IR 05000498/1981027
| ML20030D449 | |
| Person / Time | |
|---|---|
| Site: | South Texas  |
| Issue date: | 08/11/1981 |
| From: | Crossman W, Phillips H NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20030D445 | List: |
| References | |
| 50-498-81-27, 50-499-81-27, NUDOCS 8109010405 | |
| Download: ML20030D449 (7) | |
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l t . U. S. NUCLEAR REGULATORY COMMISSION , l OFFICE OF INSPECTION AND ENFORCEMENT
REGION IV
Report No. 50-498/81-27; 50-499/81-27 Category A2 ! j Docket No. 50-498; 50-499 Licensee: Houston Lighting and Power Compan3 i Post Office Box 1700 Houston, Texas 77001
j Facility Name: South Texas Project, Units 1 and 2 .! Inspection at: South Texas Project, Matagorda County, Texas Inspection Conducted: July 1981 i . Wdklo .f" 3 - F / j Inspector: - ' H.'S. Phillips, Resident Reactor Inspector Date , l Projects Section No. 3 ! , ) Approved: 049WAc(%{{ 8/// /S-/ W. A. Crossman, Chief, Projects Section No. 3 Date~ , Inspection Sumary: Inspection of July 1981 (Report No. 50-498/81-27; 50-499/81-27) Areas Inspected: Routine, announced inspection by the Resident Reactor Inspector (kRI) included independent inspection, follow-up inspections of unresolved items, and inspection of the following areas: storage of components, equipment, and materials; fire prevention / protection; safety related concrete; > safety related structural welding; electrical raceway supports; safety related piping welding; fabrication of HVAC ducts, and testing of safety related coatings.
The inspection involved seventy inspection-hours by une NRC ins 9ector.
Results: No violations or deviations were identified.
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. , . DETAILS 1.
Persons Contacted Principal Licensee Empiryees R. A. Carvel, Supervisor, Project Quality Assurance (QA) (Civil / Structural) R. A. Fra7ar, Manager, QA
- J. E. Geiger, Manager, Project QA
! S. K. Hubbard, Senior QA Specialist T. J. Jordan, Supert'sor, Quality Systems T. K. Logan, Supervisor, Project QA G. A. Marshall, Senior QA Specialist B. R. Schulte Enoineer J. A. Thursby, QA Specialist
- J. W. Williams, Manager, Project Site L. D. Wilson, Supervisor, Project QA (Mechanical)
Brown & Root Inc. (B&R) J. A. Thompson, Deputy General Manager & Site Manager Harlan Fowler. Assistant Construction Manscer The RRI also interviewed other licensee and contractor p;rsonnel including members of the engineering and 0A/QC staffs.
- Denotes attendance at the management meetings 2.
Licensee Action on Previously Identified Items (Closed) Unresolved Item (498/81-01-07; 499/81-01-07): Unable to Obtain Up To Date Chart.
The RRI was furnished upda'.ed organizational charts of the Systems Engineering Department which reflected organizational changes.
This item is closed.
(Closed) Unresolved Item (498/81-01-05; 499/81-01-05): Storage Areas Trend Should Have Been Identified.
The RRI reviewed GCP-35, Rev.4, dated May 15, 1981, Appendix "C" requires area managers to perform weekly walk through in their respective areas to prevent generic housekeeping problems. This will be in addition to the formal B&R Trend Analysis Projram.
This item is closed.
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Storage of Safety Related Components, Equipmert, and Materials The RRI inspected the following storage areas / items during the subject inspection period: Items / Areas Inspected Comments Reactor Containment Building 1 and 2, Stored per ANSI N45.2.2 Mechanical Electrical Auxiliary Building 1 and 2, stored equipment.
Raactor Vessel, Steam Generators, Stored per ANSI N45.2.2 Accumulators, Reactor Coolant Pump Volutes, Internals (in place and long term storage) for Units 1 and 2.
Warehouse "C"- 2-RHR Motors, Serial Stored per ANSI N45.2.2 Numbers (SN) riNJ824014/15; 2-Electric Hydrogen Recombiners, SN 11 and 12; 2-Essential Cooling Pump Motors, SN 998235/36-F1; 2-CRD Cooling Fans, SN 770606/01; 2-400 HP Motors, SN 2S77, SN 1577; 2-LAC Induction Motors, SN 33-77, SN-15-77; 5-Auxiliary Feed Water Pump Motors, SN 1-1, SN 2S-78, SN 3S-78, SN 3S-79, SN IS-79; 4160 Switchgear, SW 3E151ESG0E1A; Protective System Actuation Train A, SN 0002.
Warehouse "D": 2-Limitorgue valves, Storad per ANSI N45.2.2 SN 276834/33, 8-Main Steam Isolation Valves.
Laydown Areas: Areas (A-J, M): Fab Shop; Stored per ANSI N45.2.2 Rebar Storage Areas which cnntain all of the piping, cable, cable trays, valves, embeds, conduit, bar stock, plate, fuel racks and miscellaneous structural steel.
Coarse and fine aggregate.
Stored per industry standaros.
No violations or deviations were identified.
4.
Fire Prevention / Protection The RRI inspected work areas in the Reactor, Auxiliary and Fuel Handling Buildings, Units 1 and 2, to evaluate the control of flammable materials, heat sources, smoking areas, combustible waste material / rubbish and the availability of fire fighting equipment.
No violations or deviations were identified.
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Safety Related Concrete Work Activity The RRI visually inspected the surface of Reactor Containment Building (RCB) Unit 2, Shell Wall Placement CS2-W9 placed near the equipment hatch on June 25, 1981. A small void was found when the form was removed.
l The void had t,een documented on a nonconformance report; however, engineering was still evaluating the area to determine the size and ' extent of the area to be repaired. The information available to date indicates that the void can be repaired using routine repair methods.
, Diesel Generator Building, Unit 1, Wall Placement No. DGB-1-W3-E was placed on duly 14, 1981. Test celinders 5508-T and 5508-P were taken ' and tested. The strengths exceeded the minimum expected strengths after seven days of curing. The RRI observed concrete curing on the subject . wall on July 2E, 1981.
1 The RRI observed repai work on the Essential Cooling Water Intake Structure. NCR No.8460, dated May 5, 1981, documented that horizontal reinforcement steel dowels were not in place. The dowels were being ! placed to correct this ommission.
The following civil laboratory test equipment, used in testing materials for making concrete, was inspected to assure that the equipment was properly calibrated: Forney Compression Tester, 21 Kg Scales, oven for drying aggregatc, sieves (No.3/8, 4, 8,16, 30, 50,100), 20 Kg Soils Scales. The RRI observed fine aggregate tests, Lab No.C-13838 and ' Lao No.C-13360 that were in process. Test results showed that the material passed the sieve test and the fine materials / organic impurities did not exceed the maximum allowed.
No violations or deviations were identified.
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Electrical Raceway Supports The RRI observed the welding of raceway supports in MEAB 1, Elevation 27, Weld No.FSHE AX1-170-3. No unacceptable surface defects were observed.
Welder No. AXM was welt.ng in accordance with Welding Procedure MECP-2 l using 3/32-E7018 filler material and reverse polsrity. The filler material was properly controlled by using check cut slips.
Welding technicians in the area assist the welders by giving technical guidance. Quality Control Inspector, perform interim and final inspection.
Visual inspection of welds throughout the area indicated high quality
welding and adequate process controls.
No violations or deviations were identified.
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Safety Related Pipe L'alding The RRI inspected 30" Aluminum Bronze Pipe used in the Unit 2 Essential Cooling Water System, EW2303.
Field Weld Nos. FdOO29-1 cod FW0039-1 were visually inspected. The radiographs were read and compared with B&R Radiographic Reports which st. owed that the proper interpretation and review cycle had been accomplished in accordance with Radiographic Procedure ST-QAP-9.11, Rev.0, and Attachment ST-QAP-9.11k.
Penetrant testing was performed on FW0025 in accordance with Weld Dye Penetrant Examination Procedure, ST-QAP-9.6, Rev.0. Weld joint preparation on the ends of these pipes was accomplished by using an automatic cutting and grinding machine.
The RRI observed the HL&P OA Senior Specialist perform a portion of an NDE Implementation Review in accordance with Procede,e No.PSQP-A9, Rev.1.
No violations or deviations were identified.
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Installation of Structural Beel Beams The RRI visually inspected the completed welding of clip angles to embedments in the walls of MEAB 1, HVAC Room at Elevation 9.
Two beams, K7025X5706B3 and K7025X570783, were bolted to the clip agles which were welded to the embedments. Marks on the adjacent area indicated that welds had been inspected by B&R Quality Control (QC) inspectors. The welds, which had been accepted, appeared to be free of surface defects as des-cribed by AWS D.1.1.
The bolts had not been torqued / inspected. General Arrangement Drawing K7025X5 was reviewed to compare the as-built configura-tion to the drawing. Welding details were found on Detail Drawing K7025-X5 E704.
General construction techniques and progress were discussed with the B&R l Crafts Supervisor who explained the sequence of work and identified those re<.?onsible for inspections.
' No violations or deviations were identified.
Fabrication of Safety Related Heating Ventilation Air Conditioning (HVAC) 9.
~Duct Work ' Bahnson Service Comparv (BSC) has the contract to fabricate and install HVAC duct work. The RRI reviewed tte BSC QA Manual and determined that i sections for each 10 CFR 50, Appendix "B" Criteria had been established.
i The BSC Field Procedures Manual was selectively reviewed to determine that procedures had been established and these procedures described how QA manual requirements would be accomplished.
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_ ' ' . . The RRI reviewed BSC Site Organuation and interviewed the Senior QA representative. The RRI asked about current QA problems and found that B&R Specification No.3V27WS007-G and BSC Fabrication Procedure DFP-STP-001 and DFD-STP-001 did not agree in all aspects resulting in a Corrective Action Request (CAR). The RRI subsequently followed up on this item and found that the conflict was resolved by PCN #3, dated July 23, 1981.
The RRI inspected the welding of HVAC Joints J7 in the EBC2 System which will be installed in MEAB 1.
The BSC inspector was performing end item inspection of Joint 23 of the SMD 49 System. The item inspected met the dimensional requirements but some areas of the welding were marked for rework and reinspection.
The RRI verified that welder qualifications #or Welders T-3582 and W-1786 were current.
Filler materiah for the submerged arc and metal inert gas process were properly stored and controlled. Weld Rod, E7018, was in heated ovens which had been properly calibrated.
Duct work in the lay down areas was stored in accordance with ANSI N4L 2.2, Levei D requirements.
No violttions or deviations were identified.
10.
Control of Nu_ clear Coatings.
The RRI reviewed the control of nuclear coatings as a result af concerns expressed by B&R personnel.
The first concerm or statement related to the qualifications of a coatings foreman in the h.1 Handling Building. The foreman's reading ability and understanding of coating procedures were questioned.
Coatings in this area are Service Level 2 which means they are considered non-safety related and Jo not come under the requirements of 10 CFR 50, Appendix "B".
The RRI inspected this area even though the area is classified non-safety related. After a preliminary review of coating work activity and speci-fications, this matter was discussed with Houston Lighting and Power and with Brown & Root senior management. The RRI reviewed a cer+ification which certified that the subject foreman had a high school eeucation, reading ability, and training in coating orocedures. The RRI has no further questions regarding this matter.
The second concern or statement related to low pull test values on coatings applied to concrete surfaces in RCB-1. The RRI followed up on this matter by contacting the licensee's QA personnel responsible for performing an overview of the contractor's coating process. The cognizant engineer was aware of the low.ull test values and stated that this failure to meet the oull test was documented i.1 B&R * nconformance Report No. SG-6321 on July 1,1981. This deficiency was being properly controlled by the contractor's nonconformance system.
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. , . Furthermore, on September 22, 1980, the licensee notified the NRC Region IV office that a Brown & Root review of documentation of the coating i prcr.ess had identified incomplete documentation to substantiate the quality of Service Level I coating, a safety related coating.
The licensee engaged a consultant to evaluate all coatings applied prior to January 9, 1980 to determine appearance, thickness and adhesion properties.
The licensee had made periodic reportr to the NRC in accordance with 10 CFR 50.55(e) requirecents.
The RRI witnessed the part of this testing on the coating applied to the dome liner of Reactor Containment Building 1, test areas 29, 36 and 43.
It appears that the above test activity and corrective action has caused workers to have concerns, however, the licensee's and the contractor's quality assurance system appears to be adequately identifyi., con-trolling and correcting any deficiencies.
In the next several months,
a final report will be made by KTA Tator, the Coating Consultant, and i an NRC inspector will review and follow up on this construction deficiency i when the report is completed.
I Sinc ( the licensee's system was properly controlling deficiencies regarding the above concern, the RRI has no further questions regarding this matter.
This item had already been identified as a follow up item after receiving , the 10 CFR 50.55(e) report.
No violations or deviations were identified.
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Site Tours The RRI performed independent inspections during site tours which included the Reactor Containment Buildings, Units 1 and 2, Mechanical Electrical Auxiliary Building, Units 1 and 2 and Storage and Laydown Areas.
l No violations or deviations were identified.
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Management Meeting The RRI met with one or more persons identified in paragraph 1 ^n July 30, 1981, to discuss inspection findings and results.
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