ML20210R467
| ML20210R467 | |
| Person / Time | |
|---|---|
| Site: | South Texas  |
| Issue date: | 08/27/1997 |
| From: | NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20210R435 | List: |
| References | |
| 50-498-97-18, 50-499-97-18, NUDOCS 9709030130 | |
| Download: ML20210R467 (10) | |
See also: IR 05000498/1997018
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ENCLOSURE 2
U.S. NUCLEAR REGULATORY COMMISSION
REGION IV
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Docket Nos.:
50 498
50-499
1
License Nos.:
NPF-80
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Report No.:
50-498/97-18
,
50-499/97-18
Licensee:
Houston Lighting & Power Company
Facility:
South Texas Project Electric Generating Station, Units 1 and 2
Location:
FM 521 - 8 miles west of Wadsworth
Wadsworth, Texas
Dates:
July 21-24,1997
Inspector:
1. Barnes, Technical Assistant
Approved By:
Arthur T. Howell til, Director
Division of Reactor Safety
ATTACHMENT:
Supplemental information
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9709030130 970827
ADOCK 05000498
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EXECUTIVE SUMMARY
South Texas Project Electric Generating Station, Units 1 and 2
NRC Inspection Report 50-498/97 18;50-499/97-18
En_qlneerina
The Westinghouse material specifications applicable to procurement of pressure
boundary materials were found to generally conform to ASME Section lli Code
and the technical and quality requirements contained in licensee
Specification 4R129NS1014, Revision O. A violation was, however, identified
in regard to the approval by the licensee of the use of a different pressure
boundary material to that permitted by Specification 4R129NS1014, Revision 0,
without concurrent specification revision to reflect the design change
(Section E1.1).
No deficiencies were noted in the majority of vendor certifications reviewed.
However, prod method magnetic particle examination records from Ansaldo for
steam generator upper shell courses indicated use of amperage values, during
examination of longitudinal weld joint preparation surfaces and the ground root of
the initial welds, which appeared to exceed the maximum permitted by Article 7,
paragraph T-743.2, of the AS'4E Section V Code (Section E1,1).
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The licensee has established comprehensive technical and quality requirements for
the Unit 1 replacement steam generators. Numerous requirements were included in
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the specification to minimize the vulnerability of the replacement steam generator
tubing to intergranular attack and intergranular stress corrosion cracking at the tube
sheet and tube support locations, preclude significant erosion / corrosion degradation
of the feedring, and minimize tube bundle wear (Section E1.2).
Licensee engineering staf f efforts to assure that inconel 690 tubing meets current
Electric Power Research Institute requirements and has a high eddy current signal to
noise ratio were considered impressive (Section E7.1).
Overall, the licensee quality organization was considered proactive in its scope of
monitoring of Unit 1 replacement steam generator manufacture, with surveillances
performed or planned at all Westinghouse major sub-component vendors and a
resident inspector located at the Westinghouse, Pensacola plant (Section E7.1).
The effectiveness of licensee engineering representatives at Westinghouse,
Monroeville and Westinghouse, Pensacola could not be assessed due to the
absence of a work plan and documentation of their activities (Section E7.1)
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Report Details
This inspection was the first performed (using inspection Procedure 50001) in regard to
planned oversight of Unit 1 replacement steam generator design, manufacture, and
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installation activities. The primary purposes of the inspection were to review the technical
and quality requirements imposed on the steam generator vendor (Westinghouse),
ascertain the scope of planned licensee oversight of des!gn and manufacturing activities,
and make an initial review of Westinghouse procurement activities.
Summarv of Plent Status
Units 1 and 2 were at 100 percent power during the inspection period.
Ill. Engineerina
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Conduct of Engineering
E1.1
Westinohouse Steam Generator Procurement Activities
a.
insnection Scone (50001)
The inspector reviewed the Westinghouse technical and quality requirements that
were imposed on the vendors selected for manufacture of the steam generator
upper and lower shell courses, the transition cone, the elliptical upper head, and the
tubesheet. In addition, the inspector examined vendor certification for the above
pressure boundary items that had been received and accepted by Westinghouse for
use in manufacture of the first Unit 1 steam generator. The vendor certification
reviewed by the inspector was requested by the licensee from the Westinghouse
Pensacola plant, the location of raanufacture of the Unit 1 steam generators,
b.
Observations and Findinns
The inspector reviewed the technical and quality requirement that were contained
in Westinghouse Material Specifications A533C07, "SA-533 Type B Class 2 Plate
(Section lil NB)," Revision C; A508C20, "SA-508 Class 3a Tube Plate Forgings
(Section ill NB)," Revision D; A508C23, "SA-508 Class 3a Shell (Ring) Forgings
(Section lil-NB)," Revision C; and A508C24, "SA-508 Class 3a Elliptical Head
Forgings (Section lil NB)," Revision C. With one exception, the material m.
specifications were found to conform to the applicable ASME Section ill dode (i.e.,
1989 Edition, no Addenda) requirements and the technical and quality requirements
contained in hcensee Snecification 4R129NS1014, " Replacement Steam
Generators," Revision O. The exception pertained to the material selected by
Westinghouse for the manuf acture of"H" and "J" upper shell courses by Ansaldo,
Italy. Westinghouse Material Specification A533C07, Revision C, which pertained
to SA-533, Grade B, Class 2 plate, was selected for the shell courses (Purchase
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Order ES2891). The inspector noted, hovvever, during review of licensee
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Specification 4R129NS1014, Revision 0, that the specification permitted only
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SA 533, Grade B, Class 1 (a lower minimum yield and tensile strength material than
Class 2) p' ate for steam generator pressure boundary material. The licensee
approved the use of the Class 2 plate material by Letter ST-W2 HS-000040 dated
-June 4,1996. The failure to reconcile the use of a different pressure boundary
material to that permitted by Specification 4R129NS1014, Revision 0, is a violation
of Criterion til and Criterion V of Appendix B to 10 CFR Part 50(50-498/9718-01).
No problems were noted during review of vendor certification for the tubesheet,
lower shell course, transition cone, and elliptical head forgings. The vendor
documentation was, in general, comprehensive and was found to comply with
ASME Section til Code and Westinghouse material specification sampling and
testing requirements.
However, during review of the Ansaldo certification for the upper shell courses, the
inspector observed that the reported magnetic particle examination data appeared to
not conform to ASME Section V Code prod amperage requirements. Specifically,
Article 7, paragraph T 743.2 of ASME Section V Code requires an amperage range
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of 100-125 amperes per inch of prod spacing be used for conducting magnetic
particle examinations of section thicknesses 3/4 inch and greater. Ansaldo was
required by Westinghouse Drawing 6488E61 to perform a magnetic particle
examination of the longitudinal weld joint preparation surfaces, the dressed root of
the initial weld prior to completion of the weld from the second side, and the final
post weld heat treated surfaces. During review of Test Report 11581 dated
January 15,1997, which pertained to magnetic particle examination of the root of a
"J" shell (Item 006, Purchase Order E52891) longitudinal weld seam after grinding,
the inspector observed that the recorded amperage and prod spacing values were,
respectively, ~ 1000 amperes and ~ 180 m n. The maximum amperage permitted
by the ASME Section V Code for this prod spacing was calculated by the inspector
to be 886 amperes. The use of ~ 1000 amperes for the examination thus appeared
to exceed ASME Section V Code requirements. The inspector reviewed the
magnetic particle examination test report for the weld joint preparation surfaces for
the "J" shell course and the corresponding test reports for the "H" shell course, and
noted the same recorded values for amperage and prod spacing. The licensee
requested Westinghouse to obtain a clarification from Ansaldo on the issue.
Ansaldo indicated in response that the value used in the certificate was the
maximum the operators could use depending on prod spacing. The inspector
considered the reported practice to be atypical for preparation of a nondestructive
examination report. Licensee management was informed at the exit interview that
the transmittal letter for the inspection report would probably request the licensee to
furnish the corrective actions taken by Westinghouse with respect to the potential
Code violation.
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The inspector requested the licensee to obtain information regarding the compliance
by the foreign Westinghouse pressure boundary material subvendors with the
requirements of ASTM E23 in regard to: (1) the design of their Charpy impact
machines, and (2) the performance of annual calibrations using standard Charpy-V
impact specimens. This request was made because of the awareness of the
inspector that, in the past, there were differences in requirements for Charpy
impact machines between various national standerds which could affect the
developed impact test values. Similarly, while reviewing drop weight test
results, the inspector noted examples where different hardfacing electrodes
were used in specimen preparation to those specifically identified in ASTM E208.
Accordingly, the inspector requested the licensee to obtain information regarding
compliance of the Westinghouse subvendors with the requirements of ASTM E208.
The licensee indicated their intent to obtain the requested information. Review of
the furnished information regarding compliance with the requirements of ASTM E23
and ASTM E208 is considered an inspection followup item (50-498/9718 02).
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c.
Conclusio.ns
The Westinghouse material specifications applicable to procurement of
pressure boundary materials were found to generally conform to ASME
Section lli Code and the technical and quality requirements contained in
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licensee Specification 4R129NS1014, Revision O. A violation was, however,
identified in regard to the f ailure of the licensee to reconcile the use
of a different pressure boundary material to that permitted by
Specification 4R129NS1014, Revision O. No deficiencies were noted in the
majority of vendor certifications reviewed. However, prod method magnetic
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particle examination records from Ansaldo for steam generator upper shell
courses indicated use of amperage values, during examination of longitudinal
weld joint preparation surfaces and the ground root of the initial welds,
which appeared to exceed the maximum permitted by Article 7, paragraph T-743.2,
of the ASME Section V Code.
E1.2 Licensee Steam Generator Technical and Quality Reouirements
a.
insoection Scoce (50001)
The inspector reviewed Specification 4R129NS1014, Revision 0, to ascertain the
scope of the licensee technical and quality requirements for the Unit 1 replacement
steam generators and to focus on whether the licensee had incorporated in the
requirements lessons learned from the degradation mechanisms that had been
experienced in earlier steam generator models.
b.
Observat ons and Findinas
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The inspector noted from review of Specirication 4R129NS1014, Revision 0, that
the document contained comprehensive technical and quality requirements. Initial
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review of the document indicated that it appeared to provide an appropriate set of
baseline criteria for the steam generator replacement activities. with appropriate
consideration given to control of modifications (including use of 10 CFR 50.59),
accident analyses, design loads, materials and process selection, thermal hydraulics,
and rigging and handling. During the review, the inspector focused on technical
requirements that would affect susceptability to historical steam generator
degradation mechanisms. The inspector noted that the licensee had included
requirements in the following areas:
Specification of use of inconel 690 tube material to enhance resistance to
intergranular stress corrosion and intergranular attack. The licensee also
invoked the requirements of Electric Power Research Institute
Document NP-6743-L, " Guidelines for PWR Steam Generator Tubing
Specifications and Repair Specifications for Alloy 690 Steam Generator
Tubing," Volume 2, for the tubing: established additional process control
requirements for tubing manufacture; and imposed enhanced eddy current
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signal to noise requirements.
Established requirements for tube supports that would minimize denting and
promote more favorable chemistry conditions at these locations.
Provided criteria for minimizing vibration and wear in the tube bundle.
Included requirements for optimizing extent of subcooling at the tube sheet
surf ace, which should improve chemistry environment at this location and
reduce incidence of intergranular stress corrosion cracking and intergranular
attack.
Established feedring design criteria to preclude erosion / corrosion and thermal
fatigue failure concerns.
The inspector considered the specific requirements implemented by the licensee
were appropriate responses to known degradation mechanisms and, if appropriately
responded to by Westinghouse, should significantly reduce the susceptibility of the
replacement steam generators to stress corrosion, erosion / corrosion, and wear
degradation mechanisms,
c.
Conclusions
The licensee has established comprehensive technical and quality requirements for
the Unit 1 replacement steam generators. Numerous requirements were included ir,
the specification to minimize the vulnerability of the replacement steam generator
tubing to intergranular attack and intergranular stress corrosion cracking at the tube
sheet and tube support locations, preclude significant erosion / corrosion degradation
of the feedring, and minimize tube bundle wear.
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E7
Quality Assurance in Engineering Activities
E7.1
Oversicht of Steam Generator Vendor Enoineerina and Manufacturina Activities
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Lnapection Scope (50001)
The inspector reviewed: (1) licensee Audit Report 96 043 dated May 28,1996,
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which documented the licensee's initial audit of the Westinghouse, Pensacola plant;
(2) licensee quality surveillance reports for Japan Steel Works, Kobe Steel, Ltd., and
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AB Sandvik Steel; (3) selected vendor inspection reports that were prepared by a
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licensee resident inspector at the Westinghouse, Pensacola plant; (4) resident
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inspector selection of process hold points at the Westinghouse, Pensacola plant;
and (5) the AB Sandvik Steel Report MC 4601 PP, " Pre-Production Evaluation
Report," Revision 1. In addition, the inspector interviewed Quality and Engineering
personnel regarding current and planned oversight of Westinghouse activities,
b.
Observations and Findinas
The inspector noted that the licensee has either performed or plans to perform
surveillances of all major Westinghouse subvendors for the Unit 1 replacement
steam generators. The most significant licensee finding noted by the inspector
pertained to inadequate performance by a subtier agency retained by Westinghouse
to perform audits of their subvendors. The audit of the Westinghouse, Pensacola
plant was viewed by the inspector as comprehensive. The inspector was informed
by quality management that a licensee inspector was positioned at Westinghouse,
Pensacola prior to the start of manufacturing of the Unit 1 replacement steam
generators, thus providing an opportunity for the individual to familiarize himself
with the manufacturing processes by observing work that was in progress on other
steam generators. The inspector considered this a good decision, and noted from
review of the hold point selections and the reddent inspector's reports that the
individual appeared to be very active in observation of Unit 1 replacement steam
generator manufacturing activities. The inspector was informed, however, that a
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documented inspection plan had not been prepared to provide guidance to the-
resident inspector on the specific areas and subjects to focus attention on. The
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inspector considered this an area where improvement could be made, in that
preparation of such a plan provided engineering and quality the opportunity to
identify the areas of greetest significance and concern for inspection followup.
The inspector was informed that an engineering representative was assigned for
liaison and oversight of engineering activities at both Westinghouse, Monroeville
and Westinghouse, Pensacola. These individuals were reported to be spending
approximately 50 percent of their time at the Westinghouse f acilities. The inspector
was unable to meaningfully assess the role and effectiveness of these individuals,
due to the absence both of a documented activity plan and a requirement to
generate activity reports for licensee management information and review.
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The inspector was impressed with the overall efforts made by licensee Engineering
personnel to assure that the inconel 690 tubing to be furnished by AB Sandvik Steel
meets current Electric Power Research Institute requirements and has a high eddy
current signal to noise ratio. These eitcrts culminated in a visit to Sweden for a
pre production evaluation of 20 tubes from another Westinghouse project with
essentially identical tubing.
c.
Conclusions
Overall, the licensee quality organization was considered proactive in its scope of
monitonng of Unit 1 replacement steam generator manufacture, with surveillances
performed or planned at all Westinghouse major sub-component vendors and a
resident inspector located at the Westinghouse, Pensacola plant. The effectiveness
of licensee engineering representatives at Westinghouse, Monroeville and
Westinghouse, Pensacola could not be assessed due to the absence of a work plan
- and documentation pertaining to their activities, Licensee engineering staff efforts
to assure that inconel 690 tubing to be furnished by AB Sandvik Steel would meet
current Electric Power Research Institute requirements and have a high eddy current
signal to noise ratio were considered impressive,
V Manaaement Mgefinas
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Exit Meeting Summary-
The inspector presented the inspection results to licensee staff on July 24,1997, at
the conclusion of the onsite inspection. The licensee acknowledged the findings
presented. Westinghouse documents were reviewed during the inspection which
were identified as containing proprietary information, The specific content of the
documents that was considered proprietary was not identified, No information was
included in the inspection report that was considered proprietary.
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ATTACHMENT
SUPPLEMENTAL INFORMATION
PARTIAL LIST OF PERSONS CONTACTED
Licensee
T. Bosquez, Senior Nuclear Support Engineer, Central Power and Light
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D. Chamberlain, Design Engineer,
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T. Cloninger, Vice President, Engineering
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J. Conly, Licensing Engineer
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H. Domschke, Supervisor, Procurement Quality
A. Granger, Administrator, Engineering Quality
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S, Head, Licensing Supervisor
J. Haning, Engineer
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D. Hess, General Supervisor, Nuclear Contracts
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M. McBurnett, Licensing Manager
A. McIntyre, Director, Engineering Projects
W. Redd, Director, Records Management System
R. Rehkugler, Director, Quality
S T!mmaraju, Design Engineer
D Towler, Operations Quality Supervisor
D. Wohleber, Project Manager, Steam Generator Replacement Project
NRC
W. Sifre, Resident inspector
INSPECTION PROCEDURES USED
- Steam Genemtor n'eplacement inspection
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ITEMS OPENED
Ooened
50-498/9718-01
Failure to update steam generator specification to reflect
approval of use of SA-533, Grade B, Class 2 plate
50-498/9718-02
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Compliance of material manufacturers with the requirements of
ASTM E23 and E208 during mechanical testing of material
samples
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LIST OF DOCUMENTS REVIEWED
Licensee Specification 4R129NS1014, * Replacement Steam Generators," Revision 0
Operations Quality Assurance Plan, Section 7.0, " Procurement"
Westinghouse Material Specification A533C07, "SA-533 Type B Class 2 Plate
(Section lil NB)," Revision C
Westinghouse Material Specification A508C20, "SA 508 Class 3a Tube Plate Forgings
(Section Ill ND)," Revision D
Westinghouse Material Specification A508C23, "SA-508 Class 3a Shell (Ring) Forgings
(Section lil-NB)," Revision C
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Westinghouse Material Specification A508C24, "SA 508 Class 3a Elliptical Head Forgings
(Section lil NB)," Revision C
Vendor certification packages for pressure boundary rnaterials
Selected vendor inspection reports for Westinghouse, Pensacola
May 1996 Audit Report for Westinghouse, Pensacola
Surveillance Reports for Kobe Steel, Ltd., Japan Steel Works, and AB Sandvik Steel