ML19294B583
| ML19294B583 | |
| Person / Time | |
|---|---|
| Site: | Marble Hill |
| Issue date: | 01/14/1980 |
| From: | Harrison J, Williams C NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML19294B572 | List: |
| References | |
| 50-546-79-25, 50-547-79-25, NUDOCS 8003050106 | |
| Download: ML19294B583 (6) | |
See also: IR 05000546/1979025
Text
'
U. S. NUCLEAR REGULATORY COMMISSION
OFFICE OF INSPECTION AND ENFORCEMENT
REGION III
Report Nos. 50-546/79-25; 50-547/79-25
Docket Nos. 50-546; 50-547
License No. CPPR-170; CPPR-171
Licensee: Public Service of Indiana
1000 East Main Street
Plainfield, IN 46168
Facility Name: Marble Hill Generating Station, Units 1 and 2
Inspection At: Marble hill Site
Inspection Conducted: November 14-16 and 20, 1979
Inspector:
J. J. Harrison
'
//[h[hO
/
/
Approved by:
C. C. Williams, Chief
/ / //.,(/ 9 C
'
Projects Section 2
/
'/
Inspection Summary
Inspection on November 14-16 and 20, 1979 (Report Nos. 50-546/79-25,
50-547/79-25.
Areas Inspected: Routine, unannounced inspection of the Auxillary Building,
Unit 1 and 2 containments, storage areas and miscellaneous areas to verify
that activities in progress complied with the stop work order issued August 7,
1979 and the adequacy of storage and maintenance of material (Units 1 and 2).
This inspection involved a total of 28 inspector hours on site by one inspec-
tor.
Results: Of the areas inspected one apparent item of noncompliance was
identified in one area (inf raction - failure to provide proper storage and
maintenance of material - Paragrapb 2).
f
B003050 \\ 00
.
DETAILS
Principal Persons Contacted
Public Service of Indiana (PSI)
- L.
Crews, Vice President Construction
- G.
Brown, Project Director (MAC)
- J. Brewer, Construction Manager (MAC)
B. Turner, Quality Assurance Manager (MAC)
E. Shows, Consultant (MAC)
- D. Ashley, Project Engineering Manager (MAC)
- T. Burns, Project Engineering Manager
B. Roger, Area Engineer Reactor Building, Civil
- R. Ubaudi, Project Controls Manager (MAC)
M. Morris, Project Controls Manager
T. Mclarty, Construction Inspection Supervisor
L. Shuter, Quality Engineer, Civil
-
G. Weston, Superintendent Mechanical Quality Engineer
R. Hand, Superintendent Electrical Quality Engineer (MAC)
J. Frost, Area Manager, Auxiliary Building (MAC)
J. Roberts, Superintendent Inspection
- Denotes those present at the exit meeting.
- (MAC) Management Analysis Company.
Authorized Nuclear Inspector
B. Rice, Hartford Steam Boiler (ANI-PSI)
Functional or Program Areas Inspected
1.
Construction Activities
Surveillance of construction activities indicated that work in all
Category I areas, i.e. , safety-related work, remains terminated, in
accordance with confirmatory order dated August 15, 1979, except for
material receiving, storage, and maintenance.
No items of noncompliance or deviations were identified.
2.
Storage and Maintenance of Material
The inspector observed the storage and maintenance of materials in lay-
down areas, warehouses, and in interim storage (installation process) in
the auxiliary and fuel handling buildings for compliance to the require-
ments of ANSI N45.2.2 - Packaging, Shipping, Receiving, Storage and Hand-
ling of Items for Nuclear Power Plants, the Nuclear Steam System Supplier -
Westinghouse and Public Service of Indiana's Management Manual for Con-
struction Procedures, specifically CMP 4.2.
The following observa'tions
were made.
-2-
.
a.
Storage Nonconformances:
-
(1) Neutron detector positioning device assembly stored outdoors
(Level D) in lieu of indoors (Level C) as required by
Westinghouse. This item had been improperly stored (outdoors)
for the past eighteen (18) months.
(2) Motor operated main steam isolation valves were stored outdoors
(Level D) in lieu of the required indoors (Level B).
These
valves have been incorrectly stored for the past ten (10)
months, although accept tags indicated Level B storage.
Ship-
ping containers were noted to be wet internally.
(3) Motor operated reactor coolant loop stop valves were stored
outdoors (Level D) in lieu of the required indoors (Level B).
These valves were received May 1978, Unit I and May 1979, Unit
2.
The Unit 2 shipping containers were noted to be wet in-
ternally. The attached accept tags indicated storage Level C
and the attached maintenance records indicated storage Level B.
These motor operated valves have been improperly stored for
eighteen months for Unit I and six months for Unit 2.
(4)
Instruments were improperly stored in a warehouse (Cherne-
Westinghouse), and not protected from damage.
Shipping
cartons for Masoneilan Instrument ILC-HD 241 to operate valve
1HD-054B and seventeen others were partially crushed / collapsed
and stacked in a haphazard manner. Visible damage, if any,
could not be determined.
(5) Residual heat removal cooler, 24A025A Elevation 346' fuel
handling building was observed to have a constant stream of
water several inches in diameter running directly onto the
unit. The unit although covered by a plastic tarp was wet
under the tarp.
(6) The protective end caps on the reactor coolant piping were
noted to be carbon steel and were rusty. The Westinghouse
equipment manual required these caps to be "non-ferrous
chloride free caps."
This piping was also noted not to be
covered by "a watertight covering," also a Westinghouse
requirement.
(7) The eight (8) reactor coolant pump casings are required to be
stored in a Level D area and are so stored. However, the
Westinghouse equipment manual states..." protected from the
elements..."; these pump casings were currently stored with
no protective covering.
(8) The reactor coolant piping (stainless steel) was also noted
to have carbon steel banding materials attached and due to
the protective cardboard that has deteriorated is causing
rust discoloration and possible corrosion transfer on the
-3-
.
'
stainless surface. The Westinghouse equipment manual states
..." stainless steel material must not be in contact with carbon
steel."
(9) Two boxes of "0" rings (10 sets) for the reactor vessel to
reacte- head seals were currently stored outdoors, Level D.
Th. '
0" rings are required by ANSI N45.2.2 to be Level B
storage. The storage boxes are currently wet and although
covered by a plastic tarp are not properly protected.
(10) The Westinghouse equipment manual requires that tanks, filters,
demineralizers, and auxiliary heat exchangers that are to
be stored in Level D areas to be:..."under a flame-resistant,
weatherproof covering.
Covering is to be placed to provide
drainage and permit air circulation to minimize condensation.
No wrap or covering is to be placed directly on equipment...".
Contrary to the above, a total of fourteen demineralizers (e.g.
thermal regeratioregeneration and spent fuel pit), eight
auxiliary heat exchangers (e.g. residual heat removal and
chemical volume contrul', and twelve tanks.
For example:
The Boron injection tanx, Boron injection surge tank and
the volume control tanks were noted to be stored in Laydown
area No. 26 with no covering. Some of those components have
been on site since 1978.
(11) The reactor coolant system supports were stored outdoors, Level
D, as required; however, the waterproof covering required by
the Westinghouse equipment manual was not being utilized.
b.
Maintenance Monconformances
(1) The neutron detector positioning device assembly required by
the Westinghouse equipment manual to have various types of
maintenance performed at receipt and annually thereaf ter.
Although this assembly has been on site since June 1978
no maintenance had been performed.
(2) The purge pressure on the steam generators and pressurizer
has not been maintained within tae recommended 3-5 psi range
requireu by Westinghouse. Readings were noted by the inspector
to be as low as 1/2 psi and as high as 11 psi. Westinghouse
further recommends..."that gas (nitrogen) cylinders remain
connected and open, thus enabling a continuous purge in the
event of a seal leak."
Purge seal leakage is evident through
review of maintenance records for some of these components.
It
is further required that the dew point be measured (In - 60 F
and Out - 20 F) and oxygen measured (In - less than 100 ppm
and Out - less than 500 ppm); these measurements were not being
taken.
(3) The protective coatings on the four steam generators, (Unit 1),
two reactor vessels, (Units 1 and 2), and one pressurizer
-4-
.
(Unit 1) were damaged during shipment and handling. The
unprotected areas were noted to be rusting ar.d were brought
to the attention of the licensee on numerous occasions but
no timely action was taken.
(4) The desiccator plughumidity indicator reading for the reactor
vessel exceeds 80 percent for Unit 1 and 50 percent for Unit 2.
The Westinghouse equipment manual requires (a) these readings
be checked and recorded in a monthly log and (b) if the readings
exceed 50 percent regenerate or replace the desiccant, neither
of the foregoing requirements had been met.
These conditions
had existed for the last three months.
(5) Although the motor heaters on various equipment (components)
were noted to be energized during this inspection, conditions
existed that defeated the heater purpose, to eliminate damaging
moisture. Examples of these conditions were:
(a) Reactor coolant loop stop valves and main steam isolation
valves being stored outdoors: the shipping crates were
wet internally, thus creating a damp environment.
(b) The eight residual heat removal coolers located in the
fuel handling building (elevation 346' are stored above
several inches of water with the protective coverings
draped to water. Again, a damp / wet environment.
(6) The maintenance records (on the equipment) for the nitrogen
purge on the Let-down heat exchangers for Units 1 and 2
indicated that the purge reading had not been verified as
required (weekly) as follows:
(a) The Unit 1 purge had not been verified during the last
three weeks.
(b) The Unit 2 !arge had not been verified since the heat
exchanger was received on site in June, 1978.
(7) The protective caps and seals on various tanks were missing
or not properly installed, examples:
(a) Reactor coolant drain tank, nozzle protective caps not
sealed.
(b) Volume control tank, protective cap missing and other
protective caps not sealed.
(8) The nuts, bolts and studs of the three residual heat removal
heat exchangers, the two chemical chemical and volume control
heat exc'tangers, and the volume control tank were noted to be
rusty aoJ not protected. The Westinghouse equipment manual
requir<a application of a lubricant or paint to protect
-5-
.
'
and to prevent rusting should outdoor (Level D) storage be
utilized; these components were stored in a Level D area.
It is apparent from the observations made and the numerous examples
listed that the material control program lacks sufficient control to
adequately prevent damage or deterioration. Also, it is evident that
adequate planning was not accomplished in providing correct levels of
storage and sufficient space to house the material in those areas; lack
of this control was identified by the NRC in 1978.
It is further evident
that a maintenance program has not been carried out to afford the pro-
tection required.
Based on these issues, it is concluded that PSI has
not satisfactorily implemented this part of its quality assurance pro-
gram. This is contrary to 10 CFR 50, Appendix B, Criterion XIII.
(546/79-25-01 and 547/79-25-01).
Exit Interview
The inspector met with those persons deliniated in the " Persons Contacted"
Paragraph of this report at the conclusion of the inspection. The inspec-
tor summarized the scope and findings of the inspection.
-6-