IR 05000546/1980042
| ML20002C501 | |
| Person / Time | |
|---|---|
| Site: | Marble Hill |
| Issue date: | 11/25/1980 |
| From: | Harrison J, Key W, Williams C NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML20002C492 | List: |
| References | |
| 50-546-80-42, 50-547-80-42, NUDOCS 8101100378 | |
| Download: ML20002C501 (12) | |
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U.S. NUCLEAR REGULATORY C03D1ISSION OFFICE OF INSPECTION AND ENFORCEMENT
REGION III
Reports Nos. 50-546/80-42; 50-547/80-42 Docket Nos. 50-546; 50-547 Licenses No. CPPR-170; CPPR-171 Licensee: Public Service of Indiana P. O. Box 190 New Washington, Indiana 47162 Facility Name: Marble Hill Nuclear Generating Station, Units I and 2 Inspection At: Marble Hill Site, Jefferson County, IN November 4-6, 1980 Inspection Conducte
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Inspectors:(d.3.Harison Il
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Key, Jr.
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e e wn-Approved By:
C. C. Williams, Chief f
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[ CJ Projects Section 2
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Inspection Summary Inspection on November 4-6, 1980 (Reports Nos. 50-546/80-42; 50-547/80-42)
Areas Inspected: A special inspection of the Quality Assurance program of Cherne Construction Company was conducted to ascertain if receiving inspection and construction activities could be adequately supported by the Cherne program. This inspection involved a total of 56 inspector-hours on site by two NRC inspectors.
Results: No items of noncompliance or deviations were identified.
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o DETAILS Principal Persons Contacted Public Service of Indiana (PSI)
- L. Ramsett, Quality Assurance Manager
- T. Burns, Project Engineering Manager
- C. Beckham, Quality Engineering Manager
- J. Keys, QA Administrative Assistant
- M. Juvik, QA Administrative Assistant Cherne Contracting Company (CCC)
J. Mortell, Project Manager
- G. Rosier, Quality Assurance Manager (Corporate)
- T.
Francis, Principal Engineer
- A. Dolgaard, Quality Control Manager R. Horine, Quality Control Supervisor C. Jurgens, Quality Control Engineer S. Schmalz, Nondestructive Examination Foreman D. Piippo, Welding Superintendent Authorized Nuclear Inspector ( ANI-PSI)
A. Clark, Hartford Steam Boiler (ANI-PSI)
- Denotes those present at the exit meeting on November 6,1980.
The inspectors also contacted other licensee and contractor personnel during the inspection.
Functional or Program Areas Inspected This inspection was a review of' Cherno's Quality Assurance Program to ascertain if the program was adequate to support receiving inspection and construction activities. This programmatic review was conducted as follows:
1.
Quality Assurance Manual This manual was reviewed for being consistant with the licensee commitments to the NRC and the PSI Quality Assurance (PQAM) and ASME Quality Assurance Manual (AQAM). This QA Manual had previously been accepted by an ASME survey team.
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The manual as reviewed was found to be acceptable with two exceptions:
(1) Section 11.1, Revision 7 is not clear as to who performs the ins. ction on the carrier for " shipping damage" ( ANSI N45.2.2 requirement).
Implementing procedure 11.1 does clearly define this activity as a QC Inspection function. Action is necessary to clarify.
(2) Section 18.3.1 and 18.3.2 needs to be reviewed to assure that all requirements of ANSI N45.2.9 are being complied with listing " Lifetime Records" as " Permanent"; an example of a record not currently listed as permanent is a Hydrostatic Test Record and Procedure. Although the code data report meets the code (ASME) requirements for reporting hydrostatic test results, additional requirements of ANSI must also be met.
Cherne agreed to evaluate and resolve these problems. These items are unresolved (50-546/80-42-01; 50-547/80-42-01)
No items of noncompliance or deviations were identified in this.irea.
2.
Procedures The following procedures were reviewed by the NRC inspectors for conformance to regulatory and ASME code requirements:
Number Revision Title 5.1
Quality Control Personnel Qualification and Certification Manual 5.6
Marble Hill Training Program 6.1
Cherne Request for Change i
6.2
Request for Information Procedure 9.1
Design and Document Control Procedure for Marble Hill Job Site 10.4
Procurement Document Control 11.1
Reccipt Inspection of CCC Procured Safety Related Items 11.2
Verification and Control of PSI Furnished Safety Related Items.
i 11.4
Color Coding of Pipe and Tubing 11.5
Color Coding of Small Tools for usa on Stainless Steel items 11.6
General Handling Procedures 11.9
Storage and Surveillance Procedure
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Number Revision Title 11.13
Housekeeping During the Construction Phase of Nuclear Power Plants 11.16
Issuance of Material 12.3
Traveler Package 12.4
Valve and Flange Bolt Torquing
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12.6
Procedure for Safety Related Auxiliary Steel 12.7
Component Support Installation 12.8
Cold Bending of Pipe and Tube 12.10
Component Support Process Control 13.1
Welding Parameter Card 13.2
General Welding Specification 13.3
Qualification of Welders 13.4
Identification, Storage, and Handling of Weld Material 13.7
Base Metal Repair Procedure 13.9
General Weld Repair Procedure 13.10
Fitting and Alignment 13.17
Methods and Measurement of Delta Ferrite 15.2
Hydrostatic Testing. Procedure 15.4
Installation of Mechanical Equipment 15.12
Internal Cleaning Procedure, Containment Spray Rings 15.15
Pre-Installation' Cleanness 15.18
Isometric Flow and Package Development 16.1
Calibration
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17.1
The Reporting of Deficiencies to the Nuclear Regulatory Commission
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Number Revision Title 17.2
Processing of Nonconformities 17.3
Quality Holds 17.4
Corrective Action Report 18.3
Modification of Code Stamped Components 19.2
Audits and Surveys 30.4
Processing of Procedures 14.1.12.76
Nondestructive Examination Personnel Qualification and Certification Program Manual 14.2.12.76
Visible Dye, Solvent Removed Liquid Penetrant Examination 14.4.1.77
Magnetic Particle Yoke Examination 14.4.1.77
Magnetic Particle Examinstion 14.6.1.77
Radiographic Examination of Welds 14.7
Ultrasonic: Section III 14.9
Visual Examination 14.10
NDE Requirements for Marble Hill The foregoing procedures were found to be acceptable except as follows:
(1) Procedure 16.1x-Calibration, Appendix 6 states " Pressure gages to be calibrated every 6 months, Section 16.9 of the Quality Assurance Manual states pressure test gages
"...to be calibrated before each test or series of test..." Although it was explained that this requirement applied to gages other than those used for
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pressure testing, clarification is necessary.
(2) Procedure 14.4.1.
l 77, Magnetic Particle Yoke Examination, states calibration of the MT l
Yoke to be "at least once a year", procedure 16.1.
Calibration, states ".... required every 3 months....", a conflict.in intervals.
This procedure also does not include the pole spacing for the MT Yoke. Charne personnel agreed to evaluate and resolve. These items are considered unresolved.
(50-546/80-42-02; 50-547/80-42-02)
No items of noncompliance or deviations were identified.
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3.
Welding Procedure Specification (WPS)
The following WPS and supporting Performance Qualification Records (PQR's) were also examined for conformance to ASME Code Section IX requirements.
WPS No. 101B021-2-25, Revision 2, PQR, 14, 14A., P-1 to P-1, GTAW, SMAW WPS No. 10L3 021-0.750,' Revision 10 PQR-10, P-1 to P-1, GTAW, SMAW WPS No. 101GR11-0.50, Revision 3 PQR-18, 10, P-1 to P-1, SMAW WPS No. 505B021-1-812, Revision 1 PQR-51, P-SG2 to P-5G2, GTAW, SMAN WPS No. 808B021-1.0 CT, Revision 6 PQR 82, Revision 2, 83, Revision 1 P-8 to P-8, GTAW, SMAW No items of noncompliance or deviations were identified in this area.
4.
Program Implementation The following program elements were reviewed for sufficient controls to implement and for implementation to the extent possible with na activities being performed except as allowed by the NRC Confirming Order of August 15, 1979, these controls were all found to be acceptable:
a.)
Design Control - Field Changes:
FCR - 014 (old system)
CRC - 14 (new system)
b.)
Document Control:
-Isometrics - Preparation, lasuance and revision control in engineering files, document control center, field station #2 and document log for the following:
Drawing (150)
Revision 1 CSB001
1 CSB002
1 CSB004
1 CSB005
1 CSB008
1 CSB007
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-Cherne Isometrics (Piping Spool Pieces), for
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preperation, issuance and revision control in in engineering files, field station #2, and Document Control Center.
Drawings (overlay)
Revision M:IO7B065
MH07B056
MH07B066
MH07B068
MH07B069
MH07B071
MH07B084
MH07B088
MH07B087
MH07B102
-Cherne Overlays-for Component Supports, reviewed the following for preparation, issuance and revision control in the document control center and engineering files against tne issue index:
Drawing Revision 1CSB06008X
1CSB06009R
1CSB06010X
1CSB06011R
1CSB06014R
1CSB01001X
1CSB01002R
1CSB01003R
Sargent and Lundy (SEL) Drawings-The following drawings were verified for proper receipt and issuance control at Field Office Stations #1 and #2, and Field Station #2:
Drawing Sheet Revision M-535
F M-534
'4 H
M-549
D M-550
E M-567
11 M-835
A M-1221
G M-536
D M-545
D M-204
G M-3 3
C M -518
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-Sargent and Lundy (SCL) Specifications
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Reviewed for correct revision and control:
Y-2739, Amendment 4 Y-2773, Amendment A Y-2962, Amendment 2-Material Specifications (Cherne)
Reviewed for revision control and content:
MS-SA-106-2, Revision 3 MS-SA-312-2, Revision 3-Document Index, Revision 126 Reviewed for content-System Specifications Reviewed for revision and content:
Containment Spray, Revision 4 Component Cooling Water, Revision 1 c.)
Procedure Control see section 2, implementation was noted to be acceptable in each control area.
d.)
Procurement Control Review was limited to welding electrodes Purchase orders M15696, M17274, and M16307 e.)
Material Control-Inventory / Location / Issuance Checked the following piping spool piece for correct storage location and proper storage:
0-CC-27AA-03 PC #52 0-CC-2 9CB-03 PC #157 0-FC-43A-64 PC '#016 0-FC-41A-04 PC #021 1-SI-09BD-10 PC #110-Also checked the following equipment for storage location and maintenance records:
1 AB-03P, Boric Acid Transfer Pump 1 BR-01DE, Thermal Regeneration Demineralizer 1 CV-01AA, Let Down Heat Exchanger 1 WOO-lPB, Primary Containment Chill Water Pump 1 FC-01P, Spent Fuel Cooling Water Pump 2 CV-01PA, Centrifugal Charging Pump These items were also verified for marking and proper identification.
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f.)
Special Process Control Personnel Certification and Qualifications The following welder and quality control personnel records were examined for conformance to procedure and ASME Code requirements.
Quality Control Personnel MT PT UT RT R. Horine II Il G. Jergens III III III III K. Pulliam I
II S. Schmalz III III Welding Personnel
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D. J. Piippo AM W. Brown CV D. W. Proctor CW F. W. Fouts CO T. R. Redman BE C. M. Readinger BI F. B. Moody DB Equipment and Materials The following equipment and materials were examined for conformance to certification and calibration requirements:
Welding Materials E7018 Electrode, Ht. No. 401E6991/411E6091 ER308, Bare Rod. Ht. No. C3064 Electrode heating ovens S/M 9877, 11401, 9704, 9706, 9880, 9878 NDE Equipment Materials Radiographic Licensee, No. 22-18342-01 Gamma Ray Camera, Century, S/N-2248 Survey Meters, Model 252B S/N 0879, 0863, 0718 Magnaflux Cleaner, SKC-NF, Batch No. 79G075 Magaflux Penetrant, SKL-H'J/ SKI, Batch No. 80A038
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Magnaflux Developer, SKD-NF, Batch No. 79H018 g.)
Review of Weld Traveler and Process Sheet
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The following process sheets and weld travelers were examined for conformance to procedure requirements:
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ISO No.
Weld No.
Spool No.
7840-2AFCO220 FW1 ML-05, 18 to 19 7840-2AFCO220 FW2 ML-05, 19 to 20 7840-2AFC0220 FW3 ML-05, 20 to 21 7840-2AFCO220 FW4 ML-05, 21 to 22 7840-2AFCO220 FW5 ML-05, 22 to 23 7840-2CSB00501 FW1 ML-07.4 to 07.86 7840-2CSB00501 FW2 ML-07.4 to 07.3 7840-2CSB00501 FW3 ML-07.3 to 07.2 7840-2CSB00501 FW4 ML-07.2 to 07.1 7840-2CSB00501 FW5 ML-07.1 to 07.86 h.)
Receiving Inspection Reviewed the following:
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. Personnel Training and Oualification
. Receiving Inspection Checklist (Attributes)
. Calibration Control, as related to
. Procurement Document Availability
. Conditional Release
. Inspection Process
. Reporting Inspection Results i.)
Calibration Control Reviewed the records for calibration on pressure gages #8050.52 and 8052.73 for compliance with procedure 16.1.
Also see section 4.f)
j.) Nonconformance Reports (NCR)/ Corrective Action The following NCR's were reviewed for conformance to the requirements of Cherne Quality Assurance Manual Section 17.2, Revision 6.
NCR No. 01727, File No. 6.44 Hanger NO. 1AF12018X/1AF12014X NCR No. 01784 Weld No. 1, ISO No. 7840-1SXC00701 NCR No. 01793, File No. 6.45 Hanger No. 7840-1AF7006R
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NCR No. 01558, File No. 6.128 Weld No. 5, Pipe No. 2AF02CG-4-136/2AF02CG-4-137 ISO No. 7840-2AFC036 NCR No. 01546, File No. 6.132
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Weld No. 1 ISO No. 7840-1AFC06008X0
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k.)
Documentation - Review was ongoing throughout this inspection
and was acceptable.
1.)
Audits Reviewed the following internal audits and corrective action:
79-12, dated 8/20/79 80-02, dated 2/5/80 Also reviewed the Management Audit dated 4/7/80, conducted by N.C. Kist and Associates, and corrective action taken.
It should be noted that Cherne's program was surveyed and approved by ASME during November 1979.
No items of noncompliance or deviations were identified in thi = area.
5.
PSI Audits of Cherne Audits of Cherne performed by the licensee were also reviewed during this inspection. The following reports were reviewed and found to be acceptable:
Report Number Date Audit Conducted
.16-Cherne-08, August 11-13, 1980
.16-Cherne-09, September 2-3, 1980
.16-Cherne-10, September 10-12,1980
.16-Cherne-11, October 1-3, 1980
.16-Cherne-12, October 2-3, 1980
.16-Cherne-13, October 13-15, 1980
.16-Cherne-15, October 21-24, 1980 No items of noncompliance or deviations were identified in this area.
Conclusie.,
Based on this inspection it was concluded that the Cherne Quality Prcgram as written and demonstrated can:
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Support Receiving Inspection Activities 2.
Also, can further Support Construction Activities This nelusion is however subject to NRC Region III Management review and at-roval.
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R Unresolved Items Unresolved items are matters about which information is required in order to ascertain whether they are acceptable items, items of noncompliance, or deviations. Unresolved items disclosed during this inspection are discussed in Paragraphs 1 and 2.
Exit Meeting The inspectors met with the staff representatives (denoted under Persons Contacted) at the conclusion of the inspection on November 6, 1980.
The inspectors summarized the scope and findings of the inspection. The Licensee acknowledged the findings as stated.
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