ML20211F216
| ML20211F216 | |
| Person / Time | |
|---|---|
| Site: | South Texas  |
| Issue date: | 08/10/1984 |
| From: | Shelburne E NRC OFFICE OF THE SECRETARY (SECY) |
| To: | |
| Shared Package | |
| ML20150F241 | List:
|
| References | |
| FOIA-85-378 NUDOCS 8610310103 | |
| Download: ML20211F216 (1) | |
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!< g% NUCLEAR REGULATORY COMMISSION
& ,i ik ASHINGTON, D.C. 20555
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OFFICE OF THE SECRETARY ,
CERTIFICATION I hereby certify that the. attached 22 pages contain a true copy of the l etter dated lug. 1 :s , 1981 from K.V. Seyfrit to Brown & Root, Inc. regarding the LLVlV inspection so n D.F. Fox on July 20 - 24 4901, toaether with t6at inttor's attachments on file with the United States Nuclear Regulatory Commission's Public Document Room, 1717 "H" Street, N. W. , Washington, D.C.
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453 AUG 1 9 1981 co Docket No. 99900502/81-03 yM p.
Brown & Root, Inco norated "-A f .,I (@
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p cw m . o. 7. ."W. M. Rice -d OCT 5 334 ---p.!
4 Group Vice President, Power Group -; ,, _g.
s mum 4100 Clinton Drive Houston, TX 77001 g $s Gentlemen: T/@ -
This refers to the inspection conducted by Mr. D. F. Fox of this office on July 20-24, 1981, of your facilities at Houston, Texas, and to the discussions of our findings with Dr. K. M. Broom and members of your staff at the con-clusion of the inspection.
Areas examined during this 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 obser-vations by the inspector.
During this inspection it was found that you failed to meet certain cosnitments to the NRC. The specific findings and references to the pertinent requirements are identified in the enclosures to this letter.
This is the fourth inspection in which the corrective actions or preventive measures for a total of seven previous inspection findings were not cc.;;ie ac as connitted. Reference Item A of the Notice of Deviation enclosures Repeatedly o of Reports 99900502/80-01, 99900502/80-02, and 99900502/81-01.
your response to these previous findings and during a meeting with you a m members of your staff in our Region IV offices, you have committed to imple-l
- ment effective corrective and preventive measures, but this problem still persists. This suggests a more serious breakdown in the effective implemen-tation and control of your Quality Assurance Program. Consequently, provide
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us within 30 days from the date of this letter a written statement containing, l (1) a description of steps that have been or will be taken to assure that i Brown and Root commitments to NRC will be performed as stated and be effectively
! implemented; (2) a description of steps that have been or will be taken t.;
prevent future recurrence of this ites, and (3) the dates your corrective actions and preventive naamres were, or will be, completed. You are requested to take action promptly concerning this satter.
The responses directed by this letter are not subject to the clearance pro-
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cedures of the Office of Management and Budget as required by the Paperwork i
Reduction Act of 1980. PL 96-511. .
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454 Brown and Root, Inc. 2 In accordance with 10 CFR 2.790 of the Cosnission's regulations, a copy of this letter and the enclosed inspection report will be placed in the NRC's Public Docimient Room. If this report contains any information that you believe to be exempt from disclosure under 10 CFR 9.5(a)(4), it is necessary that you (a) notify this office by telephone within 10 days from the date of this letter of your intention to file a request for withholding; and (b) sub-mit within 25 days from the date of this letter a written application to this office to withhold such information. If your receipt of this letter has been delayed such that less than seven days are available for your review, please notify this office promptly so that a new due date may be established.
Consistent with Section 2.790(b)(1), any such application must be accompanied by an affidavit executed by the owner of the information which identifies the document or part sought to be withheld, and which contains a full statement of the reasons on the basis which it is claimed that the infonnation should be withheld from public disclosure. This section further requires the statement to address with specificity the considerations listed in 10 CFR 2.790(b)(4).
The infonnation sought to be withheld shall be incorporated as far as possible into a separate part of the affidavit. If we do not hear from you in this regard within the specified periods noted above, the report will be placed in the Public Document Room.
Should you have any questions concerning this inspection, we will be pleased to discuss them with you.
Sincerely, Karl V. Seyfrit Director
Enclosures:
- 1. Notice of Nonconfonnance
- 2. Inspection Report No. 99900502/81-03 bCC:
IE/V&SPB (Reinmuth)
IE Files AEOD NMSS NRC:POR QAB Reg. Directors, I, II, Ill, V JEGagliardo, RIV I
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o 455 Brcwn and Root, Inc.
Docket No. 99900502/81-03 NOTICE OF NONCONFORMANCE Based on the results of an NRC inspection conducted July 20-24,1981, it appears that certain of your activities were not conducted in accordance with NRC requirements:
Brown and Root letter of response, dated June 12, 1980, to nonconfonnance D of NRC inspection report 99900502/81-02 states in part that, "The procurement specification (S-006) for the air lock has been modified and the Technical Reference Document (TRD 5N119NQ013, Revision B) has been revised for quali-8 fying the air lock seal material to withstand a beta radiation of 3.3 x 10 Rad. This corrective action is complete. Vendor response to the material requisition for the seal materials has been requested by July 1,1981."
Contrary to the above, the vendor response to the material requisition was not requested by July 1, 1981. Furthermore, the material requisition was not completed and transmitted to the vendor by conclusion of this inspec-tion, since the procorement specification and Technical Reference Document were not issued until July 22, 1981 and June 22, 1981, respectively.
qAAIOOb Ihf3['44499 EECBRR
.j 99900502
ORGANIZATION: BROWN AND r , INC. , POWER GROUP HOUSTON, T REPORT NO.: 99900502/81-03 INSPECTION DATE(S): 7/20-24/81 INSFECTION 0%STTE HOURS: 76 CORRESPONDENCE ADDRESS: Brown and Root, Incorporated ATTN: Mr. W. M. Rice, Group Vice President Power Group 4100 Clinton Drive Houston, TX 77001 ORGANIZATION CONTACT: Mr. R. J..Vurpillat, QA Manager TELEPHONE: (713) 678-5226 PRINCIPAL PRODUCT: Architect Engineering Services NUCLEAR INDUSTRY ACTIVIT(: The total effort comitted to domestic nuclear design activities at the Houston facilities is approximately 11". of the 10,200 pennanent and contract employee staff of the Power Group. The major project design is South Texas Project Units 1 and 2.
ASSIGNED INSPECTOR: [W D. F. Fox, Reactor Systems Section (RSS) 8 /l 2. / @ l Dat'e OTHER INSPECTOR (S): D. D. Chamcerlain, RSS l APPROVED BY: }y k -CM f Date C. J. Hafe) Chief, RSS
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INSPECTION BASES AND SCOPE: l l
A. BASES: 10 CFR Part 50, Appendix B and the SAR for tne South Texas Project ,
Units 1 and 2.
B. SCOPE: Design inspection, design verification, design change control, ces1gn corrective action and status of previous inspection findings.
DESIGNA D CHIGINAL V
Certified 37 pffvve _._
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ORGyuWl7)L110N: BROWN AND' 7T, INC., POWER GROUP 457 ;
HOUSTON, .. S REPORT NO.: 99900502/81-03 INSPECT 10N RESULTS: PAGE 2 of 6 A. VIOLATIONS:
None B. NONCONFORMANCES:
Contrary to commitments contained in the Brown and Root, Inc. letter of response, dated June 12, 1981, to NRC Inspection Report 99900502/81-02, corrective action for a previously identified nonconformance had not been completed as stated. This is the fourth inspection in which correc-tive actions or preventive measures were not completed as committed.
C. UNRESOLVED ITEMS:
None D. STATUS OF PREVIOUS INSPECTION FINDINGS:
- 1. (Closed) Folicw up Item (80-02): The status of the Brown and Root (B&R),
Vendor Control Evaluation and Correction Program will be evaluated.
The NRC inspector reviewed the status of the task force established by B&R to review all procurement documents for safety-related equipment and material to assure nat all B&R and Houston Lighting and Pcwer (HL&P) commitments to NRC are met prior to release of tne items to the South Texas Project (STP) site.
B&R management stated that: (1) all purcnase orders will be reviewed and updated by November 30, 1981; (2) all affected items will be brought into full compliance and released by Decemcer 31, 1981; tne shift in the role of NUS in the program from that of an independent auditor of tne updated procurement cocuments to that of determining tne extent that tne vencor's existing programs and activities met the requirements contained in tne updated procurement documents, will be identified to HL&P by August 14, 1981; and (3) Technical Referece Document No. 7A700GPC07, will be issued by August la, 1981, to define and control all aspects of the Vendor Control and Evaluation Program. Implementation will be retrofitted to include the identifica-tion and upgrading, as necessary, of those safety-related items pre-viously released to the site for construction or installation.
This area will be examined further during subsequent inspections.
- 2. (Closed) Violation (81-02): Failure to submit a written report of a significant defect in piping supports within the -/.ne requirec by 10 CFR Part 21.
458 ORGANIZATION: BROWN AND ,T, INC., POWER GROUP HOUSTON, W AS REPORT NO.: 99900502/81-03 lNSPECTION RESULTS: PAGE 3 of 6 B&R management stated that the de. lay in submitting the report to NRC resulted from their understanding of the 10 CFR Part 21 reporting requirements at that time. The B&R 10 CFR Part 21 implementing procedure (STP-PGM-022) was revised on July 1, 1981, to require verbal notification to NRC within two calendar days and written notification within five calendar days following the determination of reportability.
- 3. (Closed) Nonconfomance (81-02): Failure to adhere to the require-ments in the B&R 10 CFR Part 21 implementing procedure.
The B&R Incident Review Committee reviewed all previously identified safety concerns to determine their reportability and the minimum supplemental documentation,needed to document B&R's decision on each safety concern. Three safety concerns were detennined report-able pursuant to 10 CFR Part 21 and the requisite notification made to NRC. Procedure STP-PGM-022 was revised on July 1, 1981, to specifically define the identification, evaluation, reporting, and documentation requirements for safety concerns identified subsequent to July 1, 1981.
- 4. (Closed) Nonconformance (81-02): Failure to submit to NRC changes in the QA program and organi:ation described in :ne B&R Topical Report.
S&R management stated that tre Topical Report has not been revised because the only current nuclear cesign activity, tne South Texas Project (STP), is not comitted to that CA program. B&R plans to revise the topical anc ceterm'ne the optimum date for sucmission to NRC by Decemcer 31, 1981.
- 5. (Closed) Nonconformance (81-02): Failure to include beta radiation resistance requirements in the specification for personnel air locx inflatacie seal material.
The subject specification was revised and issued on July 22, 1981; how-ever B&R did not complete the corrective action described in their June 12, 1981 letter of response to this nonconformance prior to the conclusion of this inspection. (See S. above.)
- 6. Failure to maintain required train-(Closed) Nonconformance (81-02):
ing records.
The training files were reviewed and the recuired training ano docu-mentation was completed for all affected STP individuals. Procedure STP-PM-006-E was revised on July 20, 1981, to include specific require-ments for tne control, maintenance, and storage of training recorcs.
ORGANIZATIONI BROWN AND ~ T, INC. , POWER GROUP HOUSTON, .S REPGRT NO.: 99900502/81-03 INSPECTION RESULTS: PAGE4 of 6 Additional B&R personnel were assigned to the training and record retention functions and affected STP supervisors were given training on implementing the requirements of the revised procedure.
- 7. (Closed) Nonconfonnance (81-02): Failure to follow procedure for authenticating copies of educational diplomas or transcripts of new employees.
The STP corporate personnel files were reviewed and the required authentication or verification was completed for all STP individuals.
Procedure DL 035 was revised on June 9, 1981, to include specific requirements for verification and documentation of the education and experience of newly hired or transferred employees assigned to the STP.
E. OTHER FINDINGS OR CCMMENTS
- 1. Desion Inspection _
The related sections of the STP PSAR and FSAR and apolicable imple-menting procedures were examined to determine the commitments con-cerning safety-related design activities. One system design descrio-tion, two specifications, two Technical Reference Documents, the plant physical model, eleven drawings, seven calculations, two design activity logs and reports, two safety concerns, two purchase orders, thirteen records of design verification, three hold tags, and other documentation relating to the containment structure, mechanical ecuipment auxiliary building and fuel nancling cuilc-ing HVAC, and the auxiliary feedwater systems were examined to verify effective implementation.
Within tne sccpe of the inspection, the committed program was being implemented. However, the following items were noted.
I a. Aporoximate'y 2500 physical interferences, encroachments on ecuio-l ment access or personnel passageways, were uncovered during the I
construction of the plant physical model and resulted in numerous documents being issued to identify changes that are needed in the related engineering drawings. Based on information from B&R personnel accroximately 3500 of the 33,300 drawings issued to date have a total of 5,000 " holds" or " hold areas" associated with them.
Certain of these drawings have oeen used by vendors to f abricate piping spool pieces that were subsequently shipped to the site prior to clearing of the " holds." The current status of these items could not be determined by examination of available B&R engineering records. B&R management stated that they would develop and imple-ment a system to identify, track, and assure clearing of design
" holds" on an item prior to the design requirements free::e date I
L
460 ORGANIZATION:. BROWN AND ' , INC., POWER GR00P HOUSTON,~4 3
. REPORT NO.: 99900502/81-03 INSPECTION RESULTS: PAGE 5 of 6 for the item. Furthermore, the need for, and methodology of, providing positive assurance against the inadvertent installation of such items will be evaluated.
- b. An August 25, 1980 reanalysis of the pressure and temperature transient of the containment after a postulated LOCA indicates that the original (May 18, 1978) analysis used to generate the data for the STP FSAR was conservative by 3 psi in peak pressure, 2.40F in peak vapor tempera-ture and 0.20F in peak sump temperature. The inspector noted that certain of the input parameters used in the reanalysis were different from those reported in the FSAR. These and other inconsistencies in the FSAR were discussed with B&R management who stated that the FSAR would be reviewed and needed changes would be identified to HL&P on a timely basis and affected design documents would be revised accordingly.
- c. Auxiliary feed water pumps, purchased from the Bingham-Williamette Company under P0s 35-1197-4053 and 35-1197-8053, were deliverd to the STP site with motor operators for the turoine trip and throttle valves that were not qualified to IEEE-323 and IEEE-344 as required by procurement specification STP-35149MSO430 dated Marcn 31, 1977.
The B&R Incident Review Coninittee (IRC) deemed this safety concern (No. 40) to be reportable pursuant to 10 CFR Part 21 and on April 10, 1980, notified the NRC. Review of B&R's engineering and procurement files did not reveal any indication that the requirement for qualified operators was waived. B&R management stated that the supplier of the turbine (Terry Corp.) had replaced the operators on one of the delivered turbines with qualified operators and reportedly is in the process of replacing the others.
- d. B&R engineering stated tnat tne heating and ventilating (HVAC) systems for the STP mecnanical equipment auxiliary building (MEAB) and the fuel handling building (FhB) appeared to provide insufficient cooling curing certain modes of plant operation or postulatec plant events. The B&R IRC ceemed this safety concern (No. 96) to be reportable pursuant to 10 CFR Part 21 and en May 8, 1981, notified the NRC. B&R management stated that the reasons for the cooling capacity of the systems, as designed, not meeting current heat removal requirements were that: (1) the capacity requirements were calculated in the mid 1970s frcm the heat loads identified at that time and were not revised nor updated since then; (2) certain heat loads were inadvertantly omitted from the analysis;
! and (3) additional capacity is needed to accomodate the new equipment and additional heat loads now required in the MEAB and FHB. B&R management stated that the calcula on of the required HVAC capacity will be updated i by October 13, 1981 anc will be revised to include the effect of pipe l
ruptures by June 1982. B&R anticipates that the procurement cocuments for the new HVAC systems, which will be used to supplement the existing HVAC systems, will be issued by July 1982.
9 461 ORGANIZATION: BROWN ANC T, INC., POWER GROUP HOUSTON,- AS
. REPORT NO.: 99900502/81-03 INSPECTION RESULTS: PAGE 6 of 6
- 2. Design Verification The related sections of the STP PSAR and FSAR and applicable imple-menting procedures were examined to determine if procedures are consistent with commitments to NRC. The qualifications of the design verifiers and the detailed documentation of the design verification of two specifications, one computer code, three caiculations, and five drawings relating to the containment structure and its post LOCA pressure and temperature transient analysis were examined to determine if the committed program was being effectively implemented.
Within the scope of this inspection, the committed program was being
- implemented.
- 3. Design Change Control The Brown and Root Quality Assurance Manual and the applicable engineer-ing procedures were examined to determine the quality assurance program commi tments . The following documents were examined to verify imple-mentation of the commitments; Design Change Tracking System (computer printout), 31 Design Change Notices,14 reviseo drawings, and six revised calculations. Relative to the documents examined, the quality assurance program commitments were being implemented.
4 Desien Corrective Action The Brown and Root Ouality Assurance Manual and the acolicable pro-cedures were examined to determine the cuality assurance crogram commi tments . Twelve identified Engineering Design Deficiencies were examined to verify implementation of the ccmmitments. Witnin the scope cf this area of the inspection, the Quality Assurance pro-gram ccmmitments were being implemented. However, it was not accarent that the present program adequately addresses recurring design errors for needed design corrective action This area will be examined further curing a future inspection.
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