IR 05000546/1982009
| ML20053E217 | |
| Person / Time | |
|---|---|
| Site: | Marble Hill |
| Issue date: | 05/17/1982 |
| From: | Harrison J, Konklin J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML20053E210 | List: |
| References | |
| 50-546-82-09, 50-546-82-9, 50-547-82-09, 50-547-82-9, NUDOCS 8206070705 | |
| Download: ML20053E217 (9) | |
Text
{{#Wiki_filter:p-- l i . U.S. NUCLEAR REGULATORY CO)D1ISSION
REGION III
Report Nos.
50-546/82-09; 50-547/82-09(DPRP) Docket Nos.
50-546; 50-547 License Nos. CPPR-170; CPPR-171 Licensce:. Public Service of Indiana.
Post Office Box 190 New Washington, IN 47162-Facility Name: Marble 11111 Nuclear Generating St ation, Units 1 and 2 Inspection At: Marble !!ill Site, Jefferson County, IN Inspection Conducted: April 1-30, 1982 WY 5lg Q ' ' Inspector: J. J. Harrison , 4f Approved By: J. F Konklin, Re ctor Projects Section 2A f/f7[[$ i ! Inspection Summary Inspection during the period of April 1-30, 1982 (Report Nos. 50-546/ ' ' 82-09; 50-547/E2-09 ( DPHP))
Areas Inspected: Inspection by the Regional Resident Inspector of activities at the site, including chipping and patching of concrete, ' installation and welding of piping systems, control rod drive mechanisms and electrical hanger supports. This inspection invnlved a total of ' 128 inspector-hours on site by one NRC, inspector, including 12 inspector-i i hours onsite during off shifts.
Results: No items of noncompliance or deviations were identified.
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- . DETAILS 1.
Persons Contacted Public Service of Indiana (PSI)
- S.
Shields, Senior Vice President Nuclear Division ,
- B.
Petro, Vice President - Nuclear Projects
- L. Ramsett, Quality Assurance Officer J. Bott, Nuclear Regulations and Affairs Manager N. Reichel, Construction Manager G. Warner, Civil Construction Engineering Supervisor
- C. Beckham, Quality Engineering Manager B. Morrison, Superintendent - Civil Quality Engineering
- J.
holfe, QA Administrative Assistant J. Borchert, Contract Manager Composite Cherne contracting Corporation (CCC) A. Sirard, Project Manager A. Dolgaard, QC Manager T. Francis, Ast;istant Project Manager Newberg-Marble liill (N-Mil) D. Stegemoller, Vice President - Power Construction C. Barbour, Project QA Manager Nuclear Installation Services Company (NISCO) M. Milem, Project Manager J. Felder, Field QA/QC Manager J. White, Lead Engineer O. McLaughlin, Senior Welding Engineer Westinnhouse Electric Corporation C. Markham, site Manager Authorized Nuclear Inspector (ANI) A. Clark, liartford Steam Boiler ( ANI-PSI)
- Denotes those present at the exit meetings.
The inspector also contacted end interviewed other licensee and contractor personnel.
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Licensee Action on Previous Inspection Findings (Closed) Unresolved Item (546/79-06-05; 547/79-06-05) Penetration data package did not contain data required from the supplier,Sargent Industries. The licensee' issued a Field Corrective Action Report, Number 1123,to document this problem. The missing data was received, reviewed, and accepted by PSI. The NRC Inspector reviewed the ultrasonic test report for missing data (level of examiner, DAC curve, and component location examined) and weld repair data on the shop traveler for penetration No. 1,pc.77.
The actions taken by the licensee and the data reviewed were found to be acceptable. This item is closed.
(Closed) Item of Noncompliance (546/79-11-03; 547/79-11-03) Failure to assure that special processes, including welding, are controlled by use of qualified procedures. The procedure that was the basis for this noncompliance was Chicago Bridge and Iron Welding Procedure Specification ETS E7018/73030. During the preparation of revision 1, the welding techniques for two welding positions were inadvertently omitted. The NRC Inspector reviewed revision 2, that corrected this problem, and found this procedure acceptable.
It should be noted that the licensee had established a Procedure Review Board (early 1980) and all PSI and Contractor procedures have been and are required to be reviewed for initial procedure approval as well as any revisions; this action should prevent recurrences. This item is closed.
(Closed) Item of Noncompliance (546/79-11-04; 547/79-11-04) This noncompliance was based on failure by the licensee to assure proper control of material that did not conform to requirements.
The mechanical contractor (Cherne) detected what was believed to be
a nonconforming condition. A Quality Control Inspector prepared and issued a Nonconformance Report Number 01425-6.94. This report was . later " Voided" by the Cherne QC Manager, when a review revealed ! this condition was not nonconforming. /Nonconformance Procedure l 17.2, Revision 1, did not,however,contain a provision for " Voiding".
The licensee issued a Deviation Control Report (DCR), C-062-79, to ,
document this problem. The procedure, Cherne 17.2, was revised and voiding requirements included in revision 2; the current ' revision is 9.
The NRC Inspector reviewed the above corrective actions and found them acceptable. This item ie closed.
(Closed) Unresolved Item (546/80-21-02; 547/80-21-02) No system existed for controlling ground and/or rain water within the boundaries i of the Essential Service Water pipe line. The licensee installed a temporary sump and a pump to control the water. The NRC Inspector has observed the effectiveness of this system for several months ' and found the backfill intact and not affected by the water.
The corrective action by the licensee is considered to be acceptable This item is closed.
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_- . . (Closed) Unresolved Item (546/80-23-02; 547/80-23-02). Some embeds in containment had about 50 percent of the nelson studs bent to such an angle that there would be questionable depth in the concrete to support the embed and ius load. The licensee issued Field Change Request (FCR) 3075 requesting tolerances for bent studs. FCR 3075 and Engineering Change Notices (ECN) S-213 and S-214 were issued establishing definitive ' acceptance criteria for bent studs.
Affected construction specifications and drawings were also revised to include these changes. The civil contractor, Newberg, also included this criteria in a work procedure WPN-13, Installation of Embedded Items. The NRC Inspector reviewed the acceptance criteria, the FCR and ECNs and the Newberg Procedure and found all to be acceptable. This item is closed.
(Closed) Unresolved Item (546/80-23-03; 547/80-23-03).Small hydraulic and air lines for the polar cranes are rusting and there is a lack of identification markers to distinguish between other crane parts.
The licensee identified the crane parts and tagged or marked each item as to location and unit number. The rusty hydraulic and air lines were identified by the licensee on Deviation Control Record (DCR) 008-79; the disposition was to replace these lines. The polar cranes also required weld repairs and recoating; this required unit disassembly. At reassembly,the lines are being replaced.
Unit 1 is completed, with Unit 2 scheduled in the near future.
The procedures and controls being utilized were considered to be acceptable. This item is closed.
(Closed) Unresolved Item (546/80-26-03; 547/80-26-03),Possible void created by washing away of the fill material around the Essential Service Water pipe. The suction piping appears to be sloped inwards. The licensee removed previously installed backfill material, placed the piping on grade and elevation, and installed new backfill material. The backfill activities were inspected and documented in NRC Report Number 546/81-20; 547/81-20. Also see previous closed item 546/80-21-02; 547/80-21-02 in this repor4 this action prevented any further washing. Licensee actions reviewed were considered adequate. This item is clcsed.
(0 pen) Unresolved Item (546/81-11-02; 547/81-11-02). Nonconformance Reports (NCR) and Corrective Action Request (CAR) were noted with questionable disposition, multiple dispositions, no documentation / basis for Usc-As-Ig and questionable status. The licensee is currently reviewing all NCRs and CARS that fall in the possible categories above,to Special Process Procedure SPP-27. This process will require several additional months to complete. The NRC will follow up on this item in a future inspection when licensee actions are complete.
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Concrete Repair The Resident Inspector observed the work and inspection activities related to chipping, evaluation, and repair of defective concrete in the Auxiliary, Fuel, and Unit 1 Containment Buildings. These activities were verified for compliance to the following Newberg Procedures: WPN-25, Concrete Patching, Revision 9 WPN-25-02, Concrete Patch and Repair Areas Evaluation, Revision 5 WPN-41, Concrete Curing, Revision 2 QCP-10.04, Concrete Curing Inspection, Revision 2 QCP-10.06, Post Placement and Patching Inspection, Revision 7 No items of noncompliance or deviations were identified.
Piping System Installation The Resident Inspector observed work and inspection activities for piping and hanger installation for the Containment Spray, Component Cooling Water, and Essential Service Water systems. Specific activities observed included control of traveler and' isometric packages, welding, filler metal control, and related quality inspection. The following Cnerne Contracting Corporation Procedures were reviewed.for implementation: 12.3, Traveler Package, Revision 5 12.5, General Requirements for Fabrication and Installation of Safety Related Components, Revision 3 12.7, Component Support Installation, Revision 5 12.10, Component Support Process Control, Revision 5 13.2, General Welding Specification, Revision 7 13.4, Identification, Storage, and Handling of Weld l Material, Revision 10 13.10, Fitting and Alignment, Revision 7
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14.3, Visual Inspection Procedure, Revision 1 ! $ , i f-5- , I i
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- _ . ________________ ________ l . . 14.9, Visual Examination, Revision 6 14.10, NDE Requirements for Marble 11111, Revision 3 14.11, AWS Visual Weld Acceptance Standards, Revision 0 15.18, Isometric Flow and Package Development, Revision 0 No items of noncompliance or deviations were identified.
5.
Electrical llanger Installation The Resident Inspector observed the installation of raceway support hangers in the Auxiliary Building on elevations 346', 364', and 383' to the following Commonwealth-Lord Joint Venture Procedures: CWP-C8A Welding Procedures General, Revision 3 CVP-C8C, Weld Filler Metal Control, Revision 2 CWP-C3B, Cable Tray System Installation, Revision 2 CWP-C24, Priming and Galvanizing Repair, Revison 4 No items of noncompliance or deviations were identified.
6.
Control Rod Drive Mechanism Installation (CRDM) During this reporting period the Resident Inspector reviewed the procedures / associated data,and observed work and inspection activities for the installation of CRDMsr 1x1 the Unit 1 Reactor Vessel Head. The Inspector specifically reviewed procedures, qualifications, and record data and observed the following activities being performed by Nuclesr Installation Services Company: a.
Procedures The following procedures were reviewed and found acceptable: .WPS 80.2.4, Revision A, Welding Procedure Specification for Manual Gas Tungsten Arc Welding (GTAW) of Austenitic Chromium-Nickel Stainless Steel to Itself on Plate, Pipe, Tube, etc., 1/16" thru 1/4", dated November 1981, and approved by PSI January 19, 1982. This procedure is being utilized to tack weld the CRDM, "Y" Insert and Penetration together. Procedure Qualification Records, (PQR) PQR-215 and PQR-216 dated August 20, 1976, qualified this procedure.
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_-.. . . .SWPS 132-8, Revision D, Special Welding Procedure Specification for the Installation and Welding of the Mechanism Lower Canopy Seal Welds (Automatic Cas Tungsten Arc Welding Method), dated July 16, 1981, and approved by PSI September 8, 1981. This procedure is being utilized to weld the CRDH canopy seal welds.
Procedure Qualification Record, PQR-132-8 dated June 28, 1979, j qualified this procedure. Six consecutive acceptable tests were required for qualification; these results were reviewed and also found acceptable.
.SWPS 132-2, Revision E, Repair Welding Procedure for Austenitic Corrosion Resisting Steel - Control Rod Drive Mechanism Seals, dated September 21, 1981, and approved by PSI November 10, 1981.
Procedure Qualification Record, PQR 132-2 dated November 13, 1974, j qualified this procedure.
.ES-300, Revision B, General Welding Procedure dated February 3, 1982, and approved by PSI March 5, 1982.
.ES-100, Revision D, Liquid Penetrant Examination dated April 1, 1982, and approved by PSI April 20, 1982.
.ES-CRDM-4004-1A, Revision F, Control Rod Drive Mechanism Installa-tion dated November 10, 1981, and approved by PSI December 8, 1981.
.ES-56, Revision C, Welding Filler Metal Control Procedure dated July 15, 1981, and approved by PSI August 4, 1981.
.ES-CRDM-4004-2A, Revision A, Closure Head Penetration Seal Hydrostatic Test Procedure dated April 8, 1982, and approved by PSL on April.15,.1982.
.ES-67, Revision F, General Cleaning dated June 11, 1981, and approved by PSI June 11, 1981.
b.
Personnel Qualification The following personnel qualifications were reviewed and found acceptable: (1) Welder Qualifications: Symbol N 7 qualified to WPS 80.2.4, SWPS 132-2, SWPS 132-8 Symbol N 9 qualified to WPS 80.2.4, SWPS 132-8 (2) Nondestructive Examination Qualifications: J. Felder, qualified Level 11 Penetrant Test, February 9, 1982 R. Shultz, qualified Level II Penetrant Test, March 31, 1980 The above individuals were qualified to Procedure ES-116-1, Personnel Qualifications.
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. c.
Calibration of Equipment The calibration of the following equipment was reviewed and found acceptable: The automatic welding machine manufactured by Dimetrics requires annual calibration by NISCO Procedure ES-140, Revision D, Calibra-tion. The calibration was performed by the manufacturer for unit serial number 085 on October 21, 1981, in accordance with Dimetrics procedure " Gold Track II Field Procedure". Master instrument utilized for calibration was a Fluke Model 8020A, Serial Number 0756550 calibrated on November 6, 1983.
d.
Filler Material Certification The Certified Material Test Reports, Inspection, and Procurement Documents were reviewed as follows and found to be acceptable: (1) "Y" Inserts - Heat number 465512, 308L, Receiving Inspection Report Number 4004-159 dated April 21, 1982, issued on a PSI Material Withdrawal Requistion (MWR) 4022 dated April 5,_1982.
Wire was manufactured by Sandvik to SEA 5.9, Section II C ASME Code and formed by Weld Ring Inc., Chemical and Physical results reviewed were acceptable as were special requirements of NB 2000/2400. PSI procured these inserts to the require-ments of specification Y-2702 on Purchase Order 1014-890/ 2014-290.
(2) Tig Lire - Bare wire 3/32" 308L to ASME SFA 5.9, Section II.C.
ASME Code Heat Number 02239, McKay Lot 21718, Receiving Inspection Report 4004-58 dated August 6, 1981. NISCO Purchase Order 3009-044-020250 procured wire for stock from Weld Star.
Chemistry, physical and special testing requirements reviewed were acceptable.
e.
Process Control Sheets The process control sheets number 4004-37 CUnit.1) and 4004-38 (Unit 2) were reviewed prior to field issue for contents including reference procedures, inspection hold points, ASME Code hold point ;, and data sheets to be used for recording dimensions, welder identification, inspector sign-off, etc.
These process sheets as reviewed were found to be acceptable.
f.
Observation of Work Activities The Inspector observed the welding of CRDM mock-ups, welder qualifications, and mock-up samples after cutting, polishing, and etching. The process sheets were also reviewed after field issue for sequential inspection sign-offs and recording of required data. This review found steps completed to date to be acceptable.
No item of noncompliance or deviations were identified.
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The inspector met with licensee representatives (denoted in Paragraph 1) throughout the month and at the conclusion of the inspection and summarized the scope and findings of the inspection activities.
Also, the Resident Inspector attended the following exit meetings: P. Pelke on April 2, 1982 i ,9 - .... . - _ _ _ - _ _ _ _ _ _ _ _ _ _ _ _ _ _ - _ }}