ML19263E690
| ML19263E690 | |
| Person / Time | |
|---|---|
| Site: | South Texas  |
| Issue date: | 04/11/1979 |
| From: | Gilbert L, Randy Hall, Hubacek W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19263E683 | List: |
| References | |
| 50-498-79-04, 50-498-79-4, 50-499-79-04, 50-499-79-4, NUDOCS 7906250051 | |
| Download: ML19263E690 (8) | |
See also: IR 05000498/1979004
Text
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U. S. NUCLEAR REGULATORY COMMISSION
OFFICE OF INSPECTION AND ENFORCEMENT
REGION IV
Report No. 50-498/79-04; 50-499/79-04
Docket No. 50-498; 50-499
Category A2
Licensee: Houston Lighting & Power Company
Post Office Box 1700
Houston, Texas
77001
Facility Name:
South Texas Project, Units 1 & 2
Inspection at: South Texas Project, Matagorda County, Texas
Inspection conducted: March 20-23, 1979
Inspectors:84 f,7k,(I/hd
/ /[77
W. G. Hubacek, Reactor Inspector, Projects Section
Date
(Paragraphs 1, 2, 3, 4, 5, 6 & 11)
- ////l79
- x
h L. D. Gilbert, Reactor Inspector, Engineering
Date
U
Support Section (Paragraphs 9 & 10)
Y//rl79
~
R. E. Hall, Chief, Engineering Support Section
Date
(Paragraphs 2,7&8)
Approved:
V////7 9
-u
W. A. Crossman, Chief, Projects Section
Date
Yf//f79
hR.E. Hall, Chief,EngineeringSupportSection
= _ -
Date
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79062500 N. k
Inspection Summary:
Inspection on March 20-23, 1979 (Report No. 50-498/79-04; 50-499/79-04)
Areas Inspected:
Routine, unannounced inspection of construction activi-
ties including observation of work related to concrete placement for Unit 2;
review of r cords related to welding of the Unit 1 containment liner dome;
review of '.sbrication records related to the Unit 1 crane girder; review of
receivint records for electrical components; review of reported 50.55(e)
items; and review of previous inspection findings.
The inspection involved
seventy-five inspector-hours by three NRC inspectors.
Results: Of the six areas inspected, one apparent item of noncompliance
was identified in one area (infraction - failure to follow concrete place-
ment procedures - paragraph 7).
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DETAILS
1.
Persons Contacted
Principal Licensee Employees
- T. R. Alford, Project Site Manager
- T. D. Stanley, Project QA Supervisor
- L. D. Wilson, Site QA Supervisor
- D. G. Long, Lead Engineer
- T. J. Jordan, Lead Engineer
M. H. Smith, Plant QA Supervisor
- R.
L'. Ulrey, QA Specialist
- D. W. Bohner, QA Specialist
- M. S. Monteith, QA Technician
C. L. Grosso, Associate Engineer
M. M. Johnsun, Senior Engineer
Other Personnel
- J. Dodd, Senior Manager of Construction, Brown & Root (B&R)
- J. H. Pepin, Project General Manager, B&R
- C. W. Vincent, Project QA Manager, B&R
- G. T. Warnick, Site QA Manager, B&R
- J. R. Monroe, Construction Project Manager, B&R
- S. A. Rasnick, Construction Chief Engineer, D&R
- A. Smith, Chief Construction Quality Engineer, B&R
G. Ewert, Internal Surveillance Supervisor, B&R
R. Allgood, Training Coordinator, B&R
K. E. Easter, External Surveillance, B&R
T. J. Foley, Site QA Manager, Pittsburgh Des Moines (PDM)
The IE inspectors also interviewed other licensee and contractor
employees including members of the QA/QC and engineering staffs.
- denotes those attending the exit interview.
2.
Licensea Action on Previous Inspection Findings
.
(0 pen) Infraction (50-498/78-16; 50-499/78-16):
Failure to Provide
Procedure for Housekeeping Inspection. The IE inspector reviewed
corrective actions described in the licensee's letters, dated
January 8,1979, and February 14, 1979.
Corrective actions have
been accomplished as described in the letters; however, Procedure
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GCP-4, " Housekeeping," Rev. 2, dated December 15, 1978, did not
sufficiently define responsibilities for planning and implementa-
tion of housekeeping requirements as required by ANSI N45.2.3.
In addition, the requirements for Safety Department inspection
of Zone IV and V areas were not sufficiently defined.
The
above concerns were also identified in a Brown & Root (B&R)
QA housekeeping surveillance report, dated March 22, 1979.
This
matter will remain open pending completion of corrective action
in response to the B&R surveillance report.
(0 pen) Unresolved Item (50-498/79-02; 50-499/79-02): Qualifi-
cation Requirements for Cadwelders. Brown & Root Quality Control
Procedure CCP-ll is undergoing revision to define Cadwelder
qualification requirements consistent with Regulatory Guide 1.10.
This item will remain open pending review of the revised and
approved procedure.
3.
Site Tour
The IE inspectors toured various areas of the site to observe con-
struction activities and to inspect housekeeping and equipment
storage.
No items of noncompliance or deviations were identified.
4.
Review of Items Reported Under 50.55(e)
The IE inspector reviewed the status of the following items which
were previously reported under 10 CFR 50.55(e):
a.
Voids in Lift 15 of the Unit 1 Reactor Containment Building (RCB)
The IE inspector was informed that grouting of voids in lift 15
of the RCB was completed on March 1,1979.
Preparations were
under way for load testing of the polar crane bracket located at
2150 azimuth which was chosen as the representative bracket for
the test. A maximum load of 375 tons will be applied at a
distance of 2'8" from the liner surface.
Loading and unloading
will be in established increments.
Deformation measurements will
be made by means of deflection gages and strain rosettes. The
deformation measurements will be used to evaluate the strain
recovery process during the unloading cycle.
This matter vill be reviewed during a subsequent inspection
following s.bmission of the final report.
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b.
Installation of Anchor Bolts Fabricated from the Wrong Material
Nonconformance Reports (NCR) S-M1080 and S-M1080A identify anchor
bolts which were fabricated from carbon steel of the wrong grades
(A36 and A193). Materials have been identified as to what was
required and what was actually used in fabrication of the bolts.
Locations where the anchor bolts have been embedded in concrete
have been identified.
The IE inspector was informed that B&R
design engineering will disposition the bolts on a case by case
basis and they will be replaced as required.
No items of noncompliance or deviations were identified.
5.
NSSS Component Supports
The IE inspector was informed that eighteen of twenty-eight vertical
~ columns, which will be located at elevation (-)ll'-3 to 16'0" in the
Unit 2 RCB, will be fabricated on site by PDM. ~ Preliminary work will
be performed in PDM's Des Moines facility with completion of the
fabrication to be accomplished in the existing fabrication shop at
the site. The remaining ten columns will be fabricated by LAMCO.
This change was stated to be necessary due to construction scheduling
requirements which require delivery of the columns in July 1979.
The IE inspector was also infomed that laminations have been detected
in nine transition pieces for Unit 1 NSSS component upper and lower
lateral supports. The laminations were found by UT at the vendor's
shop.
Eight of the transition pieces are presently located at the
vendor's shop and will be repaired by the vendor.
The remaining
transition piece located at the site will be evaluated by the licen-
see and Brown & Root engineering.
No items of noncompliance or deviations were identified.
6.
Review of Receiving Records
The IE inspector reviewed receiving records for electrical components
to ascertain whether requirements of Procedure GCP-22, " General
Material Receiving and Storage," were met.
Records for the Flux
Mapping Console, Boron Recycle Panel, Rod Control System, and a
Containment Spray Pump. motor were reviewed.
No items of noncompliance or deviations were identified.
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7.
Observation of Concrete Placement
A portion of u ncrete placement ME2-W001-01, wall at the northwest
corner of Unit 2, Mechanical Electrical Auxiliary Building, was
observed for compliance with procedural requirements of :
QCP-A040KPCCP-3, "Prepour Activities," Rev. 9, dated
July 5, 1978 (CCP-3)
QCP-A040KPCCP-4, " Concrete Placement and Finishing,"
dated July 6, 1978 (CCP-4)
The Pour Card and Examination Checklists were revie-fad.
It was
verified that all required items had been signed by Construction,
Engineering and Quality Control. The pour card was signed author-
izing start of the placement.
.
The forms were inspected by the IE inspecto:- and found to be clean
and free of debris. The surface of the construction joint was
observed to be in the saturated surface dry ' condition, s.mept that
the IE inspector observed pools of standing water in the region
between the interior wall forms and the in-place water stop on the
construction joint surface. These pools covered approximately 70%
of the length of the placement and were measured to be 1/2 inch
deep in one location. The QC inspector and B&R foreman indicated
their intent to " walk" the water ahead of the first layer of concrete
to remove it. Brown and Root Procedure CCP-3, paragraph 3.35.9
stipulates that standing water would be removed from the area of
placement in construction joints. When the IE inspector noted that
te placement crew was not " walking" the water out of the placement,
the QC inspector stopped the work until air hoses could be provided.
Subsequently the standing water was removed ahead of concrete place-
ment using the air hoses and brooms.
During placement of the first layer of concrete, two cases were
noted in which the vibrators were used 'to move placed concrete
lateral distances of 8 and 10 feet from the discharge point.
Brown
and Root Procedure CCP-4, paragraph 3.5.3 restricts lateral movement
of concrete to less than five feet.
Initiation of concrete place-
ment with standing water on the construction joint and the noted
lateral movement of concrete with vibrators appear to be examples
of failure to follow procedures as required by Criterion V of
Appendix B to 10 CFR 50.
During the placement, a rainstonn occurred. As specified in para-
graph 3.4.1 of CCP-4, placement was stopped until rain protection
'
could be provided. During erection of rain protection, rain water
accumulated on the surface of the recently placed concrete. After
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the rain stopped, placement was resumed after inspection by Engineering
and Quality Control. An NCR was initiated to confirm that the maximum
allowable water / cement ratio was not exceeded by the rainwater which
was added to the concrete. After resumption of placement, the IC
inspector verified that previously placed concrete was still in the
plastic state as required by paragraph 3.4.3 of CCP-4.
After completion of the placement, it was verified that the surface
of the concrete was adequately protected and that the water-stop was
installed.
8.
Miscellaneous
During the inspection and by telephone on March 26,1979, the IE
inspector explored the circumstances surrounding an altercation
between a quality control inspector and a construction engineer.
It was determined that management response to this matter had been
timely and effective in indicating support for the site quality
assurance program. No long range adverse effects were identified.
No items of noncompliance or deviations were identified.
9.
Containment Liner Dome
a.
Observation of Work
The IE inspector observed shielded metal-arc welding of Seam 25
and Seam Sl-13B on Course Assembly 1 for the Unit 1 Containment
Dome. The qualification and/or cartification documentation by
PDM was reviewed for the two weldeas and E7018 welding electrode
being used for welding the two seans.
In the areas inspected,
no discrepancies were noted between the documentation and the
requirements of Section III or IX of the ASME B&PV Code.
b.
Review of Records
The IE inspector selectively reviewed the completed documentation
for three seam welds on the Unit 1 Containment Liner D.ome Course
Assemblies. The seam welds were identified as Seam 21 of Course
2, Seam 22 of Course 3 and Seam 14 of Course 4.
The documentation
for each seam weld was reviewed for completeness and use of quali-
fied welders, certified welding electrode, certified nondestructive
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examination reports, and qualified examination personnel.
In the
areas inspected, no discrepancies were noted between the documen-
tation and the requirements of Section III, V or IX of the ASME
B&PV Code.
No items of noncompliance or deviations were identified.
10.
Polar Crane Girders
The IE inspector selectively reviewed the shop fabrication records and
material certification reports for the Unit 1 Crane Girder, Pc 125G2
of Drawing 125AG, Revision C.
The girder steel plate material was
certified as conforming to the ASTM A537 Class 1 specification for
chemical and mechanical properties. The gusset and backing bar materials
were certified as conforming to the ASTM A36 specification for chemical
and mechanical properties.
In the areas inspected, no discrepancies
were noted-between the PDM shop fabrication record and material cartifi-
cation reports for the crane girder and the B&R specification 2C2695S006,
Revision G, " Steel Liner Work for Reactor Containment Structures."
No items of noncompliance or deviations were identified.
11.
Exit Interview
The IE inspectors met with licensee representatives (denoted in para-
graph 1) at the conclusion of the inspection on March 23, 1979.
The
IE inspectors summarized the purpose and the scope of the inspection
and the findings. A licensee representative acknowledged statements
of the IE inspector concerning the item of noncompliance.
.
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