IR 05000498/1981004
| ML19347E474 | |
| Person / Time | |
|---|---|
| Site: | South Texas  |
| Issue date: | 03/11/1981 |
| From: | Crossman W, Phillips H NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML16251A407 | List:
|
| References | |
| 50-498-81-01, 50-498-81-1, 50-499-81-04, 50-499-81-4, NUDOCS 8104270450 | |
| Download: ML19347E474 (8) | |
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O U. S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT
REGION IV
Report No. 50-498/81-04; 50-499/81-04 Category A2 Docket No. 50-498; 50-499 Licensee: Houston Lighting and Power Company Post C ' ice Box 1700
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Houstcn, Texas 77001 Facility Name: South Texas Project, Units 1 and 2 Inspection at: South Texas Project, Patagorda, Texas Inspection Conducted:
February 1981 Inspector: 4 fy N c b 1 UN//F/
/ 1 H. S. Phillips, Resident Reactor Inspector Date Projects Section No. 3
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Approved:
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W. A. Crossman, Chief, Projects Section No. 3 Cate
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Inspection Surm:ary:
Insoection of February 1981 (Recort No. 50-498/81-04; 50-499/81-04)
l Areas Insoected:
Routine, announced inspection by the Resident Reactor Inspector (RRI) included independent inspection performed during a site tour, I
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follow-up inspections relative to noncompliances, unresolved items and Show Cause Order items.
The inspection involved fifty-nine inspector-hours by one NRC inspector.
Resul ts : No violations or deviations were identified.
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O DETAILS 1.
Persons Contacted Principal Licensee Employees
- R. A. Frazar, Quality Assurance Manager L. D. Wilson, Project QA Supervisor (Mechanical)
J. W. Soward, QC Supervisor T. J. Jordan, Supervisor Quality Systems R. A. Carvel, Project QA Supervisor (Civil / Structural)
D. W. Bohner, Project QA Supervisor (Electrical)
C. L. Harvey, Gilbert Commonwealth Consultant to Houston Lighting and Power Company (HL&P)
The RRI also interviewed other licensee and contractor personnel including members of the engineering and QA/QC staffs.
" Denotes attendance at the management meeting.
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Licensee Action on Show Cause Order, April 30, 1980 (0 pen) Show Cause Order, Item V. A.(1):
Management Consultant Review.
HL&P Management of Program to Control All Aspects of the South Texas Project; Revision of Organizational Responsibilities to Control the Design, Procurement and Construction Activities of the Licensee's Prime Contractor, Brown & Root, Inc. (B&R), and HL&P Overall Responsi-bility for QA/QC Program.
The RRI reviewed commitments listed in HL&P letter (ST-HL-AE-533), dated September 18, 1980.
Based on the review of objective evidence and actions taken, the following items are closed:
Item No.
Basis for Closing A2 Reviewed and closed under Show Cause Order Item 9 of this report.
A3; A6 The RRI determined that the commitments relative to HL&P QA Discipline and Quality Control Groups were incorporated
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into HL&P Site Procedure PSQP-Al, Revision 9, l
December 11, 1980, and Procedure PSQP-A10, Revision 0.
332; "2 The Li n..: n t :p:..:a ta i.'.a 2h.w 1 3e
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Order, dated July 29, 1980, contained the 3echtel Audit (Exhibit 1), dated July 24, i
1980.
This audit recomi. ended action l
relative to personnel cualification.
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qualifications of key QA personnel were reviewed by Bechtel and Management Analysis C0mpany (MAC).
Also the reorganization of HL&P and B&R resulted in supplementing and upgrading the staff.
Close out is also based on the close out of A13 thru A17 and H14 below.
A13; A14; A15; These items pertained to training of A16; A17; H14 quality control and construction personnel on site to improve personnel qualifica-
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tions.
Quality engineers have established training programs to update training through refresher training.
Emphasis was given te new QA procedures.
The RRI reviewed objective evidence as follows:
April and October 1980 Refresher
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Training, Lesson Plan, Sign-in Sheets and Computer Listing for Electrical, Civil and Mechanical Personnel.
Welding Inspection Lesson Plan,
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August 1980.
Weekly and Monthly Training Report,
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September 3, September 19, October 6, November 4, 12, 20 and 24, December 2, 1980.
B&R Senior Management Meeting with
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QA/QC site personnel, August 28, 1980.
B&R Corporate QA Management Meeting
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with B&R site personnel, September 9, 1980.
H2 On August 19, 1980, at a public meeting, a B&R top manager made a commitment to devote 90% of his time to the South Texas Project.
The RRI has determined that the manager h:s fr:;ucntly Sc:a :n ite to att cd QA monthly meetings as well as other meetings.
He also signed a letter dated, December 19, 1980, which stated that he has met this commitment.
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HIS The RRI reviewed manpower reviews documented in HL&P memo, dated September 10, 1980.
The basis for manpower appeared to be valid.
The following items remain open pending review / inspection:
A8 H13
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H17 (Closed) Show Cause Order, Item V.A.(6):
The Licensee Shall. Develop a More Effective System to Provide for the Identification and Correction of the Root Cause of the Nonconformances Which Occur.
The RRI reviewed commitments listed in the previously referenced letter (ST-HL-AE-533) and closed the following items:
Item No.
Basis for Closing A65; A69 These two items pertain to Show Cause
Order, Item 3, welding commitments.
The portion of this commitment that deals with nonconformances refers to welding nonconformances and will be reviewed under Shcw Cause Order, Item 3a.
M30 B&R Procedure ST-QAP-10.1, Revision 0, (October 27, 1980), paragraph 4.4 described the Inspection Report (IR)
system.
B&R Procedure ST-QAP-15.1, Revision 2 (January 5, 1981), para-graphs 3.9, 3.10 and Attachment 15.1E describe the Material Review Board (MRB)
composition, responsibility and flow diagram of actions.
M32 The RRI reviewed ST-QAP-15.4, Revision 1, dated January 18, 1981, and determined that a procedure.to describe data analysis (trending) had 5een implemented.
This comolatas the review of til lic r:ca c:m itaar.ts mada end corrective action taken relative to this Show Cause Order item.
This item is closed.
(0 pen) Show Cause Order, Item V. A. (9):
The Licensee Shall Develop and Implement an Improved Aucit System.
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The RRI reviewed commitments listed in the previously referenced letter (ST-HL-AE-533) and closed the following items:
Item No.
Basis for Closing A2 HL&P Audit Group had five full time auditors in January 1980.
On October 29, 1980, the audit staff had increased to seven full time audito s with four auditors in training.
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A150; A151 B&R Correspondence No. SQA-4327 transmitted a trend analysis and the letter indicated that copies were sent to B&R Audit Group, Project QA Management, Construction and Engineering.
The same letter showed that the HL&P Audit Group received copies of the report.
Correspondence ST-HS-HL-01456 forwarded HL&P Trend Report to HL&P Audit Group.
A159 One team member of the audit team must have experience in the discipline being audited.
HL&P Procedure QAP-5 and B&R Work Instruction WI-6, Section 5.0, paragraph 7 requires that discipline or technical specialist be on an audit team.
HL&P Correspondence ST-HL-AE-533 documented the use of such personnel.
H31 HL&P Correspondence ST-HL-16748, dated September 10, 1980, transmitted Audit No. HL-86 from HL&P Audit Group to HL&P Senior Vice President.
B&R Correspondence QAX-0284 transmitted Audit ST-43 to B&R Senior Management.
The following items remain open pending review / inspection:
A153 A161 A162
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Licensee Action on Previously Identified Items (Closed) Noncompliance (498/80-18-A):
Failure to Develop Procedures to Assure Traceability of Embed Material.
The RRI reveiwed HL&P response (ST-HL-AE-564), dated October 23, 1980.
A commitment was made to revise the procedure to control embed material.
B&R Procedure CCP-25, Revision 2 (September 22,1980), paragraph 8.5.8.2, page 116 was revised to require inspection for a mark on installed embed material.
The mark indicates traceability.
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(Closed) Violation, Level I, (498/80-27-A):
Failure to Follow Procedures Which Prevent the Us of Nonconforming Material.
The RRI reviewed HL&P response (ST-HL-AE-601), dated January 9,1981, which committed to the revision of Procedure ST-QAP-15.1, "Nonconformances,"
and committed to train appropriate personnel.
The RRI verified that ST-QAP-15.1, Revision 2 had been revised and was approved on January 5, 1981.
Sixteen quarterly refresher training sessions were held from January 12 thru 22, 1981, as documented in B&R Correspondence SQA-4484, dated January 27, 1981.
(Closed) Unresolved Item (498/79-19-17; 499/79-19-17):
Personnel Training When Procedures and Specifications are Revised.
B&R Procedures GCP-1, Revision 8, dated August 4, 1980; ST-QAP-6.1, Revision 2, dated January 22, 1981; and GCP-13, Revision 4, dated November 26, 1980, describe the action to be taken and the training given by the Training Department when a procedure or specification is developed or revised.
The originator identifies those to be trained to the Training Department and the required training results.
(Closed) Unresolved Item (498/79-19-49; 499/79-19-49):
Audit Requirements of ANSI N45.2.-12 Not in Pittsburgh DeMoines Contract.
Subsequent to the above finding, HL&P notified the Region IV NRC office on June 13, 1980, and advised that a breakdown in the quality program for the procurement cycle of purchased material and equipment, had been identified.
Interim 50.55(e) reports made on July 14, September 12 and l
October 31, 1980, outlined a comprehensive review by B&R Engineering I
Quality and Assurance as well as the NUS Corporation.
The corrective action, which is underway, will include the correction of the above item.
l Therefore this item is closed and will be considered during the final
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review of the corrective action in the final Construction Deficiency Report.
(Closed) Unresolved Item (498/80-27-01; 499/80-27-01):
QC Sign Off Based on Verbal Assurance frcm Craftsmen.
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This ' tem pertains to comments made at a September 25, 1980, meeting relative to Quality Control Inspector's signing off on required 'nspec-tions, based on the craftsman's " word" if he was known to be reliable.
Although these comments may have been made to foster better relations between construction and inspection personnel, the RRI stated that such action would be inappropriate if it occurred.
On January 6,1981, B&R QC and construction personnel met and it was made clear to all personnel that inspection or reinspection must be based on actual inspection rather than verbal assurance.
The RRI has no further questions on this matter.
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4.
Site Tours The RRI inspected various site areas as follows:
Units 1 and 2 Reactor Containment, Auxiliary and Fuel Handling Buildings; Concrete Batch Plant, Pittsburgh Test Laboratory; and various laydown areas for reinforcement bar, structural steel embeds, and piping.
No violations or deviations were identified.
5.
Management Meeting The RRI met with the person identified in paragraph 1 on February 25, 1981, to discuss the inspection findings and licensee actions and positions.
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INSPECTION PLAN IE Inspection Report No.
50-498/81-04; 50-499/81-04 Licensee:
Houston Lighting and Power Company Location:
Matagorda County, Texas Facility:
South Texas Project, Units 1 & 2
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Type of Licensee:
W, 1250 MWe, PWR Type of Inspection: Resident, routine, announced Dates of Inspection: February 1981 Dates of Previous Inspection:
January 1081 Inspectors:
HSphj]]j s p
SCOPE OF INSPECTION Resident inspection program for construction
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?eactor Inspector Date g, _
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" "4'e UNITED STATES
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NUCt. EAR REGULATORY COMMISSION
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f.7,,,.y g REGloN IV
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611 RYAN PLAZA QRIVE. SUITE 1000 ARUNGToN. TEXAS 79011
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February 13, 1981 In Reply Refer To:
RIV Docket No. 50-498/Rpt. 81-05 50-499/Rpt. 81-05 Houston Lighting and Power Company ATTN: Mr. G. W. Oprea, Jr.
Executive Vice President Post Office Box 1700 Houston, Texas 77001 Gentlemen:
This refers to the inspection conducted by Mr. W. 9. Hubacek of our staff during the period February 2-5, 1981, of activities authorized by NRC Con-struction Pemits No. CPPR-128 and 129 for the South Texas Project, Units No. I and 2, and to the discussion of our findings with Mr. R. L. Hand and other members of your staff at the conclusion of the inspection.
Areas examined during the inspection and our findings are discussed in the enclosed inspection report. Witnin these areas, the inscection consisted of selective examination of procedures and representative records, inter-views with personnel, and observations by the inspector.
Within the scope of the inspection, no violations were identified.
In accordance with Section 2.790 of the NRC's " Rules of Practice," Part 2, Title 10, Code of federal Regulations, a cocy of this letter and the enclosed inspection report will be placed in the NRC's Public Occument Room.
If the recort contains any information that you believe to be proprietary, it is necessary that you submit a written application to this office, within 25 days of the date of this letter, requesting that such information be withneld from public disclosure. The apolication must include a full statement of the reasons why it is claimed that the infomation is procrietary. The aoplication should be prepared so that any proprietary information identified is contained in an enclosure to the application, since the apolication without the enclosure will also be placed in the Public Document Room.
If we do not hear from you in this regard within the specified period. the report will be placed in the Public Docue nt Room.
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STAFF EXHIBIT NO. 87
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ovE of TI$32tro4 y)
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Houston Lighting and Power Company-2-February 13,1E31
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Should you have any questions concerning this inspection, we will be pleased to discuss them with you.
Sincerely,
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W. C. Seidle, Chief Reactor Coiistruction and Engineering Support Branch Enclosure:
IE Inspection Report Nc. 50-498/81-05 50-499/81-05
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U. S. NUCLEAR REGULATORY CO.?!SSION OFFICE OF INSPECTION AND ENFORCEM NT
REGION IV
Report No. 50-498/31-05; 50-499/81-05 Occket No. 50-498; 50-499 Category A2 Licenste: Housten Lighting and Pcwer Company Post Office Sox 1700 Houston, Texas 77001 Facility Name: South Texas Project, Units 1 & 2 Inspection at: South Texas Project, Matagorda County, Texas Ins::ection Conducted: February 2-5, 1981 Inscector: 4,M I-2/s 7//1 )?/
W; G. HucaceK, Reactor Inscector, Projects Sec:1cn Cate l
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Accroved:
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W. A. CrosstaEli, Chief, Projects Section Cate l
Ins::ection Summary:
Inscecticn on February 2-5.1981 (Recor: No. 50 198/81-05: 50 c99/81-05)
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Areas Ins::ected: 'Jnannouncea inscecticn of licensee c:: enc::ve action in res::ense i
to :ne Shcw Cause Orcer and previcus ins::ection findin9s. Tge ins::ection involved nirty-two inscector-hours by cne NRC ins::ector.
Resul ts : No violations were identified.
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r DUPLICIsTE DOCUMENT
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- ,I Entire document previously
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entered into system under:
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DETAILS 1.
Persons Contacted Princioal Licensee Employees
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L. D. Wilson, Projcct QA Supervisor C. L. Harvey, Quality Specialist
- J. B. Anderson, Quality Specialist
- T. J. Jordan, Supervisor, Quality System Other Personnel
- W. J. Friedrich, OA Manager for Brcwn & Root (B&R), Management Analysis Company (MAC)
D. J. Harris, Quality Engineering Manager for S&R, MAC
- R. L. Hand, Project General QA Supervisor for Houston Lighting and Pcwer Company, MAC T. L. Forfilio, Design Quality Engineer, 3&R D. S. McCoy, Manager Site Engineering, B&R E. Gillet, Systems Nonconformance Group, BAR J. Purdy, QA Systems Assistant Manager, B&R The IE inspector also contacted other licensee and contractor employees including members of the OA/0C and engineering staffs.
" Denotes those attending the exit interview cn February 5,1981.
2.
Licensee Action on Previous Inscecticn Findinos, (Closed) Unresolved Item (50-498/80-16-1; 50-499/80-16-1): Control of Records Removed From the QA Records Storage Facility.
The IE inscector observed tnat control of records removed from the records storage facility has been improved.
Records c n new be removed only after signed accroval to do so has been obtained from the S&R Project QA Manager.
Brown & Root Precedure ST-QAP 17.1, Revision 1, dated August 1,1980, addresses recuire-ments for removal of records from the records facility.
3rewn & Root Procedure ST-QAP 6.1 has been revised and no longer acplies to records centrol.
The IE inspector had no furcher cuestions regarding this matter.
(0 pen) Unresolved Item (50-498/79-19-44; 50-499/79-19 44): Review of Vendor Documentation.
The IE inscector was informed that vendor documentation is currently being reviewed by Brcwn & Root and a consultant as cart of their review of the vendor program to ensure that procured engineered equicment i.nd services meet the cuality commitments contained in crocurement, engineer-ng, quality assurance and licensing documents.
The olan and methods for
.he review are described in Tecnnical Reference Cocument No. 7A00GPC07, Vendor Control Program for Safety-Related Ecuipment and Material." The eview is excected to be ccmoleted in Novemcer 1981. This item will be reviewed during future IE inspections.
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