IR 05000546/1982010
| ML20054L724 | |
| Person / Time | |
|---|---|
| Site: | Marble Hill |
| Issue date: | 06/14/1982 |
| From: | Harrison J, Konklin J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML20054L713 | List: |
| References | |
| 50-546-82-10, 50-547-82-10, NUDOCS 8207080408 | |
| Download: ML20054L724 (12) | |
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U.S. NUCLEAR REGULATORY COMMISSION
REGION III
Report Nos.
50-546/82-10; 50-547/82-10(DPRP)
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 Facility Name: Marble 11111 Nuclear Generating Station, Units 1 and 2 Inspection At: Marble 11111 Site, Jef ferson County, IN Inspection Conducted: May 1-31, 1982
)J.}J.liarrisonN5
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Inspector:
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Approved By: J
'I Kon lin, Chief
_$//f/M cactor Projects Section 2A Inspection Summary Inspection during the period of May 1-31, 1982 (Report Nos. 50-546/
82-10; 50-547/82-10 (DPRP))
Areas Inspected:
Inspection by the Regional Resident Inspector of erection and welding of structural steel, included in this inspection were the review of related procedures, personnel training and qualifications, calibration of equipment, quality records and observation of work activities including inspection and special processes. This inspection involved a total of 160 inspector-hours on site by one NRC inspector, including 30 inspector-hours onsite during off shifts.
Results: One item of noncompliance was identified (Use of Inadequate Calibration Equipment - Paragraph 3.c.).
i 8207080408 820622 PDR ADOCK 05000546 g
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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
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- C. Beckham, Quality Engineering Manager
- B. Morrison, Superintendent - Civil Quality Engineering
- R.
Hughes, Contract Manager Electrical Newberg-Marble Hill (N-MH)
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Stegemoller, Vice President - Power Construction R. Donica, Project QA Manager S. Milano, Project QC Supervisor D. Mathews, Welding Engineer Westinghouse Electric Corporation C. Markham, Site Manager Authorized Nuclear Inspector (ANI)
A. Clark, Hartford Steam Boiler (ANI-PSI)
- Denotes those present at the exit meetings.
The inspector also contacted and interviewed other licensee and
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contractor personnel.
2.
Licensee Action on Previous Inspection Findings (Closed) Open Item (546/81-16-01; 547/81-16-01)
Three concerns were noted in the Project Quality Assurance Manual (PQAM)
due to changes of responsibility, typographical or the need of some form of clarification. These items were: (A) Responsibility of Nuclear Fuels Manager to Executive Director Nuclear Operations in Sections 1, 4 and 7 needing clarification.
(B) Typographical error in Section 10, tabic, as to " Level Functions", for " Reporting of Inspection and Test Results".
Level I had an "X" placed in the incorrect column.
(C) Clarify trending of nonconformance reports for PSI contractors and suppliers in sections 15 and 16.
The PQAM was revised to correct / clarify the above items and was approved and issued on March 29, 1982. The NRC Inspector reviewed the revisions and found them to be acceptable. This item is closed.
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3.
Structural Steel Erection During this reporting period the Resident Inspector reviewed procedures and records and observed work and inspection activities being performed by Newberg-Marble 11111 related to the erection and welding of Structural Steel as follows (This inspection also includes any interface controls with the Licensee):
a.
Procedures The following procedures were reviewed and found acceptable:
(1)
Newberg Procedures:
.WPN 26. Erection of Structural Steel, Revision 4, dated March 30, 1982, approved by PSI on March 29, 1982.
.WPN 5, Welding, Revision 9, dated March 29, 1982, approved by PSI March 26, 1982.
.WPN 5-01, AWS Structural Welding, Revision 2, dated October 2, 1981, approved by PSI on October 1, 1981.
.WPN 5-02, Weld Repairs, Revision 3, dated April 12, 1982, approved by PSI April 7, 1982.
.WPN 5-03, AWS Welder Qualifications, Revision 3, dated March 29, 1982, approved by PSI on March 25, 1982.
.WPN 5-04, Welding Material Control, Revision 3, dated March 29, 1982, approved by PSI on March 25, 1982.
.WPN 5-09, Welding Procedure Specification 11A34SP, Revision 1, dated October 2, 1981, approved by PSI on October 1, 1981.
.WPN 5-09-01, Cadweld Sleeve Welding, Revision 0, dated July 9, 1981, approved by PSI July 7, 1981.
.WPN 5-10, Prequalified Welding Procedure Specification 11A4S, Revision 2, dated October 2, 1981, approved by PSI October 1, 1981.
.WPN 5-11, Prequalified Welding Procedure Specification 11F6S, Revision 3, dated April 26, 1982, approved by PSI on April 22, 1982.
.WPN 5-14, Temporary Attachments, Revision 1, dated October 2, 1981, approved by PSI October 1, 1981.
.WPN 6, Receiving, Storage and Control of Materials and Equipment, Revision 7, dated April 5, 1982, approved by PSI on April 2, 1982 and ICN 6-7-1.
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.WPN 42, Engineering Document Control, Revision 9, dated March 23, 1982, approved by PSI on March 22, 1982.
.WPN 49, Design Control, Revision 4 and 5, dated February 17, 1982, and May 25, 1982, approved by PSI February 16, 1982, and May 25, 1982.
.QCP 7.01, Receiving Inspection of Material and Equipment, Revision 4, dated March 3, 1982, approved by PSI on March 2, 1982.
.QCP 9.01, AWS Welding Inspection, Revision 4, dated February 25, 1982, approved by PSI February 23, 1982, and ICN 204, dated March 8, 1982.
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.QCP 10.08, Structural Steel Erection Inspection, Revision 12, dated April 1, 1982, approved by PSI March 31, 1982.
.QCP 12.01, Control of Measuring and Test Equipment,
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Revision 5, dated February 25, 1982, approved by PSI February 23, 1982.
.QCP 12.01.04, Thermometer Calibration, Revision 0, dated August 31, 1981, approved by PSI August 26, 1981 and ICN 12.01.04-0-1.
.QAP 2.01, Training of Personnel, Revision 8, dated February 24, 1982, approved by PSI February 22, 1982.
.QAP 10.01, QC Personnel Qualification and Certification, Revision 4, dated November 25, 1981, approved by PSI November 23, 1981.
.QAP 10.02, QA Records Inspector Qualification and Certification, Revision 0, dated April 15, 1982, approved by PSI on April 13, 1982.
.QAP 17.01, Quality Assurance Records, Revision 6, dated May 21, 1982, approved by PSI May 18, 1982.
(2)
PSI Procedures:
.QCP-4, Quality Control Procedure for Structural Steel Bolt Tension Testing, Revision 6, dated April 28, 1982.
.QCP-5, Quality Control Procedure for Calibration Control of Measuring and Test Equipment, Revision 6, dated March 17, 1982 and ICN #1 and #2.
.TMP-12, Test Method Procedure for Job Inspection Torque, Revision 4, dated December 10, 1981.
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.PMP 3.01, Qualification and Certification of Quality Assurance Personnel, Revision 9, dated April 23, 1982.
.PMP 1.04. Training, Revision 6, dated April 23, 1982.
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Personnel Training, Qualification, and Certification
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The NRC Inspector reviewed records for training qualification (
and certification of QA/QC personnel. This records review l
included resumes, training attended, reading records, examinations, eye test, certification, and selected background and educational
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checks. The review was to assure certification was current and personnel were properly certified to perform the assigned task.
Also, selected personnel were observed performing inspections and were interviewed for job knowledge. The following PSI and N-MH personnel were included in this review and were found to be l
acceptable:
(1) Newberg QA/QC - to procedural rcquirements of QAP 2.01, QAP-10.01, and QAP-10.02 (see Section 3.a, Procedures)
F. Repogle
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Quality Engineer
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L. Adwell
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Structural Steel / Welding QC Inspector,
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Level I A. Corrado
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Structural Steel / Welding QC Inspector, Level II R. Mackie
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Structural Steel / Welding QC Inspector, Level II M. Harris
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Structural Steel / Welding QC Inspector, Level II J. Butler
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Structural Welding QC Inspector, Level I C. Parker
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Structural Welding QC Inspector, Level Il G. Polavaram
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Structural Welding QC Inspector, Level II D. Mitchell
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Structural Welding QC Inspector, Level II W. Smith
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Structural Welding QC Inspector, Level II S. Milano
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QC Supervisor, Level III R. Donica
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QA Manager, Level III-5-
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(2) Public Service Indiana (PSI)/ United States Testing Company (UST)
QA/QC - procedural requirements of PMP 3.01 and PMP 1.04, (see Section 3.a. Procedures)
T. Geyman (PSI) - Structural Steel Bolt Tension Testing QCP-4, Level II R. Gross (UST) - Structural Steel Bolt Tension Testing QCP-4, Level II J. Beckort (UST)
- Structural Steel Bolt Tension Testing QCP-4, Level II L. Baker (UST)
- Structural Steel Bolt Tension Testing QCP-4, Level II M. Wyatt (UST) - Structural Steel Bolt Tension Testing QCP-4, Level II B. Nourse (UST) - Structural Steel Bolt Tension Testing QCP-4, Level II P. Johnson (UST) - Structural Steel Bolt Tension Testing QCP-4, Level II c.
Calibration The NRC Inspector reviewed calibration of equipment that was being utilized during this inspection of structural steel.
Included in this review were the equipment calibration cards and records, calibration stickers, equipment condition, range and accuracy, and traceability to the National Bureau of Standards. Also off site laboratories, utilized for calibration, were verified for being on the Approved Vendors List. Equipment included in this review was:
(1) Newberg Equipment - Controls to Procedure QCP 12.01 (see section 3.a.1)
.D.C. Volt /Ampmeter, AM-3, calibration by Lousiville Meter, i
calibration was found to be acceptable.
. Contact Thermometer, ST-8, calibration by N-MH, this thermometer was previously found out of calibration,
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NCR 3673 was issued.
Equipment was determined not to have been used and was recalibrated. This action and the calibra-tion process was found to be acceptable.
l Also during this review requirements of QCP 9.01, AWS Welding Inspection Revision 4, related to calibration were verified.
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Section 12.2 required in part that "...the inspector check each electrode storage oven monthly with a temperature indicating l
device calibrated per QCP 12.01...".
A review of the " Welding-6-l l
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Electrode Storage Oven Temperature Log" revealed that daily checks were being performed utilizing temperature indicating crayons (tempil sticks) and periodically verified by using a calibrated thermometer. Several months (March, 1982 and December, 1981) were not checked with e calibrated thermometer but were verified with tempil sticks. The practice of using tempil sticks as a calibrated device is unacceptable do to the following: (1) each crayon is not uniquely identified (2) crayons do not fall within the uncertainty level of being k more accurate as equipment being calibrated /
verified (3) crayons are lot manufactured and sample tested, therefore each crayon is not tested and (4) traceability of a specific crayon to a NBS Standard cannot be provided.
It should also be noted that Newberg's internal audit program had a similar finding in January, 1982, Audit 82-1, AFR Number 10. Corrective action was to allow the use of tempil sticks and QCP 12.1 was revised accordingly.
The use of an incorrect uncalibrated equipment is contrary to 10 CFR 50, Appendix B, Criterion XII, Control of Measuring and Test Equipment, and constitutes an item of noncompliance (546/82-10-01; 547/82-10-01).
The Licensea and Newberg took immediate corrective action to remedy this condition by issuing an Interim Change Notice, ICN QCP 9.01-4-2, to revise QCP 9.01, Section 12.2 to read "...with a thermometer or pyrometer calibrated per QCP 12.01 (temperature indicating crayons may not be used for this purpose)." Quality personnel were also trained to this requirement. This corrective action was reviewed by the Inspector and found acceptable and additional NRC follow up will not be required.
(2) PSI Equipment - Controls to procedures QCP-5 and TMP-12 (see Section 3.a.2)
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. Torque Wrench S/N B1029, verified daily prior to use on a Skidmore-Wilhelm Tension Tester, process was found to be j
acceptable.
.Skidmore-Wilhelm Tension Tester S/N B386 and B423, calibration by the manufacturer, calibration was found to be acceptable.
d.
Document Control The Inspector reviewed the controls being utilized to control drawings, welding drawings and work controlling travelers; this review included file copies, field copies and record copies. The following documents were included in this review and found to be properly controlled to the requirements of WPN 42 and WPN 49; with the latest / proper revision being utilized for erection, welding and inspection:
(1) Drawings (Inryco)
Revision E1141 C
E1294 H
E1302 M
E1310 L
E1311 K
E1312 H-7-
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Drawings (Inryco)
Revision E1313AB D
E1314AB C
E1314B D
E1315AB D
E1318AB C
E1318B E
E1319AB E
E1326 G
E1327 D
E1328 B
E1329AB F
(2) Welding Drawings I
NMH W-126 Revision A NMH W-87 Revision A NMH W-84 Revision B NMH W-67 Revision D NMH W-158 Revision C (3) Welding Travelers 126-9 Revision 1 126-10 Revision 1 87-2 Revision 0 84-3 Revision 0 84-5 Revision 2 67-15 Revision 1 158-23 Revision 1 e.
Filler Material Certification The NRC Inspector reviewed the Certified Material Test Reports, Receiving Inspection and storage of filler material and found the following to be acceptable:
(1)
Electrodes, E7018, 1/8" to AWS 5.1 for Control Number EE014 Heat Number 422P3881, Lot Number 2A206Z02, Receiving Inspection Report Number 818, procurred from Weldstar on Newberg Purchase Order 104-f-171 and manufactured by Alloy Rods - Chemetron.
Chemicals and physical results were reviewed together with the other related data and found acceptable.
(2)
Electrodes, E7018, 3/32" to AWS 5.1 for Control Number BB055.
Heat Number 422N0651, Lot Number 2D129R03, Receiving Inspection Report Number 420, procurred from Weldstar on Newberg Purchase Order 104-f-163, and manufactured by Alloy Rods - Chemetron Chemical and Physical results were reviewed together with the other related data and found acceptable.
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Observation of Erection, Welding and Inspection of Structural Steel (1) Structural Steel Welding The Inspector observed the following field activities and found those controls to be acceptable:
. Welder Qualification - The review in this area was to WPN-5 and WPN 5-03 requirements and included indoctrination training, welder test for material type, welding positions, material thickness, testing qualification methods (bend test or radiography), retest and qualification records. The control of welder identification stamps and instruction for welders, were also reviewed. The qualified welders list was reviewed to verify completeness, correctness and being up-to-date.
The following welders were verified during this process:
Symbol Welder 1-3 May I-12 Haley I-19 Hogan 1-24 Shrader 1-46 Daulton 1-49 Nowbray B-12 Fella
. Weld Drawing and Traveler Preparation and Control The Inspector reviewed weld drawing and traveler preparation, revision and issuance control to the requirements of WPN-5.
The welding drawings and travelers denoted in Section 3.d (2) and (3) were included in this review and found acceptable.
. Filler Metal Control The Inspector reviewed the controls required by WPN-5 and WPN-04 including the list of authorized personnel (welder)
to withdrawn filler metal, list of authorized personnel
(foreman) to requistion, and rod room access list.
Also examined were the use of the filler metal withdrawal form, filler metal issuance and return of unused filler metal;
this also included rod segregation in ovens by type, heat /lut,
and size. The issue area was clean and controls were adequate.
l Rod storage oven temperatures were being monitored daily by the welding technician and periodically by QC personnel.
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The monthly required check with a calibrated device was not
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being properly accomplished (see Section 3.c for noncompliance).
l This inspection also revealed the work areas to be free of l
stubs and any uncontrolled filler metal.
Portable rod ovens were also being utilized for low hydrogen electrodes.
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. Welding Activities The Inspector observed that for in process welding the correct drawing and traveler revisions were being utilized. Weld quality appeared to be satisfactory. Completed welds were being identified with ID stamps; these stamps were of the low stress type. Welders were properly qualified and were per-forming to the required welding procedure. The cooperation and working relations between production, craft and inspection personnel appeared to be excellent.
. Welding Inspection Activities The Inspector observed that N MH QC personnel were inspecting to the requirements of QCP 9.01 and specifically were properly utilizing the AWS checklist, correct revisions of field drawings and travelers. Also observed were activities including joint fit-up, in process and final inspection (visual) welding current verification (D.C. volt / amps) and Inspection Hold Point notification. QC surveillance activities were observed and reviewed.
It was also noted that Newberg QC had issued a nonconformance report 3706 because of a welding / bolting interface problem. This NCR was in process and disposition incomplete. The NCR as reviewed was acceptable.
(2)
Structural Steel Erection The Inspector observed erection, location, bolting, torqueing and inspection of the following activities and found them to be acceptable:
. Erection - Controls being utilized were to the requirements of WPN 26 and included in this inspection were the following activities requisitioning of structural members, field cutting (copes), and pre-grouting inspection of columns.
Bolting activities included requisition installation of bolting materials (location, type, and orientation), tightening and verification. An area of concern was noted in the control of bolting materials in that (1) materials were not being stored in a locked metal container as required by Section 6.1.2 and (2) some bolting materials were not identified as to proper status and were stored with scrap material. PSI had, prior to this inspection, performed several inspection sur-veillances and noted the same types of conditions. This resulted in several Corrective Action Requests (CAR 282-PSI-0015, 0041, and N-MH-223 and 237) being issued.
It should be noted however, that during this inspection the bolting materials in question were properly identified and controls reestablished.
Procedures WPN-26 was revised accordingly to clarify storage on ICN WPN-26-4-1.
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The Inspector reviewed the corrective actions taken and found such action to be acceptable. The identification, responsiveness and corrective action taken by the Licensee and Newberg prevented this problem from becoming an NRC item of noncompliance.
. Inspection The Inspector selected eight bolted connections and followed these thru the inspection and verification process. Numerous other connections were also randomly inspected for correct bolts, nuts, washers, orientation, location and correct member. Newberg QC inspection personnel were observed performing daily inspections including base plate inspections, connection inspections, and final inspection of bolted connections and final structural steel erection inspections.
The selected bolted connections were identified on Newberg Final Inspection of Bolted Connections Reports, control number M-292, M-304, M-331, and M-402.
The connections were traced through the system at Newberg and to the Owners (PSI) Test Lab (OTL). All the inspections had been verified and torque checked except for M-402, still in process.
The OTL had identified some missing bolts and bolts not fully engaged, retain tags 13004 thru 13010 had been attached to those areas and corrective actions were being taken.
Equipment utilized for torque verification was checked for correct calibration and found acceptable. All personnel that were involved in inspection activities were checked for proper certification and found properly certified.
It was also noted that column splices at elevation 451' 25/Q and 23/M exceeded the allowable gap between the columns and the splice plates. NCR 3623 and 3690 had been issued by Newberg to identify this problem. The NCR's disposition on 3623 were reviewed and found to be acceptable, NCR 3690 was awaiting disposition. Nonconformance tags were also observed as being attached to each nonconforming column.
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Records The Inspector reviewed selected records related to structural steel activities that were completed, reviewed, and accepted by PSI /Newberg Quality Assurance and were being stored in the records vault. The records reviewed included:
. Personnel Training and Certification Records
. Calibration Records
. Approved Vendors List
. Welding Inspection Data Packages 11 -
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. Structural Steel Inspection Data Packages
. Receiving Inspection Reports
. Certified Material Test Reports
. Welder Qualification Records
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. Material Requisitions
.Nonconformance Reports
. Corrective Action Request Specific records reviewed are denoted throughout this report.
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i Records were reviewed by designated QC/QA personnel and had
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i the proper review stamps affixed. This review revealed
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acceptable quality records.
4.
Meeting / Visits
During this reporting period the Resident Inspector participated in l
the following:
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Meeting on May 10, 1982, with L. McGregor Region III to discuss the resident' inspection program at Marble Hill and Braidwood.
P Meeting on May 6, 1982, conducted by the licensee with the subject
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being " Bomb Threats." The meeting was attended by PSI and Contractor Managers, Union-Businese Agents and Stewarts, Security, FBI, Indiana
State Police, Sheriffs of Jefferson and Clark Counties. Subjects i
discussed were work disruption, loss of schedule, loss of pay, state
and federal laws being violated together with penalties (fine and
jail sentence). Also a large reward was suggested and discussed.
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Exit Interview a
The inspector met with licensee representatives (denoted in Paragraph 1)
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throughout the month and at the conclusion of the inspection and i
summarized the scope and findings of the inspection activities.
Also, the resident inspector attended the following exit meetings:
R. Love on May 5, 1982
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P. Pelke on May 21, 1982
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