ML20011A023

QA Program Insp Rept 99900502/81-03 on 810720-24. Noncompliance Noted:Corrective Action for Previously Identified Nonconformance Not Completed as Stated

ML20011A023
Person / Time
Issue date:	08/12/1981
From:	Chamberlain D, Fox D, Hale C NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV)
To:
Shared Package
ML20011A015	List: ML20011A014 ML20011A021 ML20011A023
References
REF-QA-99900502 NUDOCS 8110060367
Download: ML20011A023 (19)

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{{#Wiki_filter:ORGANIZATION': BROWN AND ROOT, INC., POWER GROUP HOUSTON, TEXAS REPORT NO.: 99900502/81-03 INSPECTION DATE(S): 7/20-24/81 INSPECTION ON-SITE HOURS: 16 CORRESPONDENCE ADDRESS: Brown and Root, Incorporated ATTN: Mr. W. M. Rice, Group Vice President Power Group 4100 Clinton Drive Houston, TX 77001 ORGANIZATION CONTACT: Mr. R. J. Vurpillat, QA Manager TELEPHONE: (713) 678-5226 PRINCIPAL PRODUCT: Architect Engineering Services NUCLEAR INDUSTRY ACTIVITY: The total effort committed to domestic nuclear design activities at the Houston facilities is approximately 11% of the 10,200 permanent and contract employce staff of the Power Group. The major project design is South Texas Project Units 1 and 2. ASSIGNED INSPECTOR: W 8 /j 2. / 8 l

0. F. Fox, Reactor Systems Section (RSS)

Dat'e OTHER INSPECTOR (S): D. D. Chamberlain, RSS APPROVED BY: ]'N ( --h C. J. HaJrT Chief, RSS Date INSPECTION BASES AND SCOPE: A. BASES: 10 CFR Part 50, Appendix B and the SAR for the South Texas Project Units 1 and 2. B. SCOPE: Design inspection, design verification, design change control, design corrective action and status of previous inspection findings. DESIGNATED ORIGINAL Cortified P." dL[L)UU- !$$UHe'amn PDR

ORGANIZADON: BROWN AND ROOT, INC., POWER GROUP HOUSTON, TEXAS REPORT NO.: 99900502/81-03 INSPECTION RESULTS: PAGE 2 of 6 A. VIOLATIONS: None B. NONCONFORMANCES: Contrary to commitments contained in the Brown and Root, Inc. letter of response, dated June 12, 1981, to NRC Inspection Report 99900502/81-02, corrective action for a previously identified nonconformance had not been completed as stated. This is the fourth inspection in which correc-tive actions or preventive measures were not completed as committed. C. UNRESOLVED ITEMS: None D. STATUS OF PREVIOUS.1SPECTION FINDINGS: 1. (Closed) Follow up Item (80-02): The status of the Brown and Root (B&R), Vendor Control Evaluation and Correction Program will be evaluated. The NRC inspector reviewed the status of the task force established by B&R to review all procuremer<t documents for safety-related equipment and material to assure that all B&R and Housven Lighting and Power (HL&P) commitments to NRC are met prior to release of the items to the South Texas Project (STP) site. B&R management stated that: (1) all purchase orders will be reviewed and updated by November 30, 1981; (2) all affected items will be brought into full compliance and released by December 31, 1981; the shift in the role of NUS in the program from that of an independent auottor of the updated procurement documents to that of determining the extent that the vendor's existing programs and activities met the requirements contained in the updated procurement documents, will be identified to HL&P by August 14, 1981; and (3) Technical Referece Document No. 7A700GP007, will be issued by August 14, 1981, to define and control all aspects of the Vendor Control and Evaluation Program. Implementation will be retrofitted to include the identifica-tion and upgrading, as necessary, of those safety-related items pre-viously released to the site for construction or installation. This area will be examined further durirg subsequent inspections. 2. (Closed) Violation (81-02): Failure to submit a written report of a significant defect in piping supports within the time required by 10 CFR Part 21.

, ORGANikATION: BROWN AND ROOT, INC., POWER GROUP HOUSTON, TEXAS REPORT NO.: 99900502/81-03 INSk[ TION RESULTS: lPAGE 3 of 6 B&R management stated that the delay in submitting the report to NRC resulted from their understanding of the 10 CFR Part 21 reporting requirements at that time, The B&R 10 CFR Part 21 implementing procedure (STP-PGM-02? ) was revised on July 1,1981, to require verbal notification to NRC within two calendar days and written notification within five calendar days following the determination of reportability. 3. (Closed) Nonconformance (81-02): Failure to adhere to the require-ments in the B&R 10 CFR Part 21 implementing procadure. The B&R Incident Review Conmittee reviewed all previously identified safety concerns to determine their reportability and the minimum supplemental documentation needed to document B&R's decision on each safety concern. Three safety conce.ns were determined report-able pursuant to 10 CFR Part 21 and the requisite notification made to NRC. Procedure STP-PGM-022 was revised on July 1, 1981, to specifically defir,e the identification, evaluation, reporting, and documentation requirements for safety concerns identified subsaquent to July 1, 1981. 4. (Closed) Nonconformance (81-02): Failure to submit to NRC changes in the QA program and organization described in the B&R Topical Report. B&R management stated that the Topical Report has not been revised because the only current nuclear design activity, the South Texas Project (STP), is not committed to that QA program. B&R plans to revise the topical and determine the optimum date for submission to NRC by December 31, 1981. 5. (Closed) Nonconformance (81-02): Failure to include beta radiation resistance requirements in the specification for personnel air lock inflatable seal material. The subject specification was revised and issued on July 22, 1981; how-ever B&R did not complete the corrective action described in their June 12, 1981 letter of response to this nonconformance prior to the conclusion of this inspection. (See B. above.) 6. (Closed) Nonconformance (81-02): Failure to maintain required train-ing records. The training files were reviewed and the required training and docu-mentation was completed for all affected STP individuals. Procedure STP-PM-006-E was revised on July 20, 1981, to include specific require-ments for the control, maintenance, and storage of training records.

ORGANIZATION': BROWN AND ROOT, INC., POWER GROUP HOUSTON, TEXAS l PAGE 4 of 6 REPORT NO.: 99900502/81-03 INSPECTION RESut.TS: Additional B&R personnel were assigned to '.he training and record retention functions and affected STP supervisors were given training on implementing the requirements of the revised procedure. \\ 7. (Closed) Nonconfonnance (81-02): Failure to follow procedur9 for authenticating copies of educational diplomas or transcripts of new employees. The STP corporate personnel files were reviewed and the required authentication or verification was completed for all STP individuals. Procedure DL 035 was revised on June 9,1981, to include specific - requirements for verificai. ion and documentation of the education and experience of newly hired or transferred employees assigned to the STP. E. OTHER FINDINGS OR COMMENTS 1. Design Inspection The related sections of tne STP PSAR and FSAR and applicable imple-menting procedures were examined to determine the commitments con-cerning safety-related design activities. One system design descrip-tion, two specifications, two Technical Reference Docunents, the plant physical model, eleven drawings, seven calculations, two design activity logs and reports, two safety concerns, two purchase orders, thirteen records of design verit1 cation, three hold tags, and othar documentation relating to the containment structure, mechanical equipment auxiliary building and fuel handling build-ing HVAC, and the auxiliary feeduter systems were examined to verify effective implementation. Within the scope of the inspection, the committed program was being implemented. However, the following items were noted. a. Approximately 2600 physical interferences, encroachments on equip-ment access or personnel passageways, were uncovered during the construction of the plant physical model and resulted in numerous documents being issued to identify changes that are needed in the related engineering drawings. Based on infonnation from B&R l personnel approximately 3500 of the 33,300 drawings issued to date l have a total of 5,000 " holds" or " hold areas" associated with them. Certain of these drawings have been used by vendors to fabricate piping spool pieces that were subsequently shipped to the site prior to clearing of the " holds." The current status of these items could not be detern:ined by examination of available B&R engineering l records. B&R management stated that they would develop and imple-ment a system to identify, track, and~ assure clearing of design " holds" on an item prior to the design requirements freeze date l l

ORGAN 12ATION': BROWir ANb' Rf,i, INC., POWER GROUP HOUSTON,*fEXAS REPORT NO.: 99900D02/81-03 WSPECTION RESULTS: PAGE 5 of 6 N for the item. Furthermore, the need for, and methodology of, providing }. positive assurance against the inadvertent installation of such items - *will be dvaluated.~ 1 b. An August 25,,1980 reanalysis of the pressure and temperature transient 1 o# the c6ntainment after a postulated LOCA indicates that the original (May 18, 1978) analys1: used to generate the data for the STP FSAR a ms conservative by 3 psi in peak pressure, 2.40F in peak vapor tempera-threi and 0.20F in peak sump temperature. The inspector noted that - certain of the input parameters used in the reanalysis were different from those reporJed in the FSAR. These and other inconsistencies in !3y the FSAR sere discussed with B&R management who stated that the FSAR l-would be reviewed,and needed changes would be identified to HL&P on a tirely' basis and affected design docnents would be revised accordingly. i c. Auxiliary feed vater pumps, purchased from the Bingham-Williamette Company under PCs 35-U97-4053 and 35-1197-8053, were deliverd to thed TP site with motor operators for the turbine trip and throttle valves that were not qualified to IEEE-323 and IEEE-344 as required by procurement specification STP-35149MS043D dated March 31, 1977. The B&R Incident Rsview Comittee (IRC) deemed this safety concern (No. 46) to be reportable pursuant to 10 CFR Part 21 and on April 10, 1 s1980,' notified the NRC. Review of B&R's engineering and procurement ( tiles'did not reveal any indication that the requirement for qualified operators was waived. B&R management stated that the supplier of the turbine (Terry Corp.) had replaced the operators on one of the delivered turbines with qualified operators and reportedly is in the process of replacing the'others. d. B&R engineering stated that the heating and ventilating (HVAC) systems for ty STr snical equipment auxiliary building (MEAB) and the fuel hand}ing ..J (FHB) appeared to provide insufficient cooling during certap mous of plant operation or postulated plant events. The B&R IRC deemed this safety concern (No. 96) to be reportable pursuant to 10 CFR'Fert 21 and on May 8, 1981, notified the NRC. B&R management stated that the reasons for the cooling capacity of the systems, as designed, not meeting current heat removal requirements were that: (1) the dpecity requirements were calculated in the mid 1970s from the heat loads identified at that time and were not revised nor updated since then; (2) certain heat loads were inadvertantly omitted from the analysis; and (3) additional capacity is needed to accomodate the new equipment and additional heat loads now required in the MEAB and FHB. B&R management stated that the calculation of the required HVAC capacity will be updated by October 13, 1981 and will be revised to include the effect of pipe ruptures by June 1982. B&R anticipates that the procurement documents for the new HVAC systems, which will be used to supplement the existing c4 HVAC systems, will be issued by July 1982. s n__

ORGANI'ZATION: BROWN AND ROOT, INC., POWER GROUP HOUSTON, TEXAS REPORT NO.: 99900502f81-03 INSPECTION RESULTS: PAGE 6 of 6 2. Design Verification The related sections of the STP PSAR and FSAR ar.d applicable imple-menting procedures were exas. tined to determine if procedures are consistent with co..nitments to NRC. The qualifications of the design verifiers and the detailed documentation of the design verification of two specifications, one computer code, three calculations, and five drawings relating to the containment structure and its post LOCA pressure and temperature transient analysis were examined to determine if the comitted program was being effectively implemented. Within the scope of this inspection, the committed program was being implemented. 3. Design Change Control The Brown and Root Quality Assurant e Mar.ual end the applicable er.gineer-ing procedures were examined to detmnine the nuality assurance program l comi tments. The following documents we e examined to verify imple-l mentation of the commitments; Design Change Tracking System (computer printout), 31 Design Change Notices, 14 revised drawings, and six revised calculations. Relative to the documents examined, the quality assurance program commitments were being implemented. 4. Design Corrective Action The Brown and Root Quality Assurance Manual and the applicable pro-cedures were examined to determine the quality assurance program comitments. Twelve identified Engineering Desi i Deficiencies t were e-amined to verify implementation of the comn.itments. Within the scope of this area of the inspection, the Quality Assurance pro-gram cocnitments were being implemented. However, it was not apparent that the present program adequately addresses recurring design errors for needed design corrective action. This area will be examined further during a future ifqpection.

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Inspector D. Q,_f, M M Q {p M {N Docket flo. WOO 502.. Report flo. Z31:0 3_ Scope / Module __3_7R7 B_.-.. Paqe ~~ of to~ _DoCuntn15 txanin._tD_ ~ { de 1 2 TITLE / SUBJECT 3 4 l 1 3 EnciaEERush oEsscs n6Fu rlaclES STP-DC E 7/3/5L 2 8 EncnntERinc oEsiorv oEpiciEncics EDO NO. $l- 0459 A/Jo/1L 3 - EnD Ho Bo 89 At!K FCEDWnTER llUrnP5 11HD TUR6LaE__-. 4llD/3L A- _3_ Tile EViLLURT10d AHD REP 0RTtN(, Or DtF&rT5 2/13/SL nos cornesLMcEs Ano DELLQfg dS STP-GR-ook-A l _5 S _E Do so. so-ISS ncm-SAFETY C L&_5S UHAUST LllW ? fnHS SPL C IFlc R T_I.0u EDD No. %a -13(, bocR GErd. MRPaGEmtn7 DwG OF ]bl$D &cW PVrnP 9 EDO N O. 50'310 A0X EEED3!ATER PornP5 Rao ruuRS.6/zz/go S 8 EDD No. 50 -99 cnf ! ta6 ni A GRArt), 480 6 E. 5 F. 4/15/Jo_ Lono cEn7tR eta.ELB 4 EIC 9 8 600 Na, 79-H2' 5T6655 6EFORTS [2d4%" 10 _f EDD r10 SI-SM ftCHG

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2 TITLE / SUBJECT 3 4 L 3 suura itm> rRatcr EnG>NcERmG m ccoeRE con osssGN Ic N eo CH4N66 ConTRn L STP - DC - 023-6 2 0&R GR rt] ANtiA L 56CTI0d 3.0 6/l/T]__ ftV O 3 3 065lG81 6HAN6E TRAC KIN (- SY676 r/1 [conit'cT66 PflNTCVi} 7/ /8} cHAN6es issceo 6/2q/$1 THRU 7 /17/81 4 3 Cf9IGN n!ANGL NOTICL PCN-02 FtR R -P 0- C-6043 - 0 10/27/80 6 8 06Sl6N CHAN66 NoTic E TCN-03 'l 6/70/6/ (c 6 DESICN LHANGE ncTIL6 (Y N -0 i \\l 12/M/79 7 nEstan cunucs Nerres ooN -c l Fes 2c ic - lo 3 5 - 0 lu/5t 8 3 DESIG N tlLRlFf cRTICH STP-DC - CIS-H IOM/Se 3 3 Ot-SI G N d1ANCE NOTI (E DOW - o f fcR 2c 10 - / C - /004 - 3 6/3/$/ IO 3 DESil N nian&E HOTIC E DDM-01 FtR p IC -10 %- O b/3/3/ ll DESIGd CHAtifet K tic 6 PC N - 01. fc6 t' V 2//2/77 I2 3 DESIG N cPhdGL,NuTICE Pc N - 02 fcR l'010 Alb/51 I3 DESIGN (4AN66 NoTlcE PC N -0 3 fcR lt 4//S/5/ A6t F I4 l Elec 74rc6L R6ncrcR conrAINul6HT MU1LolN6 Fr/1660 r/16Nr5 / 3 - E - 5 3 4 2455-5~ Document Types: Columns: 1. Drawing 5. Purchas Order 1. Sequential item Number 2. Specification 6. internal Memo 2. Type of Document 3. procedure 7. Letter 3. Date of Document 4. QA Manual 8. Other (Specify-if necessary) 4. Revision (If applicable)

Insperter D. D. CH AMBERLAlW gt ','oyp Sc:pe/ Module 379978 DOCUMENTS EXAMINED l 1 2 TITLE / SUBJECT 3 4 .~ 42 1 ZF S I-llol USZ PIPING 150 66V.4 43 1 PtPlaG SUPPORT ORAtoING 7Y22072037 5H. 46 RH.0 44 L PIPING s0PPcRT DRntot NG 9mISI3 I277 SU. 9 RE V. I 45 1 PIPING 50PPORT ORiite nag SM15I31299 6H. I REV 1 4G l PIPING SUPPO R T DRAWING BtA I5131299 SH. Ib REi!. L 47 5 DESIGN CHANGE Honc6 PC N-0 I FcR srn)5131299 5H Ib 5/2(/BI 4% 1 PIPING svPf0RT DRAWIMG 2rn);IJil79 SH. h ret'. O 49 8 DESIGN CHANGE Horoc6 PcN -l FOR 2MIGIJll79 4Ahl SC L PtPING suffCRT nRAWIaC 8mI513B02 5H,15 R6t.I SI S DESIGN CHANG 6 NOTICE PCN - L FCR Rrn15l3l302 W3/61 52 1 PIPtHG SUPPORT DRAT 0MG Brnl513185) SH. S 86V. I 53 I PIPtnG SOP 90RT ORAtota& sent5131373 3H. 5 Rt t' z 54 1 Pl PING St!Pfc87 DRAtolN6 2MISl33026 s# 1 (Voto)

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P\\PsaG soPPcRT nt%vt N G 2rnISI13027 Sn.1 (vmo) REi. i Document Types: Columns: 1. Drawing 5. Purchas Order 1. Sequential Item Number 2. Specifica tion 6. Internal Merco 2. Type of Document 3. Procedure 7. Letter 3. Date of Document 4. QA Manual 8. Other (Specify-if necessary) 4. Revision (If applicable)

Inspector D. O, CH AtoBER LA N Docket flo.99901502 ~ ~ aeport us. g.o'g7 Sc:pe/ Module 379968 Page _q~ of Io DOCUMENTS EXAMINED 1 2 TITLE / SUBJECT 3 4 I5~ I 3-E-20-T-E-2 bb5-8 EulcrRIcnL rnEcunsicnt MxlLlARY red S 60lLD\\NG CliRLL TRM PL AN 16 3 nRawiwG ccwTRcL STP~ Dc -co2 - K 1o// /s 19 os s\\6N cannGE st ric E Pc N - o l fcR .s - E -2I-I- E -2960-Il s/n/wi l% 8 DE st &N (HnnGE nt Titt Pc N -02 FtR n F/22kJ l9 DEstGu CHANGE NcTich Pc N - n3 fcR v G/9/r/ 20 .1 5-E 1 - E - 15 97 - 1 EuscTsocAL DI656L GCHLRATcR BUILDING 4/3/$/ EQUIPrnENT hRCANG6chlHT PLAH 2I 5 oks1GN <HnnGs nerlcE oon - 01 FcR 3-m-s-h1-Tac 17-o 34c/wi 2 2-5 DE AIGN rHRNG6 N OToc E Pc d -o l FOR \\t 3/40/81 28 8 DES I GN CHANGE NcTICE PCH - 0 i foR 3 m IGI 30366-a +/(/51 24 D6 SIGN connG6 ncTic t Pc N - ol FcR 2rn 19130952- 0 W4hl 25' 8 DES IG N C Mn c.6 HOTic f Pc N - c L f c8 3rn 191 Itc 2- 0 sk z 6/s/SI 2L 9I DEGI G n 'HANGC HOTfc6 PCM-O3 FcR S rn 191 P. %21- -3 5/27/81 17 of susc.: -hance ns Tit E pcN-02 fcR s-rn-al-l- s-A cor s G/1kki 2S S _ Db SI GH CHANGL ecToct DDR-Ol FoR 5-rn-c l-I 4050 - R Idn/wo l Document Types: Columns: 1. Drawing 5. Purchas Order 1. Sequential item Number 2. Specifica tion 6. Internal Memo 2. Type of Document 3. Procedure 7. Letter 3. Date of Document 4. QA Manual 8. Other (Specify-if necessary) 4. Revision (If applicable)

Inspect:r D. D. CHAR 4BERLA1H chet 11.MQaio2_ Report flo. f -D 3 cpNulo NN8 ~ DOCUMENTS EXAMINED 1 2 TITLE / SUBJECT 3 4 2@ DESIGN CHANGE HCTICL PCN-l FcR 5 racils ' v50-3 mn //b'(A'c 3o S D65lGN c HAN66 No r/C 6 DDrd - O l FOR M/ l l I VO 3 81-C 4/30/f/ 8l DtSIGN c o nd(-E no TItf Pc N-O l FoR l' 1/9/5I 32 D6 SIGH (HANCE HC itcE Pc H - 0 8 Fcn at I2/27/kg 'A3 nE SIC N U1ANGF H0TlcE PcH -0+ FCR SVloIV0042-G C/il/fri 34 8 DE s t(,a

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cA LCULAT10NS STP-DC - 008 - J IO///80 3 (, 3 Ecw Loop - G svF' PLY sTR6.55 CAL (ULA TICH RR289RC048-8 _4/J3l$l 37 AOK FEED wnTER A tix, FEED P0mP at.12 DIsrHARGE 6//WS~I 'dS149 R( 200 ~ 6 STRESS ( AL C ULGTitH 36 DESIGN CHANCE NOTICE PCN 62 fcR S TRESS c ALC UL A Tt0H 4//b/6) 'BR209 RC 202-A 30 DESIGN c4ANGE hot c6 PCN-of fc6 STffSS (ALc0LATled ]//llTO RR 209 Rr 2n2 - A Ab ECLU LeoP-A St!PPLY STR655 c ALc0LATrou SR289RC9(,7/} 4//q/Ro 41 X TAFE T)' INI6cTIord 6157trn STCess cALCOLATICH 2dl29RCl3M 5/II/WI Document Types: Columns: 1. Drawing 5. Purchas Order 1. Sequential Item Number 2. Specification 6. Internal Memo 2. Type of Document 3. Procedure 7. Letter 3. Date of Document 4. QA Manual 8. Other (Specify-if necessary) 4. Revision (If applicable) 1}}