IR 05000498/1986018

Insp Rept 50-498/86-18 on 860602-13.No Violations or Deviations Noted.Major Areas Inspected:Preservice Insp Program,Implementing & Insp Procedures,Observation of Insp Activities & Review of Preliminary Records

ML20214E824
Person / Time
Site:	South Texas
Issue date:	11/18/1986
From:	Ireland R, Tomlinson D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV)
To:
Shared Package
ML20214E796	List: IR 05000498/1986018 ML20214E794
References
50-498-86-18, NUDOCS 8611250105
Download: ML20214E824 (8)

Text

.

.

A APPENDIX U.S. NUCLEAR REGULATORY COMMISSION

'

. REGION IV

' ' -

.

,

NRC Inspection Report: '50-498'/86-18

,

CP: CPPR-128

' "

Docket:,50-498

. Licensee: kouston t.ighting & Pow'er Company (HL&P)

'

'P.10. Box 1700 Houston, Texas 77001

'

Facility Name: ' South' Texas' Project (STP)

- Electric Generating Station Unit No. 1 -

s Inspection At: Bay City,. Texas Inspectors: [db /w h fr.'*P. TodiliMod, Reactor Inspector

-

!!-t 8- FG Date Engineering Section Consultants: Energy Technology Engineering Center T. D. Hunnicutt F. R. Koepenick S. E. Preckwinkle Approved: i R. E. Ireland, Chief, Engineering Section

// /

Date N

pgectionSummary I;.oection Conducted June 2-13, 1986 (Report 50-498/86-18)

Areas Inspected: Routine, announced inspection of the utility's preservice inspection program, review of implementing and inspection procedures, observation of inspection activities, and a review of preliminary records generated as a result of this inspectio Results: Within the areas inspected, no violations or deviations were identifie PDR ADOCK 05000498 G PDR

.. .

.

4 - < % 9? &

'

'

, . .

,,

'

. .

'

DETAILS Persons Contacted Licensee Personnel

• D. F. Bednarczyk, Operations QA Manager, Mechanical /NDE

• R. L. Beverly, Lead Engineer, PSI /ISI

• J. E. Geiger, Manager, Nuclear Assurance

• J. L. Haning, PSI /ISI Engineer

• S. M. Head, Licensing Engineer

• S. K. Hubbard, Operations QC K. M. O'Gara, Licensing Engineering K. L. Trippel, Lead Engineer G. E. Wadkins, Test Engineer Bechtel Personnel L. E. Davis, Construction Manager

• R. H. Medina, QA Supervisor

• R. W. Miiler, Deputy Project QA Manager Ebasco Personnel

• R. G. Peck Deputy Quality Program Site Manager Southwest Research Institute (SwRI) Personnel C. M. Barrera, SNT Level III Examiner D. C. Garza, SNT Level III Examiner T. A. Mayces, Lead Auditor (QA)

J. C. Younger, Research Engineer Kemper Insurance

• C, G. Ward ANII In addition to the above personnel, the NRC inspectors held discussions with various technical and administrative members of HL&P's and SwRI staf * Denotes those present at the exit intervie . Preservice Inspection Program Review The preserv. ice inspection (PSI) program was reviewed from the 10 CFR 50.55a requirement to ASME Boiler and Pressure Vessel (B&PV) Code,Section XI through South Texas Project Electric Generating F?ation (STPEGS) Final Safety Analysis Report (FSAR), the STPEGS Operations Quality Assurance

o _ _e 1

, .

4 Plan (0QAP) Revision 3, and the STPEGS Interdepartmental Procedure IP.3.04Q, Revision 0, of December 11, 1985, "Preservice and Inservice Inspection Program," which defines a complete step-by-step plan. The final program observations were of actual examination efforts utilizing SwRI operating procedures with properly certified personnel and equipmen The NRC inspectors determined that the program, including examinations and tests was in conformance with the requirements of the ASME B&PV Code,Section XI, as specified in the STPEGS FSAR. The inspection revealed the licensee had procured the services of an Authorized Nuclear Inservice Inspector (ANII) from Kemper Insurance Company, and that the licensee's PSI program had been reviewed by the ANII in accordance with Article IWA-2120 of the ASME Code. The NRC inspectors noted that the review and approval of the PSI plan by the Nuclear Sai'ety Review Committee was incomplet This was found to be acceptable at this point as portions of the PSI plan were still in the developmental stages. The basic plan had been outlined and approved but many of the details had to be worked out as unusual situations were encoLntered. These were resolved, witnessed, and approved by the ANII and licensee representatives prior to inclusion in the inspection procedures. No violations or deviatiens were identifie . -Preservice Inspection Procedures Review The NRC inspectors reviewed a sample of the SwRI inspection procedures being used, developed, or revised at the time of this inspection. These included procedures for NDE inspections, equipment requirements and calibration, recording of inspection results, deviations to operating procedures, and onsite storage of records. This sample included the following:

HP&L PROCEDURE N0./REV TITLE DOCUMENT LOG N SwRI-NDT-200-1/62 SOLVENT-REMOVABLE LIQUID PENETRANT A41073-00003-B-SW COLOR CONTRAST EXAMINATION FOR THE SOUTH TEXAS PROJECT SwRI-NDT-300-1/30 DRY POWDER MAGNETIC PARTICLE A41037-00055-B-SW EXAMINATION SwRI-NDT-600-5/38 MANUAL ULTRASONIC EXAMINATION OF A41037-00057-A-SW NUCLEAR REACTOR PRESSURE VESSEL

FLANGE LIGAMENTS i

.

$

'

.

.. -

SwRI-NDT-600-13/37 MANUAL ULTRASONIC EXAMINATION OF A41073-00058-B-SW

-

THE REACTOR FRESSURE VESSEL

'

- FLANGE-TO-SHELL WELD SwRI-NDT-600-14/19 MANUAL ULTRASONIC EXAMINATION OF STUDS AND BOLT .SwRI iNDT-600-15/61- MANUAL ULTRASONIC EXAMINATION'0F A41073-00059-A-SW

,'

~

,

,

.-

..

i PRESSURE VESSEL WELDS

' ' *

-SwRI , l VOLUME 2 - PERSONNEL CERTIFICATIONS

+4 SOUTH TEXAS PROJECT ELECTRIC

/ , .- m . ~ 'GENERAT,ING STATION

.

.

.7

'SwRI - - -

-VOLUME 3 - CONSUMMABLES CERTIFICATIONS

,

PENCILS, MT, PT, AND GLYCERINE

,

SwRI VOLUME 4 - EQUIPMENT CERTIFICATIONS VT CARDS, PYR0 METERS, MT, STRIP CHART, OSCILLOGRAPH / MIS SwRI

'

.

VOLUME 5 - EQUIPMENT CERTIFICATIONS SONICS, MKI, MKII, MKIII SwRI VOLUME 6 - TRANSDUCER CERTIFICATIONS AER0 TECH, SwRI, AND MIS SwRI >

VOLUME 2 - NUCLEAR PRODUCTS OPERATING PROCEDURES (ULTRASONICS) INCLUDING CALIBRATION BLOCK DIAGRAMS SwRI NUCLEAR QUALITY ASSURANCE PROGRAM MANUAL REV. 2 COPY 89 SwRI NUCLEAR QUALITY ASSURANCE PROGRAM MANUAL REV. 2, CHAPTER 11-1 CHANGE 7, PERSONNEL QUALIFICATION AND CERIFICATION SwRI NUCLEAR QUALITY ASSURANCE PROGRAM MANUAL REV. 2. CHAPTER 15-3 CHANGE 10, QUALIFICATION AND CERTIFICATION OF QUALITY CONTROL INSPECTION AND TESTING PERSONNEL

'I SwRI VOLUME IS0 METRICS CLASS I CLASS II 1 IXFE PROCESS PROCEDURE

'

l

_

. , o

INCLUDING:

CLASS 1 WELD IDENIFICATION FIGURES CLASS 2 WELD IDENTIFICATION FIGURES SRI - NUCLEAR PROJECTS OPERATING PROCEDURES SwRI 1985 PRESERVICE EXAMINATION OF THE REACTOR PRESSURE VESSEL AT THE SOUTH TEXAS PROJECT ELECTRIC GENERATING STATION, UNIT I (DRAFT). VOLUME I, FINAL REPORT WITH APPENDICES SwRI PROJECT 5770 MAY 1986

'

SwRI-NDT-600-41/11 MANUAL ULTRASONIC EXAMINATION OF A41073-00062-C-SW

-

DEVIATION N0.'. 1 AUSTENITIC PRESSURE PIPING WELDS A41073-00062-D-SW

'-

---. ' SwRI-NDT-600-39/4 ' MANUAL ULTRASONIC EXAMINATION OF A41073-00089-A-SW

< - - J SMALL-DIAMETER PIPING WELDS SwRI-NDT-600:41/11 MANUAL ULTRASONIC EXAMINATION OF A41073-00063-C-SW rEVIATION'NO. 2 FERRITIC PRESSURE PIPING WELDS A41073-00063-D-SW

' ' '

'SwRI-NDT-700-6/27 MECHANIZED ULTRASONIC EXAMINATION A41073-00065-A-SW

-

, 0F FERRITIC VESSELS GREATER THAN

,

-- ' 2.0 ' INCHES IN THICKNESS

-

SwRI-NDT-700-6/29 MECHANIZED ULTRASONIC EXAMINATION A41073-00065-B-SW 0F FERRITIC VESSELS GREATER THAN

,

2.0 INCHES IN THICKNESS SwRI-NDT-800-17/31 SPECIAL PROCEDURE FOR MANUAL A41073-00090-A-SW r- ULTRASONIC EXAMINATION OF AUSTENITIC COMPONENTS WITH HIGH AC0USTIC ATTENUATION PROPERTIES SwRI-NDT-800-105/1 MANUAL ULTRASONIC EXAMINATION A41073-00067-B-SW 0F THE SOUTH TEXAS PROJECT REACTOR PRESSURE VESSEL WELDS SwRI-NDT-800-111/0 MECHANIZED ULTRASONIC EXAMINATION 8 41073-00100-B-SW 0F PIPING WELDS FOR THE SOUTH TEXAS PROJECT SwRI-NDT-800-113/0 MANUAL ULTRASONIC EXAMINATION FROM A41073-00101-A-SW THE INSIDE SURFACE OF PIPING WELDS FOR THE SOUTH TEXAS PROJECT SwRI-NDT-800-114/1 MANUAL ULTRASONIC EXAMINATION OF A41073-00102-B-SW AUSTENITIC PRESSURE PIPING WELDS FOR THE SOUTH TEXAS PROJECT

._

, , ,.

x 6 SwRI-NDT-900-7/8

~

'

VISUAL EXAMINATION OF NUCLEAR A41073-00001-B-SW

'

'. POWER PLANT COMPONENTS FOR THE

. .,-- -SOUTH TEXAS PROJECT

~ ~

N SwRI IX-FE-101-3 DEVIATIONS TO NUCLEAR PROJECTS

'

,

.0PERAT,ING PROCEDURES

,.

~? .. , \

'

>

SwRI'-IX-FE-128-0' MAINTENANCE GUIDELINES

SNI-X-FE-1013, i 'ONSITE NDE RECORDS CONTROL

} SwRI-XVII-AG-101-1 DATA STORAGE & RETRIEVAL

, SwRI EXAMINATION SUMMARY RECORD N0. 551900

'

SwRI MANUAL' ULTRASONIC EXAMINATION N0. 170078 RECORD

'

SwRI EXAMINATION SUMMARY RECORD NO. 100010 SwRI SONIC INSTRUMENT CALIBRATION RECORD N0. 190536 SwRI INSTRUMENT LINEARITY VERIFICATION N0. 370259 SwRI SCM' PLAN PARAMETER RECORD 18 84 HLP-STP-1-1-0 PROJECT PLAN FOR THE PRESERVICE EXAMINATION OF SOUTH TEXAS PROJECT ELECTRIC GENERATING STATION ~, UNIT 1 SwRI PROJECT 17-5770 SOUTH TEXAS PROJECT DRAWING REF BOOK STPEGS OPERATIONS QUALITY ASSURANCE PLAN STPEGS SPECIFICATION FOR SECTION XI PRESERVICE NDE EXAMINATION STPEGS IP-3.040 INTERDEPARTMENTAL PROCEDUR PRESERVICE

& INSPECTION PROGRAM STPEGS SPEC. 4U01HW40002 SOUTH TEXAS PROJECT. ELECTRIC GENERATING STATION SPECIFICATION FOR SECTION'XI PRESERVICE'NDE EXAMINATION

. .. .

s

1 REFERENCES

'

ASME,Section XI, 1980, through Winter, 1981 FSAR Sections 5.2, 5.3, 5.4, and ,

_

Regulatory Guides ,

'

10 CFR 50 *

ANSI N45.2 Quality Assurance ANSI N45.2.6 Certifications ANSI N45.2.9 Records The NRC inspectors' review of these procedures indicates compliance'

with the requirements of the referenced specifications and guidance document No violations or deviations were identifie . Preservice Inspection - Observation of Work Activities The NRC inspectors reviewed 13 personnel qualification and certification packages for Southwest Research Institute (SwRI) inspectors. These records were for nine persons, some of whom were certified in more than one inspection method. The certification review included one Level I, Level II, and Level III each for visual, magnetic particle, liquid penetrant, and ultrasonic inspectors. Only one Level III certification was reviewed for radiography due to the limited application of radiography in preservice inspection. Each person was found to have at leasi; the minimum hours of formal instruction, experience, education, and passing grades on formal examinations in the specific inspection methods. Each 4 certification package also contained evidence of the satisfactory completion of a current visual acuity examination including color discriminatio The NRC inspectors witnessed the SwRI personnel during the pre-examination calibration of two ultrasonic instruments. The NRC inspectors verified that the. correct instruments were being used and that each exhibited evidence 'of current calibration. Observations also included the use of correct transducer size, frequency, and angle for the tests to be performed. The calibration standard blocks were checked against the procedure for correct numerical identification. This data was compared to the specific standard drawing to assure material type and configuration along with size, shape, and orientation of the calibration reflector The NRC inspectors also reviewed the precalibration linearity verification sheets for both instruments and observed that approved couplant was used for calibration and examinatio The NRC inspectors observed the SwRI personnel during their examination of pressurizer weld L-6. This observation included verification of the correct weld, proper orientation and location of inspection station markers, application of couplant, direction of beam paths, extent of examination area, and the speed of scans. The SwRI personnel performed in

_

t

. . , .

accordance with all procedural requirements including couplant removal at the completion of the inspection. No reportable reflectors were note The NRC inspectors also observed certified SwRI inspectors perform the magnetic particle examination of one weld in the feedwater system. The NRC inspectors verified the current calibration of the magnetizing equipment, use-approval of the iron powder, acceptable magnetizing amperage, spacing of contacts, application of iron powder, absence of contact arc-strikes, and recording of the examination results. The procedural requirements were observed by the SwRI inspectors during each step of the examinatio The NRC inspectors' observations indicate that SwRI personnel are competent and are performing fully within established procedural parameters. There were no violations or deviations identifie . Preservice Inspection - Records Review The NRC inspectors noted that the onsite storage and maintenance of inspection records was in accordance with approved Procedure SwRI X-FE-101, Revision 3, and SwRI XVII - AG-101, Revision 1. Tests of the record retrieval process were successful in that current and historical inspection documentation packages were provided for the NRC inspectors'

review in a timely manne The NRC inspectors reviewed the inspection reports for the penetrant inspection of three class 1 and one class 2 piping welds, along with the records of five ultrasonically inspected class 1 piping welds. The NRC inspectors reviewed the record packages to assure that all necessary data had been included and legibly recorded on the required forms. The inspectors verified that the record packages for ultrasonic inspections contained the calibration data sheets, extent of examination, any deviations from the program or procedure, examination evaluation data, equipment utilized, any reportable reflectors, and the signatures of those performing the examination. For the liquid penetrant examination, the NRC inspectors reviewed the identification and approval of the test materials, specimen temperature, penetrant dwell times, exten' of examination, any deviations from the program or procedure, indications found, and the signatures of those performing the examinatio In each of the above instances, the record packages contained the required information recorded in a logical and orderly manner. No violations or deviations were noted during this portion of the inspectio . Exit Interwiew An exit interv;ew was conducted on June 13, 1986, to discuss the scope and findings of this inspection. Attendees are noted in paragraph