ML19310A730
| ML19310A730 | |
| Person / Time | |
|---|---|
| Site: | Clinton  |
| Issue date: | 05/13/1980 |
| From: | Knop R, Livermore H NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML19310A716 | List: |
| References | |
| 50-461-80-08, 50-461-80-8, NUDOCS 8006230061 | |
| Download: ML19310A730 (8) | |
See also: IR 05000461/1980008
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U.S. NUCLEAR REGULATORY COMMISSION
OFFICE OF INSPECTION AND ENFORCEMENT
REGION III
Report No. 50-461/80-08
Docket No. 50-461
License No. CPPR-137
Licensee:
Illinois Power Company
500 South 27th Street
Decatur, IL 62525
Facility Name: Clinton Power Station, Unit 1
Inspection At: Clinton Site, Clinton, IL
Inspection Conducted: April 14-30, 1980
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Inspector:
H. H. Live ore
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Approved By:
R. C. Knop, Chief
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Projects Section 1
Inspection Summary
Inspection on April 14-30, 1980 (Report No. 50-461/80-08)
Areas Inspected: Routine inspection by the IE Regional Resident Inspector
(SRI) of safety related construction activities including concrete place-
ment; material laydown and storage areas; and HVAC activities of the sub-
contractor Zack Co.
This inspection involved 96 inspector-hours by one
NRC inspector.
Results: Of the areas inspected, two items of noncompliance were identi-
fied: (1) inadequate control of welding processes; (2) inadequate control
of nonconforming material.
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DETAILS
Persons Contacted
Principal Licensee Employees
- J. O. McHood, Vice President
- G. M. Brashear, Site Manager, Clinten
R. J. Canfield, Director-Construction
A. J.-Budnick, Director-QA
'*E. E. Connon, Assistant Director-Construction
L. W. Dozier, Assistant Director-Construction
D. E. Korneman, Supervisor-Construction
- J. F. 'Hampton, Supervisor-QA
- R. W. Folck, QA Specialist
- J. S. Spencer, Director-DES Engineering
R. Backen, QA Specialist
R. Weber, QA Engineer
R. Becker, QA Consultant
Baldwin Associates
J. R. Holding, QA Manager
R. Selva, Manager Quality and Technical Services
- J. Linehan, QC M;aager
W. H. Harrington, Project Manager
J. E. Findley, Project Engineer
M. Merritt, Quality Control
T. F. Walker, Senior Quality Control
- R. D. Bennett, Manager, Technical Services
R. Merritt, Quality Control
General Electric Company
S.
G.~ Hall, Q- .ity Control
Zack Company
D. Burn, Project Manager
C. Nichols, Site Superintendent
- M. Franchuk, Jr. , QC Supervisor
V. Pemberton, General Foreman
F. Barnes,-Foreman
J. Nuehoff, General Foreman
Other staff and personnel were contacted during the reporting period.
- Deno,tes those attending at least one of the exit meetings.
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Functional or Program Areas Inspected
1.
Plant Tours
One or more plant areas were toured several times ach week during
the reporting period to observe general construction practices, area
cleanliness, and storage / maintenance of material and equipment.
Items of noncompliance are discussed in paragraphs 4 and 5.
2.
Concrete Placement
The inspector performed a surveillance of the concrete placement of
the fuel loading 755' level floor. The following conditions were
noted:
(1) The forms were secure and leak tight prior to the placement.
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(2) The preplacement inspection had been completed and was in order.
(3) _ Quality Control inspectors were assigned to perform periodic
concrete testing. Numbers were adequate.
(4) Concrete testing was performed at the required frequencies.
(5) Adequato numbers of crews and personnel were assigned to make
the placement.
(6) Surrounding equipment was protected from any concrete spill
during placement.
(7) Delivery and placement was satisfactory.
Concrete was pumped
to the placement area and deposited via a flexible boot which
adequately confined the concrete to a minimum fall to prevent
segregation.
(8) Concrete was observed to be properly consolidated using internal
-concrete vibrators. The vibrators were randomly checked while
operating in the concrete. The inspector checked that the test
meter was in calibration. Vibrator technique was satisfactory
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with one exception. One operator's technique was observed to be
rather lackadaisical:
inattention, not vertical when possible,
and below minimum time in one spot.
Immediate action was taken
to corrt,st the situation. Further surveillance indicated this
to be an isolated singular case.
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No items of noncompliance or deviations were identified.
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3.
Inspection of Material / Component Laydown Areas
- The resident inspector performed a surveillance of pipe, electrical,
cand rebar laydown outside storage areas. The. areas were randomly
selected. The' inspection was in relation to the requirements of
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ANSI N45.2.2: material protected and stored off the ground, caps
on pipe ends, and segregation of safety and non-safety material.
_In general, considering the massive amount of material, storage
and maintenance was adequate. The inspector noted that storage
looked excellent as one drove up and down the access roads, but a
different picture as.one walked within the confines of each area.
The inspector noted some random examples of pipe end caps missing
or damaged; one example of safety 'and non-safety rebar material
mixed together;.and some safety related. cable trays on the ground
in the electrical laydown area. The licensee was shown these ex-
amples and. initiated prompt corrective action to insure the situa-
, tion does not degenerate. The inspector will make these areas the
subject of a followup inspection.
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No items of noncompliance or deviations were identified.
4.
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HVAC Welding Activities
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The inspector performed a surveillance of the Zack Co. welding ac-
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Ltivity on the 800' level of the Control Building. Weld rod storage
and use was adequate. Weld method was SMAW of HVAC hangers, gussets,
and imbeds. The inspector questioned five working welders in regard
to their applicable weld procedure. Four of the five could not
identify the procedure by number or title, did not know where their
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procedure was located, and were not aware of its basic contents.
The inspector notes that there was only one procedure involved
(Zack QCP 24), and that it was also noted on the weld rod tickets.
This item is considerd in noncompliance with the requirements of
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Criterion XI of 10 CFR 50, Appendix B. (461/80-08-01)
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5.
HVAC Nonconforming Material Control
During a tour of the Zack HVAC safety related material laydown
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area, the~ inspector noted duct piece 5 of load 58 (with reject
tag 46) located with acceptable parts. This item was supposed to
have been moved to the Zack hold / reject enclosure some eleven days
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prior. _The inspector also noted safety related duct piece 122 lay-
.ing in the dirt behind the Zack trailer. There was no status tag
or' paper attached to the part.
Investigation of records revealed
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it was:a rejected part and should have been in the hold / reject en-
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closure for return to Chicago plant. The inspector found the safety
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related hold / reject area' in disarray, the enclosure dismantled - on
'the' ground,'and unauthorized scrap plates within its bounds. A re-
view of the records control system found that location of nonconform-
ing material has not been recorded. QCP 8' paragraph 6.3 requires
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storage location on nonconformar.ce reports (NCR). The Zack rejec-
tion tag system only records the final intended location of the part.
In review, control of nonconforming material has not been demon-
strated adequately. This is an item of noncompliance with 10 CFR 50,
Appendix.B, Criterion XV.
(461/80-08-02)
6.
Traceability of HVAC Welding Electrodes
The resident inspector performed a traceability check of welding
electrode used for safety related HVAC installation. Atom Arc 1/8"
7018 electrode, heat #421 and 9781, was chosen as it was in use and
also stored in the warming oven. The heat number was traceable to
the Certification number and to the Purchase Order number.
The Certification of Analysis produced by QC included the required
yield, tensile, chemical, and Charpy information. The certification
was notarized, reviewed by QA, and appeared complete with the excep-
tion of listing the title and date of the person signing the docu-
ment. This information is required by Zack QCP procedure 6 paragraph
4.2.1c.
The inspector was not able to completely trace the material
to the Purchase Order #C4086.
The present practice is that the
Chicago office performs this comparison function and retains the
Purchase Order. Zack ACP6 paragraph 4.2.1 states in part that the
site QC shall insure material received complies with the purchase
order. The inspector stated that this matter is considered unre-
solved pending a review of present practice and control.
(461/80-08-03)
No items of noncompliance or deviations were identified.
7.
Lifting and Rigging Program Control
The resident inspector reviewed the inspection program forms and
procedures that insure lifting and rigging of safety related HVAC
items are in conformance to requirements of ANSI N45.2.2, paragraphs
7.3'and 7.4.
Records and forms appeared to be in order with one
exception. The inspection. check sheet (QCP 14) noted only that the
inspection of slings and straps was acceptable or not acceptable.
No notation is made of any of the parameters required Ly ANSI
N45.2.2Property "ANSI code" (as page type) with input value "ANSI</br></br>N45.2.2" contains invalid characters or is incomplete and therefore can cause unexpected results during a query or annotation process. such as: wear, cleanliness, contaminants, and maximum in-
dicated load. The Zack QC Supervisor noted that individual slings
were not identified, but that complete inspection was possible due
to the small number of Zack slings and straps on site. The afore-
mentioned concerns were stated by the resident inspector and will
be explored in a future inspection.
No items of noncompliance or deviations were identified.
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Unresolved Matters
- Unresolved matters are items about which more infonmation 'is required in
order.to ascertain whether they are acceptable items, items of noncom-
pliance, or deviations. Unresolved items disclosed during the inspection
are discussed in paragraph 6.
Exit Meetings
The resident inspector attended exit meetings conducted by the RIII QA
Audit Team on April 18, 1980, and by Mr. E. Lee, RIII on April 24, 1980.
-The inspector met with the licensee representatives (denoted under Persons
Contacted) on April 25, and May 1, 1980. The inspector summarized the
scope and findings of the inspections performed. The licensee representa-
tives acknowledged the findings reported in previous paragraphs.
Attachments:
Preliminary
Inspection Findings
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0FFICE OF INSPECTION AND ENFORCEMENT
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PRELIMINARY INSPECTION FINDINGS
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LICENSEE
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REGIONAL OFFICE
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3.
DOCKET NUMBERS
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LICENSE NUMBERS
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DATE OF INSPECTION
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6.
Within the scope of the inspection, no items of noncompliance or deviation
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7.
The following matters are preliminary inspection findings:
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8.
These preliminary inspection indings will be reviewed by NRC Supervision /
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Management at the Region III Office and they will correspond with you
concerning any enforcement action.
Nuclear Regulatory Commission Inspector
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PRELIMINARY INSPECTION FINDINGS
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LICENSEE
2.
REGIONAL OFFICE
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DOCKET NUMBERS
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LICENSE NUMBERS
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DATE OF INSPECTION
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Within the scope of the inspection, no items of noncompliance or deviation
were found.
7.
The following matters are preliminary inspection findings:
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These preliminary inspection findings will be reviewed by NRC Supervision /
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Management at the Region III Office and they will correspond ith you
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concerning any enforcement action.
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SDbdAl[N Y
suelear Regulatory Commission Inspector