IR 05000546/1980039
| ML20002D476 | |
| Person / Time | |
|---|---|
| Site: | Marble Hill |
| Issue date: | 12/11/1980 |
| From: | Hawkins F, Hayes D, Neisler J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML20002D474 | List: |
| References | |
| 50-546-80-39, 50-547-80-39, NUDOCS 8101210104 | |
| Download: ML20002D476 (11) | |
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U.S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT
REGION III
Reports No. 50-546/80-39; 50-547/80-39 Docket Nos. 50-546; 50-547 Licenses No. CPPR-170; CPPR-171 Licensee: Public Service of Indiana Post Office Box 130 New Washington, IN 47162 Facility Name: Marble Hill Generating Station, Units 1 and 2 Inspection At: Marble Hill Site, Jefferson County, Indiana Inspection Conducted: October 21-24, November 5-7, and 11-14, 1980
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$O Inspectors:
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(October 21-4, November 5-7, and 11-14, 1980)
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,'c-J. H. Neisler
(November 6 and,7, 1980)
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Approved By: D W. Ha
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Engineering Support Section 1 Inspection Summary Inspection on October 21-24, November 5-7, and 11-14, 1980 (Reports No. 50-546/80-39; 50-547/80-39)
Areas Inspected: Follow-up on previously identified inspection findings; review of the SPP-2 Construction Verification Program final report; inspec-tion of the Civil Inspection and Testing Services Laboratory to assess its readiness to support construction activities; inspection of Commonwealth-Lord to assess their readiness for the electrical demonstration. The inspection involved a total of 104 inspector-hours by two NRC inspectors.
Results: No items of noncompliance or deviations were identified.
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DETAILS Persons Contacted Public Service of Indiana (PSI)
- W. M. Petro, Project Director
- L. O. Ramsett, Quality Assurance Manager
- T. R. Burns, Project Engineering Manager
- C. G. Beckham, Quality Engineering Manager
- S. J. Brewer, Nuclear Safety and Licensing Manager
- C.
S. Togni, Chief Civil Engineer M. Patel, Civil Project Engineer
- E. R. Bonnett, Document Control Supervisor D. Couch, Quality Assurance Training Supervisor
- D.
B. Ingmire, Construction Verification Coordinator
- J. W. Janecke, Quality Systems Superintendent
- G. T. Warner, Quality Engineering Superintendent - Civil
- B. R. Morrison, Quality Engineering Superintendent - Civil H. Curry, Quality Engineering Superintendent - Electrical
- L. W. Worley, Civil Inspection and Testing Laboratory Supervisor
- J. Keys, Quality Assurance Administration Assistant J. Lefman, Quality Assurance Engineer - Audits D. Kibler, Quality Engineering - Training C. T. Robinson, Senior Field Concrete Inspector D. Lanham, Civil Inspection and Testing Laboratory Site Administrator D. Cook, Lead Lab Inspector A. E. Johnson, Lead Steel Inspector T. J. Diel, Batch Plant Inspector B. A. Allman, Calibration Technician M. G. McDaniel, Technician
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G. K. Newberg Construction Company (N-MH)
D. Stegemoller, Vice Presidznt - Power Construction N. Henry, Project Quality As.surance Manager D. Maxwell, Project Quality Control Manager L. M. Elliott, Assistant Project Manager J. Coffman, Quality Control Supervisor - Concrete R. L. Ghastin, Training Administrator Commmonwealth-Lord W. Benkert - Site Quai n y.'. x rc. ace Manager W. Marini, Quality Assurance Inspector (Level III)
Other Personnel
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J. J. Harrison, RIII Resident. Inspector
- Denotes those attending the exit interview.
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O Licensee Actions on Previous Inspection Findings
(Closed) Noncompliance (546/79-03-04; 547/79-03-04)
a.
Whalen-Chilstron Joint Venture (WCJV) QC inspection personnel records did not include any record of the inspector's qualifi.:ation/certifica-tion as related to the inspection of post-tensioning work activities.
The RIII inspector serified that the qualification / certification records of personnel performing work related to post-tensioning activities were now in accordance with the requirements of WCQAP-7, Revision 6 and ANSI 5.2.6-1973.
b.
WCQAP-7, Qualification and Training of Personnel, did not provide for the indoctrination / training of personnel performing quality inspections of post-tensioning activities.
WCQAP-7, Revision 6, Attachment B, now provides for the indoctrination /
training of responsible Q/C personnel to the requirements of WCQAP-9.
WCQAP-9, Revision 7, section 4.4 delineates the WCJV QC inspector's responsibility as it pertains to post-tensioning embedment installation.
(Closed) Noncompliance (546/79-09-02; 547/79-09-02)
a.
There was no definitive procedural requirement which specified the maximum allowable lateral movement of fresh concrete during placement.
S&L Specification Y-2722, section 415.1.g. has been revised to reference ACI 309-72, Recommended Practice for Consolidation of Concrete.
This revision specifies ACI 309-72 as the " basis for determining the adequacy of the equipment used for concrete consolidation and the tech-nique of operation." In addition, N-MH WPN-9 Revision 13, section 10.1 states that, " Intentional lateral transportation of concrete with a vibrator shall not be permitted." With the addition to the quality inspection staff of qualified and trained concrete placement inspectors, these procedural revisions adequately address the proper handling of concrete during placement.
b.
The seven day cure requirement for concrete was not adequately defined in S&L Specification Y-2722 to assure the proper curing time.
S&L Specification Y-2722, section 417.1 a3A. has been revised to more specifically require that, "The curing period shall begin at the point where the concrete placement has ended and shall continue for at least 168 hours0.00194 days <br />0.0467 hours <br />2.777778e-4 weeks <br />6.3924e-5 months <br /> or until the concrete strength has reached 70% of the specified strength."
c.
S&L Specification Y-2722, section 413.6h. did not prevent the continued rapid discharge and placement of concrete during tightened sampling initiated as a result of concrete which was not within the " allowable limit" specified.
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S&L Specification Y-2722, section 413.6h. has been revised to delete the provision thich allowed' concrete discharge to be resumed imme-diately after the sample was taken, during tightened sampling.
d.
S&L Specification Y-2850, sectica 406.3 did not provide adequate control to prevent the inadvertent use of nonconforming aggregate.
PSI QCP-2, Quality Control Procedure for Sampling / Testing of Concrete Constituent Materials, now specifies that both fine and coarse aggre-gate samples shall be taken and tested daily during production and daily during delivery. The daily record tests meet the requirements specified by ANSI N45.2.5-1974 and the daily receipt tests will provide assurance to prevent the inadvertent use of nonconforming aggregates during concrete production.
(0 pen) Noncompliance (546/79-09-03; 547/79-09-03)
a.
Failure to consolidate the preceeding two foot concrete lift prior to depositioning fresh concrete in two areas (placement no. ICW-Ext.-9).
This item will be addressed in a subsequent report following the resumption of construction.
b.
Internal concrete vibrators were inserted at about thirty inch intervals, exceeding the allowable distance of about 18 inches specified by S&L Specification Y-2722 and ACI 301-1972.
This item will be addressed in a subsequent report following the resu.nption of construction.
c.
No-procedural requirements exist for the mixing, installation, and inspection of dry pack used in the repair of concrete imperfections.
The RIII inspector reviewed N-MH WPN-25 Revision 2, Concrete Patching, and N-MH QCP 10.06 Revision 0, Post Placement and Patching Inspection, to verify that they contained pertinent quality requirements for the mixing, installation, and inspection of dry pack material.
Item c. is closed.
d.
No documented instructions or procedures exist to specify the type of repair which should be used for any specific area of concrete imper-fection; based on the void size, configuration, and accessibility.
It was confirmed that N-Mll QCP 10.06 Revision 0, Post Placement and Patching Inspection, does contain instructions which govern the repair
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of different types of concrete imperfections based on their size, configuration, and accessibility.
Item d. is closed.
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It should be noted that the referenced procedures apply only to future work. A special procedure is being developed for chipping out, docu-menting, evaluating and specifying repair for the existing patched and potential repair areas identified under the Construction Verification Program (Section 5.0, Category I Concrete Surface Irregularities).
(Closed) Unresolved Item (546/79-09-04; 547/79-09-04) The effective radius of the two inch internal vibrators used to consolidate concrete for place-ment no. ICW-Ext.-9 was in question.
On October 22, 1980, N-MH staged a practical demonstration to illustrate the effective vibratory radius of the two inch internal vibrators used at the Marble Hill site. The demonstration was performed using vibrators similar to those used for placement no. 1CW-Ext.-9 and concrete with a similar slump. The effective vibratory radius was determined to be in excess of two feet. This value is 7 - 8 inches greater than the radius required to assure proper concrete consolidation in a placement config-uration similar to that of ICW-Ext.-9.
(Closed) Unresolved Item (546/79-09-06; 547/79-09-06) Marble Hill site personnel stated that N-MH QC personnel would switch the order of concrete trucks during tightened sampling in order to circumvent specification requirements.
Resolution of this item is addressed in IE Investigation Report 80-04, Allegation 13.
(Closed) Noncompliance (546/79-09-07; 547/79-09-07)
On July 20, 1979, it was determined by personnel interviews and observation of work that contractor supervision, concrete finisher craftsmen, and QC inspection personnel were inadequately trained and indoctrinated as demon-strated by numerous concrete repairs which were completed:
(1) without benefit of QC notification, (2) without adequate patch preparation, (3) using nonconforming materials, and (4) without adequate procedures.
The RIII inspector reviewed N-MH QAP 2.01 Revision 2, Training of Personnel, to verify that it included provisions to assure the training of QA/QC and production personnel who perform functions or activities relating to the repair of concrete imperfections. Additionally, QA training records were reviewed which identified class room instruction on N-MH WPN-25 Revision 2, Concrete Patching, and N-MH QCP-10.06 Revision 0, Post Placement and Patching Inspection.
Personnel from PSI and N-MH QA/QC, engineering, and the trades and labor force were in attendance at the training sessions.
(Closed) Unresolved Item (546/79-16-15; 547/79-16-15)
Deckard Allegation No. 6
" Reportedly PSI had been made aware of concreting problems in writing and had ignored the notification." (Reference IE Reports 79-16,Section I. (6) and 79-18, Section 1.0.)
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Resolution of this item is addressed in IE Investigation Report 80-04, Allegation 37.
(Closed) Noncompliance (546/79-18-01; 547/79-18-01)
This noncompliance consists of eleven parts, designated as items a. thru k.
Items a, b, c, d, e, f, g, and j are addressed in IE Report 80-06.
Items h, i, and k are addressed as follows.
h.
Five occasions in which UST personnel were certified to Level I requirements prior to completion of the interview and practical demonstration of their proficiency.
PSI has recently assumed direct responsibi.lity for the technical activities of the on-site testir.g laboratory. This responsibility includes the qualification / certification of laboratory personnel in accordance with PMP 3.01.
The review of PHP 3.01 by RIII personnel is documented in IE Report 80-24.
The qualification /
certification records for nine Level I lab inspectors and three Level Il lab inspectors were reviewed to verify that they were adequately qualified and properly certified in accordance with PMP 3.01.
i.
Two occasions in which UST personnel were certified to Level I requirements prior to receiving visual examinations.
The resolution of this item is identical to h. above.
k.
At least seven UST personnel were certified to Level I that did not meet the experience requiresents as specified in ANSI N45.2.6-1973.
The resolution of this item is identical to h. above.
(Closed) Unresolved Item (546/79-18-02; 547/79-18-02)
Further review by RIII inspectors of UST Company procedures and practices relative to the qualification / certification of laboratory inspection personnel was planned prior to the resumption of construction.
As previously discussed in the resolution of noncompliance 546/79-18-01; 547/79-18-01, PSI has assumed responsibility for the qualification /certi-fication of testing laboratory personnel. Along with the review of PMP 3.01 which is documented in IE Report 80-24, the inspector reviewed PMP 3.31 Revision D, Civil Inspection and Testing Services, to verify that it is consistent with NRC requirements and licensee commitments. These reviews did confirm that all NRC concerns dealing with the qualification /
certification of civil testing lab personnel had been adequately addressed.
(Closed) Unresolved Item (546/79-26-01; 547/79-26-01) N-MH procedure WPN-35 Revision 0, Dry Pack Repair, did not include the necessary quality require-ments.
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N-MH WPN-35 has been voided and the requirements for dry pack patching included in WPN-25, Concrete Patching. Section 9.0 of WPN-25 Revision 2, was reviewed. The review confirmed that the procedure contained the necessary quality requirements to assure the control of dry pack patching activities.
(Closed) Unresolved Item (50-546/80-10-01; 50-547/80-10-01) Inspection checklists prepared, inspection performed, and results reviewed by same individual.
Inspection procedure QCP-C18, " Inspection of Embed Conduit has been revised to delineate responsibilities for signoff of checklists for embed conduit.
(Closed) Unresolved Item (50-546/80-10-02; 50-547/80-10-02) Electrical inspection checklists included space for project manager review when applicable.
Inspection checklists have been revised to delete the space for project manager review.
(Closed) Open Item (50-546/80-10-05; 50-547/80-10-05) Review of new QA/QC procedures and revisions involving the installation, inspections and receipt of safety related electrical items at Marble Hill. The inspector examined approximately 20 procedures involving the electrical area. The procedures were considered adequate and consistent with requirements.
(Closed) Unresolved Item (50-546/80-33-01; 50-547/80-33-01) Determination of procedural requirements for on-site electrical design activities.
Procedural requirements have been established and procedure CWP-C4A Document Control (Drawing, Specification, and Procedure Control) has been revised to require the necessary checks, reviews, and approvals for site generated drawings.
(Closed) Unresolved Item (50-546/80-33-02; 50-547/80-33-02) Applicable edition of AWS welding code for structural welding at Marble Hill.
Licen-see has initiated a SAR change to commit Marble Hill to the 1979 edition of AWS D.I.l.
Contractors have been notified of the commitment to the 1979 code edition and instructed to make the necessary changes in their procedures.
Functional or Program Areas Inspected 1.
Construction Verification Program (SPP-2): Section 2.0 Final Report As committed to in the Description of Licensee Activities Addressing Order Confirming Suspension of Construction, PSI submitted to RIII on September 12, 1980, section 2.0 of the Construction and Material Verification Program.
Section 2.0, " Category I Reinforcing Steel (SPP-2), is one of the twelve sections which make up the final report on the PSI Construction and Material Verification Program. The scope of the SPP-2 program was to examine visible installed Category I rein-forcing steel to determine if placement was adequate to satisfy design requirements.
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- Specific results of inspections relating to SPP-2 are documented in IE Reports 80-08, 80-11, and 80 16.
These inspections include review of the implementing SPP-2 procedure, observation of in process work, and review of quality records which were generated as a result of PSI's inspection effort.
Using the results of the bsP-2 inspection, PSI generated Corrective
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Action Requests (CAR) to' identify all nonconforming conditions.
Typical nonconforming conditions identified included (1) incorrect bar size, (2) insufficient number of bars, (3) out of tolerance bar spacing, (4) out of tolerance concrete member thickness (5) out of tolerance clear cover and, (6) extra reinforcing bars.
The inspector selected at random, and reviewed, the following CAR's to determine whether each identified discrepancy was appropriately denoted, whether appropriate corrective action was specified, and whether the responsible personnel had reviewed and signed the CAR's.
The corrective action specified for each of the CAR's reviewed is to be implemented following the resumption of safety-related work activities.
a.
CAR PC-0546, dated June 11, 1980 b.
CAR PC-0587, dated June 24, 1980 c.
CAR PC-0648, dated July 7, 1980 d.
CAR PC-0669, dated July 11, 1980 e.
CAR PC-0675, dated July 11, 1980 f.
CAR PC-0684, dated July 11, 1980 g.
CAR PC-0685, dated July 11, 1980 h.
CAR PC-0702, dated July 17, 1980 A Sargent and Lundy engineering design analysis was performed relative to a number of the CnRs generated as a result of the SPP-2 program that assured that the actual reinforcing steel, as placed, was sufficient to resist the design loads. The Office of Nuclear Reactor Regulation will be asked, as part of their routine final design review, to verify the adequacy of a selected number of these design analyses prior to issuance of an operating license.
This added design review will pro-vide additional assurance of the acceptability of the CAR resolutions.
(546/80-39-01; 547-80-39-01)
Based on the review of Section 2.0 of the Construction and Material Verification Program Final Report, review of related quelity records, and observation of in process inspection activities, the inspector has concluded that the licensee's reinforcing steel verification activities are responsive to the commitments made to NRC by the licensee.
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Inspection of the Civil Inspection and Testing Services Laboratory The purpose of this portion of the inspection was to assess the capa-bility of the Civil Inspection and Testing Services Laboratory to support construction activities. The civil laboratory, formerly operated by the United States Testing Company, was recently reorganized. The reorgani-zation delineates all management and technical responsibilities to the PSI Quality Engineering organization. The separation of responsibilities between the civil lab and the engineering, production, and quality assurance audit groups was verified to assure the lab'. continued independence. The following programmatic and functional reviews of the Civil Inspection and Testing Services Laboratory were conducted:
a.
Procedures - The following procedures were reviewed to verify their compatibility with the PSI Quality Assurance program and that they contained appropriate inspection / test req.nirements to assure quality inspection and testing.
Number Revision Title PMP 3.31
Civil Inspection and Testing Services QCP-1
Concrete Batch Plant Inspection QCP-2
Sampling / Testing of Concrete Constituent Materials QCP-3
Concrete Field Testing / Inspection QCP-4
Structural Steel Bolt Tension Testing QCP-5
Calibration Control of Measuring and Test Equipment QCP-9
Mechanical Cadweld Splice Inspection QCP-10
Blast Monitoring and Inspection QCP-13
Testing of Concrete, Dry Pack, and Bash Compressive Strength Specimens QCP-15
Cadweld/Resteel Testing b.
Document Control - The RIII inspector examined the Inryco struc-tural steel erection (series E) drawings, S&L specifications Y-2722 and Y-2850 to verify that they were of the most recent revision and properly controlled for the civil laboratories use.
During the review, it was noted that ten of twenty-five drawings examined were not totally legible. The licensee stated that this was due to the method of reproduction used in generating those particular drawings. Licensee personnel further stated that sepias of the Inryco series E drawings would be obtained for reproduction purposes to assure legible blue line drawings. This commitment was verified by the RIII inspector on November 18, 1980 Personnel Qualifications - The records for one Level III, ten c.
Level II, and nine Level I civil laboratory inspectors / technicians were reviewed to verify that each was certified in accordance with PMP 5.01 and had received the required training in accordance with-9-i
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PHP 1.04.
Specific functional areas of responsibility for lab personnel are now defined in the lab certification program.
Additionally, controls exist to assure that personnel are only assigend to those tasks for which they are specifically qualified.
g d.
Calibration and Control of Measuring and Test Equipment - The system to assure the controlled calibration of required measuring and test equipment used in the Civil Inspection and Testing Services Laboratory was reviewed in detail. The proper implementation of the calibration program was verified through the review of records for selected pieces of equipment and calibration standards. The following lab equipment was inspected and the pertinent calibration records reviewed:
Equipment Type I.D. No.
Calibration Due Calibration Frequency Ohaus Scale B223.0 January 1, 1981 3 months 0haus Triple B528.0 January 24, 1981 3 months Beam Scale Soil Test.
B278.0 February 19, 1981 12 months 3/8" selve No. 4 sieve B597.0 October 31, 1981 12 months No. 8 sieve 3598.0 October 31, 1981 12 months No. 30 sieve 3600.0 October 31, 1981 12 months No. 200 sieve 3369.0 September 13, 1981 12 months Oven B290.0 February 7, 1981 6 months Forney Compression B322.0 April 21, 1981 12 months Machine Honeywell Temperature B358.0 December 3, 1980 3 months Recorder Slump Cone B439.0 May 16, 1981 12 months Slump Cone B441.0 June 6, 1981 12 months Unit Weight B266.0 January 24, 1981 12 months Container Air Meter - Type B B274.0 January 31, 1981 3 months Cube Mold, 2" B442.0 October 25, 1980 3 months Concrete Thermometer -
B488.0 December 5, 1980 3 months Pocket Standard Weight Set A102.0 October 15, 1981 12 months e.
Program Implementation - Interviews were conducted with laboratory personnel responsible for performing tasks in the following areas:
(1) batch plant inspection (2) sampling / testing of concrete constituent materials (3)
concrete field inspection and testing (4) structural steel inspection l
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(5) cadweld inspection and testing (6) reinforcing steel testing The interviews were conducted to assess the knowledge of each individual inspector and his ability to implement the require-ments of the civil laboratory quality program in his own field of responsibility, f.
Audits - The RIII inspector reviewed the results of PSI audits of the on-site testing laboratory and the off-site testing laboratory (UST-Hoboken).
It was noted during the review, that to date, a sound technical audit of the UST Hoboken facility has not been conducted by PSI.
Licensee personnel stated that a technical audit of the UST Hoboken facility would be conducted within thirty days.
The purpose of the audit is to provide a degree of confidence for the off-site civil material testing laboratory commensurate with that of the on-site laboratory. (5h6/80-39-02; 5h7/80-39-02)
Conclusion:
Based on these findings, it is the inspector's conclusion that the Civil Inspection and Testing Services Laboratory can adequately support all construction activities except those relating to safety-related backfill. This area will be reviewed during a subsequent inspection.
3.
Assessment of Commonwealth-Lord's Readiness for the Electrical Demonstration The inspector reviewed the program and schedule for the electrical construction demonstration for construction restart activities. The program encompasses training and qualification, receipt inspection,
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storage, issue and handling of materials, installation, inspection, and audit of cable raceway installation. Surveillances and inspection of the activities is scheduled by licensee and contractor Quality Assurance and Quality Control personnel.
(Reference IE Report No.
80-33).
Exit Interview The inspectors met with staff representatives (denoted in the Persons Contacted paragraph) during and at the conclusion of the inspection. The inspectors summarized the scope of the inspection.
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