ML19260A872

Responds to NRC 791002 Ltr Re Violations Noted in IE Insp Repts 50-546/79-18 & 50-547/79-18.Corrective Actions: Instructed Personnel to Verify Rate of Load Twice Daily for Min of 10 Intervals

ML19260A872
Person / Time
Site:	Marble Hill
Issue date:	11/01/1979
From:	Shields S PSI ENERGY, INC. A/K/A PUBLIC SERVICE CO. OF INDIANA
To:	Fiorelli G NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
References
NUDOCS 7912060057
Download: ML19260A872 (5)

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PUBLIC SERVICE INDIANA November 1, 1979 S. W. Shields Vice President Electric System Mr. Gaston Fiorelli .

United States Nuclear Regulatory Commission Region III 799 Roosevelt Road Docket Nos.: STN 50-546 Glen Ellyn, Illinois 60137 STN 50-547

Dear Sir:

In accordance with the provisions of Section 2.201 of the NRC's " Rules of Practice," Part 2, Title 10, Code of Federal Regulations, Public Ser-vice Indiana offers the following information in response to the items of noncompliance contained in inspection report 50-546/79-18; 50-547/79-18.

Item of Noncompliance (546/79-18-01; 547/79-18-01)

Marble Hill PSAR, Chapter 1, Section 1.7, commits to Regulatory Guide 1.28 (June 7, 1972) and therefore to ANSI N45.2-71. ANSI N45.2-71, Section 6, states that " Activities affecting quality shall be prescribed by documented instructions, procedures, or drawings of the type appropriate to the circum-stances and shall be accomplished in accordance with these instructions, procedures, or drawings."

Contrary to the above, the RIII inspector observed the following:

a. The loading rate applied to two compressive strength concrete cylinders were observed to exceed the 20-50 psi loading rate specified in ASTM C39.

b. Several instances were noted in which the sample fraction retained on an 8-inch diameter sieve at the completion of the sieving operation exceeded the maximum of 200g allowed by ASTM C136.

c. The specific gravity of the heavy liquid (Zine Chloride) used to perform the Test for Lightweight Pieces in Aggregate was not monitored during the test with a calibrated hydrometer to verify that it remained within 10.01 of the specified value at all times as required by ASTM C123.

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PUBLIC SERVICE 2 INDIANA Mr. Caston Fiorelli November 1, 1979

d. The specific gravity of the heavy liquid (Zine Chloride) used to perform the Test for Lightweight Pieces in Aggregate was not confirmed to be 2.0 as specified by ASTM C33 for the coal and lignite test.

e. The 2" grout cube molds were not properly pre-treated prior to use with a mixture of three parts of paraffin to five parts rosin as specified by ASTM C109.

f. Field cast 2" grout cubes were not being initially cured in accordance with ASTM C109, Section 8.5 as referenced by S&L Specification Y-2850, Section 411A.1.

g. Four occasions in which UST Level II personnel were evaluated for certification, other UST Level II personnel. This is not in accordance with UST Procedure No. UST-TQ-1, Revision 9,Section IV, paragraphs 1.5 and 1.6.

h. Five occasions in which UST personnel were certified to Level I requirements prior to completion of the interview and practical demonstration of their proficiency. This is not in accordance with UST Procedure No. UST-TQ-1, Revision 9,Section V, paragraph 4.1.

1. Two occasions in which UST personnel were certified to Level I requirements prior to receiving visual examinations. This is not in accordance with UST Procedure No. UST-TQ-1, Revision 9,Section V, paragraph 5.0.

j. Four occasions in which the required physical and visual re-examinations were overdue for periods up to two months. This is not in accordance with UST Procedure No. UST-TQ-1, Revision 9,Section V, paragraph 7.2.

k. At least seven UST personnel were certified to Level I that did not meet experience requirements. This is not in accordance with UST Procedure No. UST-TQ-1, Revision 9,Section V, paragraph 3.2.

No response is required for items 1.e and 1.f since prompt actions were taFen and completed to correct the matters and to prevent recurrence.

Corrective Action Taken And Results Achieved

a. The cylinders in question were for non safety related concrete pours.

To assure this condition does not occur when testing safety related concrete, U.S. Testing has instructed technicians breaking cylinders to verify the rate of load a minimum of twice a day, for a minimum of ten second intervals. This verification will be recorded in the remarks section of the break sheet for the cylinder tested.

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1. A PUBUC SERVICE IBK) LANA Mr. Caston Fiorelli November 1, 1979

b. U.S. Testing Co. initiated ICAR #1036-54 to document and obtain resolution of this condition. Corrective action taken is as follows:

PSI was notified and S&L was requested to give a disposition of the effects of retaining more than two hundred (200) grams on any one sieve,

c. U.S. Testing documented this discrepancy on ICAR #1036-57. The hydrometer was sent to the manufacturer for calibration which suspended all testing of this type. The hydrometer was calibrated and was found to be in calibration in accordance with standards traceable to NBS.

d. All testing of this type was suspended until a new solution of zine chloride was made which has a specific gravity of 2.0+.

g-k U.S. Testing documented these discrepancies on ICAR #1036-67. U.S.

Testing is presently in the process of evaluating these problems to determine the corrective actions necessary. This evaluation will be completed by December 15, 1979 at which time corrective actions and corrective actions to prevent recurrences will be described.

Corrective Actions To Prevent Recurrence

a. U.S. Testing Co. has written a letter dated 10-29-79 requesting the purchase of a loading pacer for the DRQC 200 compression machine.

The above mentioned pacer is in process of being procured by PSI.

b. U.S. Testing has held a documented training session with all Lab personnel on the proper method of reducing samples and performing sieve analysis in accordance with ASTM C-136. Records of this training are available at the Marble Hill Site.

c. U.S. Tcsting issued a change notice to procedure QCP 2.6 to include checking the specific gravity of the zine chloride solution before, during and after the test is performed, using a calibrated hydrometer,

d. U.S. Testing held a documented training session with all technicians on the proper method of performing this test in accordance with ASTM C-123.

g-k Corrective action to prevent recurrence has not been finalized because U.S. Testing Co. is in the process of evaluating its overall inspector qualification program. Additional time is requested to complete this action.

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PUBLIC 4 SERV!CE IBE) LANA Mr. Caston Fiorelli November 1, 1979 Dates When Full Compliance Will Be Achieved

a. January 1, 1980.

b. Training completed. The S&L Evaluation will be completed no later than December 1, 1979.

c&d Training is complete. The S&L Evaluation of ICAR #1036-57 will be complete no later than December 1, 1979.

g-k Results of the evaluation and finalized corrective action will be provided by December 15, 1979.

Item of Noncompliance (546/79-18-03; 547/79-18-03)

The RIII inspector noted the following examples of nonconformance reports which had not received the proper design organization evaluation as required by ANSI N45.2-1971, Section 4.4.

a. PSI FCAR No. 69, dated December 22, 1977

b. PSI FNR No. 018, dated February 21, 1978

c. N-MH FCR No. 314, dated January 8, 1979

d. N-MH No. 316, dated January 16, 1979

c. N-MH NCR No. 183, dated June 8, 1978 Corrective Action Taken And Results Achieved Engineering evaluation of these nonconformance reports has been included within the scope of an overall evaluation of nonconformance reports to assure completed work is adequate. This overall evaluation is not completed yet and additional time is requested to complete this action.

Corrective Action To Prevent Recurrence PSI is in the process of developing and implementing procedural and organizational changes to its nuclear project. These changes are not complete and additional time is requested to address action to prevent recurrence.

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PUBUC 5 SERVICE INDIANA Mr. Gaston Fiorelli November 1, 1979 Date When Full Compliance Will Be Achieved Complete evaluation of nonconformances, implementation of PSI Quality Assurance Procedure Changes and a description of finalized corrective action vill be complete by December 15, 1979.

Sincerely,

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ti0\ 2 ^ 1979 Docket No. 50-546 Docket No. 50-547 Public Service of Indiana ATTN: Mr. S. W. Shields Vice President - Electric System 1000 East Main Street Plainfield, IN 46168 Gentlemen:

Thank you for your letter dated November 1,1979, informing us of the steps you are taking to correct the items of noncompliance which we brought to your attention in Inspection Reports No. 50-546/79-18 and No. 50-547/79-18 forwarded by our letter dated October 2, 1979. We will examine these matters during a subsequent inspection pending completion of your corrective action.

Your cooperation with us is appreciated.

Sincerely, ffEN G. Fiorelli, Chief Reactor Construction and Engineering Support Branch cc: Mr. R. M. Brown, Construction Project Superintendent cc w/ltr dtd 11/1/79:

Central Files Reproduction Unit hTC 20b PDR Local PDR NSIC TIC LeBoeuf, Lamb, Leiby & MacRae Mr. Dave Martin, Office of Attorney General

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