ML20024C265
| ML20024C265 | |
| Person / Time | |
|---|---|
| Issue date: | 06/14/1983 |
| From: | Costello J, Hale C NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20024C255 | List: |
| References | |
| REF-QA-99900521 NUDOCS 8307120462 | |
| Download: ML20024C265 (28) | |
Text
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' ORdANfZATION:
BECHTEL POWER CORPORATION LOS ANGELES POWER DIVISION NORWALK, CALIFORNIA htrune ucFtLi 1VN 3/26-4/1 &
IN5FEG110h N0.:
99900521/83-01 DATE(S) 4/11-15/83 ON-SITE HOURS:
96 CORRESPONDENCE ADDRESS: Bechtel Power Corporation Los Angeles Power Division ATTN: Mr. L. G. Hinkleman, Vice Pres. and Gen. Mgr.
P. O. Box 60680, Terminal Annex Los Angeles, CA 90060 ORGANIZATIONAL CONTACT: Mr. R. L. Patterson, QA Manager TELEPHONE NUMBER:
(213) 807-2381 PRINCIPAL PRODUCT: Architect engineering services.
NUCLEAR INDUSTRY ACTIVITY:
The Los Angeles Power Division of the Bechtel Power Corporation is the architect engineer (AE) for seven domestic reactor units.
Fifty percent of the total personnel (approximately 6,700) are assigned to activities in connection 'fith these units and four modification / repair / service type contracts.
ASSIGNED INSPECTOR:
(\\_k.(DM,//3 g/g/g3 J.
Costello, Reactor Systems Section (RSS)
Dates OTHER INSPECTOR (S):
D. G. Breaux, RSS (Houston Inspection)
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/ b APPROVED BY:
j C.JQaie,Chidf,RSS Date INSPECTION BASES /.ND SCOPE:
A.
BASES:
10 CFR Part 21 and 10 CFR Part 50, Appendix B.
B.
SCOPE:
Design process management, followup (on previous inspection findings, and followup covering the following items:
- 1) conflicting requirements in Bechtel specification 13-EM-037A regarding use of class "R" equipment in IE systems; (2) conflicting QA requirements in purchase order and (cont. on next page)
Dr M C'I C ED CEIGINAL l
PLANT SITE APPLICABILITY:
50-528,' 50-529, 50-530, 50-498, and 50-499. Certified EI N 0307120462 830617 PDR GA999 EECBECH 99900521
- PDR,
' ORGANIZATION:
BECHTEL POWER CORPORATION LOS ANGELES POWER DIVISION NORWALK, CALIFORNIA REPORT lhSPECTION g
I
_ 99900521/83-01 RESULTS:
) AGE 2 of 10 SCOPE: (cont.) equipment specification issued to Midland Ross; (3) heating, ventilation, and air conditioning design, South Texas Project (STP);
(4) Hilti anchor bolt problem, STP; (5) discrepancies in the seismic qualification of cable trays and a Crane Deming horizontal pump, STP; and (6) the status of three Brown & Root 10 CFR Part 21 reports, STP.
A.
VIOLATIONS:
None 3.
NONCONFORMANCES:
Contrary to Criterion V of 10 CFR Part 50, Appendix B and Engineering Department Procedure (EDP) 4.33, two specifications were issued without any evidence of a design review notice (DRN) in the project file.
C.
UNRESOLVED ITEMS:
Unistrut and Superstrut commercial grade tray components were purchased as quality class "R" equipment for use in 1E (important to safety) and non-1E applications.
Quality class "R" procurements do not impose the requirements of 10 CFR Part 50, Appendix B on the supplier, but may have quality requirements similar to those for quality class "Q" equipment. Quality class "R" is above a nonsafety-related class, but below quality class "Q".
Both Unistrut and Superstrut equipment are off-the-shelf or commercial grade items and according to 10 CFR Part 21 do not become a basic component (important to safety) until after receipt and designation as a basic component; however, we are continuing to evaluate the application of QA l
requirements relative to commercial grade items.
l D.
STATUS OF PREVIOUS INSPECTION FINDINGS:
(Closed) Unresolved Item (82-05): The adequacy of the design of the con-l densate storage tank (CST) and refueling water tank (RWT) was not provided I
by the measures established, in that errors were identified in calcula-tions 13-CC-CT-010 and 13-CC-CT-015.
Subsequent checkers and reviewers, all of whom reviewed and signed these calculations as being adequate, failed i
to identify the calculation and assumption errors.
Both calculations were l
being redone to determine the safety significance of these errors.
I Calculations 13-CC-CT-010 and 13-CC-CT-015 have been completed.
Based upon independent detailed analyses of the CST and the RWT, it was determined that the existing designs of both structures were adequate for all load combinations
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ORGANIZATION: BECHTEL POWER CORPORATION LOS ANGELES POWER DIVISION NORWALK, CALIFORNIA REPORT INSPECTION N0.:
99900521/83-01 RESULTS:
) AGE 3 of 10 specified in the Project Design Criteria and a safety significant condition did not exist.
The assumption regarding scaling of the CST was not an error in judgment and the single calculational error did not affect the final result. Avoidance of any similar calculational errors can be controlled by adherence to existing procedures.
E.
OTHER FINDINGS OR COMMENTS:
1.
Follow up on Previous Areas of Inspection:
a.
During the 82-01 inspection in the area of training, a concern was expressed regarding a single project engineer being responsible for indoctrination and training, whereas 'the STP had a project engineering manager and three project engineers.
This matter has been resolved by revising the pertinent procedures and placing the responsibility on each cognizant department manager.
This item is considered closed.
b.
During the 82-03 inspection in the area of audits, a concern was exprersed regarding the conflict in procedures between QADP-3.1 and Section 18 of the Project Quality Program Manual regarding distribution of the QA Monthly Activity Report.
QADP-3.1 has been revised to eliminate this conflict regarding distribution of the QA Monthly Activity Report.
This item is considered closed, c.
During the 82-03 inspection in the area of audits, a concern was expressed regarding adequate controls on the signature and initial identification list.
This procedure entitled " Document Signature and Initials Identi-fication" (General Project Requirements-2.11) has been revised and the new system provides controls on signature and initial identification.
This item is considered closed.
i L
?
ORdANIZATION: BECHTEL POWER CORPORATION LOS ANGELES POWER DIVISION NORWALK, CALIFORNIA REPORT INSPECTION NO.:
99900521/83-01 RESULTS:
) AGE 4 of 10 d.
During the 82-03 inspection in the area of audits, a concern was expressed regarding the fact that the Quality Element Checklist and Audit Activity Report did not agree on persons contacted during audits.
l I:
The discrepant documents have been corrected and the pertinent procedure, Project Quality Assurance Audits-5.1, has been revised.
l This item is considered closed.
2.
Conflicting Reouirements in Bechtel Specification 13-EM-037 Regarding Use of Class "R" Equipment in 1E Systems: Bechtel specification 13-EM-037 specifies the requirements for conduit and tray supports for the Palo Verde project. This specification was issued to Unistrut Arizona, Inc., Phoenix, Arizona, on March 5, 1976, from Bechtel/LAPD-Norwalk on purchase order 10407-13-EM-037. On March 1, 1982, re.sponsibility for the purchase order was transferred to the Palo Verde jobsite. Material was shipped from the Unistrut Corpora-tion in Wayne, Michigan.
During the development of the purchase order in early 1976, it was decided to order these off-the-shelf catalogue items to the require-ments of the quality class "R" program. This was done with the understanding that this material could and would be upgraded by Bechtel for quality class "Q" installations.
As agreed at purhcase order issuance, the process to document the acceptability of this off-the-shelf material for class 1E system l
applications would be: (1) perform seismic calculations, (2) submission of Certificates of Compliance by the supplier, and (3) design and install under 10 CFR Part 50, Appendix B.
Specification 13-EM-037, which calls out quality class "R," states that the material in this specification will be used for both class 1E and nonclass 1E systems.
Formal quality assurance programs are required for quality class "R" specifications.
Quality class "R" is above a nonsafety-related class, but is below the safety-related class.
The applicability of 10 CFR Part 50, Appendix B to this category of components is being further evaluated by the NRC (see C. above).
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ORNANIZATION: BECHTEL POWER CORPORATION LOS ANGELES POWER DIVISION NORWALK, CALIFORNIA REPORT INSPECTION N0.:
99900521/83-01 RESULTS:
) AGE 5 of 10 3.
Conflicting 0A Require nents in Purchase Order and Equipment Specifica-tions Provided to Midland Ross: Quality Class R (Non 1E) Versus 1E:
This is a similar problem of procurement of comercial or off-the-shelf items as described in E.2, except the supplier is Superstrut, Inc.
c/o Graybar Electric Company, Phoenix, Arizona. The material being
)
procured is cable tray hanger fittings, quality class "R".
Purchase Order 10407-13-EM-076 was issued on January 6,1978, by Bechtel/LAPD-Norwalk.
On March 1,1982, responsibility for the purchase order was transferred to the Palo Verde jobsite. Material was shipped from Superstrut, Inc. (Midland Ross), Oakland, California.
As a result of a review of the documentation concerning both the Unistrut (described in E.2) and the Superstrut materials, the unresolved item in C. above was identified.
l4.
Ascertain if Brown & Root Anchor Bolt Problem is Properly Resolved:
On November 25, 1980, Hilti, Inc., notified Houston Lighting & Power Company (HL&P) of a 10 CFR Part 21 item relating to their 1-inch Hilti Kwik-Bolt concrete expansion anchor.
On December 12, 1980, pursuant to 10 CFR Part 50.55(e), HL&P notified Region IV of this item. On June 1, 1981, Brown & Root notified the Office of Inspection and Enforcement of potentially reportable item regarding the Hilti Kwik-Bolt expansion anchors.
A testing program was conducted at the STP on Hilti Kwik-Bolt expansion anchors by an independent testing agent (Wiss, Janney, Elstner, &
Associates) and a test report was issued on May 18, 1981. The major findings were as follows:
o The ultimate tensile capacity of Hilti Kwik-Bolt installed in l
grout has been reduced to 75 percent of the capacity of the bolts when installed in concrete.
o The ultimate shear capacity of Hilti Kwik-Bolts installed in grout is the same as the ultimate shear capacity in concrete except for embedment lengths, less than 6 diameters. The shear capacity was determined to be 85 percent of the ultimate capacity in concrete.
As a result of the test program, new design criteria were established j
and incorporated into the project documents and all locations and sizes of installed safety-related Hilti Kwik-Bolts were identified.
i r
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ORdANIZATION: BECHTEL POWER CORPORATION LOS ANGELES POWER DIVISION NORWALK, CALIFORNIA REPORT INSPECTION NO.:
99900521/83-01 RESULTS:
) AGE 6 of 10 In the final report concerning the 10 CFR Part 50.55(e) item, dated September 8, 1981, Brown & Root was scheduled to complete the remaining actions.
However, due to a change in the AE's responsibilities from Brown & Root to Bechtel the closecut was to be completed by Bechtel and is as follows.
o Identification of location and sizes of installed safety-related Hilti Kwik-Bolts. This is complete.
o Criteria described in final report of 10 CFR Part 50.55(e) item will be incorporated into project documents. This is complete.
o Review of previous designs to determine acceptance according to revised criteria is scheduled to be completed by July 1984.
This is an ongoing effort with the sequence of design reviews occurring in a manner to allow for timely corrective actions, if required.
The inspector considers this item closed.
5.
Discrepancies in the Seismic Qualification of Cable Trays and a Crane Demino Horizontal Pump for the South Texas Project:
Corporate Consulting & Development Company, Ltd. (CC&L) under contrac.t to Brown & Root issued two reports listing discrepancies in the seismic qualification of cable trays and a Crane Deming horizontal pump.
After the AE functions were turned over to Bechtel, the purchase order to Husky Burndy for electrical cable trays was revised. This revision removed the requirement in specification 3E209ES031 for seismic qualifi-cation by the supplier.
Seismic qualification for the cable trays will be achieved by design analysis which will be performed by Bechtel.
This is still an ongoing effort with final delivery of cable trays scheduled for July 1985.
In the case of the Crane Deming horizontal pump supplied by Cooper Energy Services, a review by Bechtel showed that the pump is safety-related, but is passive; i.e., it is only needed to maintain the pressure boundary integrity, it does not have to operate during a safe shutdown.
CC&L was treating this component as an active component. The qualification report has been sent back to Cooper Energy Services with a request to clarify their seismic analysis and other Bechtel comments.
Bechtel is awaiting their reply.
y-
ORdANIZATION: BECHTEL POWER CORPORATION LOS ANGELES POWER DIVISION NORWALK, CALIFORNIA REPORT INSPECTION NO.:
99900521/83-01 RESULTS:
) AGE 7 of 10 Both of these problems are in the process of being corrected.
Since Bechtel's actions appear proper and are being documented, the inspector considers these items closed.
6.
10 CFR Part 21 - Ascertain the Status of Three Brown & Root Problems:
The three items are: (1) diesel generator fuel oil storage tank room fan motor qualification, (2) essential cooling water gantry crane tornado design, and (3) emergency sump recirculation piping overstress.
a.
Diesel Generator Fuel Oil Storage Tank Room Fan Motor Qualification -
Each diesel generator building houses three fuel oil storage tanks in adjacent but separate rooms.
Each of the three rooms is ventilated by its respective motor-driven exhaust fan. As a result of a routine design review related to electrical loads, fan motors.iere identified as nonclass 1E to be powered from class 1E power sources.
In order to meet electrical separation requirements of Regulatory Guides 1.32 and 1.75, the motors must be IE qualified.
This item was initially reported as a 10 CFR Part 50.55(e) item on June 19, 1980, and on May 19, 1981, was determined to be reportable under 10 CFR Part 21.
To correct this deficient condition, Brown & Root proposed to replace the fan motors with motors qualified to Class 1E. After the AE functions were turned over to Bechtel, this matter was reevaluated. Bechtel concluded that just upgrading the motors would not qualify the motors to operate in the HVAC systems for the separate fuel oil storage rooms which could experience temperatures up to 2000* F if the tanks should catch fire. To preclude this probability, Bechtel has proposed to add dampers to isolate the fan motors during the fire, then when the fire is out to use the HVAC fans to clear out air and smoke from the areas.
The inspector considers this item closed, b.
Essential Cooling Water Gcntry Crane Tornado Design - The essential cooling water (ECN) gantry crane is required to be designed such that it cannot unacceptably interact with the Category I ECW intake structure as a result of severe natural phenomena; e.g., seismic or tornado events.
' ORGANIZATION:
BECHTEL POWER CORPORATION LOS ANGELES POWER DIVISION NORWALK, CALIFORNIA REPORT INSPECTION NO.:
99900521/83-01 RESULTS:
> AGE 8 of 10 Contrary to design requirements, the crare was released for fabrication without adequately accounting for design basis tornado wind loads. The crane was fabricated by the manufacturer in accordance with the specifications of the procurement document and has been shipped to the STP.
The item was initially reported under 10 CFR Part 50.55(e) on Fby 15, 1979, and on May 13, 1981, was determined to be reportable under 10 CFR Part 21.
To correct this condition, Brown & Root proposed extending the crane rail structure a sufficient distance from the ECW structure so that failure of the crane in the stored position would not result in ECW structure impact.
After the AE functions were turned over to Bechtel, the problem was reevaluated. Bechtel has now proposed to strengthen the structure of the gantry crane so it will withstand a tornado loading. This would eliminate the need for an extension of the crane rail structure.
This effort has not been completed, but the problem is in the process of being corrected.
The inspector considers this item closed.
c.
Emergency Sump Recirculation Piping Overstress - The reactor containment buildings for the STP are each provided with three l'
emergency sumps. The purpose of these sumps is to provide a collection point for water following a loss-of-coolant accident (LOCA) and provide the point of suction for the safety injection system (SIS) and containment spray system (CSS) pumps in the post-LOCA recirculation mode of operation. The suction pipe from each sump is common to the respective train of SIS / CSS pumps for a total of three trains.
The emergency sump liner-to-pipe joint is a welded connection.
During a design review performed by Brown & Root, it was discovered that the welded connection between the pipe and sump liner as designed did not adequately include all appropriate loads.
Con-sequently, it was determined that this weld would fail under design loading conditions and that operability of the associated recir-culation valve could not be guaranteed.
OR'GAN1ZAT10N:
BECHTEL POWER CORPORATION LOS ANGELES POWER DIVISION NORWALK, CALIFORNIA REPORT INSPECTION N0.:
99900521/83-01 RESULTS:
) AGE 9 of 10 The item was intially reported under 10 CFR Part 50.55(e) on October 25, 1979, and on May 13, 1981, was reported under 10 CFR Part 21.
To correct this problem, Brown & Root proposed modifying the design to include pipe anchors and adding an expansion joint to the process pipe inside the emergency sump.
After the AE functions were turned over to Bechtel, the problem was reevaluated.
Bechtel found that it was not necessary to use the Brown & Root pipe design. This eliminiated the original problem, the use of an expansion joint.
Bechtel has put an anchor point on the process pipe which will transfer the loads to the containment wall.
The inspector considers this item closed.
7.
Design Process Management: To determine the commitments and requirements relative to the Bechtel Los Angeles Power Division / Houston area office scope of activities, the NRC inspector reviewed the Nuclear Quality Assurance Manual and the Engineering Project Procedures Manual.
These procedures define specific responsibilities and measures to assure that applicable design inputs are correctly translated into specifications, drawings, procedures, or instructions. The procedures were also reviewed to assure that design activities provide adequate control and permits reviewing, checking, or verifying the results of the activities by personnel who are experienced in the subject activity.
To assure proper implementation of procedural commitments, the NRC inspector reviewed eight engineering design criteria, four technical specifications, four design calculations, and five design drawings.
In this area of the inspection, the inspector identified one discrepancy.
Design specifications 3Q159M50034, " Standby Diesel Generator," and 3V229VS0002, " Safety Class Fans," were issued with no evidence of discipline review, comment, or incorporation of comments in the project files. This design document review is usually accomplished by the generation of a DRN and distributed to design disciplines that this design document may impact.
Prior to end of the NRC inspection, Bechtel had initiated actions to correct the aforementioned discrepancy. This discrepancy was identified as a nonconformance (see B.'above).
ORGANIZATION: BECHTEL POWER CORPORATION LOS ANGELES POWER DIVISION NORWALK, CALIFORNIA
)
REPORT INSPECTION 40.:
99900521/83-01 RESULTS:
) AGE 10 of 10 During this area of the inspection, the NRC inspector observed that design calculations were not being microfilmed upon issuance as committed to in Bechtel procedures.
Corrective action had been committed to by the impacted organizations in response to a Bechtel Quality Assurance audit finding in this area.
During a future NRC inspection, this item will be examined to assure proper action has been taken.
8.
Lack of Safety-Related Cooling in Certain Areas of the Auxiliary and Fuel Handling Buildings:
This item pertains to a 10 CFR Part 50.55(e) report to Region IV office by HL&P that certain spaces and cubicles within the auxiliary and fuel handling building would require additional heating, ventilation, and air conditioning (HVAC) capacity. On July 6, 1982, HL&P expanded the scope of this item to include two items regarding the use of fail-open isolation dampers in the HVAC design and single failure criteria in the auxiliary building supply air mixing box. There was a concern that the failure mode of isolation dampers had not been adequately assessed by Brown & Root, the previous AE of the HVAC design.
The NRC inspector reviewed the final report for Bechtel's evaluation and committed corrective action for the HVAC design deficiencies.
The aforementioned deficiencies originally resulted from lack of Brown & Root interface with " user" disciplines. The HVAC system did not incorporate all the " user" requirements of safety-related cooling and cooling loads.
Since Bechtel is now responsible for the design of the STP, the NRC inspector wanted to assure that there are design controls to assure adequacy of past and future design efforts. The inspector reviewed Bechtel's assessment of the HVAC system design that was transferred to them from Brown & Root.
From this review, the inspector concluded that Bechtel is accomplishing this review of Brown & Root's past design efforts. The depth of this review by Bechtel's engineering would be of a level as to identify possible design deficiencies due to the apparent weakness in Brown & Root's design interfaces.
From the review of Bechtel's engineering procedures, the inspector concludes that controls are provided to prevent this type of deficiency from occurring in future Bechtel design activities.
The NRC inspector reviewed all of Bechtel's committed corrective actions for the aforementioned design deficiencies.
In this area of the inspection, there were no nonconformances or unresolved items identified.
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Insp:ctor J. R. Cos e c //,
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