IR 05000498/1983006
| ML20023C333 | |
| Person / Time | |
|---|---|
| Site: | South Texas  |
| Issue date: | 05/03/1983 |
| From: | Crossman W, Hill W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20023C327 | List: |
| References | |
| 50-498-83-06, 50-498-83-6, 50-499-83-06, 50-499-83-6, IEB-81-02, IEB-81-03, IEB-81-2, IEB-81-3, IEB-82-04, IEB-82-4, NUDOCS 8305170224 | |
| Download: ML20023C333 (18) | |
Text
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. APPENDIX U. S. Nt' CLEAR REGULATORY COMMISSION
REGION IV
NRC Inspection Report: 50-498/83-06 EO-499/83-06 Dockets: 50-498; 50-493 Construction Permit: CPPR-128 CPPR-129 Licensee: Houston Lighting and Power Company (HL&P) P.O. Box 1700 Houston, Texas 77001 Facility Name: South Texas Project (STP), Units 1 and 2 Inspection At: South Texas Project, Matagorda County, Texas Inspection Conducted: March 1-31, 1983 8h[8f Inspector-N" W. H. Hill, Senior Resident Inspector Date Approved: E/$M8 W. A. Crossman, Chief Date Reactor Project Section B Inspection Summary Inspection Conducted March 1-31, 1983 (Deport 50-498/83-06; 50-499/83-06) Areas Inspected: Routine, announced inspection of review of previously identified inspection findings; storage and maintenance of equipment; IE Bulletins and Notices; construction deficiency reports; nonconformance reports; construction activity packages; electrical systems; structural concrete; and QA/QC Procedures.
The inspection involved 62 inspector-hours onsite by one NRC inspector.
Results: Within the eight areas inspected, no violations or deviations were identified.
3305170224 830504 PDR ADOCK 05000498 G PDR -_
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Details l 1.
Persens Contacted Principal Licensee Employees - J. Geiger, Quality Assurance Manager D. Barker, Project Manager
- H. Walker, Project QA manager
- D.
Keating, Project QA General Supervisor
- J.
Estella, Supervisor, Quality S 3tems
J. Williams, Site Manager
- I. Morrow, Construction Superintendent
- J.
Barker, Supervising Project Engineer C. Wright, Project QA Supervisor-Mechanical /NDE S. Hubbard, Senior QA Specialist D. Bohner, Project QA Supervisor-Electrical G. Steinmann, Lead Site Engineer T. Jordan, Project QA Supervisor-Design / Procurement D. Bednarczyk, Project QA Supervisor-Civil / Structural J. LeBlanc, General Supervisor, Records Management and Information Processing W. Moye, Construction Engineering Supervisor C. Grover, Sepicr Quality Assurance Engineer-M. Powell, Licensing Engineer D. Long, Special Coordinator Other Personnel - Bechtel Power Corporation (Bechtel)
- B.
R. McCullough, Manager of Construction J. R. Downs, Deputy Manager of Construction D. T. Krisha, QA Manager / Projects J. Linebarger, Unit 2 Manager
- H.
R. Reuter, Resident Project Engineer R. F. Schulman, Resident Engineer / Civil S. Bernsen, Project Licensing Manager L. W. Hurst, Project QA Manager K. R. Botterer, Project QA Engineer
- R.
W. Miller, Project QA Engineer R. A. Meggison, Project QC Engineer J. Morton, Lead Field Planner J. Senecal, Lead Resident Engineer / Civil ! .,e e ,n.., ., -n , n.
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Ebasco Services, Inc. (Ebasco) J. A. Thompson, Site Manager
- J. Crnich, Construction Manager J. Christesen, Assistant Site Manger
- C. L. Hawn, Quality Program Site Manager R. A. Cummings, QA Site Supervisor R. P. Grippardi, QC Site Supervisor J. C. Murphy, Unit 1 Superintendent F.. Miller, Welding Construction Superintendent N. M. Donlick, QC Supervisor-Concrete J. L. Swanner, Senior Inspector-Concrete J. B. Cleere, Site Quality Training Coordinator
- Denotes those individuals attending one or more management meetings during the inspection period.
2.
Licensee Action on Previous Inspection Findings (0 pen) Unresolved Item (50-498 and 50-499/8204-02) Gage Calibration Practices.
The licensee has determined that gages used to monitor inert pressures as required for storage, need only be checked periodically to determine satisfactory operatidn.
The gages are required to indicate that the pressure monitored is maintained greater than zero.
The NRC inspector confirmed that this was being done periodically.
flowever, the maintenance procedure permits "zero" as an acceptable reading.
This is in contrast to the vendor's recommendation " greater than zero."
The maintenance super-visors indicated that inert gas purges were being recharged before the gages indicated "zero."
This item is open until the maintenance procedure has been changed accordingly.
3.
Site Tours Routine tours of the site were conducted by the NRC inspector to observe housekeeping activities; general cleanliness; protection and preservation ' of equipment and material; personnel access control; and plant status as follows: a.
Units 1 and 2 Reactor containment buildings, mechanical-electrical auxiliary l buildings, fuel handling buildings, and diesel generator buildings.
. l b.
Site i ! Reservoir, essential cooling pond, and storage areas, including the warehouse, laydown areas, and the welding fabrication shop.
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With regard to the above areas, the NRC inspector confirmed the following: (1) Safety-related and storage areas were free from accumulations of trash, refuse, and debris.
, (2) Work areas were clean and orderly.
(3) Tools, equipment, and material were returned to their proper storage locations when no longer in use.
No violations or deviations were identified in this area of the inspec-tion.
4.
Storage and Maintenance The NRC inspector observed activities in several warehouses and other designated storage areas with particular attention to the following: a.
Equipment in various storage areas was segregrated and classified as Levels A through D to provide appropriate storage and environmental control for various types of equipment.
b.
Storage areas were not being used to store food, drink, or salt.
c.
An active program was in effect to control rodents and small animals.
d.
Racks, crates, and cribbing were carrying the full weight without component distortion.
, , e.
All iter.s were labeled and stored in a manner that allowed access for . inspection.
l f.
Fire protection systems and equipment were available for use.
g.
Sufficient donnage was available to protect materials and components in storage.
. l h.
Canvas or plastic covering was available for weather protection, as required.
1.
Protective covers and seals were properly attached.
J.
Personnel access to the storage locations was adequately controlled.
The NRC inspector had no further questions relative to site storage and , I maintenance.
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5.
IE Bulletins and Notices a.
IE Bulletins The NRC inspector conducted a review of bulletins and determined their status to be as follows: Bulletin Open/ Closed No.
Subject Issued To (Report No.)
80-01 Operability of ADS Valve BWR Closed Pneumatic Supply 80-02 Inadequate Quality Assurance BWR Closed for Nuclear 80-03 Loss of Charcoal From Tray Power Reactors Closed (81-32) Absorber Cell 80-04 PWR Main Steam Line Break PWR (OL & NTOL) Open (OL & NT0L) Analysis 80-05 Vacuum Damage to CVCS Holdup PWR Open (81-32) Tank 80-06 ESF Reset Controls Power Reactors Open (OL) - OL 80-07 BWR Jet Pump Assembly Failure BWR Closed 80-08 Containment Liner Penetration PWR Open (81-32) Welds 80-09 Hydramotor Actuator l'ower Reactors Closed (81-32) Deficiencies 80-10 Contamination of Nonradioactive Power Reactors Open (OL) System and Potential for - OL Environmental Release 80-11 Masonry Wall Design Power Reactors Open (OL) - OL 80-12 Decay Heat Removal System Power Reactors Open (OL) Operability - OL 80-13 Core Spray Spargers BWR Closed 80-14 Degradation of Scram Discharge BWR Closed Volume Capability
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80-15 Loss of Hotline with Loss of Power Reactors Open (OL) Off-Site Power - OL 80-16 Rosemount Pressure Transmitters Power Reactors Closed (81-32) 80-17 Failure of Control to Insert BWR Closed " During a Scram (3WR) 80-17 Supp. 1, 2, 3, 4, & 5 BWR Closed 80-18 Minimum Flow Through PWR (OL & NTOL) Open (OL & NT0L) Centrifugal Changing Pump 80-19 Mercury-Wetted Matrix Relays Power Reactors Closed (81-32) ' 80-19 Revision 1 Power Reactors Closed (81-32) 80-20 Westinghouse Type W-2 Spring Power Reactors Closed (81-32) Return Switches 80-21 Valve Yokes Supplied by Malcolm Power Reactors Closed (81-32) Foundry Company 80-22 Radiographic Sealed-Source Licensee Closed Connectors 80-23 Valcor Solenoid Valves Power Reactors Closed (81-32) 80-24 Water Leak in Containment Power Reactors Open . . 80-25 Target Rock Safety Valves BWR Closed L 81-01 Surveillance of Mechanical Power Reactors Closed f Snubbers 81-01 Revision 1 Power Reactors Closed 81-02 Failure to Gate Type Valves Power Reactors Open (83-06) to Close 81-02 Supplement 1 Power Reactors Open (83-06) 81-03 Flow Blockage of Cooling Power Reactors Closed (81-32) Water to Safety System Reopened (83-06) Components by Clams and Mussels 82-01 Alteration of Radiographs As Listed Closed _, _ _ _ _ -. _ _. _ _. _ _ _. _ - - _ - _ -. _. _ _ _ _, _ - _ _ _. - _ _ _ _. _ _,... _ _ _. _ _ _ _ _ _ _ _ - -. _.... _ _..
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82-01 Revision 1 As Listed Closed 82-01 Revision 1, Supplement 1 As Listed Closed 82-02 Degraded Threaded Fasteners PWR (OL) Open (OL) at RCS Pressure Boundary 82-03 Stress Corrosion Cracking in BWR Closed Larger Diameter BWR Piping 82-03 Revision 1 BWR Closed 82-04 Electrical Penetration Powar Reactors Open (83-06) Assemblies ! 83-01 Failure of Reactor Trip Power Reactors Open (OL) Breakers - OL 83-02 Stress Corrosion Cracking in BWR Closed Large Diameter BWR Piping 83-03 Check Valve Failures in Raw Power Reactors Open Cooling Water Systems in Diesel Generators 83-04 Failure of Reactor Trip Breakers PWR (OL) Open (0L) OL Operating License NTOL Near Term Operating License For the IE Bulletins listed below, the NRC inspector verified that the written response was within the time period stated ~in the bulletin; the written response included the information required to be reported; the written response included adequate corrective action commitments based on information presentation in the bulletin and the licensee's response; the licensee management forwarded copies of the written response to the appropriate management representatives; information discussed in the licensee's written response was accurate; and corrective action taken by the licensee was as described in the written response.
The following bulletin responses were reviewed: I ' (1) IEB 81-02 (Supp.1) Failure of Gate Valve to Close Against Dif- ' ferential Pressure.
The NRC inspector reviewed correspondence from the licensee to NRC, dated November 27, 1981, which states, "However, Westinghouse, is currently working or, a schedule under which the modifications to the affected valves will be completed This bulletin is open pending review of these modifica- " .... tion * .
(2) IEB 81-03 Flow Blockage of Cooling Water to Safety System Components by Corbicula Sp. (Asiatic Clam) and Mytilus Sp.
(Mussel).
The NRC inspector reviewed the licensee response dated July 9, 1981, which stated that the design was to minimize " dead spots" and reduce the environment for breeding, growth, and potential for plugging..The fresh water cooling would preclude concern for the salt water Mytilus species of mussel.
The licensee's response, dated February 11, 1983, provided additional information.
The potential impact of the Asiatic clams on STP will be minimized by the implementation of procedures to detect buildup on clams in the essential cooling water (ECW) systein and limit the clam infestation through chemical control.
Based on predicted growth rates, the licensee intends to monitor specific heat exchanger flows quarterly and take appropriate actions.
Field monitoring will be performed approximately 12 and 6 months prior to Unit 1 operations.
This bulletin remains open pending further review of these monitoring activities.
(3) IEB 82-04 Deficiencies in Primary Containment Electrical Penetra-tion Assemblies.
The NRC inspector reviewed the licensee response, dated January 26, 1983, which stated that no Bunker Ramo electrical penetration assemblies are installed or planned to be installed at STP.
This bulletin is open pending inspec-tion of the completed installation.
b.
IE Notices For the notices listed be low, the NRC inspector confirmed that the notice was received by the licensee management and forwarded to the responsible licensee personnel.
The notices were reviewed for applicability, and appropriate actions established and scheduled in a timely basis.
The following notices were reviewed: i (1) IEN 82-01 and (Rev.1) Auxiliary Feedwater Pump Lockout Result-ing from Westinghouse W-2 Switch Circuit Modification j (2) IEN 82-02 Westinghouse NBFD Relay Failure in Reactor Protection Systems at Certain Nuclear Power Plants (3) IEN 82-03 Environmental Tests of Electrical Terminal Blocks (4) IEN 82-04 Potential Deficiency of Certain AGASTAT E-7000 The NRC inspector had no further questions with regard to the above notices.
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, 6.
Construction Deficiency Reports (CDR) The NRC inspector reviewed licensee corrective actions taken relative to matters reported to the NRC in accordance with the requirements of 10 CFR 50.55(e).
The following items were reviewed: a.
Limitorque Motor Operators (IRC 128) On August 5, 1982, the licensee reported an item regarding sheared pinion keys in Limitorque motor operators (IRC 128).
On August 4, 1982, Westinghouse notified the licensee of a potential failure of valves supplied with Limitorque motor operators.
The failure could result due to sheared pinion keys.
An investigation of the models of Limitorque motor operators supplied to STP has determined that the suspect model numbers have not been supplied for use on STP.
Since tha suspect model numbers have not been supplied for use on STP.
Since the suspect motor operators are not used at STP, no further action is considered necessary.
b.
Design Loadings for the-Isolation Valve Cubicle Walls (IRC 130) On September 1, 1982, the licensee reported an item regarding the design pressure loading for the isolation valve cubicle (IVC) walls (IRC 130).
The design pressure loading of the IVC auxiliary feed-water (AFW) pump compartment walls could be exceeded in the event of a feedwater bypass line break.
Failure of the AFW pump compartment , walls may lead to unacceptable safety hazards in the adjacent cubicles.
The design of the AFW pump cubicles is being reviewed and revised.
Sufficient venting will be available to maintain the integrity of the cubicle.
A final pressure / temperature analysis will be performed in confirm the revised design.
c.
Essential Cooling Pond Analysis (IRC 132) On October 19, 1982, the licensee reported an item regarding the calculated temperature of essential cooling water (ECW) servicing safety-related equipment.
Calculations indicated the temperature of the water servicing the safety-related equipment on the ECWS and the CCWS may exceed the maximum temperature limit as specified by the equipment manufacturer.
The equipment manufacturers were contacted to confirm that the subject equipment would perform its design function at the calculated temperature.
The evaluation did not identify any areas where the elevated temperatures wculd represent either an unanalyzed event or significant safety hazard.
The NRC inspector had no further questions relative to these 50.55(e) , reports.
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i i 7.
Nonconformance Reports (NCR) The NRC inspector reviewed NCR BN-00034 and BN-00035. These NCR's indicated the following conditions: BN-00034 - Steam Generator 1 (1-A) has been determined by optical survey to be out of plumb approximately 0.164" per foot, or approximately (0.78) degrees.
Project documents do not presently provide a dimensional tolerance for SG plumbness.
Westinghouse letter 4ST-WY-YS-00022 attached states that an acceptable tolerance is (0.5) degrees.
Both NCR's were dispositioned "USE-AS-IS."
The NRC inspector reviewed correspondence from the Westinghouse site manager to the Bechtel site , manager dated March 7, 1983, which stated that Westinghouse design engineers have reviewed related survey data and have made evaluations in the follow-ing areas: a.
Performance characteristics b.
System analysis I c.
Structural design and analysis e l d.
Seismic analysis i f.
Piping analysis Responses to additional concerns were provided in correspondence from Westinghouse site manager to the Bechtel site manager, dated March 14, . i 1983.
Based on a review of this correspondence, the NRC inspector had no
further questions relative to the NCR disposition, "USE-AS-IS."
8.
Construction Activity Packages The construction manager has established a computerized management control system which consists of work activity packages.
Each package scopes a certain amount of work which is normally area orientated and discipline associated.
The system is described in project control procedure (PCP) 3.11, " Activity Package System." The activity package has discrete boundaries in terms of buildings, elevations, and areas.
The activity package contains all of the engineering documents and lists of materials and equipment for a given construction activity.
Each package is identified by a specific number which correlates to the unit, building, type of activity, power block area, and power block level.
The types of activities are separated into the following: a.
Concrete b.
Steelwork c.
Nuclear Steam Supply System
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d.
Mechanical Equipment e.
Piping f.
Instrumentation and Control g.
Electrical Equipment and Material When the packages are ready for construction, the activity package is ! listed on the "3-week" schedules by package number.
The "3-week" schedules are updated and issued weekly.
They include all construction activity schedule for the next 3 weeks.
The NRC inspector identified no unaccept-able areas with respect to the activity package system or the "3-week" schedule.
9.
Electrical Systems The NRC inspector reviewed Ebasco Construction Site Procedure CSP 40, "EE580 Cable, Raceway and Tray Tracking." The NRC inspector confirmed that a system was established to control installation of electrical cables, raceways, and cable trays.
The procedure references a progran manual, "The EE580 Cable and Raceway Construction Manual." The system provides for a cosputer to track the installation status of cables and raceways.
CSP 40 delineates the requirements for flow of installation cards and associated reports and detail instructions for completing the cards.
The NRC inspector reviewed Bechtel Procedure WPP/QCI-18.0, "EE580 Cable and Raceway Tracking Procedure." The procedure assigned various responsi-bilities between Ebasco and Bechtel.
Specific installation cards were identified and flow paths for the cards were specified.
EE580 coordina-tors are required for both Bechtel and Ebasco. Quality control responsi- ' bilities were assigned to Ebasco Quality Control Organization.
The NRC , inspector had no further questions relative to the EE580 system for ! control of cables, trays, and raceways.
The NRC inspector reviewed the following structural drawings for locations of cable tray supports: 3M-35-1-5-37001 Rev. 0 3M-35-1-5-37008 Rev. 0 3E-35-9-E-56003 Rev. 2 3E-35-9-E-58029 Sheet 1, Rev. 0 3E-35-9-E-58029 Sheet 2, Rev. 2 The NRC inspector discussed these drawings with Ebasco QC inspectors.
The i QC inspectors explained the drawing requirements, installation, and inspection status.
Field installations were examined and nonconforming conditions were identified with NCR's.
The QC inspectors took appropriate actions when installation drawings did not provide enough detail to i . - - - - --~ m.- . - - - _ - _. - _ _ _ - - -, _... _.... _.. - _. -. _,, , _ _ _., _ _ _. _.. - _ _ - _ _ _ _
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determine acceptance criteria.
The NRC had no further questions re7ative to the QC coverage of cable tray structural supports.
, 10.
Structural Concrete-i a.
Concrete Placement Activity The NRC inspector observed selected portions of the following concrete placements: (1) 1-RC-W-194-007-Reactor Containment Wall'elev. 194'5" to 200'1" (2) 2-RC-W-103-003 Reactor Containment Wall elev. 103'0" to 113'0" j The NRC inspector confirmed that concrete placement activities were being accomplished in accordance with applicable drawings, specifica-i tions, codes, and procedures in the following areas: (1) Proper mix specified and delivered (2) Testing at placement location proper tests, frequency, and acceptance criteria - use of calibrated test equipment.
(3) Adequate construction crews and quality control personnel (4) Proper equipment and placement techniques - vibrators properly , j used.
The NRC inspector did not identify any unacceptable areas during , these pours, b.
Quality Assurance Records Quality Assurance Records for the containments concrete pours, ' 1-RC-W-194-007 (CSI-R7) and 2-RC-W-103-003 (CS2-W13), were reviewed for completeness and compliance with licensee procedures, specifica-
tions, and commitments.
The records examined were as follows: i 1-RC-W-194-007/CA1-R7
Records Requirements Index/ Document Checklist Concrete Placement
Concrete Preplacement Inspection Report ! Concrete Placement Release l Construction Concrete Preplacement Release i Concrete and Grout Order / Method Form Concrete Placement Control Record (2) Daily Cadweld Inspection Report (4) l Concrete Curing Inspection Report _ _ . - - - - . .
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Post Tensioning Inspection Report (not on document list, will be added) Visual Rebar Inspection Report Containment Liner Plate Inspection Report (not on document list, will be added) Rebar Fabrication Inspection Report (8) . Report of Plastic Concrete Test Results (PTL Form CF-1, 18) 2-RC-W-103/CS2-W13 Concrete and Grout Order / Method Form Construction Civil Concrete Preplacement Release Record Concrete Placement Release Concrete Preplacement Inspection Report Containment Liner Plate Inspection Report Rebar Visual Inspection Report Post Tensioning Inspection Report 2-RC-W-103-003/CS0-W13 i Concrete Placement Inspection Report Concrete Placement Control Record (south pump 1, middle pump 2,
north pump 3) l Rebar Fabrication Inspection Report (4) The NRC inspector reviewed the following information on " Batch Tickets" 57585-57631 (less 57604 and 57606) and 57436-57544, for these same concrete placements: l Ticket Number Formula Number Batch Size (yd.)
Stone 1 (wt.)
Stone 2 (wt.)
Sand (wt.)
Percent Moisture in Sand Cement (wt.)
Water (wt.)
Ice Admixtures Time Truck Number Location Accumulated Yards Heated / Cooled Accepted by All weights were in pounds unless otherwise specified.
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Both sets of records were "in process" and had not completed final review and approval.
No unacceptable records were identified.
c.
Site Concrete Testing Laboratory The NRC inspector observed the laboratory compression tests for the following concrete cylinders: Serial Nos.
Break Time 6050 7 days 6052 7 days 6053 7 days 6076 7 days 6078 7 days 6077 7 days 5984 28 days 5985 28 days 5987 28 days 6003 28 days 6004 28 days All cylinders exceeded the minimum strength requirements.
The NRC inspector had no further questions relative to strength tests for concrete cylinders.
d.
Concrete Bedding Beneath ECW Piping The NRC inspector observed the removal of forms from the recently poured concrete bedding beneath the ECW piping.
Some surface honey-combing was observed at one location as the fortes were being removed.
Subsequently, the NRC inspector observed soil work adjacent to this area without any activity relative to the honeycombing.
The NRC inspector expressed his concern to the licensee who promptly investi-gated the matter.
This item was identified during a post placement inspection, but since it was not structural concrete, i.e., contain-ing reinforcing steel, the honeycombing was considered cosmetic.
This reasoning may be acceptable from an engineering perspective; however, it was not within quality control to make this determina-tion.
The soil was removed, and a deficiency was written against the exposed honeycombing.
Additional concrete had been poured extending the bedding beneath the ECW piping.
An NCR was issued to address any honeycombing covered by the extension of the bedding and will be disposition by engineering.
This item is unresolved (8306-01) pending further review of practices involving placement of concrete bedding beneath ECW pipin F
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11.
QA/QC Procedures a.
Ebasco quality control functions are performed in accordance with quality control procedures (QCP).
Changes to QCP's are normally processed as revisions; however, changes that are required immediately may be implemented by a procedure change report (PCR).. The PCR's are attached to the front of the affected procedure.
The NRC inspector observed PCR's where parts of sentences were changed or deleted.
This system required anyone using the procedure to switch back and forth from the basis procedure to the PCR attached to the front of the procedure.
The NRC inspector expressed his concern about the possibility of misunderstanding particularly when multiple PCR's had been attached to the procedure.
The quality control representative stated that whole paragraphs would'be changed in PCR's in the future to avoid any misunderstanding.
This item is unresolved (8306-02) pending further_ review of PCR's.
b.
During a tour of of Unit 1 containment, the NRC inspector observed the removal of structural steel and disassembly of bolt connections.
Some structural steel was being removed to permit relocation of other components.
The NRC inspector discussed reentry controls on previously accepted work with the Ebasco quality site manager.
He stated that a reentry procedure had been drafted and was in routing for approval.
Such a procedure was needed not only to control rework and reinspec- ' tion, but to void completed QA/QC records of completed activities.
This item is unresolved (8306-03) pending issue of a reentry control procedure.
12.
Unresolved Items Unresolved items are matters about which more information is required in order to ascertain whether they are acceptable items, violations, or deviations.
Three unresolved items disclosed during the inspection are discussed in paragraphs 10 and 11.
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Management Meetinas Meetings were held periodically with licensee management personnel during.
the course of this inspection to discuss inspection scope and findings.
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