IR 05000498/1978003

Insp Repts 50-498/78-03 & 50-499/78-03 on 780221-24.No Noncompliance or Deviations Noted.Major Areas Inspected: Const Activities,Including Receipt of Class 1E Electrical Cables & Observation of Concrete Placement for Unit 1

ML20211F479
Person / Time
Site:	South Texas
Issue date:	03/03/1978
From:	Crossman W, Randy Hall, Hubacek W, Kelley D, Renee Taylor NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV)
To:
Shared Package
ML20150F241	List: IR 05000498/1977013 IR 05000498/1978001 IR 05000498/1978003 IR 05000498/1978004 IR 05000498/1978007 IR 05000498/1978010 IR 05000498/1980017 ML20150F239 ML20209B066 ML20211E985 ML20211F004 ML20211F025 ML20211F065 ML20211F072 ML20211F096 ML20211F114 ML20211F193 ML20211F216 ML20211F234 ML20211F262 ML20211F280 ML20211F398 ML20211F419 ML20211F435 ML20211F458 ML20211F473 ML20211F489 ML20211F500 ML20211F514 ML20211F518 ML20211F541 ML20211F573 ML20211F578 ML20211F583 ML20211G038
References
FOIA-85-378 50-498-78-03, 50-498-78-3, 50-499-78-03, 50-499-78-3, NUDOCS 8610310173
Download: ML20211F479 (8)

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.l.'. " U. S. NUCLEAR REGULATORY COMMISSION

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. OFFICE OF INSPECTION AND ENFORCEMENT

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n Report No. 50-498/78-03; 50-499/78-03 ,,

a Docket No. 50-498; 50-499 Category A2

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I- Licensee: Houston Lighting and Power Company

$ Post Office Box 1700 4 Houston, Texas 77001

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1. Facility Name: South Texas Project, Units 1 & 2

, ;. . Inspection at: South Texas Project, Matagorda County, Texas

e! Inspection conducted: February 21-24, 1978

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E . Inspectors:' 56 f) 9/. /LsI 3/3/7% W. G. Hubacek, Reactor inspector, Projects Section Date 1;. (Paragraphs 1, 3, 5, 7 & 8)

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1. 2 P/ d ( /b I 7/3 /? T Date

' (". .I/ i R.(Paragraphs G. Taylor, 2Reactor

& 4) Inspector, Projects Section

L _3l3/ 7R or. Engineering Support D&te'

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D. L. Kelley, RudoT/Insp

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Section (Paragraph 6) ,

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S[f!78 Approved: _e - - =

W. A. Crossman, Chief. Projects Section Date

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R. E. Hall, Chief .

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Engineering Support Section ods'.rMo Date

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Inspection Summary _:

. , 1978 (Report No. 50-498/78-03;50-499/78-03_)

,. Inspection on Areas Inspected: FebruaryRoutine, unannounced inspection of construction activities

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including receipt of class IE electrical cables; major component support structures for Unit 1 reactor coolant pumps and steam generators; observation "

li t of concrete placement for Unit 1; and follow up on previously identified

' inspection findings. The inspection involved seventy-eight inspector-hours Il? by three HRC inspector Results: No items of noncompliance or deviations were identifie .?

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. DETAILS Persons Contacted Principal Licensee Employees ..

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• F. D. Asbeck, Construction Supervisor R. A. Frazar. QA Manager W. N. Phillips, Project QA Manager

• S. A. Viaclovsky, QA Supervisor

• T. K. Logan, QA Civil Lead Engineer

• L. D. Wilson, QA Mechanical Lead Specialist

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• M. H. Smith, Electrical QA Specialist -

D. G. Long, QA Civil Associate Engineer

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. . Other Personnel

'I *C. L. Crane, Project Manager, Brown & Root (B&R)

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. *T. H. Gamon, QA Manager, B&R

• T. P. Gardner, Project QA Manager, B&R D. A. Robertson, Senior Geotechnical Field Engineer B&R

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The IE inspectors also interviewed other licensee and contractor personnel

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2 including members of the QA/QC staf * denotes those attending the exit intervie lf '

~ Licensee Action on Previous Inspection Findings l -

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i (Closed) Deficiency (50-498/77-12; 50-499/77-07): Failure to maintain audit records. The IE inspector verified that the actions indicated

? in the licensee's letter dated December 26, 1977, have been complete '

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t QAP-5, Rev. 4; QAP-SA, Rev. 2; QAP-5B, Rev. 2; and QAP-SC Rev. 2 were

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reviewed along with randomly selected audit files. The IE inspector had no further questions relative to this matter.

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, - Site Tour _

The IE inspectors walked through various areas of the site to observe

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construction activities in progresp and to inspect housekeeping and equipment storag No items of noncompliance or deviations were identifie . .

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- Ma.jor Component Support Structures

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The IE inspector selected the support systems for the reactor coolant f

' pumps and steam generators in Unit 1 for examination in this activity

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area. The load support system is comprisedEach of three support structures structure in turn is for each pump and four for each generato ..

A composed of two columns fabricated from low alloy, high strength stee n-O Lower Structure The lower portion structure was originally fabricated by LAMCO under k' ? a Brown & Root purchase order while the upper portion was fabricated

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by Teledyne-Brown, Inc. in accordance with a Westinghouse purchase h The LAMCO structures were the subject of a 10 CFR 50.55(e)

'I order.1/

report with necessary repairs accomplished at the site on nineteen2 /,

elements. This activity was the subject of previous NRC inspections.,

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Eight additional columns, repaired by LAMCO, have been received at L the site. The IE inspector reviewed the LAMCO documentation package R for columns 973 and 974 covering both the original fabrication and

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i No items of noncompliance or deviations were identifie "

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,9 Upper Structure

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The upper sortion of the support system attaches to the active com-

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i' ponents anc carriesthe corrponent loads into a concrete floor and on y,' into the lower support columns and hence into the containment i

foundation. The supports were fabricated to the requirements of P Westinghouse Specification G-952628, " Fabrication Requirements for ( Reactor Coolant System Component Supports," and Drawings 1459F29 i

and 1459F3 It was noted that each component in the site storage was in " hold" status as evidenced by appropriate tags. Licensee personnel indicated the hold action had been taken as a result ofwhich i a licensee vendor surveillance report (TB263770-1)

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questionable practices relative to required ultrasonic tests of full penetration welds attaching clevis sections to the flange-beam colum The IE inspector questioned how four fillet welds y?

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1/ Licensee letter dated November 11, 1977 50-498/77-10(paragraph 4), 50-498/77-11 (paragraph 4),

1/ Inspection reports 50-498/77-13 (paragraph 4),50-498/78-01(paragraph 3)

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i attaching the clevis sections to the base had been ultrasonically i ( tested as required by Revision 5 of Drawing 1459F31. Available

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on-site vendor documentation failed to provide any detailed infor-

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mation on the problem nor could it be ascertained where the det-

> tailed documentation is actually locate ,

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.. This matter will be considered unresolved until such time as the .. previously referenced vendor surveillance report item has been J dispositioned and the vendor's detailed documentation package ir has been reviewe . Observation of Concrete Placement i

i kJ The IE inspector observed concrete placement activities related to 6 wall ME 1-WOO 6-03A in the Unit 1 Mechanical and Electrical Auxiliary i

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Building and reviewed the preplacement checklist which had been completed in accordance with B&R Procedure ST-QCP-4.4, " Concrete

[- Inspection."

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y; . The IE inspector observed performance of slump and air content tests at the truck discharge. Air content was within the requirements of L B&R Specification 2A010CS028. " Concrete Construction." The slump T was observed to be 4-1/2" which exceeded the specified 4" maximum.

(l.' Permission to place the 4-1/2" slump concrete was obtained as per-j. . mitted by the specification. Six concrete cylinders were prepared 7

~ fo.' strength testing at 7 and 28 days.

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Ih The IE inspector reviewed the certifications of the two B&R concrete i inspectors who performed preplacement and placement inspections.

O 1 No items of noncompliance or deviations were identifie ..

j. . Class IE Cable Receiving and Storage i;. The IE inspector reviewed the following procedures, specifications *

l6 and records pertaining to the purchase, shipping, receiving and l f- storage of class IE electrical power and control cables:

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!,. Specification 3E189E5020-D, "600 Volt Class IE Power Cable" p.

' . Specification 3E189ES018-D, "500 KV Power Cable" Purchase Order No. 35-1197-4060, "600 Volt Power Cable"

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Purchase Order No. 35-1197-4060,"5 KV Power Cable"

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! Purchase Order No. 35-1197-4058,"600 Volt Control Cable" h.:

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I, ST-QCP-1.1, " Receiving and Storage Inspection," Reissue 12/14/77

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ST-QAP-4.1, " Vendor Surveillance," Reissue 5/13/77

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'ST-QAP-6.1, " Project QA Records," Reissue 12/14/77

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s' STP-DC-005-11. " Preparation and Control of Specification," Rev. /7/78 ff DDR H-116 (concerning Form 200.59)

kc i During the course of the review, it became evident that there was a i?

lack of continuity in the information flow from one documentation area These to the other with respect to cable test and certification records.

.i ig areas are described below:

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r The procurement specifications identify the testing requirements L for the cable, but do not identify which test results are to be E shipped in the data package to the sit b The purchase order documents identify some, but not all, of the tests to be included in the purchase orders. Like the specification purchase orders also do not specify what test results are part of

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the data packag '

+.. Form 200.59, which makes up part of the standard purchase order, is

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preprinted and generic in nature. The item identification on the

.( form is not specific enough to identify the individual test or tc test records in the specifications. This leads to interpretations of the item's specific meaning by at least three different groups

[F (the original specification writer, the vendor surveillance f inspectorandthereceivinginspector). This problem with Form 200.59 has been identified by the licensee in Deficiency and

• [ Disposition Report (DDR) H-116 dated January 27, 197 (:

The overall effect of this lack of continuity in procurement documents

,[ is a lack of definitive inspection criteria for the receiving inspection

group and the scattering of test results between the site and the

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project engineering department. This leads to the expenditure of consid-

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erable time and effort to verify that specification requirements have C been met and increases the probability of misplacing required documenta-

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tio These findings, in addition to the item identified in DDR H-116, were

!. . discussed with the licensee representative. A program to resolve the i problems has been initiate * '

This item will be considered unresolved pending review of the ifcensee

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actions during future inspection Y y

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j* Unresolved Items

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- Unresolved items are matters about which more information is required I in order to ascertain whether they are acceptable items, items of non-compliance or deviations. The following unresolved items were disclosed i.; during this inspection regarding ultrasonic testing of welds for reactor "

3 coolant system component supports and documentation packages for class IE J[ electrical cable received at the site:

$ Identifier Title Reference v

{ 78-03-1 Ultrasonic Testing of Welds . Paragraph 4-r 78-03-1 Documentation Packages for Paragraph 6 lt'

Class IE Electrical Cable

' Exit Interview r

E.' The inspectors met with licensee representatives (denoted in paragraph ) at the conclusion of the inspection on February 24, 1978. The f inspectors summarized the purpose and the scope of the inspection and

?.- the findings. A licensee representative acknowledged the statements of the inspectors concerning the unresolved iter.s (paragraphs 4 and 6).

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OFFICE MEMORANDUM #

To Mr. R. A. Frazar February 24, 1978 , !SA -

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from Mr. W. N. Phillips SF -05

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Subject South Texas Project Electric Generating Statio NRC Exit Interview Su-ary CUCCIO-$ gif, -

February 24, 1978 yg The NRC conducted an inspectica on February 21-24,1978, to ae-quaint Mr. W. G. Hubacek wit!' site procedures, personnel, and con-struction activities; exam the status of the Teledyne-Brown sup-

ports and documentation pertaining to the La=co colu=n repairs; and

' review documentation, procedures and storage of IE electrical power j cable. There were no ite=s of nence=pliance identified as a esult

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of the audi [ SSL_ _ ,

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The NRC identified two new unresolved ite=s as follovs:

, HL&P had previously identified a proble= pertaining to . 2,

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'g ultrasonic tests (UT) performed on Teledyne-Brown sup-

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ports. Also, Westinghouse drawing nu=ber lh59F31 showed O that UT vas specified for a filet veld which appears to . -

be contrary to the application of the UT techniqu N There were no data packages on sita to determine wh inspections have actually been perfor=ed, therefore this

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proble: vill be carried as an unresolved ite=.

O There vere inconsistencies found in the purchase order, a specification and 200.59 for regarding IE power cable i supplied by Okenite. It is not clear what documentatien Y is required and where it is to be sent. Another concern l was that the certified test report did not indicate what

, g specific tests were being certified. It was indicated a by the NRC that it appears that this is a B&R generic prob-le=. ,

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In addition,'the following general ite=s were =entioned:

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' The NRC indicated that they planned to go to the HL&P Ec=e Office after the interview to verify i=ple=entatien of act-ions taken pertaining,to a previous NEC nonco=pliance found at the He=e Offic . They were concerned about the filing of documents in the

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B&R QA vault. Several ite=s were found =isfiled. B&R QA j '

stated that action is underway to i= prove the filing syste=.

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SAV:pe I

cc: Messr G. W. Oprea, J ;

MARO1 1979 W. M. Meneer r D. G. Barker .QUAUTY ASSURANCE f H. L. Key L DEPARTMER *

S. A. Viaclovsky _l i F. D. Asbeck

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