ML20135H780
| ML20135H780 | |
| Person / Time | |
|---|---|
| Issue date: | 09/17/1985 |
| From: | Zech G NRC OFFICE OF INSPECTION & ENFORCEMENT (IE) |
| To: | Benaroya V Office of Nuclear Reactor Regulation |
| References | |
| REF-QA-99900521 NUDOCS 8509240222 | |
| Download: ML20135H780 (2) | |
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September 17, 1985 Docket No. 99900521 MEMORANDUM FOR:
Victor Benaroya, Chief Chemical Engineering Branch Division of Engineering Office of Nuclear Reactor Regulation FROM:
Gary G. Zech Chief Vendor Progra,m Branch Division of Quality Assurance, Vendor Office of Inspection and Enforcementand Technic
SUBJECT:
INSPECTION REPORT NO. 99900521/85 IN SOUTH TEXAS PROJECT SITEOF BECHTE An inspection was conducted by Messrs. P. D. Milano and R this office on February 4-8, 1985,
. L..Cilimberg of the Bechtel site procurement control processat the South Texas Project site to revie inspectors identified several questions conce. During the inspection,'the acceptability of the coating system on the containment linerrning the suit Unit 1.
A copy of the subject inspection report is enclosed of South Texas these questions were discussed during a telephone conv Additionally, Craig, Ray Cilimberg, Prasad Kadambi, and Frank Witt on A ersation between John ugust 8, 1985.
Questions concerning the containment coating systems at So the suitability of an epoxy system without a zine prim 1
environment, dry film thickness specifications nvolve er coating in a humid i
zinc containment coating to hydroxides by opera and potential exposure of the ii system.
other questions related to the coating systems was requested b nment spray but was not available for review.
ng these and y the inspectors 8509240222 850917 P,DR GA999 EECBECH
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o Victor Benaroya September 17, 1985 While these questions are being referred to NRR for resolution, containment coating materials and their application may be reviewed during future Vendor Program Branch inspections.
Please provide a description of information submitted to the NRC related to specifications, codes, standards, and testing upon which NRR approval of a containment coating is based.
If you have any questions concerning the report or this request please contact John Craig at X-29043.
ORH31NAL SIGNED BY:
GARY 6.ZECH Gary G. Zech, Chief Vendor Program Branch Division of Quality Assurance, Vendor and Technical Training Center Programs-Office of Inspection and Enforcement
Enclosure:
Inspection Report No. 99900521/85-01 cc w/ enclosure:
R. Baer, IE G. Knighton, NRR P. Kadambi, NRR L. Constable, RIV C. Johnson, RIV J. Kudrick, NRR Diskribution:
vpMB:lE:09 VPB RDG DQAVT RDG JCraig-RCilimberg.
PMilano
- SEE PREVIOUS PAGE FOR CONCURRENC VPB:0QAVT*
SC/VPB:DQAVT*
PB:DQAVT RCilimberg: sam JWCraig GGZech 9/11/85 9/11/85' 9/]h/85
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UNITED STATES 8'
t NUCLEAR REGULATORY COMMISSION WASHINGTON, D. C. 20555 9,
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August 1, 1985 Docket No. 99900521/85-01 Bechtel Power Corporation Western Power Division / Houston Project Office ATTN: Mr. L. G. Hinkleman, Vice President and General Manager Post Office Box 60650 Terminal Annex Los Angeles, California 90060 Gentlemen:
This refers to the inspection conducted by Mr. P. D. Milano, R. L. Cilimberg, T. L. Bridges, and K. A. Ward of this office on February 4-8, 1985, of your facility at the South Texas Project site and to the discussions of our findings with Mr. J. Gatewood and members of your staff at the conclusion of the inspection.
The purpose of this inspection was to review the site procurement control process. Areas examined during the inspection and our findings are discussed in the enclosed report. Within these areas, the inspection consisted of an examination of procedures and representative records, interviews with personnel, and observations by the inspector.
While no items of nonconformance were identified, the adequacy of Bechtel receipt inspection activities was an area of concern identified during this inspection.. This includes implementation of receipt inspection requirements and the resolution of nonconformance reports.
In accordance with 10 CFR 2.790 of the Commission's regulations, a copy of this letter and the enclosed inspection report will be placed in the NRC's Public Document Room.
Should you have any questions concerning this inspection, we will be pleased to discuss them with you.
Sincerely,
[
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d.v Ga.?
- ech, ief Venoor Program Branch Division of Quality Assurance, Vendor, and Technical Training Center Programs Office of Inspection and Enforcement
Enclosure:
Inspection Report 99900521/85-01 l
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ORGANfZATTON: BECHTEL POWER CORPORATTON WESTERN POWER DIVISION / HOUSTON PROJECT OFFICE l
LOS ANGELES, CALIFORNIA i
REPORT INSPECTION INSPECTION NO.: 99900521/85-01 DATE(S):
2/4-8/85 ON-SITE HOURS:
120 CORRESPONDENCE ADDRESS: Bechtel Power Corporation Western Power Division / Houston Project Office ATTN: Mr. L. G. Hinkleman Post Office Box 60650, Terminal Annex Los Angeles, California 90060 ORGANIZATIONAL CONTACT: Mr. J. Gatewood TELEPHONE NUMBER:
(512) 972-3611 X4168 PRINCIPAL PRODUCT: Architect-Engineering Services NUCLEAR INDUSTRY ACTIVITY. The Houston Project Office is currently providing principal architect-engineering and construction management services for the South Texas Project.
A i
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7///15 ASSIGNED INSPECTOR:
.m PJ(D.Milano,SpecialProjectsIppectionSection SPIS)
Dath i
OTHER INSPECTOR (S):
R. L. Cilimberg, SPIS T. L.y' Ward, Bridges, EG&G Idaho, Inc.
K..
G&G Idah Inc.
APPROVED BY:
f 7/F[?3 M
l fpnW.Craig, Chief,SPIQVendorProgramBranch Date INSPECTION BASES AND SCOPE:
A.
BASES:
10 CFR Part 21 and 10 CFR Part 50, Appendix B.
B.
SCOPE: Site procurement process control for material and services.
PLANT SITE APPLICABILITY: South Texas Project, Units 1 & 2 (50-498, 50-499).
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o ORGANfZATION: BECHTEL F0WER CORPORATION WESTERN POWER DIVISION / HOUSTON PROJECT OFFICE LOS ANGELES, CALIFORNIA REPORT INSPECTION NO.: 99900521/85-01 RESUllS:
PAGE 2 of 7, A.
VIOLATIONS:
None.
B.
NONCONFORMANCES:
None.
C.
UNRESOLVED ITEMS:
1.
(0 pen) 85-01: Questions concerning the qualification of the coating system on the steel containment liner of Unit I will be reviewed by the NRC. This item will remain open pending completion of this review.
D.
STATUS OF PREVIOUS INSPECTION FINDINGS:
Previous findings were not covered during this inspection.
Previous inspection findings are discussed in Nonconformance B.1 and Unresolved Items C.1 thru C.4, of the previous inspection report.
84-01.
These items will be covered during a future inspection.
E.
OTHER FINDINGS AND COMMENTS:
1.
Site Procurement Process Control A review of the Bechtel field office procurement process for the purchase of material and services was conducted and focused upon the area of mechanical and electrical procurements.
Purchase order packages for nine orders including any changes processed after contract award were reviewed. The majority of the changes to the orders for these packages were the result of Specification Change Notices (SCNs) and nonconformance reports (NCRs). With one exception, none of the purchase orders involved any source inspection.- Thus, the acceptance of the material was done by receiving inspection along with, in some ca:es, receipt of Supplier Certificates of Conformance.
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ORGANIZATION: BECHTEL POWER CORPORATION WESTERN POWER DIVISION /HOU.STON PROJECT OFFICE LOS ANGELES, CALIFORNIA REPORT INSPECTION N0.: 99900521/85-01 RESULTS:
PAGE 3 of 7' Procedure change number NPC-27 to South Texas Project (STP)
Procedure WPP-QCI-4.0, " Receiving Inspection," Revision 8 dated January 24, 1985, made changes to indicate what Bechtel responsibility will be for the review of Westinghouse Electric Corporation documentation supplied with the shipment of ASME materials for which Bechtel has and maintains Code responsibility for the system design.
In these cases, the procedure now states that "Bechtel QC shall perform a technical review of the Westinghouse documentation supplied with shipment...." A review of the purchase order for inspection and repair of high pressure safety injection, low pressure safety injection, and containment spray pumps (P.O. BF-2255 with Westinghouse / Pacific Pump),
identified that neither of the two Receiving Inspection Plans were performed by Bechtel QC. While one of the plans had this QC inspection requirement deleted by a "N/A" (not applicable) in the signoff area, the other inspection, as described by the responsible Quality Control Inspector, only verified the physical receipt of the Westinghouse data that came with the shipment.
The documentation for Receiving Inspection Plan No. 1387 for P.O.
BF-2255 was reviewed, a Westinghouse Quality Release for Shipment was attached describing the information that the Westinghouse source inspector reviewed prior to accepting the items. While other documentation stated that no repairs were necessary on the pumps, the Quality Release indicated that Welder Performance Qualification Records (PQRs) were reviewed. The NRC inspector was not able to determine the type of work that was done which would require welder certifications on this order, i
The purchase order for machining services on the Reactor Vessel Lateral Restraints (BF-0689), while found to be adequate, contained a nonconformance report with a questionable resolution.
Nonconformance Report BM-00154 was prepared when it was determined that the precision straight edge used in verifying the surface flatness requirement had not been calibration checked. Rather than recheck the instrument, as the original disposition stated, the disposi. tion was changed to~ accept the data as-is stating that the straight edge does not need to be calibrated. Additionally, the order requirement for flatness within.001 inch could not be accurately measured by the system utilized.
First, a piece of
.001 inch shim stock was checked with a 0 to 1 inch micrometer.
Then, the shim was used as a feeler gage with the straight edge.
This method of record measurement transfer leads to potential l
ORGANIZATION:
BECHTEL POWER CORPORATION WESTERN POWER DIVISION / HOUSTON PROJECT OFFICE LOS ANGELES. CALIFORNIA REPORT INSPECTION NO.: 99900521/85-01 RESULTS:
PAGE 4 of 7' inaccur.acies that are greater than the actual measurement required.
The purchase order for a replacement valve positioner (BF-2828) was reviewed. When the NRC inspector questioned why a second positioner was ordered after the first was received, it was stated that the person specifying the replacement did not completely record the correct model number from the damaged unit. The supplier initially sent and the constructor installed an incorrect unit. The error was identified when the unit would not function properly when tested.
The purchase order for the repair of a damao::d weld on a gate valve (BF-2687) was also reviewed and 'oi!r.d to be adequate.
However, the Certified Material Test Reports (CMTRs) were not included with the Receiving Inspection Documentation nor was their location referenced. The CMTRs were later found in an equipment file.
2.
iteceiving Inspection of Home-office Procured Transmitters The receiving inspection criteria were reviewed for the pressure and differential pressure transmitters procured from Rosemount (P.O. 14926-4332). This order was selected to be reviewed even though the purchase order was initiated by the Houston Project Office because these items do not receive source inspection prior to shipment. The Bechtel procurement policy identifies these instruments as standard, off-the-shelf, commodities and thus, do not warrant source inspection. Therefore, acceptance of the material is based on the receiving inspection and Certificates of Compliance.
The review of the Receipt Inspection Plans for this order indicated that Certified Material Test Reports (CMTRs) were to be received and evaluated per the technical specification requirement.
However, the specification requires that, if the vendor does not submit the, required information that is required, the vendor is required to maintain and not destroy the data. Approximately half of the Receiving Inspection Plans gave no indication that the CMTRs did not arrive although this was stamped as approved.
Rosemount provided only a statement in a Certificate of Compliance that " Records are kept on file which identify the process wetted surface materials used in the transmitter. The materials are in accordance with applicable material specifications; the chemical i
l
ORGANIZATION: BECHTEL POWER CORPORATION WESTERN POWER DIVISION / HOUSTON PROJECT OFFICE LOS ANGELES, CALIFORNIA REPORT INSPECTION NO.: 99900521/85-01 RESULTS:
PAGE 5 of 7/
and physical reports are on file."
In order to determine whether the materials used at the Project Site are correct, the Rosemount installation drawings must be reviewed. However, these are not utilized during receiving inspection.
The same Certificate of Compliance is utilized for acceptance of the cleanliness inspection and hydrostatic test. The actual hydrostatic test pressure specification is not provided. But a statement that the test was conducted at 150% of maximum rated i
pressure or a minimum of 2000 PSI is included. The Certificate l
also indicates that the transmitter was tested for nuclear service. Rosemount Qualification Report 0830040 was identified but did not contain a statement to indicate that the hydrostatic test results were acceptable.
In accordance with Section 10.2 of ANSI N45.2.13-1976, Quality Assurance Requirements for Control of Procurement of Items and Services for Nuclear Power Plants, the Purchaser should provide a means to verify the validity of Supplier certificates and the effectiveness of the certification system, such as during the performance of audits of the Supplier or independent inspection or test of the items. Such verifications should be conducted by the Purchaser at intervals connensurate with the Supplier's past quality performance. The validity of Certificates takes on an added importance when the acceptance of the item, such as the case of the transmitters, is based solely on this document.
The Bechtel Quality Assurance Program for Nuclear Power Plants.
BQ-TOP-1, Rev. 3A, dated October 1980, which forms Section 8 of the STP Quality Assurance Program Description, Rev. 9, dated December 28, 1984, provides Bechtel's alternate interpretation to the ANSI N45.2.13.
It states that the means of verification may include source witness / hold points, source audits, and document reviews; independent inspections at the time of material receipt; user tests on selected commodities, such as concrete components; and tests after installation on selected components and systems. All of these means verify whether or not a supplier has fulfilled procurement document requirements and whether or not a certification system is effective.
In the case of the Rosemount transmitter purchase order, independent inspections are not done upon receipt and the material properties are not independently tested. The absence of source inspection and the lack of source audits that verify Certificate validity for these transmitters raise questions l
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ORGANIZATION: BECHTEL POWER CORPORATION WESTERN POWER DIVISION / HOUSTON PROJECT OFFICE LOS ANGELES, CALIFORNIA REPORT INSPECTION NO.: 99900521/85-01 RESULTS:
PAGE 6 of 7 -
concerning the effectiveness of this system.
It appears that the present Bechtel approach is:
not question the validity unless a problem occurs which may relate to the area addressed by the Certificate. A further review of this area may be performed at a later date.
3.
General Comments on Receiving Inspection The STP procedure WPP-QCI-2.2, Control of Inspection Planning, Rev. 6, dated June 20, 1984, requires that Receiving Inspection Plans (RIPS) be approved by the Project Management Coordinator, Project Quality Assurance Engineer, and the Project Quality Control Engineer. Generally, a preprinted " Receiving Inspection Plan for Permanent Plant Items" (form STP-010A) is utilized which contains the information listed in Section 5.2 of ANSI N45.2.2. This form is not formally approved for each use and is usually modified at the discretion of the QC inspector.
The QC Inspector fills out the form including the reference documents such as the technical specification and deletes those attributes that he considers not applicable. Although modified in cases, this form is considered by the Project to be preapproved since it is included as a " Typical form" in STP Procedure WPP-QCI-4.0.
Section 1.7 of the Receiving Inspection Plan (RIP) for Permanent Plant Items states that the QC should sign and date the Material 4
Receiving Request (MRR). When reviewing the MRRs, it was noted that the QC inspector signs a block on the MRR stating "QC Approved." When reviewing MRR S11827 and RIP 4043, en purchase order BF-2255 for the inspection and repair of selected pumps, l
the NRC inspector identified that the MRR was approved on August 2,1984 but the RIP was not completed indicating item acceptance until January 30, 1985.
4.
Protective Coatings During the, review of purchase orders and specifications for i
protective coatings it was determined that a zinc rich primer and an epoxy top coat was applied to the steel containment liner i
of Units 1 and 2.
The NRC inspectors reviewed the procurement and receiving inspection documents for these coatings. A material Certificate of Compliance was not provided by the coating supplier (Eastern Imperial Coatings) for the 27 RIPS reviewed. The coating supplier did provide the following statement on all but three RIPS:
u
01 ORGANIZATION: BECHTEL POWER CORPORATION WESTERN POWER DIVISION / HOUSTON PROJECT OFFICE LOS ANGELES, CALIFORNIA REPORT INSPECTIO3 NO.: 99900521/85-01 RESULTS:
PAGE 7 of 7
" Eastern Imperial Coatings Corporation certifies that the coating material supplied to Bechtel Energy Corporation (South Texas Project) on Purchase Order 1496-BF-1788, essentially has the same required performance properties and composition as the coating material on which approval was granted.
Discussions with the NRC Resident Inspector and Bechtel representatives revealed that the coatings on the Unit 1 containment liner were removed down to bare steel from all areas except those areas behind installed ducts, Bechtel Specification No. 5A819AQ1001.
Revision 2 dated July 18, 1984, requires that the Unit I containment liner plate be coated with two coats of epoxy and the Unit 2 containment liner plate retain the initial coating system (zinc primer with epoxy top coat).
The inspectors questioned the suitability of this coating system for Unit 1 since the coating will be routinely exposed to high humidity during outages when containment integrity is not maintained. The inspector noted that this two coat epoxy system may result in accelerated corrosion if the bare steel should become exposed to moisture through voids in the coating system. A potential concern noted by the inspectors was that corrosion may result in separation of the coating from the steel with subsequent entrapment in the containment sump.
At the exit meeting the inspectors stated that this item would be an unresolved item pending additional NRC review of the specification and acceptance tests for the two coat epoxy system used on the liner of Unit 1.
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