IR 05000498/1999010

Insp Repts 50-498/99-10 & 50-499/99-10 on 990405-09.No Violations Noted.Major Areas Inspected:Review of Licensee Inservice Exam Program Plan & Schedule & Implementation of Program Plan for Facilities

ML20206B630
Person / Time
Site:	South Texas
Issue date:	04/22/1999
From:	NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV)
To:
Shared Package
ML20206B612	List: IR 05000498/1999010 ML20206B609
References
50-498-99-10, 50-499-99-10, NUDOCS 9904300014
Download: ML20206B630 (11)

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ENCLOSURE U.S. NUCLEAR REGULATORY COMMISSION

REGION IV

Docket Nos.: 50-498;50-499 License Nos.: NPF-76; NPF-80 Report No.: 50-498/99-10;50-499/99-10 Licensee: STP Nuclear Operating Company Facility: South Texas Project Electric Generating Station, Units 1 and 2 Location: FM 521 - 8 miles west of Wadsworth Wadsworth, Texas Dates: April 5-9,1999 Inspector: Claude E. Johnson, Senior Reactor Inspector Engineering and Maintenance Branch Apprcved By: Dr. Dale A. Powers, Chief Engineering and Maintenance Branch Division of Reactor Safety j i

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ATTACHMENT: Supplementalinformation

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9904300014 990422 PDR ADOCK 05000498 G PDR 3a j

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2-EXECUTIVE SUMMARY South Texas Project Electric Generating Station, Units 1 and 2 NRC Inspection Report No. 50-498/99-10; 50-499/99-10 This inspection consisted of a review of the licensee's inservice examination program plan and schedule, and the implementation of the program plan for the facilities. The inspection report covers a 1- week period onsite by a region-based inspecto Maintenance

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The licensee had developed a wel! defined first 10-year inservice examination program plan for Units 1 and 2, in that, the examination category, examination method, weld identification figures, augmented inspections, relief requests, code cases implemented, and changes to the examination plan were clearly delineated. The licensee was implementing the program requirements in accordance with the requirements of 10 CFR 50.55a (Section M1).

The external material condition of the Unit 2 component cooling water (Train B) system piping, valves, and the ring duct was good, in that, no visible oil or excessive water leaks were noted. Overall appearance of the safety-related trains and components was excellent, in that, they were color-coded and labeled for proper identification (Section M2).

• Nondestructive examination procedures were in compliance with regulatory and ASME code requirements, and were sufficient to perform the intended inservice inspection work activities (Section M3).

• The performance of (1) visual examinations, (2) liquid penetrant examinations, j (3) system pressure testing, (4) snubber functional testing, and (5) an observed portion of remote ultrasonic examination of the Unit 1 reactor vessel welds was in accordance ,

with approved site procedures (Section M4). )

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• The inspector noted specific deficiencies: (1) welding procedure specifications and work )

instructions did not provide clear guidance when to verify interpass and preheat temperature, (2) an inconsistency was noted among craft and inspection personnel as to when interpass temperature should be monitored or verified, and (3) a poor work practice was identified when a welder did not have all necessary equipment and tools (i.e., temperature stick or pyrometer) in the immediate area to perform a task. Condition Report 99-5468 was initiated to address these observations (Section M4).

• Licensee personnel were effective in coordinating contractor inservice inspection activities, as evidenced by their conduct of detailed job prebriefs prior to implementing significant work activity and the scheduling of daily inservice inspection examinations (Section M4).

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• Nondestructive examination personnel were properly certified in accordance with the applicable supplement of SNT-TC-1 A (Section MS).

Self-assessments and qua3ty surveillance reports were satisfactory. Deficiencies identified in the self-assessments and quality surveillance reports were documented in condition reports and tracked by the licensee's corrective action program (Section M7).

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-4-Report Details Summary of Plant Status Unit 1 was shutdown for Refueling Outage 1RE08; Unit 2 was at 100 percent powe . Maintenance M1 Conduct of Maintenance M1.1 Inservice inspection Inspection Scoce (73753)

The inspector performed a thorough review of the licensee's "First 10-Year Long-Term Inservice Examination Plan For the South Texas Project Electric Generating Station," J Revision 0, Supplements 1 and 2, for both Unit 1 and 2. In addition, the inspector reviewed ASME code cases implemented, correspondence from the licensee to the NRC about the first 10-year interval to determine if the licensee had submitted relief requests for those Code Class 1,2, and 3 weld examinations where 100 percent full examination coverage could not be achieve Observations and Findinas The inspector found that the licensee has committed to ASME Section XI," Rules for Inservice inr,pection of Nuclear Power Plant Components," 1983 Edition with Addenda through Summer 1983. The examination program plan identified the examination categories, components to be examined, weld identification figures, nondestructive examination methods, augmented inspections, and the applicable code cases implemented. The inspector verified that (1) program changes were documented appropriately, (2) ASME code cases implemented that were not listed in Regulatory Guide 1.147," Inservice inspection Code Case Acceptability ASME Section XI Division 1," Reusion 11, had been granted approval by the NRC, (3) code walds not receiving 100 percent full examination coverage were documented on relief requests, and (4)

augmented inspections were performed as planned. The inspector determined that the licensee had developed a well-defined first 10-year inservice examination plan and was implementing the program in accordance with the requirements of 10 CFR 50.55 Conclusions Overall, the licensee had developed a well-defined first 10-year inservice examination program plan for Units 1 and 2, in that, the examination category, examination method, weld identification figures, augmented inspections, relief requests, code cases implemented, and changes to the examination plan were clearly delineated. The licensee was implementing the program requirements in accordance with the i

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requirements of 10 CFR 50.55 F'

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5-M2 Maintenance and Material Condition of Facilities and Equipment Insoection Scooe (73ia3)

While verifying the implementation of Unit 2 component cooling water (Train B) pressure testing, the inspector observed the external material condition of the system piping, valves (at elevations -11,19,37, and 52 foot), and the ring duct (at elevation 19 foot).

The inspector also observed several liquid penetrant examinations and external material conditions of the piping and valves of the chemical and volume control system located in Room 237U of the mechanical auxiliary buildin Observations a id Findinas The inspector found that the Unit 2 component cooling water (Train B) system piping, valves, and the ring duct were in good external material condition, in that, no visible oil or excessive water leaks were noted. Piping systems and components were easily identified by labels. Minor leaks were observed in the ring duct, however, the licensee had documented these during a previous walkdown of the syste ,

The external material condition of the chemical and volume control system piping and valves located in Room 237U was good. No oil or water leaks were note The overall appearance was excellent, in that, the safety-related trains and components were color-coded and labeled for proper identificatio Conclusions

, - The external material condition of the Unit 2 component cooling water (Train B) system piping, valves, and the ring duct was good, in that, no visible oil or excessive water leaks were noted. The overall appearance of the safety-related trains and components were excellent, in that, they were color-coded and labeled for proper identificatio M3 Maintenance Procedures and Documentation Insoection Scope (73753)

The inspector reviewed nondestructive examination procedures to determine if they had been developed in accordance with regulatory and applicable ASME code requirement The inspector also reviewed an inservice pressure test procedure. The crocedures reviewed are listed in the Attachmen ...

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' Observatons and Findings The inspector found that nondestructive examination procedures reviewed contained

sufficient detail and inspection criteria to perform the intended examinations, and were Lin compliance with regulatory and ASME code requirement The licensee had established and implemented effective controls (administrative procedures and an inventory checklist) in maintaining current status and inventory of

' ultrasonic calibration blocks for inservice inspection activities, Conclusions The nondestructive examination procedures were in compliance with regulatory and ASME code requirements and were sufficient to perform the intended inservice inspection work activitie ;

M4' Maintenance Staff Knowledge and Performance Inspection Scone (73753)-

The inspector assessed the knowledge and performance of licensee and contractor

-. personnel by observing nondestructive examinations and system pressure testing activitie The inspector observed the work activities of Reactor Coolant Pump 1B design modification in Unit ' The inspector also assessed the effectiveness of the licensee's controls as they related to inservice inspection activities (i.e., scheduling examinations, oversight of inservice

- inspection contractors, and control of ultrasonic calibration equipment). Observations and Findinas

Personnel Knowledae The inspector found that contractor inservice inspection personnel were knowledgeable of the nondestructive procedures and applicable ASME code requirements use Licensee system engineering personnel accompanied on the Unit 2 component cooling water inservice pressure test were knowledgeable of pressure test procedures, code requirements, and the corrective action process, b.2 Performance The inspector found that (1) visual examinations, (2) liquid penetrant examinations, (3) system pressure testing, (4) snubber functional testing, and (5) an observed portion of remote ultrasonic examination of the Unit 1 reactor vessel welds were performed in L a

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accordance with approved site procedures. hersonnel responsible for the inspection activities performed were knowledgeable of site requirements and applicable committed codes. No deficiencies were noted by the inspector during these various inspection )

observations. The examination records reviewed are listed in the Attachmen j b.3 ASME Code Repair and Replacement

The inspector observed welding activities for Reactor Coolant Pump 1B design modification. This design modification involved the removal and replacement of reactor cooling pump piping for easy removal of the reactor coolant pump moto During this activity the inspector questioned welders on various welding parameters and 1 procedures, specifically interpass temperature for Weld HFW 0195. Discussions with the welder indicated that the welder had verified interpass temperature of the weld, however, when asked to see the temperature stick or pyrometer, the welder did not -

have it in the immediate area. The responsible engineer in the area indicated that interpass temperature could be verified anytime during the process. The inspector disagreed with the responsible engineer and explained why. The responsible engineer also stated these welding parameters were verified on a monitoring basis. The q inspector noted that the general welding procedure clearly states that interpass and i preheat temperature shall be verified, however, the general welding procedure and the I welding specification did not indicate when. It was not clear to the inspector that the instructions gave clear guidance when interpass temperature should be monitored or verified. Subsequent discussions with the welding engineering supervisor indicated that prior to welding activities, contractor welders are given an orientation that discusses welding requirements including adherence to welding parameter From this review, the inspector identified the following observations:

(1) Procedures do not have clear guidance when to verify interpass and preheat temperature, (2) There is inconsistency between craft and inspection personnel when interpass temperature should be monitored or verified, and (3) A poor work practice was identified when a welder did not have all necessary equipment and tools in the immediate area to perform an assigned tas After discussing these observations with the welding supervisor, Condition *I Report 99-5468 was initiated addressing the observation Effectiveness of Licensee Control The inspector found that licensee personnel were effective in the day-to-day ,

coordination of contractor inservice inspection activities, as evidenced by their conduct of detailed job prebriefs prior to implementing significant work activity and the scheduling of daily inservice examinations. The inspector noted extensive oversight by i

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-8-licensee management personnel during the installation of the remote examination equipment for the reactor vessel and the performance of reactor vessel 10-year

inservice examination '

c. Conclusions Contractor inservice inspection personnel were knowledgeable of applicable nondestructive examination procedures and ASME code requirement '

The inspector found that (1) visual exan anations, (2) liquid per,etrant examinations, (3) system pressure testing, (4) snubber functional testing, and (S) an observed portion of remote ultrasonic examination of the Unit i reactor vessel welda were performed in accordance with approved site procedure I The inspector noted specific deficiencies: (1) welding procedure specification, and work instructions did not provide clear guidar ce when to verify interpass and preheat temperature, (2) an inconsistency was r,oted between craft and inspection personnel as to when interpass temperature should be monitored or verified, and (3) a poor work practice was identified when a welder did not have all necessary equipment and tools (i.e., temperature stick or pyrometer) in the immediate area to perform an assigned task. ;

The licensee initiated Condition Report 99-5463, which addressed these observation Licensee personnel were effective in coordinnting contractor inservice inspection activities as evidenced by their conduct of de tailed job prebriefs prior to implementing significant work activity and the scheduling c f daily inservice examination MS Maintenance Staff Training and Qualification ) Inspection Scope (73753) l l

The inspector reviewed the licensee's contractors (Sonic International and WesDyne International) nondestructive examination personnel certification records for Level ll and lli examiner Observations and Findinas l

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The inspector found that persnnnel certification records contained adequate documentation, such as examinations results for each certified condestructive examination method, work experience, education, and the annual vision acuity '

examination. The certification records were current and legible. The inspector i determined that personnel were properly certified and qualified in accordance with ASME code requirements and the applicable supplement of SNT-TC-1 A,' Requirements for the Qualification of Nondestructive Examination Personnel."

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-9- . Conclusions The nondestructive examination personnel were properly certified in accordance with the applicable supplement of SNT-TC-1 M7 Quality Assurance in Maintenance Activities M7.1 Licensee Self-Assessment Activities Inspection Scope (73753)

The inspector reviewed the licensee's previous ins..vi.:e inspection self-assessments and quality surveillance reports performe Observation and Findinas The inspector found that self-assessments and quality surveillance reports were satisfactory. The inspector verified that deficiencies identified in the self-assessments and quality surveillance reports were documented in condition reports and tracked by the licensee's corrective action progra Conclusions Self-assessments and quality surveillance reports were satisfactory. Deficiencies identified in the self-assessments and quality surveillance reports were documented in condition reports, and were tracked by the licensee's corrective action progra V. Manaaement Meetinas

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The inspector presented the inspection results to members of licensee management at the conclusion of the inspection on April 9,1999. The licensee representatives acknowledged the findings presente The inspector asked the licensee representatives whether any materials examined during the inspection should be considered proprietary. No proprietary information was identifie j l

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ATTACHMENT SUPPLEMENTAL INFORMATION PARTIAL LIST OF PERSONS CONTACTED 1.icensee P. Arrington, Licensing Specialist W. Bullard, Supervisor, Health Physics T. Cloninger, Vice President, Engineering and Technical Services

' W. Cottle, President and Chief Executive Officer L. Earls, Health Physicist R. Gangluff, Manager, Chemistr J. Groth, Vice President, Nuclear Generation S. Horak, Quality Specialist T. Jordan, Manager, Systems Engineering F. Mangan, Vice President, Business Services R. Masse, Plant Manager, Unit 2 M. McBurnett, Director, Quality and Licensing S. Phitiips, Quality Specialist T. Powell. Manager Health Physics P. Serra, Manager, Emergency Response and Public Affairs and Communications J. Sheppard, Vice President and Special Assistant to President M. Smith, Manager, Plant Support, Quality B. Wedgeworth, Manager, Personnel Safety NRC N. O'Keefe, Senior Resident inspector M. Shannon, Senior Radiation Specialist  !

INSPECTION PROCEDURES USED IP 73753 Inservice Inspection LIST OF DOCUMENT REVIEWED UTI-050 ." Ultrasonic inservice Inspection Calibration Block Controls,"

Revision 0 OPGPO4-ZE-0304 " Inservice Inspection Program For Welds and Component Supports,"

Revision 1 OPOP05-ZA-0010 " Solvent Removable Liquid Penetrant Examination," Revision 0

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2-OPSP11 SN-0003 - " Mechanical Snubbers Functional Test," Revision 5 OPMP02-ZW-0001 " General Welding Requirements," Revision 5

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WPS P1-T: Welding Procedure Specification," Revision 3 ,

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OPSP11-RC-0015 "ASME Section XI inservice Inspection," Revision 2 UTI-051 " Manual Ultrasonic Examination of Reactor Pressure Vessel Flange

' Threads," Revision 1 1 OPOP05-ZA-0012 " Color Contrast Solvent Removable Liquid Penetrant Examination For ASME XI PSI /ISI," Revision 2

' OPOP05-ZA-0004 " General Ultrasonic Examination," Revision 1 OPOP05 ZA-0018 " Dry Powder Magnetic Particle Examination For ASME XI PSI /ISI,"

Revision 2 TGX ISI-254 " Remote Inservice Ultrasonic Examination of Reactor Vessels for the

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South Texas Project, Units 1 and 2," Revision 0 Miscellaneous Documents 1RE07 Inservice inspection Summary Report For Welds. And Component Supports, November 1987

2RE06 Inservice inspection Summary Report For Welds And Component Supports, January 1999 First 10-Year' interval Long-Term inservice Examination Plan For The South Texas Project Electric Generating Station, Unit 1, Revision 0, Supplement 1, May 1989 First 10-Year interval Long-Term inservice Examination Plan For The South Texas Project Electric Generating Station, Unit 2, Revisica 0. Supplement 1, May 1989 Examination Plan for the 1999 - 1 RE08 Inservice inspection of Welds and Components

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Supports at the South Texas Project Nuclear Operating Company - Unit 1 Reactor Vessel Examination Program Plan, Unit 1, March 1999

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Nondestructive Examination Weld Records PT - 99 - 0079 NDE - 90 - 0095 NDE - 95 - 0050 PT - 99 - 0080 NDE - 95 - 0049 PT - 97 - 0202 UT - 97 - 0148 NDE - 90 - 0123 PT - 97 - 0194 UT - 97 - 0143 ND - 95 - 0038 NDE - 95 - 0032 PT - 97 - 0189 UTWTP - 97 - 0008 UT - 97 - 0139 NDE - 92 - 0851 NDE - 92 - 0875 NDE - 92 - 0876 PT - 97 - 0199 UTWTP - 97 - 0009 UT - 97 - 0149 PT - 99 - 0071 PT - 99 - 0072 VTW - 99 - 0070 VTW - 99 - 0071 Assessments / Quality Surveillance Reports Assessment of Houston Lighting and Power's South Texas Project's NDE and ISI Program, by Electric Power Research Institute (EPRI)  !

Quality Audit Report No. 98-14 (CA), " Corrective Action Program," January 6,1999 Qualiy Surveillance Report No.98-034,"The inservice inspection Program and the !

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Implementation of Modifications," June 30,1998 Quality Surveillance Report 98-052, " Check Valve Inservice Testing," October 14,1998 -

Quality Surveillance Report 98-043," Inservice inspection Relief Requests,"

September 9,1998 Relief Reauest N RR-EMG-18 RR-ENG-19 - RR ENG-20 RR-ENG-21 RR ENG-22 RR ENG-23 RR-ENG-25 RR-ENG-26

. RR-ENG-27 RR-ENG-28 RR-ENG-29 ASME Code Case N N-401-1 N-408-2 N-4161 N-427 N-429-1 N-461 N-581 N-546

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