ML19291B926

Final Deficiency Rept Re Breakdown of S&M Constructors Inc QA Program Regarding Control Over Subcontractors.Deficient Parts Replaced.Periodic Audits & Surveillance Performed During Various Stages of Fabrication

ML19291B926
Person / Time
Site:	Perry
Issue date:	12/07/1979
From:	CLEVELAND ELECTRIC ILLUMINATING CO.
To:
Shared Package
ML19291B922	List: ML19291B921 ML19291B926
References
NUDOCS 7912140371
Download: ML19291B926 (5)

Text

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FINAL REPORT ON SIGNIFICANT DEFICIENCY

' S & M CONSTRUCTORS, INC.

QUALITY ASSURANCE PROGRAM BREAKDOWN ,

REGARDING CONTROL OF S.& M GUBCONTRACTOR, THE HALVORSEN BOILER AND ENGINEERING CO.

PERRY NUCLEAR POWER PLAlfr DOCKET NOS. 50-440; 50-441 THE CLEVELAND ELECTRIC ILLUMINATING COMPANY DECEMBER 7, 1979 1582 204 y:nvia : 37)

FINAL REPORT ON SIGNIFICANT DEFICIENCY INTRODUCTION In accordance with the requirements of 10CFR50.55(e), this is the Final Report on the Significant Deficiency on S & M Constructors, Inc. Quality Assurance Pr,ogram breakdown regarding control of S & M Subcontractor, The Halvorsen Boiler and Engineering Company, and includes: (a) A description of the deficiency; (b) An analysis of the safety implications and (c) Suf ficient information to permit analysis and evaluation of: (1) the deficiency and (2) Corrective Action._

. DESCRIPTION OF DEFICIENCY A. INTRODUCTION ,

The Interim Report regarding this Significant Deficiency was trans-mitted to the NRC on February 12, 1979. Although the transmittal to this Interim Report states' in the last paragraph that the Final Report is scheduled to be in your office by June 1, 1979, there were two (2) letters written extending this date. One (1) letter dated May 29, 1979, requested an extension to August 31, 1979, and the other letter, dated August 29, 1979, requested an extension to December 15, 1979.

B. PROGRAM DEFICIENCIES ,

Numerous hardware deficiencies identified on various Nonconformance Reports and audit reports led Project Organization personnel to determine that major deficiencies were present in S & M Constructors, Inc. Quality Assurance Program.

The Interim Report details the specific program deficiencies known at the time of that writing. However, two (2) program review audits, Audit Numbers 214 and 249, revealed deficiencies in S & M Constructors, Inc. Quality Assurance Program in other areas of 10CFR50, Appendix B, and resulted in S & M Constructors, Inc. revising in total their Quality Assurance Manual. This revised Quality Assurance Manual, along with the Corrective Action section of this report is sufficient action to assure repetition in this area does not occur.

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FINAL REPORT ON SIGNIFICANT DEFICIENCY PAGE 2 DESCRIPTION OF DEFICIENCY (CONT'D.)

C. HARDWARE DEFICIENCIES A detail of the hardware deficiencies existent in the work performed by Halvorsen Boiler and Engineering Company were identified on Non-conformance Report CQA 035 and was limited to the welds on the two (2) Intake Structures. A summary of the specific deficiencies on the two (2) Intake Structures is proVided in the Interin Report.

Since the issuance of the Interim Report, a detailed study was made in regards to other velds made by The Halvorsen Boiler and Engineering Company. These other velds are limited to certain areas of the Discharge Structure. A summary of the fabrication of the Discharge Structure is as follows: -

1. The Discharge Structure consists of three (3) components:

a. The Discharge. Nozzle

b. The Outer Shell

c. Associated Connections (Interior Bracing)

2. The Discharge Nozzle including the six (6) foot diameter discharge shaf t was fabricated by others than The Halvorsen Boiler and Engineering Company.

3. The outer shell and associated connections were fabricated by The Halvorsen Boiler and Engineering Compan'y. The latter consists of non-safety related material which is attached to the outer shell, and was for the purpose of assisting in installing the Discharge Structure in the lake. The outer shell is attached to the Discharge Structure via this interior bracing.

Since the issuance of the Interim Report, Engineering has re-analyzed this structure to determine the requirement for the outer shell as a load carrying member.

. 4. In addition to the above, there is a cover plate with an assortment of valves bolted to the discharge nozzle. This cover plate is non-safety related, and is used to seal the Discharge Tunnel from the intrusion of water.

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FINAL REPORT ON SIGNIFICA!C DEFICIENCY PAGE 3 ANALYSIS CF SAFETY IMPLICATIONS As stated in the Interim Report, "The safety implications of the effects of the Quality Assurance Program breakdown will be identical to the safety implications of the hardware deficiencies."

A. INTAKE STRUCTURES ,

The results of the analysis of the two (2) Intake Structures have revealed them to be unsuitable for licensing. As a result of this decision, the two (2) Intake Structures fabricated by The Halvorsen Boiler and Engineering Company have been dispositioned scrap, 'and two (2) additional Intake Structures are to be fabricated by Chicago Bridge and Iron Company.

B. DISCHARGE STRUCTURE .

Since the submittal of the Interim Report, Engineering has re-analyzed the Discharge Structure to determine the requirement for the outer shell as a. load carrying member. These evaluations have shown that the outer shell was required only as a form for the concrete and is not required as a load carrying member. This permits the declassification of all steel parts of the structure except the nozzle itself and the six (6) foot diameter discharge shaft.

Engineering's opinion is that the quality of welds attaching brackets (supporting internal braces) to the nozzle and that attach the nozzle to the outer liner have no affect on the ability of the structure to perform its intended function. No credit is taken for the strength of these velds.

Therefore, the questions concerning the S & M's QA Program do not affect- the acceptability of the Discharge Structure.

CORRECTIVE ACTION TAKEN In order that the significant conditions adverse to quality as detailed herein do not re-occur, the following corrective actions have been taken:

1. The two (2) Intake Structures fabricated by The Halvorsen Boiler and Engineering Company have had the numerous defects defined on nonconformance reports with the disposition being

" scrap".

2. Two program audits have been performed on S & M Constructors, Inc., resulting in S & M Constructors, Inc. revising their Quality Assurance Manual. .

Chicago Bridge and Iron Company has been awarded a contract to 3.

f abricate two (2) additional Intake Structures.

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FINAL REPORT ON SIGNIFICANT DEFICIENCY PAGE 4 CORRECTIVE ACTION TAKEN (CONT'D.)

4. Chicago Bridge and Iron Company will fabricate these two (2)

Intake Structures in accordance with the applicable requirements of SP-29-4549-00, Rev. 3, (i.e. , Engineering Change Notice 2940 <

29-61) and utilizing the Chicago Bridge and Iron Company Quality Assurance program.

5. The licensee, jointly with S & K Constructors, Inc., will review the Chicago Bridge and Iron Company Quality Assurance program, including applicable procedures. Approval of these documents from the licensee will be required prior to the start of fabrication.

6. The licensee shall have a representative from the Construction Quality Control Element closely monitoring the initial fabri-

• cation by Chicago Bridge and Iron Company. This activity will continue until a satisfactory level of confidence has been established.

7. Periodic audits and/or surveillances will be performed on Chicago Bridge and Iron Company during various stages of fabrication.

These audits and/or surveillances will be performed by S & M Constructors, Inc. Quality Assurance Element personnel, together with representatives from the licensee's Construction Quality Engineering Element.

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