ML19256B625
| ML19256B625 | |
| Person / Time | |
|---|---|
| Site: | Zimmer |
| Issue date: | 06/11/1979 |
| From: | NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML19256B624 | List: |
| References | |
| 50-358-79-15, NUDOCS 7908150362 | |
| Download: ML19256B625 (5) | |
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Appendix A
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NOTICE OF VIOLATION Cincinnati Gas and Electric Docket No. 50-358 Company Based on the results of an KRC inspection conducted on May 8-11, and 17-18, 1979, it appears that certain of your activities were in noncompliance with NRC requirements as noted below.
Items 1 through 5 are infractions and item 6 is a deficiency.
1.
10 CFR Part 50, Appendix B, Criteria V, states, in part that "Ar'ivities affecting quality shall be prescribed by documented instractions, procedures
. of a type appropriate to the circumstances and accomplished in accordance with these instructions, procedures, or drawings.
Wm. Zimmer Nuclear Power Station, Unit 1, FSAR, Chapter 17, Paragraph 17.1.5, states, in part that " Activities affecting quality of the facility are accomplished in accordance with written instructions, procedures,
. which prescribe acceptable methods The CG&E Quality Assurance Manual, Section 5, states in context that written and approved procedures shall control quality related activities.
The Kaiser Engineers, Incorporated quality assurance procedure No. 8, Revision 4, Paragraph 2.0, states, in part that "When more detailed procedures are required, or.
. a construction methods instruction (QACMI) will be prepared.
. to assure compliance with requirements".
a.
Contrary to the above, on May 8-11, 1979, it was observed that metal grinding tools and other such devices used in the suppression pool modifications were not positively identified and controlled to preclude possible contamina-tion as is prescribed by Kaiser Procedure QACP.I M-9, Revision 6 and applicable welding procedures.
b.
Contrary to the above, on May 10, 1979, an adequate docu-mented and approved anchor bolt tensioning procedure including the operation of the modified tensioning device (Biach Model No. 130) was not available, although anchor bolt tensioning had been initiated.
7908150mt
Appendix A
/ c.
Contrary to the above, during May 9-11, 1979, it was determined that portable weld rod beater boxes were not being adequately controlled, identified, and verified relative to their operability.
That is, heater boxes had multiple identifying symbols, " expired" dates of tempera-ture verification.
Operability status was not adequately traceable and documented relative to these devices.
Adequate procedures to control this activity were appar-ently not available.
2.
10 CFR Part 50, Appendix B, Criteria VII, states, in part that
" Measures shall be established to assure that purchased material conform to procurement documents. These measures shall include provisions as appropriate for.
. objective evidence of quality.
. and examination upon delivery.
Wm. Zimmer Nuclear Power Station, Unit 1, FSAR, Chapter 17, Paragraph 17.1.8.3, states, in part that " Objective evidence of quality is established by inspection.
." Further paragraph 17.1.7.5.2 states, in part that "The KII QA/QC program contains procedures for source inspection and receiving inspection...
and Paragraph 17.1.7.6 states, in part that " Documentary evidence of an item's conformance to procurement requirements is required to be available at the construction site prior to installation or use of that item" The Wm. Zimmer Nuclear Power Station Quality Assurance Manual Paragraph 7.7 (Documentary Evidence) states, in part that
" Documentary evidence that material.
. conform to procure-ment requirements is required to be at the site prior to use."
a.
Contrary to the above, on May 10, 1979, it was determined that Purchase Order (P0 No. 33336) requirements for 100%
ultrasonic examination for the quencher base plate material, was not complied with, in that the certified NDE reports provided, show that apparently the base plate material was examined only in areas outlined by the intersections of a 24-inch grid. This discrepancy was not identified prior to use of this material.
b.
Contrary to the above, documented evidence to certify that special grout material (EMBECO-636) met the requirements of S&L Specification No. H2174 and manufacturer formulation
Appendix A e requirements, was unavailable at the site. Material receipt inspection old not identify this omission prior to use of this material.
3.
10 CFR Part 50, Appendix B, Criteria VIII, states, in part that
" Measures shall be established for the identification and control of materials
." and "These measures shall assure that identification is maintained by.
. appropriate means throughout fabrication and use of the item."
Wm. Zimmer Nuclear Power Station, Unit 1, FSAR, Chapter 17, Paragraph 17.1.8, states, in part that " Essential materials, parts and components.
. bear identification as to heat
- number,
. serial number, etc."
" Identification is main-tained.
. throughout fabrication.
The CG&E Wm. H. Zimmer Nuclear Power Station Quality Assurance Manual Section 8.2, states, in part that ".
. The identifi-cation of items will by maintained.
." "This identifica-tion may be on the item or on records traceable to the item."
The identification is maintained throughout fabrication.
a.
Contrary to the above, on May 9,1979, it was observed that weld filler material maintained in the disbursement center (rod shack), was being placed in holding ovens with out benefit of the required material heat number trace-ability system; in that, weld rod location maps were not maintained.
It was apparent from discussion, that the attendants were relying on memory to identify these materials.
b.
Contrary to the above, on May 9, 1979, NRC examination of the liquid penetrant " dye" material used on the suppression pool welds and materials, disclosed that the dye material was not identified, and documented traceability'to quality records could not be established. Moreover, the liquid penetrant dye container appeared contaminated with foreign matter.
4.
10 CFR Part 50, Appendix B, Criteria IX, states, in part that
" Measures shall be established to assure that special processes, including welding, beat treating... are controlled and accomplished.
in accordance with.
specification and other special requirements."
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Appendix A Wm. Zinner Nuclear Power Station, Unit 1, FSAR, Chapter 17, Paragraph 17.1.9.2, states, in part that "Special processes are accomplished.
in accordance with applicable codes, standards, specifications, criteria, or other special requirements."
The Wm. Zimmer Nuclear Power Station Quality Assurance Manual, Section 9, Paragraph 9.2, states, in part ".
. assure that implementation of special processes is in accordance with approved procedures."
Contrary to the above, and in context, the Special Process a.
Procedures Manual, Section 3.3, Revision 4; on May 10, 1979, the NRC inspector observed that filler material holding oven No. 57 (within the primary rod shack) was being used to cook food products (rod attendant lunches).
b.
Contrary to the above, and in context to weld procedure specification Nos. 3.1.57, 3.1.59, and 3.1.80, it was determined through observation and discussion, that gas fired torches were being used for pre-heat and " moisture" control, whereas only electrical beating is specified.
Contrary to the above, and in context to weld procedure c.
specification Nos. 3.1.57, 3.1.59, and 3.1.80, on May 8 and 9,1979, NRC inspection determined that welding inter-pass temperature requirements were not being verified.
Tools needed for such verification were not immediately available to personnel performing and verifying accepta-bility of the welding.
5.
10 CFR Part 50, Appendix B, Criteria XV, states, in part that
" Measures shall be established to control materials.
. which do not conform to requirements
" "These measures shall include.
. procedures for identification, documentation, segregation, disposition.
The Wm. Zimmer Nuclear Power Station, Unit 1, FSAR, Chapter 17, Paragraph 17.1.15.7, states, in part that " Nonconforming items are conspicuously marked and whenever practical are physically segregated to prevent their inadvertent use or installation."
The CG&E, Quality Assurance Manual, Section 15, Paragraph 15.4, requires in context that nonconforming items be identified and segregated.
Appendix 3
. The Kaiser Engineers Quality Assurance Manual, Procedure 16, Revision 3, Paragraph 2.2, states, in part that "All noncon-forming items will be segregated, where possible from acceptable items, clearly identified with applicable hold or deficiency tag.
a.
Contrary to the above, in excess of 50 containers of acknowledged nonconforming weld filler material were observed for several days (May 8, S, s ad 10,1979) within the primary weld rod disbursement room, witho"t benefit of nonconformance identifying tags or controlled segregation.
6.
10 CFR Part 50, Appendix B, Criteria XVII, states in part that
" sufficient records shall be maintained to furnish evidence of activities affecting quality."
Wm. Zimmer Nuclear Power Station, Unit 1, FSAR, Chapter 17, Paragraph 17.1.17.1, states that " Sufficient records to furnish evidence of activities affecting quality are maintained at the site....
Paragraph 17.1.17.2, states, in part that "The records to be retained include... monitoring of work pe r fo rmance,"
The CG&E Quality Assurance Manual, Section 17.1, states, in part that ".
the QA records will document that every prac-tical effort to assure a safe and reliable nuclear installation has been considered and performed during fabrication.
Contrary to the above, on May 8, 9, and 10,1979, field a.
welding checklist (KE-1 forms) located in the suppression pool for documenting modification welding activity, did not adequately reflect the status of fabrication as is required by Special Process Procedures Manual, Section 8.
Records are in part maintained in inspectors' note books.