ML20086P162

Interim Potential Deficiency Rept 55-84-03 Re Irregularities in Installation of Concrete Expansion Anchors.Initially Reported on 840111.Caused by Craftsmen Not Instructed Properly & Failure to Perform in-process QC Insp

ML20086P162
Person / Time
Site:	Clinton
Issue date:	02/14/1984
From:	Hall D ILLINOIS POWER CO.
To:	James Keppler NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
References
1605-L, 55-84-03, 55-84-3, U-10123, NUDOCS 8402270021
Download: ML20086P162 (3)

Text

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1605-L ILLIN0/8 POWER COMPANY U-10123 CLINTON POWER STATION. P.O. box 678 CLtNTON, ILLINOIS 61727 February 14, 1984 Docket No. 50-461 Mr. James G. Keppler Regional Administrator .

Region III U.S. Nuclear Regulatory Commission 799 Roosevelt Road Glen Ellyn, Illinois 60137

Subject:

Potential 10CFR50.55(e) Deficiency 55-84-03 Installation of Concrete Expansion Anchors

Dear Mr. Keppler:

On. January 11, 1984, Illinois Power Company notified Mr. R. C. Knop, NRC Region III (ref: IP memorandum Y-18981 dated January 11, 1984) of a potentially reportable deficiency per 10CFR50.55(e) concerning the improper installation of concrete expansion anchor bolts at Clinton Power Station (CPS). Our investigation of this issue continues, and this letter represents an interim report in accordance with 10CFR50.55(e).

Statement of Potentially Reportable Deficiency Irregularities were identified in the methods of installing concrete expansion anchors (CEAs) at CPS. These irregularities include welded anchors, embedment depth, and foreign material in the anchor bolt holes. An evaluation of this issue is being performed to determine the extent of these problems, and their

- significance on the safety of operations at CPS.

Investigation Results/ Background During an Institute of Nuclear. Power Operations (INPO) evaluation

-of CPS. construction activities in late November 1983, irregular-

, ities were identified in the installations of CEAs by the constructor, Baldwin Associates (BA). As a result of these irregularities, Illinois Power directed BA to cease the installation of CEAs until appropriate corrective action was established and implemented. In early December, 1983, an allegation was received that a CEA installation by a particular craftsman was_ improper. Investigation of the installation found fDO o

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Mr. Jam 2s G. Keppler February 14, 1984 anchors were improperly installed. Further investigation of all known CEA installations performed by the craftsman identified additional examples of improper installation. Nonconformance Reports have been written to document and obtain resolution of the identified hardware irregularities.

A Reinspection Plan has been established at CPS to further investigate the extent of the problem. This plan initially includes a reinspection of a sample of completed piping and mechanical CEAs installed by BA to provide a 95% confidence level that less than 5% defects exist in the presently-installed CEAs.

The sample size will be based on Military Standard 105.D. Based on the results of this initial reinspection, a determination will be made of th; level of sampling to be performed in other disciplines. The steps required to implement this sampling / reinspection program are being developed.

Corrective Action (Interim)

Evaluation of the above issue identified several root causes resulting in the identified irregularities:

- Craftsmen were not properly trained in CEA installation requirements, and

- In-process Quality Control (QC) inspections were not performed to identify CEA installation irregularities, only final installations were inspected.

The following corrective actions have been taken to correct the identified causes of this issue and to prevent recurrence of inadequate CEA installations:

1. Baldwin Associates Procedure BAP 2.16 and Quality Control Instruction QCI-105 have been revised to inccrporate several in-process QC inspections and QC hold points.

2. BA craftsmen and QC personnel involved in CEA installation are receiving documented training in the requirements of the anchor bolt installation specification and applicable procedures.

3. BA craftsmen are now being qualified prior to being allowed to install CEAs. Qualification is based upon receiving training to the requirements of CEA specification and procedures.

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4. A construction hold on CEA installation by BA was placed in effect at CPS on November 29, 1983. The hold was lifted on January 6, 1984, after the initiation of the correcti"e actions identified above.

e .

Mr. Jam s G. Keppler February 14, 1984

5. A reinspection of all CEAs known to be installed by the suspect craftsman was performed, and irregularities noted by the reinspection were documented on Nonconformance Reports (NCRs). Resolution of these NCRs will assure that the nonconforming installations meet design requirements.

6. A reinspection plan has been developed and is being imple-mented to determine the extent of CEA installation irregularities, and to re-establish confidence in past CEA work.

Safety Implications / Significance Illinois Power Company's investigation of this potentially reportable deficiency is continuing. The safety implications and significance of this issue wi'l be assessed after further re-inspections are conducted and any resulting NCRs are analyzed.

It is expected that approximately six (6) months will be necessary to complete the investigation and to file a final report on the issue. Illinois Power Company intends to provide you an update on the investigation in approximately ninety (90) days.

We trust that this interim report provides you sufficient background information to perform a general assessment of this potentially reportable deficiency and adequately describes our approach to resolve this issue.

Sincerely yours, D. . Hall Vice President RDW/ lag cc: NRC Resident Office Director, Office of I&E, USNE tington, DC 20555 )

Illinois Department of Nuclear ,

INPO Records Center

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