IR 05000546/1981013
| ML20030C787 | |
| Person / Time | |
|---|---|
| Site: | Marble Hill |
| Issue date: | 08/13/1981 |
| From: | Harrison J, Little W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML20030C780 | List: |
| References | |
| 50-546-81-13, 50-547-81-13, NUDOCS 8108280157 | |
| Download: ML20030C787 (10) | |
Text
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. ! ' , U.S. NUCLEAR REGULATORY COMMISSION OF1CE OF INSPECTION AND ENFORCEMENT j r i
REGION III
Report Nos.
50-546/81-13; 50-547/81-13 I Docket Nos.
50-546; 50-547 License Nos. CPPR-170; CPPR-171 ' Licensee: Public Service of Indiana Post Office Box 190 New Washington, IN 47162 o Facility Name: Marble Hill Nuclear Generating Station, Units 1 and 2 l Inspectior. At: Marble Hill Site, Jefferson County, IN l Inspection Conducted: July 1-31, 1981 , s- < s7
' ' Inspector: H rrison . . , . ,
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! Approved By: W. S( Li#[tle, Chief / Reactor Projects Section 2C [/8[[ ' , ,- Inspection Summary Inspection during the period of July 1-31, 1981 (Report Nos. 50-546/ 81-13; 50-547/81-13) . Areas Inspected: Inspection by the IE Regicnal Resident Inspector of activities at the site to(verify that the activities being performed
complied with the NRC Confirming Stop Work Order, dated August 15, 1979, and were within the r ' ope of the Graduated Recission of the Order as ,Jentified in letter dated July.7, 1980 (authorization for PSI to resume receiving inspection activities), November 13, 1980 (authorization
for two firms, Cherne and Commonwealth-Lord JV, to resume receiving i inspection activities), December 5, 1980 (authorization for two firms Cherne and Commonwealth-Lord JV, to resume construction activities ' with certain conditions being specified), and March 27, 1981 (authoriza-tion for Newberg-Marble Hill to resume receiving inspectton and ' construction activities with certain conditions being specified).
The inspection also consisted of a review of storege and maintenance activities for safety related items and construction activities being conducted by the mechanical, electrical and civil contractors, a
i follow-up on 10 CFR 50.55(el reportable items and a review of internal a udits was also conducted. This inspection involved a total of 110 < , inspector-hours on site by one NRC inspector, including 14 inspector-i hours onsite during off-shifts.
nesults: No items of noncompliance or deviations were identified.
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_ DETAILS 1.
Principal Persons Contacted Public Service of Indiana (PSI)
- S. Shields, Senior Vice President Nuclear Division
- B. Petro, Exp;utive Director - Nuclear P::aject Management
- L. Ramset*, Executive Director - Nuclear Quality Assurance
- T. Burns, Project Engineering Manager N. Reichel, Contract Manager Civil
, ! G. Farner, Civil Construction Engineering Supervisor <-C. Beckham, Quality Engineering Manager J. Roberts, Inspection Superintendent B. Morrison, Superintendent - Civil Quality Engineering
11. Curry, Superintendent - Electrical Quality Engineering
- J. Wol fe, QA Administrative Assistant J. Bott, Nuclear Regulation and Affairs Manager S. Brewer, Nuclear Safety and Licensing Manager
- T. Geib, Nuclear Licensing, Project Engineer
. Cherne Contracting Corporation (CCC) J. Mortell, Project Manager A. Dolgaard, QC Manager T. Francis, Principal Engineer Newberg-Marble Hill (N-MH) D. Stegemoller, Vice President - Power Construction L. Elliott, Project Manager C. Barbour, Project QA Manager Westinghouse Electric Corporation
C. Markham, Site Manager P Authorized Nuclear Inspector ( ANI) A. Clark, Hartford Steam Boiler (ANI-PTI) . Nuclear Regulatory Coramission, A. Toth, Sr. Resident Inspector, Region V, WPSS Unit 2 F. Hawkins, Reactor Inspector
- Denotes those present at the exit meetings.
, The inspector also contacted and interviewed other licensee and contractor personnel.
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2.
Licensee Action en Previous Inspection Findings (Closed) Unresolved (546/81-11-03; 547/81-11-03): Audit responses appeared to lack a timely submittal of an acceptable response.
That is, numerous submittals and rebuttals were required to reach a final acceptable solution to the audit finding. A review indicated that audit finding responses were up to date and that the responses were acceptable. The previous audit noted in 81-11-03 as being several months overdue is closed.
This item is closed.
3.
Functional or Program Areas Inspected a.
Construction Activities Inspection of construction activities were performed by the Resident Inspecter to assure that work in Category 1 areas was being performed within the scope of the NRP Confirmatory order dated August 15, 1979 and Graduated Recission to the Order by NRC letters of July 7, November 13, December 5, 1980 and March 27, 1981.
The activities observed were within this scope. Two inspections were conducted during off-shift periode.
Also during this reporting period the Resident Inspector observed the following: . (1) Civil - The chipping, evaluation and repair of defective concrete areas in the Auxiliary, Fuel, and Unit 1 Containment Buildings.
The Resident Inspector observed the work and inspection activities as detailed in Newbcrg Procedures: WPN-25, Concrete Patching, Revision 7 WPN-25-02, Concrete Patch and Repair Area Evaluation, Revision 4 WPN-41, Concrete Curing, Revision 1 QCP-10.04 Concrete Curing Inspection, Revision 1 QCP-10.06, Post Placement and Patching Inspection, Revision 3 Also during the month the Resident Inspector observed concrete preplacement and post placement activities to the following t ! Newberg Procedures: WPN-41, Concrete Curing, Revision 1 QCP-10.02, Concrete Preplacement inspection, Revision 3 QCP-10.03, Concrete Placement Inspection, Revision 1 QCP-10.04, Concrete Curing Inspection, Revision 1-3- _
. . (2) Electrical - The installation of electrical hangers in the Auxiliary Building, elevation 383, to the following Commonwealth-Lord JV Procedures: , CKP-C8A, Welding Procedure General, Revision 2 . CWP-C3B, Cable Tray System Installation, Revision .1 CWP-C24, Priming and Galvanizing Repair, Revision 1 (3) Mechanical - The installation of the Containment Spray System in the Unit 1 and 2 dome areas to the following Cherne Contracting Company Procedures: 13.10, Fitting and Alignment, Revision 7 WPS 808B021 - 1.0 CT, Revision 8 No items of noncompliance or deviations were identified.
b.
Storage and Preservation of Material and Equipment The Resident Inspector observed the storage conditions and maintenance activities in laydown areas, warehouses, and interim storage in the Auxiliary and Fuel Randling Buildings, and other storage areas of material and equipment. These inspections were performed to assure compliance with the requirements of ANSI N45.2.2 Packaging, Shipping, Receiving, Storage and other requirements of the Nuclear Steam System Supplier (Westinghouse) and the Public Service of Indiana's Project Management Manual.
No items of noncompliance or deviations were identified.
c.
Evaluation of Items Reported per the Requirements of 10 CFR 50.55 (c) (Closed) 10 CFR 50.55 (c) reportable item (547/79-01) Licensee Number SRC 79-01: Inadvertant radiography of sister piping assembly for repaired areas, assembly is embedded in concrete, required areas not radiographed. This item was reported by the Licensee on April 3, 1979 to Region III and retracted by final report on July 28, 1980.
The following correspondence identified by PSI Document Sequence Number (DSN) was reviewed: 0116804000, 0404790034, 0426790046, 0430790056, 0430700025, 0503790022, 0502790031, 0502790030, 0805804008 and 0728804006.
The review revealed the followings Chicago Bridge and Iron (CBCI) recommended nondestructive testing be accomplished using the ultrasonic method in lieu of radiography due to piping assembly being inaccessible, " buried in concrete".
PSI and Sargent and Lundy evaluated and concurred in this test method. CBCI procedures VSR-46A1, Revision 0, Verification of Shop Repair to Scam K1 Pipe Assembly 46 A/1 (Unit #2) and UTLX, Revision 1, Ultrasonic Examination Procedure for Carbon and Low Alloy Welds 3were reviewed and found acceptable. Also Ultrasonic Test report 5-4493 for seam K-1, X-Ray Intervals 1-2, 2-3, 5-6, 6-7 dated 6-26-79, reporting "do Unacceptable Indications" -4- , -. ..
. was reviewed and found acceptable. The review of this item substantiated that reporting requirements were met and basis for retraction was adequate. This item is closed, i (Closed) 10 CFR 50.55 (e) reportable item (546/79-05; 547/79-05) i Licensee Number SRC 79-07: Use of a unqualified welding procedure on a safety related piping system. This item was reported to , i Region III on May 5, 1979 and retracted by final report on July 6, l 1979.
The following correspondence identified by PSI DSN was reviewed: 0806790066, 0515790045, 0516790058, 0521790036, 0615790066, 0611790051, and 0706790094. This review revealed that a Procedure , ~ Qualification Record (PQR) number 10 was found aften reporting.
This PQR qualified welding procedure specifications 101BR11-4.5 and 1018021-5.0, the procedures included thicknesses up to and , including 3/4".
The PQR and welding procedure specifications' were found to be acceptable. The welding in question was performed on ' i the' Auxiliary Feed Water System and contained no welds greater j than 3/4".
The review of this item substantiated that reporting i requirements were met and basis for retraction was adequate.
This i item is closed.
! (Closed) 10 CFR 50.55(e) reportable item (546/79-09 547/79-09) Licensee number SRC 7 9'11: Tack weld inspection being performed by the same individual performing that activity, welding, on ' safety related piping systems. This item was reported to Region i III on June 21, 1979 and retracted by telecon on July 20,-1979.
The following correspondence identified by PSI DSN was reviewed: 0808790030, 0706790027, 06279002, 0725790014, 0421814001, 0603816300, and 0723814002. This review revealed that a ASME ! code interpretation was made stating " Tack welds may be visually inspected by craftsman without formal documentation, as a normal inprocess activity". ASME issued a Code Case,-number 302, to this effect and was approved by S E L.
PSI requested NRC approval on April 16, 1981 ard approval was granted by.the NRC on May 6, 1981. Although considerable time evolved between item , j reporting, retraction and problem resolution, no real departure from requirements occurred due to no safety related welding-
performed during this time period. The review of this item substantiated that reporting requirements were met and basis for retraction was adequate.
This item is closed.
j (Closed) 10 CFR 50.55 (e) reportable item (546/79-11; 547/79-11) I Licensee number SRC 79-14: Void in concrete around spent fuel i transfer canal drain sump. This item was reported to Region III on July 31, 1979 and retracted by final report on November 19, 1980.
The following correspondence identified by PSI DSN was. reviewed: 0116807006, 080179001, 0802790006, 0829790040, 0831790020, i 0830790042, 0429805031, 0623805006, 0626804001, 0805804008, 0718804009, 0725806525, 0730804008, and 0918806536.
This review
revealed that on February 18, 1980 nondestructive testing (ultrasonic) was performed by Portland Cement Association (PCA), i this testing was documented in PCA report to Gust R. Newberg dated April 16, 1980. Both the North and South sumps were i-5-
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. . tested and revealed no honey-combing or voiding. The review of this item substantiated that reporting requirements were met and basis for retraction was adequate.
This item is closed.
(Closed) 10 CFR 50.55 (c) reportable item (546/79-15; 547/79-15) Licensee number SRC 79-21: Temporary urinal system piping installed in safety related concrete with self drilling anchors without approved procedures.
This item was reported to Region III on September 19, 1979 and retracted by final report on October 17, 1980.
The following correspondence identified by PSI DSN was reviewed: 0116804009, 0921790047, 0925790022, 0921790046, 0924790079, 1002794016, 1023790097, 1023790076, 1016790021, 0711804002, 091180415, 0922804008, 092980538, 092580413, 1002804009, 0925801013, 1008805095, 1113804020, 1021804006, and 1028804022.
This review revealed that PSI and S C L had conducted an evaluation of temporary anchors installed in the Auxiliary Building. The result of this engineering evaluation was "...from a desi gn standpoint the safety of the structure was not impaired." The review of this item substantiated that reporting requirements were met and the basis for retraction was adequate. This item is closed.
(Closed) 50 CFR 50.55 (e) reportable item (546/79-16; 547/79-16) Licensee number SRC 79-22: Contractor (Cherne) installed safety related component supports without approved procedures. This item was reported to Region III on September 19, 1979 and retracted by final report on November 20, 1980.
The following correspondence identified by PSI DSN was reviewed: 0116804010, 1009790026, 0928790079, 1026790120, 1030790055, 0820805300, 1015806512, 112480412, and 1120804008. This review revealed that a Cherne procedure 12.7, component Support Installation was prepared on 5/29/79 and approved on 6/12/79. All basic work controls remain on a process traveler but was not described in a procedure.
During the construction verification program conducted by PSI /Cherne to procedure SPP-4, Physical Inspection and Verification In-place Safety Category I Piping and Hangers, and SPP-12, Documentation Verification Procedure for ASME Section III Piping, Ilangers, and Materials and by Cherne to procedure 12.7, Component Support Installation, all hanger traveler packages and items installed were reinspected and found acceptabic. The review of this item substantiated that reporting requirements were met and the basis for retraction was adequate. This item is closed.
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. ~ ' ' . ' . . (Closed) 10 CFR 50.55 (e) reportable item (546/79-17; 547/79-17) Licensee number SRC 79-23: The incorporation of design changes
j into Newberg Construction Activities was not a part of the ! Quality Assurance Program. This item was reported to Region III ' on October 17, 1979 and retracted per telecon on November 15, 1979.
! The following correspondence identified by PSI DSN was reviewed: I 0116804011, 1206790044, 1105790093, 1023795000 and 0108804003.
-This review revealed that basic system was part of the QA l program and was being implemented. This system was however, ' cumbersome and a cross reference system would have aided implement-l ation,but was not a requirement. Currently a computerized listing i is being utilized together with posting on each document to ensure all changes are included. -The review of this item substantiated
that reporting requirements were met and the basis for retraction j was adequate. This item is closed.
(Closed) 10 CFR 50.55 (e) reportable item (547/80-04) i Licensee number S 80-05: Ringer crane boom struck Unit 2 i containment liner causing minor damage. This item was reported to Region III on January 22, 1980 and retracted by final report , l on April 17, 1980.
The following correspondence identified by { PSI DSN was reviewed: 0125804006, 0207804004, 0212805037, 0213 804000, 0226805028, 0314805056, 0331805031, 0603804005 and 0417804011. This review revealed that a S S L evaluation,
conducted on 2/8/80, and a CBCI_ evaluation, conducted on { 3/5/80, concluded ".... damage to flange stiffener only and
does not affect structural integrity of the Liner... Leak tight-i ness of the liner is not affected..." and that "... repair is
not necessary...". The review of this item substantiated that j reporting requirements were met and the basis for retraction was-adequate. This item is closed.
- (Closed) 10 CFR 50.55 (e) reportable item (546/80-05; 547/80-05) l' Licensee number S80-06: The use of non-code materials in the l fabrication of Category I component supports. This item was f reported to Region III on February 8, 1980 and was retracted by ( final report on April 25, 1980. The following correspondence identified by PSI DSN was reviewed: 0527804002, 0311804003, ' 0212804004, 0324805017, 0527804001, 042790075, and 0428804001.
( The review of this documentation revealed a confusion in the i designation of code boundries to ASME Section III, Division l NF - Component Supports and included material and welding l requirements.
S C L clarified /redesir ated the code boundries.
j_ Originally twelve (12) component supports were in question, l eleven (11) of these supports were in conformance with the I clarified / revised boundries. The other one was scrapped.
The above ..a additionally c.1 arified by Stewart Mechanical letters OT-020880-007 and OT-041180-002 with numerous attachments.
The review of this item substantiated that reporting requirements were met and the basis for retraction was adequate. This item is closed.
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, . (Closed) 10 CFR 50.55 (e) reportable item (546/80-08; 547/80-08) Licensee number S80-10: Design changes are not being incorporated into Newberg Construction. This item was reported to Region III on March 7,1980 and retracted by final report on November 3, 1980.
The following correspondence identified by PSI DSN was reviewed: 0527804009, 1206790044, 0324804004, 0409805064, 1008804017, 1201804010, 1031804015, and 1103804020. The results of this review were that over 300 design changes had been initiated by PSI /S&L.
Of these, all but sixty-four were verified as being incorporated through a records review, fifty-seven of the sixty-four changes were verified as being incorporated by visual verification and the remaining seven areas were inaccessible due to form work.
A high degree of confidence was however established. In addition, the entire Newberg QA program has been rewritten and accepted by the NRC since this occurrence (see report 546/80-44; 547/80-44).
The review of this item substantiated that reporting requirements were met and the basis for retraction was adequate. This item is closed.
(Closed) 10 CFR 50.55 (e) reportable item (546/80-09; 547/80-09) l Licensee number S80-12: Questionable filler metal utilized in-vendor supplied pipe, that is the. filler metal utilized was certi-fied on the Certified Material Test Report (CMTR) as " Typical" for test results in lieu of " actual" test results and/or a Certificate of Compliance was furnished in lieu of a actual CMTR.
This item was reported to Region III on March 28, 1980 and retracted by final report on January 28, 1981. The following correspondence identified by PSI DSN was reviewed: 0527804007,. 0522804007, 0414804000, 0425804002, 0411806503, 0710804008, 0630804000, 0929804013, 1024804018, 1215804023, 0129814001, and 0129814004. The results of this review were that the ASME code effective date in use for this contract,1974 Edition, Winter 75 Addenda, allowed use of only a certificate of compliance (or typicals). This requirement of the' Code was verified by ASME letter to PSI dated August 6, 1980. A total of seven Corrective Action Requests #PC004N to PC-0010N were issued by
PSI and were all disposition "Use-As-Is".
The review of this item substantiated that reporting requirements were met and' the basis for retraction was adequate. This item is closed.
(Closed) 10 CFR 50.55 (e) reportable item (546/80-19; 547/80-19) Licensee number S80-26: As a result of the verification program the adequacy of certain equipment pads in the Auxiliary Building is questionable, that is reinforcing steel dowels appear to not be installed. This item was reported to Region III on August 19, 1980 and retracted per telecon on September 12, 1980. The following correspondence identified by PSI DSN was reviewed: 0915804003, 0915804001, 0919804013, and 0916804020. The results of this review was that fifty-seven equipment pads possibly had dowels left out during construction. An additional review of Newberg records together with those of subcontractors provided-8- _ _ - _ _ _ _ _ _.
. . . documentation that thirty-nine pads had the dowels installed.
A metal detector was utilized to verify that the dowels wer, installed in the remaining eighteen pads. Details of this verification are denoted in PSI Construction Verification Report, dated May 1981, specifically section for SPP-2 Category 1 Reinforcing Steel.
The review of this item substantiated that reporting requirements were met and that the basis for retraction was adequate.
This item is closed.
(Closed) 10 CFR 50.55 (e) reportable item (546/80-20; 547/80-20) Licensee number S80-29: Review of documentation packages associated with design specification Y-2766, Stainless Liner Work, revealed the substitution of certain types of material other than that allowed by the specification. This item was reported to Region III September 23, 1980 and was retracted by final report on November 11, 1980.
The following correspondence identified by PSI DSN was reviewed: 0929804007, 1021804005, 1002804016, 0924804006, 1002804017, 1003806509, 102380412, 1117805015, 1113804016, 0108814002, and 1121804002. The results of this review were that CBCI had obtained prior approval to substitute material from SCL, documented in Marcos/Kengon letters dated 9/29/77, 12/18/77, 10/1/78, and incorporated into drawing changes. One vendor nonconformance was issued by SCL to CBCI dated 11/13/80, this substituted material was also accepted. The review of this reported item substantiated that reporting requirements were met and that the basis for retraction was adequate.
This item is closed.
. d. ' audits During this reporting period the Resident Inspector reviewed the audits of two site contractors recently qualified and released to begin construction activities. This review consisted of examining the audit plans, audit checklist, audit reports (including findings), and audit responses. The audits of two contractors, Nuclear Installation Services Company (NISCO), report number .-NISCO-02 (audit conducted June 1-3, 1981), ! and Chicago Bridge and Iron (CBCI), report number 81-CIIIBRDG-01 l (audit conducted June 18 C 19, 1981), were conducted to evaluate l the quality assurance programs. The implementation part of the audits was limited due to the fact no work was in progress during the audit.
The Licensee plans to conduct an in-depth l implementation audit within ninety days of initiation of ' work activities.
No items of noncompliance or deviations were identified.
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.. .. 4.
Meeting / Site Visits , During this reporting period the Resident Inspector participated in l the following: On June 14, 1981, Mr. A. Toth, NRC Region V Sr. Resident Inspector, Washington Public Power Supply System, Project No. 2, visited the site.
During this visit quality assurance and construction problems were discussed and any problems unique to Marble Hill or WPSS-Unit 2 were also exchanged.
On June 15, 1981 the Resident Inspector met with key licensee and contractor personnel (approximately thirty attendees) to discuss welding and other construction related problems that had occurred at other construction sites.
5.
Exit Meetings The Resident Inspector participated in the exit meetings conducted on: July 23, 1981, F. Hawkins July 24, 1981, J. Ilarrison The Resident Inspector also met with licensee representatives (denoted under Persons Contacted) periodically throughout this reporting period collectively and individually. The Inspector summarized the scope and findings for each part of this activity.
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