ML20206D914
| ML20206D914 | |
| Person / Time | |
|---|---|
| Issue date: | 04/01/1987 |
| From: | Baker E, Conway J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE) |
| To: | |
| Shared Package | |
| ML20206D872 | List: |
| References | |
| REF-QA-99901085 99901085-87-01, 99901085-87-1, NUDOCS 8704130459 | |
| Download: ML20206D914 (11) | |
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ORGANIZATION: UNITED STATES TESTING COMPANY HOB 0 KEN, NEW JERSEY REPORT INSPECTION INSPECTION NO.: 99901085/87-01 DATES: 03/09-11/87 ON-SITE HOURS: 18 CORRESPONDENCE ADDRESS: United States Testing Company Unitech Services Group ATTN: Mr. Gene Basile President 0 1415 Park Avenue Hoboken, New Jersey 07030 ORGANIZATIONAL CONTACT: William Coles, CA Manager TELEPHONE NUMBER: (201) 792-2400 NUCLEAR INDUSTRY ACTIVITY: Testing of subsurface soils and construction materials, nondestructive examination (NDE), welder qualifications, QC inspection support, and vendor surveillance / source inspection.
ASSIGNED INSPECTOR: 6\% Mie ~!~N J. T. Conway, Reacti e Inspection Section (RIS) Date
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OTHER INSPECTORS: T. Tinkle, Consultant APPROVED BY: / /M bV E. T. Baker, Acting Chief, RIS, Vender Program Branch Da'te 7
INSPECTION BASES AND SCOPE:
A. BASES: 10 CFR Part 50, Appendix B and 10 CFR Part 21.
B. SCOPE: The purpose of this inspection was to conduct a programmatic evaluation of the implementation of the 0A program in the areas of reporting of defects and nondestructive examination (NDE).
PLANT SITE APPLICABILITY: NDE - St. Lucie 1 & 2 (50-335/389), Turkey Point 3 & 4 (50-250/251), Clinton (50-461), J. A. Fitzpatrick (50-333), Indian Point 2 (50-247), Rancho Seco (50-312) (continued on next page) 870413o459 87040s PDR GA999 EECUSTES 99901085 PDR
ORGANIZATION: UNITED STATES TESTING COMPANY H0BOKEN, NEW JERSEY REPORT INSPECTION wn . anoninAR/A7 01 1 RESULTS: PAGE 2 of 11 PLANT SITE APPLICABILITY: (continued) Susquehanna 1 & 2 (50-387/388), Surry 1 & 2 (50-280/281), North Anna 1 & 2 (50-338/339), Arkansas Nuclear One 1 & 2 (50-313/368), Limerick 1 & 2 (50-352/353), Watts Bar 1 & 2 (50-390/
391), Diablo Canyon 1 & 2 (50-275/323), Dresden 3 (50-249), Waterford 3 (50-382), Wolf Creek (50-482), San Onofre 1, 2, & 3 (50-206/361/362), Palo Verde 1, 2, & 3 (50-528/529/530), Grand Gulf 1 (50-416), Pilgrim (50-293),
Crystal River 3 (50-302), Trojan (50-344), and Point Beach 1 & 2 (50-766/301).
A. VIOLATIONS:
None.
B. NONCONFORMANCES:
- 1. Contrary to Criterion V of Appendix B to 10 CFR Part 50, Section 6.5.3 of Unitech Services Group (USG) Procedure No. 2.3.1, and Section 8.4.1 of SNT-TC-1A, it was noted that examinations were not administered by a Level III examiner or a designated representative for the following NDE examiners: Nos. 818 (July 1985), G. Tope (February 1987), 767 (August 1985),
R. Jones (September 1986), 38 (March 1986), and 40 (March 1986). (87-01-01)
- 2. Contrary to Criterion V of Appendix B to 10 CFR Part 50, Sections 6.7.1 and 6.7.2 of USG Procedure No. 2.3.1 and Section 9.6.1 of SNT-TC-1A, it was noted that eye examinations for 1986 were missing from the qualificaticn records for Level 11 examiners J. Bemis and G. Tope. (87-01-02)
C. UNRESOLVED ITEMS:
None.
D. STATUS OF PREVIOUS INSPECTION FINDINGS:
None. This was the first NRC inspection at this facility.
E. OTHER FINDINGS AND COMMENTS:
- 1. United States Testing Company (USTC)
USTC is an independant laboratory that provides services and products in the field of testing, inspection, research, engineering, product development, and scientific instruments. The Power
1 ORGANIZATION: UNITED STATES TESTING COMPANY H0B0 KEN, NEW JERSEY REPORT INSPECTION NO.- 999010E5/87-01 RESULTS: PAGE 3 of 11 Generation Service Division (PGSD) was formed in 1971 to handle nuclear customers. In 1983, the Swiss firm Societe Generale de Surveillance (SGS Group) became the parent company of USTC. At this time, PGSD became the Quality Assurance Services Group (0ASG). The SGS Group purchased GE0 Construction Testing (formerly Peabody Testing) from Magnaflux Corporation in 1984, and GE0 became Unitech Testing (UT) in 1985. In 1986, UT and CASG merged to become Unitech Services Group.
- 2. Unitech Services Group (USG)
The organizational structure of the USG is headed up by a President.
A 0A Manager and Group Vice President report to the President.
Activities of the 0A department, headed up by the 0A Manager, include maintenance of records in accordance with program documents; which includes project documents (e.g., QA Plan, audits, procedures, etc.), personnel radiation exposure records, personnel certification records, and training programs.
A QA Administrator, Corporate Level III, and Document Control Clerk report to the OA Manager. The QA Administrator is responsible for certification record processing, grading or verification of test scores, writing procedures, managing the maintenance of the certification and project files, and nonitoring the radiation exposure record keeping. The Corporate level III is responsible for the NDE Certification Program and NDE procedure development.
The Document Control Clerk processes radiation exposure records and maintains the certification log and files.
Activities of the USG for nuclear customers include testing of subsurface soils and construction materials; resident and on-call NDE - magnetic particle (MT), ultrasonic (UT), dye penetrant (PT), visual (VT) and RT, both gamma and x-ray; metallurgical and failure analysis; welder cualifications; OC inspection during retrofits, outages and nuclear refueling; OA and inspection training programs; and vendor surveillance / source inspection.
USG is composed of five Regions, and each Regional Manager reports to the Group Vice President. Branch Managers (nine) also report to the Group Vice President who is located at the corporate offices in Hoboken, New Jersey. The Branch offices which are located in San Leandro, Modesto, Oceanside, and San Diego, California; Colorado Springs, Colorade; Memphis, Tennessee; Chicago, Illinois; and Orlando and Miami, Florida are not invc1ved with activities conducted at nuclear facilities. A Project Manager (PM), who reports to a Regional Manager, is responsible for perforning work
ORGANIZATION: UNITED STATES TESTING COMPANY HOBOKEN, NEW JERSEY REPORT INSPECTION sn . ooon1n95/97 01 RESULTS: PAGE 4 of 11 in accordance with a OA Plan for a particular nuclear facility.
The PM is the senior individual on site and in most cases is a Level III examiner. NDE reports are signed by the PM and/or the Level III and are transmitted to the customer. In the case of RT, all the film is retained by the customer usually at the site.
USG has performed vendor surveillance activities for Northern States Power since 1980 and Arizona Public Service for the past four years. They have a contract with Illinois Power, but no work has been performed to date. For these activities, the lead auditors are qualified to ANSI N45.2.23 " Qualification of Quality Assurance Audit Personnel for Nuclear Power Plants." The QC inspection activities performed at nuclear facilities are undertaken by personnel qualified to ANSI N45.2.6 " Qualifications of Inspection, Examination and Testing Personnel for the Construction Phase of Nuclear Power Plants." Individuals performing NDE are qualified to the Recommended Practice No. SNT-TC-1A of the American Society for Nondestructive Testing. The following list identifies the nuclear licensees and the facilities at which USG performed NDE in the timeframe of 1983 to the present.
Nature Customer Site Date of Service Florida Power & Light St. Lucie 1/2 1973-Present All NDE Turkey Point 1981-1983 All NDE Quad Cities 1/2 1982-1983 RT, UT Commonwealth Edison Dresden 3 1985-1986 All NDE All plants 1982-1984 All NDE Illinois Power Clinton 1976-1986 All NDE New York Power Fitzpatrick 1982-Present RT Authority Indian Point 2 1972-Present PT, MT Consolidated Edison Sacremento Municipal Rancho Seco 1982-Present All NDE Utility District Pennsylvania Power & Susquehanna 1986-Present All NDE Light Virginia Electric Power Surry & North Anna 1984-Present RT
ORGANIZATION: UNITED STATES TESTING COMPANY !
HOBOKEN, NEW JERSEY REPORT INSPECTION Nn . oonninRR/R7-01 RESULTS: PAGE 5 of 11 Nature Customer Site Date of Service Arkansas Power & Light Arkansas Nuclear 1987 All NDE One Philadelphia Electric / Limerick 1972-Present All NDE Bechtel Watts Bar 1986-1987 RT-Film TVA/EG8G Interpretation Pacific Gas & Electric Diablo Canyon 1986-Present RT Louisiana Power & Light Waterford 3 1972-Present All NDE Kansas Gas & Electric Wolf Creek 1983-1986 All NDE San Onofre 1982-1986 RT Southern California Edison Arizona Public Service Palo Verde 1983-Present RT Mississippi Power & Grand Gulf 1983-1986 All NDE Light Boston Edison /Bechtel Pilgrim 1986-Present RT Florida Power Crystal River 3 1986-Present RT Corporation Trojan 1986 UT, MT, PT Portland General Electric Wisconsin Electric Point Beach 1983-1984 MT, PT Power
- 3. Quality Assurance Plan The USG policy for providing on-site support is to develop a QA Program based on requirements that.are tailored specifically for a particular project. The on-site QA Program is developed and issued in a document called a QA Plan. The inspector reviewed the QA Plans which were developed for nine nuclear facilities -
ORGANIZATION: UNITED STATES TESTING COMPANY H0B0 KEN, NEW JERSEY REPORT INSPECTION NO - QQ4n10PE/R7-01 pESULTS- PAGE 6 ef 11 Clinton, Arkansas Nuclear One, Limerick, Diablo Canyon, Dresden 3, Waterford, San Onofre, Palo Verde and Grand Gulf. A typical 0A Plan consists of five sections.Section I describes the organizational structure. The OA and Administrative Procedures are contained in Section II. Five subsections in II address areas such as correspondence / filing systen, procedures (development / changes),
qualification / certification of NDE personnel, document control, and procurement control.Section III contains the Inspection, Exanination, and Test Procedures. These technical procedures, including changes, are reviewed and approved by the customer prior to their use. The OC Procedures are included in Section IV, and they cover activities such as Project Operations Plan; Receipt of Material; Handling, Storage, and Shipping; Inspection; Nonconformances/ Corrective Actions; Calibration of Measuring and Test Equipment; and 0A Records.
- 4. Quality Assurance Program Various portions of the USG QA Program, Revision 1, dated March 4, 1986, were reviewed. The statement of management policy which is signed by the President and Group Vice President indicates that USG provides a variety of OA and OC services which include nondestructive examination, testing of soils, concrete and structures inspection, and testing of electrical and mechanical systems, and other related inspection functions. The 0A Program is organized to comply with the requirements of 10 CFR 50, Appendix B.
The section for internally gererated records states that these records are collected and maintained as required by the client, applicable code, standard, or specification. The QA Plan applicable to a project specifies the documentation requirements for each project. In general, the following are collected and maintained:
test and inspection documentation, personnel cualifications and certifications; and equipment, calibration, and procurement records.
- 5. Administrative Instructions (AI)
AI No. 0AI-100-3 was reviewed. The document which outlines the duties of the QA department personnel had been signed by the current QA Manager who stated the instruction was placed into effect in August 1986. This document identifies responsibilities for maintaining various records such as project documents, personnel
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.. 1 ORGANIZATION: UNITED STATES TESTING COMPANY !
HOBOKEN, NEW JERSEY l
INSPECTION l REPORT '
NO - QQQOlnR9/A7 n1 PFSUITS- PAGF 7 of 11 I
radiation exposure and personnel certification records, personnel certification computcc programs, and training programs. The primary responsibilities of the:OA Administrator, Corporate Level III, Document Control Clerk and Clerical Assistant are also described.
Certification flowcharts for developing, maintaining, and reviewing NDE personnel certification documentation; and developing, reviewing, and approving QA procedures are included.
AI No. UST-AI-501-1 for certification process flow including background verification of examiners, inspectors, and auditors was reviewed. The stated purpose of this document, which was signed by the QA Manager, is to establish a method of providing assurance that personnel cualification and background verification are accurate and complete for meeting the requirements of SNT-TC-1A, ,
ANSI N45.2.6, and ANSI N45.2.23. It requires that only those personnel whose background verifications are accurate and complete and whose certification packages are in compliance with USG qualification and certification procedures will be assigned by the USG as an nondestructive examiner, inspector or auditor. The responsibilities for the Personnel Manager, QA Administrator, and Project Managers are described. It indicates that Project Managers are responsible for: assuring personnel assigned to perform work on their project have a complete Certification Package prior to assigning them to tasks / pro.iect, review and approval of background verifications and Personnel Certification Packages of the personnel assigned, and assuring that records are current and transmitted or maintained for the customer. It also requires that certification packages of the exaniners, inspectors, and auditors shall be maintained with copies being sent to the Project for filing.
- 6. UGS Written Practice for NDE The inspector reviewed Procedure No. 2.3.1, " Qualification and Certification of Nondestructive Examination Personnel," dated October 11, 1985. The procedure establishes minimum requirements for all UGS NDE personnel certified in the folicwing examination methods: RT, MT, UP, PT, ET and LT. The procedure defines the duties and responsibilities of NDE personnel; describes the methods of NDE personnel selection, recruitment, and training; and establishes the requirements and methods of qualification and certification of NDE personnel. It was noted that the President, Group Vice President or Quality Assurance Manager are responsible for directing personnel qualification and certification and designating examiners to
e ORGANIZATION: UNITED STATES TESTING COMPANY H0B0 KEN, NEW JERSEY l
REPORT INSPECTION Nn . qqani nM /87-01 RESULTS: PAGE 8 of 11 administer the certification process. A current listing of certified personnel and a copy of Certification Statements, cover sheets of current examinations, and current vision test for each applicable examiner is retained at the project office. Actual exams and other supportive documents are maintained in the Corporate QA office.
- 7. NDE Qualification Records Qualification records for a number of NDE personnel were selected for review. In general, the type of information found in the record files included: documentation cf verification of experience, certificates of training completed, certification statements, examinations (general, specific, practical), educational background / transcripts, eye exams, and resumes. The records were selected to provide a sample of NDE work performed at 13 nuclear facilities. The level III examiners in the following list were selected to provide a random check on Level III personnel identified during the documentation review.
Project Examiner (No.) Discipline Waterford S. Toomer (705) II - PT, UT Waterford M. Ritchie (818) II - RT, MT, PT/I-UT Waterford D. McCray II - RT, MT, PT Waterford P. Magee (346) II - RT, MT, PT Limerick G. Spencer (112) III - RT, MT, PT Limerick M. McAllister (559) II - RT, MT, PT, UT Limerick C. Rose (719) II - RT, MT, PT, LT Limerick G. Saulter II - RT, MT, PT Limerick M. Hicks II - RT, MT, PT St. Lucie B. Outten II - MT, PT, UT Surry G. Johnson II - RT, MT, PT Surry M. Porter (2159) II - RT, PT
ORGANIZATION: UNITED STATES TESTING COMPANY HOB 0 KEN, NEW JERSEY REPORT INSPECTION Nn . coan1nRR/R7 01 RESULTS: PAGE 9 of 11 Project Examiner (No.) Discipline Surry M. Hosken II - RT, MT, PT Susquehanna D. Leimbach II - RT, MT, PT, UT Susquehanna R. Stearns II - RT, MT, PT Wolf Creek B. Smith II - RT, MT, PT, UT R. Moore II - MT, PT, UT Wolf Creek North Anna / R. Lee II - RT, MT Crystal River 3 Crystal River 3 T. Hall II - RT, MT, PT, UT North Anna G. Cavins II - RT Indian Point 2 R. Henry II - PT Indian Point 2 M. Fitzpatrick II - PT R. Sweet (293) III - RT, MT, PT Dresden 3 Dresden 3 K. Ostergrem (767) II - RT, MT, PT, UT, LT, VT Dresden 3 J. Norton II - RT, MT, PT Dresden 3 W. Penny (514) III - RT, MT, PT, UT Dresden 3/Palo D. Waples (482) II - RT, MT, PT Verde / San Onofre Dresden 3/Surry/ D. Mann II - RT, MT, PT San Onofre Arkansas R. Jones III - RT, MT, PT Arkansas M. Davis (639) II - RT, MT, PT, VT Grand Gulf R. Green (40) II - RT, MT, PT i
Grand Gulf M. Cross (38) II - RT, MT, PT
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D ORGANIZATION: UNITED STATES TESTING COMPANY HOB 0 KEN, NEW JERSEY l REPORT INSPECTION NO - 00001095/87-01 RESULTS- PAGE 10 of 11 Project Examiner (No.) Discipline Diablo Canyon A. Morrill, Jr. (910) II - RT, MT, PT l Diablo Canyon A. Morrill (12) III - RT, MT, PT, UT Diablo Canyon R.Specht(617) II - RT, MT, PT, UT Palo Verde G. Tope II - UT l Palo Verde J. Nash (926) II - MT, PT, UT l
Palo Verde A. White (478) III - RT, MT, PT Palo Verde D. Fightnaster (419) II - PT, VT San Onofre J. Traner (501) II - RT, MT, PT, UT, VT San Onofre J. Bemis II - RT, MT, PT San Onofre R. Mallory III - RT, MT, FT M. Lang3 ton ( 036) II -
Corporate Level J. Grimm III - RT, MT, PT, UT III P., Jacobs (17'i) III - RT, MT, PT, UT G. Lambert (615) III - RT, MT, PT, UT C. Johnson (808) III - RT, MT, PT, UT B. Penley III - RT, MT, PT G. Robertson III - RT, MT, PT, UT J. Dreilbelbis (3240) III - RT, MT, PT, UT J. Farley III - RT, MT, PT, UT It was noted that a number of examinations were administered and/or graded by the following personnel who were not level III examiners nor were they delegated the responsibility to perform this function (See.*bnconformance 87-01-01):
ORGANIZATION: UNITED STATES TESTING COMPANY H0B0 KEN, NEW JERSEY REPORT INSPECTION un . oconsnnginn_n1 pFSULTS- PAGE 11 of 11 M. Cross (No. 38) administered a Level 1 - UT test to M. Ritchie (No. 818) in June 1985.
J. Nash (No. 926) administered a Level II - UT test to G. Tope in February 1987.
> R. Green (No. 40) administered Level II - RT, MT, PT tests and graded a Level II - LT test to K. Ostergren in July and August 1985.
M. Davis (No. 639) administered Level III - RT, MT, PT tests to R. Jones in September 1986.
M. Langstron (No. 6436) administered Level II - RT, MT, PT tests to M. Cross (No. 33) and R. Green (No. 40) in March 1986.
The eye examination for J. Bemis and G. Tope were missing for 1986 (see Nonconformance 87-01-02). Three examiners were not given a color check as part of their eye examination in 1981 through 1983 (M. Ritchie and M. McAllister) and in 1984 (J. Farley). It was also noted that the color check on 1986 eye examinations was by surveillance for C. Rose, G. Saulter, and G. Johnson.
F. PERSONNEL CONTACTED:
- J. Fuchs, President
- D. Wright, Group Vice President
- W. Coles, Vice President Quality Assurarce
- H. Lindstrom, QA Administrator
- Attended exit meeting.
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