ML20037D465
| ML20037D465 | |
| Person / Time | |
|---|---|
| Site: | Hope Creek  |
| Issue date: | 06/15/1981 |
| From: | Martin J, Schneider F Public Service Enterprise Group |
| To: | Grier B NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| Shared Package | |
| ML20037D463 | List: |
| References | |
| NUDOCS 8107100266 | |
| Download: ML20037D465 (6) | |
Text
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Thomas J. Ma, tin Public Service Electric and Gas Company 80 Park Plaza Newark, N.J. 07101 201/4304316 Vice President Eng;neering and Construction June 15, 1981 Mr. Boyce H.
Grier, Director U. S.
Nuclear Regulatory Commission Office of Inspection and Enforcement Region I 631 Park Avenue King of Prussia, Pennsylvania 19406
Dear Mr. Grier:
NRC INSPECTION REPORT 50-354/81-05 AND 50-355/81-05 NO. 1 AND 2 UNITS HOPE CREEK GEN 2 RATING STATION We have reviewed your report of the inspection conducted on April 6 - May 3, 1981, at the Hope Creek Generating StL-tion,.
ihe report, which was received by PSE&G on May 27, 1981, requires a response within 25 days of May 21, 1981, which is the date of the Notice of Violation.
10CFR50, Appendix B, Criterion VII states, in part, that:
" Measures shall be established to assure that purchased material... conform to the procurement documents...
The ef-fectiveness of the control of quality by contractors and subcontractors shall be assessed by the applicant or de-signee at intervals consistent with importance...and quan-tity of the product or services."
Section 16.4.7 of Chapter 16 of the PSAR states, in part, that: " supplier evaluations... assure that the supplier has the ability to comply with those requirements of 10CFR50, Appendix B, that are applica.ble to the type of material...
heing procured."
Additionally, it is stated in this section that:
"Bechtel shop inspectors are... responsible...for as-suring that work is complete...
When, during the course of surveillance inspection, the inspector discovers any noncon-formance to the procure.nent documents in the supplier's per-formance of the work, he shall notify the supplier...before proceeding with further work or release for shipment..."
Paragraph 9.1 of the Technical Specification for Purchase of Miscellaneous Metal for Category I Structures which is the applicable purcnase document states, in part, that:
"The extent and method of NDE shall be 100% visual examina-tion...in accordance with Articles 6.7 and 8.15 of AWS Dl.l."
8107100266 810630 PDR ADOCK 05000354 0
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Mr. Boyce H.
Grier 6/15/81 Contrary to the above, as of April 17, 1981, safety-related embeds supplied by ACME Steel Engineering Co.,
Inc., were in use on the Hope Creek Project with an excessive amount of the welding not in accordance with procurement document requirements.
Corrective Steps Taken and Results Achieved On April 3, 1981, Bechtel identified and documented on NCR 1086 weld deficiences in ACME Steel supplied embeds.
The l
weld deficiencies were detected during Bechtel modification I
i of the embeds.
A.
Inves tigation Bechtel conducted a visual inspection of 270 similar ACME 5 teel embeds.
The results of the inspection re-vealed that 127 embeds did not meet AWS visual accept-ance criteria.
The inspection revealed excessive poros-ity, c:tcessive undercut, and undersize welds.
A sample of the visually inspected embeds were then ex-amined for subsurf ace porosity.
o Fifteen (15) embeds which passed visual inspection were RT examined.
o Ten (10) embeds which failed visual inspection were RT examined.
o Three (3) embede which failed visual inspection with air-arc gouged in layers 1/8" thick.
Results of this examination revealed welds with unac-ceptable subsurface poro..ity in each case.
The defi-cient weld problem on ACME supplied embeds was then ver-bally reported to the NRC as a potential significant de-ficiency on April 22, 1981, in accordance with 10CFR50.55(e).
B.
Embed Installations 1.
ACME Embeds:
All ACME embeds having shear bars, anchor lugs, anchor plates, and combinations thereof, shall be RT examined.
Welds not meeting RT examination accept-ance criteria shall be repaired.
Alternatively, em-beds may be replaced with conforming embeds.
A con-forming embed is defined as a non-ACME embed that has passed visual examination.
Mr. Boyce H.
Grier 6/15/81 2.
Non-ACME Embeds:
All non-ACME embeds having shear bars, anchor lugs, anchor plates and combinations, thereof, shall be visually inspected on a sample basis such that each affected release from each supplier is properly rep-resented.
If there is an insuf ficient sample.'ize of any release available, all accessible embeds from that release will be inspected.
3.
Sample and Test Program:
A sample and test program has been developed to evaluate the effect of porosity on embed weld strength.
A sample of embeds showing excessive porosity has been tested by Lehigh University for ultimate pullout and shear capacity.
The results of the testing are being evaluated for correlation with a report to follow.
Pcrtions of these tests were witnessed by an NRC Inspector from Region I, (50-354/81-07).
4.
Supplier Surveillance:
Bechtel's Procurement Supplier Quality Department conducted an iatensive investigation at the jobsite of the hardware deficiencies and also into the sup-plier quality representative activities during the life of the ACME quality surveillance assignment.
The results or this investigation show that the Bechtel supplier quality area supervisor was demoted farino this assignment.
The supplier quality repre-sentativc has been formally reprimanded as a result of this investigation.
Corrective Steps Which Will Be Taken To Avoid Further Violations A.
ACME Steel There are no active or6ers with ACME S' eel on the Hope Creek Project, and no future orders for safety related embeds will be placed with ACME.
B.
Procurement Supplier Quality Department Instructions have been issued to the present supplier quality area supervisor to monitor closely for the next 60 days the work of the supplier quality representative A
Mr. Boyce H.
Grier 6/15/81 who was respotsible for the quality surveillance at ACME.
At the end of this period, an evaluation of his performance will be prepared by the area supervisor and submitted to supplier quality management.
An instruction will be issued by Bechtel's Supplier Quality Department defining the importance of rigorous inspection of miscellaneous metals.
This is a result of an apparent perception by field supplier quality repre-sentatives that miscellaneous metals are less critical than complicated types of fabricated steel.
Technique sheets on fit up and welding inspection are in process of being prepared for use by supplier quality representatives.
The technique sheets give detailed in-structions on the inspection criteria to be followed.
Bechtel's Hope Creek management is in the process of formulating plans with the supplier quality department i
to assign four (4) project dedicated supplier quality 1
representatives in the field.
These four (4) people will assist the assigned supplier quality representa-tives in problem suppliers' facilities.
Date When Full Compliance Will Be Achieved A.
A report addressing the results of the sample and test program and the effects of the weld deficiences on ACME l
Steel supplied embeds is scheduled for June 26, 1981, completion.
This information will subsequently be sub-j mitted to the NRC as indicated in our letter to the NRC dated May 26, 1981, under 10CFR 50.55(e) requirements.
B.
Bechtel's Procurement Supplier Department has scheduled July 31, 1981, for completion of their actions.
Should you desire any additional information, we will be pleased to discuss it with you.
Very truly yours, t
gn-i I
I
Mr. Boyce H.
Grier 6/13/81 CC:
Office of Inspection and Enforcement Division of Reactor Construction and Inspection Washington, D.C.
H.
E.
Morris Bechtel Power Corporation NRC Resident Inspector Hope Creek Site HP1 1/5 J
STATE OF NEW JERSEY)
)
SS:
COUNTY OF ESSEX
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FREDERICK W.
SCHNEIDER, being duly sworn according to law deposes and F.nys :
I am a Vice President of Public Service Electric and Gas Company, and as such, I find the matters set forth in our letter dated June 15, 1981, concerning combined NRC Inspection Report 50-354/81-05 and 50-355/81-05 are true to the best of my knowledge, information, and belief.
- _1L' U
__ 4 FREDERICK W.
SCHNEIDER Subscribed and sworn to before me this /6 day of 1981 U
1 Notary Public of New Jersey My Commission expires on I
MI8 i
L J