Text

Forwards Integrated Assessment of Region IV Implementation of IE Programs.Rept Assesses 10 Selected Areas within IE Programs for 1985-86
	ML20147H033
Person / Time
Issue date:	06/06/1986
From:	Taylor J; NRC OFFICE OF INSPECTION & ENFORCEMENT (IE)
To:	Martin R; NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV)
Shared Package
ML20147G863	List: ML20147G859; ML20147G870; ML20147G915; ML20147G948; ML20147G990; ML20147H005; ML20147H010; ML20147H020; ML20147H033;
References
	FOIA-87-847 NUDOCS 8803080369
	Download: ML20147H033 (19)
	v • d • e

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June 6, 1986 MEMORANDUM FOR:

Robert D. Martin, Regional Administrator Region IV FROM:

James M. Taylor, Director Office of Inspection and Enforcement

SUBJECT:

ASSESSMENT OF REGION IV PERFORMANCE Enclosed is the integrated assessment of the Region IV implementation of IE programs.

This report assesses ten selected areas within the IE programs for the 1985-1996 Assessment Year:

July 1985 to June 1986.

During the course of the year, my staff provided yours with an interim report addressing formal programmatic assessment results and an evaluation of interactions on routine and special projects.

I would be happy to discuss the particulars of these assessments with you.

I also encourage your division directors to discuss any questions they have with

,the appropriate IE division director.

[ Original Signed by J. M. Taylor)

James M. Taylor, Director Of fice of Inspection and Enforcemnt

Enclosure:

as stated cc:

V. Stello J. Sniezek CONTACT:

Barry Zalcman, IE x2-4905

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1 8803000369 080304 PDR FOIA CONNOR87-847 PDR

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i 0FFICE OF INSPECTION AND ENFORCEMENT REPORT OF REGIONAL ASSESSMENT OF IE PROGRAMS ASSESSMENT YEAR JULY 1985 - JUNE 1986 REGION IV

[ Original Signed by J. G. Partlow]

James G. Partlow, Director Division of Inspection Programs

[ Original Signed by E. L. Jordan]

Edward L. Jordan, Director Division of Emergency Preparedness and Engineering Response

[0riginal Signed by 8. K. Grimes]

Brian K. Grimes, Director Division of Quality Assurarice, Vendor and Technical Training Center Programs

[ Original Signed by J. Axelrad]

Jane Axelrad, Director Enforcement Staff

[ Original Signed by J. L. Blaha]

James L. Blaha, Director

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Program Support and Analysis Staff e

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l Regional Assessment Report i

Region IV Introduction Assessments of regional implementation of IE programs were conducted in accordance with IE Office Procedure 0200.

Assessment criteria and/or guidance for the selected segments of the program areas were provided to the regions and used as the basis for the assessments.

During the course of the planning process, an effort to integrate the assessment for IE programs was undertaken.

For those situations where a particular activity was assessed, the region was given the opportunity to respond to the assessment findings during and follow-ing each assessment visit.

Those individual assessment reports were transmitted to the regions under separate cover.

An interim assessment report s

was compiled to provide feedback to the regions and encouraged establishing the necessary dialog to ensure that an acceptable level of implementation could be achieved.

A table summarizing the rating of each of 10 program areas assessed by IE follows.

The rating scheme used in this report is the same as that for

,praisals:

0-Outstanding E-Excellent FS - Fully Successful MS - Minimally Satisfactory U

' Unsatisfactory Those are to be taken as the overall region's performance of the selected IE i

programs.

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g61e.: 4 3, po'r$ 3pcb 1 Wfib d N RWJb-Summary of Ratings of IE Programs hyohy n naJ R gion IV 1

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Program Areas Rating (M g rcriiM

)

1) Operating Reactors FS

2) Reactors Under Construction FS p> d

3) Fuel Facilities and E

Materials 4)

Events Reporting h6N

> M-

5) TMI Action Tracking FS 6)

Incident Response E

7)

Emergency Preparedness E

Enforcement MS 4

Y M-

9) Technical Training FS 10)

Resource Utilization MS (

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6 R'EACT0[tS CONSTRUCTION INSPECTION RATING: FS

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The reactor construction inspection program for Region IV was assessed based on the CAT inspection performed at the South Texas facility during October-November 1985.

The results of this assessment were discussed in the J. G.

Partlow memorandum to Region IV dated May 2,1986.

The summary includes:

s The completion status of the inspection program does not correspond to the reported stage of construction.

The CAT findings do not support the improved performance SALP ratings in the areas for Corrective Action and Reporting and the Design and Design Change Control.

The remaining areas were in general agreement.

There was evidence that the Region was aware of some delays in the implementation of the inspection program and was working to correct these deficiencies.

Overall Region IV is rated Fully Successful in this program area.

The implementation of the construction inspection program at South Texas is generally adequate. The CAT inspection findings were generally in agreement with and supportive of the regional inspection findings in most construction It is recognized that the CAT inspection sample in various areas was areas.

findings that were not covered by the smaller region samples.large re However, the CAT C did identify a number of different concerns in the area of civil and st onstruction, where the region's inspection program is essentially complete.

ihe CAT also identified some weaknesses in the mechanical construction area which the region did not identify during their inspection of the construction in this area.

The regional inspections that have been performed appear to have been thorough and their reporting has been detailed and concise.

hardware is consistent with the current program policy.The inspection emphasis on However the completion status of the program does not correspond to the repor,ted ;. age of completion of construction for the site.

This apparently is partly due to the previous assignment of inspection resources to other regional NTOL priorities and the region's schedule for program completion based on the view that the licensee's estimate for completion of site construction is optimistic.

The region's current reevaluation of the status of program completion and trescheduling of inspection requirements should assure the completion of the remaining elements of the construction inspection program.

The CAT findings also support the most recent SALP evaluation in the areas of Piping Systems and Supports, Electrical Power Supply and Distribution, and Licensing Activities.

However, they do not support the improved performance indicated for Corrective Action and Reporting and for Design and Design Change Control.I d wdl

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15 EMENT PROGRAM

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RATING: MS e enforcement packages submitted by Region IV have declined noticeably in recent months, with extensive rework required on many cases. Enforcement actions at Severity Levels IV and V from inspection reports in the security / safeguards area lacked sufficient detail and several examples were found of failure to cite violations (e.g., Inspection Report 50-458/85-67.)

Inspection Reports in the reactor operations area generally conformed to the enforcement policy, guidance and precedents.

The Region has submitted a number of cases recently, particularly in the safeguards area, that were substantially in excess of the six-week timeliness goal (e.g., EA 86-82, Fort St. Vrain - 31 weeks; 86-44, Cooper - 30 weeks; 86-82, ANO - 26 weeks; 86-81, Fort St. Vrain -

24 weeks; and 86-84, Wolf Creek - 22 weeks).

These delays have seriously affected the Region's timeliness performance since the Interim Assessment. The 1

overall rating for Region IV in this area is Minimally Satisfactory.

The performance of Region IV in submitting escalated enforcement packages has slipped considerably in both timeliness and quality during the assessment period.

Many of the cases required significant rework.

For example, EA 86-3, Cooper; EA 86-44, Cooper; EA 86-74, River Bend and EA 86-50, Waterford required significant changes. Notices of Violation frequently had to be rewritten to create supportable citations and remove extraneous material.

As discussed during the Management Meeting in November,1985, we strongly recomend additional involvement by the Regional counsel to improve the quality of the packages. Supporting documentation frequently did not accompany the packages and was not forthcoming af ter several requests. EA 86-55, Comanche Peak, was submitted as a Severity Level IV, although it fit an exp, licit example

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in the policy for a Severity Level III. No explanation was provided for the l.

ategorization nor had an inspection report been written or an enforcement conference been held.

Efforts to expedite enforcement packages which were already submitted late by the Region to Headquarters have been hampered by the Region's refusal to approve minor changes by telephone._Further, in the Jrea of enforcement for willful violations, even af ter havi_0_a a problem in~ a

_ case and receiving an EGM on the subject, the Region issued as a Severity Level IV violation a case that was wilitut on its face and naa been referred to 01.

3n another instance, tne Megion was directed by IE manaaement to transcribe

_ninutes of_ an enforcement meetina and, without informing IE manaaement, decided not to transcribe it. Despite repeated efforts by the Enforcement Staff to

' cbtain minutes of tfie meeting, they were not provided until four months later.

These instances indicate that additional attention needs to be devoted to the enforcement program in Region IV.

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, Inspection Reports

. A review of 10 inspection reports selected at random from reports issued by Region IV during the period November 30, 1985 - May 15, 1986 was conducted in the reactor operations area.

This review of enforcement actions issued at Severity Level IV and/or V indicated that most of the findings were usually supported by the facts detailed in the inspection reports.

In Inspection Report 50-382/85-31, the licensee was cited for the failure to adequat61v acenrnance with 10 CFR PutJ1.

qaluate and recort a datact in report details explain that the licensee evaluated this f ailure underHoweve Q he x

16 f

h CFR.-Ra.r_t 21 and determined the de f pH not po7Ta~b b he details as m

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Indicate thatto why the license s evaluation was inadequate are not orovided, except to failed to report a legitimate defect, the violation should have beenLnis d characterized as a Severity level III.

Inspection Report 50-458/85-77 cites a failure of the design control program at River Bend in that a Field Change Notice was misleading and difficult to follow.

This same Field Change Notice was cited in Inspection Report 50-458/85-69 because of its use contrary to site procedural requirements.

Two Severity Level IV violations for the same deficient change notice are not appropriate, particularly when the second violation was cited during the period of the licensee's response.

A review of enforcement actions (5 inspection reports) isst.ed by Region IV during the period July 1 - December 31, 1985 in the security / safeguards area was conducted.

This review of enforcement actions issued at Severity Level IV and/or V indicated that some cited violations may be under-classified and that some apparent violations were not cited.

The lack of detailed information in the inspection reports made it difficult to determine with certainty whether this was the case.

Specifically, Inspection Report 50-267/85-24 involved an unlocked, unalarmed and uncontrolled door to a vital area.

Although the circumstances fit a Severity Level III example in the policy, this violation was categorized at Severity level IV.

The inspection report did not provide details to explain why this violation should not be considered a Severity Level III.

Another example, Inspection Report 50-458/85-67, of a contractor employee (who was badged for escorted access) without aninvolved the d which involved failure to control key card badges.That same inspection escort.

report contained little more detail than the Notice of Violation.However, the inspection

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it could not be determined whether the key card violation was appropriately Therefore, categorized.

Several examples of apparent failures to cite a violation were observed.

Inspection Report reporting violation concerning an unsecured vital area door.50-458/85-67(

However, the enforcement action did not cite for the unsecured door.

Timeliness

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The Commission has established a goal of issuance of escalated actions within an average of eight weeks from identification of a violation.

To meet this goal, packages must be submitted by the Regions for IE concurrence within six weeks of identification of a violation.

The average time for submittal of i

' g escalated enforcement actions to IE for concurrence was 12.56 weeks which does j

not come close to meeting the goal of six weeks.

.part cularly in safeguards cases Delays have been increasing, i

i

, and they have more than doubled since the j

cid year review.

they shoul~d not delay the earlier cases, particularly cince precede available in other Regions which Region IV could have followed to resolve the The Region persisted in its approach and the timeliness statistics cases.

reflect this decision.

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In Reply Refer To:

4 Dockets:

50-445/83-49

.M 2 2 m 0-J 50-446/83-23 jr;1 k

Texas Utilities Electric Company ATTN:

N. D. Spence, President, TUGC0 Skyway Tower

'400 North Olive Street

' Lock Box 81 1

_ Dallas, Texas 75201 Gentlemen:

Report of the Comanche Peak Steam Electric Station, Uni W facility for the period October 1,1982, through OctoberBoard m The SALP v performance analyses and the resulting 31, 1983. The enclosed SALP Board Report.

evaluation are documented in the with you at the Comanche Peak site on MayThese analyses and evaluations were 25, 1984.

I should like to emphasize that this report covers an appraisal of your performance for a limited per.ad of time and may not be indicative of current conditions k

.t is my view that the Texas Utilities Electric Company's overall regulatory performance at the Comanche Peak facility is satisfactory for the period in question.

As the attached report indicates, your performance in five functional areas received the highest performance category rating of 1 addition, I note that in three functional areas your performance went from i

. In Category 1 to Category 2.

concerned because the changes are in the wrong direction.Although the r i

I hope that these j

assure that this trend does not persist. changes will cause you to see One functional area received a rating in performance Category 3.

fuel storage, and the Category 3 rating indicates a need This area management attention and oversight on your part.

i Your letter, dated May 29, 1984, in response to the SALP Board findings the SALP Board report with two errata, appear as enclosures to this lette

, and which issues the SALP Board Report as an NRC report.

r, Title 10, Code of Federal Regulations, your letter of May of May 30 and May 22, 1984, 29, 1984, our letters letter will be placed in the NRC's Public Document Room.a copy of the 1983 SA 8/2 h RPB2 ORSS 0

LMHunnicutt EHJohnson RP0enise PCh k JT llins pA 6/g/84 6/1) /84 6/g/84 qja4 6/. /84 a e-M m e A r f M yy ~q 1 - -

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2.

Preoperational Progress The startup testing is approximately 67% field complete, and the preoperational test procedures have essentially been written, reviewed, and approved.

The writing and approval of initial

. star. tup procedures continues.,

A sign'ific' ant reduction in testing activitiss occurred after hot functional testing (HFT).

At this time, the testing activities have not reached their previous level.

The reduction was the result of a large amount of rework initiated by the licensee after HFT. Testing activities are not expected to attain their previous. level before the end of 1983.

C.

_ Inspection Activities 1.

Construction Appraisal Team Insoection During this appraisal period, an inspection by the Construction Appraisal Team (CAT) was perfonned at CPSES on January 24-February 4,1983, and February 14-March 3,1983, (NRC Inspection Reports 50-445/83-18 and 50-446/83-12).

The areas inspected

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and results are listed below:

a.

Electrical innd. Instrumentation Construction Three potential enforcement findings b.

Me'chanical Construction' Three potential enforcement, findings, c.

Welding / Nondestructive Examination One potential enforcement findings j

d.

Civil and Structural Construction One potential enforcement findings Procurement, Storage, and Material Traceability e.

One potential enforcement finding f.

Quality Control Inspector Effectiveness Two potential enforcement findings g.

hJalityAssurance Three potential enforcement findings h.

Design Change Controls and Corrective Action System Two potential enforcement findings I

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-- Failure to implement an effective QA program for the installation of the HVAC system in that supports had significant quantities of undersized welds duct system joints had numbers of instances of loose an;d missing

,(Severity IV - 8318) bolting; gaskets were missing or incomp

-- Failure to implement a QA program in regard t' the fabrication of support posts for undentater lights installed o

in the refueling pools and fuel storage pools.

(Severity V - 8303)

In addition, the licensee reported two deficiencies in accordance with 10 CFR 50.55(e).

These were as 'follows:

-- By letter dated May 31, 1983, the' licensee informed the NRC that it had been discovered that the anchoring of the new fuel storage racks had been improperly implemented.

was developed and installed and was examined by the SRICA new des prior to use of the storage racks.

-- By letter dated September 26, 1983, the licensee reported

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that during startup testing it was found that temperatures in excess of established parameters were experienced in the reactor vessel annulus.

The licensee reported that it is planned to increase the cooling capacity for the area and +,o remove, air flow restrictions in the area.

In response to the first violation above, the licensee ins HVAC support welds to determine the worst case condition. pccted HVAC designer has in turn determined that under worst case The the allowable strength limits. loading, the load on the worst c this analysis is required.

As noted below, NRC review of joints were attributed to lack of proper interface between th startup organization and the contractor for HVAC installation.

2.

_ Conclusion he licensee's performance in the functional area must be considered to be in Category 3 since their audit programs failed to identify the HVAC problem discussed above.

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The NRC inspections in this area revealed two deficiencies as follows:

Failure to follow procedures for design review in that mathematical calculation packages contained errors that were not identified in the check review.

(SeverityV,8230)

' Failure to remove obsolete and illegible drawings from -

construction work areas.

(Severity IV 8318) 2.

Conclusion While the licensee has made significant im 1.,

design and design change control programs,provements in histhese impro Dy *\\ y only began.to be effective in the latter portion of the revjew period.

Taken as whole for the review period, the licensee performance is considered to be in Category 2.

3.

Board Recomendations a.

Recomended NRC Actions The NRC should continue to evaluate this functional area through the "as-built" assure that the licensee (room turnover) inspections to i

meets his comitments.

b.

Recomende'd Licensee Actions The licensee should assure that the design drawing package program continues to be practiced without compromise.

Mh licensee should also continue his efforts to update the The parent design drawings to reflect field changes CMCs.

l N.

Quality Assurance - Preoperational Testino 1.

Analysis The licensee has established a separate quality assurance plan for the preoperational testing phase.

The preoperational described in the CPSES Startup Quality Assurance There were no specific inspections of the licensee's startup quality assurance program during this reporting period.

However, of the various preoperational testing activities. quality

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l f-26 There were no violations issued in this functional area during this reporting period.

However, it is felt that had a final quality assurance review of records transfer been required, the violation associated with the startup records would not have occurred.

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2..

Coriclusions There is evidence of management attention in this area.

Audits and reviews by the Quality Assurance department of preoperational test activities are adequate.

. performance is being achieved in the preoperational qual assurance area.

The licensee is considered to 'be in performance Category 2 in this area.

3.

_ Board Recommendations a.

_Recomended NRC Actions NRC inspection will continue at the present level in the

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preoperational testing area.

Specific attention will be given to final records retention and transfer since the function is expected to increase as testing nears completion.

i b.

Recomended t.icensee Ictions i

The overall implementation of. the preoperational quality assurance effort is considered' adequate and should be continued at the present level.

However, a more vigorous involvement t

in the form of an independent review, of the final preope, rational test data packages to ensure that all required documents to support test accestance are retained for permanent storage should be underta ten.

O.

_ Quality Assurance - Construction 1.

Analysis The NRC did not co_nduct spec.ific inspections dedicated to qua T as u n e.

All of the NHL, inspections however, examining various c

facits of the licensee's QA program as,it affects the~above func-tional areas relating to construction.

These inspections included examination of such items as the qualifications of the QC person the control of nonconformances, the distribution of documents, etc O

The NRC findings in each of the preceding functional areas also a indicative of the perfomance in this area.

The licensee has had 0/F m>

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3.

Board Recomenations a.

Recomended NRC Actions The NRC should continue to monitor the licensee's activities

..in this area at a. normal level. Consideration should be given to the fact that most of the efforts in this area will be directed toward replacement or spare parts for already purchased components, b.

Recomended t.icensee Actions The licensee should continue his e'fforts to train and upgrade the personnel in the vendor procurement control

. section of the QA department.

The licensee should also devote effort to identify those quality elements of various products that are most likely to be over looked by the vendor.

Q.

Manacement Controls and Involvement 1.

Analysis

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The licensee has placed TUEC employees in the key areas of site operations, including engineering, construction, and QA. As an examp.le, the suparvisors of each of the onsite. discipline engineering, groups are licensee employees, who ar.e also degreed engineers.'

The license.e lias also placed onsite a cbrporate officer to manage the site activities.

This officer. is the vice president and genen) manager for the project. This officer has an assistant who is also the project engineering and construction manager as well as the n.anager of startup testing activities.

All of the persons in various supervisory positions report to the assistant project manager except for the site QA supervisor who reports to the QA manager in the corporate offices.

The project general manager and his assistant provide a weekly briefing to the corporate officers. These officers have been observed to frequently visit the site to view the status of censtruction and to assist in the resolution of major problez.I.

2.

Conclusion The licensee's level of involvement and the degree of hvd A(3 h control over the site activities is considered to be in performance Category 2.

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i JAN s y g3 Dockets:

50-445/82-24 50-446/82-12 Texas Utilities Generating Company ATTM:

R. J. Gary, Executive Vice President & General Manager 2001 Bryan Tower Dallas, Texas 75201 Gentlemen:

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This refers to the Systematic Assessment of Licensee Performance (SALP) Board Report of Comanche Peak Steam Electric Station, Units 1 and 2.

The SALP Board met on November 9,1982, to evaluate the performance of the subject facility for the period October 1,1981, through Feptember 30, 1982.

The performance j

analyses and resulting evaluation are provided in the enclosed SALP Board Report.

These analyses and evaluition sere discussed with you onsite on December 3, 1982.

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For MRC scheduling purposes, there are 3 months not included in either this report or the 1981 report.

The NRC staff has reviewed the data for the period and has noted nothing that would change the conclusions of this review.

The SALP Board evaluatien process consists of categorizing performance in each functional area.

The categories which we have used to evaluate the performance of yout facility are defined in Section II of the enclosed SALP l

Board Report. As you are aware, the NRC has changed the policy for the conduct of the SALP program based en sur experiences and the recently implemented reorganization which emphasizes the regionalization of the NRC staff.

This report is consistent with the revised policy.

We have reviewed your letter of December 27, 1982.

We would recommend continuing discussion between site management personnel and our Senior Resident Reactor Inspector fcr Operations in the areas of nuclear experience and scheduling of tests.

We will continue to follow your efforts in the area of improving inspections of vendor supplied welds.

The December 8,1982, meeting was productive and gave us a better insight into your operations.

It also gave us the opportunity to give you the perspective of how we viewed the conduct of your operations from the regulatory viewpoint.

RPS-A 878 M RPB[

ORRP&E fpq' y TWesterman/dsm GMad en JGagl 6

JC6 lins

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1/ #/83 Id/83 1M /8 (

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Appendix I

U. S. Nuclear Regulatory Commission Region IV Systematic Assessment of Licensee Perfonnance i

Report:

50-445/82-24; S0-446/82-12 Dockets :

50-445; 50-446 1

Licensee: Texas Utilities Generating Company 2001 Bryan Tower Dallas, TX 75201 i

Facility Name:

Comanche Peak Steam Electric Station, Units 1 and 2 Appraisal Period: October 1,1981 - September 30, ?.982 Appraisal Completion Date:

November 9,1982 Licensee Meeting:

December 8,1982 SALP Board:

G. L. Madsen, Chief, Reactor Project Branch 1 S. B. Bumell, licensing Project Manager, NRR T. F. Westerman, Chief, Reactor Project Section A

0. L. Kelley, Senior Resident Inspector-Operations R. G. Taylor, Senior Resident Inspector-Construction Reviewed:

[6

///2 y/f 2.

T. F. Westerman, Chief Qate' Reactor Project Section A Approved:

Ad h

///2 9/f 2.-

G. L. Madsen, Chief Date Reactor Project Branch 1 SALP Board Chairman h3fZi 3h

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In addition, SALP Board members considered other criteria, as appropriate.

Based upon the SALP Board assessment, each functional area evaluated is

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classified in one of three categories.

The definition of the performance

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categories are:

Category 1:

Reduced NRC attention may be appropriate.

Licensee management attention and involvement are aggressive and oriented toward nuclear safety; licensee resources are ample and effectively used such that a high level of performance with respect to operational safety or construction is being achieved.

Category 2:

NRC attention should be maintained at normal levels.

Licensee mar.1gement attention and involvement are evident and are concerned with nuclear safety; licensee resources are adequate and are reasonably effective such that satis factory performance with respect to operational safety or construction is achieved.

Category 3:

Both NRC and licensee attention should be increased.

Licensee management attention or involvement is acceptable and considers nuclear safety, but weaknesses are evident; licensee resources appear to be strained or not effectively used such that minimally satisfactory performance with respect to operational safety or construction is being achieved.

III. Summary of Results

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The licensee's performance in each functional area, as applicable, was determined by the SALP Board and are as tabulated below:

_ Performance Category Functional Area 1981 1982 A.

Plant Operations - Preoperational Testing N/E 3

B.

Construction Activities j

1 Soils and Foundation N/E N/E 2.

Containment and Other Safety-Re'ated Structures i

N/E 2

3.

PipingSystemsandSupports(includes i

welding, NDE, and preservice inspection) 1 2

4.

Safety Related Components (includes vessel, internals, pumps, etc.)

1 1

5.

Support Systems (includes HVAC, radwaste, fire protection) 2 N/E

[5 Electrical Power Supply and Distribution 1

1 6.

7 Instrument and Control Systems 1

1 endor Procurement Cycle Controls N/E Licensing Activities 2

1 Note: The notation N/E indicates that the functional area was not evaluated for the reason indicated in Part IV of this report.

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b.

Conclusions control efforts in this area are well de quality demonstrated to be effective and the licensee'and hav is, therefore, considered to be in Category 1 s performance Board Recommendations c.

The Board recommends that NRC inspection resources be redirected to this critical area when more active w undertaken in Unit 2.

7 Instrument and Controls a.

Analysis extensive inspections of this functional are se wo period.

Those inspections concentrated on the physical installation of instrument devices and the connecti tubing runs as distinguished from the electrical ng impulse previous functional ca tegory. connections since the latter cabling during the period,No violations or deviations were identified in thi s area b.

_ Conclusion The licensee's procedural controls for the install ti place the licensee in Category 1 from a perf a on and and andpoint.

B_oard Recomendations c.

The Board would 'ote of instrument sysseas has been and will be perfor licer.see directly through the plant operations group rath

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by the construction forces.

ment sheuld be evaluated by the NRC.The effectiveness of this arrangean er th 8.

Vendor Procurement Cycle Controls a.

Analysis

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conducted onsite during the review period.There h r

unctional area Region IV Vendor Program Branch has conducted insIn addition, t vendors on either a generic basis or on a site-specific b pections at asis s

t I

that provide indications of the effectiveness of the licensee's One violation was detected within the scope of this program.

L _- area as follows:

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g- - Inadequate Control of Procuremant Document and Purchased

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Materials (Severity IV-8203) y In addition, there have been two other instances involving e

O "8 substantial questions relative to this functional area that did

% ot result in violations but have consumed considerable NRC dresources.

These are the problems associated with pipe whip g restraints (fabricated by Chicago Bridge and Iron Company and Reliance Electric Company).by NPS Industries) and the main c w$ integrity of the components was in questionwas 5

] $ licensee source inspection organization had documented acc In each case, the h j welds which, in turn, were not reinspected at the site by reason g of source inspection acceptance, I f b.o Conclusion J

J h this functional area since it appears that not e.

g 4

,A resources have been assigned to this area or thost resources that were directed were not fully trained arid indc:trinated.

N c.

Board Recommendations The licensee has committed to an extensive reinspection program involving vendor-supplied welded components to detertaine if yet 1

Participants:

4!N 'Y

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K. T. Seyfrit, Direct egi'on IV Date b

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///f/fD W. C. Seidle, t.hief, Reactor Construction and Date Engineering 'upport Branch

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W. A. Crossman, Chief, Projects Section Date Hff/8D n_

R. G. Taylor, Resident Reactor Inspector, Comanche Date Peak Station wha.0$dw ft.-

/ t//o/ s<e p S. B. Burwell, Licensing Project Manager, NRR Fite Approved:

g/f//6 m-_ = -

W. A. Crossman, Chief, Projects Section Oath y < ~ g[9(h c tf> t ? tode on

1 OETAILS

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).

Persons Attending Meeting Licensee Participants R. J. Gary, Executive Vice President and General Manager, TUGC0 L. F. Fikar. Executive Vice President and General Manager, TUSI B. R. Clements Vice President, Nuclear Operations, TUGC0 J. B. George, Vice President and Project General Manager, TUSI

0. N. Chapman, Quality Assurance Manager, TUGC0 R. G. Tolson, Site Quality Assurance Supervisor, TUGC0 NRC Participants K. V. Seyfrit, Director, Region IV Office of Inspection and Enforcement W. C. Seidle, Chief, Reactor Construction and Engineering Support Branch W. A. Crossman, Chief, Projects Section R. G. Taylor, Resident Reactor Inspector, Comanche Peak Station S. B. Bumell, Project Manager, Licensing Branch 2, NRR 2.

Meeting With Texas Utilities Generating Comoany Management a.

Purpose of Meeting The purpose of this meeting was to describe the regional evaluation under the Systematic Assessment of Licensee Perfonnance program.

This evaluation is an intergal part of the Systematic Assessment Perfomance with the com(SALP) program which is being implemented in accordance itments of the "Action Plan for Implementing Recommen-dations of the President's Commission and Other Studies of the TMI Accident."

The attached Appendix B is the perfonnance evaluation for July 31, 1980,the Comanche Peak facilities for the period August 1,1979, th Board.

compiled by the NRC participants and a Regional Review To begin the meeting, the Regional Director outlined the following objectives for the Systematic Assessment of Licensee Perfonnance program:

Identify exceptional or unacceptable licensee performance Improve licensee performance Improve the IE inspection program Provide and achieve a means of regional consistency in evaluating licensee perfomance s

,d a

Enforcement Action Responses - The NRC personnel indicated that the licensee's responses have been concise, effective i

and to the point.

g.

Effectiveness and Attitudes of Licensee Personnel in Complying with NRC Requirements Licensee Quality Assurance personnel - The NRC personnel stated that the overall impression was that the licensee had upgraded the quality of their personnel at all levels during the past two years.

Licensee Construction and Engineering Management - The NRC cersonnel stated that it appears there is a continuing tendency

_ to enoineer away construction oroblems rather than enforce

_ compliance to drawinos and specifications.

The licensee stated that he is taking several management actions with the engineering and construction personnel to alleviate this situation.

The NRC personnel stated that there was no specific regulatory concern since safety does not appear to have been compromised as yet but could possibly be sometime in the future if appropriate actions were not taken as indicated above.

Brown and Root Quality Atsurance - The NRC personnel stated that overall abilities of the Brown and Root QA personnel appeared to have been improved during the past year, in part because of much improved procedural direction being given to them.

Brown and Root Construction Supervision and Labor Force - The NRC participants indicated that their impression of this area indicated that there is a need to make this group more awars of nuclear power plant construction requirements.

That there is a considerable difference to those of a conventional fossil plant.

The licensee responded that he has issued instructions to Brown and Root to reduce the labor crew size reporting to foremen and the number of crews reporting to general foremen. The licensee stated that it is expected that this will provide increased control over the quality affecting actions of the labor force.

3.

Sumary of Licensee Perfonnance The Region IV Director, at the conclusion of the meeting, emphasized that i

the licensee has the principal and legal responsibility for all matters regarding the construction and operations of a nuclear power plant as specified in the law and in the Regulations.

Corporate management is essential in all phases of the project to P.ssure appropriate execution of the licensee's responsibilities.

The licensee responded that he is aware of his responsibilities and that in response to these responsibilities, he continuously increased his involvement in the project during the past three years until he is now essentially in complete control of the project except for the imediate line supervision of the labor force.

The licensee indicated that as new or additional involvement becomes necessary, he will

(

respond accordingly..

ar s 4,:

The Director stated that the region's evaluation'of 'the licensee per-fonnance is that it is gene

ally acceptable although continued improve-

+

ment in certain areas, already discussed, would certainly be desirable.

The Director stated that, on the basis of the evaluation, Region IV does not currently see a nead to make any adjustments in the IE inspection program as it relates to the Comanche Peak facilities.

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UNITE D STATES NUCLEAR REGULATORY COMMISSION

~ NNo *.

$iN?t "

t July 21, 1980 Docket No. 50 498 50-499 MEMORANDUM FOR:

. C. Seidle, Chief, RC&ES Branch

@NW. A. Crossman, Chief, Projects Section FROM:

H. S. Phillips, Resident Reactor Inspector, STP

SUBJECT:

SOUTH TEXAS PROJECT INVESTIGATION 79-19 LESSONS LEARNED Past history, including QA history, is only valuable if it leads to an improved present or future condition.

Team members stated, after the investigation, that NRC managers, supervisors, inspectors and investi-gators should be made aware of lessons learned from the subject investi-gation which started on November 2, 1979 and ended January 24, 1980.

The following are my observations based on 22 years of QA and technical experience, as well as, the past few years working / observing the NRC inspection system. These coments are constructively offered so that the NRC might improve future investigations and so that the NRC might detect QA program breakdowns at the earliest possible time.

Some of the comments are specifically related to the conduct of the investigation

(

while the QA program coments address more generic issues relative to the NRC inspection system.

1.

Lessons Learned Relative to OA Programatic Breakdown The saying that, "An ounce of prevention is worth a pound of cure" mhy well apply to the STP South Texas Project QA program partial breakdown.

I believe Region !Y did the best they could to identify the problems at South Texas Nuclear Project, but were unable to conclusively show a QA programatic breakdown because they did not have adequate manpower to perfom a lengthy and in depth review.

It was a very difficult task for the investigation team.which spent nearly 3 months on site,to identify the problems.

after the investigation documenting the results.The team also spent considerab After extensive evaluation of the results, the parts of the puzzle came together to give a clear picture of a partial program breakdown.

I It is important for NRC managers to realize that QA programs can only be adequately evaluated by more extensive reviews than have been the practice in the past,

a. Needed Improvement:

The NRC does a fair job of evaluating the licensee's establishment of a QA/QC program durin i

ruction Permit (PRECP) inspection phase, however,g the Pre Const-after that the NRC's inspection system shifts it's primary attention to random

A.

PROJECT HISTORY _

1.

Chronological Project Milestones The application for construction pennits for Comanche Peak Steam Electric Station (CPSES), Units 1 and 2 were docketed on July 20, 1973.

The construction pennits (Nos. CPPR-126 and CPPR-127) were issued on December 19. 1974.

An LWA was granted to the licensee on October 17, 1974, and ground breaking occured on October 18, 1974.

There has been no change in principle contractors.

Unit 1 is presently in preoperational testing. Precore hot 4unctional testing began on February 20, 1983.

The licensees' present projected fuel load date is September 1983.

The licensee was granted a license to receive and e

storefuel(SNM-1912)onApril 26, 1983 and began receiving fuel on May 4, 1983.

The process will continue over the next several months until all of the 193 fuel elements and associatedinserts are received.

The fuel is being stored in the new fuel storage facility and spent fuel pool for Unit 1 in the fuel building.

2.

Principle Contractors Gibbs & Hill, Inc. (G&H) is the architect-engineer, and Brown & Root,Inc.

is the constructor.

Construction management is being perfonned by Texas Utilities Services, Inc., a wholly own4d subsiderary of the owner.

Texas Utilities.

The nuclear steam supply systen vendor is Westinghouse Electric Corporation.

B.

QUALITY ASSURANCE ORGANIZATIONAL STURCTURE The licensees present QA organization is shown it. Exhibit 1.

The present structure has not appreciably changed from description in The SAR.

The licensee has recently undergone review of the QA program persuant to 10CFR50.55(c) No reduction in the QA program were identified.

C.

SALP REVIEW Three SALP reviews have been conducted to evaluate TUGCO's perfonnance.

The SALP periods were:

August 1,1979 through July 31,1980(Reports 50-445/80-25 and 50-446/80-25)

July 1,1980 through June 30,1981( Reports 50-445/81-20 and 50-446/81-20)

October 1,1981 through September 30,1982( Report 50-445/82-24 and 50-446/82-12) l

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3 -9' Ps.lh$ TEXAS UTILITIES SERVICES INC. OFFICE MEMOR ANDUM M-Pro.iect Civil Enaineer w m rto T.u. May 26. 1983 sub).et COMAN0iE PEAX STEAM El.ECTRIC STATION NCR-M-82-1589 WELD CRACKS The subject NCR denoted four welds rejected for cracks. I have evaluated these welds with the following results: 1. D-157, Weld 48 - Crack in weld approximately 4 inches long. This weld appears to hav'e cracked during bolting fabrication and is being evaluated by G & H. New York. 2. D-153-1, Weld 23 - Crack from base metal at toe of weld { prppagating into the weld. The crack was originally 3 raported as 31/2" in length;further evaluation re-yfaled a total length of approximately 8". T,' .~op,

3. ~ D-138-1-D, Weld 221 - No evidente or crack indication.

4. D-140-A (West), Weld 23 - Cracked tack weld not evaluat-ed. Tack should not have any effect on the structural integrity of the component. i'f you require any additional information, please advise. s .e A-4 R.C. Barber ) i Weld Engineer RC8/sgr cc: M.R. McBay E.I.. Bezkor

R.E. Ballard

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FORT WORTH STAR-TELEGRAM Friday rnorning, August 3,1984 Identifying informant is pol

icy 1

1 By BRUCE MILLAR names uere obtained from other sneiation for Sound Energy, a Dal-sur.Telepsto u tder sources. las based group opposed to the A federal inspector said he was In the suorn statement he rna h plant, said she was shocked by Tay. following an unwritten ecmmon-July 17. Ta> lor was unsure c.f his h*

de scription of NRC policy.

sense pohey" w hen be teld a mana. , exact words. "The impliestions are trerr.cn 'get at Comanche ea nuc ear p w. "I identified Mr. Atchison to the dous. it would encourage the utiht) P k l o er plant the name of an informant utility - precise words not recol. to fire those people they thought two years ago.aecording to a sw orn !ccted -on the l3th of Aprilfl982i." w ere whistle blowers," she said. the statement said. She said Taylor's"common sense statement. Rnbert G. Taylor,former resident Atchison vas fired April 12.1982. policy" e ncou ra ges th e very p ra c tie. Inspector for the y s Nuclear Regu. He lo<t his job af ter a Texas !. tilities es that confidentialityis supposed to I latory Commission at Comanche .*upermor criticiaed him for report. help prevent:It discourages uork I Peak,said it is NRC policy to protect ing welding deficiencies and for ers from coming forward and l the names of informants only as faulting training programs outside heightens fears about blacklisting. : (' long as they vork at the plant. of hisimmediatearea of responsibit. Although Taylor uas remosed i Once employees are fired or ter-ity. from his Comanche Peak post in I j s. minated.the guarantee of(onfiden-Atchison has sued his forrr.er em. January. he is still assigned to the. tiality is lif ted, he said in the state-ployer. Brow'n & Root, the general Arlington regional office of the ment that he made in preparation contractor for the plant, claiming NRC. j f or h e a rin gs on allega t ions of intiini-that his dismissal has resulted in his He earns S51,500a year as a reactor i dation and l;arassment of plant in-blackballing in the nuclear power inspector for the Wolf Creek nucle-

spectors, ind ustry.

at pow er plant in Kansas. NRC offi-ne day afterthe firingof quality PaulCheck. deputy administrator cials in Arlington have said that his ' controlinspector Charles A. Atchi-of theNRCregionalofficeln Arling. reassignment wasalateraltransfer. ' son of Atle, Taylor identified him to ton, declined to comment on Tay-RonTolson,whowastnanagerof the lor s sworn statement. He said he on. site quality control program for v ould feelout of placecommenting 1 Texas Utilities Generating Co. De on a statement prepared for U.S. company is the primary owner of Atomic Safety and Licensing Board 4 the plant. hearings. Taylor's breach of confidentiality ne board is scheduled to start 1s apparently not a violation of NRC hearings Aug. 27 in Fort Worth on policy. Dick DeYoung, director of allegations that plant management inspection and enforcement in the harassed and intimidated inspec-NRC s Washmgton headquhrters, tors to keep them from doint, their said nursday. jobs in a statement released through a The plant is under construction spot esman.DeYoung said.'Out pM. near Glen Rose. about 45 miles ' icy is not to disclose the namL iI V'uthwe St of Fort Worth s histle blow ers. Period.- Juanita E!hs.leade r of Citizens As. Taylor said in his statement that Atchison was the only "whistle blow er" whose name he divulged to plara of ficials. Taylor decided to name Atchison bwause hesensed a

lack of sincerity" on Atchison's pa rt, the statement said An NRC internal report re!cated in MarchsaidTaylor resca:ed Att hi-son's identity to a plant offatal by saying. "%(re goes pur inn al-leger." The re[ ort relused by the N RC l.ad names blacked out.but the}}

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