3251 1.3.4 It appeared apparent that neither the owner or the subcontractors had the necessary information for determining the specific Code Edition and addendas material was purchased to.
Consequently.
- the proper documentation, receiving procedure, etc; could not be determined by either the subcontractors or the National Board Team.
1.4 Public Service Company of Indiana, Inc., the owner, purchases all material over 2 " diameter for their sub-contractors, Cherne Contracting Corporation, and Gust K. Newburg Construction Company for their subsidiary Stewart Mechanical Services Inc.
- NCA-5261 1.4.1 Public Service Company of Indiana Receiving Inspection consists NCA-4134.4 of checking the part number on the part or material against the EA.s%1 material manufacturers or suppliers transmittal. No documentation NCA-3500 is supplied to the subcontractors. The subcontractors receive the material by means of a P. S. I. equipment / material issue form, (see attachment #2).
Public. Servira Company of Indiana Ansists th'at should the sub-contractor or their A. N. I. find it necessary to review the CMTR's, or other material or parts data reports they may do so by visitin8 sP.S.I.
and reviewing their. micro-fiche records.
WCA-3800 1.4.2 Public Service Company of Indiana is procuring material and components and supplying their sub-contractor's thereby acting as a material supplier. They have audited their supplier, primarily IIT Crinnell, and have been audited by Cherne for pipe fittings and flanges and fasteners and appear on Cherne's qualified vendor list for those items only but have not been audited by Stewart Mechanical Enter-prises, Inc., according to Mr. Cash of Stewart Mechanical and Mr. Guy, Q. A. Supervisor for Cust K. Newberg Construction Company.
, NCA-38 /1.4.3 Public Service Company of Indiana does a t have an ASME Quality Systems Certificate, do not have a documented identification and verification program and are not a Certificate of Authorisation Bolder (footnote 8 NCA-1140(b)). t 1.4.4 AtthetimeoftheMttional Board vi.ait of June 12-14,'1979 ', neither the owner of any contractor or subcontractor on the g Marble Hill site had or had applied for an ASME Certificate of Authorization to use the "N" symbol at the Marble Hill site.
- .e . NCA-1220 1.4.5 Some Certified Mill Test Naports for material procured by Public mca-lieu \\ service Company at Indiana for their subcontractor *a which were ~ 1382 063 '
-- -;yg . u:m=w - - .M . Page (5) g D '~~U l f 9'f:' m m' - Mr. Crews q
'".- "
6 July 10, 1979 , .. reviewed at Public Service Company of Indiana inrHe seed material such as A-515-74-Gr. 65 produced under ASTM A 155-75 Cr. KC63, '~ C1. 1 as welded pipe with filler metal added to be ASTM rather than SA, the C.M.T.R. did not indicate the material to be for Section III Nuclear, the class, ASME Section III Code Edition and addenda, a Quality System Certificate number and/or as having been audited as required. E2at Treat Charts or radiography film, or applicable information.
In addition, as previously noted some of the material supplied was Section I material for Section III work (example: see attachment #3). The CMTR's were generally stamped as approved by the manufacturers Q. A. (National Aan==1-ing Box Company) by ITTG-IPI the suppliers Q. A. (IIT-Grinnell Industrial Piping), and the purchasers,ii.
A., (Public Service . Company of Indiana).
Although it was requested that some Public Service Company of Indiana purchase orders be made available for review, none were, s during the three fays the National Board Team was at the Marble . Bill site.
' NCA-3252 1.4.7 Information was requested on several occasions during the visit whether the ownet had designated impact testing per paragraph MCA-3252. No answer was forthcoming.
CA-8122 1.4'.8 Public Service' Company of Indiana has an inspection agreement with Hartford Steam Boiler Inspection and Insurance Company. Paragraph NCA-8122 requires such an agreem.ent with an Authorized Inspection' Agency to provide inspection and audit services. According to , 2 - Mr. Bodges, Q. A. Manager, no such services have been provided since the initial owners Ce'rtificate interview. The only available Bartford Authoris.ed Nuclear Inspector on the site.is Cherne Contracting Corporations A. N. 1. who advised the National Board Team he had been instructed not to provido such nervices to Public Service Company of Indiana.
NCA-3510 1.5 Public Servich Company of Indiana, Inc., advised the National - Board team that they, as the owner.had over all responsibility for the design and construciton of the Marble Hill Nuclear C-*nera-ting plant and they did not propose to delegate that responsibility to others.
. Paragraph NCA-3510 c...ines the "N" Certificate Holder as that organizacion swaming responsibiliry ror code compliance vitu respect to material, design, f abrication, installation, aw==4n= tion, testing, inspection, certification and stamping for items requiring an N symbol stamp and requires the N Certificate holder to retain - overall responsibility including certificatica and stamping.
1382 064 .. / - - . . . ! ... . .k ~ -
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, Page (6) Mr. Crews ' July 10, 1979 ' . Paragraph NCA-3551(b) in addition, states that the N Certificate - Holder is ultimately responsible for the design of the component NCA-3551(b) and for the adequacy and completeness of the design documents.
Public Service Company of Indiana, Inc., has not been issued an ~ N Certificate of Authorization for this site, nor has any other - organization been issued that required Certificate of Authorization for this site.
It appears, therefore that the owner, Public Service Company of Indiana having assumed overall responsibility is apparently in 1.5.1 violation of NCA-3510 and NCA-3551(b) as indicated above.
may also be in apparent violation of paragraph BCA-3530 PSI since they intend that the construction of the NSSS be in ECA-3530 1.5.2 compliance with the Code and NCA-3530 requires an N Certificate NCA-1210 of Authorization,to be obtained for the construction of any item NCA-8000 intended to be in compliance with the requirements of this section NCA-8233.10 Table 8210-1 and to be stampe4 with an N Code Symbol.
NCA-3500 In addition t.here may be an apparent violation of paragraph NCA-3461 which requires the N Certificate Holder to be responsible for NCA-3461 1.5.3 surveying, qualifying and auditing suppliers of subcontracted - There are suppliers of services including NDE contractors.
subcontracted services on this site, however under the Code they apparently are not responsible to anyone since there is no N Certificate holder on site.
It would also appear that in assuming the responsibilities of an N Certificate Holder without having obtained a valid Ce ECA-4134 1.5.5 violation of paragraph NCA-4134.
' Public Service company of Indiana, Inc., supplies material to - NCA-3800 1.6 their sub-contractors on this site.
. They do not hava a matarial identification and verification . program as required for a material supplier and do not appear - to meet any of the requirements of NCA-3800.
Public Service Company of Indiana refusal to supply Code material documentation such as Certified Mill Test Reports to their sub- -1.6.1 contractors for whom they are acting as a material suppliar, NCA-3867.5 ', apparently violates paragraph NCA-3867.5.
Some of the documentation accepted by Public Service Company of Indiana for material to be used in safety related Code construction 1.6.2 - ' for this site indicates the material is not acceptable for nuclear NCA-3867.6 Code construction and in addition is not documented as required (, by liCA-3867.6. - The owner Public Service Company of Indiana, Inc., acting et the , - 1.7 ' 1382 U65 ? ' ' . a
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D $D f F b Mr. Crews @ u a t , July 10, 1979 s N Certificate of Authorization holder appears to be in appar,ent- ' violation of paragraphs NCA-1140,1220, 3251, 3252, 3461, 3500, 3510, 3530, 3551(b), 3800, 3867.5, 3867.6, 4134, 4134.4, 5261, and Table 8210-1 of Section III, Division 1 of.the 8000, 8122 ASME Boiler and Pressure Vessel Code.
i
Cherne Contracting Corporation _ 2.0 12, 1979 the National Board team . On the afternoon of June visited the Cherne Contracting Corporation site offices and 2.1 met with Mr. James Morte11, Vice-President and Project Engineer, Craig Jergens, Q. C. Manager.and William Braden, A for Cherne.
the Team met with Cregory A. Rosier, Manager of - On June 13, 1979 Quality Assurance for Cherne at their site of fice.
, . The documentation submitted to Cherne by their ' material supplier Public Service Company of Indiana with the 2.2 materini supplied, in some cases consists only of Public Service Company of India'na equipment / material issue form on which the Public Service Company of Indiana equipment number and/or the vendor equipment number appears with Public Service Company of Indiana ticket number.
No evidence is available for that material, that the required Code receipt inspection was performed, no certified mill test , 2.2.1 reports are available to identify the material as acceptable for nuclear code work and that it is in compliance with the design and material specifications Cherne is required to work with.
In those cases where Cherne has been supplied with CMTR, those documents in some cases are not acceptable since the acterial 2.2.2 manufacturer / material supplier Certificate of Authorization or Quality Syste's Certificate identification and date is missing,tte Code Edition is not included, the Code addenda and Code class is - not included and NCA-3800 statement is not indicated.
As a result of this lack of documentation Cherne is unable to ~- use the material with confidence that it will meet the Code 2.3 requirements and their Authorized Inspection Agency A. N. I.
Conse-William Braden, NBf7448-N will not accept the material.
ified.
quently, the material is on hold until it can be properly ident A copy of Cherne nonconformity report listing 94 material items by Public Service Company of Indiana piece number which have no yet been identified by Public Service Company of Indiana, isAlso enclosed as attachment #4.
1979 to Public Service Company of Indiana, attachment #5, Cherne's information request of May 3, 1979 to Public Service Company of Indiana, attachment #6 and Cherne's information reque to Public Service Company of Indiana, attachment of May 21, 1979 ,
- 7.
. 1382'066 .
. . . . g..-L*. q E - .+ 'w'.*-t,mp ' , D Mr. Crews - gD Page (8) g[] g - n
d
July 10, 1979 3.0 Stewart Mechanical Enterprises. Inc.
' s 3.1 Stewart Mechanical Enterprises. Inc., P a subsidiary of Gust .- K. Newberg Cons *truction Company, the gt.naral contractor on this site.
3.2 On June 13, 1979, the National Board team met with Ed Guy, Q. A.
Supervisor for Gust K. Newberg Constructio:. Company and J. Chris Maron, Project Eagineer Barry Cash, Q. C. Inspector and Welding Supervisor and Terry Vititoe, Q. A. document control, both of Stewart Mechanical, in the Stewart site trailer offices.
3.3 The Team was advised that Stewart Mechanical Enternrises. Inc.
was surveyed by an ASME Nuclear Survey Team on site on January . 19, 1979.
3.4 Mr. Guy, Mr. Cash and Mr. Vititoe stated, as did Public Service RCA-4134.7 Company of Indiana representatives previously, that all material NCA-4134.8 over 2 " diameter was purchased by Public Service Company of Indiana and supplied to $ewberg who in turn acted as a material supplier in supplying Stewart Hechanical Enterprises, Inc., and that no documentation for the material was received other than Public Service Company of Indiana equipment /naterial issued form and Newburg transmittal form #4 to which the Public Service Company of Indiana issue form was attached.
(See attachment #8). Public Service Company of Indiana is not on Stewart's approved vendors list and they have not audited Public Service Company of Indiana - as either a vendor or a material supplier.
3.5 On June 13, 1979 Stewart representatives stated that they also NCA-4134.8(a) receive some fabricated pipe subassemblies from Public Service - NCA-3800 Coupany of Indiana but do not receive any documents other than confirmation from Public Service Company of Indiana that the piping sub-assembly is acceptable for installation.
' Mr. Guy of Cust K. Newberg Enterprises, Inc., stated that Newberg in transmitting the material from Public Service Company of Indiana to Stewart Hechanical did not consider themselves a material supplier, did not have a Quality System identification and verification . program and had not been audited by Stewart Mechanical Enterprises Inc.
, 3.6 Stewart Mechanical at their Louisville, Kentucky shop purchases NCA-3867.6 small diameter pipe less than 2h" in diameter for use on this site. Receiving inspection is performed at Louisville (see attachment #9) and sent to Stewart Mechanical at the Marble Bill site with the CMTR.
, The CMTK does not inficate the material is for nuclear work, does not include Code Edition and addenda dates and does not include the material manufacturers Quality System number and expiration date or statement of audit to NCA-3800 as required by paragraph NCA-3867.6 (see attachment #10). There was no evidence that U. S. Steel Lorain, the material manufacturer had been audited - by Stewart.
1382 067 ' -
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, - O Ju i c' I Page (9) a Mr. Crews July 10,1979 . 3.7 on June 13, 1979, the A. N. I. Herbert Moran National Board' . number 6182-N-S, an employee of Stewarts A. I. A.. Lumber' mans - Mutual Casualty insurance Company was not on the site. The A. N.. I. Previously assigned to Stewart on this site by lumbermans were G. W. Bryant National Board number 4292 and George Deaton National Board Number 7905.
. 3.8 The National Board team returned to the Stewart Hechanical.
trailer site office on June 14, 1979 to meet with the A. N.
I., Herbert Moran.
' He stated he spends part of his time at Stewart Hechanical Louisville shop inspecting piping subassemblies fabricated there for the Marble Hill site and part of the time at the site.
He stated he had this day inspected his first welded joint . (tack welds) for Stewart at the site, being on the central service wator lines, . 3.9 hr. Moran produced a considerable number of NPP-1 Manufacturers Data Report form & on June 14, 1979 for the National Board Teams review.
. These NPP-1 Data Reports cover pipe material and spool piacas procured by Public Service Company of Indiana for Stewart. The saaecrial is pipe w1Lh the lung weam welded with filler metal added (SA 155 KC 65 Class 2). All of this material is tened " spool pieces" although auch of it apparently had no fabrication performed other than the long neam.
(See attachments fil).
3.9.1 When asked why the Nationa Board Team had been informed the previous day that Public Service Company of Indiana supplied no documentation for any material procured for Stewart and that no documentation of any kind was available for review at Stewart, the A. N. I. stated the Newberg and Stewart reprasant.atives did not understand what documentation the team wanti! to review.
. 3.9.2 The material apparently is documented on EPP-1 data forms because its design and procurement preceded the Code require-ment to report such welded piping on MM-1 data report forms.
No documentation was presented for review covering the piping NCA-8415 3.10 sub-assemblies fahricated at Stewart Hechanical Enterprises. Inc., Louisville' shop and shop inspected by A. N. I. Moran or others.
- Stewart-Louisville apparently ;repares the traveler for Stewart 3.11 NCA-4134.4 Marble Hill site and includes the SA-eaterial.
Stewarts-Marble Hill Q. A. Manual in paragraph 5.4 requires the welding supervisor NCA-4134.8-i to record the identification of the material on the travaler.
The' identification serial number on the Louisville receiving report with the identification of the item and that number is added to " the traveler at the Harble Hill site.
- . U 1382 068 ' - - -. - ,.. -
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q.g - # . Page (10) D*7
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' ' M' MA. Ga es wo ob yj July 10, 1979 o . .. a ,, . _:q', - - 3.12 It appears that Stewart Hechanical Enterprises. Inc., are.in, , - . ' apparent violation of paiagraphs NCA-4134.4, NCA-4134.7, NCA-4134.8, NCA-3800, NCA-3867.6, and NCA-8415.
4.0 Chicago Bridge and Iron company . 4.1 The National Board team visited the Chicago Bridge & Iron Company site trailer office on June 14, 1979 and met with Fred Lusch, welding and Q. A. Superintendent and J. Trickle, Welding Supervisor of Chicago Bridge & Iron. The A. N. I. Bruce Montana National Board Number 8130 was not on the site at the time of this visit.
It was noted that C. M. Duckee NBf7740 and Donald Donobo NBf3981 A. N. I. for Hartford Steam Boiler had also been on this site for Chicago Bridge & Iron.
- 4.2 Chicago Bridge and Iron had left the site in March, 1979 and had returned June 13, 1979.
- 4.3 Chicago Bridge and Iron is constructing the containment vessels metal liners (not Code stamped) and some penetrations (code stamped).
- Jn addition they are field assembling class 3 storage vessels with
, capacities to 11'2,000 gallons for 15 psi and low vacuum. They are working to the 1974 edition and winter 1475 addenda of Section III.
The vessel parts are formed and sub-assembled at Chicago Bridge ' and Iron Greenville, Pennsylvania shop.
They propose to field assemble 16 such class 3 vessels and tiavs field assembled one (1) to date, which was NB number 4217. It has not yet been hydrostatic tested and signed off by the site A. N. I.
4.4 Chicago Bridge and Iron had an ASME Nuclear Survey on this site in January 1979.
. 4.5 According to Mr. Lusch, Public Service Company of Indiana does not procure material, parts or appurcenances for Chicago Bridge and Iron.
4.6 Chicago Bridge and Iron welding procedures available on this site were reviewed and the following apparent Code violations were noted; . QW-200.1 4.6.1 Non-essential variables are required to be listed and described on WPS per paragraph QW-200.1 and QW-201.1 of Section IX.
QW-201.1 TheWPSdidnotlishindetailthemethodofinitialorinterpass QW-410.5 4.6.1.1 cleaning per paragra,ph QW-410.5.
The WPS did not describe the method of backgouging per paragraph Qd-410.6 4.6.1.2 QW-410.6 The WPS did not list the use of non-setallic or non-fL.ing retainers . QW-410.13 4.6.1.3 - per paragraph QW-410.13.
1382 069 ' ' '
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D Page (11) g Mr. Crews July.10, 1979 . . s The WPS did not indicate the root spacing per paragraph QV-4k)2.10 QW-402.10 4.6.1.4 QW-201.1 4.6.2 WPS 7018/73030 Rev. 1 June 20, 1977 LBR had been revised by crossing ' Stringer Bead' and insercing ' weave bead technique'. That out The re71mion was not noted and approved per paragraph QW-201.1 - material in use was SA 516 Cr. 70.
Whalen-chilstsom. Louisville. Kentucky and Milwaukee, Wisconsin 5.0 Whalen-Chilstrom Company is a sub-contractor of Cust K. Newberg Construction Compa.sy. They are doing the re-bar work on the containment vesse7 s.
Since the design is to the 1974 adition of Section III t*osy are not required to hold an ASME Certificate of Authorization for that work, do not hold such a Certificate, and were therefore not visited by the National Board Team.
. 6.0 _ Recommendations . 6.1 Public Service Company of Indiana, Inc.
Since Public Service Company of Indiana, Inc., has stated that 6.1.1 only they will assume overall responsibility for Code compliance with respect to material, design, fabrication, installation, evamina-tion, testing, inspection, certification and stamping, it is the National Board's opinion that the owner's ASME Certificate of . Authorization should be withdrawn until such time as Public Service Company of Indiana, Inc., has obtained a valid Certificate of Authorization to use the ASME "N" syabol and have corrected the apparent Code violations indicated in paragraph 1.7 of this report.
, It is the National Board's opinion that Public Service Company 6.1.2 of Indiana, Inc., should cease acting as a material supplier of ASME Code material to their sub-contractors for ASMr. Code construction until such time as Public Service Company of Indians has complied with all of the up,ilicable requirements of NCA-3800 of Section III of the ASME Boiler and Pressure Yessel Code.
Stewart Hechanical Enterprises Inc.
6.2 It is the National Board's opinion that Stewart Hech=nh*1 Enter-prises, Inc., should correct the apparent Code violations indicated 6.2.1 in paragraph 3.12 of this report without delay and should cease for ARMF Mar.tinn TTT f'nde fahrtsarinn 6:nr11 fe can be identified as meeting the requirements of Sections II_and unine material III of the ASME Code.
6.3 chicago Bridge and Iron Company.
It is the opinion of the National Baord that Chicago Bridge and Iron Company should cease using the welding procedure specifica- - 6.3.1 tions they now have on the Harble Hill Nuclear plant site until such time as those specifications and their revisions meet the s J requirements of ASME Codes Sections III and II.
1382 070 .
_ . . .- - ..... ?.h . . Page (12) Mr. Crews July 10, 1979 s '. . 7.0 Other apparent Code violations may exist in addition to those indicated in paragraphs 1.0, 3.0, 4.0 and their sub-paragraphs of this report and it is reconnended that Public Service Company of Indiana, Inc., Stewart Mechanical Enterprises, Inc., and Chicago Bridge and Iron Company, review in depth the applicable parts of Section III'and IX and their respectiva Q. A. Manuals with their respective A. N. I. and their Authorized Inspection Agency's Inspection Specialist.
Very truly yours, ( W ' \\ I Royal Beckwith Assistant Director of Inspections .
RB/did ' William Ward, Nuclear Construction Ngr., PSI cc: "' [ p n t Chairman of SC/Nc D]] ]D - ~~ - Arlene Spadafino, ASME q U b Robert Johnson, Chief Inspector of Indiana Hartford Steam Boiler Ins. Er Insp. Co.
Kemper Insurance Co.
Uldis Potspovs. NRC Gary Ra?.cliffe, Pres., Cherne Contracting Corp.
Marvin Mitchell, Pres., CBI George Duthie, Pres. Stewart Mechanical Enterprises Robert Luedeking, Pres., Gust K. Newberg Construction Co.
Enclosures: Attachments - , .. 1382 071 . . . , I .' - c ! l ' l 1, -
m _qy n asar - = = = = * " ".. ".. ' "."".."._ NEMM 'C?bk - g, _ w. _ _ _. _. . _ Arreenme=T #1 %<. , '% , 2 ~ < ,
\\ Y'*2 7D . lO cn L S A R G E N T 8: L.UN DY , UU d M u
- '
sN gin e ens CA, 05-25-78 coucaso , . $WG - ) ' I.E..n of the Specification.
Furthermore, ignorance is not acceptable as "'~ ,h basis for any claim whatsoever for additional or extra compensation.
. .. W' 120.2 Contractor shall at all times have a competent superintendent on - p,s. the premises to represent him and to whom instructions may be given.
<p - Contractor shall maintain a representative on the premises until J..- finst acceptance of the WORK has been ahtained from 1%r I a.es.
Contractor shall properly protect and be responsible for the equip- ' [$c,20*3 ment and materials to be unloaded and/or erected hereunder, in L k accordance with manufacturer's instructions. from the time of arrival c at the site, until the work is accepted in its entirety by Purchaser, h except during such time as said equipment or materials are removed i from the control of Contracter by specific instructions of Purchaser.
Contractor shs11 have cou plete responsibility for the equipment or s.aterials while being unloaded and handled for him by others.
p' . I 120.4 It shall be Contractor's responsibility to furnish the services of Mi all trades involved in the LORK.
%' . C Contractor will be held liable for all repairs and/or replacements f120.5 of any and all associatert facilities damascJ as a result of said f.
Contractor's activities in the area, subject to Purchaser's accept-ance.
, - CONFORMANCE WIT 11 10 CFR PART 21 ,g.
121* The Work indicated in this specification and/or on the drawings as (- Nuclear Safetv-Related requires the application of the provisions of I, ' title 10, Chaptnr 1, code ut Federal Hegulations, Part 21, Ecporting of Defects and Noncomplianc~e (10 CFR Part 21).
It ic the responsi-6- , h bility of the Contractor to implement the provisions of 10 CFR Part 21-t S.' insofar as they are applicable to the concreceer'. Hva under cnis specification.
e . REVISION OF SPKCIFICATION AND AWARD 'ID CONFORM 'ID PURCHASE ORDER / 122.
Within six weeks af ter award, and at option of Purchaset, Contractor e
will revise his proposal to conform to the actual award. The revised k propr, sal will incorporate all changes up to and including the award.
I The specification will be similarly revised by the Consulting Engineers.
f. ' g3* ^ m CODES AND STANDARDS ! t All Work, material, and equipment shall conform to the following codes I I where applicabic: , s / 23.
ASME Boiler and Preasure Vessel Code Section III - 1977. with addends '
and code cascas in ef fect (see subarticle 113.1).
a e , h 123.2 ANSI Standard Code for Pressure Piping ~ ANSI B31.1 - 1977, with all ' applicabic addenda (see subarticic 113.1). =
- 6 1382 072 l
i-n , N , _.
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. . .., .. n.;,,S9p ".dk G'
SARGENT & LUNDY
INNI'N " ' ' @**g
- **
o D '9' N S.}' h ffb _, - g.. The words " nuclear safety related" are used in this Specification to 1[109*10 desi5nate systems, subsystems or pieces of equipment that coc:pr.ise ' systems that are required to accomplish the safe shutdown of the .. nuclear power plant or that are required to operate following a y[; - - postulated accident.
b Wherever Work is indicated as being by " Piping Contractor", P.C.
. ? 109.g1
or Y-2739 Contractor, it, shall be construed as being work by Con-tractor as coverad under this Specification Y-2739.
'; E~
k.109.12 The term " rough set" shall be construed to mean " set within 1 inch , of final position".
g
Wherever " Class A, B, C, D, or G piping" is used in this Specification, i; 107.13 it shall be construed to snean the S&L pipe classes defined in paragraph 113.1 hereof.
. ll SPECIFIED PRODUCTS AND SUBSTITITTIONS - y'110.
Rention of materials, or components by name as products of certain ssanufacturers in this Specification is made to insure that the proper
Quality and/or type eis provided.
Products of other manufacturers ! I will be acceptable if Contractor furnishes proof to the Consulting en or beeeer Engineers that the proposed substitute products are equal than the specified products in quality, performnce, design and suit-ability for the intended use, k . ORIGIN OF COMPONENTS ggg, Contractor agrees that no components of any nature manufactured out- , side the U.S.A., Canal Zone, Puerto Rico or Virgin Islands shall be t I included in his scope of supply unless specifically agreed upon in , writing by Purchaser.
If any foreign fabricated components are included, Contractor shall, upon notice in writing, replace them entirely at his own expense, including installation, and shall be , ' liable to Purchaser for any damage to Purchaser's plant and any losses [
due to any delay caused Purchaser by such replacement.
- ., omm ASSURANCCAND Com0L 12.
f orth in Purchaser's Quality Assurance Specification " Piping , As set System Installation", Rev. O, 6-30-77, Y-2739.
r ^ P 'ME SECTION III DESIGN SPECIFICATION REQUIREMENTS ' ' g3, I ),1 C assification (NCA-3253): gg , Tfie piping furnished and/or fabricated under this Specification is classed as Class 1, Class 2 or Class 3 piping per Section III of s.
ASME boiler and Pressure Vessel Code, Non-Section 111 piping per the < - ANSI Standard Code fop Pressure Piping - ANSI B31.1 or Non-Section j
III piping per acceptable industry standards.
y ! . I l382 073 '- i < h .
. . _ - . ., y ~t , , SARGENT8: L.U N DY Y-2 TP) CA UM-25-78 " " U " *af * . , hTTAC'94MN M $ - ); pasE 3 eF3 ' 1, 2 and 3 piping shall be designed and' con- . The Section III Class structed in accordance with the rules of the respective subsection, [ b.
(NB, NC or ND) of Section III of the ASME Boiler and Pressure vessel g, The Non-Section III ANSI B31.1 piping stiall be designed and ( constructed in accordance with the rules of the ANSI S Code.
, ' '. For Owner's purposes, e'ach individual piping line (or system) classi- .l , (column 7) feming
fication is as designated in the Piping Line List c.
. , a part of this Specification, as follows: ,. S&L Piping Line Code List Classification Classification ', ' ! A Section III - Class 1 piping............ I cl.1 B r$. Section III - Class 2 piping............ cl.2 C Seu c les III - Cidas 3 pipins............ cl.3 a-Non-Safety Related* Category II Piping: I c2.
S&L Piping Line Code L List Classification A Classification '. D ANSI B31.1 (Non-Section III) piping..... It-c2.1 g, Mon-Section III per industrial C 9E c2.2 standards............................... f;
Document Distribution NCA-3256 (Section III Piping):
313.2 owner will file a copy of this Specification with th'e enforcement h NCA-authority in accordance with Section III of the Code, Paragrap [ ,, 3256, bef ore the system is ptaceo tn service.
? I ~ Any consnunication between the enforcement authority and the manu- .. s.
Y f acturer or installer shall be sent to Owner for f orwarding to the " - b.
respective party, unless Section III of the Code states otherwise.
- f', In the latter-. case, copies of the correspondence shall be sent to owner for prior acceptance before being forwarded.
i p, Owner will file a copy of this Specification with the Inspector at n the manuf acturing site and crection site before construction begins.
c.
j Manuf acturer shall provide the Inspection Agency w t d.
- $ Section III of the Code.
' &- .
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invoict e.o in Lgg, OF. POSE 5 d!'t 'SAY$ - ~ WTHivs'W6._ - N0dESTE40 dD4XS _ 1/05/TR LFt3485 163*12606 THAT THE THEi4IC AL AMALTSF - . , , 4 'll a ? HOMESTLADe PA/ 15120 ]gg PRR JaiS19 ,100 AN0/DR TEST RCstitis $404t.
IN THIS REPORT ARE cflRRCr-AS CONTATNEn'IN Tar RECO: NATIONAL ANNEALING R0x c0HpANY
NAT!DNAL ANyEAlfNQ BOX COMPANT OFTHECOHPLMis'h'. . H f 77[/.<.' M PA WAfHINGTON
P O 80X 571 r . ' T IGNATU11E leNLMEkUI)aEJ . NASHING704 PA 15301 ' . o
S T A T E O f FtW s_,06/ ? 8 , onre Off VL INT A V 45tM A=515=T4B GRADE o> PRE 55URL VE55EL QJALITY.
DESCALE DRY N0 D
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LL 0nENT E counTT or A - lTM SUH$cRIGED AND SitpR4 fn Arrt14C IL . . , hp DLY Or /Mt- '1974 - THIS t , j i PLATES HILL SWO1N T/R = ANALTSfs Y **** "Y ' ..w " " * * * * * A * P- . vtsv sa eite _,,K s t K$t ' ~. ~ 'n s-aata.
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TO LAW, orPOSE3 4Nn IAY N' . 55482 11/2 3 n7 LF13485 .163-1248? THAT THE CHEMIC AL ANA.T /* y y F 160 AND/OR TT5T nt.;Utts 11tc.
' k, ; HOMESTEAD ndRNS WMhrv cR 522570 IN THIS nrPORT ARE CCGT' l'.HONESTEAQs PA, 15120 A5CONTAINEDIN, Tut ()
NATIONAL ANNEALING BOX COHPANy
.e NATIONAL AffNEALING 00X COMPANY 0F THE CO:sPANY 2.f - i WASHINGTON PA
- P , P O BOX 521 MASHINGTON PA 15301 T SIGNATURE M.W. N ATSL J A . O . , . oAre 11/_27/77 . - DESCALE ORY NO O ST ATE OF PLNNSYLV4HLA ASTP A='>15=748 GR ADE 65 PRES $UR.* VESSEL QUALITY, COUNTY OF ALLEG9E4Y C- ' SUBSCRIDED afin t =0[9fe, 3 70 AEmW P.
IL [f"lH 1977 THIS ,' OAy or - e '# ? Q-lM gAbw._ (. . h PLATES ANALYSIS NILL Sa0RN T/R sn
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Dear Tom:
' , In review of owner furnished material CMTR's for AS!'I. Code compliance we have noted the following discrepancies in general: , 1.
Material manufacturer /sapplier N-certificate nunter and expiration date missing.
2.
Applicable code of manufacturing not identified.
' s.
no code class or addenda.
- 4.
Statement relative to NCA 3800 for material manufactured not shown when applicable.
~ Since Cherne is not aware of all facts concerned, we are requesting PSI to review the situation to determine acceptablility of the material.
In the interim we are placing a hold on the effected material for installation until such time as we receive further notification from PSI.
Sincerely, . CHERN CONTRACTING CORPORATION ., . NT 1382 090 - Craig Jergens Quality Control Manager CJ:kk R. Horine /
CC: J. Morte11 G. Shibayama ' T. Francis G. Rosier .B. Braden r . ;_.
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. Intest edition..with addenda and. codt. cases in effect. as. of..thm nr#r.da.te... _. _ ..
y of the.Jaterlala. to be.inspec.ted... Specifications Y-2*Il41 &.Y-2962 are the.... . '; =rmi4r=hia. specifications.for.the. furnishing and purchasing.of. materials.... _. -. [ r-riping systems...~..-.......-.. .... .. -............... _ . - _. - ._.
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05-02-79 N/A Date; Latter No: Stewart Mechanical To: 757 Grade Lane Louisville, KY 40213 Reference: S r. L sope. v-???? , Attnt Dave Hicnite
WE ARE SEND!NG YOU: @ Attached C Under separate cover - THE FOLLOWING ITEMS: Osacifictica O Pr 'i=>a rv < aart O ria.i r aart O Drawi ofd O Photofsl Coov of document (s) O rroc e a - , O Ota.- - . Refer.nce Description Copies
F:I Ecuipment/ Material Issue Ticket Nos. 1117, 1126, 1127, 1129. 1130.
l - 1137, 1238.
j . l i .
THESE ARE TR ANSMITTED AS CHECKED BELOW: Returned to you C For your intormation - file Approved C For review & comment O Aaarov o >aot e ] For your use
O ois aar o C For your approvat 0 ^=*ao-i oo.a t * tura ta > ad r O ^> voo r auest.d - Remarks: . o . O oet oveo O stoma a voia Superseded Doc ment Semler.
A-J-w...':ff r.:nt: . Copy to.
.
W"##*^ . Date: j '
.h: h Ondigt nJtify us at once if enclosures or data is not w..n.t.
_- \\
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RECEIVING INSFECTION REPORT . ' ' '. . '.- l'
,
MATERIALS . ~ >; ~ ~ ' /0C Z ITot sERIA1.seo.
DAtt 4. 4-79 ~ .733 CID 2 EO.
PA2r No.
- DRAWiNC NO. _ ?5./O 7 ~7 EZY, comun 6 Fe S.
20'-6"i.octs /Do 2 /2 9 v. o. no.
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Sire Ordered size seceived ~ . Imagth /00 1.ength /O#2.- 2 TML.
6 pe=3.
"/ O* S'# " - Width ~ Width . [/ O _ * Thickness _. f l CJ
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43 Diameter S O' Diaceter , Visual Condition Accept,, [ _ Rejec.t II. Documentetion Re qui r,c,ernt_n,. .
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Certified it terial Test Pcpurt Yes a) Heat Number or Identificatio~n on TW L Report L V 6 {$ y. 9 Ikrat Nu=. er on Pitee(s) L t/-5 8 M - b)
c) Material 5 sec.'3A-/04 (or: 8 2.
Certificate '6Y s".ompliance Yes geo . a)- Material * c.
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' Receivins Inspector _ f f . , EDTEt Forward to Quality Assurance Mnnager for review of documentation.
- . Do not release materfat.
. 1382 095 ' - - D"*D
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Marking Instructi.ing ' - _ . - - atens vill be identified nr..uiepted by: _e[[0sJf/f/N -
. . . ;. - h 6aratation Ac,'.ew . a) Documentation ^ Review satisfac tory. Release to the Storer Area.
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FOR31 NPP.1 DATA REPORT FOR FABRICATEDhUCLEAR PIPING , . i *- E g - t '. - (As Reigelred by the Provtsions of the ASIE Code Rates) , ,,. ' w.
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ATTACHMENT F STEWART M ECHANICAL - - a! a r.
E NT E R PRI5L5. INC y . $k Anaf/dning.$f,&viaGn. 'Skaf&ty an<l Yen he ~~~ ' . O)kef % &r/ S fik a la n ' .!dEnrAnyand $afaMM - y - / s 757 ORADE LANE LouisvsLLE. KENTUCMY 40213 ...........
c' July 14,1977 16.03-071477-002 Mr. Frank Hodges Public Service Indiana Plainfield, Indiana 46168 RE: Vendor Survey
Dear Frank:
On June 24, 1977 we sent to you a Vendor Quality Questionnaire which we requested that you fill out and return with a non-controlled copy of your Q. A. Manual. Under the conditions that now exist we must, unfortunately, treat P.S.I.
as a vendor for all Safety Category I items provided by P.S.I. that are to be installed by Stewart Hechanical Enterprises.
If our survey and approval of P.S.I.'s Quality Assurance Program is not completed by the time these Safety Category 1 items begin to arrive at the job site, Stewart Mechanical will be placed in the embarrassing position of being unable to accept the items which we are, in effect, being paid by P.S.I. to install.
I realize this places both of us in a position which, I'm sure, neither cares to be.
However, under existing circumstances. Stewart Mechanical has no other course (to follow), which would allow us to comply with - the requirements of the ASME Code and thus our " Certificate of Authort-zation" or " Interim Letter".
Ycur continued attention to this problem is greatly appreciated.
Respectfullv.
. 1382 100 > seph L. Butt Q.A. Manager ' - ' JLB/mrl cc: Newberg-Marble Hill . b' ' NMH 18077700.7 - _._.._____ .... -
' . . b f EWART M ECH AN s CAL kTTAcHMENTG E NTE R P RIS E S. IN C .$Suthy and SchliC<thiy cA ({wdYaniny.d?QvwGn. ;$)!
[$cel 9Actad.%Jaca(&n.
!/htmhaand:954ank& hey 757 GftADC LANc Louisv LLE, KENTUCKY 40213 esoas asi-4 os June 2,1978 0T-15.71 -001 A c ' v y V PE Public Service Indiana Marble Hill Nuclear Generating Station fqq OM . P.O. Box 190 New Washington, Indiana 47162 . -- Attention: Frank Hodges - RE: Loose (Non Stamped) 36" Pipe Flanges for Essential Service Water
System - Marble Hill Nuclear Gen: rating Station Frank: It has come to my attention that although we have discussed verbally the receipt and installation of the material referenced above, no written record has been made of Stewarts inability to receive and install this material.
Under the rules of the ASME Code, Se*: tion III, Division 1, Subsection NA, Paragraph NCA 3820 (b), PSI must either be the Holder of a " Quality Systems Certificate (Materials)" or allow Stewart Mechanical to audit and approve and perform periodic surveillances of your " Identification & Verification Program".
Since PSI does not possess a " Quality Systems Certificate" and will not allow SME to audit them, under the rules of the ASME Code Stewart is unable to receive or install these 4 - 36" flanges.
Respectfully, - STEWART MECHANICAL ENTERPRISES, INC.
}}h} j]) / #1 J.L. Butt Q. A. Manager JCB/ojm, ' cc: Newberg-Marble Hill, Chicago ' . JMH 050678108 7 $ _
. . . STEWART M ECH ANICAL ATTACHMENT H E NTE R P RISE 5. INC
. etbblef ancf Yt'/t(r$1{//trf
'Y U$nthwandd,4dth/3/fo<im %<.1 Whfal [kStk.afie n , , 757 GRADE LANC LouisvlLLE, KENTUCKY 40213 iSOff 364-4405 ~ OT-071378-027 July 13, 1978 , ,% Public Service Indiana ' d *A 1000 E. Main Street d, C % Plainfield, Indiana 46168 k Attention: Mr. Jeff Roberts Q' --- % " RE: Your Letter No. 0710780025 ' . ASME Letter of April 20, 1978 f ~ --
- ASME File #N177-453 % I ~ __/ i Jeff: ~... I have received and reviewed the above reference letters. Your letter to me addresses a non-stamped pipe flange with " Certificates of Conformance," while the letter to the ASME references only " Stamped" items with " Data Reports."
While the answer to your inquiries t'o the ASME are correct (SME is now accept-ing from PSI, Code Stamped items with data reports) the question should be "under what conditions can an owner, not holding a " Quality Systems Certificate" or a " Certificate of Authorization," 1) Procure non-code stamped material 2) Receipt inspect non-code stamped material with " Certificates of Conformance" 3) Release approved (by owner) non-stamped material with " Certificates of Conformance" to an installer (Certificate Holder) for installation in a code stamped component.
I am as anxious as you to resolve this question. However, I do not believe that we have, as yet, done so.
Respectfully, I382 102 STEWART MECHANICAL ENTERPRISES, INC.
seph L. Butt Quality Assurance Manager , JLB/ojm ,q cc: B. Hamilton HMH 200778047 - 4. Kueck h B. Gutermuth ,, .
._._.
_ _ _ . . CHERNC . ATTACHMENT I ........ CIIElf S E COFrlf.W'fl NU ColwoltXrloN D m.
~/!2 7!?? unmett mit t u i. c a r e. n r. e i r W 3'O WI posv oe r ec c som soo ' c 6 c a-o t se a-.. , . ,, ',
N Ew WA S H I NOTON, IN DI AN A 17 p i.. o,, , May 14, 1979 Public Service Company of Indiana, Inc.
Box 190 New Washington, Indiana 47162 ATTENTION: Tom McLarty Q.A. Construction Supervisor Re: Public Service Company of Indiana, Inc.
Marble Hill Nuclear Generating Statinn Units 1 & 2. Contract Y-2739A & B, t.-2962 Cherne File #7340-70B-1035
Dear Tom:
In review of owner furnished material CMTR's for ASME Code compliance we have noted the following discrepancies in general: 1.
Material manufacturer / supplier N-certificate number and expiration date missing.
2.
Applicable code of manufacturing not identified.
3.
No code class or addenda.
4.
Statement relative to NCA 3800 for material manufactured not shown when applicable.
Since Cherne is not aware of all facts concerned, we are requesting PSI to review the situation to determine acceptablility of the material.
In the interim we are placing a hold on the effected material for installation until such time as we receive further notificatinn from PSI.
Sincerely, CHERN CONTRACTING CORPORATION 1B2 103 yn - -- - ' ^^ Craig Jergens Quality Control Manager
l CJ:kk t-CC: J. Mortell G. Shibdyama R. Ilorine / T. Francis G. Rosier B. Braden ~,-,<..... . .. . . .....,..,.... _. _ -. , ..: .- -
. - .. _
' - . . c,4cauc y ATTACHMEST J - ..mes.... . CIIERSE CONTHACTING ColWOHNflON ,. , , 'st6ce. omtone meno e a e, t orrect as o p p 7 t, ,
, "* ; I March 7, 1979 - ' M . :. .
. . Public Service of Indiana, Inc.
-- ~~ -- 1000 East Main Street ' Plainfield, Indiana 46168 I Attention: Mr. Frank Hodges , , _ Re: Public Service of Indiana, Inc.
Marble Hill Nuclear Generating Station - Units 1 and 2, Contracts Y-2739A & B, Y-296 Cherne File #7840-708-42 Subject: Cherne Survey of 2/28/79 and 3/1/79 _ . - _ _ _ _ - - Qualification for Materials Supplier
Dear Mr. Hodges:
As a result of our recent survey, PSI is qualified as a Materials Supplier and has been placed on our qualified nuclear vender list.
, . Please address and respond to the finding and coment, as noted in the enclosed Survey Report and Survey Log, by March 30, 1979.
Please sign and date the Survey Log and return it to Cherne to indicate the ite:a has been closed.
Please contact me should you require further information.
- .
Sincerely, , CHERNE CONTRACTING CORPORATION bb4 W ' IM 2 104 Mark D. Anderson . QA Engineer , _ _ , cc: G. Rosier , ,J.Joberts -- - -- \\y McLarty _ - , . S ,
8%**9'% d
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ATTACHMENT K . . cwcAur w.co n^u 7M7df we .. u.... CHERSE CONTH.WTING ColmOHNrlON 94 A R S L E H8LL P8UCLEAR f, 01 C i f 6 f 6.s t,t. f P 's e a d C,- P O f. T OrrecE ts o m aoo , , 1 m = e s o-P.,o-e a e 4 NEW h*A S111 N OT O N. I N D I A N A t r a f t '.! . June 6, 1979 Public Service Company of Indiana, Inc.
U Box 190 g f New Washington, Indiana 47162 m D]o @UU ^ ATTEN110N: Tom McLarty , Q.A. Construction Supervisor Re: Public Service Company of, Indiana, Inc.
Marble Hill Nuclear Generating Station Units 1 & 2, Contract Y-2739A & B, Y-2962 Cherne File 3 7840-70B-1045
Dear Tom:
To date PSI has been providing the cover page of ITT Grinnell furnished fiPP-1 Data Reports, for Code Stamped Components provided under Y-2741, to Cherne In review of syste n for component identification and verification nurposes.
turnover requirements associated with the Installers N-5 l>ata Report, we tind including any attached pano.
it necessary to have the complete'NPP-1 rep,mtThese pages are generally an as when applicable.
Confirming my conversations of June 4,1979, with yourself and Terry Sheets.
Cherne feels it would be advantageous for both PSI and Cherne if the original This would avoid additional copyir:0 as well as NPP-1 reports were provided.
permit Cherne to resubmit the originals as a part of our neiqinal ti-5 Data Report.
Please advise by June 18, 1979 as to PSI's pnsition in this matter.
Sincerely . CllLRN1 CONltACllNli CORPORA 110N /w) (p p ~< - 1382 105 , g Craig Jergens ( Q.C. Manager , . CJ:kdk CC: J. Mortell ' G. Rosier - G. Shibayama t.
T. Francis 6. Braden t - - ~~... -.. ... -. ......,. _ -..,... .... . .- -- -_.,.------,----.--..--.r.-, ..... -
. ... - - _- _ , e.
""'""' ATTACHMENT L 4 taw ms'/rr/ ...cr...o C.IIEl?N13 CONTit.\\CTI NG (I()lti'()lf.\\Ti t )N 04AROLE MILL NUCLEAR te s T L ' ELL""0"L
.\\' l * W Y ANlllN(iTilN. INint.%N.g tilft iw a cio. 3% FJee . June 6, 1979 Public Service Company of Indiana. Inc.
Box 190 New Washington, Indiana 47162 ATTENTION: Tom McLarty Q.A. Construction Supervisor ' D**D D
' Y '$
P.c : Public Service Company of Indiana, Inc.
6*p 'J~ ,
Marble Ilill Nuclear Generating 'tation Units 1 & 2 Contract Y-2739A & B, Y-296.' Cherne File # 7840-70B-1046
Dear Tom:
This letter is to request from PSI all CMTR'e./CaC*r. or d.ita rtports for material or components installed by others such as Stewart flechinical which Cherne will be incorporating into Safety'Related systems.
Cherre requires these documents for verification purposes and for inclusion in the installers N-5 Data Report.
lhese documents should be identified when applicable, as to inbed or spool number that the documents support.
Please respond by June 20, 1979, as to when these documents will be available and how they will be " turned over" to,Cherno.
Sincerely . CilERNE CONTRACTING CORPORATION f./ 1382 106 . o..y.,.. Craig.lcrqens;. , 0.C. Manager f.1:kdk R: J. Mortell
G. Rosier - G. Shibayamo 1. Francis V Braden R. liorine . % .. ...w.,,,,~.....--..c,....~ t .. .. . . .
% .073 0795079 . . _.. ..
==c " ,.., Attachment M seicsesis . CIlERNE CONTIMCUNG CORPORATION MARSLg HOLL NUCLEAR SIT E Tnt * ONcses eso.
. posv orrect sox 300 ,, Twm aso-aso.p ?e.
Nzw WASHINGTON, INDIANA 47182 - July 27, 1.979 . ce Company of Indiana, Inc.
[ M11 e bbdb*' tiew Washington, Indiana 47162 A11EtiT10il: Tom lictarty, QA Construction Supervisor Re: Public Service Company of Indiana, Inc.
24arble liill l'uclear Generating Station Units 1 & 2, Contract Y-2739A & B, Y-2962 mm a 3-Cherne File ! 7840-70B-1068 A.
- ee o _,. OWiiER FURillSHED MATERIAL
Dear Tom:
We are experiencing great difficulty in getting DSil numbers and applicabic ~ supporting data from your organization for all items procured by Public Service Indiana. This includes hangers, fabricated piping and equinnent.
At present your DS;l is the mechanism used by Cherne in order to release these items for construction.
' A,ttached is a list of 76 component supports which our engineering departnent wants to release for installation. This list was submitted to your docunent group almost one (1) month ago and as yet we have not received any of the information requested. This is creating a burden on our scheduling and pro-duction forces.
Please note that seven (7) other similar requests have been transmitted in Pe nonth of July which are also pending. Your attention and response is nee:n-) in this matter by August 3,1979.
Sincerely, CHERfiE C0tlTRACTIllG CORPORATION ]}82 lQ/ b "
. Craig ergen QC fianager CC: J. tiortell R. Horine F. Hodges (PSI) . T. Francis G. Shibayama - 'A. Sirard B. Fouts ' . -m k MM4 WM &M OOY M $ M $PS* - M ^""
!. ' , . wewc r
sseeCE ISIS e C11EltNE CONTitACTING CORPORXfJON . MAnstg MILL NUCLEAM &lT C
TEttee owc a23...o.
N EW WA5 211NOTON. INDI AN A 4r102 g...,,.33,,,3,. ' Document Control i Public Service Indiana, Inc.
.
Da te: 6/29/78 Attn: . Terry _ Shoots Plea *,c supply Cherne with the following DSN's and supporting data as applicable for the items listed below.
lAF01002R 2CC15015X 2CS02012R 2CS02027R SX 17R 13R 28R 2C508012X 1BR04020R 14R 29R 1FP07003R 2CS01049R 15R 30R 1FP15019X SOC 16R 31R 1FP15013X 02002C 17R 32R 1FPO4025X 3R 18R 33R ' - IM5010185 4R 19R 34V 1RH01005V SR 20R 35C 1SIO6005R 6R 21C 37C . 7R 7R 22C 38R 24X BR 23V 39R 39X 9R 24R 40R . 74R 10R 25R 41R . ISil8021R 11R 26R 42C 2SX42005R 1MS010105 25X20002X 2SX4100lR . 2SX42008X IBR03023R IWF01003R IWF01004R IWF01005R IWF01006R 7R BR 9R 11R 12R 13R w'\\' - - Thank you.
CHERNE CONT A TING CORPORATJON g3g . g /Q. ' , ' Ron Horine
Quality Control upervisor Rit:kdk . Attachment . . . . _. . ,. - . =. - -.. -
....a -... .. --- -- . - _ _. -- .__
'
CIIF.llNF. CONTI!A(TING (W)lti'OllATION . -
. , ,.., . Document Control June 29, 1979 Page Two s . ~ 1CC04AB-12-64 INS 01CD 30k-30 1M501CA 30"-25 2CC05GC-16-66 M10SX03A-30"-66 M110SX03A-30-67 4tHOSX24A-30*:71 sHHISXCIA-144-MHISXCIA-4-293 MH1SC54-AA-3"-291 MHISX54AA-3"-292 MiOCC028-16-37 N diXC4 &l44 MHISXC1A-293 MHOSX24A-30 -71-WilSXBl AD-3-50 ML2SX07HA-20-54 MH2SX07HA-20-56 ML2CC02CB-12-37
MH1CC04AB TZ:60- ML2CC02CB-12-37 MHICC04AB-121'-60-55 -
67
og /fJ 3LUE SPE DGtFt.D 1382 109 . e O' . G e e e e l ' t . . .
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ATTACHMENT N . PUBLIC SERVICE July 28,1979 - INDIANA S. W. Shields Vice Presdent Electric system Mr. D. J. Mcdonald, Director of Inspections The National Board of Boiler and Pressure Vessel Inspectors 1055 Cnipper Avenue Columbus, Ohio 43229 .
Dear Mr. Mcdonald:
In accordance with your telephone conversation with Mr. R. F. Reedy of NUTECH, Public Service Indiana is committed to the following actions as they relate to Mr. Beckwith's letter of July 10, 1979 to Mr. Crews.
1.
PSI comits to ASME that it will N stamp all appropriate piping systems in the project.
2.
PSI has applied to ASME for an N stamp for Class 1, 2 and 3 piping systems.
3.
PSI has also requested an Interim Letter and is sending our ASME Quality Assurance manual to ASME under separate cover.
Harttord Steam Boiler is the Authorized Inspection Agency and they have reviewed this manual.
4.
PSI has requested Hartford Steam Boiler to furnish full-time inspection on this pro ject as soon as possible.
5.
PSI management understands that the Owners' Certificate does not pennit the same activities as allowed by the ASME Code for an N Certificate Holder.
6.
PSI assures that all personnel involved with N Stamp activities will be fully trained for their ASME duties under the Code.
7.
PSI is taking full responsibility for all ASME activities relating ' to the applicable piping systems.
. . 8.
Each of the details of the July 10 letter will be responded to in a report to be mailed to National Board by August 8,1979.
1382 110 317. 839.9611 1000 East Main Street. Plainfield, Indiana 46168
__ _ _ _ _ . . , ' PUBUC senvics - "2* INDIANA Mr. D. J. Mcdonald July 28,1979 The National Board of Boiler and Pressure Vessel Inspectors 9.
PSI intends to be fully responsive to the requirements of the . ASME Code, the State of Indiana, the National Board and the NRC.
In addition to the other infomation which was Telexed to you on Friday *, July 27,1979, I have the following statement to add to Item #7: The ASME Program which will be shown to the ASME Survey Team is the same Program which has been used from the start of all purchasing and construc-tion activities relating to the piping systems which will receive an ASME Code Symbol Stamp.
There has been no change to the Program since the start of any of these activities for the piping systems. PSI has been acting on all the activities as the responsible party for the complete system and, therefore, has not been perfoming as a Material Supplier.
Since all material is controlled by PSI as the responsible party, tSe Code does not require that PSI be designated as a Material Supplier.
I hope this infomation will be helpful to yot pending our report on the July 10 letter which will be forwarded to you by August 8.
Should there be any further infomation you desire in the interim, please let me know.
Very truly yours, y S. W. Shields Vice President-Electric System SWS:gm cc: R.R. Johnson, State of Indiana Boiler & Pressure Vessel Board W.G. Reinmuth, U.S. NRC Victor Stello, Jr., U.S. NRC J.G. Keppler, U.S. NRC l}gy !;;; A.W. Henry. Hartford Steam Boiler - Uldis Potapovs, U.S. NRC Arlene Spadafino, ASME E.J.Hemzy,Commonwealthd;. dison Co.
W . O e e . }}