ML20151R052

Insp Repts 50-498/88-38 & 50-499/88-38 on 880627-0701. Violations Noted.Major Areas Inspected:Routine Preservice Insp of Components & Component Supports.No Insp of Unit 1 Conducted

ML20151R052
Person / Time
Site:	South Texas
Issue date:	07/14/1988
From:	Barnes I, Gilbert L NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV)
To:
Shared Package
ML20151R035	List: ML20151R031 ML20151R040 ML20151R052
References
50-498-88-38, 50-499-88-38, NUDOCS 8808120035
Download: ML20151R052 (5)

See also: IR 05000498/1988038

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APPENDIX B

U.S. NUCLEAR REGULATORY COMMISSION

REGION IV

NRC Inspection Report: 50-498/88-38 Operating License: NPF-76

50-490/88-38 Construction Permit: CPPR-129

Dockets: 50-498

50-499

Licensee: Houston Lighting & Power Company (HL&P)

P.O. Box 1700-

Houston, Texas 77001

Facility.Name: South Texas Project (STP), Units 1 and 2

Inspection At: STP, Matagorda County, Texas

Inspection Conducted: June 27 through July 1, 1988

Inspector: /

L. D. G Hbert, Reactor Inspector, Materials

7/N/' 6

Uate

and Quality Programs Section, Division of

Reactor Safety

Approved: b% 7//4/P7

I. Barnes, Chief, Materials and Quality Date

Programs Section, Division of Reactor Safety

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Inspection Summary

I_nspection Conducted June 27 through July 1, 1988 (Report 50-498/88-38)

Areas Inspected: No inspection of Urit 1 was conducted.

Results: Not applicable.

Inspection Conducte'd June 27 through July 1,1988 (Report 50-499/88-38)

Areas Inspected: Routine, unannounced inspection of preservice inspection of

coniponents and component supports.

Results: Within the area inspected, one violation was identified (failure to

follow instructions, paragraph 2.b).

8808120035 880720 "

gDR ADOCK 05000498

PNU

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DETAILS

1. . Persons Contacted

HL&P

• J. T. Westermeier, Project Manager

• T._J. Jordan, Manager,ProjectQualityAssurance.(QA)

• L. Giles, Operations Manager . Unit 2

• D. C. King, Construction Manager

• A. R. Mikus, General Supervisor, Construction

• R. L. Beverly, Preservi- Inspection (PSI)/ Inservice Inspection (ISI)

Supervising Engineer

• W. G. Wellborn, Supervising Project Engineer

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• J. R. Mertink, Lead Engineer

• W. W. Trujillo, Supervisor, Project QA

• D. A. Murdock, ISI Coordinator, Piping

Bechtel Engineering Corporation (BEC)

• R. W. Miller, Project QA Manager

• R. H. Medina, QA Supervisor

• R. D. Bryan, Construction Manager

• R. Parekh, Project Engineer

Ebasco Services Incorporated (ESI)

• D. D. White, Construction Manager

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• R. Apel, Quality Program Site Manager

• B. Higby, Piping Quality Control Supervisor

• W. M. Pardee, QA Site Supervisor

The NRC inspector also interviewed other contractor personnel during the

inspection.

• Indicates the personnel that attended the exit meeting. The NRC resident

inspector also attended the exit meeting.

2. Preservice Inspection (PSI)

a. Review of Program (73051)

Initial NRC inspection of the Unit 2 PSI program is documented in NRC

Inspection Report 50-498/88-36; 50-499/88-36. During this

inspection, the NRC inspector selectively reviewed changes to the

licensee's PSI Examination Program Plan for Unit 2. The review

included changes through Change No. 20.

No violations or deviations were identified.

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b. Observa_t_i_on of Work Activities (73053)

The NRC inspector reviewed the repairs required as a result of the

. PSI examinations. Six items required to be repaired were selected

for this review. Each item required to be repaired was identified in

a nonconformance report (NCR). The repair was accomplished by Ebasco

under the construction program requirements and procedures. Two

items required repair welding in order to repair indications of lack

of fusion identified during the PSI ultrasonic examination. The

repairs were nondestructively examined as required by the

construction program requirements and then reexamined under the PSI

examination program. The repairs reviewed are listed below:

Item Repaired NCR Number

RPV Closure Stud 10B AN-03557

Pipe 6-SI-2106-2 SP-05103

Pipe 6-SI-2106-1 SP-05104

Pipe 8-AF-2008(C)-15PL4&8 SS-05552

Pipe 8-AF-2012(C)-20PL5 SS-05553

In the areas inspected, the repairs and examinations were performed

in accordance with the requirements of the ASME Section III

construction code and the ASME Section XI preservice inspection code.

However, during the review of the repair of a surface indication on

auxiliary feedwater pipe spool AF-2012-H identified by PSI

examination of Item 8-AF-2012(C)-20PL5 the NRC inspector noted that

NCR SS-05553 required that the pipe minimum wall thickness after

repair be determined by mechanical or ultrasonic methods and

recorded. The NCR further stated that the wall thickness was not to

be reduced below 0.437 inch. Since only the excavation depth was

recorded, the NRC inspector requested that the minimum wall thickness

be verified. The actual wall thickness was ultrasonically measured

to be 0.418 inch at its thinnest area which is 0.019 inch below the

minimum wall thickness specified by the NCR. The nonconforming

condition was documented on NCR SP-05258. The NRC inspector

determined that QC personnel had measured the depth of excavation as

1/64 inch and then subtracted it from the 0.500 inch nominal wall

thickness specified for schedule 80S pipe. This method of

determining minimum wall thickness, although indicated as common

practice, is neither authorized by any procedure nor conservative, in

that it fails to recognize that pipe manufacturing tolerances would

permit an actual wall thickness of up to 121 percent below nominal to

be supplied. The failure to follcw documented instructions for

measuring the minimum wall thickness is an apparent violation

(498/8838-01; 499/8838-01).

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c. Review of Records (73055)

The NRC inspector reviewed the following 25 PSI examination records

for completeness and retrievability. The records included

visual (VT-1), liquid penetrant (PT), magnetic particle (MT), and

ultrasonic-(UT) examinations for components such as piping

longitudinal and circumferential welds, flange bolting, RCP flange

surface,-steam generator channel head cap to support ring, pipe lugs

for hangers, and pump body welds.

Exam Number Method Category

2(1.5)-CV-2126-BB1-2 PT B-J

2(1.5)-CV-2126-BB1-2FB VT-1 B-G-2

4-RC-2422-BB1-1 PT & UT B-J

6-RC-2015-NSS-1 PT & UT B-F

SG-28-SR1 UT B-B

31-RC-2102-NSS-LOOP-1-2 PT & UT B-J

16-RC-2412-NSS-3 PT & UT B-J

2-CV-2121-BB1-1 PT B-J-

12-RH-2101-BB1-3A PT & UT B-J

6-S1-2327-B81'-7 PT & UT B-J

RCP-2B-FS VT-1 B-G-1

8-AF-2006-GA2(C)-20PL1 MT C-E

through -20PL8

8-CS-2102-PB2-2 & -2LU PT C-F

B-RH-2103-KB2-3 & -3LU PT C-F

RHARHS-2A-IWA1 PT C-C

SIAPHH-28-PCW2 PT C-G

No violations or deviations were identified.

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3._ Exit Interview

The NRC inspector met with the licensee representatives denoted in

paragraph 1 on July 1, 1988, and summarized the inspection scope and

findings.--  !

The licensee comitted to a review of the Unit-1 records for potential

minimum wall violations resulting from QC inspectors using nominallwall

thickness tables and depth of excavation for detemining remaining wall

thickness. The licensee estimated the review would be completed by

July 10, 1988.

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