IR 05000498/1980019
| ML19338E285 | |
| Person / Time | |
|---|---|
| Site: | South Texas  |
| Issue date: | 08/08/1980 |
| From: | Crossman W, Randy Hall, Tapia J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19338E284 | List: |
| References | |
| 50-498-80-19, 50-499-80-19, NUDOCS 8009250405 | |
| Download: ML19338E285 (5) | |
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U. S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT Report No. 50-498/80-19; 50-499/80-19 Docket No. 50-498; 50-499 Category A2 Licensee: Houston Lighting and Power Company Post Office Box 1700 Houston, Texas 77001 Facility Name:
South Texas Project, Units 1 and 2 Inspection at:
South Texas Project, Matagorda County, Texas Inspection conducted:
July 22-24, 1980 7 f-M Inspector:
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gJ.1.Tapia,ReactorInspector,EngineeringSupport Date
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Section i
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Approved:
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W. A. Crossman, Chief, Projects Section Date C
f" f-TD R. E. Hall, Chief,' Engineering Support Section Date Inspection Summary:
Inspection on July 22-24, 1980 (Report No. 50-498/80-19; 50-499/80-19)
Areas Inspected:
Routine, unannounced follow-up inspection of construction activities including observation of work and review of records pertaining to the NRC Inspection Report No. 50-498/79-19; 50-499/79-19 findings related to earthwork and concrete. The inspection involved twenty inspector-hours by one NRC inspector.
Results:
No items of noncompliance or deviations were identified.
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DETAILS 1.
Persons Contacted Principal Licensee Employees
- R. A. Frazar, Manager, Quality Assurance
- T. J. Jordan, Supervisor, Quality Systems T. K. Logan, Lead Engineer, Quality Assurance
- R. A. Carvel, Supervisor, Civil / Structural Quality Assurance
- L. English, Site Construction Manager Other Personnel G. T. Warnick, Quality Control Manager, Brown & Root (B&R)
C. M. Singleton, Civil Quality Control Supervisor, B&R V. Berger, Quality Assurance Administrator, B&R J. L. Murphy. Quality Engineer, B&R A. Fernan w
' raining Supervisor, B&R J. Ruud, e m wisor of Civil Quality Engineering, B&R B. Horniag, consultant, Management Analysis Corporation The IE inspector also interviewed other licensee and contractor personnel including members of the engineering and QA/QC staffs.
- Denotes those attending the exit interview.
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Licensee Action on Previous Inspection Findinas During this inspection, certain corrective actions described in the Houston Lighting and Power Company (HL&P) letter to the NRC, dated May 23, 1980, were inspected. The lette: was in response to the items of noncompliance resulting from the special 'nvestigation as reported in Investigation Report No. 50-498/79-19; 50-499/79-19.
This inspection is a continuation of the follow-up activities initiated during inspection No. 50-498/80-17; 50-499/80-17, and specifically addresses those items related to Category I structural backfill and concrete.
Those items were identified as Infractions No. 5, 7, 13, 16 and 20 in Appendix A to the NRC letter to HL&P dated April 30, 1980.
In the discussion below, the track numbers from IE Investigation Report No. 50-498/79-19; 50-499/79-19 are indicated.
(Closed) Infraction (50-498/79-19-24; 50-499/79-19-24):
Failure to Document Soil Lift. Thickness and Number of Passes of Equipment as Part of QA Records.
The IE inspector reviewed the changes in procedures effected by Revision 4 to Brown & Root (B&R) Quality Construction Procedure A040KPCCP-2, " Structural-2-
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Backfill," and by Pittsburg Testing Laboratory (PTL) Field Change No.
PT-FCR-046 to PTL Procedure QC-ST, Revision 7, " Soils Inspections and Tests - Field." These document changes were reviewed for content, and applicability of the proposed changes to the items of noncompliance.
The changes now require documentation of loose lift thicknesses and number of roller passes.
The specific roller pattern to be used is also defined.
Based on this review, the IE inspector determined that the changes effected in the procedures by the above documents resolve the item of noncompliance.
This item is closed.
(0 pen) Infraction (50-498/79-19-10; 50-499/79-19-10):
Ineffective Corrective Action to Resolve Previously Identified Concrete Placement Ceficiencies.
During this inspection, the IE inspector reviewed the newly issued B&R Quality / Concrete Construction Procedure No. A040KPCCP-25, which replaces and incorporates the following procedures:
A040KPCCP-3, "Prepour Activities" A040KPCCP-4, " Concrete Placement and Finishing" A040KPCCP-6, " Grouting" A040KPCCP-8, " Form Removal, Concrete Curing and Repair" A040KPCCP-il, " Reinforcing Steel Mechanical Splicing (Cedwelds)"
A040KPCCP-12, " Installation of Waterstop and Waterproofing Membrane System" A040KPCCP-19, "Shotcrete" The new procedure prescribes the methods and requiremer,ts for all activities involved with concrete construction.
Improper consolidation and excessive lift thickness are addressed in the procedure by specification of the maximum limit for deposition and definition of proper vibrating techniques.
Documentation of retraining to the new pro-cedure for 188 personnel was reviewed by the IE inspector.
Those retrained included concrete placement foremen, field engineers, and QC inspectors.
The new procedure requires concrete consolidation training every 90 days for all concrete placement craft personnel.
The IE inspector reviewed records of such training for the last two classes held.
These training classes specif-ically emphasize consolidation procedures and ACI recommended practices.
Concrete placement planning is addressed by requiring formal preplacement and postplacement meetings for all safety-related concrete placements.
The required agenda includes discussion and documentation of the specific placement techniques to be utilized; and postplacement discussions of all-3-
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deviations from plans for the purpose of initiating any required changes in future placements.
In addition, inadequate li$ ting is addressed by inclusion of an additional inspection item on the "Special Prepour Checklist" entitled, " Adequate Provisions for Light."
Implementation of this requirement for adequate lighting was verified by the IE inspector during a preplacement inspection of concrete placement No. ME2-W008-03A.
The placement plan for concrete placement No. ME2-W019 048 was also reviewed during this inspection.
The problem with last minute construction activity resulting in undue pressure on QC personnel has been resolved by revising the procedure to require the completion of the preplacement inspection and sign-off of the pour card by the B&R QC inspector as a prerequisite to the delivery of concrete to the placement.
The new procedure also specifically defines the QC inspector authority to " hold work" when he believes that the quality of work is unacceptable or indeterminate.
The license has also committed, in the response to the infraction, to provide additional QC preplacement inspectors to assure that oreplacement inspections are conducted in a thorough manner.
This commitment is intended to reduce production pressures on QC inspectors.
Since there exists a stop-work order on all complex concrete placments, the implemen-tation of this commitment could not be reviewed during this inspection.
This infraction remains open pending verification of increased QC presence following resumption of normal concrete construction activities.
(0 pen) Infraction (50-498/79-19-03; 50-499/79-19-03):
Failure '.o Take Corrective Action When Cadwelders Needed Requalification.
The issuance of Procedure No. A040KPCCP-25 specifically addresses the authority of the QC inspector to " hold work" when he believes that quality of work is unacceptable or indeterminate.
All affected personnel have been indoctrinated in the definitive responsibilities and authorities addressed in the new procedure (see previous item).
This corrective action requires that work will be stopped when a potentially nonconforming condition is identified until a satisfactory resolution is achieved.
A revision to Specification 2A010CS028, " Concrete Construction," has been issued, which allows a Cadwelder to continue working without requalification when two unacceptable visual tests within a unit of fifteen consecutive test samples are accumulated.
This change is inconsistent with site Pro-cedure A040KPCCP-25 and current licensee commitments.
The licensee has proposed amendment to the FSAR, paragraphs 3.8.1.6.3.l(a) and 3.8.3.6.3.l(a).
This infraction will remain open pending review and disposition of the proposed FSAR amendment by the NRC licensing review group.
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(Closed) Infraction-(50-498/79-19-27; 50-499/79-19-27):
Failure to Control the Use of a Nonconforming Hammer for Penetration.
The IE inspector reviewed the revised Woodward-Clyde procedures which now define the handling of nonconformances.
Revision 2 to the Woodward-Clyde STP Quality Assurance Manual also establishes the position of Quality Assurance Monitor (s) for the purpose of reviewing, monitoring and reporting on the quality assurance of work items assigned.
A Nonconformance and Corrective Action Report form generated for the purpose of reporting and processing nonconformances was also reviewed.
Previous corrective actions to this infraction have already been reviewed by the IE inspector (see Inspection Report No. 50-498/80-17; 50-499/80-17).
This completes inspection of the committed corrective action.
This item is closed.
(0 pen) Infraction (50-498/79-19-11; 50-499/79-19-11):
Failure to Inspect Reinforcing Steel for Loose Rebar Prior to Concrete Placement.
Since the cause of this infraction can be attributed to the same cause for part of infraction 50-498/79-19-10; 50-499/79-19-10; i.e., production pressures on QC inspectors, the corrective actions taken by both infractions are applicable. As noted above, implementation of the commitment to provide additional QC inspectors will be reviewed during subsequent inspections.
This infraction remains open.
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Exit Interview The IE inspector met with licensee representatives (denoted in paragraph 1) at the conclusion of the inspection on July 24, 1980.. The IE inspector summarized the purpose and the scope of the inspection and the findings.
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