IR 05000498/1982019
| ML20028E750 | |
| Person / Time | |
|---|---|
| Site: | South Texas  |
| Issue date: | 01/05/1983 |
| From: | Boardman J, Crossman W, Hubacek W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20028E740 | List: |
| References | |
| 50-498-82-19, 50-499-82-19, NUDOCS 8301280171 | |
| Download: ML20028E750 (11) | |
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APPENDIX U. S. NUCLEAR REGULATORY COMISSION
REGION IV
Report: 50-498/82-19 50-499/82-19 Dockets: 50-498; 50-499 Category:
A2 Licensee:
Houston Lighting and Power Company (HL&P)
P.O. Box 1700 Houston, TX 77001 Facility Name:
South Texas Project, Units 1 and 2 Inspection At:
South Texas Project, Matagorda County, Texas Inspection Conducted:
December 6-17, 1982 Inspectors:
d4 4 J.
' Boardman, Reactor Inspector Date Rea or Project Section B (par. 6)
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/l5/88 W. A. Crossman, Chief Date Reactor Project Section B (pars. 1-4, & 7)
< -;k97~&%&0
/l1lTB W. G. Hubacek, STP Coordinator (par. 5)
Date Approved:
/[f/82
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W. A. Crossman, Chief Date Reactor Project Section B Inspection Summary Inspection Conducted During the Period of December 6-17, 1982 (Report 50-498/82-19; 50-499/82-19)
Areas Inspected:
QA program development and implementation by the licensee, Bechtel Power Corporation (Bechtel), and Ebasco Services, Inc. (Ebasco), in the areas of design, engineering, procurement, and construction.
The inspection involved 74 inspector-hours by three NRC inspectors.
Results:
Within the scope of the inspection, no violations or deviations were identified.
9301200171 830110 gDRADOCK05000
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4 Details 1.
Persons Contacted Principal Licensee Employees
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- H. Walker, Project QA '% nager
- D. Keating, Project QA General Supervisor
- J. Williams, Site Manager
- J. Estella, Supervisor, Quality Systems
- J. Barker, Supervising Project Engineer D. Bednarczyk, Project QA Supervisor - Civil / Structural-
- C. Wright, Project QA Supervisor - Mechanical /NDE
- I. Morrow, Construction Superintendent Other Personnel Bechtel Power Corporation (Bechtel)
- B. McCullough, Construction Manager
- J. Downs, Deputy Construction Manager
- L. Hurst, Project QA Manager
- H. Reuter, Resident Project Engineer R. Carter, Assistant Project Field Engineer W. Houston, Project QA Engineer D. Krisha, QA Manager, Projects J. Little, Deputy Resident Engineer Ebasco Services, Inc. (Ebasco)
- J. Crnich, Construction Manager J. Thompson, Site Manager
- C. Hawn, Quality Program Site Manager
- R. Grippardi, QC Site Supervisor R. Bedford, Senior Resident Engineer
- 0.
Potter, Resident Engineer - Office
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The NRC inspectors also interviewed other licensee and contractor employees during the course of the inspection.
- Denotes those persons attending the exit meetings on December 10 and 17, 1982.
2.
General The NRC inspectors continued their review of QA program implementing procedures of the licensee and major contractors (Bechtel and Ebasco) in the areas of design, procurement, and construction to ascertain whether the development of the procedures was consistent with the status of the
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project and regulatory requirements.
A detailed review of QA program descriptions and QA manual was performed during a previous inspection in April 1982 and was documented in NRC Inspection Report 50-498/82-06; 50-499/82-06.
An ongoing inspection of the QA program as it applies to site activities was performed in August 1982 and documented in NRC Inspec-tion Report 50-498/82-14; 50-499/82-14.
3.
Status of Project The NRC inspectors discussed the project status and manpower schedules with the responsible HL&P representatives.
Safety-related construction began in August 1982 with commencement of radiographing and repair of emergency cooling water (ECW) pipe welds.
Placement of the Unit 2 diesel generator building concrete slab in November 1982 marked the commencement of safety-related concrete work.
Unit 1 containment building dome concrete placement was scheduled to begin in December 1982.
Present manpower for HL&P is 205 including 34 QA/QC personnel.
Bechtel, as construction manager, has 377 nonmanual and 39 QA/QC personnel.
Ebasco, as constructor, has 1.127 craft, 475 nonmanual, and 78 QA/QC personnel.
Present schedules indicate peak manpower loads at mid-1985 with Ebasco showing the most significant increase to approximately 5,250 craft, 700 nonmanual, and 114 QA/QC personnel.
Fuel load is scheduled for December 1986 for Unit 1, and December 1988 for Unit 2.
4.
Engineering and Design
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The NRC inspector performed an ongoing inspection of the South Texas Project (STP) engineering and design activities as they relate to the site.
The inspection was directed to the site based organizations of HL&P site engineering, Bechtel engineering, and Ebasco cc.struction engineering.
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HL&P Site Engineering The HL&P site project engineering organization's functions and responsibilities are defined in Project Engineering Procedure PEP-2.01,
" Project Engineering Organization and Responsibilities." Their primary function is to coordinate engineering activities at the STP l
site with the components and systems engineering section.
The supervising project engineer (SPE), site engineering, is responsible for assisting the HL&P manager, engineering, and the site manager with the management and coordination of engineering activities at the STP site.
Site project engineering performs this responsibility by overview of 8echtel project engineering in a one-on-one discipline related manner.
Review activities as related to engineering and
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construction include:
field change requests (FCR) (including FCR's which result in design changes); nonconformance reports (NCR);
specification changes; and engineering and construction procedures.
Review of construction procedures includes a check to determine that design requirements are incorporated.
During periodic meetings with Bechtel, HL&P reviews and discusses the backlog of FCR's including root causes of both FCR's and NCR's.
The NRC inspector reviewed revisions to HL&P project engineering procedures (PEP) to ascertain the substance and extent of the revisions for the following procedures:
PEP-1.02 Preparation and Control of Project Engineering Proce-dures, Rev. 1, June 21, 1982 PEP-1.05 Personnel Training, Rev. 2, September 1,1982 PEP-3.01 Performance of Owner's Reviews, Rev. 1, September 1, 1982 PEP-5.03 Processing Supplier's Deviation Requests, Rev. 1, June 28, 1982 b.
Bechtel STP Engineering Team Bechtel, as architect engineer and construction manager, is responsible for engineering, design, and design verification which includes such site specific activities as field design changes, drawing, and specification control and review of construction procedures.
The Bechtel Project Engineering Team (PET) under the direction of the project engineering manager / project engineer has the overall responsibility for the design of STP.
The organization and responsibilities of the PET are described in Engineering Department Procedure 2.13, " South Texas Project Engineer-ing Team Organization and Responsibilites," Rev. O, STP, August 3, 1982.
The NRC inspector reviewed the following Bechtel engineering depart-ment procedures (EDP) and associated revisions to determine the extent of the revisions and adequacy of the procedures.
EDP 2.13 South Texas Project Engineering Team Organization and Responsibilities, Rev. O, August'3. 1982 EDP 4.60 Processing Corrective Action Requests, Rev. O, STP, October 5, 1982 EDP 4.61 Nonconformance Reports, Rev. O, STP, October 5, 1982
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EDP 4.66 Substantial Safety Hazard and Significant Deficiency Reporting (Deficiency Evaluation Report), Rev. 2, i
October 24, 1980 Work plan procedures / quality control instructions (WPP/QCI) that
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translate commitments into working procedures for implementation were reviewed.
The review included applicable procedure change notices (PCN), revisions and new procedures.
WPP-3.0 Field Control of Design Documents, Rev. 2, July 21, 1982 WPP/QCI-5.3 Review and Processing of Nonconformance Reports for Deficiency Evaluation Reporting, Rev. 2, October 21, 1982 WPP/QCI-6.0 Control of Quality Records, Rev. 2, November 9, 1982 WPP/QCI-20.0 Field Change Request, Rev. 3, November 17, 1982 WPP/QCI-4.0 Receiving Inspection, Rev. 2, March 21, 1982 WPP/QCI-5.0 Nonconforming Materials, Parts and Components, Rev. 4, November 8, 1982 WPP/QCI-5.2 Supplier / Contractor Corrective Action, Rev. 1, October 13, 1982 WPP/QCI-5.4 Control of Nonconfor.'ances Discovered During Construc-tion, Rev. 3, Novembe. 8, 1982 c.
Ebasco Construction Engineering
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Construction engineering, under the supervision of the senior resident engineer, is responsible for administering and coordinating site construction engineering activities, including interpretation of design documents and specifications and furnishing technical assistance to the construction forces.
Construction engineering functions are delineated in Ebasco administra-tive site procedures (ASP).
The NRC inspector reviewed the Ebasco construction engineering organiza-tion as it is described in ASP-2, " Organization and Responsibility,"
Rev. O, March 22, 1982, and held discussions with several of the engineering personnel.
The NRC inspector performed an ongoing review of ASP's and applicable interim changes as follows:
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ASP-1 Preparation of Site Procedures, Rev. 2, October 7, 1982 ASP-6 Document Control, Rev. 1, October 19, 1982 ASP-16 Corrective Actions, Rev. O, March 22, 1982-5.
Construction
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The NRC inspector reviewed the following Bechtel and Ebasco construction, quality assurance, and quality' control procedures for compliance with regulatory requirements and licensee commitments:
a.
Bechtel Procedures WPP/QCI-2.0 Control of Work Plan Procedures and Quality Control Instruction Manual, Rev. 2, October 25, 1982 WPP/4CI-2.1 Preparation and Control of Work Plan Procedures /
Quality Control Instructions, Rev. 3, September 23, 1982 WPP/QCI-2.2 Control of Inspection Planning, Rev. 2, August 27, 1982 WPP/QCI-2.3 Procedure Change Notice, Rev. 2, September 30, 1982 QCI-2.4 Quality Control Surveillance / Redundant Inspection Requirements, Rev. 2, May 12, 1982 QCI-2.6 Control and Use of Stamps by Quality Control Field Personnel, Rev. 1, August 31, 1982 WPP/QCI-5.5 Processing of Brown & Root Initiated Nonconform-ances, Rev. 1, September 10, 1982 WPP/QCI-5.6 Master Computer System Tracking of Nonconformances, Rev. 1, September 10, 1982 WPP/QCI-7.0 Calibration and Control of Construction Measuring and Test Equipment, Rev. 2, November 9, 1982 QCI-8.0 Qualification, Certification, and Training of Quality Control Personnel, Rev. 2 WPP/QCI-11.0 Indoctrination and Training of Site Personnel, Rev. 3 WPP/QCI-12.0 Storage Control of Permanent Plant Items, Rev. 3, November 1, 1982 WPP/QCI-13.0 Housekeeping, Rev. 1, August 11, 1982
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WPP/QCI-15.0 Rigging of Equipment, Rev. 1, May 24, 1982 WPP-16.0 Site Geotechnical Engineering Program, Rev. O, March 31, 1982 WPP/QCI-17.0 Control of Consumable Materials, Rev. O, October 13, 1982 WPP/QCT-18.0 EE580 Cable Raceway Tracking Procedure, Rev.1, November 4, 1982
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WPP/QCI-28.0 Maintenance of Materials and Equipment, Rev. 2, August 30, 1982 QCI-28.1 Quality Control Inspection Instructions for Maintenance /
Surveillance, Rev. 2, May 20, 1982 WPP/QCI-28.2 Insulation Resistance Testing, Rev. O, November 1,
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1982 WPP/QCI-34.0 Organization and Responsibilities, Rev. O, April 26, 1982 b.
Ebasco Procedures CSP-4 Concrete Placement, Rev. O, August 20, 1982 CSP-11 Storing, Installation, Cadwelding, and Modification of Reinforcing Steel, Rev. O, September 14, 1982 CSP-21 Field Preparation of Coatings of Surfaces Outside of the Reactor Containment Building, Rev. 1, October 8, 1982 CSP-22 Valve / Pump Work, Rev. O, Octrber 6, 1982 CSP-40 EE580 Cable. Raceway, and Tray Tracking, Rev. O, November 1, 1982 QCP-2.2 Indoctrination, Training, and Qualification of Quality Control Personnel to ASME Section III Division 2 Requirements, Rev. O, October 22, 1982 QCP-9.5 Weld Inspection (AWS), Rev. O, November 16, 1982 QCP-10.1 Cadweld Inspection, Rev. O, September 23, 1982 QCP-10.6 Stud Welding Inspection, Rev. O, October 20, 1982 QCP-10.9 General Inspection, Rev. O, September 27, 1982 i
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QCP-10.22 Receipt Inspection of ASME Related Equipment / Materials, Rev. O, August 25, 1982 OCP-10.23 Waterstop/ Waterproofing and Joint Filler / Sealer Material Inspection, Rev. O, October 26, 1982 QCP-10.24 Grouting Inspection, Rev. O, September 21, 1982 QCP-13.2 Verification of Rigging and Handling Activities, Rev. 1, September 20, 1982
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QCP-15.1 Indentification and Control of Discrepancies and Nonconforming Conditions, Rev. 1, June 25, 1982 ASP-4 Heavy Handling and Rigging, Rev. O, June 18, 1982 ASP-5 Material Control, Rev. O, August 24, 1982 ASP-12 Development of Construction Field Sketches, Rev. O, September 10, 1982 ASP-14 Impact Review of Bechtel/HL&P Issued Documents, Rev. O, October 25, 1982 ASP-81 Confined Workplace Procedure, Rev. 2, June 14, 1982 ASP-82 Fire Protection and Prevention, Rev. O, September 29, 1982 ASP-83 Scaffolding Tagging Procedure, Rev. O, September 29, 1982 The NRC inspector observed that procedure QCP-15.1 did not require I
that the orginator of a NCR be informed in the event that the NCR was determined to be not warranted by the originator's supervisor.
A licensee representative stated that a procedure revision to include feedback to the originator would be considered.
The NRC inspector had no further questions regarding these procedures at this time.
6.
Procurement gnd Supplier Control for the Construction Phase The NRC inspector reviewed the following procedures for compliance with regulatory requirements and licensee commitments.
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SPC Project Procurement Procedures PPP No.
Title Rev.
Date 1. 0 Project Procurement Procedures
7/30/82 Purpose and Policy 1.1 Project Description
7/30/82 10/29/82 1. 2 Project Procurement Organization
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(not approved by HL&P)
2.0 Prime Contract Requirements
7/30/82 2.1 Client Requirements
7/30/82 2.2 Specification Review
8/2/82 2.3 Foreign Procurement
7/30/82 2.5 Procurement Document Distribution
7/30/82 (only covers Jistribution to client)
3.0 Evaluation and Selection of
8/2/82 Potential Suppliers 3.1 Processing of Purchase Memorandums
7/30/82 and Material Requisitione 3.2 Bid Requests for Purchase Orders
8/2/82 3.3 Bid Package Control
7/30/82
3.4 Receipt, Distribution and Evaluation
8/2/82 of Bids 3.5 Pre-Award Meetings
8/2/82 3.6 Preparation, Processing and Content
8/2/82 l
of Purchase Orders 3.8 Purchase Order Revisions
7/30/82 3.9 Purchase Order Files
7/30/82 3.10 Heckle Sheet
7/30/82 4.0 Construction Contract Formation
8/2/82 and Processing
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4.1 Receipt and Evaluation of Proposals
7/30/82 for Construction Contracts 4.2 Preparation, Processing, and Content
7/30/82 of Construction Contracts 4.3 Formation, Processing, and Content
8/2/82'
of Technical Services Contracts
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5.0 Expediting
7/30/82 6.0 Procurement Supplier Quality Purpose
8/2/82 and Policy 6.1 Quality Surveillance Reports and
8/2/82 Quality Plans 8.0 Field Procurement
7/30/82 b.
BPC Procurement Supplier Quality Manual, Rev. 1, dated September 15, 1982 No violations or deviations were identified.
7.
Exit Meetinas Exit meetings were held with licensee management personnel (denoted in paragraph 1) on December 10 and 17, 1982, to discuss the inspection scope and findings.
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