IR 05000498/1983011
| ML20024E646 | |
| Person / Time | |
|---|---|
| Site: | South Texas  |
| Issue date: | 07/22/1983 |
| From: | Crossman W, Dubois D, Hill W, Hunnicutt D, Clay Johnson NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20024E633 | List: |
| References | |
| 50-498-83-11, 50-499-83-11, NUDOCS 8308160284 | |
| Download: ML20024E646 (15) | |
Text
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APPENDIX B U. S. NUCLEAR REGULATORY COMMISSION I
REGION IV
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NRC Inspection Report: 50-498/83-11 50-499/03-11
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Dockets:
50-498; 50-499 Construction Permits:
CPPR-128 CPPR-129
Licensee:
Houston Lighting & Power Company (HL&P)
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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
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Inspection Conducted: May 15-June 30, 1983 Inspectors:
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& W. M. Hill, Senior Resident Inspector Date o
(pars. 1, 2, 4, 5, 9, & 10)
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- C. E. Johnson, Reactor Inspector Date '
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Engineering Section (pars. 1, 3, 6, 7, 8, & 10)
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bl aY At b 3 c,
tN D. L. DuBois, Senior Resident Inspector tate '
Cooper Nuclear Station (pars. 1, 2, & 4)
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8308160284 830725 PDR ADOCK 05000498 G
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/_3 Approved:
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W. A. Crossman, Chief Date
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Reactor Project Section B I
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ak Y 2. Y 8 3 D. M. Hunnicutt, Chief
[ Tate J Engineering Section
Inspection Summary a'
Inspection Conducted May 15-June 30, 1983 (Report 50-498/83-11; 50-499/83-11)
.i Areas Inspected:
Routine, anr:ounced inspection of storage and maintenance; i
site tours; nonconformance reports; structural concrete; procurement practices; i
records; and follow up on previously identified inspection findings. The inspection involved 106 inspector-hours onsite by three NRC inspectors.
Results: Within the seven areas inspected, one violation was identified (inadequate procedures / instructions, paragraph 8).
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Details t
1.
Persons Contacted Principal Licensee Employees D.' Barker, Project Manager
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- J. Barker, Supervising Project Engineer
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~ *D. Bednarczyk, Project QA Supervisor-Civil / Structural D. Bohner, Project QA Supervisor-Electrical
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- J. Estella, Supervisor, Quality Systems J. Geiger, Manager, Quality Assurance J. Goldberg, Vice President, Nuclear Engineering and Construction C. Grover, Senior Quality Assurance Engineer i
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S. Hubbard, Senior QA Specialist i
T. Jordan, Project QA Supervisor-Design / Procurement
- D. Keating, Project QA General Supervisor J. LeBlanc, Manager, ' Records Management and Information Processing I. Morrow, Construction ~ Superintendent a
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W. Moye, Construction Engineering Supervisor G. Oprea, Executive Vice President
- D. Pelengaris, QA Specialist M. Powell, Licenseing Engineer
- G. Steinmann, Lead Site Engineer
- H. Walker, Project QA Manager
- J. Williams, Site Manager C. Wright, Project QA Supervisor-Mechanical /NDE
- T. K. Logan, QC Engineer Other Personnel Bechtel Power Corporation (Bechtel)
- J. Downs, Deputy Manager of Construction
- D. Haavik, Engineering Specialist-Concrete-
- L. Hurst, Project QA Manager
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J. Futrell, PFE J. Little, Assistant Project Reside.it Engineer
- B. McCullough, Manager of Construction
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- R. Miller, Site Project Quality Assurance-Engineer i
- W. Priest, Construction Manager j
- H. Reuter, Resident Project Engineer
- L. Tollery, Res;uent Engineer l
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Ebasco Services, Inc. (Ebasco)
J. Christesen, Assistant Site Manager
- J. Crnich, Construction Manager R. Cummings, QA Site Supervisor
- R. Grippardi, QC Site Supervisor
- C. Hawn, Quality Program Site Manager F. Miller, Welding Construction Superintendent
- J. Murphy, Unit 1 Superintendent J. Swanner, Senior Inspector-Concrete J. Thompson, Site Manager
- Denotes those individuals attending one or more management meetings during the inspection period.
2.
Site Tours Routine tours of the site were conducted by the NRC inspector observing 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 Buildings, Fuel Handling Buildings, and Diesel Generator Buildings b.
Site Reservoir, essential cooling pond, and storage areas, including the warehouses, laydown areas, and the welding fabrication shop With regard to the above areas, the NRC inspector confirmed the following:
a.
Safety-related and storage areas were free from accumulations of trash, refuse, and debris.
b.
Work areas were clean and orderly.
c.
Tools, equipment, and material were returned to tneir proper storage locations when no longer in use.
The NRC inspector expressed his concern about the construction opening on ground level of Unit 1 ccntainment.
This opening provides normal access for equipment and personnel.
The present configuration permits an excep-tional amount of sand and dirt to enter the opening and accumulate on the floor or equipment stored on the elevation below.
This situation is l
aggrevated by water from rainfall or post concrete placement curing
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activities on the dome of the containment.
Periodically the site person-nel clean up the sand, dirt, and residual water.
The NRC inspector
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expressed his concern that-additional management attention was needed to
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establish preventative measures to avoid the condition.
The licensee acknowledged the NRC inspector's concerns and stated that corrective actions would be taken.
The NRC inspector had no further questions relative to site tours.
3.
Licensee Action on Previous Findings (Closed) Unresolved Item (50-498/8303).
NRC Inspection Report 50-498/83-03 identified the following:
During the review of CSP-54, " Miscellaneous Metal Fabrication Inspection,"
the NRC inspector observed that under the inspection attribute " bending of anchor bolts," there is no witness or hold point for construction to notify QC for a visual inspection.
Drawing 5A-010-C0005, Note 10, states that visual inspection must be made after bending or straightening to insure that the anchor bolts are not cracked or damaged.
QCP-10.2,
"Preplacement Concrete Inspection," does not address inspection of bending anchor bolts, instead, it merely addresses the inspection of proper alignment and location.
Interim Change (ICP) 2 to CSP-54 has added a witness point for QC to perform visual inspection as per Drawing 5A-010-C0005, Note 10.
This item is closed.
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Storage and Maintenance The NRC inspectors observed activities in several warehouses and other designated storage areas with particular attention to the following:
Equipment in various storage areas were segregated and classified as a.
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 rodent.s and small animals.
d.
Racks, crates, and cribbing were carrying the full weight without component distortion.
e.
All items were labeled and stored in a manner that allowed access for
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inspection.
f.
Fire protection systems and equipment were available for use.
g.
Sufficient dunnage was available to protect materials and components in storage.
h.
Canvas or plastic covering was available for weather protection.
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Protective covers and seals were properly attached.
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Personnel access to the storage locations was adequately controlled.
The NRC inspector reviewed the Bechtel site Maintenance Procedure WPP/QCI 28.0, Revision 4, dated June 21,1983, " Maintenance of Materials and Equipment."
This procedure detailed the construction manager's maintenance program for permanent plant materials and equipment until release of that equipment to the constructor.
Various responsibilities are assigned to different supervisors and engineers.
Generally, the maintenance requirements shall be consistent with the requirements specified by the vendor.
Included in the procedure are minimum maintenance requirements for various types of equipments.
These must be adhered to unless otherwise specified by the vendor.
If a scheduled maintenance activity is not performed by the due date, a
" Missed Maintenance Evaluation" is completed and sent to engineering for-evaluation and disposition.
If an unsatisfactory maintenance condition is observed, a maintenance discrepancy sheet is generated and set to engineer-ing for review and disposition.
Through discussion with responsible personnel, the NRC inspectors learned that a computer printout listing overdue maintenance actions was periodically generated, but the procedure made no provisions for providing this information to personnel responsible for generating the missed maintenance evaluation.
The responsible super-visor stated he understood the NRC inspector's concern and would investigate
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appropriate action.
This item is unresolved (pending further review and revision to the procedure as necessary).
(8311-01)
The NRC inspectors reviewed the maintenance action cards (MAC) for the following equipment:
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V-1640 M-4751 E-0030 M-1393 E-0744 V-0783 E-0031 M-1394 V-4204 V-1573 E-0595 M-1395 V-4208 V-1575 E-1054 M-1538 i
V-4272 V-6766 E-1055 M-4553 V-4206 V-6767 E-1056 M-4554 V-4205 V-6768 E-1058 E-0743 M-0902 V-6770 E-1059 E-0744 I
E-1052 V-6769 E-1238 E-0001 (
E-1053 V-6771 E-0740 E-0002 M-1443 V-1347 E-0741 E-0003'
M-3024 E-0028 H-0846 E-0054 M-3764 E-0029 M-1392 E-0055 The NRC inspectors also reviewed two transmittal packages dated June 17 and 24, 1983.
These packages included a total of 81 missed maintenance evaluations.
Although the procedure was being followed, the NRC inspector expressed his concern about the large number of missed maintenance _evalua-tions.
The maintenance supervisor stated that these occurred during the time of the transition from the manual to the computer system and all of
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the missed maintenance action had been evaluated by support engineering.
This item will be reviewed as part of the regular inspection program.
The NRC inspectors had no further question relative to the maintenance program for permanent plant equipment.
5.
Concrete Placement Activity On June 13, 1983, a licensee QA representative informed the NRC resident inspector that a concrete pour (1-RC-W-210-013) for Unit 1 dome had been performed on the previous day, and the surface had visual imperfections which were unacceptable.
The NRC inspector observed the concrete surface and concurred with the licensee's assessment.
The NRC inspector confirmed that curing activities were in process to ensure the quality of the concrete was unaffected.
The NRC inspector also confirmed that an NCR (CC00565),
had been writter. to ensure that proper evaluation of the visual imperfec-tions was performed and corrective actions were completed as necessary.
At the conclusion of the report period, the evaluation was still in process and corrective action had not been established.
This item is unresolved (8311-02) pending completion of the evaluation and the necessary corrective actions.
The NRC inspector observed selected portions of other concrete
placements:
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1-FH-S-120-005
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9-EW-A-018-007 and 009
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1-RC-W-218-017 and 214-015 The NRC inspector confirmed that these concrete placement activities were being accomplished in accordance with applicable drawings, specifica-tions, codes, and procedures in the following areas:
a.
Proper mix specified and delivered b.
Testing at placement location proper tests, frequency, and accept-ance criteria - use of calibration test equipment c.
Adequate construction crews and quality control personnel d.
Proper equipment and placement techniques vibrators properly used With respect to subsequent Unit 1 dome pours, 1-RC-W-218-017 and 214-015, the NRC inspector confirmed that placement activities and techniques had been improved to avoid surface irregularities experienced during the previous dome pour, 1-RC-W-210-013 (CSI-R10).
The NRC inspector did not identify any unacceptable areas during these pour.
Site Concrete Testing Laboratory The NRC inspector observed the laboratory compression tests for the following concrete cyclinders:
Serial Nos.
Break Time 6308 (B)
28 days 630s (B)
28 days 6310 (B)
28 days 6311 (B)
28 days The NRC inspector reviewed the laboratory compression tests results for the following concrete cyclinders:
Serial Nos.
Break Time 6308 (A)
7 days 6309 (A)
7 days 6310 (A)
7 days 6311 (A)
7 days These cyclinders were made from the concrete from the previous dome pour, 1-RC-W-210-013.
All cyclinders exceeded the minimum strength requirements.
The NRC inspector hr.d no further questions relative to strength tests for concrete cyclinders.
7.
Records The NRC inspector conducted a review of Ebasco QC records.
The NRC inspector confirmed that completed quality control records required by the QC procedures were being forwarded to the QC records group.
The NRC inspector examined the following selection of records:
Title QCP Quantity AWS D1.1 Structural Welding Inspection Report 9.5
Stud Welding Inspection Report 10.6
Protective Coatings Storage Inspection Report 10.8
Steel Coatings Inspection Report 10.8
l Concrete Surface Preparation Inspection Report 10.8
Concrete Coatings Inspection Report 10.8
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Title QCP Quantity l
Curing Inspection Report 10.8
j Backfill Inspection Report 10.10
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Wacker Compactor Qualification Program 10.10
Inspection Report
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Discussions with the responsible records supervisor indicated that no
completed records had been received for the following inspection procedures:
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Title
QCP
Quantity
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Mechanical Equipment Installation Inspection
10.11
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Component Support and Restraint Installation
10.12
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Inspection
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Mechanical Instrumentation Installation
10.13
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Inspection
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System / Subsystem Walk-Down Inspection
10.14
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Electrical Equipment Installation Inspection
10.15
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Electrical Raceway Installation Inspection
10.16
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Electrical Cable Installation Inspection
10.17
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Electrical Cable Termination Inspection
10.18
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This is consistent with the NRC inspector's visual observations of con-
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struction activities in the field. The NRC inspector observed that
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several logs were required to be maintained by supervisors'in accordance
with procedures.
The records supervisor stated that none of the logs had.
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been received.
Review of the procedures indicated.that clear instructions
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for the disposition of the QC logs were not provided. 'The' quality' site
manager stated the procedures would be changed to disposition the logi.
This item is unresolved pending adequate instruction relative to disposi-
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tion of the QC logs (8311-03).
The NRC. inspector had no-further questions
concerning the records that were reviewed.
8.
Concrete Placement (1-RC-W-210-013/CSI-R10)
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a.
Observation
The NRC inspector observed Concrete Placement 1-RC-W-210-013/CSI-R10
for the purpose of. reviewing the licensees / constructors engineering
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evaluation and disposition of Nonconformance' Report (NCR) CC00565 by
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the request of the NRC resident inspector.
This concrete placement
is located between elevations 210' 1" and 214' 5" on the Unit 1
containment structure.
Quality control generated this NCR because
the placement exhibited the following:
(1) Sand / Rock Pockets
(2) Unconsolidated Concrete at Surface
(3) Unacceptable Finish and General Appearance
Upon visual inspections by the NRC inspector, the placement did
exhibit the conditions listed above.
An estimated 70 to 80 percent
of the surface area was affected.
The NRC inspector also inspected
approximately ten areas that had been bush hammered to sound concrete.
There were two locations that were chipped to exposed rebar and these
areas appear to have sound concrete.
The NRC inspector was informed
that the ten areas observed appeared to be the most severe cases and
were chipped down so that some evaluation could be made by engineer-
ing.
The NRC inspector and a Bechtel concrete engineer discassed
the possibility of structural repairs and both agreed that no final
decision could be made on whether cosmetic or structural repairs are
needed, until all visually unacceptable concrete has been removed.
At this point, construction is in the process of bush hammering all
unacceptable concrete to sound concrete.
The NRC inspector informed
the licensee / constructor that tolerances for placements on the dome
should be adhered to in accordance to specifications.
b.
Interviews With Personnel
The NRC inspector interviewed a QC inspector and some craft personnel
who observed Placement 1-RC-W-210-013/CSI-R10.
The QC inspector
informed the NRC inspector that the placement, consolidation, and
slump test results were satisfactory. QC and the craft personnel
both stated that finishing was of some problem.
After some inquiring
and discussion with QC and craft personnel by the NRC inspector, it
appears that lack of instruction and insufficient experience by some
of the craft involved may have contributed to problems of a placement
of this type.
Appropriate instructions should have been given to all
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construction personnel involved prior to this concrete placement.
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c.
Review'of Procedures
The NRC inspector reviewed four procedures and one specification
pertaining to concrete inspection and placement. While reviewing the
procedures / specification, the NRC inspector looked for guidance and
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instructions for placement of complex or special placements such as
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Placement 1-RC-W-210-013/CSI-R10.
There was no such instruction.
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The constructor informed the NRC inspector that they don't consider
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Placement 1-RC-W-210-013/CSI-R10 as a complex placement nor any other
placements of this type.
However, interviews with QC/ craft personnel
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and the observation of Placement 1-RC-W-210-013/CSI-R10 by the NRC
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inspector indicates that lack of instruction was apparent. There are
no instructions / procedures that adequately address the placing of
concrete on a sloping surface or the free-form method.
This is not
in compliance with 10 CFR Part 50, Appendix B, Criterion V.
This is a violation.
(8311-01)
Procedures reviewed:
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OCP-10.3, Revision 2, " Concrete Placement Inspections"
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CSP-4, Revision 1, " Concrete Placement"
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QCP-10.2, Revision 2, "Preplacement Concrete Inspection"
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QCP-10.4, Revision 2, " Post Placement Concrete Inspection"
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Specification for Concrete Construction 2A010CS0028
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d.
Review of Records
The NRC inspector reviewed all records pertaining to the placement
inspection and post placement inspection of 1-RC-W-210-013/CSI-R10.
Placement inspection records indicated that all inspection points
were acceptable, correlation tests were performed, and slump at point
of placement were within limits.
Post placement visual inspection
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indicated unsatisfactory results which generated NCR CC00565.
There
were no discrepancies observed during the review of records for
Placement 1-RC-W-210-013/CS1-R10.
9.
Procurement
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~The NRC inspector conducted a review of procurement practices.
The item
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relected was a purchase order of 12 quality Class 2 (safety-related)
- 5 degree stainless steel elbows, Purchase Order (P0) 14926-BF-1065.
Appended to the purchase order were two attachments.
Attachment A con-
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tained the material requirements such as the following:
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a.
Conformance with ASME boiler and pressure vessel code
b.
Certificate of conformance to the procurement document
c.
Source inspection
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d.
Certified material test reports
e.
Condition of the material
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Attachment B provided for the identification and marking of the material.
Although the NRC inspector observed no unacceptable conditions in the P0,
he observed that the P0 did not reference or include the Bechtel piping
material specification.
This is in constrast to the P0 examined in the
previous inspection (re:
NRC Inspection Report 83-07).
The previous P0
included the specification.
This practice is unresolved pending further
review (8311-04).
The NRC inspector walked through the receiving and receipt inspection
procedures with receiving QC personnel.
Receipt inspection was in process.
The material was in the receiving lay down area and had not been entered
in the material inventory in the computer.
No problems were identified
with the material, receiving activiites, or receipt inspection of the
stainless steel elbows.
10.
Nonconformance Reports
The NRC inspector conducted a review of the following NCR's:
DE-00058 - 03
HP-00141
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EM-0002 - 01
CC-00535
HC-00534
EC---307 - 01
DC-00047
BS-00089
CC-00435 - 01
DP-00038
CM-00180
CC-00518
CC-00564
HM-00164 - 01
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BP-00244
CC-00563
CE-00048 - 48
BE-00089 - 02
BP-00100
BE-00088 - 02
BM-00133 - 01
BE-00090 - 02
BP-00221 - 04
BE-00098 - 03
CC-00396 - 02
CC-00600 - 01
EC-00169 - 03
CP-00135 - 01
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EC-0003 - 03
EW-0021 - 01
BC-00155 - 01
BN-00054 - 01
BP-00241
CC-00529-
EW-00030
BC-00127
BE-00132
The NRC inspector reviewed the description of the nonconforming conditions
and the disposition of the NCR's.
The NRC inspector had no further
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questions with respect to the NCR's reviewed.
11.
Unresolved Items
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Unresolved items are matters about which more information is required in
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order to ascertain whether they are acceptable. items, violations, or-
deviations.
Four unresolved items disclosed during the inspection are
discussed in paragraphs 4, 5, 7, and 9.
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12.
Management Meetings
Meetings were held periodically with licensee management personnel during
the course of this inspection to discuss inspection scope and findings.
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