IR 05000498/1981006
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U.S. NUCLEAR REGULATORY COMMISSION
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O 0FFICE OF INSPECT:0N AND ENFORCEMENT
REGION IV
(This Report Contains Investigation Results in Paragraph 3)
Report No. 50-498/81-06; 50-499/81-06 Docket No. 50-498; 50-499 Category A2
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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: February 23-27, 1981
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Inspectors: C. V. 'iomli'mrefi, Reactor Inspector, Engineering & Materials Date
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Section (Paragraphs 1, 2, 3 & 4)
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0/, N0id--ud Date W. G. Hu6acek, Reactor Inspector, Projects Section No. 3 (Paragraph 2)
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Approved:
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Date W. A. Crossman, Chief, Projects Section No. 3
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R. E. Hall, Acting Chief, Engineering & Materials Section
- ns aection St.c...ury:
23-27, 1981 (Recort No. 50 498/81-06; 50 499/81-06),
{nscection on FebruaryUnannounced rollcw-up inspection or construction activities
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nreas Inscected:
50 298/79-19; pertaining to the review of responses to NRC Inspection Report No.
50 a99/79-19 and other insoection findings. The inspection involved 14 inscect:;r-hours by two NRC inspectors.
Resul ts : No violations were identified.
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OETAILS
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1.
Persons Contacted Principal Licensee Employees
- R. Frazar, Manager, Quality Assurance
- L. Wilson, Supervisor, Mechanical /NDE
- T. Jordan, Supervisor, Quality Systems
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Other Personnel
- R. Hand, Project GA General Supervisor, Management Analysis Company (MAC)
F. G. Miller, Senior Welding Engineer, Brown and Root (B&R)
The NRC inspectors also contacted other licensee and contractor employees including members of the QA/QC and engineering staffs.
- Denotes those attending the exit interview.
2.
Licensee Action on Previous Inspection Findinas During this inspection, certain corrective actions concerning the findings of Investigation Report No. 50-498/79-19; 50-499/79-19, additional items extracted from the NRC transcript of the Public Meeting with HL&P/B&R cn August 19, 1960, and commitments from management meetings were reviewed:
The following six items, relating to existing.ASME piping welds, were individually reviewed; but are being addressed together in this report:
(Closed) Public Meeting Commitments H-24, A-38, A-52, A-53, A-82 and A-83.
All radiographs, including those for ASME oiping, have been reviewed by a B&R Level III as part of the Task Force effort.
All inspection records for ASME piping welds have been evaluated by the Task Force for completeness and coinpliance to Code require-ments.
The NRC inspector reviewed the preliminary results of this evaluation to verify that the review commitment was being met.
Final results will be incorocrated into the Task Force Final Reoort which is due within the next month. Any radiograph exhibiting film quality less than required will be reshot. Any radiograph that exhibits inferior or questionableweld quality will be cause for rejection and repair of that weld.
The NPC inspector's review of TRO SAiu0GP004, Attachment 2, Revision 1 indicates that 100% of the ASME oiping socket welds and butt welds are currently being reinscected.
The results of t.his reinssciica es e bebg cacerdad and all rascubis indications will be repaired.
Disposition of all welds buried in con-crete will be based on an engineering analysis of data gathered during this re-examination of accessible welds.
These six items are closed.
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The following four items, relating to welds on ASME, Subsection NF, welds on pipe supports and hangers,were individually reviewed; but are being addressed together in this report:
(Closed) Public Meeting Connitments A-54, A-84, A-85 and A-86.
A data and documentation review is being conducted by the Task Force to determine the adequacy and acceptability of site-produced welds on ASME, Subsection NF pipe supports and hangers. Concurrent with this review, a visual and liquid penetrant re-examination is being conducted on 100% of the welds to identify any discrepant conditions.
Deficiencies notad during this inspection will be repaired as part
of the re-examination and repair program.
The NRC inspector reviewed TRD 5A700GP004, Attachment 2, Revision 1 to verify the extent of this reinspection.
The NRC inspector, by reviewing personnel qualification and certification records, verified that all inspectors and welders involved in this re-examination and repair phase have been retrained and recertified.
These four items are closed.
The following two items, relating to welder qualirications, were individually reviewed; but are being addressed together in this reoort:
(Closed) Public Meeting Commitments A-60 and A-62.
Improprieties were noted in the radiography and acceptance criteria for welder test coupons.
The NRC inspector verified that all ASME and AWS welders are being requalified in accordance with Procedure MECP-1.
The NRC inspector also verified that only ASME piping weld test coupons are being evaluated by radiographic examination. This
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change was made to eliminate the possibility of the wrong acceptance i
standard being applied to a qualification radiograph. All test
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coupons for ASME and AWS plate welding qualifications are being evaluated by the bend test method.
An NRC review of training records l
indicates that all film interpreters have been retrained and are i
aware of the procedural change to the bend test method. As part of I
the re-examination and repair program, all ASME and AWS welds produced l
prior to April 30, 1980, are being reinspected to assure the accepta-l bility and integrity of the welds.
The NRC inspector reviewed several interim reports written for this inspection and found the inspections to be in accordance with the program as described in TRD 5A700GP004, Attachment 2, Revision 1.
These tuo items are closed.
The following two items, relating to the Code reclassification of the fuel transfer tube and icwer steam generator suoports, were individually reviewed; but are being aooressed together in this report:
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(Closed) Public Meeting Ccmmitments A-51 and A-55.
The steam generator support columns are 3 part of the system that transfers component loads to the Reactor tentainment Building structure.
The upper columns are part of the duclear Steam Supply System (NSSS)
furnished by Westinghouse, while the lower supports were fabricated-by Lamco Industries. Although the lower supports had been Code stamped, defects were discovered in the welds attaching the columns to the baseplates after the columns arrived on site. The corrective action was to gouge out the defects and reweld. A review of the ASME Code failed to discover any requirements for major repairs on large parts which had been previously accepted by an ANI and shipped
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to the construction site. -
The Code boundary for ASME classified material is at the concrete slab at the 19'-0" elevation.
The upper supports and thru anchor bolts are therefore Code classified items; but this requirement does not extend to the lower supports as they are below this level.
An ASME/HL&P conversation confirmed this rationale and the design specification (TRD 1C1195Q002) and fabrication specification (TRD 1C119S5035) have been revised to show lower supports as being Category I structural steel members under the American Institutue of Steel Construction (AISC) Code. This reclassification deleted the necessity for Code stamping and the previously applied Code stamps were removed.
All repair work was accomplished as stated in Section III and was witnessed by a Pittsburg-Des Moines Steel Company (PDM) ANI, even though there was no Regulatory, ASME or State requirement for this.
Under the B&R QA program, all subsecuent welding of itens to these columns must be done in accordance with the higner Code classification of either of the members to be joined.
The welding of any structural steel member to these columns must be done in accordance with the AWS Code and the welding of the ASME Code item to these columns must be done in accordance with the required ASME Code.
The NRC inspector interviewed cognizant engineering personnel and reviewed the inspection reports and other correspondence relative to the fuel transfer tube. The transfer tube was delivered to the site as two pieces, which were welded together by site welders and inspected by the ANI. The bellows were then welded to the tube assembly. The required NDE of the welds was performed and the entire assembly was hydrostatically tested and the results documented on October 9,1978.
The ANI was not notified of the hydro test, did not witness the test and did not Code stamp the final fuel transfer tube assembly. Brown and Root engineering redefined the Code jurisdictional boundaries and removed the Code stamo requirements for the fuel transfer tube making it consi' stent with the other containment mechanical penetrations.
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NCR S-M 1513-A, with attachments, removes the Code stamp requirements thus relieving tne ANI of resconsioility for witnessing the hydro Les.
The ANI issued a memo, dated December 7,1978, which stated, "All previous and future ANI involvement with the subject assembly is no longer acolicable for Units 1 and 2."
The assembly classification has been clarified, the Code stamo recuirement removed and ANI involvement deleted.
These two items are closed.
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(Closed) Infraction (50-498/80-07-A; 50-499/80-07-A): Failure to Follow Procedure for Storage of Material. The NRC inspector reviewed licensee corrective action and recurrence control described in HL&P letter ST-HL-AE-468, dated May 23, 1980.
Nonconformance Report No. S-M3645, relative to damaged Penetration M-39, has been dispositioned and Corrective Action Report S-285, relative to violation of Procedure A040GCP-35, has been closed. The NRC inspector observed that Penetration M-39 has been repaired and that the weld preparations of other penetrations were ade-quately protected from damage.
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(Closed) Deficiency (50-498/79-13-A.E; 50-499/79-13-A.E): Failure to Destroy or Stamp a Deleted Procedure.
Review of all QA manuals for completeness and presence of deleted procedures was completed by Brown and Root QA in October 1979. No other cases of manuals containing deleted procedures were found.
During August and September, a complete recall of all controlled manuals was completed and new manuals were issued. At present, the Systems Development Group of the Brown and Root Quality Systems Section issues transmittals which request the return of superseded or deleted procedures. Where possible, the System Development Group hand carries QA procedures to the manual holders and makes the changes.
This item is closed.
3.
Investication of an Allecation (Closed) Allegation 13-A (Tracking No. 50-498/79-19-05): The allegation that a pipe sleeve weld defect was located at azimuth 300, elevation
8'-0" in Reactor Containment Building No.1 near work panal 15 could not be substantiated.
The NRC inscector and one HL&P supervisor toured a wide area around the location described, but could not find the alleged
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defect.
There were no pipe sleeves within twenty feet of the location given and the alleger declined to give more specific directions when the NRC inspector contacted him by telephone.
The NRC inspector visually examined the welds on the only pipe located in this vicinity and reviewed l
the NDE inspection reports for these welds. The welds aopeared to be
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acceptable and did not exhibit any visible defects.
The inspection reports also indicated that the welds were found to be acceptable by the liquid penetrant NDE method.
This allegation could not be substantiated.
Exit Interview I
The NRC insoectors met with licensee representatives (denoted in caragraph 1)
at the conclusion of the insoection on February 27, 1981.
The findings
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of this inspection were discussed with emanasis on the need for closure of the remaining open items.
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INSPECTION PLAN II Inspection Report No.
50-498/81-06; 50-499/81-06 Licenses:
Houston Lighting and Power Company Location:
Matagorda County, Texas Facility:
Sout[hTexasProject, Units 1&2
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Type of Licensee:
W, 1250 MWe, PWR Type of Inspection: Routine, unannounced Dates of Inspection:
February 23-27,1981 Dates of Previous Inspection:
February 2-5, 1981 nspectors:
DPTomlinson, WGHubacek scope OF INSPECTION 92702B 92706B 307038
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Cace Rasctor Inspec:cr Appr:ved Data
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UNITED STATES
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NUCt. EAR REGULATORY COMMISSION
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REGION IV
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- 4 8 811 RYAN Pt.AZA oRIVE. SUITE 1000 ARUNGToN.TIxAS 79011
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March 16, 1981 In Reply Refer To:
RIV Docket No. 50-498/Rpt. 81-08 50-499/Rpt. 81-08
HoustonILighting 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. L. D. Gilbert of our staff during the period March 2-6, 1981, of activities authorized by NRC Construction Permits No. CPPR-123 and 129 for South Texas Project, Units No.1 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. Within these areas, the inspection consisted of
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selective examination of procedures and representative records, interviews 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 copy of this letter and the enclosed inspection report will be placed in the NRC's Public Document Room.
If the report 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 withheld from public disclosure. The application must include a full statement of the reasons why it is claimed that the information is proprietary. The application snould be prepared so that any proprietary information identified is contained in an enclosure to the aaplication, since the application without the enclosure will
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also be placed in the Public Document Room.
If we do not hear from you in this regard within tne specified period, the report will be placed in the Puolic Document Room.
STAFF EXHIBIT N0. 89
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Houston Lighting and Power Company-2-March 16, 1981 Should you have any questions concerning this inspection, we will be pleased to discuss them with you.
Sincerely,
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' gW. C. Seidle, Chief Engineering Inspection Branch Enclosure:
IE Inspection Report No. 50-498/81-08 50-499/8'-08