ML19282B472

Responds to NRC Ltr Re Violations Noted in IE Insp Repts 50-546/78-08 & 547-547/78-08.Corrective Actions:Lifts W/Suspension to Be in Accordance W/Correct Beam Configuration of Heaviest Object

ML19282B472
Person / Time
Site:	Braidwood
Issue date:	02/08/1979
From:	Coughlin J PSI ENERGY, INC. A/K/A PUBLIC SERVICE CO. OF INDIANA
To:	Heishman R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
Shared Package
ML19282B457	List: ML19282B472
References
NUDOCS 7903150039
Download: ML19282B472 (4)

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0209790062 e

PUBLIC SERVICE INDIANA James Coughhn vece Pedent . February 8, 1979 Nuclear Mr. R. F. Beishman United States Nuclear Regulatory Cor: mission Region III 799 Roosevelt Road Docket Nos.: STN 50-546 Glen Ellyn. Illinois 6G_37 STN 50-547

Dear Sir:

In accordance with the provisions of Section 2.201 of the NRC's " Rules of Practice," Part 2, Title 10, Code of Federal Regulations, Public Service Indiana offers the following information in response to Infractions No.

546/78-08-01 and 546/78-08-02 identified in NRC Inspection Report No.

50-546/78 and 50-547/78-08.

Infraction No. 1 (546/78-08-01)

Contrary to the requirements of 10CFR50 Appendix B Criterion V and Public Service Indiana QA Procedure CMP 3.9 " Review of Contractor's Procedures,"

it was determined that:

(c) The hoisting equipment used to lift two of the steam generators was not properly rerated in accordance with ANSI N45.2.2 and NRC Regulatory Guide 1.38.

(b) The Site Surveillance Checklist used in the surveil'ance of special lifts did not require a load test at least equal to 110% of the lift weight to be made.

(c) The Site Surveillance Report and Site Surveillance Checklist had several documentation errors.

Corrective Action Taken and Results Achieved Devimtion Control Record #001-79 was written to document:

(a) The steam generator was raised using a configuration that had not been rerated in accordance with ANSI N45.2 and Regulatory Guide 1.38, 7 9 0 315 0 0 3ct IB U M 1000 East Main Street, Plainfield, Indiana 46168 317. 839 .9611

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t PUBUC SERVICE INDIANA Mr. R. F. Beishman February 8,1979 Page 2 (b) The Site Surveill*,nce Checklist conreined inappropriate references and entries.

(c) Accurate determination of the two type "A" weights had not been determinr.d prior to the lift.

(d) S&L had not signed the associated Aycock drawings.

Deviation Control Record #001-79 was subsequently resolved and closcd based on the following:

(a) Future lifts, requiring suspension beams will be accomplished in accordance with the correct beam configuration for the heaviest object being raised.

(b) The Site Surveillance Checklist was corrected to record the cor-rect references and appropriate entries.

(c) The two indcterminate type "A" test weights were determined to be correct by weighing one test weight on a scale calibrated in the 62,000 lb. range. An error factor was established by comparing the two weights. The error factor was used to determine the cor-rect weight of the second "A" type test weight.

(d) Aycock drawings MHR 1 Rev. 3, MER 2 Rev. 3, MHR 4 Rev. 1, MHR 8 Rev. 7, and MHR 10 Rev. 4 which had not been signed by a Sargent

& Lundy engineer were brought to the attention of S&L. S&L cor-rected this condition on the next revision of these drawings.

Corrective Action Taken to Avoid Further Noncompliance Public Service Indiana and Aycock procedures were reviewed for noncompli-ance with ANSI N45.2.2 and Nuclear Regulatory Guide 1.38 and those non-compliances corrected. A training session was given to the entire PSI Construction Management Organization on the requirements of ANSI N45.2.2 and Nuclear Regulatory Guide 1.38.

Date When Full Compliance Will Be Achieved February 10, 1979

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PUBUC SERVICE INDIAKA Mr. R. F. Heishman February 8,1979 Page 3 Infraction No. 2 (546/78-08-02)

Contrary to the requirements of 10CFR50 Appendix B Criterion X and Public Service Indiana QA Procedure CMP 3.8 " Surveillance of Site Activities,"

it was found that U.S. Testing Co. inspection of the B-type cadwelds in

1. 1 Containment was inadequate in the following areas:

(a) Cadwelds that had been determined acceptable by U.S. Testing were found to be in noncompliance with the specification re-quirements of allevable void area.

(b) The U.S. Testing inspector's performance of the computation of the void area was incorrect.

(c) The U.S. Testing Procedure QCP-ll used for cadweld inspection did not include an inspection checkpoint relative to porosity in the filler metal.

Corrective Action Taken and Results Achieved (a) Cadwelds P-693-3(F) and P-685-11(F) have been rejected, cut out and replaced, and a reinspecticn of all "B" and "T" type splices was made for voids on Unit #1 interior and exterior walls. This reinspection yielded no additional cadweld re-jections. The reinspection package indicated that during the above-mentioned reinspection void calculations were per-formed for other cadwelds that were visually questionable in the judgnent of the inspector and in accordance with QCP-ll Rev. I and BY/BR/MCS Rev. 7.

(b) The calculations for void areas were corrected to those values referenced on page 9, subparagraph a. However upon review by PSI QC Records Reviewers, it was determined that three of the four were wrong. PSI wrote FCAR #527 identifying mathemati-cal calculation errors on the referenced cadwelds and corrected copies of the Cadweld Inspection Report were issued.

(c) Reinspection showed no significant porous metal on any of the cadwelds. On November 20, 1978, U.S. Testing began to write in the remarks section of the first QCP-ll checklist form of each requisition that porous metal was checked. U.S. Testing stated the welds prior to November 20, 1978, had no porous metal visible even though it was not noted. All cadwelds are visually inspected for porous metal.

PUBUC SERVICE INDIANA Mr. R. F. Beishman February 8, 1979 Page 4 Corrective Action Taken to Avoid Further Noncompliance (a) U S. Testing QC Inspectors have had refresher training on the luirements of QCP-ll Rev. I and BY/BR/MCS Rev. 7 for inspect-echanical cadweld splices with emphasis on the calculation

.. reid areas.

(b) Each QC Inspector was given a training quiz to compute void area in filler metal and the inspectors are now noting on the Cadweld Inspection Reports when spe void areas are too small for spot void area calculations.

(c) PSI approved for use a U.S. Testing Change Notice 1 to QCP-ll Rev. 1 on November 10, 1978, to incorporate a checkpoint re-quiring porous metal be checked for each cadweld inspection.

Date When Full Compliance Will Be Achieved February 10, 1979

,('Verytru17'yours,

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,W\ ( OA .

s Coughlin  ;

V ge President -(Ruclear JC:sbb cc: Edward R. Schweibinz, P.E.

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