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. . , U.S. NUCLEAR REGULATORY COMMISSIONOFFICE OF INSPECTION AND ENFORCEMENT

REGION III..

Report No. 50-329/80-07; 50-330/80-07

Docket No. 50-329; 50-330 License No. CPPR-81; CPPR-82

Facility Name: Midland Nuclear Power Plant, Units 1 and 2

Investigation Co ducted: March 3-4 and 11, 1980

Investigation At: Midland, MI

Investigator: O'

C. H. Weil Date

Inspector: ft?<

K. D. Ward / Ifate

Reviewed By: N. k . O ' 0, . 1 ,//,, hgC. E. Norelius DateAssistant to the Director

hwL~kk~ ddnD. H. Danielson, Chief ' DateEngineering Support Section

Number Two

Investigation Summary

Investigation on March 3-4, 1980 (Report No. 50-329/80-07; 50-330/80-07Areas Investigated: Special, unannounced itvestigation into allegationsconcerning the construction of the two borated water storage tanks byGraver Energy Systems, Inc., at the Midland Nuclear Power Plant Construc- |tion Site, Units 1 and 2. The investigation involved 30 investigative lhours, both on and off-site, by two NRC personnel. |

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| Results: The allegations were not substantiated, and no items of noncom- |pliance with NRC requirements were identified during the course of the l'

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., REASON FOR INVESTIGATION

On March 3, 1980, Individual 'A' advised Nuclear Regulatory Commi,ssionRegion III (RIII) personnel of three allegations concerning the construc-tion of the two borated water storage tanks by Graver Energy Syste.ms atthe Midland Nuclear Power Plant construction site.

SUMMARY OF FACTS

Individual 'A' advised RIII personnel of three allegations concerning theconstruction of the two borated water storage tanks by Graver Energy Systems,Inc., at the Midland Nuclear Power Plant construction site. The allegations

e, were: (1) a separation had occurred in the lamination of r. vertical seamJ' in the east storage tank, and the separation was " padded-in" by welding over'

, c' the lamination; (2) a crack in the floor of the east tank was discovered and' repaired by grinding to a depth which did not meet the minimum thickness-

specifications for the tank floor; (3) the floor of the west tank did notextend the required 15 inches beyond the tank shell, and the floor was ex-terded by using weld metal to extend the floor plan the required distance.Insd-tigation by RIII personnel disclosed the two borated water storagetanks were not completed (completion expected in May-June, 1980), andthe problems described in allegations numbers one and two had been dis-covered by Graver personnel, recorded on Graver Nonconformance ReportsNumbers 300 and 301, and had been marked for repair. The third allegation,concerning the use of weld metal to extend the floor plate was partiallysubstantiated in that the floor plate did not extend the minimum distance.However, the floor plate was repaired using Graver Energy System Specifi-cation Number WG-6, Procedure Specification for Plate Edge Build-Up. Theinvestigation did not disclose any items of noncompliance with NRC require-ments.

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s. DETAILS

1. Persons Contacted**

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l* Consumers Power Company

,-*T. C. Cooke, Project SuperintendentD. B. Miller, Site Manager

*J. L. Corley, Section Head-IE&TYD. R. Keating, QA Group Supervisor

*D. K. Martin, QA Representative*R. Ostrowsk., QA Engineer*W. F. Szabo, Engineer

Bechtel 'ower Company

J. W. Lillywhite, Field Contracts Administrator*M. A. Dietrich, QA Engineer -

*E. Smith, QA Representative*D. A. Patee, Subcontracts Engineer*W. L. Barclay, QC Engineer

Graver Energy Systems, Inc.

*G. M. Ault, Program Manager*B. K. Warren, Corporate QA RepresentativeT. Charette, Site QA Engineer

* Denotes attendance at exit meeting.

2. Receipt of Allegation From Individual 'A'

Allegations

On March 3, 1980, Individual 'A,' a boilermaker, formerly employed atthe Midland Nuclear Power Plant Construction Site, provided to RIIIpersonnel three allegations concerning the construction of the two

; borated water storage tanks by Graver Energy Systems at the Midlandl Site. Individual 'A' provided the following information:

The design of the floor plate of the west storage tank required theplate to extend 1 inches beyond the exterior of the water tank shell.This was discovered in late October, 1979, and the Graver Field Super-visor instructed the welders to use weld metal to extend the floorplate to the required length.

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, ,, A separation occurred in the lamination of vertical sean number tLree,- ring two, (south side) of the east storage tank. The Graver field

supervisor instructed a welder to " pad in" the separation to " coverit up." The separation in the laminated seas was found during October,1979.

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During October, 1979, a crack in the floor plate inside of the east.

storage tank was discovered, and the crack was brought to the atten-tion of the Graver field supervisor. The Graver field supervisorinstructed the Graver boilermakers to use a grinder to blend,out thecrack in the floor. Individual 'A' was concerned that the griodingof the floor crack was too deep and the floor plate no longer. net theminimum density requirement.

Findings1

The Midland Nuclear Power Plant was designed to have one borated waterstorage tank for each operating unit. The two tanks, designated IT60 |(West) and 2T60 (East), were to support Unit I and Unit II, respec-tively. The design capacity of each tank was 500,000 gallons. Thedesign and erection of the two water storage tanks were sub-contractedto Graver Energy Systems (formerly Graver Tank and ManufacturingCompany), East Chicago, IN. Erection of the two tanks began onSeptember 21, 1979, and proceeded until mid-January,1980. In January,1980, the rate of construction had exceeded the capacity to conductnon-destructive examinations by the Graver Quality Assurance Section.Construction was halted and the construction crews were laid-off until ;

the Quality Assurance Section could complete the non-dest'ructive exam-inations. Completion of the two borated water storage tanks was l

expected for the May-June, 1980, time period. )On September 28, 1979, the bottom plate of the east (2T60) water storagetank was found to have been scratched and gouged during the materials 1

handling and installation processes. The scratched and gouged areas |were marked for repair and Graver Nonconformance Report (NCR) Number ;300 (Exhibit 1) was prepared. All scratched areas were repaired in I

accordance with Graver Energy System Procedure Number RP-3, " Repair |Procedure Base Metal Defects." This procedure permits, "all material '

imperfection detected . . . chip marks, blemishes, or other surfaceirregularities may be removed by grinding . . . after the surface hasbeen corrected it shall be blended smoothly into the adjacent area."The procedure continues, " replace removed material as requested tomeet minf.aum dimensions with shielded metal are process . . The.

surface shall be blended smoothly into the surrounding area." Therepaired areas were measured by ultrasonic thickness gauge and foundto be within the design requirements.

On November 2, 1979, the crack in the lamination of vertical seamnumber three on the east storage tank (2T60) was reported underGraver NCR Number 303 (Exhibit 2). The imperfection was found duringthe tank erection. The imperfection was marked for later repair inaccordance with Graver Energy Systems Procedure Number RP-3, RepairProcedure, Base Metal Defects (described in the preceding paragraph.

- The cause of the imperfection was suspected of being a surface defect |-

- caused during hot mill rolling. Graver NCR Number 303 directed the |

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area of the vertical lamination to be reworked. Graver Erection...

Control Sheet Number WP-001 (Exhibit 3) was prepared to keep trackof the progress of the repair, including final radiographing. |

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. During October, 1979, Graver personnel discovered the floor plate ofi*. the west, borated water storage tank (IT60) extended only one inch j

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beyond the exterior of the tank shell on the southwest side of the '

tank (approximately 31 feet clockwise from the Ring 1, Vertical Seam 3).)

The extension of the floor plate of only one inch beyond the tank shell !-

did not meet the drawing requirements of 1 1/4 inches. The addition 1

of 1/4 inch to the base plate was achie ved by buttering (weld build-up) !1/4 inch of weld metal to the base plate for a length of 1 1/2 feet. 1

Gary M. Ault, Graver Program Manager stated the buttering techniquewas done in accordance with Graver Energy Systems Specification NumberWG-6, Procedure Specification for Plate Edge Build-up. This repairwas not documented at the time of the completion of the repair, but I

was made a matter of record on March 4,1980 with the preparation of )

Graver Energy Systems Surveillance Report Number 3 (Exhibit 3). j

The buttering technique was used, rather than moving the tank shellplate, as a change in the position of the tank shell plate would havecaused the tank shell to be out-of-round. Consumers Power Company 1

prepared a nonconformance report pertaining to the extension of )the tank base plate. D. K. Martin, Consumers Power Company Quality IAssurance Representative stated the Consumers Power Company Quality )Assurance Engineering Section was in the process of determining the ,

welding techniques and procedures utilitzed, as well as the indentityof the welder, to extend the tank base plate. Martin advised thatonca this information has been obtained the Quality Assurance Engi- |neering Section will decide whether the welded extension of the tank ;

base is within acceptable standards or if the welded extension shouldbe removed by grinding and re-welded.

During the period September 1979 thru February 1980, the perform-'

ance of Graver Energy Systems in the erection of storage tanks, in- |cluding the IT60 and 2T60 tanks, at the Midland Construction Site was 1

laudited three times. Graver Energy Systems was audited by BechtelPower Corporation (the prime contractor at the Midland Construction |

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Site), the Consumers Power Company corporate audit team from Jackson,MI, and the Quality Assurance Section of the Consumers Power Company atthe Midland Construction Site. Additionally, the Graver Energy' Systems'procedures in erecting the tanks was inspected by the American Society

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of Mechanical Engineers (ASME) during November, 1979. None of theaudits or the ASME inspection disclosed any major findings or discre-

| pancies in the procedures or practices used by Graver Energy Systems || at the Midland Construction Site. 1

3. Receipt of Additional Allegation

' -Allegation

During the course of this investigation the appearance of linear indi-cations in radiographs of the welds of the two borated water storage |

tanks was brought to the attention of RIII personnel.

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|Findings.

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The Graver Energy Systems' Quality Assurance Section had radiographed |

the seams of the two, incomplete, borated water storage tanks. During ;

the course of analyzing the radiographs the linear indications werefound. Evaluation of the linear indications remains pending,*tyCraver Energy Systems, Bechtel Power Company (the prime contractor at ;

the Midland Site), and the licensee. This matter has been brought ;

to the attention of the RIII Reactor Construction and Engineering ;

Support Branch for inclusion in future RIII inspections of the |IMidland Nuclear Power Plant Construction Site.

4. Discussion with Midland Nuclear Power Plant Management

On March 4, 1980, the allegations and the results of this investiga-'s tion were discussed with Mr. T. C. Cooke, Project Superintendent,-

e Midland Nuclear Power Plant Construction Site, and the members of .

*| -' the staff identified in paragraph one. |1

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iAttachments:1. Exhibit 1, Graver Nonconformance

Report 300, Sept. 28, 1979.2. Exhibit 2, Graver Nonconformance

Report 303, Nov. 2, 1979.3. Exhibit 3, Graver Erection Control

Sheet Number WR-001.4. Exhibit 4, Graver Surveillance Report

Number 3, March 4, 1980.1I

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Ordtr No. 61593-N.

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.C.R. No. MNORTHEAST

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Date 9-28-79...

NONCONFORMANCE REPORT*.,

NONCONFORMITY: San)c NO. 2T-60 ELL Plate 3AS, Beat No. V-90774, MPO No. 9147'

; DRN,iING 10: NIcl2051-2 ELL Plate has grind area wwc. 2" wide X 8" Iangth,; 88" frczn straight Edge adjoiniDg A2 ELL Plate, and 454" frczn straigic. edge| adjn%49 AS ELL Plate: 'Ihis area is appr=x.1/32" in dep*dl.

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, CAUSE: Excessive <p-4T5 A-im fab:-icatica

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ACmON TO PREVENT RECURRENCE: All grind areas A''-4_m Wr-ation W b.

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, w 2R . 1979 29-79Corfective Action Date

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Sgn'ature & Dargfv .

INITIAL DISPOSITION:-

b MRB Review G.F. IJL-2h-79 P.A. 9-28-7c# Sgnat & Date Sgnature DaO Replace . P~S.S h /7 u9-29_79 Q.C.S.%.t..b .te% 9-29-7c.

Egnardre & Date g Egnature & Date-

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. MATERIAL REVIEW BOARD: -

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O Regi.ce E Use As is b Rework' See Comments.

Customer Approval O Requiree Not Requireo'

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Comments: e., fTTT~ ib.The thickness of the area in question was measured yby ultrasonic +Mehess gauge and is within the h,. .

1 assign 1.quir.ments..-. -

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{ eng. Angrovw a om. V o.A. 9w a om/ /~

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A N i WR.51klIt) 10 'l0 '77 -

Required . .Not Required'

'.* ,.m a me Exhibit 1 - page 1 of 1-, ...

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303N.C.R. N o.N,ORTHEAST EV. 2,1979Data

NONCONFORMANCE REPORT*.

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NONCONFORMITY: FFlL PIATE NO: M2-016-000B2.

MPO-91274 *

NL-12046 Er. V-90758 .

2T-60 CERI NO: 04497-

IAMI2RTICH AREA IN PIATE 4" IN II:NGIH Flui EIXE T PIATE.SEE ATDGED SICIG.

Defect inCAUSE: Surface imperfection in slab or damage during hot rolling.plate not seen by final inspector.

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We have cautioned our inspector to use greaterACTIC N TO PREVENT RECURRENCE:

care .'n inspecting for defects, se that defects may be detected and el4minatedby corrective grinding before shipping.

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INITIAL D!SPOSITION: ,A "-.

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b MRB Review G.F. We'Ih 2-79 P.A.*

S4 nature Date#

,Sgn{uretT^L ur3I 11-2-79 C.C.S. %.t A - 11-2-7!*

O Replace P.S.i Sigdeture & Date T Signature & DateI L-

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O Replace Use As is b Rework M See Comments

Customer Approval O nequireo O Not Requiree,

f Comments: Rework in accordance with an approved araction controlsheet utilizing procedure RP-3 and 47N.-

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A N I 8M M MI dRequired O Not Requiree* * Exhibit 2 - page 1 of 2

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eascrios cournot saser |.feP1 7,' 1 i,g" GRAVERENERGY SYSTEMS lNC *'

. CONTRACT NO. 61593-N ..

ASSEMBLY IDENTIFICATION & DESCRIPTION: (RENDRK) y ge, 2.- Vf*p7 3 [NE# 3 0 3) P. NO. 1*

'i iDRAWING USED IN PREP. OF ECS: NIrl2046, Rev. 2~

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STEP OPERATION DESCRIPTION SAT UNSAT DRAWING REY. PROC. RFV. INITIAL DATE ,

! NL-12046 2 N/A 2 Od ' _ m _ / 9'l Iav out Area of Repair,

2 Mr Arc /or Grird Bepair Area

h(RP-3) & (47-N) . / D p 1 $ i,

b$ ic3 N.D.E. Examine Cavity IPE-12 / LPE-12 0,

4 Weld Cavity of Repair (47eN) 47-N 6 ';;

5 Grind Area Suitable for N.D.E, IPE-12 0~

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61593-Nso m-

tecy sysrtus.ec ORDER

SURVEILLANCE REPORT 3SIR NO-,

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3-4-80DATg

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* .:. .IKyrIU1 SKEn3I PIATE 3A7 Hr: V-90733, MPO 91284l. TEM

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Plate edge was buttered for approxinately l' 6" X %" to extend b-/ " - stickoutto meet drawing requirments of 1 " NL-12046. Work ms perfonned withoutproper Erectim Otratrol Sheets, but agrroved Procedures wre used.

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REPLY:,

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ENGINEERING DISPOSITION:

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QUAUTYCONTROL DISPOSITION: '

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Exhibit 4 - page 1 of I

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DO NOT DISCLOSEContains identity of,

5,confidential source

Investigation at Midland Nuclear Power Plant Construct. ton site onMarch 3-4,1980 (Report No. 50-329/80-07; 50-330/80-07).

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Individual Identifier Codes .

Individual Name Position

A Joseph Daniel Holmes Boilermaker,

9555 East Adams Founer employee ofRoute 1 Graver Energy Systems, Inc.Wheeler, MI 486f?

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