IR 05000546/1980017
| ML19320C227 | |
| Person / Time | |
|---|---|
| Site: | Marble Hill |
| Issue date: | 06/06/1980 |
| From: | Harrison J, Schweibinz E, Williams C NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML19320C222 | List: |
| References | |
| 50-546-80-17, 50-547-80-17, NUDOCS 8007160479 | |
| Download: ML19320C227 (9) | |
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U.S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT
REGION III
Reports No. 50-546/80-17; 50-547/80-17 Docket Nos. 50-546; 50-547 Licenses No. CPPR-170; CPPR-171 Licensee:
Public Service of Indiana 100 East Main Street Plainfield, IN 46168 Facility Name: Marble Hill Nuclear Generating Station, Units 1 and 2 Inspection At: Marble Hill Site, Jefferson County, IN (April 22-25 and May 13,~1980)
Region III Office, Glen Ellyn, IL (April 30, 1980)
Inspection Conducted: April 22-25, 30, and May 13, 1980
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Inspectors:
E. R. 'Schweibinz (Apr'
22-25 and 30, 1980)
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J. J. Harrison (April 22-25 and 30, and b-b d May 13, 1980)
Ha kins 1 22 25, 1980)
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/dx; Kon lin Ap 11 2-25 and 30, 1980)
Se K. R. Naidu Ap i 24, 1980)
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Accompanying Personnel:
D. W. Hayes (April 22-25, 1980 (
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Approved By:
C. C. Williams, Chief b/b Project Section 2 (April 25,1980)
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Inspection Summary
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Inspection on April 22-25, 30 and May 13, 1980 (Report No. 50-546/80-17; 50-547/80-17).
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e Areas Inspected: Project Quality Assurance Manual (PQAM); Personnel Qualifications; and Physical Verification of Structural Steel Activities.
This inspection ir.volved a total of 220 inspector-hours on site by seven inspectors.
Results: No items of noncompliance or deviations were identified.
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DETAILS
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Persons Contacted Public Service of Indiana (PSI) and Management Analysis Company (MAC)
- S. W. Shields, Vice President - Electric System
- G. N. Brown, Project Director (MAC)
+*L. O. Ramsett, Quality Assurance Manager
- C. G. Bet:kham, Manager, Quality Engineering
- J. H. Brewer, Construction Manager (MAC)
- D.
B. Ingmire, Construction Verfication Coordinator (MAC)
+*C. E. Chmielewski, Quality Systems Superintendent
- J. M. Roberts, Superintendent - Inspection
- B. R. Morrison, Quality Engineering Superintendent - Civil
- C. T. Warner, Quality Engineering Superintendent - Civil (MAC)
- T. R. Burns, Project Engineering Manager
- R. J. Kime, Assistant Construction Manager T. Mays, Personnel Manager
+J. M. Norris, Manager, Quality Engineering (MAC)
+S. Brewer, Nuclear Safety and Licensing Manager
+J. U. Bott, Licensing Manager The inspectors also contacted and interviewed other licensee and con-tractor personnel.
- Denotes those attending the exit meeting on April 25, 1980.
+ Denotes those attending the meeting on April 30, 1980.
Licensee Action on Previous Inspection Findings (Closed) Open Item (50-546/79-11; 59-547/79-11 paragraph 5b(5): Verifi-cation of the material certifications on piping penetration sleeves.
It
was previously reported that in Monconformance Report 6-28, Cherne, the mechanical piping contractor, identified multiple linear indications after welding to piping penetration sleeve identified as 2AB-3 located in the auxiliary building. During the current inspection, the NRC inspect ^r
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received Corrective Action Report No. 19 dated August 1, 1979.
Magnetic Particle tests were performed on six other assemblies manu-factured from the same heat No. N-73457, identified as IAB-3, IAB-50, IAB-140, 1AB-141, 2AB-113, and 2AB-114, and linear indications were identified. Re-examination after slight grindfug revealed no indica-tions. Based on this, it was concluded that the linear indications were surface conditions. The depth of the indications measured with a calibrated caliper were determined to be 0.0185 inch minimum below the surface. A 12.5% reduction in the nominal wall thickness reduction is permissible according to ASME Section II, Part A SA-106 paragraph 18.3; in this case the nominal wall thickness of the pipe is.375" and the-3-
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maximum reduct, permissible is.0468.
Therefore, it was concluded that
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the.0185" reduction was permissible. The corrective action taken by Stewart Mechanical is considered acceptable.
(Closed) Unresolved Item (50-546/79-10-01; 50-547/79-10-01):
It was previously reported that American Bridge, a subcontractor to Gust K.
Newberg Associates to install structural steel in the auxiliary building, did not address the purchase of services in their procedure QAPN-3, Revision 0, and that the auditing of subcontractors was not included.
During the current inspection, an " Approved Vendor's List" was made available which included H. H. Robertson, the subtier contractor who supplied and installed Nelson Studs. Records indicate that an audit was performed by American Bridge of H. H. Robertson on June 11, 1979.
Corrective actions taken on the two audit findings were identified and were verified and determined satisfactory on February 12, 1980. One nonconforming condition, that H. H. Robertson did not establish measures to review and approve their subtier suppliers, was closed on February 8, 1980 after H. H. Robertson audited TRW-Nelson Studs and Ohio Welding Products.
(Closed) Unresolved Item (50-546/79-10-02; 50-546/79-10-02):
It was previously identified that Nelson Stud Welding was performed under unacceptable conditions. Records indicate that en July 12 and July 17, 1979 extensive training was provided to Nelson Stud gun operators, which included four important aspects of Nelson Stud welding.
Functional or Program Areas Inspected Details of functional or program areas inspected are discussed in Section I, II, and III of this report.
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Section I
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Prepared by E. R. Schweibinz J. J. Harrison Reviewed by C. C. Williams, Chief Projects Section 2 Review of the Project Quality Assurance Manual (PQAM)
Three Region III inspectors reviewed the PQAM to evaluate it with respect to the requirements of 10 CFR 50 Appendix B and for consistency with previous commitments made by the licensee. On April 30, 1980, a meeting with the licensee was held to discuss the RIII comments on the PQAM in the RIII office in Glen Ellyn, Illinois. The licensee agreed to incorporate the RIII concerns into its PQAM. This item remains open pending incor-poration of the concerns addressed during the meeting.
(546/80-17-01; 547-80-17-01).
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Section II Prepared by J. E. Konklin F. C. Hawkins Reviewed by C. C. Williams, Chief, Projects Section 2 Review of Personnel Qualifications The two RIII inspectors reviewed the education and work experience of 27 supervisory and management level Marble Hil.1 personnel.
Included in the review of work experience was the evaluation of nuclear experience, re-lated experience, total industrial experience and, where applicable, quality assurance experience. Education and work experience for the following personnel was reviewed:
1.
Vice President-Electric System (PSI)
2.
Project Director (MAC)
3.
Construction Manager (MAC)
4.
Project Control Manager (PSI)
5.
Project Engineering Manager (MAC)
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Project Control Manager (MAC)
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Project Engineering Manager (PSI)
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Material Procurement Manager (PSI)
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Mechanical Procurement Super'isor (PSI)
10.
Nuclear Procurement Supervisor (PSI)
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Manager, Material Management (PSI)
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Supervisor, Storage and Maintenance (PSI)
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Area Construction Manager, Reactor Building (MAC)
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Area Construction Manager, Reactor Building (PSI)
15.. Quality Assurance Manager (PSI)
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Quality Assurance Manager (MAC)
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Manager, Quality Engineering (PSI)
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Superintendent, Inspection (PSI)
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Superintendent, Quality Systems (PSI)
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Electrical Superintendent, Quality Engineering (MAC)
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Mechanical Superintendent, Quality Engineering (EDS)
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Welding /NDE Superintendent, Quality Engineering (PSI)
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Civil Superintendent, Quality Engineering (MAC)
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Civil Superintendent, Quality Engineering (PSI)
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Procurement Superintendent, Quality Assurance (PSI)
26. Receiving Inspection Supervisor, Level III (PSI)
27.
Receiving Inspection Supervisor, Level II (PSI)
As part of the review, the RIII inspectors verified specific selected items on the personnel resumes, by telephone, with educational institu-tions and previous employers.
The review by the RIII inspectors verified that the education and work experience for 26 of the 27 individuals is sufficient to justify the positions held. With regard to the other person reviewed, the inspector questioned whether that individual possesses sufficient quality assurance experience to justify his Level III certification for inspection and testing. During a subsequent meeting at the RIII offices, on April 30, 1980, the licensee agreed to provide a more detailed written justification for the amount of quality assurance experience credited to that individual.
That written justification was provided to Region III during the week of May 5, 1980. On May 13, 1980 the RIII Resident Inspector interviewed the individual in question to evaluate his QA experience. Based on the written justification and the interview, Region III concluded that the individuals education, experience, and training do adequately support his Level III certification for inspection and testing.
No items of noncompliance were identified.
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Section III
Prepared by K. R. Naidu Reviewed by D. W. Hayes l
Observation of Physical Verification of Structural Steel Activities The inspector witnessed the Structural Steel Survey Teams 1 and 2 petiorm physical verification of the installed structural steel in the auxiliary building at elevation 451' and 463'.
Special Process Procedure SPP-3 was used to perform the verification. The inspector concurred with the following observations:
1.
Bolt on beam connection 1086C1 to 1048B1 appeared to have incomplete nut engagement. The boltup sheet indicated that the correct size bolt 7/8" diameter 2-1/4" long was used. However, the nut had not been tightened.
2.
Beam 1105B2 was not installed at elevation 451'0" according to draw-ing E1309 Revision N.
It was subsequently determined that the erec-tion was done to Revision H of drawing E1309, which did not show beam 1105B2. Due to the shutdown order, no additional erection was per-formed subsequent to August 15, 1979, after which the drawing was revised.
3.
Beam 3073B9 Division 3, identified on drawing E1568B Revision.C, was bent.
It was apparent that the beam was bent to fit the connection because it was slightly longer and as currently installed the sweep exceeds the AISC permissible variation.
4.
At elevation 463'5" a hole pattern was added to beam 3073B11, identi-fied on drawing E1568B Revision C, to connect the beam according to Sargent & Lundy erection drawing S1568B.
It was obvious that the bolt pattern on Inryco's shop drawing was incorrect.
5.
Several framing member bolted connections did not meet established torque requirements.
Subsequent discussions with the site contractor, American Bridge, in a letter dated October 2, 1979 indicated a dis-crepancy in the torque values used by US Testing Services (UST); UST was verifying the torque on A490 type bolted connections using the value for A325 type bolts which was considerably less. For example, a 3/4" A325 bolt is torqued to 350 foot pounds (ft lbs), whereas the same size A490 bolt should be torqued to 438 ft lbs.
6.
Washers used in long slotted holes in the web connection angles, for a beam connection to an embedment plate, did not completely cover the
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hole. This matter was reported by the licensee as a 50.55(e). The
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inspector determined that the Inryco shop drawings (which were approved by S&L) did not show the special plate washers which should be used and consequently not shipped to site; as such they were tit available at the time of erection. Subsequent to the shutdown of construction activities, plate washers have been shipped to the site.
The inspector selectively reviewed the documented test reports and determined them acceptable.
No items of noncompliance were identified.
Exit Meeting The inspectors met with site staff representatives (denoted in the Persons Contacted paragraph) at the conclusion of the inspection on April 25 and April 30, 1980.
The inspectors summarized the scope and findings of the inspection.
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