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#REDIRECT [[IR 05000498/1985021]]
{{Adams
| number = ML20151V035
| issue date = 01/17/1986
| title = Const Appraisal Team Insp Repts 50-498/85-21 & 50-499/85-19 on 851021-1101 & 12-22.Potential Enforcement Action Noted: Failure to Provide Adequate Interface Between Design Organizations (A/E) & NSSS
| author name = Garrison D, Georgiev G, Heishman R, Mclellan T, Nemoto J, Peranich M, Phillips H, Phillips H, Stein S
| author affiliation = NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV), NRC OFFICE OF INSPECTION & ENFORCEMENT (IE)
| addressee name =
| addressee affiliation =
| docket = 05000498, 05000499
| license number =
| contact person =
| document report number = 50-498-85-21, 50-499-85-19, NUDOCS 8602110181
| package number = ML20151V027
| document type = INSPECTION REPORT, NRC-GENERATED, INSPECTION REPORT, UTILITY, TEXT-INSPECTION & AUDIT & I&E CIRCULARS
| page count = 200
}}
See also: [[see also::IR 05000498/1985021]]
 
=Text=
{{#Wiki_filter:UNITED STATES NUCLEAR REGULATORY COMISSION
                            OFFICE OF INSPECTION AND ENFORCEMENT
                              DIVISION OF INSPECTION PROGRAMS
                            REACTOR CONSTRUCTION PROGRAMS BRANCH
    Report No.:            50-498/85-21,499/85-19
    Docket No.:            50-498, 50-499
    Licensee:              Houston Lighting and Power Company
    Facility Name:        South Texas Project
    Inspection At:        Matagorda County, Texas
    Inspection Conducted:      October 21-November 1 and November 12-22, 1985
    Inspectors:          /              M '#
                    M. W. Peranich, Chief Construction Programs /
                                                                                                                            /////74
                                                                                                                            Date 51gned
                    CAT Section, Team Leader
                            W    hr          /
                                                'Inspedtor
                                                            h    (Region IV)
                                                                                                                            Y'/fC
                                                                                                                            D&te' Signed
                    <D.L.Garytson,feside
                          N. 4.      5 /\lm LE&                                                                            /f/0 86
                              )rgiev, Sr. Retctor Co truction Engineer                                                      Date S4gned
                  /G.B.Ge
                    I      r  Y Y?Yk
                    T. K. McLellan, Reactor Construction Engineer
                                                                                                                              ///r/d4
                                                                                                                            D4te' Signed
                          L            ll                                                                                    ///O/86
                            gmoto, Reac      Construction Engineer                                                          Ddte S'igned
                    & M 2 . kto
                    M. W. P ipips, Reactor            struction Engineer
                                                                                                                            egu
                                                                                                                            Date Signed
                    . ' {&J.'Jn            -
                                              '
                                                          ~^
                  ' S. R. Stein, Riactor Construction Engineer
                                                                                                                            /  ok6
                                                                                                                            Date Signed
                    Consultants:    S. L. Baron, A. V. duBouchet, D. C. Ford,
                                      J. B. McCormack, O. P. Mallon, E. Y. Martindale
                                      W. J. Sperko, Jr. , D. G. Whatley,
                          /,
    Approved By:      /                                                                                                                  _
                    Robert F. Heishman, Chief                                                                              0(te' Signed
                    Reactor Construction Programs Branch
                                                                    0602110101 06020S ,-
    *R. !!. Compton was inadvertently omitted                        PDR                              ADOCK 0500                0
      from the list of consultants.                                  O
._.                                      _    _    -_      _ - _    - _ _ - _ _ _ _ _ _ _ _ _ _ _ _ - - _ _ _ - - _ _ _ -
 
                                                                                                                              _ _ _ _ _ _ _ _ _ _ _ _ _ _
                                                                              TABLE OF CONTENTS
                                      TOPIC                                                                          SECTION
                                        INSPECTION SCOPE AND OBJECTIVES...............................                  I
                                      ELECTRICAL AND INSTRUMENTATION CONSTRUCTION...................                    II
                                    MECHANICAL                  CONSTRUCTION.......................................  III
                                      WELDING AND NONDESTRUCTIVE          EXAMINATION........................          IV
                                      CIVIL AND STRUCTURAL              CONSTRUCTION.............................        V
                                    MATERIAL TRACEABILITY AND CONTR0L.............................                    VI
                                      DESIGN CHANGE CONTR0L.........................................                  VII
                                      CORRECTIVE ACTION SYSTEMS.....................................                  VIII
                                    ATTACHMENT A - PERSONS CONTACTED AND DOCUMENTS REVIEWED
                                    ATTACHMENT B - GLOSSARY OF ABBREVIATIONS
                                                                                                                                                          l
                                                                                                                                                          I
_ _ _ . _ _ _ . _ _ _ _ . _ . _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ .
 
. _ _ _ .        _ _ . _              ._          _.                  . _                              _ _ _ _    _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
                          I.  INSPECTION SCOPE AND OBJECTIVES
                            The objective of this inspection was to evaluate the adequacy of
                            construction at the South Texas Project site. This objective was
                            accomplished through review of the construction program, evaluation nf                                                                    ;
                            project construction controls, and review of selected portions of the                                                                    i
                            Quality Assurance Program, with emphasis on the installed hardware in the                                                                i
                              field. The scope and significance of identified problems were also                                                                      i
                            determined.                                                                                                                              '
                                                                                                                                                                      F
                            Within the areas examined, the inspection consisted of a detailed
                            examination of selected hardware subsequent to quality control
                            inspections, a selective examination of procedures and representative
                            records, and limited observation of in process work.
                            For each of the areas inspected, the following was determined:                                                                          )
                            *
                                          Were project construction controls adequate to assure quality                                                                i
                                          construction?
                            *
                                          Was the hardware or product fabricated or installed as designed?
                                                                                                                                                                      r
                            *
                                          Were quality verifications performed during the work process with
                                          applicable hold points?
                            *
                                          Was there adequate documentation to determine the acceptability of
                                          installed hardware or product?                                                                                                !
                            *
                                          Are systems turned over to the startup organization in operable
                                          condition and are they being properly maintained?
                                                                                                                                                                      ,
                                                                                                                                                                      i
                                                                                                                                                                      ,
                                                                                                                                                                      &
                                                                                                                                                                      :
                                                                                                                                                                      r
                                                                                                                                                                      (
                                                                                                                                                                      ,
                                                                                                                                                                      i
                                                                                                                                                                      1
                                                                                                                  1-1
          _ _____              __-__-                        - _ _ - - _ _ _ _ _ _ - - - - - _ _ _ - - _ _ _ _
 
W
  II. ELECTRICAL AND INSTRUMENTATION CONSTRUCTION
i
      A.  Objective
          The primary objective of the appraisal of electrical and
          instrumentation construction was to determine whether safety-related
          components and systems were installed in accordance with regulatory
        . requirements, Safety Analysis Report commitments, and approved vendor
          and construction specifications and drawings. Additional objectives
          were to determine whether procedures, instructions, and drawings used
          to accomplish construction activities were adequate and whether
          quality-related records accurately reflect the completed work.
      B.  Discussion
          Within the broad categories of electrical and instrumentation
          construction, attention was given to several specific areas. These
          included electrical cable, raceways and raceway supports, electrical
          equipment, and instrumentation tubing and components. Additionally, a
          review as made of a selected number of documents associated with design
          change control and nonconformance reporting.
          A number of documents were generated by the applicant to record
          individual observations of the NRC Construction Appraisal Team (CAT)
          inspectors, and are referenced directly in the discussions that follow.
          1.  Electrical Raceway Installation
          a.  Inspection Scope
              Seventy-two segments of installed Class 1E cable tray, representing
              a total length of about 1,000 feet, were selected from various
              plant areas for detailed examination by the NRC CAT. These
              segments were inspected for compliance to requirements relative to
              routing, location, separation, support spacing and configuration,
              identification, protection, and physical loading. Additionally, 28
              runs of installed conduit, with an aggregate length of about 1,600
              feet, were inspected for compliance to specified requirements such
              as routing, location, separation, bend radii, support spacing, and
              associated fittings.
              Twenty-eight raceway supports were examined in detail for such items
              as location, material, anchor spacing, weld quality, bolt torque, and
              installed configuration.
              See Table 11-1 for a listing of cable tray, conduit, and raceway
              support samples.
              The following documents provided the basic acceptance criteria for
              the inspection:
              *
                  Bechtel Specification 3E189ES1000, " Conduit and Tray Supports,"
                  Rev. 6
                                          11-1
                                                                                    -
 
                                                            ___ __________-____-___ _ _ _ _ _ _
    *
        Ebasco Quality Control Procedure (QCP) 10.16, " Inspection of
        Electrical Raceways," Rev. 4
    *
        Ebasco QCP-10.30, " Inspection of Installation and Fabrication of
        Electrical Cable Tray Hangers, Conduit Supports and Auxiliary
        Steel," Rev. 1
    *
        Ebasco Construction Site Procedure (CSP) 40, "EE580 Electrical
        Installation," Rev. 4
  b. Inspection Findings
    In the area of electrical raceway the NRC CAT inspectors observed
    that, in general, Class 1E raceway installations were in accordance
    with applicable design criteria. Quality attributes such as
    material type, location, identification, and installed
    configuration were found to be as shown on approved construction
    drawings.    However, several deficiencies in design or construction
    or both were identified and are discussed below.
    (1) Raceway Separation
:          The South Texas Project (STP) Final Safety Analysis Report
l          (FSAR) section 8.3.1.4, entitled " Separation of Redundant
'
          Systems," provides the basic criteria for acceptable Class 1E
          circuit and electrical raceway installations. This FSAR
          section describes commitments for physical arrangement of
          raceways which pertain to the requirements of Regulatory Guide
          (RG) 1.75 for independence of redundant systems. In general,
          these FSAR criteria specify the physical separation which must
          be maintained between components of redundant electrical
          divisions.    Additionally, physical separation is required
          between components performing Class 1E and non-Class 1E
          functions.
          During the examination of the selected raceway sample, NRC CAT
          inspectors observed that a number of installations were not in
          accordance with the FSAR requirements.        Deficiencies were
          identified in several areas of the plant but were most common
          in the Mechanical / Electrical Auxiliary building. In this area
'
          numerous Class 1E raceway components had been installed
          without the required physical separation. See Table Il-2 for
          a listing of the identified raceway segments that violated
          separation criteria.
          NRC CAT inspectors discussed this issue with licensee personnel
          and reviewed relevant inspection procedures, design drawings
          and plant historical records to determine why those deficien-
          cies exist. The review indicates that the licensee had
          identified problems in the area of electrical separation as
;
'
          early as 1984.    Corrective Action Report (CAR) G-434, dated
          May 8, 1984, details specific violations of relevant FSAR
l          criteria.    Additionally, other site initiated documents such
l          as the " Final Report for STP Pre-CAT Verification," dated July
j          18, 1985, highlight deficiencies in this area.
1
                                Il-2
 
                                                                    _ _ _ _ - _ _ _ _
  In reviewing these documents NRC CAT inspectors expressed
i
  concerns with regard to actions taken to correct existing
  deficiencies. As an example, in response to the deficiencies
  identified in CAR G-434 the licensee elected to postpone the
  inspaction of raceway division separation until the time of
  area turnover.    Relevant inspection and construction procedures
  were then revised to reflect this decision by eliminating the
  attribute of division separation from inspection of cable tray
  and conduit. Discussions with licensee personnel indicate that
>
  this decision was made based upon the fact that construction
  activities are ongoing and thus it is not prudent to identify
  separation violations prior to completion of any given area.
  At the time of area turnover, a walkdown of each area is
  planned by Ebasco engineering to identify violations in
  separation and determine the course of action necessary to
  alleviate those problems. Additionally, Ebasco Quality
  Control (QC) personnel will perform an inspection after the
  installation of required barriers in accordance with the
  applicable Quality Control Procedure.
  NRC CAT inspectors noted that many of the deficiencies identi-
  fled during the examination of the raceway sample involved
i components which were part of a system turned over to Houston
!
  Lighting and Power Company (HL&P) Startup.    Consequently,
  component modification or installation of barriers which may
  result from future inspection activities may adversely affect
  plant systems which have been turned over and accepted.
  Several aspects of the licensee's proposed inspection and
  engineering walkdown programs were evaluated, including a
  review of Standard Site Procedure SSP-45. This procedure,
  issued on October 25, 1985 during the NRC CAT inspection,
  provides the basic acceptance criteria which will be used for
  future inspection of separation between electrical components.
  The procedure content appears thorough, but because inspection
  activity has not commenced an evaluation of program effec-
  tiveness could not be made.
  In summary, while it is clear that the licensee is aware of
  existing separation deficiencies, the implementation and
  effectiveness of actions planned to correct these and other
  currently unidentified deficiencies requires further evalua-
  tion.
  NRC CAT inspectors also observed several raceway installations
  in which redundant divisional cable tray or conduit had been
  attached to a common raceway support. NRC CAT inspectors
  expressed concern that this configuration does not meet the
  intent of RG 1.75 position C.3 which states that "In general,
  locating redundant circuits and equipment in separate safety
  class structures affords a greater degree of assurance that a
'
  single event will not affect redundant systems. This method of
  separation should be used whenever practicable and where its
  use does not conflict with other safety objectives."
                        !!-3
 
  . _ _ _ _  _    _ __-_-____ ______- ___      . _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ - _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ -
                This concern,.and its relationship to plant missile protec-
                tion, was discussed with licensee personnel. With regard to
                  the common support of redundant raceways, it.is postulated that
                a single event (i.e., missile impact) could adversely affect
                the function of redundant divisional circuits.
                NRC CAT inspectors reviewed section 3.5 of the STP FSAR. This
                section and its Table 3.5-1 contain criteria for missile
                protection for South Texas Project. Specific attention was
                given to the FSAR discussion under the heading Internally
                Generated Missiles Outside of Containment, ar.d the protective
                measures required by the referenced table. NRC CAT inspectors
                also reviewed Bechtel Project Engineering Directive PED-039
                entitled " Engineering Evaluation Walkdowns" and the Systems
                Interaction Design Guide PED-016 entitled " Internally Generated
                Missiles."
                One area of concern was identified during this review and was
                discussed with licensee personnel. FSAR Table 3.5-1 describes
                safety class systems and components and seismic category I
                structures which require missile protection. The table appears
                to provide exclusions for the categories of cable raceway
l                systems and electrical supports based on component redundancy.
i                However. as previously discussed the NRC CAT inspectors noted
I
                that redundant raceway installations that are attached to a
                common support would be equally affected by missile impact.
                As a result of this observation the licensee has issued FSAR
l                Change Notice 779 to more appropriately reflect the intent of
!
                Table 3.5-1 to include raceways and raceway supports in missile
                protection evaluations. This resolves the NRC CAT concern in
                this area.
            (2) Electrical Conduit
'
                With exception of the specific deficiencies listed below, the
                conduit sample inspected conformed to applicable design and
                installation requirements relative to such attributes as size,
                routing, identification and proper supports.
l                Conduit C1XM3ER5204'was found to have a support distance
                violation between two supports, and conduit AIXE2ARY102 was not
                identified with its safety division marking at the required 15
i                feet intervals. These two isolated deficiencies were sub-                                                                    ,
                sequently recorded on Nonconformance Reports (NCRs) CE-03207
                                                                                                                                              '
l
                and CE-03213 by the licensee.
                The strap bolts for eight QC accepted conduits did not exihibit
l
                torque seal as required by project instructions. QCP-10.30
                requires QC to verify the torque on at least one bolt from each
                connection and requires the verified bolt to be marked with
!                torque seal. Discussion with the licensee indicates that the
l                lack of or partial application of torque seal for QC accepted
l                conduits is due to removal and reinstallation without reinspec-
l                tion by QC. NRC CAT inspectors concluded that the licensee's
l                ccentrol of QC accepted conduit installation is not completely
                                            II-4
l
 
          effective.    The inadequate torque sealing was subsequently
            recorded on NCR CE-03213 by the licensee.
      (3) Raceway Supports
          The examination of raceway supports included conduit and cable
          tray supports. Attributes such as location, material type and
          size, anchor spacing and embedded length, welds (location, size
          and general quality), and installed configuration were found to
          be in accordance with design requirements. However, several
          isolated hardware deficiencies and one documentation deficiency
          were identified.'
          It was noted by the NRC CAT inspectors that the traveler
          package for cable tray hanger 2-002-H3 included the inspection
          report for a different hanger. The licensee's subsequent
          investigation revealed a number of documentation errors and
          omissions attributable to hangers inspected by the same QC
          inspector. The licensee has issued Standard Deficiency
          Reports (SDRs) E-361 and E-362 to document and correct these
          deficiencies.
          The torque of approximately 150 bolts and 50 concrete anchors
          of various sizes on raceway supports was verified by the NRC
          CAT inspectors. Three cable tray supports, 2-103-H61,
          1-010-H84 and 1-024-H52, each contained several 1/2-inch strut
          bolts which did not meet minimum torque requirements. These
          deficiencies were documented on NCRs CK-03111, and CE-03229.
          Independent of the bolt torque sample, hanger 1-065-H11 was
          also found to contain several loose 1/2-inch strut bolts even
          though the bolts were marked with torque seal. In addition,
          the embedded lengths of 17 concrete anchors were verified using
          an ultrasonic inspection method with no items of concern noted.
          It was noted by the NRC CAT inspectors that virtually all the
          1/2-inch strut bolts had no markings on the bolt heads making
          identification of the material indeterminate. Beginning with
          Rev. 3 in 1983, Bechtel specification 3E189ES1000 requires
          these strut bolts to be from material conforming to American
          Society for Testing and Materials (ASTM) A-307, Grade B, but
          specifically negates the ASTM requirement for manufacturers'
          markings. The use of ASTM A307 bolting materials without
          manufacturer's identification marks is also discussed in
          Section VI, Material Traceability and Control, of this report.
          Other than the indeterminate traceability of bolt material, the
          documentation and hardware discrepancies identified by the NRC
          CAT in this area are considered isolated cases,
  c. Conclusions
;    Except as noted, raceway systems have been installed in accordance
l
'
    with applicable design and installation requirements. However,
    numerous installations have not naintained the physical separation
    required by the licensee's commitment in the FSAR.    In this area, it
i
                                II-5
l
 
    was determined that pertinent procedural.and administrative controls
    have only recently been developed. As such, the adequacy of
    electrical raceway separation after implementation of these controls
    at South Texas Project will require further evaluation by the
    licensee and NRC personnel.
    The number of reworked conduit installations that were found lacking
    QC reinspection of bolt torque indicate that rework of QC accepted
    conduit installations requires increased control.
  2. Electrical Cable Installation
  a. Inspection Scope                                                        i
    The NRC CAT inspectors selected a sample of installed Class 1E
    cable runs that had been previously accepted by QC inspectors. The
    sample included medium and low voltage power, control, and instru-
    mentation cabling. For each of the cable runs, physical inspection
    was made to ascertain compliance with applicable design criteria
    relative to size, type, location, routing, bend radii, protection,
    separation, identification, and support.
    Additionally, the NRC CAT inspectors selected approximately 108        l
    cable ends for examination of terminations. These were inspected to    l
    applicable design and installation documents for items such as lug
i    size and type, proper terminal point configuration, correct identi-
l    fication of cable and conductors, proper crimping of lugs or
;    connectors, and absence of irmulation or jacket damage.      See Table
l    II-3 for a listing of cable terminations examined.
    The following medium and low voltage power cable totaling about
    1,700 feet were selected from different systems, electrical
    trains, and locations:
                          Cable                        Type
'
                        AIDJAKC1LA                  1/C No. 4 AWG
                        B1CSABC1EA                  1/C 250 MCM
I
                        B1CHABC2LB                  3/C No. 6 AWG
                        BIRHADC1LE                  3/C No. 10 AWG
                        C1PKACC1GA                  3-1/C 750 MCM
                        D1VAABC1HB                  3/C No. 4 AWG
                        D1DJABC1LE                  1/C 750 MCM
    The.following control cables totaling approximately 1,100 feet were
    selected from different systems, electrical trains, and locations:
                          Cable                        Type
                        A1FWO7CISC                  5/C No. 12 AWG
                        A1JWO2C1SA                  7/C No. 12 AWG
                        C1PK01C3SK                  3/C No. 16 AWG
                        01VA10C25A                  7/C No. 12 AWG
                                  II-6
                _ __        ____  _______-____ __        __
 
                                                  .    _            _
  The following instrument cable totaling approximately 1,000 feet
  were selected from different systems, electrical trains, and
  locations:
                          Cable                        Type
                        AIDG04CIPA                2/C No. 16 Shielded
                        AIDG04C1PC                2/C No. 16 Shielded
                        A11114CAXF                2/C No. 16 Shielded
                        BIRH03C2WD                2/C No. 16 Shielded
                        D1VA10C2XA                2/C No. 16 Shielded
                        D1DJ10C4XC                2/C No. 16 Shielded
  The following documents provided the basic acceptance criteria for
  the inspection:
  * Bechtel Specification SE189ES1007, " Cable Installation In Trays,
      Conduits and Ductbanks," Rev. 5
  * Bechtel Specification SE189ES1004, " Cable Splicing, Termination,
      and Supports," Rev. 5
  * Bechtel Specification 5A230ES1008, " Installation of Electrical
      Cable, Raceway, and Equipment Identification," Rev. 6
  * Ebasco QCP-10.17, " Electrical Cable Installation Inspection,"
      Rev. 2
  * Ebasco CSP-19, " Safety and Non-Safety-Related Cable Pulling,"
      Rev. 4
  * Ebasco CSP-8, " Cable Termination and Splices," Rev. I
b. Inspection Findings
  (1) Routing
            In general, the routing of Class 1E cables through design
          designated raceway systems was found to be in accordance with
          specified criteria. Each of the Class 1E cables examined by
          NRC CAT inspectors had been installed in accordance with the
          routing detailed on the EE580 pull cards.
          The examination of Class 1E cables did disclose an
          apparent deficiency-in the routing of medium voltage cables
            into cable spreading areas. NRC CAT inspectors observed
          that these installations do not meet the requirements of IEEE
          384-1974 section 5.1.3 which limits cable installation in a
          cable spreading room to circuits which perform control and
          instrumentation functions.
          Subsequent discussions with licensee personnel disclosed that
          the " cable spreading areas" were inaccurately defined on
          drawing SE-03-0E-0100 sheet 6AA Rev. O. Consequently, the
          medium voltage cables identified by NRC CAT inspectors were
                                  11-7
    .  .-.          . .    . -      - . - _ - -                --  .
 
  .
e
          acceptably installed outside of actual cable spreading areas
          and were in accordance with IEEE-384 and RG 1.75. As a result
          of this observation the licensee has issued Design Change
          Notice (DCN) I to revi'se and clarify the referenced drawing.
    (2) Separation
          In general, the separation of Class 1E cables was found to be
          in accordance with requirements.
          NRC CAT inspectors did identify a number of Class 1E cable
          installations which exhibit inadequate separation at the
          entrance to Class 1E equipment. However, these deficiencies
        were the subject of Bechtel Deficiency Evaluation Report (DER)
          85-034 issued September 10, 1985, which was subsequently
          determined to be potentially reportable pursuant to 10 CFR
          50.55(e). Evaluation of actions taken to correct existing
          deficiencies are in.accordance with this process and as such,
        NRC CAT inspectors have no additional observations in this
          area.
          In~ general, the separation of Class 1E cables located inside
        of electrical equipment was found to conform with requirements.
        One area where a deficiency was identified is in cubicle 3 of
        4160V switchgear 3E151ESCOE1C. The physical separation between
        a non-Class 1E pull out~ fuse block and Class 1E wiring was less
        than the required six inches. As a result of this observation
        the licensee has issued NCR SE-03233 to identify and correct
        this condition.
        No other deficiencies were observed in this area.
    (3) Power Cable Spacing and Derating
        STP po.ter cable installations have been designed in accordance
        with Insulated Power Cable Engineers Association (IPCEA)
        publication P-46-426, 1963 " Power Cable Ampacities - Volume I
        - Copper Conductors" and P-54-440, 1972 "Ampacities - Cables
          in Open Top Trays." The STP FSAR further requires that SkV
        and 15kV cables in tray be installed with spacing maintained
        at 1/4 of the cable bundle diameterc In general, the installa-
        tion of Class IE power cables was found to comply with these
        requirements. However, spacing had not been maintained in tray
        segments B1XE3FTEAE, B1XE3FTEAF and B1XE3FTEAJ. Deficiencies
        in cable tie down requirements were also observed in these tray
        segments. As a result of these observations the licensee has
        issued NCR CE-3211.
        No other deficiencies were identified in this area.
    (4) Cable Damage
        Although no damaged cable was found, two situations with'the
        potential for cable damage were identified by the NRC CAT
        inspectors. A number of cable tray segments above equipment
                                II-8
 
    were found to be missing required edge softeners where cable
      breaks out of the tray over the. tray side rail into the equip-
      ment. Numerous examples were noted in the switchgear rooms.
      Based on this observation, the licensee documented an
      individual occurrence on NCR CE-03210 and addressed the generic
      issue with a procedure change. The change will add a visual
      check for the presence of edge softeners to QCP-10.32,
      "Walkdown/ Turnover of Safety-Related Systems, Sub-Systems,
    Areas, or Components."
    The second situation involves vertically run free air cable
    between-spreading rooms on elevations 60 ft. and 74 ft. The
    cables run through flame cut holes in metal decking with no
    protection provided for the cut edges. This item was
      subsequently documented on NCR CE-03256 for evaluation.
      In addition, the quantity of Class 1E cable coiled throughout
    the plant is of concern in that the potential for damage is
      increased whenever cable coils are exposed to general construc-
    tion activities.    As a result of an NRC CAT observation, the
    licensee issued NCR CE-03310 to document minimum bend radius
    violations and other workmanship problems with cable
    temporarily coiled in panel C1PNZLP803.
    The area of cable protection merits continued licensee atten-
    tion.
(5) Cable Identification.
    In general, the identification of Class 1E cable installations
    was found to be in accordance with applicable design criteria.
    In connection with an issue which had been previously identi-
    fied in both licensee and Region IV inspection reports, NRC CAT
    inspectors noted that the color coding of numerous Class 1E
    cables had faded due to weathering, aging or both. In some
    installations fading had resulted in cable coloring which did
    not accurately represent the functional division of the instal-
    led cable.    For example a purple cable (Division A) had faded
    to blue (Division B).
    Discussions with licensee personnel and the review of the
    response to a previously issued nonconformance report indicates
    that, although color fading of Class 1E cabling does cause some
    confusion during performance of a visual inspection, a detailed
    examination of any particular cable will confirm proper routing
    and divisional separation based upon the divisional code
    applied to each cable jacket. In addition, the cable identi-
    fication at termination ends indicates the cable's safety
    division.
    NRC CAT inspectors conf % ed this during the field examination
    of Class 1E cables but - ed that the divisional code had not
    been applied to cable supplied by Rockbestos. However, no
    examples of color fading in Rockbestos cable were identified
    by the NRC CAT inspectors or site inspection personnel.
                          II-9
 
                No other concerns were identified in this area.
-
      (6) Terminations
                In general, cable termination activities performed by
                construction personnel conformed to requirements. However,
                several isolated construction deficiencies and one procedure
                conflict were identified by the NRC CAT inspectors.
                * Cable B1DJACC1LL, the power feed from the safety Division
                  B battery, is trained such that it is in contact'with the
                  battery rack.    This observation was subsequently recorded
                  on NCR SE-03241 by the licensee.
                * Terminal block 200 in panel A1SIABC1HH has a broken separator
'
                  between the positive and negative terminal points for cable
                  A1SPAAC1SA.    This was subsequently documented on NCR
                  CE-03222 by the licensee.
                * Cables A1SPIABCICA and A1SIABC1HH-are terminated on their
                  respective breakers in reverse order to the specification
                  requirements. The specification requires black,. red, orange
                  terminated top to bottom and the cables.are terminated black,
                  red, orange bottom to top. This was subsequently recorded
-
                  on NCR CE-03258.
                * During the inspection of control cable terminations, several
                  adjacent cable conductors were found to violate the. require-
                  ment for minimum bend radius.      The cables involved are.
                  A1SP25CBSC and A1SP25CBSE in panel A1PNETCA04, and cable
                  A1SP21 COSH in panel A1PNETCA02. Based on this observation
                  the cables were documented on NCR CE-03205 by the licensee.
                  QCP-10.13 Section 5.2.2.1 requires inspection for nicked or
                  missing conductor strands. This characteristic is required
                  for and is being recorded acceptable on inspection records
                  for post termination inspections where the conductor strands  ,
                  are inaccessable for-inspection.
  c. Conclusions
      With the exception of concerns or deficiencies identified in the
      areas of cable identification and cable damage, and the apparently
      isolated deficiencies identified with terminations, the installation
      of Class 1E circuits and wiring was found to be in accordance with
      applicable design requirements'        .
  3. Electrical Equipment Installation
  a. Inspection Scope
      Over 40 pieces of installed or partially installed electrical
      equipment and associated hardware items from the various safety
      divisions were inspected.
                                        11-10
        - . - .      -  -      .
 
                                                                              .
        The following specific electrical components were inspected in
        detail:
        (1) Motors
                The installation of ten motors and associated hardware was
                inspected for such items as location, anchoring, grounding,
                identification and protection.    The motors inspected were:
                Essential Cooling Water Pump Motor        3R281NPA101A
                Essential Cooling Water Pump Motor        3R281NPA101B
                Containment Spray Pump Motor              2N101NPA101A
                Containment Spray Pump Motor              2N101NPA101B
                Containment Spray Pump Motor              2N101NPA101C
                Safety Injaction Pump Motor                2N121NPA101C
                Essential Lnilled Water Pump Motor        3111VPA004
                Reactor Makeup Water Pump Motor            3R271NPA101A
                EAB Air Handling Unit Fan Motor            3V111VFN014
                EAB Air Handling Unit Fan Motor            3V111VFN016
        (2) Electrical Penetration Assemblies
              .The following containment penetration assemblies were
                inspected:
                            C1PHEP046          Instrumentation
                            C1PHEP054          480V Power
                            B1PHEP028          Instrumentation
                            A1PHEP018          Control
                            B1PHEP032          Control
                            B1PHEP036          480V Power
                The location, type, mounting, identification, and maintenance
                of these penetrations were compared with the installation
                drawings and vendor manuals.
        (3) Circuit Breakers
                Circuit breakers for the following Class 1E motors were
                examined to determine compsiance with design and installation
                documents for size, type, system interface, and maintenance:
                                  Containment Spray
                                  Safety Injection
        (4) .Switchgear and Motor Control Centers
                The following switchgear and motor control centers were
                inspected:
                                      II-11
. - - -      .    .
 
              Motor Control Center              B1PMMCEB1
              Motor Control Center              C1PMMCEC3
              Motor Control Center              A1PMMCEA2
              Motor Control Center              A1PMMCEA3
              Motor Contro1~ Center              A1PMMCEA4
              4160V Switchgear                  B1PKSG0ElB
              4160V Switchgear                  AIPKSG0E1A
  (5) Station Batteries and Racks
        The 125V battery rooms including the installed batteries,
        battery racks and associated equipment were inspected. .The
        location, mounting, maintenance and environmental control for
        installation of the batteries were compared with the
        applicable requirements and quality records.
              125VDC Battery                    C1DJBT045D
              125VDC Battery                    AIDJBT045A
  (6) 125VDC System Equipment
        The following equipment comprising portions of the 125Vdc
        systems were inspected for compliance to design documents for
        such items as location, mounting (welds, concrete anchors and
        bolting) and proper configuration:
              Battery Charger              B1DJBC047E
              Battery Charger              AIDJBC047B
              Battery Charger              AIDJBC047A
              Distribution Panel            A1VADP1201
              Distribution Panel            B1DJPLO39B
              Distribution Panel            C1DJPLO39C
              Static Inverter              A1VAIV1201
              Inverter / Rectifier          A1VAIV001
  (7) Control Panels
        A number of safety-related electrical control panels were
        inspected for compliance to requirements for items such as
        location, mounting and type. The panels inspected were:
              Diesel Generator Control Panel    A1PNZLP101
              Diesel Generator Control Panel    B1PNZLP103
              Remote Shutdown Panel            A1PNZLP100 B1PNZLP100
                                                C1PNZLP100 D1PNZLP100
              Main Control Boards (2)
  (8) Motor Operated Valves
        The following 16 motor operated valves were examined in detail:
                              11-12
~                              _ - - - _ .
 
                                                                i
                                                                l
                CICVMOV01128        B1SIMOV0001B
                B1CVM0V0113A        CISIMOV00016
                A1RCMOV0001A        A1SIMOV0004A
                B1RCMOV0001B        B1SIMOV0004A
                B1SIMOV0016B        CISIMOV0016C
                B1SIMOV0018B        CISIMOV0018C
                C1RHMOV0061B        A1RHMOV0061C
                C1CCMOV0209        CICCMOV0199
The following documents provided the basic acceptance criteria
for the inspections:
*
    Bechtel Specification 3E319ES1040, " Class 1E' Induction
    Motors (250HP and Below)," Rev. 0
*
    Bechtel Specification 4A479ES1018, " Environmental
    Qualification of Safety-Related Electrical and
    Mechanical Equipment," Rev. 2
    Bechtel Specification 3E159ES0012, "5KV Class IE Metal-Clad
    Switchgear," Rev. 2
    Bechtel Specification 3E269ES1091, "Special Electrical
    Penetration Assemblies," Rev. 2
*
    Bechtel Specification 5A230ES1008, " Installation of
    Electrical Cable, Raceway and Equipment Identification,"
    Rev. 6
    Bechtel Specification SE329ES1002, " Valve Electric Motor
    Actuators," Rev. 3
*
    Bechtel Procurement Appendix G, "Large AC Induction Motors
    for Class 1E Service (250 HP and Larger)," no revision
*
    Ebasco QCP-10.15, " Electrical Equipment Installation
    Inspection," Rev. 4
*
    Ebasco QCP-10.20, " Electrical Penetration Installation
    Inspection," Rev. 3
    Ebasco SP-2, " Installation of Permanent Electrical and
    Mechanical Plant Equipment," Rev. 4
*
    Ebasco CSP-44, " Installation of Electrical Penetration
    Assemblies," Rev. 3
*
    Ebasco Construction Maintenance Instruction CMI-1, " Caring
    and Maintenance of Permanent Plant Items," Rev. 7
*
    Applicable design drawings and design change documents
                          II-13
                                __
 
    b.    Inspection Findings
          . (1) Motors
                In general, the Class 1E motors inspected were found to conform
                with applicable design documents. The motors examir, d were of
                the type, size, and configuration specified. A limited review
                of maintenance records indicated that construction maintenance
                had been performed in accordance with approved procedures.
                However, several specification deficiencies were found with-
                several 480V motors and mounting deficiencies were noted with
                several 4160V motors.
                Bechtel specification 3E319ES1040 requires motors under 250
                horse power (HP) rating to have vendor installed terminal lugs
                on the motor leads. The two air handling unit fan motors
                inspected, 3V111FN014 and FN016, did not have the required
                terminal lugs. The braided jackets on the fan motor leads were
                also found to be frayed. A third fan motor, FN002, identified
                by the NRC CAT mechanical inspectors was also found in this
                condition. Although these are not considered significant
                hardware deficiencies by the NRC CAT, the appropriate terminal
                lugs need to be installed when the fan motors are terminated to
                their permanent power source. Fans FN014 and FN016 were
                subsequently documented on NCR BE-03335 and fan FN002 on NCR
                BE-03334.
                The Bechtel specification also requires motors under 250 HP
                rating to have an insulation rating of Class F (135*C) or H
                (150*C). The nameplate and vendor manual for the reactor make
                -up water pump motor 3R271NPA101A indicate the motor insulation
                is only Class B (110*C). This requires evaluation by the
                licensee to assure the motor is adequate for its intended
                service environment.
                Approximately half of the motor hold down bolts for containment
                                                      ~
                spray pumps 2N101NPA101B and C and high head safety injection
                pump 2N121NPA101C were unmarked ana of indeterminate material.
                The remainder of the' bolts were marked as ASTM A-449 in lieu of
                the required A-193, Grade B7. These and other pump motor hold
                down bolt-discrepancies were subsequently dotumented on NCR-
                CM-03078. These are discussed further in Se.ctions III,-
                Mechanical Construction, and VI, Material Traceability and
                Contt01, of this report.
                In an isolated finding, containment spray pump motor
                2N101NPA101A did not have a sight glass for the upper bearing
                oil reservoir although the maintenance records indicated
                adequate oil level. The missing sight glass was subsequently
                documented by the licensee on Deficiency Report (DR) 1-505M.
          (2) Electrical Penetrations
                The penetrations examined were found to have been installed in
<
                accordance with the applicable design documents. A review of
                                      II-14
  .    -.
 
                            ~
        relevant maintenance records indicates that a number of
      maintenance discrepancies such as 0 psi pressure and no
        internal heaters were documented and adequately dispositioned
        on Maintenance Discrepancy forms or determined to be unneces-
        sary by the equipment vendor.
      No deficiencies were observed in this area.
  (3) CircuitBreakers
'
      Thi. examination of the selected circuit breakers for the
      containment spray and safety injection pump motors indicated
      that they had been purchased, installed and maintained in
      accordance with the applicable design documents. Important
        installation attributes such as proper alignment, main contact
      penetration, and safety interlocks were verified by physical
        inspection and review of construction and test records.
      Maintenance records were also reviewed and indicate that
      appropriate activities had been performed.
      Circuit breakers which serve various 480V motor control
      centers were also examined and are discussed in Section
      II.B.3.b.4, below.
      No deficiencies were observed in this area.
  (4) Switchgear and Motor Control Centers
      The examination of Class 1E motor control centers disclosed
      several deficiencies with regard to installation of circuit
      protection devices. NRC CAT inspectors observed that load-side
      terminal extensions on ITE type HE molded case circuit breakers
      had been attached using connecting screws which lack sufficient
      thread engagement to achieve and maintain a tight connection.
      Additionally, insulating barriers installed between the
      terminal extensions were found to be loose or missing. As a
                                                  ~
      result of this condition two concerns were noted and discussed
      with licensee personnel.
      (a) Potential for Inadvertent Circuit Interruption
            Actual measurements indicate that terminal connecting
            screws have an engagement of less than 1/4 inch into the
            circuit breaker housing. This engagement was found not to
            be adequate to assure that a tight connection will be
            maintained between the terminal and circuit breaker in a
            number of these installations. Many of the circuit
            breakers examined, including QC accepted and turnover
            items,. exhibited terminal extensions which were loose as
            received from the vendor or due to normal construction
            activity; i.e. , attachment of field cables or work in
            adjacent cubicles and wireways. The potential for
            inadvertent circuit interruption exists in that terminal
                              II-15
                                                                      }
 
                                              .  -  -          .    - - . .
        connecting screws may work' loose during construction or
        startup activities or due to the vibrations typically
        experienced during plant operation.
    (b) Phase to Phase Faultina
        As detailed in (a), above, many of the Class IE circuit
        breakers examined contained loose terminal extensions.
        The' length and spacing of these extensions was such.that
        phase to phase contact is possible. . Additionally, many of
        the insulating barriers installed between terminals were
        loose or missing due to inadequate vendor-installation or
        construction or startup damage. As a result, the potential
        for phase to phase faulting exists.
                                  _
; , These concerns were. discussed with licensee personnel in an
    attempt to determine the reason for use of load terminal
'
    extensions on molded case circuit breakers at South Texas
    Project, and why the previously mentioned deficiencies had not
    been identified by site inspection or source surveillance
    personnel.
    These discussions and a review of the relevant Bechtel purchase
    specification, 3E179ES1054, indicate that although the specifica-
    tion does detail a requirement for breaker terminals which can
    accomodate attachment. of a two hole termination lug, no
    specific renuest for use of terminal extensions had been made
                                                                    .
    by the licensee to the motor control center vendor.    It was
    also observed that load terminal extensions were not-detailed
    on any of the applicable. design and vendor documents available
    for review.- Additionally, based upon review of relevant vendor          ,
    documentation and the equipment seismic qualification report it
    could not be determined whether the Class 1E motor control
    centers had been tested with circuit breakers in this                    ~
    configuration. As a result of this observation and at the
    request of NRC CAT inspectors, Bechtel engineering issued
                                    ~
    letter ST-YB-00-74 to the motor control center vendor
    (Telenecanique) requesting additional information on this
    subject. No response had been received from the vendor during
    the NRC CAT inspection.
    During meetings with the licensee regarding the possible
    reasons for use of the terminal extensions, the licensee's
    criteria for cable sizing were discussed. At the request      of
    the-NRC CAT, the licensee evaluated the cable sizes and
    limiting factors for the Unit 1 circuits connected to
    breakers'with terminal extensions. Their evaluation showed
    that although the cables for several circuits were one size
    larger than required, all the circuits but one could be
    terminated directly to their breakers. The one circuit    with
    terminal lugs too large for direct connection to its breaker
    (MCC E1A4, cubicle F3L) was size limited for ampacity and not
    voltage drop. Prior to the NRC CAT inspection, the licensee
    had identified one circuit with a cable size limited due to
                          II-16
                                                                              1
 
        voltage drop (MCC E1C2, cubicle H2R) and has since re-routed
        the circuit eliminating the voltage drop problem.
        As a result of deficiencies identified in this area the
        licensee has issued NCRs BE-03208 and SE-03201 to document and
        identify the extent of this problem. Preliminary reviews
        indicate that approximately 30 Unit 1 Class 1E circuit
        breakers exhibit this configuration with an equal. number
        existing in Unit 2.        See Table 11-4 for a listing of motor
        control centers, breakers, and safety-related loads affected by
        this condition.
        On November 18, 1985, the licensee notified NRC Region IV that
        this issue is potentially reportable pursuant to 10 CFR
        50.55(e).
        In general, the installation of Class 1E 4160V switchgear was
        found to be in accordance with requirements. Attributes.such
        as location, mounting and installed configuration were as
        specified by. approved design documents.      However, several
        specification deficiencies were identified.
        Appendix C of Bechtel specification 3E159E50012 establishes
        requirements for control wiring within SkV metal-clad
        switchgear.
        *
              Subsection E states in part..."The preferred terminal
              blocks are G.E. Catalog CR-151B2, connection U2 or
              connection NU2.    Each terminal block shall have no less
              than 12 points." Contrary to this requirement NRC CAT
              inspectors identified severai cubicles of the 4160V
                  'tchgear which contain terminal blocks with less than
              t'w 12 points specified.
        *
                    section Q states in part'.." Adequate space shall be
                                              .
              t c .ded on both sides of the terminal blocks for connect-
              ing wires and wire markers. To allow for stripping and
              bending on incoming cables, terminal strips shall be
              located a minimum of 8-inches away from cable entrances
              either at top or bottom." Contrary to this requirement
              NRC CAT inspectors observed the location of terminal strips
              to be less than 8 inches from cable entrances in several
              switchgear cubicles.
        These specification deviations were observed in several
        cubicles of 4160V switchgear.
        As a result of this observation the licensee has issued NCR
        SE-03225 and initiated Specification Change Notice SCN-3 to
        document and correct this condition.
        No other deficiencies were identified with 4160V switchgear.
                                II-17
--- - -    .-                              -              -      -    --.
 
(5) Station Batteries and Racks
      The condition of the battery rooms was found to be in good
      order and clean and free of debris. . Ventilation systems were
      installed and in operation. Access to these areas was
      controlled by keyed entry, and the appropriate danger signs had
      been posted to prohibit smoking or open flames.-
      The 125V batteries were examined and found to be in good
      condition. Maintenance _ activities were reviewed, and in
      general, had been performed in accordance with requirements.
      The inspection of the 125V battery-racks disclosed that
      indeterminate bolting materials had been used in the assembly
      process. This issue is discussed in detail in Section VI,
      Material Traceability and Control, of this report.
(6) 125VDC System
      In' general, the examination of components which comprise
      portions of the 125Vdc system indicates that construction
      activities had been accomplished in accordance with the
      applicable procedures and design documents. However,
      deficiencies in the area of equipment mounting and product
      quality were identified on several pieces of Class IE
      equipment.
          The examination of distribution panels B10JPLO39B and
          C1DJPLO39L disclosed a weld configuration which does not
          match the mounting details specified by applicable design
          documents.    Field Change Request (FCR) CE-04475 specifies a
          1/4 inch fillet weld of 4 inches length on 6 inches centers
          to be installed on two sides of the equipment and a
          continuous 1/4 inch fillet weld on the front. Actual
          field conditions exhibited a 1/4 inch fillet weld on 8
          inches centers on both front and sides of the panels.
          Relevant inspection records which indicate acceptable
          irstallations do not account for this discrepancy.
          As a result of this observation the licensee has issued
          NCR SE-03325 to document and correct this condition.-
      *
          Each of the three Class 1E battery chargers examined by
          the NRC CAT exhibited loose soldered connections on the
          equipment " firing boards." Inadequate solder joints were
          observed at both pin-to-conductor and pin-to-circuit board
          connections. Discussions with licensee personnel revealed
          that this condition had been identified and evaluated on
          Startup Work Request (SWR) 01757, and that, pending
          delivery of qualified solder material, approved corrective
          action would be implemented.
      No other deficiencies were identified in this area.
                              II-18
 
                                                                      i
                                                                      l
                                                                      ,
(7) Control Panels
      In general,-the installation of Class 1E control panels was
      found to be in accordance with applicable requirements.
    Mounting, location, and installed configuration were as
      specified. Several discrepancies were identified with regard
      to fastening materials used in the assembly of some panels.
    This issue is discussed in detail in Section VI, Material.
    Traceability and Control, of this report.
                                  ~
    The NRC CAT inspectors also noted several non-Class 1E equip-
    ments with identification tags color-coded as Class IE equip-
    ment. Ten nonsafety relay panels had white identification tags
    which indicate safety Division D 'and the nonsafety heater in an
    emergency diesel generator high voltage panel had a blue tag
      indicating safety Division B. The licensee .bsequently
    documented the relay panels o'n DR E-0632 and all three diesel
    generator high voltage panels on NCR BE-03300 for corrective
    action.
(8) Motor Operated Valves
    The NRC CAT -inspected 16 valve operators for installation to
    the latest design requirements and identified deficiencies in
    all 16 operatort examined. In addition, discrepancies were
    found in the control and execution of design changes to certain
    motor operated valves (MOVs) supplied by Westinghouse
    Corporation (W).
    Several deficiencies were noted in virtually all of the MOVs
    inspected.    These included loose vendor terminations,-jumper
    wires containing bend radius violations, and the use of No. 16
    AWG wire in lieu of No. 14. In addition, the licensee was
    unable to provide the NRC CAT with evidence of qualification
    for the No.16 wire. Other deficiencies were noted in one or
    more operators and included more than two wires on one terminal
    point, duct seal melted onto terminal points, unidentified
    terminal points, Raychem wire installed in lieu of the required
    Fire Wall III wire , a cracked terminal lug, and damaged
    conductors.    The damaged conductors and several of the minimum
    bend radius violations appear to be generic to Limitorque model
    SMB operators due to the minimal clearance between the cover
    anr1 the rotor. Table II-5 lists the MOVs inspected and the
        ficiencies found with each. The licensee subsequently issued
    hCR BE-03209 to document the deficiencies observed by the NRC
    CAT in valve motor operators.
    During the first week of inspection the NRC CAT inspectors
    observed in process field wiring changes in motor operated
    valves and attempted to verify their field installation. A
    number of problems ~ arose resulting in the investigation
    continuing through the final weeks of the NRC CAT inspection.
    The sequence of events is as follows:
                            II-19
 
        * NRC CAT inspectors observed design changes being performed
            during implementation of Configuration Control Package (CCP)
          '1-N-WN-0021 by Westinghouse.
    -
        * NRC CAT's field. verification of.CCP 0021 resulted in the
            identification of numerous hardware deficiencies as discussed
            above.
      ~
        * NRC CAT inspectors requested CCPs for ongoing design changes
            with MOVs and were provided CCPs 1-E-EM-0243.and 1-E-ST-0339.
            The subsequent NRC CAT evaluations of these packages resulted
"
            in the identification of conflicts with CCP 0021.
        * Based on NRC CAT observations and licensee reviews of the
            identified problems for MOVs, the licensee issued a
            voluntary stop work order.
        * No further documentation was provided to the NRC CAT, pending
            the completion of a review of the overall MOV problem by the
            licensee.
        * The licensee. informed NRC Region IV of a potentially
            reportable deficiency relating to the wiring of MOVs.
        CCPs-0021 and 0339 were initiated by W FCNs to modify valve
        closure indications and bypass an unqualified terminal block
        respectively. CCP 0243 was initiated by Bechtel to brirg the
        valve operators up to Bechtel's current design. -W was per-
        fonning the work and QC inspection under CCP 0021 while .
        Ebasco was making the design changes under CCPs 0339 and 0243.
        While performing the wiring changes under CCP 0021, W added
        additional jumpers outside the stated scope of the CEP.      The
        NRC CAT review indicated that these jumpers were the same as
        several jumpers being removed by Ebasco under CCP 0243. The
        review also showed that one of the required jumpers of CCP
        0021 was being deleted by CCP 0339. In addition, jumpers had
        been added to several MOVs such that a continuous close indica--
        -tion would be displayed regardless of the actual valve posi-
        tion.- These jumpers were required by and installed in
        accordance with the site's EE-580 field wiring program. These
        NRC CAT observations indicate that there was a lack of coordi-
        nation for the sequence of work for'the CCPs and between the          '
        CCPs.and the ongoing EE-580 program.      This also indicated
        inadequate control of wiring changes for the MOVs and the
        potential for installed wiring not conforming to design.
        When an earlier wiring discrepancy in a motor operator was identified
        by Ebasco under CCP 0243, Bechtel issued Engineering Request
        for Site Action (ERSA) 0121-E in September 1985 to determine,
        the actual wiring configuration of 58 W MOVs.
        Discussions with the licensee and Bechtel at the site and
        Bechtel's Houston office regarding the design changes being          !
        made to the W MOVs indicated several items:
                                                                              1
                                                                                l
                                II-20                                          '
  _
 
..
    * The status of QC . inspection for the design changes is
      indeterminate.
    * The licensee was unable to specifically identify the
      original wiring diagram which represented the configura-
      tion of the MOVs as they were received and upon which
      design changes were being based.
    * Bechtel changes to MOV wiring were not appropriately reviewed
      by W'or provided for incorporation into W design drawings.
      A similar problem in another area was identified in a licensee
      audit report S15-501 dated April 15, 1985. This is discussed
      further in Section VII, Design Change Control, of this
      report.
  * Bechtel verification of the ERSA as-built wiring details
      revealed discrepancies between the reported configuration and
      the actual configuration of the MOVs. As a resu'.t of these
      observations the licensee has initiated a walkdown to      .
      establish the current wiring configuration of Class 1E MOVs.
  Further discussions with the. licensee revealed that an MOV
    inspection program was being planned because of a history of
  problems reported by vendors, other sites, and the NRC.
  However, the documents provided to the NRC CAT, specifically
  Bechtel Interoffice Memorandum 10M-3885S dated October 21,
  1985,.with the subject " Problems Associated with Limitorque
  Valve Operators," propo w d a sample surveillance of only
  warehoused valves. Such a program would not have identified
  all the problems found with the installed MOVs.
  As a result of the continued problems witn the valve motor
  operators, the constructor instituted a r luntary stop work
  order on November 13, 1985, and the licensee informed NRC
  Region IV on November 19, 1985 of a potentially reportable item
  under 10 CFR 50.55(e).
  The interface for design between the A/E and NSSS is further
  discussed in Section VII, Design Change Control, of this
  report.
  In summary, numerous hardware deficiencies were found with the
  MOVs inspected.    In addition, a lack of effective design
  change control for the wiring of W supplied valve motor
  operators has resulted in the licensee not being certain as to
  their wiring baseline or current configuration. Corrective
  action by the licensee is required to assure that all
  safety-related MOVs meet their required design configuration.
  An ancillary concern was rais*.( by the NRC CAT inspectors
  during discussions with the licensee regarding the control of
  design documents for MOV wiring.    It was noted that Bechtel's
  elementary wiring diagrams, wnich are the controlled design
  documents, did not provide point-to point wiring information.
                          II-21
 
        The NRC CAT inspectors were concerned that HL&P startup and
        operations personnel would need point-to-point information for
        perfoming tests, troubleshooting and modifications. The
        discussions with Bechtel indicated that they would review this
        issue,
c. Conclusions
  In general, the installation of Class IE equipment conforms to
  design requirements. However, of concern were the hardware
  deficiencies identified in Class 1E motor control centers and
  motor operated valves, and the specification c'eviations identified
  in Class IE switchgear and motors.
  The examination of ITE type HE molded case circuit breakers
  disclosed deficiencies with regard to attachment of load-side
  terminal extensions. Consequently, installations which exhibit
  this configuration have the potential for inadvertent circuit
  interruption or phase to phase faulting.
  Numerous hardware deficiencies were identified in the wiring of
  V0Vs. A lack of effective design control for the MOV wiring has'
  resulted in the inability to correlate their actual configuration
  to the required design.
  Several cubicles of Sky switchgear were found to deviate from the
  applicable specification requirements for the location of terminal
  strips and the minimum number of teminal block points. Four
  motors were also found to deviate from their applicable
  specification. Three air handling unit fan motors did not have the
  required vendor installed terminal lugs, and the insulation of a
  reactor makeup water pump motor is Class B in lieu of the required
  Class F or H.
4. Instrumentation Installation
a. Inspection Scope
  The NRC CAT inspectors selected a sample of 10 installed and
  inspected instruments for examination to requirements for location,
  mounting details, and instrument type and range. The instrument
  tubing for these instruments were also examined to specification,
  procedure, and isometric drawing requirements. A total of 16
  supports from these runs were also inspected. Table II-6 details
  the inspection sample for the instrumentation installation.
  In addition, the internal wiring configuration of an
  instrumentation process panel was verified.
  The following documents provided the acceptance criteria for the
  inspection:
                              II-22
 
    * Bechtel Specification 4Z519ZS1040, " Instrument Installation
      Seismic Category 1,"  Rev. 3
  '' Ebasco QCP-10.13, " Mechanical Instrument Installation
      luspection," Rev. 4
    * Fbasco CSP-47, " Instrument Installation," Rev. 4
b.  Findings
    The sample of instruments inspected by the NRC CAT represents half
    of all the instruments the licensee had inspected, accepted and
    turned over to the startup organization at the time of the NRC CAT
    inspection. The limited sample examined revealed numerous
    construction deficiencies and several program weaknesses.
    Deficiencies were found in the installation of the instrument-or
    tubing in eight of the ten instr 2ments inspected. .The deficien-
    cies found with more than' one installation included out of tolerance
    dimensions, and loose conduit fittings._ Other deficiencies which
    appear isolated to individual installations included a hanger weld
    not meeting the drawing configuration, the actual instrument identi-
    fication not corresponding to the drawing, a missing tubing clamp,
    and a loose pressure transmitter. Two weaknesses were also identi-
    fied through the installation inspections. These were QC inspec-
    tions performed with drawing revisions other than the latest
    revision, and existing supports used without the required engi-
    neering approval. The deficiencies were subsequently recorded
    on nonconformance documents by the licensee. Table II-7 details the
    findings for the eight instrtnent instellations with deficiencies.
    Discussions with the licensee indicated that a sample surveillance
    of. instrument installation was being performed under their QC
    Effectiveness Inspection Program. Two of the five instruments.
    A1EWFT6854 and C1EWFT6873, inspected by the Effectiveness Program
    coincided with the NRC CAT sample. Although the Effectiveness
    Program has identified installation deficiencies similar to those
    found by the NRC CAT, they failed to identify the out of tolerance
    dimensions found with the installation of C1EWFT6873.
    The NRC CAT inspectors verified wiring changes conducted under
    CCP 1-N-WN-0083 (W FCN TGXM-10585 Revs. A, B, C) to instrument
    process panel 3Z121ZRR018. Attributes such as circuit board
    changes, point-to-point wiring changes, wire type and size, and
    contrasting wire color met'the CCP requirements. However, the
    jumper locations on two circuit cards were not as required. The
    jumpers on the circuit cards in locations C3-247 and 248 are in
    the "high" position while the CCP requires them to be in the " low"
        ~
    position. This discrepancy was subsequently documented on NCR
    SE-03341. In additon, HL&P's Station Procedure OPCP03-ZM-0011
    " Plant Instrumentation Scaling Program" has provisions for document-
    ing the configuration of circuit cards with jumpers or plug-in
    components for use in calibrating.and testing process instrumenta-
    tion by plant staff.
                                II-23
 
c.  Conclusions
    The number of construction deficiencies found in the limited sample
  ~o f. instrumentation indicates that the licensee's inspection and
    surveillance programs are not completely effective. In addition,
    weaknesses were identified in the use of latest drawing revisions
  .for i.nspections and obtaining required engineering approval for
    additional attachments to existing supports. This area requires
    additional management attention.
                                                                        !
                              II-24
                                                                        i
                                                                        l
 
                                        TABLE II-1
                                RACEWAY INSPECTION SAMPLE
Cable Tray:
    B1XC4ATHAP            B1XC4ATHAG            B1XC4ATHAF      B1XC4ATHAE
    B1XC4ATHAD            B1XC4ATHAC            B1XC4ATHAB      B1XC4ATHAA
    B1XC4BTHAA            B1XC4BTHAB            B1XC4BTHAC      AIXE1HTTAM
    AIXE1HTTAG            AIXE1HTTAH            AIXE1DTTBH      AIXE1DTTBG
    A1XE1DTTBF            AIXE1DTTBE            AIXE1DTTBD      AIXE1DTTBC
    AIXE1DTTBJ            A1XE1DTTBK            AIXV1ATSAA      AIXVIATSAB
    B1XE3FTHAN            B1XE3FTHAP            B1XE3FTHAR      B1XE3FTHAS
    B1XE3FTHAT            B1XE3FTHAU            B1XE3FTHAF      B1XE3FTHAE
    B1XE3FTHAD            B1XE3FTHAC          .B1XE3FTHAB      B1XE3FTHAA
    B1XE4GTHAA            B1XE4GTHAB          -AIXFIBTJAG      AIXF1BTJAF
    AIXF1BTJAE            AIXF1BTJAB            A1XF1BTJAA      AIXF1BTJAH
    A1XF1BTJAV            AIXF5AKTVA            AIXF5AKTAB      A1XF5ATTAA
    A1XF5ATJAA            AIXM4KTJAC            AIXM4KTJAB      AIXM4KTJAA
    A1XM4JTJAB            AIXM4JTJAA            AIXM4DTJAS      A1XM4CTJAB
    AIXM4CTJAA            A1XM4BTJAC            AIXM4BTJAB      AIXM4BTJAA
    C1XG1ATSAN            C1XG1ATSAM            C1XG1ATSAG      C1XG1ATSAF
    C1XG1ATSAE            C1XG1ATSAD            C1XG1ATSAC      C1XGIATSAB
    C1XG1ATSAA
Cable Tray Supports:
                1-019-H109            1-106-H4        2-103-H23
                1-100-H51            1-019-H704      2-002-H3
                1-105-H30            2-103-H41        2-002-H47
                1-105-H702            2-103-H92        2-002-H23
                1-152-H109            2-103-H61
Conduits:
    Number          Length (Feet)              Number          Length (Feet)
    ~A1XC4DRJ004            100-                  B1XE2ARY005          79
    AIXC4DRT005            100                  B1XE2ARY006          79
    A1XE1FRS006            32                  B1XF1BRS008          89
    A1XE1FRH001            35                  B1XM2ER5073          48
    A1XElGRLO33            49                  B1XM3ERJ068          33
    AIXElGRLO32            44                  C1XF1ARH004          55
    A1XE2ARY102            51                  C1XF1ARS004          67
    AIXE2BRX004            39                  C1XFIARS010          63
    'A1XF1BRF001            64                  C1XF1FRS009          45
    AIXF1BRF002            58                  C1XM3ERS204          39
    A1XF1BRF003            49                  D1XElGR2037          15
    A1YC4 DRY 003          95                  D1XElGRX002          30
    B1XE2ARY003            79                  D1XE2BRX004          84
    B1XE2ARY004            79                  D1XE2CRS081          32
                                          II-25
                                                                                1
 
                                    TABLE II-1 - (Continued)
                                    RACEWAY INSPECTION SAMPLE
      . Conduit Supports:
                          ~ 1120005            1532512        1625783
                            1120008            1541547        1651000B
                          '1134931            1613130        1651001
                            1134932            1613132        1654548
                            1153322            1625779
i
,
    Y
;
  l'
                                              'II-26
  L
 
                                      TABLE II-2
                                  SEPARATION FINDINGS
Raceway segments listed in the A columns do.not maintain required separation from
the corresponding raceway segments in the B columns. The (*) indicates physical
separation of less than one inch between the two raceway segments.
          Column A        Column B            Column A        Column B
          AIXE1HTTAM      NIXE1HTTAD          AIXE1DTSBB      N1XE1DTSAA
          D1XE1HTXAJ      N1XE1HTYAH          AIXE1DTXBB      N1XE1DTCAA
          AIXE1DTHBH-    N1XE1DTJAV          A1XE1DTXBS    N1XE1DTCAC
          AIXE1DTXBB      N1XE1DTYAA          AIXE1DTXBC    NIXE1DTXAE
          A1XE1DTXJB      N1XE1DTHBF          A1XE1DTHBK    N1YE1DTHAX
          AIXM4KTYAC      N1XM4KTYAC          AIXF1BTFAF *  N1XF1BRJ011
          A1XM4JTYAA      N1XM4JTTAA          AIXM4JTJAA    N1XM4JTYAA
          A1XM4CTYAA      N1XMiCTYAA          A1XM4BTJAC    NIXM4BTSAE
          AIXM4BTJAC      N1XM4BTJAE          AIXM4BTYAF    N1XM4BTYAC
          AIXM4BTFAB      NIXM4BTHAC          AIXM4BTFAB    NIXM4BTTAC
          B1XC4ATHAJ      NIXC4ATAAJ          AIXM4BTFAB * N1XM48R031
          B1XC4ATHAP      N1XC4ATHAJ          B1XC4BTJAE * N1XC1BRX278
          B1XC4BTXAF      N1XC4BTHBA          B1XCABRT852 * N1XC1BRX278
          B1XE4GTHAB      N1XE4GTHBA          AIXE2ARY102 * C1XE2ARY103
          B1XM1ERYO48    AIXM1MTYAB
                                        II-27
 
                      TABLE II-3
                    TCPMINATIONS
  Location    Termination        Description
  A1B52RR014  A1BSAAC23B        Control Cabinet
  A1BS2RR014  A1SP12C1XA2        Control Cabinet Plug
  A1CCMOV0050  A1CC04C1WA2        MOV
A1MB2CP1822  A1AM10C1XA2        Control Panel
A1PMMCEA152  A1AF01C1WA1        MCC EIA1
A1PMMCEA1G1  A1RH03C1WD1        MCC E1A1
A1PMMCEA1V42  A151AAC1HJ2        MCC ElAl
A1PMMCEA2F3  A1SP23CASC2        MCC E1A2
A1PMMCEA2J3  A1SP23 CASA 2      MCC EIA2
A1PMMCEA2R2  A151ABCILA        MCC E1A2
A1PMMCEA2R3  A1S1ABC1HH1        MCC ElA2
'A1PMMCEAA2E1  A1CC04C1WC1        MCC E1A2
A1PMMCEAE1    A1CC04CID1        MCC E1A2
A1PN2LP10052  A1AF01C1WE2        Control Panel
A1PN2LP100S2  A1AF0361WF2        Control Panel
AIPN2LP659    A1AF01C1SA2        Control Cabinet
A1PN2LP700    A1AP02C1WB1        Control Panel
A1PN2LP700    A1AP02C1WA2        Control Panel
A1PN2LP801    A1AF01C1WF2        Control Panel
A1PNERR118A  A1AF05C1WA2        Control Panel
A1PNERR130A  A1AF08C1WA1        Control Panel
A1PNERR130A  A1CC2VC1WA1        Control Panel
A1PZRR002-2  A1SP17CCSA1        Control Cabinet
A1502R0011    A1SP12C1XC1        Control Cabinet Plug
A1502RR008I  A1SP12C2XA1        Control Cabinet Plug
A1S12RR051    A15129C1XB2        Control Panel
A1SP2RR001I  A1SP12C1XB1        Control Cabinent Plug
A1SP2RR002-1  A1SP27CCSC1        Control Cabinet
A1SP2RR002-2 'A1SP17CHSB2        Control Cabinet
A1SP2RR0081  A1SP12C2XB1        Control Cabinet Plug
A1SP2RR002-1  A1SP27CCSB1        Control Cabinet
A1SP7RR002-2  A1SP17CDSA1        Control Cabinet
B10SPLO37C7  B1PKACCILA1        DC Switchgear
B1852RR017    BIBSABC26A2        Control Cabinet
B1B52RR018    B1HC30C1XB-1      Control Cabinet
81DJBC047E    B1DJACCILG1        Charger / Inverter
B1DJBC047F    B1DJACC1LH1        Charger / Inverter
B1DJBT045LN  B1DJACCILL2        Battery
-B10NERR137    B1HC18C1SD2        Control Cabinet
B1FMMCEB1J1  B1HC20C2SC1        MCC E181              I
B1MB2CP22T11  B1HC18C1SC2        Control Panel
BlMB2CP4T30  BlMB04C1501        Control Panel
B1MB2CP4T30  BlMB04C1SS1        Control Panel
B1M82CP4T30  B1MB04CIST1        Control Panel
B1PK2GD0E183  B1SP22CUSB2        MCC E182
B1PKSG0E187  B1EW01C2WH1        4160V Switchgear EIB
B1PMMCEB122  BlAF03C2WC1        MCC E181
B1PMMCEB1F1  B1CCADC1LC1        MCC ElB1
B1PMMCEB1F3  B1HC18CISE1        MCC E181
                        II-28
 
              TABLE II-3 - (Continued)
                    TERMINATIONS
Location      Termination            Description
B1PMMCEB1LIL  B1CCADL1LK1            MCC ElB1
B1PMMCEB1P3  B1CCADC1LM1            MCC E181
B1PMMCEBIR2  B1AF03C2WA1            MCC E181
B1PMMCEBIT1  B1CC1C1WA1              MCC ElB1
B1PMMCEB203    B1CC0525El              MCC ElB2
B1PMMCEB253    B1CHABC2LB1            Distribution Panel
B1PMMCEB2F3    B1CC642WD1              MCC E182
B1PMMCEB2F3    B1CC04C2WC1            MCC ElB2
B1PMMCEB2G    B1C006C2SB1            MCC E182
B1PMMCEB2G1    B1CC06C2SC1            MCC ElB2
B1PN2LP654    B1AF01C2WD1            Control Panel
B1PN2LP660    B1CC06C2SA2            Control Cabinet
B1PN2LP678    B15129C1XB1            Control Panel
B1PN2LP678    B1HC30C1XB2            Control Panel
B1PN2LP678    B1B509C1XA2            Control Panel
B1PN2LP802    B1CC01C2WB2            Control Panel
B1PNERR1208    B1C010CBSB              Control Panel
B1PNERR121B    B1CC01C2WA2            Control Panel
B1PNTB678      BlAMABC2SR1            Termination Box
B1512RR052    B1S129C1XC1              Control Panel
BISP2RR004-1  B1SP22CMSD              Control Cabinet
B1SP2RR004-1  B1SP24CASD1              Control Cabinet
81SP2RR004-1  B1SP24CASB1              Control Cabinet
81SP2RR004-2  B1SP22CUSA1              Control Cabinet
B1SP2RR004-2  B1SP22CVSD1              Control Cabinet
B1VA1V1203    B1VAACCILA2              Charger / Inverter
C1BS2BR019    C1FW11C2PA1              Control Cabinet
C1BS2RR019    C1CV10C5PA2              Control Cabinet
C1BS2RR019    CIRC 10C7PB1            Control Cabinet
C1DN2LP679-1  C1FW23C9XC2              Control Panel
ClMB2CD4T50  C1MB04C1SF1              Control Panel
ClMB2CP1T35  C1B504C1XA2              Control Panel
C1MB2CP1T35  C1MB01C1SC1              Control Panel
ClMB2CP3T45  C1MB03C15El              Control Panel
C1MB2CP3T45  C1MB031SE1              Control Panel
C1MB2CP4T50  ClMB04CISG1              Control Panel
ClMB2CP4T50  C1MB04CISH1              Control Panel
C1PN2LP10055  C1AMACG1SC2              Control Panel
C1PN2LP679    CIAMACCISG2              Control Panel
C1PN2LP679    C1RA13C1XB2              Control Panel
C1PN2LP679    C1RA13C1XH2              Control Panel
C1PNETCC01    ClMB04C1SH2              Control Cabinet
C1PNTB679    C1AMACC15G1              Termination Box
D1DJBC047D    D1DJABCILG1              Charger / Inverter
01DJBC047G    D1DJABC1LB1              DC Switchgear
D1DJPLO37813  D1AF09C1SL1              DC Switchgear
D1DJPLO37B3  D1DJABC1LG2              DC Switchgear
D1DJPLO37B4  D1VAABC1LA1              DC Switchgear
                        11-29
 
    "
                                                                                                                                                            i
                                                                              TABLE II-3 - (Continued)
                                                                                    'TERNINATIONS.
                                  ~ Location                                  Termination                                Description                    !
                                    D1DNERR141                                D1PNAEC3SA2                                Control Cabinet
                                    D1M82CP1817                                D1CC17CISA2                                . Control Panel
                                    01PNERR1240                                01CC17C1SB1                                Control Panel
                                    DIPMERR124P                                DIPN10CNA2                                  Control Panel
                                    DISP 2RR0011                              DISP 12C1XC1                                Control Cabinet Plug
                                    DISP 2RR008I                              DISP 12C2XA1                                Control Cabinet Plug            i
                                    DISP 2RR0081-                              DISPT2C2VB1                                Control Cabinet Plug.
,
                                    DISP 2RR008I                              DISP 12C2XC                                Control Cabinet Plug            :
                                  ' DISP 2RR008I-                                                                          Control Cabinet
'
                                                                              DISPABCISB2
                                    01VADP1202                                D1BSA8CISA1                                Distribution Panel
                                    D1VATV11202                                D1VAABC1LA2                                Charger / Inverter
V
i
l
                                              6
l
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l
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1
                                                                                                  II-30
-
>
L
l
      - . . , . . . - - . . . . .              . . - . . ..- , . . . - - - .        - , - - . . .      -,- , -. ,.. , ,          -.- -_-..-..- - , ~. -
 
m
                                            TABLE'II-4
                      UNIT l' CLASS 1E E0UIPMENT AND LOADS AFFECTED BY
                          MOLDED CASE CIECUIT BREAKER DEFICIENCIES
                                                                        .
                                Motor Control Center:  3E171MCE1A2
  Cubicle / Breaker Type:  A4L/HE3-8050
  Class 1E Load: Distribution-Panel Transformer
                                Motor Control Center:  3E171EMCE1A4
  Cubicle / Breaker Type:  C1R/HE3-8015
  Class 1E Load: Containment Hydrogen Monitoring Panel
  Cubicle / Breaker Type: C1L/HE3-8015
  Class 1E Load: 120Vac Distribution Panel Inverter Channel II
  Cubicle / Breaker Type:  C3R/HE3-B030
  Class 1E-Load: -Spare
  Cubicle / Breaker Type: C3L/HE3-B015
  Class 1E Load: Battery Room Reheat Coil
  Cubicle / Breaker Type:  EIR/HE3-8040
  Class 1E Load: Accumulator 1A Discharge Isolation MOV
  Cubicle / Breaker Type:  E1L/HE3-B015
  Class 1E Load: Containment Cubicle Exhaust Fan
  Cubicle / Breaker Type:  F3R/HE3-8050
-
  Class 1E Load: Voltage Regulating Transformer
  Cubicle / Breaker Type:  F3L/HE3-B100
  Class 1E Load: Battery Room Charger
  Cubicle / Breaker Type:  H3R/HE3-B030
  Class 1E Load: Spare
  Cubicle / Breaker Type:  H3L/HE3-8015
  Class 1E Load: Battery Room Reheat Coil
  Cubicle / Breaker Type: J2R/HE3-8050
  Class 1E Load: Distribution Panel Transformer
  Cubicle / Breaker Type: J2L/HE3-B015
  Class 1E Load: Starter for Chiller Oil Lamp
                                              II-31
 
          ;
  --
                                        TABLE II-4 (Continued)
                          UNIT'l CLASS 1E EOUIPMENT AND LOADS AFFECTED BY
                              HOLDED CASE CIRCUIT BREAKER DEFICIENCIES
                      .
                                  - Motor Control Center: 3E171EMCE184
      Cubicle / Breaker Type: B2R/HE3-B015
      Class 1E Load: Starter for Chiller Oil Pump
      Cubicle / Breaker Type:    B3R/HE3-8015
      Class 1E Load: Spare
      Cubicle / Breaker Type: B3L/HE3-8015
      Class 1E Load: Containment Cubicle Exhaust Fan
      Cubicle / Breaker Type: C2L/HE3-B015
      Class 1E Load: Battery Room Reheat Coil
      Cubicle / Breaker Type:    C2R/HE3-8030
      Class 1E Load: Spare
      Cubicle / Breaker Type: C3R/HE3-8030
      Class 1E Load: EAB Main Area Heating Coil
      Cubicle / Breaker Type:  C3L/HE3-8030
      Class 1E Load: Spare
      Cubicle / Breaker Type:    E4R/HE3-8020
      Class 1E Load: Spare
                                    Motor Control Center:  3E171EMCEIC.!
      Cubicle / Breaker Type: H2R/HE3-B050
      Class 1E Load: Heat Tracing Transfomer
                                ~~
l                                  Motor Control Center:  3E171EMCE1C4
      Cubicle /Breater Type: C3R/HE3-8040
      Class 1E Load: Accumulator 1C Discharge Isolation MOV
      Cubicle / Breaker Type: C3L/HE3-8015'
      Class 1E Load: Containment Cubicle Exhaust Fan
l      Cubicle / Breaker Type: D1R/HE3-8015
l
      Class 1E Load: 120Vac Distribution Panel Inverter
'
      Cubicle / Breaker Type:  D1L/HE3-8050
      Class IE Load:    Power Distribution Panel Transformer
l
l
    -
(                                                  II-32
:
L
 
. _
                                                                                          TABLE II-4 (Continued)
                                                                          . UNIT 1 CLASS 1E EQUIPMENT AND LOADS AFFECTED BY
                                                                                MOLDED CASE CIECUIT BREAKER DEFICIENCIES
    Cubicle / Breaker Type:                                                      D3R/HE3-B015
    Class 1E Load: ' Spare
    Cubicle / Breaker Type: D3L/HE3-8015
    Class 1E Load: Containment Hydrogen Monitoring Panel
    Cubicle / Breaker Type: LElR/HE3-8015
    Class 1E Load: Starter for Chiller Oil Pump
    Cubicle / Breaker Type: E1L/HE3-8015
    Class 1E Load: Battery Room Reheat Coil
                                                                                                  11-33
    _ _ - - _ _ _ _ - _ _ - - - _ _ - - - _ - _ _ - _ _ _ _ _ - _ _ _ _ _
 
              -
_.
                                          TABLE II-5
                            VALVE MOTOR OPERATOR DEFICIENCIES
  Motor Operated Valve CICVMOV0112B:*
        a.    Jumper wires contain bend radius violations.                                ,
                                                                                        i
        b.    Loose vendor terminations on the power terminal block, heater coils, and    l
              torque switch points 24, 25, 26, and 27.                                .'
        c.    No. 16 AWG wire is installed in lieu of No. 14 AWG wire on the limit
              switch between points 22 and 37 and between points 11 and 36.
        d.    More than two-wires terminated under one terminal point.
  Motor Operated Valve B1CVMOV113A:*
        a.  Loose vendor terminations on the terminal blocks, heaters, and limit
              switches.
        b.    No. 16 AWG wire used in lieu of No. 14 AWG wire.
        c.  Jumper wires contain bend radius violations.
        d.  More than two wires terminated under one terminal point.
  Motor Operated Valve A1RCMOV0001A:*
        a.  Loose vendor terminations'on the terminal blocks, craters, and limit
              switches.
        b.  No. 16 AWG wire is installed in lieu of No. 14 AWG wire.
        c.  Jumper wires contain bend radius violations.
l        d.  More than two wires terminated under one terminal point.
  Motor Opreated Valve BIRCMOV0001B:*
        a.  Loose vendor terminations on the terminal blocks, heaters, and limit
!
              switches.
        b.  No. 16 AWG wire is installed in lieu of No. 14 AWG wire.
        c.  Jumper wires contain bend radius violations.
        d.  'More than two wires tenninated under one terminal point.
                                            II-34
                                        _        _ _ _ _ _ _ _ _ - _ _ _ _ _
 
                              TABLE II-5 - (Continued)
                          VALVE MOTOR OPERATOR DEFICIENCIES
Motor Operated Valve B1SIMOV00018:*
      a.  Loose vendor terminations on the terminal blocks, heaters, and limit
          switches.
      b.  Lug at terminal point 26 was cracked and then broke off during
          inspection.
      c.  Jumper wires contain bend radius violations.
      d.  More than two wires terminated under one terminal point.
Motor Operated Valve CISIMOV0001C:*
    a.  Jumper wires cont'ain bend radius violations.
    b.  Loose vendor terminations on the power terminal block, heater coil
          and torque switch points 24, 25, 26, and 27.
    c.  More than two wires terminated under one terminal point.
Motor Operated Valve A1SIMOV0004A:*
    a.  . Loose vendor terminations on the terminal blocks, heaters, and limit
          switches.
    b.  An additional jumper was installed which was not on drawing 9-E-SI13,
          sheet 1 DSP.
    c.  Jumper wires contain bend radius violations.
    d.  More than two wires terminated under one terminal point.
Motor Operated Valve B1SIM0V0004B:*
    a.  Loose vendor terminations on the terminal blocks, heaters, and limit
        . switches.
    b.  Duct seal used to cover temporary power cabic opening has melted onto
          the termination points.
    c.  Jumper wires contain bend radius violations.
    d.  More than two wires terminated under one terminal point.
                                        II-35
            .
 
'
      ,
                                          TABLE II-5 - (Continued)'
                                    ' VALVE MOTOR OPERATOR DEFICIENCIES-
  .
      Motor Operated Valve B1SIMOV0016B:*
            a .'    Loose 1 vendor terminations on the terminal blocks, heaters,:and limit    ;
                    switches.                                                                '
          .b.      Jumper wires contain bend radius violations.
            c.      More than two wires terminated under one terminal point.
                                                                                              I
    : MotorL0perated Valve CISIMOV0016C:*
            a.      Loose vendor terminations on the terminal blocks, heaters, and limit
                    switches.
                                                                                              C
            b.      Jumper wires contain bend radius violations.
            c.    -Terminal point 10 is not identified.
                  .
            d.    .More than two wires-terminated under one terminal point.                  .{
      Motor Operated. Valve B1SIMOV00188:
                                                                                              i
            a.      Loose vendor terminations on the terminal blocks, heaters, and limit
                    switches.
            b.      Temporary power cable is shorting against the MOV housing and the
                    vendor wires.to'the heater have been deformed by the cover installation.  j
            c.      Jung r wires contain bend radius violations.
          ' d.      No. 16 AWG wire in lieu of No. 14 AWG wire is installed between-
                    points 22 and 37.                                                        ;
                                                                                              -
            e.      More than two wires terminated under one terminal point.
    Motor Operated Valve CISIMOV0018C:*
            a.      Loose vendor terminations on the terminal blocks, heaters, and limit
                    switches.
            b.      Numerous jumper wires contain bend radius violations.                    ;
            c .-  . Wire manufactured by Raychem was installed on site instead of              '
                    Firewall III as required.
                                                  11-36
 
      ,
      .  .
    s
  '
                                                  . TABLE II-5 - (Continued)
                                              VALVE MOTOR OPERATOR ~ DEFICIENCIES
                fd.        (Jumperwirescontainbendradiusviolations.
              -
                - e.    .More than two wires. terminated under one terminal' point.
                        ~
            MotorOperatedValveN1RHMOV0061C:*-
                  a.        Loose vendor terminations'on.the terminal blocks, heaters, and. limit
                          . switches.
                - b.    -No. 16 AWG wire'is installed in lieu of No. 14 AWG wire.
                  c.    " A jumper between point 35 and 36 has been installed that is not
                            identified on the scheme drawing; 9-E-RH02, sheet 1.
                ' d.        Jumper. wires contain bend radius violations.
                  e. ' More than two wires terminated under one terminal point.
          -Motor Operated Valve C1CCMOV0209:
                  a '.      Damaged conductors.from. removal /re-insta11ation of motor-operated valve
                            cover. -(This appears to be a generic problem due to lack of cover / rotor
                            clearance'on limitorque SMB models).
                  b.        Jumper wires contain bend radius violations.
            Motor Operated Valve CICCMOV0199:
                          ~
                  a.        Insufficient motor operated valve cover clearance with wires on top'of
                            rotors.  (Similar to problem with CICCMOV0209).
                  b.        Jumper wires contain bend radius violations.
                  N'TES:
                    O
                  *Def.iciencies for these valves were subsequently recorded on NCR BE-03209 by
                  .the licensee.
:
        '
.
l                                                            II-37
 
E
                                    TABLE II-6
                          INSTRUMENTATION INSPECTION SAMPLE
  Hangers:
  Field Sketch            Hanger                Field Sketch Harger
  -IC-EW-02                  A                  IC-EW-03      F
  IC-EW-02                  B                  IC-EW-03      G
  IC-EW-02                  'C                  IC-EW-03      H
  IC-EW-03                  A                  IC-EW-03.      I
  IC-EW-03                  B                  IC-EW-03      J
  IC-EW-03                  C                -IC-EW-05      A
  IC-EW-03-                  D                  IC-EW-12      A
  IC-EW-03                  E                  IC-EW-12      C
  Tubing:
                Field Sketch                    Field Sketch
                IC-CC-22                        IC-EW-09
                IC-EW-02'                        IC-EW-10
                IC-EW-03                        IC-EW-11
                IC-EW-04                        IC-EW-12
                IC-EW-05                        IC-EW-13
  Instruments:
                A1EWFT6854                      CICCFT4522
                A1EWFT6856                      C1EWFT6873
                A1EWFT6904                    .C1EWFT6874
                B1EWFT6864                      C1EWFT6876
                B1EWFT6866                      CIEWFT6906
                                        II-38
 
e
l                                    TABLE II-7
L -
                        INSTRUMENTATION INSPECTION DEFICIENCIES
,
    -Field Sketch        Instrument                          Findines
      IC-EW-12, Rev. 2    A1EWFT6856          1. Har.ger C welded at one end only.
                                                  Drawing 4201-9-2-45080 Sheet 126,
,                                                  Detail A requires both ends welded.
                                              2. Hanger A not installed in accordance
                                                  with the correct drawing detail.
      IC-EW-10, Rev. 3    C1EWFT6906          1. Seven dimensions outside'of
                                                  tolerance.
'
                                              2. Sketch identifies instruments as
                                                  FT-9606 and FI-9606.
                                              3. Loose conduit fittings at FT-6906.
                                              4. Inspected and accepted to ICEW-10,
                                                  Rev. O. Rev. 3 in effect at time
                                                  of inspection.
      IC-EW-02, Rev. 3    A1EWFT6904          1. Two dimensions outside of tolerance.
                                              2. Loose conduit fitting at FT-6904.
                                              3. Inspected and accepted to IC-EW-02,
                                                  Rev. O.  Rev. 2 in affect at time
                                                  of inspection.
!    IC-EW-09, Rev. 3    C1EWFT6874          1. Missing clamp east of hanger E.
i
                                              2. Hanger E 17 inches east of sketch
                                                  location.
l                                              3. Hangers A and B attached to existing
'
  .
                                                  support without required engineering
                                                  concurrence.
                                              4. Inspected and accepted to IC-EW-09,
,                                                  Rev. O.  Rev. 3 was in effect at
                                                  time of inspection.
      IC-EW-03, Rev. 3    A1EWFT6854          1. Conduit fittings loose at FT-6854.
                                              2. Flow transmitter loose at base
                                                  plate.
                                              3. One dimension outside of tolerance.
,
      IC-EW-04, Rev. 2    C1EWFT6873          1. Five dimensions outside of tolerance.
      IC-EW-05, Rev. 2    B1EWFT6864          1. Hanger B attached to existing support
i
                                                  without required engineering
                                                  concurrence.
                                              2. Conduit fitting loose at FT-6864.
      IC-CC-22, Rev. 5    CICGFT4522          1. Three dimensions outside of tolerance.
I
                                        II-39
 
~III. MECHANICAL CONSTRUCTION
      A.  Objective
        The~ objective of the appraisal of mechanical construction was to
        determine if the installed and Quality Control (QC) accepted mechanical
          items conformed to engineering design, regulatory requirements and
          licensee commitments.
      B. Discussion
        The specific areas of mechanical construction evaluated were piping,
        pipe supports / restraints, concrete expansion anchors, mechanical
        equipment, and heating, ventilating and air conditioning (HVAC)
        systems. To accomplish the above objective, a field inspection of a
        sample of QC~ accepted hardware was performed in each arec. In
        addition, certain programs, procedures'and documentation were reviewed
        as required to support or clarify hardware inspection findings.
        1.    Piping
        a.    Inspection Scope
              Piping depicted on the sixteen Bechtel isometric drawings listed in
              Tabe III-1 was inspected by the NRC CAT.    Approximately 140 feet of
              2 inch diameter and smaller. piping, and approximately 1680 feet of
              greater than 2 inch diameter piping, which had previously been
              accepted by Ebasco QC, was inspected.    The inspection sample
              included piping located in the Unit 1 Reactor Containment Building
              (RCB), the Mechanical and Electrical Auxiliary Building (MEAB), the
              Fuel Handling Building (FHB), and the Diesel Generator Building
              (DGB); the~ Unit 2 MEAB; and the Essential Cooling Water structure.
              Piping sizes ranged from 3/4 inch to 30 inches and pipe classifi-
              cations were ASME 1, 2 and 3. Attributes inspected included
              configuration (component orientation and dimensions), component
              locations and types, valve operator orientations, clearances,
              flanged joints (gasketing, bolting material, proper makeup), and
              hydrostatic testing. In addition, site construction practices were
              observ.ed.
              As identified in Table III-1,'six of the piping isometrics included
              in the NRC CAT inspection sample had been walked down for turnover
              to the Houston Light and Power (HL&P) Startup organization, for
              flushing and hydro-testing in accordance with Ebasco Quality
              Control Procedures (QCP) 10.14. One piping isometric included
              piping which had been hydrostatically tested. The h3 Jro-test
              documentation package was also reviewed.
              Verification of installations in accordance with current design
              change documents were also selectively examined for the sixteen
              piping isometric drawings, involving 28 design change documents
              including Design Change Notices (DCN), Field Change Notices (FCN),
              and Field Change Requests (FCR), as listed by Section VII, Table
              VII-78.
                                          III-1
 
  The NRC CAT inspectors reviewed, and discussed with responsible
  inspectors and engineers the execution of the following procedures
  related to final walkdown inspections and engineering reconciliation
  of as-built conditions, developed to meet the requirements of IE
  Bulletin 79-14, " Seismic Analysis for As-Built Safety-Related Piping
  Systems."
      Ebasco QCP-10.14, Rev. 3, " System / Subsystem Walkdown Inspection"
      Standard Site Procedure (SSP) -34, Rev. 0, " Technical Requirements
      and Walkdown Procedure for As-Building of Piping Systems"
    -SSP-39, Rev. 0, " Engineering Procedure for As-Built Reconciliation
      of Safety-Related Piping Systems and Associated Pipe Supports"
  The following documents provided the acceptance criteria and
  background .information for the NRC ' CAT inspection:
      Bechtel Specification, 5A010PS002, Rev. 7, " Piping Erection and
      Field Fabrication"
      Bechtel Specification, SL019PS004, Rev. 8, " Criteria for Piping
      Design"
      Bechtel Specification, 4UO10PS007, Rev. 6, " Pre-service and
      In-Service Inspection"
      Ebasco Construction Site Procedure, CSP-16, Rev. 5, " Piping
      Installation Procedure"
.
  * Ebasco Construction Site Procedure, CSP-17,'Rev. 4, " Hydrostatic
    and Pneumatic Testing"
    Ebasco Construction Site Procedure, CSP-22, Rev.~3, " Valve / Pump
    Work"
  * Ebasco Quality Control Procedure, QCP-9.1, Rev. 6, " Weld
    Inspection ASME"
    Ebasco Quality Control Procedtre, QCP-10.11, Rev. 5, " Mechanical
    Equipment Installation Inspection"
    Ebasco Quality Control Procedure, QCP-10.14, Rev. 3,
    " System / Subsystem Walkdown Inspection"
    Ebasco Quality Control. Procedure, QCP-11.1, Rev. 4, " Hydrostatic
    and Pneumatic Pressure Test Inspection"
  In addition. the NRC CAT inspection included observation of the
  modificatio, of Unit 1 Reactor Coolant Piping by Westinghouse
  Construction in accordance with Westinghouse traveller T-TGX-059.
  This modification involving Fast Response RTD's was accomplished
  under a Westinghouse Field Change Notice (FCN).
                              III-2
 
e
  b.  Inspection Findings
      NRC CAT inspections associated with specific piping isometric
      drawings are listed in. Table III-1. In general, piping conformed to
      design aid procedural requirements. However, several deficiencies
      were identified.
      On six lugged wafer valves. in the Unit 1 Essential Cooling Water
      System (EW-0016, 0019, 0052, 0055, 0089, and 0092), the hex-head
      cap screws in the flange-to-valve joints were determined through
      ultrasonic testing (UT) to be shorter than required by the asso -
      ciated isometric-drawing and bill of materials, reducing thread
      engagement in several locations to less than one-half bolt diameter.
      Licensee and NRC CAT inspectors subsequently performed a physical
      verification for the six lugged wafer valves, resulting in a con-
      firmation of the UT findings. In a number of other installations of
              ~
      this type of valve in Unit 1, hex-head cap screws have been substi-
      tuted for threaded studs and nuts, without appropriate changes to
      the isometric drawing and/or bill of materials. In addition, the
      applicable Ebasco inspection procedure, QCP-10.11, does not require
      verification or documentation of the length of headed bolts used in
      assembly of bolted flange connections. Thus, the bolt length in
      lugged wafer valves installed with hex-head cap screws (in place of
      studs) is currently indeterminate, and based on NRC CAT findings,
      are likely to be incorrect. A Nonconformance Report (NCR CM-03068)
    was initiated to disposition the first valve found with unauthorized
      substitution of cap screws for studs. Standard. Deficiency Reports
      (SDR E-353 and -354) were initiated to evaluate the extent of the
    construction deficiency and the inspection procedure deficiency. A
    Deficiency Evaluation Report (DER 85-057) was also initiated to      '
    evaluate the reportability of this-deficiency.
    Undersize socket weld fillets were found on twelve of the thirty QC
    accepted field welds on isometric 4C369PCV417, SH. A02 for 2 inch
    Schedule 160 pipe fittings. During the NRC CAT inspection, a
    Nonconformance Report (NCR CP-03139) was issued to disposition
    the undersize welds. This deficiency is discussed in more detail
    in Section IV of this report.
    Two Annubar flow probe mounting flanges on isometric 3M369 PEW 229
    Sh. 18, were mislocated with respect to the distance from the pipe.
    outer wall, based on the installation dimensions supplied by the
    vendor. However, these probes were located within the field piping
    erection tolerances provided in Bechtel Specification 5A010PS002.
    There are 33 such installations in the Essential Cooling Water,
    Component Cooling Water, and Chilled Water Systems. After discus-
    sions between Bechtel and the vendor to determine the extent to
    which these tolerances could be relaxed, Nonconformance Reports (NCR
    SJ-3008 and -3111) were initiated to rework the seven Annubar
    mounting flanges which did not meet the relaxed installation
    tolerance. A Deficiency Evaluation Form (DEF 85-80) was initiated
    to determine if field installation tolerances may impact other
    unspecified installation tolerances for vendor supplied pipe mounted
    instrumentation.
                                III-3
 
      At several locations on the support columns for Unit 1 steam genera-
      tors, the NRC CAT inspection noted zero clearance to steel work
      platform supports. A Nonconformance Report NCR BC-03193 was
        initiated. In a number of locations, piping exhibited zero or very
      small (less than 1/2 inch) clearance to adjacent components and
      structures. A further discussion of this issue is contained in
      paragraph III.B.2.b below.
      The NRC CAT inspectors considered the procedures related to final
      system walkdown inspections and engineering reconciliation of
      as-built conditions to meet IE Bulletin 79-14 requirements, to be
      thorough and well written. Responsible personnel were
      knowledgeable of requirements and responsibilities.
      No prcblems were noted in the inspected hydro-test packages or in
      the implementation of design. change documents.
  c.  Conclusions
    ' Piping was found generally to conform to design documents. However,
      the improper flange bolting on lugged wafer valves indicates impro-
      per documentation / control of hardware changes and inadequate proce-
      dures and inspection effort for bolted joint makeup. The Annubar
      flow probe installation criteria deficiency indicates a design
      error, which requires resolution by engineering.
  2.  Pipe Supports / Restraints
  a.  Inspection Scope
      Thirty-two ASME Class 1, 2 and 3 supports / restraints which
      represented a variety of types, sizes, systems and locations were
      selected for detailed inspection. As a result of the licensee's
      Pre-CAT inspection performed earlier this year, the basic support /
      restraint inspection program was revised and previously accepted
      hardware was subjected to a reinspection for many attributes. The      ,
      sample selected by the NRC CAT included ten that had been through      l
      the reinspection program and 22 that had been QC accepted under the
      new inspection criteria. These supports / restraints were inspected
      for proper configuration, clearances, member size, location, weld
      size, fasteners, expansion anchor installation and damage. See
      Table III-2 for a listing of the inspection sample.
:    Documentation packages for five of the inspected supports /
l    restraints were examined for completeness, accuracy, and conformance
      to procedural requirements. The Field implementation of seven
      Field Change Requests (FCRs), four Field Change Notices (FCNs) and
      one Nonconformance Report (NCR) applicable to the inspected hard-
      ware were also inspected. See Section VII, Table VII-78.
      Acceptance criteria for the above described inspections were
      contained in the following documents:
      * Bechtel Construction Specification SL340JS1002, Rev. 7, SCN
          24, " Pipe Support Field Fabrication and Installation"
                                  III-4
t
 
    * Ebasco Construction Site Procedure (CSP) 7, Rev. 5, ICP 4, " Pipe
        Support Installation"
    * Bechtel Work Plan Procedure / Quality Control Instruction (WPP/QCI)
      23, Rev. 6, " Fabrication and Furnishing Pipe Support Items"
      Ebasco Quality Control Procedure (QCP) 10.12, Rev. 4, " Component
      Support Fabrication and Installation Inspection"
    * Applicable design drawings and change documents
b.  Inspection Findings
    At the time of the CAT inspection, of the approximately 9,000 ASME
    pipe supports / restraints to~be installed in Unit 1 and common
    systems, approximately 1200 had been QC accepted. Approximately 500
    had been accepted under the revised inspection program and 700 had
    been previously accepted and reinspected to the new criteria by
    retrained inspectors. A review'of the licensee's Pre-CAT
    inspection report indicated a thorough study of pipe supports /
    restraints. Improvements in specifications, procedures and person-
    nel training were implemented and reinspections performed as
    required.
    Discrepancies were noted on seven of the 32 supports / restraints
    inspected by the NRC CAT. Discrepancies included out of tolerance
    angularity of a strut and a restraint brace member, undersized /
    missing welds (two supports), undersized U-strap restraint, improper
    expansion anchor embedment and an oversized spacer plate installed
    that could have decreased support capacity. With the exception of
    the undersized U-strap, the discrepancies were not a major concern
    from a structural integrity standpoint although they were items.that
    should have been identified by QC during the inspection / reinspection
    process. In addition,- conditions were noted on several installa-
    tions relating to unclear criteria and/or work control.
    Restraint SI-9106-HL5009 consisted of a pipe clamp with welded lugs
    restraining the pipe laterally in a box frame. However, the ears
    of the pipe clamp were only about 3/8 inch from the horizontal
    members of the box frame. The construction specification allowed a
    1/2 inch tolerance on clearances in the unrestrained direction. As
    no clearance in the unrestrained direction was specified on this
    drawing, it was not clear what was acceptable in this situation.
    The following actions were taken as a result of the NRC CAT inspec-
    tion findings: A change to the specification was issued to provide
    a tolerance on the installation of the pipe clamp for this type of
    configuration; a drawing review by engineering identified 47
    restraints of this design including 11 that could still have
    potential interference due to thermal or seismic movement (including
  .four that had previously been QC accepted); nonconformance reports
  were issued to provide for reinspection of the four supports and
    Design Change Notices (DCNs) were issued to specify the necessary
    clearance on the remaining seven.
                              III-5
 
                      .
      A temporary hanger for a 30 inch pipe had been welded to support
      EW-9406-HL5001.    Although the installation of this temporary support
      was specified on a Request for Conditional Release form and a
      Startup Work Request (SWR), the only reference to removal was a note
      on the installation sketch. The NRC CAT inspectors consider that a
      more formal method of control is warranted with at least an
      inspection signature that the temporary support has been removed.
    ~The inspector notes that this is a programmatic issue and that in
      this case the temporary support would most likely have been removed
      and system walkdowns should identify ~this type of oversight if left
      installed.
      A large number of potential or actual interferences u e observed.
      during inspection by the NRC CAT, between piping, supports /
      restraints and other hardware, and installation and inspection
      criteria for this attribute did not appear to be adequate. It was
      determined that this issue had been identified months earlier by an
      INPO evaluation and had been reported to Region IV pursuant to 10
      CFR 50.55(e). Although a program to address this concern has been
      developed, it has not yet been' implemented. More aggressive and
      timely action to provide craft and QC with acceptance criteria
      is warranted.
      After identification of the undersize (under capacity) U-strap on
      restraint SI-9118-HL5009 the NRC CAT inspector selected and
      examined ten additional restraints that had heavy duty U-straps
      specified on the drawing. All were found to have the correct
    material installed.
    The NRC CAT inspector noted two large (1500 pounds each) air
    operated valves on a three inch diameter Safety Injection line
      (SI-1117) in a high traffic area that were not supported, were
    visibly leaning and could easily be moved by hand. This was
    questioned by the inspector. Although not considered required by
    Bechtel site engineering, temporary supports were installed on these
    valve operators and installation of the permanent' designed supports
    was initiated.
    The change documents associated with the supports / restraints
      inspected had all been properly implemented and closed out.      No
    problems were noted in the documentation packages reviewed.
    See Table III-3 for a summary of inspection observations.
  c. Conclusions
    In general, pipe support / restraints were found to be installed in
    accordance with drawing, design change and procedural requirements.
    However, due to the one undersized U-strap and number of other
    discrepancies noted, it appears that further improvement by craft
    and QC in attention to detail is required. Also, improved controls
    for the installation and removal of temporary supports is warranted.
                                  III-6
.                      .                                .        -.
 
    3.  Concrete Expansion Anchors
    a.  Inspection Scope
        Fifty-six concrete expansion anchors (CEAs) on 12 pipe
        supportshestraints and 97 CEAs on 17 HVAC supports were inspected
        in detail.      Inspection attributes included length, marking,
        embedment, spacing, edge distance, damage, angularity and residual
        torque. In addition, the CEAs on pipe' supports were verified to be
        the proper length by ultrasonic testing (UT). Various systems,
        sizes, and locations were included in the anchor sample. Table
        III-4 provides a listing of the anchors inspected. Anchors were
        torqued to the designer specified test torques which were 70% of
        minimum installation torques.
        Seven FCRs, four NCRs and one DCN related to expansion anchors
        were inspected for conformance to as-built conditions.      See Section
        VII, Table VII-78.
        Acceptance criteria for these field inspections were contained in
        the following. documents:
            Bechtel Construction Specification 5A010SS1000, Rev. 7,
            " Installation of Expansion Anchors, Rock Bolts, Grouted Anchor
            Bolts, and Core Drilling"
            Bechtel Construction Specification SL340JS1002, " Pipe
            Support Field Fabrication and Installation"
                                                                      "
  .    * Ebasco CSP-41, Rev. 6, " Installation of Expansion Type Anchors"      -
        * Ebasco CQP 10.19, Rev. 7, " Inspection of Anchoring Devices
            Installed Within Concrete Structures"
        "
            Applicable design drawings and change documents
    b.  Inspection Findings
        Nut rotation at test torque or less was observed on approximately
        20 of the 153 CEAs tested and most turned very close to the test
        torque value. Only one anchor took as much a one turn to achieve
        minimum installation torque. Only one anchor was determined to
        have less than the specified embedment (on pipe-support
        EW-1329-HL5001) although many were at the exact minimum and many
        had been previously identified by QC as not meeting original
        specifications and were dispositioned by FCR or NCR. During the
        NRC CAT's inspection of pipe supports / restraints and mechanical
        equipment several cases of CEAs with out of tolerance embedment and
        anchor to concrete edge distances were identified. Other attri-
        butes were within design tolerances or had been previously identi-
,      fied and dispositioned by engineering. The FCRs, NCRs and DCNs were
        verified as being acceptably implemented.
l
                                    III-7
 
  -_
        See Section-V.B.4.b (Civil / Structural) for a discussion of qualifi-
        cation testing and other design aspects of the concrete expansion
        anchor program at STP.
    c.  Conclusions
        Generally with the exception ~of minor deficiencies as noted above, the
-
        concrete expansion anchors for pipe supports / restraints and HVAC
        supports were installed and inspected in accordance with design and
        procedural requirements.
    4.  Mechanical Equipment
    a.  Inspection Scope
        Twelve pieces of mechanical equipment including six HVAC mechanical
        components which are part of the STP's equipment specification, five
        ASME pumps, and one ASME tank were inspected for conformance to
        design and procedural requirements.      In addition the insertion of a
        Roto-lock reactor vessel stud insert (#35) in the Unit I vessel was
        observed.
        The installation documentation for the inspected equipment was
        examined and the process control and QC verification documentation
        for assembly of the Unit I reactor vessel upper internals by
        Westinghouse Construction was also reviewed.      Table III-5 provides
        a listing of the mechanical equipment inspection sample.
        The following documents provided the acceptance criteria and
        background information for the NRC CAT inspection:
          Bechtel Specification 4C1195S1008, Rev. 2, " Reactor Coolant System
          Component Supports and Other NF Steel Items"
        * Ebasco CSP-22, Rev. 3, ICP-1, " Valve / Pump Work"
        * Ebasco CSP-2, Rev. 4, ICP-5, " Installation of Permanent Electrical
          and Mechanical Plant Equipment"
          Ebasco SSP-24, Rev. O, " Disassembly / Reassembly of Safety and
          Non-Safety Related Valves"
          Ebasco QCP-10.11, Rev. 4, PCR-5, " Mechanical Equipment Installation
          Inspection"
          Ebasco QCP-9.1, Rev. 6, " Weld Inspection ASME"
        * Bechtel Drawing 3A01-0-C-0010, " Concrete Standard Details-Embedded
          Plates-Misc. Supports"
        * Bechtel Drawing 3A01-0-C-0012, " Concrete Standard Details-Embedded
          Plates-Misc. Supports"
        * Applicable design drawings, vendor technical manual and drawings.
l
[
                                  III-8
1
 
b.  Inspection Findings
    Discrepancies were noted on most of the mechanical equipment
    installations examined by.the NRC CAT inspectors. Programmatic /
    procedural weaknesses as well as inadequate QC inspection are of
    concern.
    The discrepancies listed below were noted in the reassembly of
    the following Unit 1 pumps; Containment Spray (CS) pump B, Low Head
    Safety In.jection (LHSI) pump B, and High Head Safety Injection
    (HHSI) pump 8:
    * Fasteners installed for bolting the motor stand to the motor and
      the motor stand to the foundation were of various material types
      or were unmarked. Washers specified for the motor stand to motor
      connections were missing. These installations had been accepted
      by QC and the joints sealed with " torque seal". Refer to Section
      VI, Material Traceabil'ty and Control, for further discussion of
      this concern.
      Although the process control sheet referred to the vendor manual,
      which required installation of new 0-rings, the old 0-rings were
      reinstalled.
      Although the applicable construction procedure, CSP-22, requires
      bagging of fasteners and small parts, disassembled fasteners -from
      the pump-motor couplings were observed stacked on the pumps
      and pump flange fasteners were observed scattered on the floor,
      and the QC inspector involved with the pump work was unaware of
      the bagging requirement.
    Discrepancies noted on four of the six mechanical equipment HVAC
    components inspected, included missing and undersize welds,
    unshimmed foundations, backed off foundation mounting nuts, improper
    concrete expansion anchor embedment and spacing to concrete cored
    holes, attachment welding to edge of embedment in possible violation
    of structural drawing requirements, damage, and support bracing that
    did not conform dimensionally to design. The current site program
    for inspecting non-ASME equipment does not provide for inspection of
    equipment support configuration dimensions etc. Based on a review
    of structural drawings 3A01-0-C-0010 and 3A01-0-C-0012 and discus-
    sions with pipe support and mechanical equipment QC inspectors it
    was apparent that the design requirements for welding near the edge
    of embedded plates was not clearly delineated. Site engineering
  . committed to evaluation of existing criteria and revising drawings
    and retraining inspectors as required.
    On the Reactor Water Make-up Tank the NRC CAT inspectors found that
    a design specified ring of cushion material (Flexcell) had been
    removed after QC acceptance of the tank installation. The tank
    mounting flange was in contact with the concrete floor at some
    locations and had more than a one inch gap at others. At the time
    of the inspection the tank was partially filled with water for
    flushing operations. The licensee was unable to provide evidence
    that formal documentation and/or controls existed to identify,
                              III-9
 
  track and restore the installation of the tank to design require-
  ments. At the request of the NRC CAT inspectors the licensee agreed
  to perform the following actions:
  * Determine the nature and distribution of the remaining
      cushion material and other sandy material under the tank.
      Evaluate the activities related to removal (and eventual
      replacement) of the cushion material.
  * Evaluate the stresses imposed on the tank due to loading the
      tank with the existing gaps around the foundation.
  During the NRC CAT inspection of piping it_was noted that vendor
  assembled piping spool flanges on Diesel Generator 1A had been
  disconnected, apparently to facilitate the installation of an
  adjacent field installed expansion joint. There was no documenta-
  tion authorizing this disassembly as required per QCP 10.27. During
t
  the course of this inspection these joints were remade, apparently
  to eliminate leakage during testing, again without authorization or
  control / documentation of proper joint makeup.  A Procedure Violation
  Notification (M-17) was initiated to address this problem.
  During the observation of the installation of the Roto-lock insert,
  it was observea that a case of Molycote 505 anti-seize lubricant,
  which is no longer recommende~d by Westinghouse for nuclear-
  applications (Westinghouse letter DL-82-01 and WCAP-9464, 1979),
  had been requisitioned and delivered to the reactor vessel flanga
  area. However, Ebasco personnel did use a recommended lubricant
  and the 1%tAe :etete rmined unopened. The Molycote was
  removed and NCR BN-03021 was initiated. The Inspectors note that
  the installation traveler for the RHR pumps listed as an acceptable
  lubricant FEL PRO N1000, whic- is . iso on the Westinghouse "not
  recommended" list. Again a .aeck of installation records indicated
  that an approved lubricant 'nd been used on the RHR pumps.    However,
  it appears that additional .ittention to ensure control and use of
  approved lubricants is we ranted.
  On RHR pumps A and C, the construction process sheet (CPS) specifies
  as sequencing step 1 the installation of the pump supports per the
  vendor manual and drawing 3C01-9-S-1600. This is checked in the CPS
  column for " work sequence installation" as a prerequisite step to
  pump and motor installation. A QC HOLD point was not specifici.
  Subsequent steps of the CPS had been completed including machin.ng
  and leveling of the pump feet and support pads to a precise.0.00z
  inch tolerance. However, the ASME Equipment Support Checklist used
  in conjunction with the CPS, indicated that the torquing of the pump
  support foundation bolts had not yet been performed. The condition
  was considered acceptable based on the engineering response that
  the pump had not been accepted for levelness and location, nor had
  the pump alignment been performed. However, as the RHR pump instal-
  lation is still in progress, it appears that specific sequence
  requirements of the CPS should have been more clearly controlled
  with the review of exceptions taken to an intended prerequisite
  appropriately documented prior to completing subsequent work steps to
                            III-10
 
<
        ensure that leveling during subsequent torquing of foundation
        bolting is not degraded.
        It should be noted that the installation of the lugged wafer valves
        with the fastener control problems previously discussed in the
        piping section of this report was under the control of the
        mechanical equipment installation program and the valves were
        inspected by mechanical equipment inspectors.
        No problems were identified during the review of reactor vessel
        upper internal installation documentation.
        Table III-5 provides a number of NRC CAT observations for the
        mechanical equipment items inspected.
    c. Conclusions
        Significant deficiencies were noted in regard to mechanical
        equipment installation. A lack of attention to detail by craft and
        QC inspators was apparent. Programmatic / procedural weaknesses
        regarding control and documentation of bolting activities, lubri-
        cants, inspection of non-ASME equipment support framework, and
        acceptance criteria for location of attachments to embedded plates
        was also apparent.
        Licensee action is necessary in areas of mechanical equipment
        installation to provide assurance'that hardware is installed and
        inspected in accordance with design and procedural requirements.
        Subsequent rework activities must be controlled, documented and
        provide for QC reverification of hardware acceptability.
  5. Heating, Ventilating and Air Conditioning (HVAC)
    a. Inspection Scope
        Fifteen HVAC seismic supports / restraints, forty-seven duct sections,
        and five fire-dampers were selected from both Units 1 and 2 at
        random and inspected in detail.
        The supports / restraints were inspected for location, configuration,
        member size, weld size and connection details. Duct sections and
        fire dampers were examined for proper configuration, companion angle
        size, joint make-up and free operation of fire dampers.
        In addition, adjacent HVAC hardware, including approximately 20 other
        HVAC supports / restraints, 25 duct sections, and 10 dampers was
        observed at random for the following attributes: loose or missing
        fasteners, joint makeup, improper clearances or angularity,
        disassembled, and damaged items.
        Ten Field Change Requests (FCR) associated with the NRC CAT HVAC
        hardware samples were verified for conformance to as-built
        conditions. Also, twenty-four construction traveler packages were
        reviewed for completeness and accuracy.
                                  III-11
 
      Acceptance criteria for these field inspections were contained in
        the following documents:
        *
              Bechtel Specification SV279VS1003, Rev. 5. " Installation
              of Safety Class and Non-Safety Class HVAC Equipment and Duct
              Work."
      *
              Bechtel Specification 3V279VS1000, Rev. 8, " Safety Class
              HVAC Duct-Work Fabrication."~
      *
              Ebasco Procedure CSP-6, Rev. 4, " Installation of HVAC Duct
              Hangers and Equipment klangers."
      *
              Ebasco Procedure CSP-9, Rev. 4, " Inspection of Duct and
              Duct Accessories."
      *
              Ebasco Procedure CSP-95, Rev. 2, " General Welding Requirements
              for HVAC."
      *
              Bechtel Procedure QCP-10.21, Rev. 5, "HVAC/ DUCT / HANGER
              Installation Inspection."
      *
              pplicable Duct Support / Restraint and Layout Drawings.
  -b.  Inspection Findings
      Approximately 39 percent of the seismic supports, 22 percent of
      the duct sections, and 9 percent of the fire dampers had been QC
      accepted by Ebasco at the time of the NRC CAT inspection. During
      the inspection by the NRC CAT, workmanship appeared to~be good and
      no installation deficiencies were found for HVAC hardware (supports,
      . duct sections, and fire dampers). However, during the observation
      of adjacent HVAC hardware, QC accepted tornado damper number
      3V11V0A0302 was'found installed upside down. This apparent isolated
      case of questionable. installation was subsequently dispositioned
      "use-as-is" by Bechtel Engineering on NCR BH-03037.
      Ten " Field Change Requests" (FCR) associated with the HVAC hardware
      inspected were reviewed and found to conform to the as-built condi-
      tion.    See Section VII, Table VII-78.
      The NRC CAT was informed of an reinspection program under
      " Deficiency Evaluation Report (DER 85-031) conducted by Ebasco QC
      for direct attachment welds and expansion anchor bolt / base plate
      installation. During the inspection of HVAC supports the NRC CAT
      did not observe weld attachment discrepancies as described in
      DER-031.
      Six of the twenty-four " construction traveler packages" reviewed by
,
      the NRC CAT for completeness and accuracy, were noted to have
      documentation omissions on the " Construction Cover Sheet" (Form
'
      CS-AD-852). A Standard Deficiency Report (SDR) was subsequently
      issued by the licensee to Construction (SDR E-350) and to Quality
      Control (SDR E-351) to prevent the recurrence of these deficien-
      cies.
.
!                                III-12
 
      -    _.
        --
    .
                c.  Conclusions
                  .HVAC safety related support / restraints, duct sections, and fire
                  .
            ,        dampers conformed to design and procedural requirements.  More
                    attention to the review of documentation is required to ensure
                    completeness and accuracy of the construction traveler packages.
  ,
                                                                                      9
              *
                  4              ,
i
i                                                                                      '
.
!
;
i
I
,
                                            III-13
 
                                    TABLE III-1
                    PIPING IhSPECTION SAMPLE AND OBSERVATIONS
Isometric        Diameter
  (Note 1)      (Inches)        Class      Notes        Observations
2C369PAF402      6, 8                2              None
.Sh. 01, Rev. 3
~2C369PCV417          4              2        -
                                                      Clearance to hanger
Sh. 03, Rev. 2
2M369PRH259          8              2        2, 4  Deficient ISI prep (NCR
Sh. 02, Rev. 2-                                      SP-03152)
3M369 PEW 229 . 6, 8                3        2, 4  Annubar flow probe mounting
Sh. 18, Rev. 0  10, 30                              flange (NCR SJ-03008 & 03111)
3M369PRM263    4, 6                3        2, 4  Broken flex conduit
Sh. 03, Rev. 4                                      (SWR-01921)
3Y361 PEW 729  3, 24, 30            3        2    None
Sh. 03, Rev. 3
4C369PCV417'        2              2        4      Undersize socket welds (NCR
SH. A02, Rev. 4                                      CP-03139, SDR E-349 DER 85-049)
4C369PCC407      16                2        2, 4  Luggedwafervalvebbiting(NCR
SH. 34, Rev. 3                                      NCR CM-03068, SDR E-353
                                                      & -354, DER 85-057)
                                                      Uncapped MOV housing.  (Main-
                                                      tenance Discrepancy MD 1-0868)
4C369PRC457      3/4, 2            1, 2        -
                                                      Only partially inspected
SH. A06, Rev. 4                                      during CAT.  Reviewed hydro-
                                                      test records.
                                                      3/32" saw-cut in coupling
4C369PRH459      4, 12            1, 2        -
                                                      Masking tape on pipe.
Sh. 04, Rev. 6                                        Uncapped opening
SD369 PEW 329    4, 6, 10            3        2      Broken temperature probe.
Sh. 01, Rev. 1
SD369 PEW 329    4, 6, 10            3        4      Valve reversed and handle
Sh. 03, Rev. 1                                        blocked (NCR SP-03148)
                                      III-14
                                                                              _ - _ - _ _ _ _ _ .
 
                                                                                  _ _ _ _ . _____ __ __ - -
  .
                                      TABLE III-1 - (Continued)
                              PIPING INSPECTION SAMPLE AND OBSERVATIONS
    -Isometric              Diameter
      (Note 1)-              (Inches)        Class    Notes            Observations
    SD369 PEW 329          4, 10              3        -
                                                                  Clearance to support
    SH._04, Rev. 1
                                                                  Wood blocking
    50369 PEW 329          4, 6, 10          3        -
                                                                .None.
    SH. 06, Rev. 1
    SF369PFC530            4, 10, 20          3        -
                                                                  None
    SH. 04, Rev. 4
    5M369PCC207            14, 20            3        3        No gaskets on temporary
    Sh. 10, Rev. 4                                                flange assembly (poor
                                                                  construction practice)
    Notes
    1.    Letter in second position of isometric drawing number
          identifies pipe location.
                                          "
                  C = RCB
                  M = MEAB
                  Y.= Yard (Essential Cooling Water Intake Building)
2                0 = DGB                                                                                    '
                  F = FHB.
    2.    This isometric had been walked-down in accordance with Ebasco QCP-10.14,
          and turned over to HL&P Startup for flushing and hydro-testing.
    3.    All isometrics are Unit 1 except SM369PCC207
    4.    HL&P and Ebasco discrepancy reports are a result of NRC CAT observations
          and are shown in parentheses ( ).
                                                III-15
 
  _                                                                    _ _ - - . - - - - - - _ - - - - - - - - - - - - - _ _ _      _ _
7_
                                            TA8LE III-2-
                            PIPE SUPPORT / RESTRAINT' INSPECTION SAMPLE
        Support / Restraint                      .
                                                                                                                                ASME
              Number            M          (Inches)-      Location (1)                                                        Class
      .RH-9215-HL5004 (2)-      Strut        8                C                                                                2
      -SI-9105-RR0031 (2)      Strut        8                C                                                                2
        CC-9105-HL5007 (2)-      Strut        16                C                                                                3
        SI-9106-HL5009 (2)      Box          6                C                                                                2
    .
        SI-9105-RR0038 (2)      Box          8                C                                                                2
        RH-9206-HL5006 (2)    ' Strut        8                C                                                                2
        RH-9102-SH0001(2)      Spring        12                C                                                                2
        CC-9426-SH0001          Sprir.g      12                FHB                                                                3
        SI-9102-RH0007          Strut          8                FHB                                                                2
        CC-9427-HL5005          Strut        12                FHB                                                                3
        CC-9427-HL5004          Strut        12                FHB                                                                3
        EW-9406-HL5001 (3)      Strap          3              EWPH                                                                3
        SI-9102-HL5001          Strut          8                FHB                                                                2
        EW-9113-HS5001.(3)      Anchor        2                MAB                                                                3
        EW-9383-HL5001 (3)      Box          10                MAB                                                                3
        EW-9283-HL5001          Box          10                MAB                                                                3
        SI-9117-RR0004          Strut          3                MAB                                                                2
        SI-9118-HL5009 (3)      Strap          6                MAB                                                                2
        EW-9102-HL5001          Strut        30                MAB                                                                  3
        EW-9205-HL5008          Strut          4                MAB                                                                  3
        EW-9102-HL5003 (3)      Strut        30                MAB                                                                  3
        EW-9202-HL5001          Strut        30                MAB                                                                  3
        RH-9205-HL5011          Box            8                MAB '                                                                2
        RH-9205-HL5001          Box            8                MAB                                                                  2
        SI-9118-RH0011          Strap          6                MAB                                                                  2
                                              III-16
 
                                                                                                            _ _ _ _ _
  e
!                                  -TABLE III-2 - (Continued)
                          PIPE SUPPORT / RESTRAINT INSPECTION SAMPLE
    Support / Restraint                                                      ASME
          Number              Type      (Inches)      location (1)        Class
    RH-9205-HL5009              Box          8              'MAB                              2
    CH-9203-HL5004 (2)          Box          6                EAB                            3
    SI-9337-HF5005 (2)        U-Bolt        2                FHB                        '2
    CV-9032-H15015 (2)        Box            4              MAB                            3
l  CC-9413-GU1004 Unit 2      Strap        4              MAB                              3
    CC-9413-HL5002 Unit 2      Strap          4              MAB                            3
    SI-9201-HL5009            . Strut        12              FHB                            2
    NOTES:
,  (1) C = Containment Bldg.
!
          'FHB = Fuel Handling Bldg.
          EWPH = Essential Service Water Pump House
          MAB = Mechanical Auxiliary Bldg.                                                                ,
          EAB = Electrical Auxiliary Bldg.
    (2) Through licensee reinspection program
l  (3)' Document package reviewed
l
I
l
i
!
                                              III-17
                                                                      . _ _ _ _ _ _ _ _ - _ - _ _ _ _ . -
 
y
                                          TABLE III-3
                      PIPE SUPPORT / RESTRAINT INSPECTION OBSERVATIONS
  Support / Restraint                                    Observations (1)
  SI-9105-RR031                              Strut angularity exceeds tolerance by 4
                                              degrees (NCR CS-3181)
  SI-9106-HL5009                              Minimal clearance between pipe attachment
                                              and support structure in unrestrained
                                              direction (NCR CS-03314)
  ~ SI-9105-RR0038                            Undersize skewed fillet welds (NCR CS-00875)
  RH-9102-SH001                              1/2. inch clearance to adjacent support'
  EW-9406-HL5001                              Temporary support attached
  SI-9118-HL5009                              undersize U-strap installed (NCS CS-3189)
  EW-9102-HL5003                              Three expansion anchors with less than
                                              specified embedment (NCR CS-3182)
  EW-9202-HL5001                              Oversized plate installed but not properly.
                                              documented / evaluated.  (NCR 55-3227)
  CC-9413-HL5002                      *
                                              Missing flare bevel fillet cap weld
      (Unit 2)                              -(NCR CS-03263)
  SI-9201-HL5009                              Brace angle exceeds design' tolerance
                                              (NCR CS-03228)
  NOTE:
  (1) Ebasco NCR issued as a result of the NRC CAT
        observation (s) shown in parentheses.
f
                                            III-18
 
                                                        TABLE III-4
                              CONCRETE EXPANSION ANCHOR INSPECTION SAMPLE AND OBSERVATIONS
                                                Number / Diameter
                                                    (Inches)
                                                    of Anchors
                Support / Restraint                Inspected                  Observations
                  Pipe S/R's:
                CC-9318-HL5002                8 - 3/4
                CC-1317-HL5006                  4 - 1/2
                CC-1317-RR13                    4 - 3/4
                CC-1114-GU19                    4 - 3/4
                CC-1317-HL5001                  4 - 1 1/4
                CC-1428-HL5016                  4 - 3/4
              CV-1006-HL5017                  4-1
              CC-9422-HL5005                  4 - 3/4
              CC-1414-HL5010                  4 - 3/4                  *(One CEA)
*
              CC-1424-HL5004                  4 - 3/4
              CC-1301-HL5002                    8-1
              EW-1329-HL5001                  4 - 1/2                  Embedment violation on
                                                                          one CEA:  3 3/16 actual
                                                                          vs. 3 1/2 required (NCR
                                                                          SS-03264)
              HVAC S/R's:
              1-6-0144-5012                    4 - 3/4
              1-6-0144-S016                    12 - 1/2                  *(Four CEA's)
              1-6-0144-5046        -
                                                3 - 5/8                  *(One CEA)
              1-6-0144-5017                    12 - 1/2                  *(FourCEA's)
              1-6-0144-5019                    16 - 1/2                  *(Eight CEA's)
              1-6-0144-S037                    4 - 3/4
            1-6-065-5045                      4 - 1/2, 4 - 1 1/4
                                                          III-19
  - - - - _ - - _ _
 
7_ _
                                                                                    .. ..
                                                                                          -
                                  TABLE III-4 --(Continued)
                CONCRETE EXPANSION ANCHOR INSPECTION SAMPLE AND OBSERVATIONS
                                    Number / Diameter
                                        (Inches)
                                        of Anchors
    Support / Restraint                Inspected                  Observations
    HVAC S/Rs:                                                                              I
    1-6-0065-5025                  4 - 5/8
    1-6-0065-5075                  4 - 3/4, 3 - 1
    1-6-065-S008'                  2 - 3/4, 2 - 1          *(One CEA)
    1-6-0144-5083                  6 - 1 1/4
    1-6-0128-5083                  8 - 1/2, 4 - 1 1/4      *(Two CEA's)
    1-6-0128-5002                  2 - 3/4
    1-6-0128-S058                  4 - 3/4                  *(Two CEA's)
    * Nut turned at or below torque value but minimum installation torque acbieved
      in less than 1 full additional turn of the nut.                                      ;
                                                                                            ,
                                                                                            .
                                            III-20
 
p--
'
                                                                          TABLE III-5
                                                        MECHANICAL EQUIPMENT SAMPLE AND OBSERVATIONS
                        Equipment (All Unit 1)                                          Observations
                        Reactor Water Makeup Tank                            Alteration to tank foundation configura-
                                                                              tion without proper documentation / control.
                      Containment Spray Pump B                              1.    Incorrect /indeterminant fastener material.
                        Low Head Safety'Injecton Pump B                      2.  0-ring reused when technical manual
                      High Head Safety Injection Pump B                          specified replacement.
                                                                              3. Fasteners not controlled.
                      RHR Pumps A and C                                      Torquing of foundation bolts not completed
      .                                                                      prior to leveling and setup of critical
                                                                              support framing.
                      Charging Pump Supply Cooler-                            One mounting pad not shimmed as required
                                      3V101VAH010                            and damage to flange of foundation beam.
                                                                              (NCR CM-03087).
                      EAB Return Air Fan-3V111VFN002                        1.  Gusset plate welded to edge of embed
                                                                                  exceeding tolerance.
                                                                              2.  Undersize attachment weld.
                                                                              3.  Missing welds on 4 gusset plates.
                                                                              4.  Damage frame member on fan.
                                                                              5.  Notches in bracing not shown on drawing.
                                                                              6.  Bolt hole locations in brace gusset
                                                                                  plates'not per drawing. (NCR CM-3092)
                    Control Room Return Fan -                                None
                                      3V111VFN026
                    MEAB HVAC Chiller - 3V111VCH001                          None
                    Charging Pump Supply Cooler -                            1.  North end of attachment welds 1/16 to
                                      3V101VAH004                                  1/8 inch undersize entire length.
                                                                              2.  Attachment welds to edge of embed
                                                                                  plate violates drawing requirement.
                                                                              3.  Two maxibolts to cored holes in concrete
                                                                                  violate minimum spacing requirements.
                                                                                  (12 1/2 inch required, 5 inch actual)
                                                                              4.  Nut is tight on foundation stud but
                                                                                  is 1/4 inch from mating with contact
                                                                                  surface.  (NCR CM-03091)
i                    Fuel Handling Building Filter                            1.  Undersize unit to embed fillet welds.
l                                      Train-3V121VXV003                      2.  Expansion anchors violate minimum
i                                                                                  spacing to cored holes.
                                                                              3.  Expansion anchors do not have required
                                                                                  embedment.
i
r
                    NOTE:                  Ebasco NCR's generated as a result of the NRC CAT observation (s) shown in
,                                          parenthesis.
l
,
                                                                          III-21
l
I
    .  - _ _ - _ _ - _ _ _ - - _ _ _
 
,-
                                                                                TABLE III-6
                                                                HVAC INSPECTION SAMPLES AND OBSERVATIONS
                                                                          (Supports / Restraints)
                                                                                                    Inspection
                    Support                                Duct.                        ~FCR        Traveler
                    Number                              Size In.    Unit'  Building 1  Review      Reviewed  Observation
                    1-1-0083-S014                          8 dia.    1      RCB        None          Yes        None
                    1-1-0083-S039                        16 dia.    1      RCB        BH-00827      Yes        None
                    1-1-0083-5040                        16 dia.    1      RCB        CH-01546      Yes        None
                    1-1-0083-5046                          8 dia.    1      RCB        BH-00559      Yes        None
                    1-1-0083-5048                        16 dia.    1      RCB        CH-00845      Yes        None
                    1-1-0083-5049                        16 dia.    1      RCB        None          Yes        None
                    1-1-0087-5-004 14x10                            1      RCB        CH-01800      Yes-      None
                    1-6-0143-5016                        30x72      1      EAB        DL-00152W -    Yes        None
                    1-6-0144-5017                        12x12      1      EAB        CH-02181W      Yes      None
                    1-6-0144-5019                        12x12      1      EAB        EAB-314        Yes      None
                    2-6-0050-S033                        14x16    2        EAB        None          Yes    Document
                                                                                                                discrepancies
                                                                                                                on content
                                                                                                                sheet of
                                                                                                                construction
                                                                                                                traveler.
                    2-6-0051-5007                          24x20    2        EAB        None          Yes    Document
                                                                                                                discrepancies
                                                                                                                on content sheet
                                                                                                                of construction
                                                                                                                traveler.
                                                                                                                            .
                                                                                  III-22
._ _ _ _ ______ _ _ _ - ____-_ - _ ___- _ __ - __ _ - -_ _                                                                      _~
 
                                  TABLE III-6 (Continued)
                          HVAC INSPECTION SAMPLES AND OBSERVATIONS
                                    (Supports / Restraints)
                                                                          Inspection
  Support          Duct                                        FCR      Traveler
  Number        ' Size In.  Unit  Building 1                  Review    Reviewed  Observation
  2-6-0124-5003  20x18      2        EAB                      None        Yes    Document        i
                                                                                    discrepancies
                                                                                    on content
                                                                                    sheet of
                                                                                    construction
                                                                                    traveler.
  2-6-0124-S066  22x22      2        EAB                      None        Yes    Document
                                                                                    discrepancies
                                                                                    on content
                                                                                    sheet of
                                                                                    construction
                                                                                    traveler.
  2-6-0125-S005  20x18      2        EAB                      BH-01844    Yes    Document
                                                                                    discrepancies
                                                                                    on cover sheet
                                                                                    of construction
                                                                                    traveler.
    'RCB = Reactor Containment Building
    EAB = Electrical Auxiliary Building
                                                          III-23
--
                                _        _ _ _ _ _ _ _ _
 
,
                                  TABLE III-6 (Continued)
                        HVAC INSPECTION SAMPLES AND OBSERVATIONS
                                      (HVAC Sections)
                                                        Inspection
  -Orawing Number                          FCR          Traveler
  & Duct Sections    Unit    Building 1  Reviewed      Reviewed      Observations
  5-V-14-1-V-          1      RCB        None            None        None
  0083-A-10
  Rev. 5
  HVAC Section Nos.
  P-005 thru P-019
  5-V-14-1-V-          1      RCB        None            None        None
  0083-B-1D
  Rev. 5
  HVAC Section Nos.
  P-101 thru P-114
  5-V-11-1V-            1      EAB        BH-01142        Yes          None
  0144-A-1D                                                (P-011,
  Rev. 0                                                    012, 015,
  HVAC Section Nos.                                        016, 021,
  P-011 thru P-025,                                        and P-025)
  P-027, P-028
    2RCB = Reactor Containment Building
    EAB = Electrical Auxiliary Building
                                          III-24
 
. -
                                  TABLE III-6 (Continued)
                          HVAC INSPECTION SAMPLES AND OBSERVATIONS
                                        (Fire Dampers)
                                                              Inspection
    Drawing      Fire Damper                          FCR    Traveler
    Number          Number      Unit    Building 1 Reviewed  Reviewed  Observations
    5-V-11-1-V-    FF-01          1        EAB        None        No    None
    065-A-ID,
    Rev. 4
                    FF-04          1        EAB        None      No    None
    5-V-11-1-V-    FF-319        1        EAB        None      Yes    None
    0128-A-ID
    Rev. 3
                    FF-320        1        EAB        None      Yes    None
                    FF-321        1      EAB        None      Yes    None
    IRCB = Reactor Containment Building
      EAB = Electrical Auxiliary Building
                                      .
                                            III-25
 
  _ _ - _ _ _ - _ - _ _ _ _ _ _          _ _ _ _ _ _ _ _ _ _ _ _ _ _ - _ - - _ _ _ _ _ _ _ _ _ _              __ _______ __ _. _ _ _ - _ _ . - _ - _ - _ _ _ - _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ -
                                IV. WELDING AND NONDESTRUCTIVE EXAMINATION
                                    A.  Objective
                                        The objective of the appraisal of welding and nondestructive examination
                                        (NDE) was to determine if Quality Control accepted work related to
                                      welding and NDE activities was controlled and performed in accordance
                                      with design requirements, Safety Analysis Report commitments, and
                                        applicable codes and specifications.
                                      An additional objective was to determine if personnel involved in
                                      welding and NDE activities were trained and qualified in accordance
                                      with established performance standards and applicable code
                                        requirements.
                                    B. Discussion
                                      To accomplish the above objectives; welds and welding details for
                                      piping; pipe supports /retraints; field and shop fabricated tanks;
                                      structural steel installations; heating, ventilating and air condition-
                                        ing (HVAC) installations; electrical supports; and instrumentation
                                      control tubing and supports were inspected. The inspected welds were
                                      selected to provide a representative sample of the applicant's
                                      contractor welding activities in terms of welding processes used,
                                      materials welded and existing weld-joint configurations. Considera-
                                      tions such as physical location, difficulty of welding and limited
                                      accessibility were also used in sample selection. Design changes
                                      related to welding such as increase or decrease of weld sizes and a
                                      change from one welding process or procedure to another welding process
                                      or procedure were also reviewed for technical adequacy and
                                      implementation.
                                      NDE activities were appraised through the review of radiographs for
                                      both field and vendor fabricated welds, the review of NDE procedures
                                      and personnel qualifications, the inspection of the calibration status
                                      of NDE equipment and the witnessing of in process NDE activities. The
                                      NRC construction assessment team (CAT) inspectors reviewed a sample of
                                      radiographic film in final storage in the vault of the licensee's
                                      facility.                                      In addition, a sample of NDE documentation was requested for
                                      review which was stored by the Nuclear Steam System Supplier,
                                      Westinghouse and was not yet transmitted to the licensee.
                                      During the inspection of structural welds in the pipe supports' area,
                                      the NRC Construction Appraisal Team (CAT) identified welds which did
                                      not meet the weld size requirements specified by the Architect Engineer,
                                      Bechtel Power Corporation (Bechtel). Undersized socket welds were also
                                      identified in 2 inch schedule 160 piping spools. Some undersized weld
                                      reinforcements were also found in nozzle to shell joints (ASME Code
                                      Category D Joints) on tanks and heat exchangers. A detailed discussion
                                      concerning these welds is included later in this section.
                                      In the area of NDE, the NRC CAT inspectors reviewed. film for field and
                                      shop fabricated pipe welds, film involving equipment and hardware
                                      supplied under the Westinghouse (NSSS) scope of supply and film supplied
                                      by various vendors and contractors for the balance of plant.
                                                                                                          IV-1
.
 
                                                                          !
                                                                          l
                                                                          l
A relatively small number of deficiencies were found in the reviewed
sample of radiographs. However, in the area of NDE documentation,
with the exception of the Westinghouse file, the team encountered
difficulties in establishing the number of NDE vendors and suppliers.
The inspectors also observed that in general the project has difficul-
ties in identifying existence and location of film and documentation
related to the balance of plant suppliers. For equipment and hardware
supplied under the NSSS scope of supply the licensee has instituted a
program in which, Westinghouse is required, to submit monthly reports
identifying the current status of film and NDE documentation. The
program was instituted in May 1985 after the project identified missing
radiographs of the reactor head supplied by Combustion Engineering. The
NRC CAT believes that some similar program is needed for the balance of
plant suppliers, to insure film and documentation could be readily
identified. A detailed discussion concerning NDE deficiencies,
retrievability and availability of film and documentation is provided
later in this section.
The welding and NDE activities were examined in order to ascertain
compliance with the governing construction codes and specifications.
This effort involved the review and inspection of the following
contractors:
                            Field Activities
1.    Bechtel Power Corporation:      architect engineer.
2.    Ebasco Services Inc.:      piping installation and piping supports /
      restraints, fire protection system fabrication and installation,
      electrical, instrumentation, HVAC installation and structural steel
      erection.
3.    Pittsburgh Des Moines Corp. (PDM): containment liner and contain-
      ment penetration fabrication and installation, reactor and spent
      fuel liner fabrication.
4.    Westinghouse:    reactor internals-modification and installation.
5.    Babcock and Wilcox:    Steam Generator Eddy current preservice
      inspection and examination.
                            Shop Fabrication
1.    Southwest Fabricating & Welding Company, Inc.:      shop fabricated
      piping spools.
2.    Copes-Vulcan:    valve manufacturer.
3.    Westinghouse:    nuclear steam supply system.
4.    Anchor / Darling Valve Company:    valve manufacturer.
5.    Teledyne Brown:    steam generator supports fabricator.
                                  IV-2
 
6.  Esco Corporation:  material supplier.
7.  Sandansky F&M Company: material supplier.
8.  Brown Minneapolis Tank Manufacturers: tank fabricator.
9.  RECO industries:  tank fabricators.
10. Fisher Controls:    valve manufacturer.
11. Joseph Oat Corporation:    heat exchanger manufacturer.
12.~TRW Mission Manufacturing Co.:    material supplier.
13. Richmond Engineering:    tank fabricators.
14. Pacific Pumps: pump manufacturer.
15. Pacific Valve:    valve manufacturer.
16. Master Craftsman Inc.: ' heat exchangers suppliers.
17. Pall Trinity Micro. Corporation:    cartridge filters supplier.
18. Lamco Industries:    tank fabricators.
19. Quaker Ally Casting Co.:    castings supplier.
20. Wollaston Alloys: material supplier.
21. McJunkih Corporation:    material suppliers.
22. Combustion Engineering:    reactor vessel fabricator.
23. Sabine Steel:  tank fabricators.
24. GW Energy Product Corp.:    tank fabricators.
25. Atlas Industrial manufacturing:    heat exchangers manufacturer.
26. Struthers Wells Inc.:    heat exchanger manufacturer.
27. PDM - tank fabricators.
The results of the inspection activities involving each of these
areas and contractors are documented as follows:
                              IV-3
 
1. Pipe and Pipe Support Fabrication
a. Inspection Scope
  (1) Welding Activities
        The NRC CAT inspectors reviewed activities relating to fabrica-
        tion contracts in the areas of piping system welds, support /.
        restraint welds, welding procedures, welder qualifications, NDE
        procedures, personnel qualifications, and the review of radio-
        graphic film for shop and field fabricated welds. Field
        welding involving pipe fabrication was performed by Ebasco.  .
        Southwest Fabricating and Welding supplied the shop fabricated
        piping spools.
        The NRC CAT inspected 41 pipe supports / restraints involving
        approximately 450 welds to verify conformance of welding to
        drawing requirements, and to confirm the visual acceptability
        of welds. Thirty-four of the pipe supports had been inspected
        by QC inspectors, 4 supports were "in process" and were not yet
        inspected by QC, and 3 supports were identified as Class 7
        supports which does not require QC inspection except on a
        random basis. The "in process" and Class 7 pipe supports were
        inspected in order to verify the initial quality of work
        performed by craft personnel. See Table IV-1 for a listing of
        supports subjected to detailed inspection. Additionally,
        another 14 supports / restraints involving 150 welds were-
        visually inspected to verify the quality of the completed
        welds.    See Table IV-2.for a listing of supports inspected.    '
        The NRC CAT inspectors also inspected the welds on the upper
        and lower lateral supports.for two steam generators.    The
        steam generator supports were fabricated by Teledyne Brown.
        Three sets of Bechtel calculations for the design of skewed
      welded supports were also reviewed for adequacy.
        The NRC CAT inspection of piping welds consisted of visual
        inspection during walkdown of piping systems and inspection of
        pipe welds located near the supports restraints being inspected.
      Approximately 62 piping spools involving 1200 American Society
        of Mechanical Engineers (ASME) Class 1,.2 and 3 welds were
        inspected. Four of those piping spools were subjected to
        detailed inspection which included the review of pertinent QC
        documentation while the remaining 58 spools were only visually
        inspected. Both field and shop welds were inspected in order
        to assure compliance with the requirements of the ASME Cooe.
      See Tables IV-3 and IV-4 for listings of piping spools
        inspected.  In addition, 60 welding filler metal test reports,
      27 welder qualification test _ records and 6 welding procedures
      were reviewed for' compliance with applicable specifications,
      procedures and the ASME Code requirements.
                              IV-4
 
                        .                            .    . .. .                    . . -            - _ .    .              .        . .      .              .-    ~,  .-          .
    '
                                                                                                                                                                                            :
                                                                                                                                                                                            ,
                                                                                                                  ~
                                                                                                                                                                                            '
                                                            (2) Nondestructive Examination Activities.
J-
                                                                  JThe NRC CAT inspection of NDE activities in the pipe fabri-
                                                                    cation area included the review of 46 shop and 145 field
                                                                    fabricated welds which involved 1,905' film. The-field welds
                                                                    were fabricated by Brown and Root (SR) and-Ebasco and the shop
;                                                                  fabricated pipe spools were supplied by Southwest Fabricating
i                                                                  and Welding. _In addition, 6 NDE procedures and 4 NDE personnel
                                                                  ' qualification records were reviewed in order to verify compli-
                                                                                                                                                                  ~
:
                                                                    ance with the governing codes and specifications. Three NDE                                                              ,
I                                                                  technicians were observed while performing in process inspec-                                                            '
                                                                    tions and were evaluated for their ability to follow the                                              .
                                                                                                                                                                                            ,
                                                                    applicable inspection procedures. Twenty pieces _of NDE equip-                                                          "
,                                                                ' ment were inspected for calibration and one NDE procedure was.
                                                                    reviewed for adequacy.
1
                                                                                                                                                                                            ,
                                                                                                                                                                                            ;
                                                                                                                                                                                            I
.                                                      b.  Inspection Findings                                                                                                              !
;                                                          (1) In general, the inspected pipe and pipe supports / restraints
                                                                  welding activities were found to comply with' governing codes
                                                                    and specifications. However, discrepancies were identified
l                                                                  involving undersized welds'in pipe supports / restraints.
                                                                    Specifically, eight QC accepted skewed welds were found to be.
                                                                    undersized and two other-skewed welds were located on the acute
                                                                    side of the joint instead of the obtuse side as required on the'                                                        '
                                                                  drawing.                      Ten nonskewed welds were also found to be undersized
                                                                  with~ respect to.the specified acceptance criteria. As a result
                                                                                                                                                      ~
                                                                                                                                                                                            4
                                                                'of these findings-the licensee issued nonconformance reports
                                                                  and the deficient' welds will be reviewed and evaluated by~
                                                                  Bechtel.
,
                                                                  In the area of "in process"-and class 7 pipe supports inspec-
;                                                                -tions, the NRC CAT inspectors also identified welds which did
:                                                                  not conformed to the specified acceptance criteria. Twelve
                                                                  "in process" welds were found'to be undersized and two gusset
:                                                                plates were missing in one of the inspected supports. 10 of
,
                                                                  the inspected welds in class 7 supports were also found to be                                                            ;
                                                                  undersized. As a result of this finding Ebasco and HL&P
                                                                  indicated that they will conduct additional training for both                                                            ;
L                                                                  craft and inspection personnel.                                                                                          ;
,
''
                                                                  One of the three sets of calculations reviewed for the design                                                            l
                                                                  of supports having skewed joints.did.not have any calculations
*
                                                                  for the welds in the skewed connections. The calculations
                                                                  also did not provide compensation for the loss of weld throat                                                              ,
                                                                  thickness in. skewed welds.                                                                                                '
.
''
                                                                  The lack of calculations for skewed joints had been previously-
                                                                  identified on a number of supports.during a third party design
                                                                  assessment performed in March and April 1985. The project'has
                                                                  committed to review the design calculation and such review was
i                                                                  underway during the time of the NRC CAT inspection.
                                                                                                                                                                                            1
.I
i
                                                                                                            IV-5
;-
      .._. ~ . , . . . _ . . . . . . . . _ _ . . . ,                    _ , _ . - - . _ - . - . _                  _ _ . . . . , , . ,    _ _ , _ . - , _ _ _ . , , _        . , , . -
 
Undersized reinforcing fillets on groove welds and undersize
fillet welds were found on the upper and lower steam generator
lateral supports. NRC CS-03201 was written against this
finding. Ebasco performed additional inspection consisting of
mapping out the undersized conditions, which were evaluated and
accepted by Bechtel without rework.
During the inspection of pipe welds the NRC cal inspectors
identified undersized socket welds in 2 inch schedule 160 pipe
spools. As a result of this finding the licensee issued NCR
CP-03139. A Standard Deficiency Report (SDR E-349) was issued
to determine the extent of the undersize condition in other
small-bore socket welds, and a Deficiency Evaluation Report
(DER 85-049) was issued to evaluate the reportability of the
condition. Results of the reinspection conducted by Ebasco
QC indicated that the undersized condition is limited to
2 inch Sch.160 socket welds fabricated in the field (not the
site fabrication shop). Of the approximately 200 QC accepted
field welds of this type, at least 15 percent were reported
to be undersize. No undersized socket welds were found in
other pipe schedules and sizes by the_NRC CAT inspectors or
the Ebasco reinspection effort.
The NRC CAT inspectors also visually inspected ~55 socket welds
for proper fitup and gap. In addition, 7 socket welds ~were
radiographed to determine that the required gap exist between
the pipe and the fitting. No discrepancies were identified
during the visual and RT inspections. Two of the-100 inspected
" weld-o-let" pipe branch connections were found to have inade-~
quate weld sizes. NCR HP-3238 and NCR HP-03164 were written to
document this condition.
During the review of Welding Procedure Specifications,_one of
the supporting qualification records for WP-89 was found to
violate ASME Code requirements regarding the size of tensile
specimens which were in effect at the time the qualification
tests were performed. Ebasco Welding Engineering performed a
review of the applicable qualification record against current
code requirements, which had deleted the tensile specimen
restriction, and it was found acceptable.
During review of the Material Test Reports for welding filler
metal, it was observed that the purchasing specifications and
test reports did not specifically address the requirements of
ASME Section III regarding the cooling rate of post weld heat
treatment to be followed during welding of the test coupons.
Bechtel agreed to add the cooling rate requirements to the
purchasing specification, as well as the specific tensile
strength requirements for material tested in the heat treated
condition. Based on review of 60 welding filler metal test
reports, this discrepancy has no consequence on hardware.
                      IV-6
 
  (2) Nondestructive Examination Activities
        In general, the inspected NDE activities were found to comply
        with the applicable codes and specifications. No deficiencies
        were identified with the inspected shop fabricated pipe welds.
        However, during the review of the radiographic film for field
        fabricated welds some deficiencies were identified which
        involved the following four welds:
        * Weld EW 1202 - FW 0027 was found to have low weld thickness.
        * Weld EW 1205 - FW 14 had a linear. indication adjacent to a
            repair area.
        * Weld EW 2205 - FW 0009 had a penetrameter shim extending into
            the area of interest; one repair-view indicated that the
            complete area repaired had not been covered; and one view
            exhibited porosity with a crack extending from_it.  NCR
            #BP-03221 was written to document this deficiency.
        * During the review of circumferential weld C52007 - FWOO6
            the adjacent area of the logitudinal weld seam showed a crack
          .like indication in the seam. The licensee indicated that the
            crack like indication may be caused by microbiological
            induced corrosion (MIC) attack which has taken place during
            the storage of the pipe. The licensee committed to investi-
            gate further the cause and nature of this indication.
        It should be noted that weld EW1202 - FW0027 and weld EW1205 -
        FW14 identified above have been reviewed during HP&L audit
        #M11-301 of the radiographic activities prior to the NRC CAT
        inspection.
        The HP&L audit did not ideritify any deficiencies with those
        two welds which indicates that the audits were not effective.
        See Section VIII'of this report for additional details
        concerning project audits and corrective actio~ns.
c. Conclusion
  (1) Welding Activities
        In general, the inspected welding activities were found to
        comply with the requirements of_the applicable codes and
        specifications. However, the NRC CAT found structural welds on
        pipe supports / restraints which did not meet the weld specifi-
        cations. Skewed connections did not meet drawing requirements
      .for size and location and some were not supported by calculations.
        In addition, undersized socket welds were found in 2 inch
        schedule 160 piping spools.
                                IV-7
 
.
                                                              _.                          ..
      (2) Nondestructive Examination
            In general, the inspected NDE~ activities were found to comply
            with the requirements of the governing codes and specifica-
            tions. However, the NRC CAT found some welds which had linear
            indications and another weld which had low weld thickness. In
            addition, the reviewed NDE audits were found to be ineffective.
  2.  Reactor Internals Modification and Installation
  a.  Inspection Scope
      Approximately 30 tack welds on the bottom mounted Instrumentation
      (BMI) locking caps were~ visually inspected. The documentation
    packages for the welds on the Core Barrel Assembly and tie plates
      for the lower internals were reviewed. The documentation package
      for the welds on the Energy Absorber Installation was also reviewed.
      In addition, one welding procedure and the qualification test
      records for two welders were also reviewed for adequacy. The
    modification work was performed by Westinghouse.
  b.  Inspection Findings and Conclusions
    No problems were identified in the area of irispected welding
    activities. Activities were found to meet the specified acceptance
    criteria.
  3. Preservice Inspection (PSI)
  a.  Inspection Scope
    Approximately 30 steam generator tubes requiring preservice and
    inservice inspections were witnessed while performing Eddy current
    inspections in order to verify compliance with the requirements of
    Section XI of the ASME Code.          In addition, the qualification test
    records for four Eddy current technicians were reviewed and 2
    technicians were observed while performing Eddy current inspections.
    The NDE procedure and 10 data records, were reviewed for adequacy.
  b. Inspection findings and Conclusions
    No problems were identified in the inspected preservice inspection
    activities.    Activities were found to comply with the requirements
    of the governing codes and specifications.
  4. Electrical Installation and Electrical Supports
  a. Inspectior Scope
    The NRC CAT inspected approximately 110 welds in the area of
    electrical installation.    This involved the inspection of welds on 6
    cable tray -supports, 2 junction ' box supports, 9 conduit supports
    and the installation welds for 3 electrical panels. Two welding
    procedures and the qualification test records for five welders were
    reviewed.    In addition, the personnel qualification test records for
                                IV-8
                        _  _        . _ -
                                                      ___  -    .  _ _ _ _ _ _ - _ _ _ _
 
    four welding inspectors were also reviewed and two inspectors were
    observed and evaluated for their ability to follow the visual          I
    inspection procedures.    The welding activities in the electrical
                                                                            '
    area were performed by EBASCO.
b.  Inspection Findings
    During the inspection of Electrical supports 1-016-H99 and
    1-016-H100 it was established that those supports were QC accepted
    -for integrity and tightness of technical connections on September
    15, 1984. Since that date, two bolted connections on support H-100
    have been changed to welded connections without obtaining the
    required Modification / Removal Form prior to installation of the
    welded connections.    As a result of this finding a Quality Control
  . Notification of Procedural. Violation #C-8 was generated and the
    connections will be inspected by QC to determine the acceptability
    of the welded connections.
c.  Conclusions
    No major problems were identified in~the area of inspected welding
    activities. With the exception of the uncontrolled modification
    discrepancies, all inspected activities were found to comply with
    the applicable construction codes and specifications.
5.  Instrumentation Tubing Installation and Instrumentation Supports
a.  Inspection Scope
    Approximately 80 welds involving 10 instrumentatic.. supports were
    visually inspected to ascertain compliance with_the specified
    acceptance criteria. Two welding procedures and qualification test
    records for four welders were reviewed. The qualification records
    for five NDE inspectors were also reviewed. Two visual welding
    inspectors were observed and evaluated for their ability to follow
    the applicable inspection procedures. The radiographs for one
    instrumentation tubing weld was also reviewed for adequacy. The
    welding in the instrumentation area was performed by Ebasco.
b.  Inspection Findings
    During the review of documentation of instrument stand EWR~#A03134
    it was discovered that the stand has been fabricated and installed
    without the welds being inspected as required by QC procedure QCP-95
    paragraph 5.2.1. As a result of this finding the licensee issued
    NCR C503004. The paint was removed from the welded areas and the
    welds were inspected as required by the inspection procedures and no
    other problems were noted.
    During the inspection of supports.for instrument #N2ED-FT-7822A it
    was noted that a double type globe strut (G5812A strut) was used
    instead of.the required single type globe strut.      As a result of
    this finding Ebasco generated Deficiency Report (DR) I-0021 and all  *
                                IV-9
 
      double type globe strut (G-5812-A) will be removed. The construc-        l
      tion personnel was instructed in the correct use of the G-5812-A        ;
      strut.
                                                                              l
                                                                              ;
  C.  Conclusions
      No major problems were identified in the area of inspected welding
      activities. With the exception of the globe strut installation
      discrepancies, all inspected activities were found to comply with
      the applicable construction codes and specifications.
6.  Heating, Ventilating and Air Conditioning
      Installation and Supports
a.  Inspection Scope
    Approximately 120. welds involving 16 supports were inspected for
    compliance with the specified acceptance criteria. Two welding
    procedures and the qualification test records for five welders were
                                    ~
      reviewed.  In addition, four personnel qualification test records
    were also reviewed and two welding inspectors were observed and
    evaluated for their ability to follow the visual inspection
    procedures.        The welds on four duct pieces, two air blowers and two
    dampers were also included in this inspection. The welding in the
    HVAC area was performed by Ebasco.
b.  Inspection Findings and Conclusions
    No problems were identified in the area o.f inspected welding activi-
    ties. Activities were found to comply with the applicable construc-
    tion codes and specifications.
7.  Structural Steel Fabrication, Erection and Modification
a.  Inspection Scope
    Approximately 120 welds comprising 70 field and 50 shop welds
    involving 16 structural beams and columns.were visually inspected in
    order to ascertain compliance with the specified acceptance
    criteria.
    Two welding procedures and the qualification test records for five -
    welders were revie, sed.    Visual inspection procedures and the quali-
    fication records for four inspectors were also reviewed. Four
    welding inspectors were observed and evaluated for their ability
    to follow the visual inspection procedures. The structural steel
    field welding was performed by Ebasco.        American Bridge Steel-
    Company supplied the structural steel to the project.
b.  Inspection Findings
    No problems were identified in the area of inspected field welding
    activities.- However, several original welds involving clip to beam
    web connection welds were found to be deficient. Specifically, the
    design drawings required fillet welds all around, while the connec-
                                  IV-10
.            .    . .
 
r
      tion was seal welded on the top and bottom of the clip.    As a result
    of this finding the licensee issued NCR #HC-03182, HC03183 and
    HC-03184. The welded connections were evaluated by Architect
      Engineer, accepted "as is" and determined to be adequate for the
      intended application.
  c. Conclusions
      In general, the . inspected welding activities were found to comply
    with the governing Code and Specifications. With the exception
    of the deficient undersized clip to web welds, which required.
    engineering evaluation, the inspected welding activities were
      found to comply with the specified requirements.
  8. Refueling Cavity and Spent fuel pool Liner Fabrication
  a. Inspection Scope
    The NRC CAT visually inspected approximately 80 feet of welded seam
    on the spent fuel pool and the Reactor Pool Liner. The attachment
    welds for four brackets and the welds' on two erriedment plates were
    also inspected in order ~to ascertain compliance with the specified
    acceptance criteria. One welding procedure was also reviewed for
    adequacy.    In the area of NDE, the NRC CAT reviewed the NDE docu-
    mentation for the required vacuum box testing of the inspected
    welds. The Refueling Cavity and spent fuel pool Liner fabrication
    was performed by PDM.
  b. Inspection and Findings and Conclusion
    No problems were identified in the areas of inspected welding and
    NDE activities. Activities were found.to comply with the applicable
    construction codes and specifications.
  9. Containment Liner and Containment Penetration Installation
  a. Inspection Scope
    The NRC CAT visually inspected approximately 60 feet of liner seam,
    the welds on two incert plates, four welded plugs, the welds on one
    construction opening, and the attachment welds for two mechanical
    and two electrical penetrations. Two welding procedures and the
    qualification test records for four welders were also reviewed.    In
    the area of NDE, the NRC CAT reviewed the radiographs for 41 welded
    seams which involved 674 films. One radiographic examination
    procedure was also reviewed as a part of this inspection.      The
    containment liner and penetrations were installed by PDM.
  b. Inspection Findings and Conclusions
    No problems were identified in the area of inspected welding and
    NDE activities. Activities were found to comply with the require-
    ments of the governing codes and specifications.
                                  IV-11
 
    -10. LVendors-and Shop Fabricators Other Than Those Previously Addressed
    -a.    Inspection Scope
          .The NRC CAT visually inspected nine vendor supplied tanks and heat
            exchangers. See Table IV-5 for inspected vendor supplied equipment.
          -In addition to'the welds inspected and listed in Table IV-5, the NRC
          CAT inspectors reviewed radiographs related.to work performed by 25
          vendors which have supplied various equipment and hardware to the
          South Texas Power-Station project. .A total of 2,271 feet'of welded-
            sean involving 3,168 radiographs and 20 welds involving 145 film
          were. reviewed. The radiographs for 74 valves, pumps and castings
            involving 1,170 film, and the radiographs-for 105 spot welds
            involving 105 film were also~ reviewed for compliance.with the
-
          governingLcodes and specifications.
      b.    Inspection Findings
  -
          During the inspection of tanks and heat exchanges supplied by the
          vendors-listed in.T%1e IV-5, the NRC CAT found that the size of
          the nozzle and manway weld reinforcement did not meet the require--
          .ments stated in the' vendor drawings. In addition, the welds on some
          of the inspected supports-were also found to be undersized. A total
          of seven tanks an~d heat exchangers'were found to deviate from the
          required drawing sizes. See Table IV-5 for details. -The NRC has
          issued.Information Notice 85-33 on the subject of undersized weld
          reinforcement in ASME Code nozzle to shell joints. The project has
          not performed any. inspection of tanksLand heat exchangers prior to
          :-the NRC CAT inspection, indicating the licensee may not have
          performed an adequate review of the content.of this notice for
          applicability to the South Texas = site.
          In the area of NDE the NRC CAT inspectors identified disorganized
          reports, . linear indications and yellow film in radiographs and NDE
          documentation supplied by vendors. See Table IV-6 for details.
          Prior to the NRC CAT inspection the NRC requested that the project
          provide a list of. vendors which have supplied radiographs in
          conjunction with vendor supplied equipment and hardware.      Such a
          list was still unavailable at the end of the first two weeks of
          the NRC CAT inspection.
          At the beginning of the second.two week period, film from several
          vendors picked at random was requested. This list included; Guyon
          Alloys, Rockwell, Lonergan, Target Rick, Valtek, Yarway, Clow, and
          Posi-Seal, among others. A computer search failed to locate any
          record of. film for these vendors. Furthermore, there appears to be
          no way to readily determine whether film is required or not required
          for these purchase orders. If the film is required for any of these
          orders, there seems to be no convenient method to determine where
          the. film is located, or even if it exists.
          A document search for four of the above vendors was conducted using
          only one purchase order per vendor and the following results were
          obtained: Target Rock-P.O. 4050 included some 8 inch ASME III
                                      IV-12
 
                                                                    .
            valves which probably would require radiographs. Further search
            is~necessary to determine this. Valteck-0.0. 4409 includes many
            valves requiring weld end radiographs. A search for these radio-
                                        -
            graphs has been started by the applicant. Yarway-P.O. 6455 includes
            ASME III Valves which, if cast would require weld end radiographs.
            Clow-P.O.6452, as above, if the valves are castings, weld end
            radiographs probably would be. required.
            Early in the first week of the inspection the NRC CAT requested the
            radiographs for three Component Cooling Water (CCW) heat exchangers
            fabricated by Struthers Wells.      In the third week another request
            was made for film based on P.O. No. 4018, FID NO. P0610 and PID N05.
            3R201NMX101A, 3S201NMZ101B and 3R201NMX101C. The computer found no
            film. Also no information could be obtained as to whether the film
            existed or where it could be found. A document search.found that
            the film had been reviewed by the vendor, that verification of the
            review had been made, but no indication of a request for the film to
            be sent to the site was found.
            During the last two weeks much effort was expended to come up with
            a computer program which would expedite retrieval of information-
            concerning the radiography program. A program was developed that
            does improve accessibility of information concerning radiographs in
            the film storage vault. However, the ability to determine if a
            verdor should have performed radiography is still a tedious and time
            cons 1 ming task.  After a brief scan of the vendor list the
            possibility that there could be in excess of 60 vendor purchase
            ordera that may require radiography and for which there is no
            program for expeditious retrieval of this information.
            It should be noted that the Code of Federal Regulation 10 CFR 50
            Appendix B, Criterion VII requires that documentary evidence that
            the material and equipment conform to the procurement requirements
            be available at the site prior to installation or use of the
            material and equipment.    The documentary evidence is to be retained
            at the site and shal1 be sufficient to identify the specific
            requirements, such as codes, standards or specifications met by the
            purchased material and equipment. Since the NDE requirements are
<
            specified by the ASME code, the NRC CAT team believes that the
            project should have instituted a program to identify location and
'
            existence of NDE film and documentation for the Balance of Plant
            vendors and suppliers.
                                                              ~
            The NRC CAT also reviewed NDE documentation and film which was under
            the Westinghouse scope of supply and in general the retrievability
            and availability of NDE documentation was found to be satisfactory.
            It should be noted that the project has instituted a program
            requiring Westinghouse to suomit monthly reports concerning status-
            and availability of NDE film and documentation. This program was
            instituted after missing radiographs were identified for the reactor
            vessel head. The NRC CAT inspectors believe that the project
            should have instituted the program to cover both, the Westinghouse
i,
            suppliers and the balance of plant suppliers so that the existence
            and location NDE film and documentation could be promptly
            identified.
                                        IV-13
    .- _ --                                    -                              ._
 
        -
c. Conclusions
  In general, the inspected welding and NDE activities'were found to
  comply with the requirements for the governing codes and specifi-
  cations. However, seven tanks and heat exchangers were found to
  deviate from the requirements stated in the applicable drawings and
  specifications.  In the are of NDE, several radiographs and NDE
  documentation supplied by vendors were found to be deficient with
  respect to the_ required quality. In addition, difficulties were
  encountered in retrievability, availability and location of NDE film
  and documentation for the balance of plant suppliers which indicated
  that the licensee had performed inadequate corrective action after
  the discovery of missing radiographs for the reactor vessel head in
  May 1985.
  The difficulties encountered in retrievability, availability and
  location of NDE film and documentation pertaining to the Balance
  of Plant Scope of supplied equipment, indicates a need for a formal
  program to identify requirements, location and existence of NDE
  film and documentation.
                              IV-14
                                                        -              --
                                    _
                                                .
 
                                  TABLE IV-1
LIST OF SUPPORTS WHICH WERE INSPECTED AGAINST DRAWING REQUIREMENTS
    SA-1756-HF5025 (1)          CC-1318-HL5002          'CC-1403-HL5001
  FW-10160-HL5001-            .CC-1402-RR3002          FW-1018HL5001 (4)
  CC-1401-HL-5003              CS1001-RR0029 (2) .CC-1106-HL5016
  CV-1209-RR002 (5)            FP-1560-GUO412          CV-1046-GU1001 (6)
  CC-1106-HL5015                RH-1201-RR0004          CC-1504-RR0013
  CC-1412-HL5001                FC1016-HL5001            EW-1285-HL5001
  'BA-1003-HF5005                CH-1203-HL5017          CS-1001-RR0012 (2)
  'EW-1383-HL5006                CS-1001-HL5007          CV-1088-RR0019
  CC-1474-GU01.                CV-1047-RR1004 (7) CC-1317-HL5006 (3)
  EW-1383-HL5007.              CC-1480-RR0011.(8) SI-1201-HL5015 (11)
  .SI-1301-HL5010 (9)            CC-1103-HL5003          SI-1201-HL5009 (10)
  CC-1210-SS01 (12)            'CC-1101-HL5001 (13)'CC-1209-HL5004
  - RH-1205-HL5002 (14)-        CC-1210-HL5001          CC-13-3-HL5003 (15)
  SIl05-RR0038 (16)            CV-1046-RR1002
  (1)''7 of 14 fillet welds undersized. Class 7 item.            Item still
        '"in process".
        -
  :(2) Two undersized skewed fillet welds and two undersized
          fillet welds.    Item still "in process".
  (3) Fillet' weld from spring can to base plate undersized.            NCR-CS-3215.
  (4) 'Two fillets un'dersized.
                                                                          ~
                                        NCR-CS-03205.    Item still "in process".
  (5) Seven fillet welds undersized.          NCR-CS-03198.
  (6) One' undersized fillet.        Class 7.    Engineering accepted "as-is"
          during' audit.
  (7) Two fillet welds undersized.          Class;7.    NCR-CP-03147.
  (8) Three of four skewed fillet welds undersized.            NCR-CS-03200.
  (9) One skewed fillet welds undersized.            NCR-CS-03199.
  (10) Two skewed welds specified as groove welds were actually seal
          welds. NCR-CS-00840.
  (11) Four skewed fillet welds undersized, two gusset plates missing.
          Item still "in process".
  (12)~W8X31 section bent through the web.          NCR-CS-03197.
'(13) Two undersized fil.lets.        Item still "in process".
  (14) Two welds located on the accute side of a skewed joint instead
          of'the obtuse side as specified on the drawing.- NCR-CS-03169.
  (15) One skewed fillet weld undersized on throat. Two fillet welds
          undersized.    NCR-CS-03201.
.(16) One skewed fillet weld undersized.            NCR-CS-00875.
                                      IV-15
                                                                                      }
 
  =
                          -TABLE IV-2
              SUPPORTS WHICH WERE VISUALLY INSPECTED
      DW-1501-HF5005      DW-1501-HF5006      DW-1501-HF5004
      SI-2205-HL5020      CC-2317-RR0012      CC-2115-RR0006-
    ' CC-2115-RR0005      CV-2088-HL-5006      CV-2086-HL5010-
      CC-2209-RH0009      CC-2209-RH008        CC-2109-RR0009
      CC-2109-RR0008      CV-1214-HL5002
4
                              IV-16                                        ;
                                                        . _ . - . _ __ _ ,
 
                    .    ._        .  .      .. .        .._ _        . _ _ .                . __
                                                  TABLE IV-3
                            LIST OF PIPING'WHICH WAS VISUALLY INSPECTED
      '
          ITEM        DESCRIPTION.                      PIPE' SIZE (IN.)        MATERIAL
,
'
          CC-2116.  ' Component Cooling                        '10            Carbon Steel
          CC-2114      Component Cooling                        '10            Carbon Steel
          CC-2117L    Component Cooling                        14            Carbon Steel
          CC-2317      Component Cooling                        10-            Carbon Steel
          CC-2115      Component Cooling                        10            Carbon Steel
          .BA-2001      Breathing Air.                            2            Stainless Steel
          CV-2086    ' Chemical / Volume Control                  4-            Stainless Steel
          CV-2088      Chemical / Volume Control                  4            Stainless Steel
          CV-2006'    Chemical / Volume Control                  4            Stainless Steel    ;
          CV-2092      Chemical / Volume Control                  4            Stainless Steel    !
        -CC-2109      Component. Cooling                12, 24                Carbon Steel
        -CC-2209    -Component Cooling                          30            Carbon Steel
          CC-2410    _ Component Cooling                        12            Carbon Steel
          CC-2110      Component Cooling                        24            Carbon Steel
          CC-2109      Component Cooling                        20            Carbon Steel
          EW-2202.    Essential Service Water                  30            Aluminum Bronze
          CV-1111      Chemical / Volume Control                  2            Stainless Steel
          .CV-1112      Chemical / Volume Control                  2            Stainless Steel
          CV-1209      Chemical / Volume Control                  2            Stainless Steel
        .CV-1106      Chemical / Volume Control                  2            -Stainless Steel
          CV-1205      Chemical / Volume Control                  2            Stainless Steel-
          .CC-1515      Component Cooling                          2            Carbon Steel
          CC-1479      Component Cooling                          2            Carbon Steel
          CC-1401:    Component Cooling                          3            Carbon Steel
          CC-1402    Component Cooling                          3            Carbon Steel:
          CC-1403-  -Component Cooling                          3            Carbon Steel
          SA-1756    Station Air                                l'            Carbon Steel
          FP-1506    Fire Protection                            4            Carbon Steel.
                                                                                                    '
          CC-1106    Component Cooling                          16-            Carbon Steel
          FC-1016  _ Fuel Pool Cooling                          10            Stainless Steel
        ~CC-1504      Component Cooling                          6            Carbon Steel
          CS-1002    Containment Spray                          8            Stainless Steel
        .CC-1417      Component Cooling                          14            Carbon Steel.      '
          FW-1016    Feedwater                                  18            Carbon Steel
          FW-1018    Feedwater                                  18            Carbon Steel
          RH-1201    Residual Heat Removal                      12            Stainless Steel
          CC-1474    Component Cooling                          6            Carbon Steel
          CC-1318    ' Component Cooling                        14            Carbon Steel
    '
          CS-1001    Containment Spray                          8            Stainless Steel
          EW-1285    Essential Service Water                    30            Aluminum Bronze
          EW-1383    Essential Service Water            30, 10                Aluminum Bronze
          CV-1088    Chemical / Volume Control                  4            Stainless Steel
          CV-1047    Chemical / Volume Control                  4            Stainless Steel.
          CC-1480    Component Cooling                          8            Carbon Steel
          CC-1103    Component Cooling                          16            Carbon _ Steel
        ~CC-1201      Component Cooling                          24            Carbon Steel
          SI-1201    ' Safety Injection                  12, 16                Stainless Steel
        .SI-1301      Safety Injection                          12            Stainless Steel
        .CC-1412      Component Cooling                          4            Carbon Steel
                                                                                                      i
                                                    IV-17
  -
  __
                                                                                                    l
 
        .      .      ._  .    _            _ .        _        .                                  _ ._ . _ . . --
                                      TABLE IV-3      .(Continued)
                            LIST OF PIPING WHICH WAS VISUALLY INSPECTED
            ITEM-    DESCRIPTION                        PIPE SIZE (IN.-)          MATERIAL
            CC-1209' Component Cooling                      20                  Carbon Steel
          ' CC-1309  Component Cooling                      20                  Carbon Steel
4
            CC-1203- Component. Cooling                      20                  Carbon Steel
            CC-1209. Component Cooling                      20                  Carbon Steel
            CC-1527  Component Cooling                      12                  Carbon Steel
            CH-1029; Chilled Water                          12                  Carbon Steel
            CH-1053- Chilled Water                          12                  Carbon Steel
            CC-1425  Component Cooling                        4                  Carbon Steel'
          - RH-1102  Residual Heat Removal                  12                  Stainless Steel
.
                                                                                                                        I
. -
?
                                                                                                                        1
                                                  IV-18
    . -.                                                            . _ _ - _ . _      __ _ - _ . ,          ,    ,
 
                                  TABLE IV-4
              PORTIONS OF' PIPING SYSTEMS VISUALLY EXAMINED AND
                      FOR WHICH DOCUMENTATION WAS REVIEWED
  ITEM      DESCRIPTION                    PIPE SIZE (IN.)      MATERIAL
  MS-1004  -Main Steam                        30              Carbon Steel
  FW-1014-  Feedwater.                        18              Carbon Steel
  FW-1012  Feedwater.                        18              Carbon Steel
  SI-1201  Safety Injection                  16              Stainless Steel
:
i.
1
                                      IV-19
 
-
                                            TABLE IV-5
                          TANKS PRESSURE VESSELS AND HEAT EXCHANGERS
                                WHICH WERE VISUALLY INSPECTED
          ITEM                                    MANUFACTURER                      NOTES
  Accumulator. Tank SIATAT-02            Southwest Fabricating and Welding          (1)
  CCW Surge Tank 3R201NTS101A            Brown-Minneapolis Tank                      (2)
  CCW Heat Exchanger 3R201NHX101A        Struthers-Wells, Inc                        (3)
  RHR Exchanger 2R161NHX101B            Jcseph Oat Corporation                      (4)
  Dimineralizer' Tank 3R171NDM102A      Westinghouse Pensacola
  Spray Additive Tank.TGXSIATSA-03      RECO Industries, Inc.                      (5)
  DFO. Storage Tank 3Q15MTF0337TK21    Brown-Minneapolis Tank                      (6)
  Volume Control Tank'TGXCSATVC-01      RECO Industries, Inc.                        (7)
  Fuel Pool Cooling HXTXSFAHSF-02      Atlas' Industrial Manufacturing
  -(1) Bolting ring fillet welds intermittently undersized on one leg.
        NCR HM-03081
  (2) Reinforcing fillet weld at various nozzles, manway neck to flange fillet
        weld and support fillet welds undersized.-      NCR HM-03075.
  (3) Fillet weld from nozzle reinforcing pad to shell undersized. One reinforcing
        fillet weld at a 1" nozzle to shell weld undersized. NCR HNO3074.
  (4) Reinforcing fillet at three nozzle to shell welds intermittently undersized.
        NCR HN-03029.
  (5) -Arc strike on vessel shell.      NCR HM-03088.
  (6) Shell access hole re'inforcing fillet at nozzle to shell and fillet at
        flange face undersized. Manway to shell reinforcing fillet undersized.
        Roof vent nozzle to roof reinforcing fillet weld undersized.      One fillet
        weld undersized.    NCR~HM-03094.
  (7) Manway nozzle fabricated as a nozzle with reinforcing pad instead of
        integrally reinforced butt welding fitting as required by drawing.
        Stiffening ring to vessel shell fillet welds undersized. .NCR HM-03095.
                                              IV-20
 
                                    TABLE IV-6
                            VENDOR RADIOGRAPHS-REVIEWED
                              Castings
                              Valve.    Spot      Feet of
Contractor          Welds  Pumps    Welds      Welds  Film Notes
G&W Energy            4                                    8
  -Products
TRW Mission                    2                          8  (1)
  Manufacturing
Anchor Darling                56                          775
Pacific Valve                  1                          4
Quaker Alloy.                  6                          42
Teledyne~ Brown                                    8      8
Pall: Trinity        8                                    72
Sandusky.Fo6ndry                                  39    169
Master Craftsman-                      16                  16
Lanco                                  46                  46
Joseph Oat                                      114      114
Richmond Engineering                            206      206  (2)
Brown Minneapolis                                508      508  (3)
Westinghouse                                    1041    1436  (4)
PDM                                              100    '200
Southwest Fabricating                            149.    260  (5)
Copes-Vulcan                  4                            98
Esco                          1                            88
Reco Industries      8                                    65
Pacific Pumps                                      8      67
-Wollaston Alloys-            1                            22
McJunkin Corp.                                    18      18
                                      IV-21
 
                                      . TABLE IV-6 --(Continued)
                                      VENDOR RADIOGRAPHS REVIEWED
                                        Castings              .
                                                                    .
        ._                      .      Valve      Spot    Feet of
    Contractor'            _ Welds    Pumps'    _Welds.    Welds          Film    Notes
    Combustion Eng.                                          80'            182
    Fisher Controls                      3                                  133
    Sabine Steel-                                  43                        43      (6)
    NOTES:
    (1) Reader sheet was not found in the. package. The sheets were later found and
              film was reviewed and no further problems were identified.
    (2) Yellow film was found in the film packages for the Volume Control tank and
            Lthe Pressure Relief Tank. The licensee issued SDR #-192 to cover this
              deficiency.
  ~(3)' Microbiological Induced attack was found to have occurred during the storage
  -
      '
                                                  -
            period of the tanks.    However, '.he-licensee has rework all BMT supplied tank
            -and the final condition of the tanks is considered acceptable.
  _( 4) Linear-indications found in the backing ring welds in the demineralizer tank
              serial #37740. Yellow film was found in a.16 inch surge line, however the
              line was deleted by a design change.      NCR #AN-03028 and AN-0329.
    (5) Cylinder P4131, weld W-K-H-69 showed no evidence of retakes although the
            reader sheet indicates some were shot. Cylinder _4133, weld W-K showed a
              linear indication 3/4 of an inch long at interval no. 2. This appears on
            the films for intervals 1-2 and 2-3.
  .(6) Problem areas included questionable film,. disorganized reports, some pages
            were unreadable due to light copy, it was therefore unable to coordinate
            film-with data sheets. Also some repair _ film for rejects seemed to be
            unavailable. After some time HL&P determined that the light data sheets were
            apparently duplicates of other readable data' sheets. Also it was determined
            that the apparently missing film areas-were covered by film shot by Ebasco
            after.they had. repaired the questionable areas. The film was reviewed and
            - no further problems were identified.
                                                  IV-22
:
 
-
  V. -CIVIL AND STRUCTURAL CONSTRUCTION
      A.  Objective
          The objective of-the appraisal of civil and structural construction
          was to determine by evaluation and review of Quality Control (QC)
          accepted work and documentation whether civil and structural construc-
            tion areas were completed in accordance with regulatory requirements,
          Safety Analysis Report commitments, and project specifications,
          drawings and procedures.
      B.  Discussion
          The specific areas of civil and structural construction evaluated
            included: reinforced concrete construction including mechanical
          splices, and concrete pour packages; structural steel installation
            including high strength bolting for structural steel friction and
          sliding connections; backfill and earthwork construction; the concrete
          expansion anchor bolts; and the containment post tensioned system.
          This evaluation included hardware and selected documentation.
          This portion of the NRC CAT inspection of concrete expansion anchors
          was limited to the review of the qualification test report. The
            inspection of installed concrete expansion anchors was performed by
          NRC CAT electrical and mechanical groups (see Sections II and III).
            Parts of the above hardware inspection included verification of
          hardware to a sample of design change documents. The documents
            reviewed are listed in Section VII, Table 7C.
            1.  Reinforced Concrete Construction
          a. . Inspection Scope
                Reinforced concrete construction ~ areas inspected by the NRC
                Construction Appraisal Team (CAT) included reinforcing steel
                configuration, activities for two concrete placements, in-process
                mechanical splicing, Quality Control (QC) documentation for -
                mechanical splices and concrete placement, and general concrete
                surface quality.
                The reinforcing steel for three concrete placements were inspected
                for proper bar diameter, spacing and length. Embedded plates and
                anchor bolts which were part of the concrete placements were
                inspected for proper size and spacing.
                Activities for two concrete placements were observed by the NRC
                CAT. Activities observed were batch plant mixing operations,
                concrete placement, tests for slump, air content and unit weight,
                length of time required. for concrete placement from truck mixers,
                and preparation of concrete cylinder test specimens. For one of
                                              V-1
 
                        . _ .        .  _ _ _            _ _ _          _ . _ _ _ _                          _ _ . . _  .__
  ,
                                                                                                                                  k
                                  the two concrete placements, the general surface quality after
                                  the forswork had been removed was_ inspected.          In process mechanical
i                                splicing activities were observed by the NRC CAT. QC documentation
~
                                  and appropriate field procedures were reviewed for. concrete
                                  placements and mechanical.' splices completed by Ebasco Constructors.
                                  A review of the licensee's Phase A statusing of_QC documentation
                                              _
                                  for concrete placements and mechanical splices was performed. The
                                  purpose of the licensee's Phase A statusing was to determine the                              -l
                                  status of construction and QC documentation of work performed by                                '
                                  Brown and. Root at the time when engineering and construction
                                  services were turned over to Bechtel Engineering and Ebasco                                    ,
i                                Constructors. In addition, the qualification records for four
                                  cadwelders were reviewed. ~
$'                              Concrete placement. records reviewed included concrete pour
                                pre placement checklist, in process concrete pour placement
'c                              checklist, concrete pour curing and post placement checklist,
                                and concrete compressive strength test. report. The reviews
                                checked the forms for' adequate completion by the QC inspectors,
                                existence of senior QC inspectors' signature for evaluation of
                                completed forms when necessary, and acceptable coverage of various
,                                inspection attributes.
;                              'Cadweld QC documentation reviewed by the NRC CAT included the                                  5
j                                cadwelder test record report, the tension test report of cadweld
;
                                rebar splices, the cadwelder qualification report, and the cadweld
;
                                :(visual) inspection report. This review also verified whether or
i                                not the forms had been adequately completed by the QC inspectors,
.'                              had been signed off by a senior QC inspector, and had acceptable-                                *
]                                coverage of various inspection attributes.
                              ,  By a general walkdown, the surface' quality of completed concrete
                                work was observed by the NRC CAT.                                                                -
1
                                The requirements and acceptance criteria for reinforced concrete
                                construction were obtained from the drawings listed in Table
i                                V-1 and the following specifications and procedures:
i
                                * Bechtel Construction Specification 2A010CS1004, Rev. 2, "Spect-
.                                  fication for Mechanical Splicing of Reinforcing Bars,"
*
                                    January 18, 1985
                                * Bechtel Construction Specification 2A010CS1009, Rev. 4, "Speci                                ,
                                    fication for Forming,.P13cing, Finishing, and Curing of Concrete,"
                                                                                                                          .
,
                                                                                                                              -
<                                  March 28, 1985
4
                                * Ebasco CSP-4, Rev. 5, " Concrete Placement," June 28, 1985
                                * Ebasco QCP-10.1, Rev. 5, "Cadweld Inspection," September 20,
,
                                    1985
i
i                                * Ebasco QCP-10.2, Rev. 5, "Preplacement Concrete Inspection,"
;                                  August 14, 1985
i
[                                                                    V-2
!
    - - - - - . - . - . -                                      - - . - ,            - . . - - - . - . - - - -
 
              .- . -                - -.- -                    -.-                      .            . - -
,
4
                              * Ebasco QCP-10.3, Rev. 5, " Concrete Placement Inspection,"
                                August 12,-1985
                          b.  Inspection Findings
<
                              The inspection of installed reinforcing steel for the two
                              concrete placements found no hardware deficiencies.
                              Activities observed for the two concrete placements as well as
                              in process mechanical splicing of reinforcing steel were found
                              to be adequate.
                              The licensee's Phase A statusing for concrete pour packages and
                              grouting packages reviewed a list of documents for 100 percent .
                              of the activities. This list was. developed from the requirements.
                              in Brown and Root Procedure CCP-25. A concrete document checklist
~
,                            had been prepared by the licensee for Phase A statusing of concrete
                              pour packages to-identify existing and missing (if any) QC documen-
                              tation. The NRC CAT sampled one concrete pour package including
                              six sets of associated QC documentation to verify if the contents
                              in the concrete pour package matched those indicated on the
                              concrete document checklist. No concerns were identified.
                              The licensee's Phase A statusing for mechanical splice QC docu-
                              mentation reviewed the documentation of cadwelds made by Brown and
>
                              Root.        Two forms, a cadwelder qualification and testing report
                              and a cadweld walkdcwn and documentation checklist, were prepared
<
                              by the. licensee for Phase A statusing to identify existing and
.                            any missing records related to mechanical splices. The NRC CAT
                              reviewed the Phase A statusing work by sampling one cadwelder and
                              one cadweld.' One concern was identified with the cadwelder
.,                            qualification and testing report for cadwelder No. 43. The space
                            . box for the "two in ea. subsequent 100" column of the " horizontal-
                              requalification" row had been marked "S" for satisfactory.
                              However, it should have been marked "U" for unsatisfactory. The                ,
                              NRC CAT was informed that cadwelder No. 43 was the only Brown and
                            . Root cadwelder requalified. Based on the information that no other
                              cadwelder was requalified and that the error was only with the
                              tensile testing frequency implemented after cadwelder No. 43 was
'
e                            requalified, the NRC CAT feels the error to be an isolated one.
                              Nonconformance Report (NCR) No. GC03199 was issued to address the
                              concern. Also, the dates listed in the " Dates Qualified To" spaces
                              for the " vertical qualification" and " horizontal qualification"
                              parts of the cadwelder qualification summary were found to be
E                            reversed. The licensee subsequently documented this concern.
                              The NRC CAT found no concern with the cadweld sample checked
                              against the contents of the cadweld walkdown and documentation
                              checklist.
                              During a general walkdown, the NRC CAT identified a crack in the              ,.
                              Unit 2 azimuth 304* tendon access wall at elevation (-)13 ft. 3
                              inches. This area was subsequently chipped out. It was then
                              identified that the 3 inch seismic joint material had not been
                              installed as required by drawing 3M01-9-C-4230R0 between the                  l
                              Reactor Containment Building mat and the tendon access wall.
                                                                    V-3
  ._ u - ,_ ,      - - -            .      - - . -      . _ . - - - -  - - - - . . - - . . . - - -
 
-
      "Y
                            ~Bechtel Engineering (BEC) issued NCR HCO3170.and state'd that-the
  ~
                              disposition-of. this' NCR would be to use as is. The stated basis of
              -              ;the disposition was that all settlements had taken place, the
                              bearing surface area was small, and the -vertical seismic movements
                              would be small at this location.
                              The NRC CAT's review of this issue found that BEC's disposition did
                              not adequately address the seismic movement of the mat and the
                            'previously predicted unfavorable relative heaves of the two
                              adjoining buildings once the dewatering system is discontinued.
                              Whether predicted unfavorable soil heave between the Reactor
                              Containment Building and the Mechanical and Electrical Auxiliary
                              Building could. create added unacceptable forces on the tendon
                              access wall r.eeds to be addressed.
          ,      c.            Conclusion
    -
                              In general, reinforced concrete construction appeared to be
                              adequate. The review work performed for Phase A statusing on the
                              Brown and Root concrete pour and mechanical splicing QC documenta-
                              tion appear ~ed to be thorough. The documentation concerns with the
                              mechanical splice QC records did not appear to affect the hardware.
                              Under certain conditions the omission of the seismic joint between
                              adjacent concrete structures could cause significant structural
                              damage.
                2.            Structural Steel Inspection
                . a.          Inspection Scope
                              Installed and QC accepted structural steel members and connections
                              were-inspected by the NRC CAT. Attributes ' inspected were member
                              size, configuration, and bolted connections. For bolted connec-
                              tions, both friction and sliding connections were tested by using a
,.                            calibrated torque wrench to detemine whether the bolts had proper
L                              pretension. In addition, the bolts were inspected for proper
                              . material and nut engagement on the bolt.
                              The 1, ample used in the structural steel verification for correct
?                              member size and configuration is described in Table V-2. A total
                              of 93 structural steel members and 39. connections were inspected.
                              The location, bolt size and material type, and number of ~ friction
                              and sliding type connections which were checked for proper pre-
                              tension are shown in Tables V-3 and.V-4 respectively. These
                              bolts were sampled from structural steel connections although both
                              samples are separate from those nentioned above as inspected for
                              configuration. Test torque v0 ns were obtained by using a
                              Skidmore Whilhelm tension testm to establish the proper torque-
                              tension relationship.
                              The requirements and acceptance criteria for structural steel
                                installation are included in the drawings listed in Table V-5
                              and in the following specifications and procedures:
            .
                                                                                                        V-4
                  _ _ _ ___                _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
 
                                                                                  -_
    . _ _
              * Bechtsi Construction Specification 3A010SS0012, Rev. 3,
F                " Category I Structural Steel," December 4, 1984
                                                                            ~
              * Bechtel Construction Specification 3A010SS0030, Rev. 5,
                " Erection of Structural Steel and Miscellaneous Steel,"
                July 26, 1985
              * Ebasco CSP-10, Rev. 6, " Erection and Boltup of Structural-
                Steel," September 19,'1985
              * Ebasco QCP-10.5, Rev. 5, " Inspection of Structural Steel
                Erection and Bolting," July 19, 1985
          b.  Inspection Findings
              Of the-93 structural steel members and 39 connections inspected
              for correct member size and configuration, only one hardware
              configuration deficiency was identified. This deficiency involved
                  ~
            .one column base connection being installed without nuts on one of
              its anchor bolts. Deficiency Notice 2-510-C was issued to repair
              the condition.
              A total of 648 7/8 inch diameter A325 high strength bolts were
              checked _ for proper installed torque for structural steel friction
              type _ connections.-- The installed torque values of twenty-three
              (approximately 4 percent) of the 648 7/8 inch diameter A325 bolts
              were significantly below the inspection torque of 450 ft-lbs. . Four
              of the 23 were found to be installed loose. NCRs CC03132 and
              CC03134 were written to repair the improperly installed bolts. All
              twenty-three bolts were to be properly tightened. The remaining
              625 bolts were determined to be acceptable.
              Thirty-two 7/8 inch diameter A490 high strength bolts were checked
              for proper installed torque. The sampled bolts were installed
              above the inspection torque value of 550 ft-lbs and determined to
              be acceptable.
                                                    '
              For the sliding type structural steel connections, a total of.
              68>7/8 inch diameter A325 high strength bolts were inspected for
              proper installation torque. Forty-three of the 68 A325 bolts were
              installed at torque values greater than the inspection torque
              value of 150 ft-lbs. Twenty-five of the 43 'over-tightened bolts
              were installed at torque values greater than 500 ft-lbs. NCR-
              CC03190 was written to document and disposition the deficiency.
              All of the sampled ' sliding connections had inspection markirgs
              indicating that they had been inspected. The inspection criteria
              for sliding connections states that the bolts be installed snug
              tight. : Snug tight is defined as the full force of a man on a
  ~
              spud wrench. Based.on such a vague inspection criteria, neither
              the NRC. CAT'nor the licensee was able to. determine how these  _
              connections could have been inspected. The NRC CAT finding
              indicates that more specific inspection criteria is necessary to
                                                      V-5
                    -    _ _ - _ _ _ _ _ _ _ _ _ _      _ _ _ _ _ _ _ _ _        -- A
 
                                        ..
    inspect the sliding connections adequately. The licensee has
    committed to write adequate inspection criteria in the current
    specifications and to reinspect all sliding. connections.
    It was found that project specifications allow welding across the
    flanges on fully loaded structural steel members. The NRC CAT
    asked if an engineering evaluation had been performed (similar to
    that indicated in AWS D.1.1, Section 7.5.1) to determine, due to
    extent of cross-section heating, whether or not a member is permit-
    ted to carry a live-load stress while welding on it. No specific
    analytical evaluation of whether the welding across the flange
  could weaken the affected structural steel member was provided to
  the NRC CAT. BEC ju'stified the specifications based on general
  engineering judgement and historical knowledge. This engineering
    response, without the supporting evaluation, is considered
    inadequate.
c. Conclusion
    In general,-utructural steel members and connections for size and
  configuration verification were .found to be installed properly.
  The high strength A325 and A490 bolts for friction type structural
  steel connections were generally determined to be installed
  adequately. The lack of adequate inspection cri_teria for sliding
  connections resulted in the acceptance of a deficient installation.
  All sliding connections should meet the new inspection criteria
  when established by the licensee.
  An evaluation should be conducted. showing that the practice of
  cross flange welding has not and will not overstress loaded
  members.
3. Backfill and Earthwork Construction
a. Inspection Scope
  The daily reports and backfill compaction records'for the
  Essential Cooling Water (ECW) pipe trench backfill were
  reviewed. The backfill compaction work activities and in situ
  sand cone tests in area II40, northeast of the Unit 1 Diesel
  Generator Building, were witnessed by the NRC CAT.
  The requirements and acceptance criteria are contained in the
  following specifications:
  * Bechtel Construction Specification SY069YS0043, Rev. 12,
      " Structural Excavation and Backfill".
  * Bechtel Construction Specification 2Y060YS0044, Rev. 5, " Field
      and Laboratory Testing of Earthwork Construction".
                              V-6
 
            .    __ ._ .        .      -_.      . _ . __        _              _ _    .      .__            .._              __ -          .        _
d
                                                                                                                                                                  t
                                      Inspection Findings
{                              b.
                                      The daily. reports and backfill compaction records appeared _to
  3                                    be complete'and in accordance with the project specifications.
  J                                    The backfill work activities observed by the NRC CAT northeast
  '
                                      of the Unit'l Diesel Generator Building at elevation +26.0 was
L                                    properly placed and compacted.
2
F                                    -The NRC CAT inspectors-identified a potential problem which may
  ,                                    not.have been addressed by the licensee. The ECW pipe trench is
  i
          .                            supported on a highly plastic A  2 clay layer.                    This clay layer
                                      will shrink when dried and expand as the clay particles absorb
'
        _
-
                                      water. Since 1975 the. site dewatering system has been in operation
                                      and the ground water level has fallen below the A2 clay layer.                                                            -+
,
                                      During this dewatering period the clay layer could have lost
'
  i
                                      significant moisture. The site dewatering system is scheduled to
                                      be discontinued prior to plant operation. When this occurs, the.                                                          s
<
                                      ground water level will be re-established to about-its pre-1975
                                      level. If,the moisture. content of the clay layer during the
                                    1 dewatering period has been reduced significantly and then the
,                                    dewatering system is discontinued, the clay layer when exposed to
,                                    the returned ground water is expected to expand. The issue _of
                                      whether this clay layer will expand and whether.the expansion will
-
                                      occur uniformily_ appears not to have been properly considered to
                                      date. This along with other data on the thickness of the clay
                                                                                                                                                                  ,
,                                    layer, the placticity index of the clay, the confining pressure and
,                                    'the quantity of water absorbed by'the clay particles, and the in
                                      situ moisture content of several points at various levels in the
      '
                                    ' clay layer during the dewatering period will also need to be
,
                                      considered. The concern is whether the expansion of the underlying                                                        ,
                                    - and adjacent clay could cause differential-displacements of the ECW                                                        ;
                                      pipes. Also, whether.this potential.for ground movement could
'
                                      cause the ECW pipes to become overstressed. The licensee was not
                                      able to provide information on such.a review during the NRC
                                      inspection.
                              c.      Conclusions
1
                                    The structural backfill compaction records and the structural
                                      backfill reviewed by the NRC CAT inspectors were generally _found
'
                                                                                                                                                                -
l                                    to be acceptable.
                                    The licensee should investigate the potential of the expansive
                                    . clays to swell upon return of ground water to normal levels and
                                      the potential affect of this swelling on the ECW piping.
4
:                            4.    Concrete Expansion Anchor Bolt Qualification Test Report
,
                              a.      Inspection Scope                                                                                                          "
i-
;
'
                                    The qualification test report for the wedge type concrete expansion
                                    anchors was reviewed for technical adequacy, conformance to
.
                                    project specifications and demonstration of satisfactory anchor
:                                    performance.
L
i
    -
                                                                  V-7
:
,
*                                                                                                                                                                &
                                        '
              ,-w  ey,=. < ,                                            ,,w,,,,-    - .
                                                                                            ,.,,e    y,,,,_,w,y    .-.r_.my, .-,      ,--,.g ..
                                                                                                                                                    .,,my,  ,
 
<
      The following qualification test report was reviewed:
      * Wiss, Janey, Elster and Associates, Rev. 2, " Tension, Shear and
        Relaxation Testing of Expansion Anchors at the South Texas
        Project, Bay: City Texas", May 29, 1981
      The requirements and acceptance criteria are contained in the
      following documents:
      * Bechtel Construction Specification 5A010SS1000, Rev. 7,
        " Installation of Expansion Anchors, Rock Bolts, Grouted
        Anchor Bolts, and Core Drilling"
        Ebasco CSP-41, Rev. 6, " Installation of Expansion Type Anchors"
    * Ebasco QCP 10.19, Rev. 7, " Inspection of Anchoring Devices
        Installed Within Concrete Structures"
  b.  Inspection Findings
    The allowable loads used in the design of concrete expansion bolts
      (CEAs) was based on the average results of the tests divided by
    a factor of safety of 4. For the 1/4 inch diameter CEAs with
    1-1/8 inch embedment the average maximum load for 4070 psi concrete
      is 890 lbs. The allowable tensile load is 250 lbs. This allowable
      load does not meet the factor of safety of 4 criteria specified in
      Inspection and Enforcement Bulletin 79-02.
    For the 1-1/4 inch diameter CEAs, the anchor slip at the design
    tension loads is greater than 1/16 inch for 8-1/2 inch embedment
    and 3/16 inch for 10-1/2 inch embedment. The shear tests show
    similar results. The licensee has stated that the 3/16 inch
    movement at the design loads was unacceptable and that the
    allowable loads will be reduced. The licensee stated that for
    the 1/16 inch slip, the current design load is acceptable.
    The-NRC CAT finds the licensee's response for the 1/16 inch slip
    at the current design loads to be inadequate. The results in the
    test program for anchor bolts are for one time loading. However,
    reliance solely on the referenced test program without considering,
    in actuality, that within the plant the maximum design load may
    be applied more than one time, is considered inadequate. Since
    most of the slip is likely to be permanent, these deflections will
    tend to accumulate with each load application. Also, the 1/16 inch
    deflection in shear and tension may be considered unacceptable in
    many piping analysis.
  c. Conclusion
    The licensee should reevaluate the~ allowable design loads used for
    concrete expansion anchors. This reevaluation should take into
    account the magnitude of anchor slip at the design load and
    consider the shear, tension, deflections, and the piping systems
    that are supported.
                                  V-8
                                                                          1
 
            _-
5. Containment Post-Tensioned System
a.  Inspection Scope
  The installation records of 8 Unit 1 prestressed tendons were
  reviewed. The NRC CAT also observed.various stages of tendon
    installation work activities which include the pulling, button-
  heading, stressing, and greasing of the tendons.
  The requirements and acceptance criteria were included in the
  following specification and procedures.
  * Bechtel Construction Specification 2C239CS0003, Rev. 4,
      " Containment Post Tensioning System," July 15, 1985
  * FIM-STP-01, Rev. O, " Procedure for Cleaning and Checking-
      Post Tensioning Embedded Items," August 8,1984
  * FIM-STP-H-1, Rev. 1A, " Installation, Buttonheading, Stressing
      and Greasing of Horizontal Tendson," August 29, 1985
  * FIM-STP-V-1, Rev. 3A, " Installation, Buttonheading, Stressing
      and Greasing of Vertical Tendons," August 29, 1985
  * FIM-VCP-01, Rev. 2, " Tendon Void Clearing Procedure," May 22,
      1985
      FQCP-STP-03, Rev. 3, " Quality. Control Procedures - Vertical
      and Horizontal Tendons," July 9, 1985
  * STP-FTP-1, Rev. 4, " Friction Test Procedures," August 13, 1985
b. Inspection Findings
                                                                        . ,
  The review of installation records and the observation of various
  stages of tendon installation work activities indicated that the
  post-tensioned system was being installed in accordance with
  the specifications and procedures.
c. Conclusions
  The installation of the containment post tensioned system was found
  to be in accordance with applicable instructions and specifications.
                              V-9
                              _
 
                                              .-      .          .  -                    -          ~.      ..              . _ - _ _ -
b
        _
                                                                    TABLE V-1
                              DRAWINGS USED FOR REINFOR'C D CONCRETE CONSTRUCTION INSPECTION
                [DrawingNo.          Rev.                                    Title
                                                                                                                                              t
                  193AB-              -B          (Shop Drawing)
t                193BC                C.        (Shop Drawing)
]                193C                  A          (Shop Drawing)
                -2C22-9-S-1012        1          Steel Reactor Containment Building Dome Liner - Plans -
                                                  -and Sections and Details
,
                  2C22-9-C-1033        5        -Concrete-Reactor Containment Building Dome Reinforce-                                      '
,
'
                                                  ment.- Plan
                  2C22-9-C-1034        2          Concrete Reactor Containment Building Dome Shell"-
i                                                Sections and Details
                :2C22-9-C-1036        0          Concrete Reactor Containment Building Dome Tendon -                                        i
                                                  Anchorage Location
j                J2C23-9-C-1021        1          Concrete Reactor Containment Building Post Tensioning
                                                  System
'
                  3A01-0-C-0001        20      -Concrete Structural St'andards General Notes
                  3A01-0-C-0011        14        Concrete Structural Standards General Notes-
                  3M01-2-C-4026        9.        Concrete Mechanical & Electrical Auxiliary Building
,                                                  Floor Plan 9 E1. 41'..-0"
  i
                  3M01-9-C-4241        2          Concrete Mechanical & Electrical Auxiliary-Building =
                                                  Std.: Wall Reinf._ Details E1. 29'-0" to Roof (U.N.0.)
p'
                  3M01-9-C-4242        1          Concrete Mechanical and Electrical Auxiliary Building
                                                  Miscellaneous Details                                                                    .i
j                3M01-9-C-4309        3        ' Concrete Mechanical and Electrical Auxiliary Building                                      i
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                                                  Miscellaneous Sections-and Details
          -
                  3M05-9-C-4009        5          Concrete Mechanical and Electrical Auxiliary Building
j.                                                Foundation Plan 9 El. 10'-0"
:                                                                                                                                            i
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                                                                          V-10
    .-.    - -.        -
                                  . . - . . . - _ _ - . . .. a .-.      - . - -      . . . . . . - . -    ...-.;-. . . - - - -.
 
                            -          -                              . - . .                          ..        .      -                  . . _ . -                                -.        .. .
    -
.
j
                                                                                  . TABLE V-2
                                            INSTALLED STRUCTURAL-STEEL INSPECTION SAMPLE
i.                                                                                                                                                                                                      i
              Unit ~ Number  Approximate                                                                                                  Truss
            . and Building-    Elevation                                                                                                                      Comments
                                                          Beans Braces Columns Connection @ @ers
.
              Unit 1-                  68 ft                14                        -
                                                                                                            2            3                              -
                                                                                                                                                                                                        '
              Reactor                                  .
'
            - Containment              52 ft                5                        .1                    -            -                              -
,
                                      37 ft                2                          -                --
                                                                                                                      .-                                -
                                      -2 ft                2                          -
                                                                                                            1            3                              -
            Unit 11              118 ft                    5                          -                  -
                                                                                                                        8                              11    Sample Taken
            Fuel Handling-.                                                                                                                                  From Roof
                                                                                                                                                              Trusses and
                                                                                                                                                              Framing                                -'
            Unit-1                    69 ft                ~5-                        -                  -
                                                                                                                        5                              3
,            Mechanical'&              and
            Electrical                6 inches
t          . Auxiliary
.
                                      74 ft                3                          -
                                                                                                            3          3                              -
                                                          _                            _                  _        _                              _
                  Total                                  36                            1                  6        22                              14
                                                                                                                                                                                                        '
                                                                                                                                                                                                        ,
1
t
                                                                                                                                                                                                        L
4
e
$-
:                                                                                                                                                                                                      t
,
                                                                                                                                                                                                        k
                                                                                                                                                                                                        r
;
                                                                                              V-11
  ,
4
      ,. ,          ..
                                        -
                              ~,__,.._.,,-_,-w,,,,,,,_        , _ . . _ _ . . _ , . , - . ,  ,,_,,_.r,      _._,,_m.,.    _ . . ~ . , . . , .          . ,  . , . . , . . _ , . _ , , ..,,.%
 
  . - .            -    -                    - - . _ .          .        ..  . . - - -                              .    .-
1
                                          -TABLE V-2 (Continued)
,
                              INSTALLED STRUCTURAL STEEL INSPECTION SAMPLE
~
        Unit Number-  Approximate
        and Building    Elevation        Beams          Columns            Connections                        Comments
        Unit 2    .
                          10 ft              -              -
                                                                                    1                          Deficiency Notice
.      Mechanical &                                                                                            2-510-C was issued
        Electrical                                                                                              to repair the
      Auxiliary                                                                                                anchor bolts of
                                                                                                                column base
                                                                                                                connections.
                          20 ft              5              2                  6
                          35 ft              3              2                  3
.
                          58 ft              8                3                  5
      Unit 2            52 ft              5              -
                                                                                  1
      Reactor
      Containment        68 ft              8                -
                                                                                  1
                                          _                _                  _
-
            Total                        29                7                  17
.
                                                                                                                                                  .t
i
I
4
v
'
                                                          V-12
                        - - .      ..      .      .. -    . _ . . - - - -      -
                                                                                            . . _ . - - - _ - _ . - . - -    . - _ _ . - . .
                                                                                                                                              . .
 
,
                                                                                              I
                                          TABLE V-3
              HIGH STRENGTH BOLTING FOR FRICTION CONNECTION INSPECTION SAMPLE
                                              Number of            Number of
                              Number of    Bolts Checked      Bolts Installed
  Unit Number- Bolt Size      Friction        for Proper        Below Inspection
!
  -and Building and Type-    Connections * Installation-Torque
                                          -
                                                                      Torque      Comments
  Unit 1          7/8 inch      .15            144                    5        See note 1
  Reactor        dia. A325
  Containment
  Unit 1          7/8              8-            77                    8
  Mechanical & dia. A325
  Electrical
  Auxiliary
  Unit 2          7/8 inch        12            172                    0
  Reactor        dia. A325
  Containment
  Unit 2          7/8 inch        20            255                    13
  Mechanical & dia. A325'
  . Electrical
  Auxil'iary
  Unit 2          7/8 inch        1              32                    0        See note 2
  Reactor        dia. A490
  Containment
  Note 1:    The inspection torque value for 7/8 inch dia. A325 bolts was 450 ft. lbs.
  Note 2: The inspection torque value for 7/8 inch dia. A490 bolts was 550 ft. lbs.
  *The connections sampled are separate from the structural steel connections
    inspected in Table V-2.
                                              V-13
 
-
                                          TABLE V-4
                        HIGH STRENGTH BOLTING FOR SLIDING CONNECTION
                                      INSPECTION SAMPLE
                                                        Number of Bolts
                                  Number of Bolts      Installed Above
          _      Number of        Checked for        Inspection Torque
  Unit Number      Sliding      Proper Installation    and the Installed
  and Building  Connections *        Torque            Torque Range        Comments
  Unit 1              1 10              67            10 installed between All bolts were
  R; actor
                                                        160 and 200 ft-lbs    7/8 inch dia.
                                                                              A325. Approxi-
                                                        5 installed between 'mately 63% were
                                                        200 and 250 ft-lbs    found to be
                                                                              installed
                                                        28 installed above    overtorqued.
                                                        300 ft-lbs
  "The connections sampled are separate from the connections inspected in Table
  Table V-2 and V-3.
                                                V-14
 
, :. :
                                  TABLE V-5
        DRAWINGS USED FOR STRUCTURAL STEEL INSTALLATION INSPECTION
                    American Bridge Detail Drawings
        Order No.              Sheet No.            Revision No.
        K-7023                E12                        8
                              610AD                    .A-
                              ~6100                      -
      'K-7024                E2                        C
                              E5                        F
                              E18                      G
                              E20                        E
                              E22-                      G
                              E301-                      E
                              E302                      G
                              123                      B
                              176                      C
                              506                      A
                              526                        -
                                                                  ,
        K-7025                E4                        D
                              E12                        H
                              E702                      A
                              718                        -
        K-7029                E17                        C
                              E22                        C
                              405                        -
                              413                        -
                                                                  ,
                              508                        B
                              516                        C
        K-7030              'El                        -
                              E2                        -
                              E6                        B
                              E7                        A
                              E9                        0
                              102                        A
                              106                        A
                                    V-15
 
                                TABLE V-5 (Continued)
            DRAWINGS USED FOR STRUCTURAL STEEL INSTALLATION INSPECTION
                              Bechtel Design Drawings
Drawing No.    Rev.                              Title
1C01-9-S-1532    4      Reactor Containment Building Steam Generator,
                        R.C. Pump Vertical and Pressurizer Lateral Support
IC01-9-S-150      5    Reactor Containment Building Internal-Steel Framing
                            Plan @ E1. 68-0"
3A01-05-0001    12      Steel Structures Standards General Notes
3C01-9-S-1502    8      Reactor Containment Building Internal - Steel Framing      i
                          Plan 9 El. (-)2'-0"
3C01-9-5-1505    4.    Reactor Containment Building Internal - Steel Framing
                          Plan @ El. 37'-3"
3C01-9-S-1508    5      Reactor Containment Building Internal - Steel Framing
                          Plan 9 El. 52'-0'
3C01-9-S-1509    4      Reactor Containment Building Internal - Steel Framing
                          Plan @ El. 68'-0"
3C01-9-S-1510    5      Reactor Containment Building Internal - Steel Framing
                          Plan 9 El. 68'-0"
3C01-9-S-1511    1      Reactor Containment Building Coluc.n Schedule and Details
3C01-9-S-1528    8      Reactor Containment Building Internal Sections and Details
3C01-9-S-1539    2      Reactor Containment Building Internal - Miscellaneous
                          Plan Sections and Details
3C01-9-S-1619    6      Reactor Containment Building Internal - Steel Alterations
                          @ El. (-)2'-0"
3C01-9-S-1621    5      Reactor Containment Building Internal - Steel Alterations
                          0 E1. 37'-3"
3C01-9-S-1622    3      Reactor Containment Building Internal - Steel Alterations
                          O El. 52'-0"
3C01-9-S-1623    3      Reactor Containment Building Internal - Steel Alterations
                          9 E1. 68'-0"
3C01-9-S-1624    6      Reactor Containment Building Internal - Steel Alterations
                          Details and Tables
3C01-9-S-1625    2      Reactor Containment Building Internal - Steel Alterations
                          Details and Tables
3C01-9-S-1629    6      Reactor Containment Interal - Steel Alterations
                          Details and Tables
3F01-9-S-3003    3      Fuel Handling Building Roof Framing Plan (Plan - Roof
                          Truss 9 Top Chord and Roof Truss MK-TI)
3M01-9-S-4043    3      Mechanical and Electrical Auxiliary Building Framing
                          in HVAC Areas El. 69'-6" U.N.
3M01-9-S-4060    4    Mechanical and Electrical Auxiliary Building Framing
                          Plan @ Els. 21'-0" and 23'-0"
                                          V-16
 
      ,
                                            TABLE V-5 (Continued)
                  DRAWINGS USED FOR STRUCTURAL STEEL INSTALLATION INSPECTION
                                            Bechtel Design Drawings
  Drawing No.        Rev.                                      Title
  '3M01-9-S-4065        4            Mechanical ~and Electrical Auxiliary Building Framing
                                        Plan 9 El. 35'-0"
  3M01-9-S-4071        1            Mechanical and Electrical Auxiliary Building Framing
                                        Plan 9 El. 60'-0"
  3M01-9-S-4082        4            Mechanical and Electrical Auxiliary Building Framing
                                        Plan 9 El. 72'-0", 74'-0" and 76'-0"
  3M01-9-S-4090        4          Mechanical and Electrical Auxiliary Building Coluns
                                        Schedule and Standard Details
:
-
4
i
                                                                                                    W
                                                      V-17
              ,_.      -    .. ,_ -_ -                      .            , _ _ _ . _ -. -_- - _ .
 
VI. MATERIAL TRACEABILITY AND CONTROL
    A.  Objective
        This part of the inspection effort was to verify that the identifi-
        cation and marking of materials and equipment used in the fabrication
        and construction processes have been maintained, and that the docu-
        mentation required to support traceability, to both the. design
        drawings / specifications and to the material sources, was retrievable
        and met regulatory requirements, PSAR commitments, and applicable
        codes and standards.
    B. Discussion
      A total of 219 items were selected at random and identified as samples
        for the inspection. The items inspected were located in the storage
      yards, laydown areas, storage warehouses, outlying buildings, and
      various elevations and rooms in the reactor containment, auxiliary
      building, diesel building, and fuel handling building for both Unit
      1 and Unit 2. Some items inspected were in storage and others
      were being installed. Some had been installed and were in a storage
      mode, and others had been installed and turned over to the operations
      group.
      Tables VI-1 through VI-8 indicate the areas where material / equipment
      samples were selected, and adequacy of the identification, trace-
      ability and documentation. The applicable reference documents
      reviewed and used during the inspection included the following:
          Site Final Safety Analysis Report.
      * Specification 4A010GS1009, Safety Related Non-ASME Bolting
          Materials, Rev. 1.
      * Specification 5A010GS1007, Civil / Structural Construction
          Materials, Rev. 3.
      * Specification 3E189ES1000, Conduct and Tray Supports, Rev. 6.
      * Procedure SSP-13, Material Control, Rev. O.
      * Procedure ASP-5, Material Control, Rev. 8.
      * Procedure WPP/QCI-12.4, Material Identi*ication and Marking
          Requirements, Rev. 10.
      * Procedure QCP-9.4, Verification of Weld Filler Material
          Control, Rev. 3.
      * Procedure WPP/QCI-18.0, EE580 Cable and Raceway Tracking
          Procedure, Rev. 12..
      * Procedure QCP-10.22, Receipt Inspection, Rev. 12.
      * Engineer and Constructor ASME Procedure.
                                  VI-1
 
' * American Society for Testing Materials standards.
  Equipment and components were inspected in order to verify that
  required identification codes were maintained on items such as civil
  construction materials, electrical cable and equipment, welding
  supplies, vendor supplied equipment assemblies, structural and
mechanical items.
  1.  Material Traceability
  a.  Inspection Scope
      Two hundred nineteen samples were examined to determine if the
      identification and markings were traceable to the applicable
      specification, drawing, purchase. order, code data package, mill
      test report or a combination thereof.    The licensee's records
      management group. retrieved the requested documentation which was
      analyzed and compared to site requirements and field notes by the
      NRC CAT inspector.
b.  Inspection Findings
      During the inspection it was determined that a program for
    . identification of materials and retrievability and adequacy of
      documentation was generally in place and functioning.
      (1) The following were found to be satisfactory:
            (a) The records management group uses a computer assisted
                program for retrieval of most documents that are
                considered complete. In process records are processed
                manually or by using sub programs (i.e., electrical
                EE580 program for. routing, terminations, cable type,
                etc.)
            (b) Eighteen samples of different types of welding
                consumables as noted'in Table VI-1 were examined for
                markings, retrievability of documentation and adequacy
                of the documentation.
            (c) Fourteen samples of different types and sizes of
                electrical cables were inspected for identification,
                documentation and qualification requirements. These
                results were satisfactory as shown in Table VI-2.
            (d) Civil / Construction materials were inspected for
                compliance to the specification requirements. Thirty-
                one items were sampled and were found to meet the
                specification requirements as shown in Table VI-3.
            (e) Anchor bolts and embedded items were not a part of the
                traceability program due to the fact that a major
                program in this area was previously undertaken by the
                licensee and is awaiting review by the NRC. The NRC CAT
                inspector reviewed the structural bolting for an
                              VI-2
 
  =
{
                Accumulator and Residual Heat Removal Heat Exchanger and
                noted that both were included in the licensee's report.
          (f) Table VI-4 summarizes materials and equipment that was
                inspected and is used in the Heating, Ventilating and
                Air Conditioning (HVAC) discipline including fans,
                motors and dampers. Tracability was.found to be
                satisfactory.
    (2) Significant' weaknesses in the program were found in the
          following areas:
          (a) The action taken for the disposition of FCR BE-00088 on
                the clarification of bolting material requirements for
                cable tray.and conduit supports was not effective in
                that it allowed the option of not .aposing the manufac-
                tures marking requirements of the specified national
                bolting standard without appropriate consideration of
                the measures needed to maintain the traceability and
                control of unmarked fasteners throughout the plant.
        (b) Verification of markings / traceability of bolting
              materials used in the fabrication of large vendor
                supplied skid mounted equipment and used by the
                construction crafts in the fabrication and installation
              of electrical equipment.
    (3) The following' observations were made by the NRC CAT inspector
        and found to be unsatisfactory:
        (a) Code data packages for the' Unit 1 Radwaste Holdup' Tank
              7R32IXTS101A and Reactor Internals Disconnecting Device
              Pressure Housing, Board #18288 could not be_ located. As
              a result of the NRC CAT finding, the licensee issued
              Nonconformance Report BN-03015 to document the
              deficiency of Board #18288 and provide for appropriate
              corrective action. No written corrective action was
              noted during the NRC CAT inspection concerning the'
              Radwaste Holdup Tank.
              The code data package for an ASME 8-inch check valve was
              incomplete and a corrected copy of the certificate of
              welding was generated. As a result of the NRC' CAT
              finding, the licensee issued a Document Deficiency
              Notice QC-RN-150.1.    The material type'as indicated on a
              code data report for an ASME 8 inch Safety Injection
              Check Valve Bonnet (valve #V1423) was different than
              that indicated on the mill test report. As a result of
              the NRC CAT finding, the licensee initiated NCR BN-03013
              to document this discrepancy for corrective action.
              These and other ASME code data packages inspected are
              indicated in Table VI-5.
                              VI-3
 
  (b) Some documents that were requested to confirm bolting
          traceability of certain selected equipment samples
          summarized in Table VI-6 were not located and furnished
          for review by the NRC CAT inspector prior to the end of
          the inspection. Licensee representatives stated that
          actions would be. continued to locate applicable
          documentation and review bolting traceability.
  (c) It was found by the NRC CAT inspectors that the specific
          requirement of the national standard ASTM A307 Grade B
          for marking of fasteners has been deleted by engineering
          from a specification for electrical raceway supports,
                                                                ~
L
        without requiring adequate on-site material control
        during their installation (Reference FCR BE-00088 and
        Specification 3E189ES1000 for conduit and tray supports).
        The deletion of marking / identification requirements for
        electrical equipment bolting has resulted in the
        uncontrolled distribution of bulk quantities of these
          items throughout the plant. This condition may have
        resulted in the indiscriminate use of the unmarked
        fasteners in other types of equipment installations
        because the bolting is readily available and presumed to
        be adequate.
        Based on the above observations, the NRC inspector could
        not ascertain the appropriate use and traceability of
        the unmarked fasteners for the various electrical
        installations of the NRC CAT sample, and thus the
        quality of the fasteners is considered indeterminate.
  (d) The bolting in 10 of 11 samples of electrical equipment
        was not found to be traceable when inspected for
        conformance to specifications or seismic reports.
                                                    ~
        Bolting used in fabrication and/or installation of the
        ten samples were not marked or had mixed markings.    The
        results are tabulated in Table VI-7.
  (e) Two sections of 2 inch schedule 160 stainless piping in
        storage were found to be mismarked. As a result of the
        NRC CAT finding,.QCI report G1649 was issued by the
        licensee to scrap the pieces.
  (f) Mechanical material and equipment was inspected to the
        specification requirements. Regarding bolting, several
        items were found to be of the correct type, identified
        and traceable. However, traceability deficiencies were
        found in 14 of 20 samples of bolting for large mechani-
        cal installations listed in Table VI-8. The following
        are five examples of such deficiencies:
                        VI-4
 
                  * Mounting bolts for the Essential-Coo. ling Water Wash
                    Screen (3R281NPA102A) Motor were unmarked.      These are-
                      required to be ASTM A193-87.    As a result of the NRC
                    CAT finding, the utility has issued NCR AM-03072
                    documenting the discrepancy for corrective action.
                  * Motor mounting bolts for the Auxiliary Feedwater Motor
                    #13 were identified as~ ASTM A193-B7 and were required'
                    to be ASTM A307. The licensee, during the NRC CAT
                      inspection, did not issue documentation to record this
                    -discrepancy for corrective action.
                * Bolti~ng for the Containment Spray, High Head Safety
                    Injection and Low Head Safety Injection Pumps, motors
                    and transition pieces Nos lA, 2A, 3A, IB, 2B, 3B and
                    IC, 2C, 3C were observed to be either unmarked, A307,
                    A325 or A449.    The correct bolting for these units is
                  ~ ASTM A193-B7. As a result'of the NRC CAT finding, the
                    licensee issued NCR'CM-03078 to document this
                    discrepancy for corrective action.
                * Auxiliary Feedwater Turbine (3S141MTU01) driver
                    bolting to the base was not identified or marked.
                    This material is required to be SA193-B7. As a result
                    of the NRC CAT finding, NCR BM-03076 was issued to          '
                    document this item for' corrective action.
                * Bolting on the Essential Cooling Water Strainer Flange
                    .(3R281NSP101A) by drawing was required to be cadmium
                    plated. The specification allowed for cadmium or zinc
                    plating, and the sample appeared to be zinc plated.
                    As a result of the NRC CAT finding, the licensee
                    issued Field Change Request BP-00891 to change the
                    drawings to include zinc ~ plating.
  c. Conclusions
      In general, the material traceability and control program was
      considered to be satisfactory. However, lack of traceability was
      found for fastener materials for certain large sendor supplied
4
      mechanical / electrical equipment assemblies mounted on skids and
      for certain electrical equipment and cable tray / conduit supports.
      Also, documentation to permit verification of traceability of
      fasteners for certain equipment was not located by the licensee
,'    during the inspection.
                                  VI-5
                                                                                i
 
L
                      TABLE VI-1-
                  WELDING CONSUMABLES
..  ITEM            LOCATION            COMPLIANCE
    3/32 E7018      Test Shop          Satisfactory
    .093 E6010      Test Shop          Satisfactory
  '3/32 E7018      Test Shop          Satisfactory
    1/8 E6010      RCB II            Satisfactory
    1/8 308L-16    RCB II            Satisfactory
    3/32 308-16    RCB II            Satisfactory
    1/8 316-16      RCB I              Satisfactory
    .045 ERNICR-3  RCB I              Satisfactory
    1/8 E12018-M    RCB I              Satisfactory
    5/32-308-16    RECO              Satisfactory
    5/32 308-16    RECO                Satisfactory
    3/16 309-16    RECO              ' Satisfactory
    3/32 E7018    DG Caddy            Satisfactory
    3/32 E7018    MEAB Caddy          Satisfactory
    5/32 E7018    MEAB I Caddy        Satisfactory
    5/32 E7018    MEAB I Room        Satisfactory
    .035 wire      MEAB I Room        Satisfactory
    1/8 308-16    MEAB I Room        Satisfactory
                        VI-6
 
            ._  -                                                        ..                            _ _ _ _ .
:
'
                      TABLE VI-2
                  ELECTRICAL CABLE
    ITEM            LOCATION                                                                  COMPLIANCE
    3/c #12
'
                    Reel yard                                                                  Satisfactory
    7/c #12        . Reel yard                                                                Satisfactory
    3/c #12          ECW Structure                                                              Satisfactory
  '2/c #16          Unit I laydown                                                            Satisfactory
-
    1/c 500MCM      Unit I laydown
                          ~
                                                                                                Satisfactory
    3/c #8          Unit I laydown                                                            Satisfactory
    5/c #12          Unit I RCB El 68                                                          Satisfactory
    9/c #12          Unit I RCB El 50                                                          Satisfactory
    3/c #8          Unit I RCB El 24                                                          Satisfactory
    3/c #10          Unit I FHB El 73'                                                          Satisfactory
i  2/c #12          Unit I MEAB El 65                                                          Satisfactory
    3/c #12          Unit I MEAB                                                                Satisfactory
    5/c #12          Unit I MEAB El 35                                                          Satisfactory-
    7/c #12          Unit I MEAB El 10                                                          Satisfactory
i
1
1
                                                                                                                    ,
*
                            VI-7
                -            _ _ _ , . . . . . . _ . . . _ _ _ - _ . . _ . - . _ _ . . _ , _ - _ . _ _ _.
 
                                      TABLE VI-3
                          CIVIL / CONSTRUCTION MATERIALS
  Item              Identifier            Location                  Compliance
  #9 Rebar        T5-6275                Laydown                  Satisfactory
  #10 Rebar        S-16741                Laydown                  Satisfactory
  #11 Rebar        S-25074                Laydown                  Satisfactory
  Cadweld Powder  N-7178                  Storage warehouse        Satisfactory
  Cadweld Powder  D-24409                Storage warehouse        Satisfactory
  Cadweld Sleeve  S-2068                  Storage warehouse        Satisfactory
  Cadweld Sleeve  S-1901                  Storage warehouse        Satisfactory
  W.R. Admixture  B-12120-09W            Batch plant                Satisfactory
  A.R. Admixture  B-11293-09V            Batch plant                Satisfactory
  Cement          Grind #13              Batch plant                Satisfactory
  Paint            111488                  Paint warehouse          Satisfactory
  Paint Cure      108220B                Paint warehouse            Satisfactory
  Paint Mix        112389                Paint warehouse            Satisfactory
  Paint Powder    112260                  Paint warehouse          Satisfactory
  Cadweld Sleeve  S-1798                Unit II RCB springline    Satisfactory
  Cadweld Sleeve  S-2082                Unit II RCB springline    Satisfactory
  Structural Seam  J72499                Unit II El 72 RCB          Satisfactory
  Wall Embed      70479                  Unit II El 45 RCB          Satisfactory
  Structural Nuts  2H                    Unit II stairwell RCB      Satisfactory
  Steel Column    K7029                . Unit II RCB              Satisfactory
  Floor Embed      2907                  Unit'II El 35 control Room Satisfactory
  Threaded Rod    NA                    Unit II MEAB El 10        Satisfactory
  Nuts            DH                    Unit II MEAB El 10        Satisfactory
  Stainless Plate -13721                  Condensate Tank Unit I    Satisfactory
  C.S. Plate      401C7601              Condensate Tank Unit I    Satisfactory
  3" Shim          680015                Unit I FHB roof            Satisfactory
  Wall Embed      52028                  Unit I RCB El 60          Satisfactory
  Liner Plate      2425                  Unit 1 RCB El 57          Satisfactory
  Anchor Bolts    NA                    Unit I RCB El 2            Satisfactory
  Anchor Bolts    NA                    Unit I RCB El 32          Satisfactory
  Floor Plate      3E1846                Unit 1 RCB Refuel Pool    Satisfactory
i
a
                                        VI-8
                                                    __ -    -
 
F                                                                              1
                                    TABLE VI-4
                      HEATING, VENTILATING AND AIR CONDITIONING
  Item            Identifier                  Location            Compliance
  Joy Fan        3V112VFN003                Warehouse C        Satisfactory
  Bolts          TB-                        Unit II MEAB El 60  Satisfactory
  Bolts          STB.                        Unit II MEAB El 60  Satisfactory
  Hanger.        2-6-0052-S056-RSI-28075    Unit II MEAB El 35  Satisfactory
  Damper          8V141VDA-043                Unit I RCB El 5    Satisfactory
  Ventilation Fan 8V141VFN-023                Unit I RCB El 6    . Satisfactory
  Cooling Coil    8V141VHX-004                Unit I RCB El 6    Satisfactory
  Fire Damper    1-3-0073-VD-101            Unit I.FHB El 47    Satisfactory
                                        VI-9
 
._
                                        -
                                                          _                                        l
  3                                                                                                  ,
        .                                                                                            ,
    [                                              TABLE VI-5'
                                        ASME CODE DATA PACKAGES REVIEWED
            Item                                                Location'            Compliance
            8". Check Valve:                                  Warehouse D          -Unsatisfactory-
            16" Gate' Valve                                  : Warehouse D          Satirfactory
-
          : Instrument- Valve -                              -Unit II RCB          Satisfactory
            Component Support                                - Unit II RCB          Satisfactory-
            12" Pipe and Flange                                Unit II FHB-          Satisfactory
            Spent Fuel Pool Heat Exchanger                    Unit II FHB-          Satisfactory
            10" Gate Valve.                                    Unit II FHB          Satisfactory
            Ball Valve                                        Unit II MEAB El 10"  Satisfactory
            6" Bronze Pipe                                    ECW Building          Satisfactory
            24" Bronze Pipe
                -
                                                              ECW Building          Satisfactory-
            2" Pipe and Elbow      -
                                                              Unit I FHB            Satisfactory
          :8" Containment Spray Ring Pipe                      Unit I FHB            Satisfactory
          :2" Globe Valve                                      Unit I FHB            Satisfactory
            Reactor' Internal Disconnect Device Housing        Unit I RCB            Not Retrievable
          '30" Main Steam Pipe                                Unit I RC8 El 65      Satisfactory
          ~30" Main. Steam Pipe                                Unit I RCB El 35      Satisfactory
            Pipe'Pentration                                    Unit I RCB            Satisfactory
      -
            RHR Heat Exchanger                                Unit I RC8 Rm 306  . Satisfactory _
          : Flexible Instrument Line-                          Unit I RC8 El'35'    Satisfactory
          -24". Gate. Valve ~                                Unit I RCB El 24      Satisfactory
            31" Crossunder Pipe-                              Unit I RCB El 2      Satisfactory
            8" Safety Injection Check Valve                    Unit I RC8 El 6      Unsatisfactory
            Pressure Sensor                                    Unit I RCB E1 32    Satisfactory
            2": Solenoid Valve        .                      ' Unit I DG8 El 32'  ~ Satisfactory
            Spent Fuel Pool Heat Exchanger                    Unit I FH6 El 4      Satisfactory
            Spent Fuel Cooling' Pump                          Unit 1 FHB El 35    Satisfactory
            14" Fabricated Pipe                                Unit I FH8 El 17    Satisfactory
            3" Plug Valve        .                            Unit I MEAB El 74    Satisfactory
            Component Cooling Water Surge Tank                Unit I MEA 8 El 65  Satisfactory
            Recycle Evaporator Condensate Tank                Unit I MEA 8 El 56  Satisfactory
            Waste Evaporator Condensate Tank                  Unit I HEA8 El 56    Satisfactory
            FTD Filter                                        Unit I MEAB El 65    Satisfactory
            2" Valvc                                          Unit I MEAB El 65    Satisfactory-
            Radwaste Holdup Tank                              Unit I MEAB El 57-  Not Retrievable
            Chemical & Volume Control Tank                    Unit.I MEA 8 El 46  Satisfactory
            Component Cooling Heat Exchanger                  Unit I MEA 8 El 29  Satisfactory
            Seal Water Heat Exchanger                          Unit I MCAB El 10    Satisfactory
                                                    VI-10
 
t -
                                          TABLE VI-6
                    TRACEABILITY DOCUMENTATION FOR BOLTING NOT FURNISHED
      Item                                            Location            Compliance
    Chilled Water Pumps                              Unit II MEAB El 10  Not Retrieved
    Centrifugal Charging Pump                        Unit II MEAB El 10  Not Retrieved
    Fire Pumps                                      Fire Pump house      Not Retrieved
    Reactor Internals Disconnect Device *          Unit I RCB          .Not Retrieved
    Feedwater Booster Pump Motor                    Unit I TGB            Not Retrieved
    Feedwater Booster Pump                          Unit I TGB            Not Retrieved
    Steam Generator Feed Pump                      Unit I TGB            Not Retrieved
    Diesel Generator                                Unit I DGB            Not Retrieved
    Spent Fuel Pool Skimmer                        Unit I FHB El 27      Not Retrieved
    Load Center E1C-1                              Unit I MEAB El 65    Not Retrieved
    Chemical and Volume Control Monitor            Unit I MEAB El 35    Not Retrieved
    Relay Cabinets                                  Unit I MEAB El 35    Not Retrieved
    Pressurizer Heater Controller                  Unit I MEAB El 35    Not Retrieved
    '2" Carbon Steel Pipe Spoo1*                    Unit I MEAB El 46    Not Retrieved
    Radwaste Holdup Tank *                          Unit I MEAB El 57    Not Retrieved
    Load Center Transformers                        Unit I MEAB El 10    Not Retrieved
    Liquid Waste Pumps                              Unit I MEAB El 10    Not Retrieved
    Essential Cooling Water Pump                    Unit I MEAB El 10    Not Retrieved
    "Except for those items indicated by an asterisk, the NRC CAT inspector requested
      documentation to determine bolting requirements. Since documentation was not
      provided, traceability was not verified.
                                            VI-11
 
                                        TABLE VI-7
.
                              ELECTRICAL EQUIPMENT BOLTING
!
  Item                                            Location-        Compliance
  Relay' Rack Cabinets                          Unit I MEA 8 El 35 Unsatisfactory
  Computer                                      Unit I MEAB El 35  Satisfactory
;
'
  Pressurizer Heater-Controller                  Unit I MEAB El 35  Unsatisfactory
  Load Center Transformers                      Unit I MEAB El 10  Unsatisfactory
  Battery Racks                                  Unit I MEAB El 10  Unsatisf actory
  Battery Racks                                  Unit I MEAB El 35  Unsatisfactory
  Battery Racks                                  Unit I MEAB El 65  Unsatisfactory
  C&VC Control Board Monitor                    Unit I MEAB El 35  Unsatisfactory
  Bi-Stable Status Control Board Monitor        Unit I MEAB El 35  Unsatisfactory
  Load Center Transformers                      Unit I MEAB El 65  Unsatisfactory
  Diesel Generator. Control Panels              Unit I DGB El 35  Unsatisfactory
l
!
i
<                                          VI-12
l
l
k.
 
=-
                                                                        ,
                                      TABLE VI-8
                                    MECHANICAL BOLTING
  Item                                      Location                Compliance
  Chilled Water Pump                        Unit II MEAB El 10      Unsatisfactory
  Centrifugal Charging Pump                  Unit II MEAB El 10      Satisfactory
  Charging Pump Gearbox                      Unit II MEAB El 10      Unsatisfactory
  Positive Displacement Charging Pump        Unit II MEAB El 10      Satisfactory
  Recycle Evaporator Feed Pump              Unit II MEAB El 10      Satisfactory
  ECW Wash Screen Pump                      ECW Building            Satisfactory
  ECW Wash Screen Motor                      ECW Building            Unsatisfactory
  FCW Motor                                  ECW Building            Satisfactory
  Fire Pumps.                                Fire Pump House          Unsatisfactory
  RHR Pump Support                          Unit 1 RCB El 3          Satisfactory
  Feedwater Booster Pump                    Unit 1 TBG              Unsatisfactory
  Steam Generator Feed Pump                Unit 1 TGB                Unsatisfactory
  Auxiliary Feedwater Pump                  Unit I Valve Cubicle 1  ' Satisfactory
  Auxiliary Feedwater Motor                Unit I Valve Cubicle 1    Unsatisfactory
  Diesel Air Compressor                    Unit I DGB                Unsatisfactory
  Fire Protection Actuators                Unit I Deluge House #12  Unsatisfactory
  Spent Fuel Cooling Pump                  Unit I FHB El 35          Satisfactory
  HHSI, LHSI & Containment Spray Pumps (9) Unit I FHB El 15          Unsatisfactory
  HHSI, LHSI & Containment Spray Motors (9) Unit.I FHB El 15          Unsatisfactory
  Spent Fuel Pool Skimmer                  Unit I FHB El 27          Unsatisfactory
  Liquid Waste Pump                        Unit I MEAB El 10        Unsatisfactory
  ECW Turbine Driver                        Unit I Valve Cubicle 4    Unsatisfactory
                                          VI-13
 
  VII. DESIGN CHANGE CONTROL
'
      A.  Objective
          The primary objective of the appraisal of design change control was to
          determine whether design change activities were conducted in compliance
          with regulatory requirements, Safety Analysis Report commitments and
          approved licensee, engineer, constructor and vendor procedures. An
          additional objective was to determine that the changes.to structures
          and hardware prescribed in a sample of design change documents were
          accurately completed.
      B.  Discussion
          10 CFR 50 Appendix B, Criterion III " Design Control" and Criterion VI
          " Document Control" establish the overall regulatory requirements for
          design change control. These requirements are elaborated in Regulatory
          Guide (RG) 1.64 Rev. 2, June 1976, " Quality Assurance Requirements for
          the Design of Nuclear Power Plants," which endorses American National
          Standards Institute (ANSI) Standard N45.2.11-1974 " Quality Assurance
          Requirements for the Design of Nuclear Power Plants." The licensee's
          commitments to comply with RG 1.64 is stated in Chapter 17 of the South
          Texas Project (STP) Final Safety Analysis Report (FSAR).
          The areas of design change control evaluated by the NRC Construction
          Appraisal Team (CAT) inspectors were control of changes to design
          documents and control of design changes. In each of these areas,
          interviews were conducted with persor.nel responsible for the control of
          activities, procedures were reviewed, and a sample of the controlled
          documents was reviewed. In addition, a sample of the completed
          structures and hardware which had been inspected and accepted by on-
          site contractor quality control (QC) personnel was inspected by the NRC
          CAT inspectors. These evaluations were performed on an interdiscipline
          basis.
          1.  Control of Design Documents
                The specific aspects of the control of design documents inspected
              were the availability to the users of the latest approved design
                documents and design change documents, and the methods of assuring
                that approved changes not yet incorporated into design documents
                are provided to the users prior to work being performed,
          a.  Inspection Scope
                (1) The following general quality assurance (QA) program manuals
                      and procedures primarily related to distribution and control
                      of design documents and design change documents were reviewed
                      to establish the acceptance criteria for this portion of the
                      inspection:
                    '
                          Houston Lighting and Power Company (HL&P) Project Quality
                          Assurance Plan for South Texas Project, Rev. 7, dated
                          August 7, 1985.
                                            VII-1
                                                                                    ]
 
                        *
                                                      Bechtel South Texas Project Quality Program Manual, Rev. 3,
                                                      dated July 15, 1985.
                        *
                                                      Ebasco Nuclear Quality Assurance Program Manual ETR-1001
                                                        for South Texas Project, Rev. 12, dated July 26, 1985.
                        *
                                                      South Texas Project Procedure No. RMSP 1.02, " General
                                                      Operating Description-RMS," Rev. 3, dated August 1, 1985.
                        *
                                                      South Texas Project Procedure No. RMSP 2.03, " Design
                                                      Drawing and Drawing Change Notice Control," Rev. 3,
                                                      dated June 14, 1984.
                        *
                                                      South Texas Project Procedure No. RMSP 2.05, " Specifications,
                                                      Specification Change Notices and Procurement Document Control,"
                                                      Rev. 4, s ted March 14, 1984.
                        *
                                                      South Texas Project Procedure No. RMSP 3.16, " Quality
                                                      Records," Rev. 6, dated May 20, 1985.                          '
                        *
                                                      Bechtel Procedure No. WPP 3.0, " Field Control of Design
                                              ' Documents," Rev. 17, dated November 13, 1985.
                        *
                                                      Bechtel . Procedure No. WPP 3.2, " Field Supplier Document
                                                      Control," Rev. 3, dated March 29, 1983.
                        *
                                                      Bechtel Procedure No. WPP-QCI 6.0, " Control, Review and
                                                      Processing of Quality Records," Rev. 9, dated March 25, 1985.
                        *
!                                                    Bechtel Engineering Department Procedure (EDP) No. 4.46,
                                                      " Project Drawings," Rev. 8 STP, dated March 6, 1985.
                        *
                                                      Bechtel EDP 4.49, " Project Specifications," Rev. 6 STP,
                                                      dated January 23, 1985.
                        *
l                                                    Ebasco Quality Assurance Instruction (QAI) No. 019,
l                                                    " Review, Processing and Turnover of Quality Records,"
                                                      Rev. 2, dated March 25, 1985.
'
                        *
                                                      Ebasco Quality Control' Procedure (QCP) No. 6.2, " Document
                                                    Control," Rev.1, dated January 21, 1985.
t
                        *
                                                      Ebasco QCP No. 17.1, " Quality Assurance Records," Rev. 3,
                                                    dated March 8, 1985.
                      *
                                                      Ebasco Procedure No. ASP-6, " Document Control," Rev. 7,
                                                    dated May 17, 1985.
  (2) Bechtel, Ebssco and HL&P QA audit and surveillance reports
                      concerning det.ign document control were reviewed for findings,
                        trends and corrective actions.
                                                                        VII-2
      _ _ - _ _ _ _ _ _ _ _ _ _ _ _ _ - _ _ _ _ _ _ _ _ _
 
          . . . --              -.-                _- - . - . -                        -        . -_ - -..- - . -                          . - -
1
      4
                      ' (3) Bechtel, Ebasco and HL&P document control, engineering,
1                              construction and QA personnel were interviewed concerning
:                              design document and design change document distribution and
                              control.
  i..
                  b. -Inspection Findings
                                                                                                                                                      i
                        (1) Design documents and design change documents are issued by                                                                :
                              Bechtel; issue at the site is through the Bechtel Field                                                                !
                              Document Control Center (FDCC) to various satellite document
                              stations in accordance with a distribution matrix. The
:                              satellite stations are also controlled by Bechtel. A.compu-
i
                              terized Field Revision List (FRL) is the data base which gives                                                          i
                              the current design document revision and lists the unincor-                                                            f
i
'
                              porated design changes; a " historical" version of the FRL'                                                            ,
                              showing each revision of design documents and the change
'
                              documents written against each revision is also available.
                              The unincorporated design changes are posted on the design
                              documents in the reference stations to relieve the users of
i                              the need to review the FRL.
;.                                                                                                                                                    i
*
                        (2) The NRC CAT inspectors reviewed against the latest FRL a series
                              of procedures, specifications and drawings at the Bechtel FDCC,
                              at Bechtel Reference Station A02 (located in the Unit 1 con-
                              struction office, Building 10), and at Bechtel Reference
:                            Station B49 (located in the Unit 2 construction office,
                              Building 16). Tables VII-1A through IE summarize the NRC                                                                ,
                              CAT findings for this review, which was performed to check                                                              :
                              that documents were being distributed, posted and otherwise
                                                                                                                                                      ~
                              controlled in accordance with Bechtel Procedure WPP 3.0,
                              " Field Control of Design Documents,'' and other applicable
                              requirements.
*
                              The team reviewed eleven Bechtel and Ebasco procedures and
                              five Bechtel specifications against the latest FRL at Reference
                            - Station A02.                Four of the sixteen documents had deficiencies
                              (i.e. , did not accurately reflect all approved changes) as
                              recorded in Table VII-1A.
<
                              Fifteen Bechtel large and small bore piping' isometric drawings                                                          '
'
.
                              were reviewed at Reference Station A02. The active change
                              documents listed in the field revision log for these drawings
                              were posted on the drawings with minor exception, and only a
                              few superseded change documents were found posted on the
                              drawings (Table VII-1B).
.
4                            A total of 49'Bechtel electrical drawings.were reviewed
        .                    against the latest FRL at Reference Stations A02 and B49
i                            (Tables VII-1C-D). Four of the nineteen drawings reviewed at
*
                              Reference Station B49 exhibited an unacceptably high rate of                                                              '
                              discrepancies (Bechtel drawings 3E359E58020, -029, -191 and
,
                              -317, Table VII-10). The NRC CAT inspectors are particularly
                              concerned about the active change documents not posted on the
                              drawings, since this information is lost to the users. These
;                            drawings were all cable tray support detail " cookbook"
                                                                                                                                                        '
<
:                                                              VII-3
L
4
                +                        --m,,,m+-----e-.            ,-e,  ,  , - - , , m-,r-            * -.-- - ~ + -.m., ,--y , + - -      ew -
 
F
            drawings. The cable tray support " cookbook" drawings posted
            in the reference stations are maintained by reference station
          personnel for reference use only. However, FDCC maintains the
          master copies of these drawings, and issues bound sets of these
          detail drawings at five-day intervals to check-out-stations
          where their issuance for use by the construction craft is
          also controlled.
            In order to determine if incorrect information was being issued
          to the construction crafts, the team reviewed 21 electrical
          drawings at the Bechtel FDCC against the latest field revision
            log, including 11'of the detail drawings reviewed at Reference
          Station B49. The team found these drawings to be properly
          controlled (Table VII-1E).
    (3) The NRC CAT reviewed a sample of ten pipe support detail
          drawings for large and small bore safety class pipe. The
          latest issue of each pipe support drawing was checked to
          confirm that any change documents issued against the previous
          revision to the drawing had been properly incorporated. No
          discrepancies were observed.
    (4) A Bechtel in-house study entitled " Overview of the Design
          Change Control Program" was prepared at the request of the
          NRC CAT inspectors and issued on November 11, 1985. This study
          describes the scope and trends of change documents issued for
          the South Texas Project, as well as compliance with respect to
          the number and time constraints detailed in existing site
          procedures; i.e., documents must be revised every "x" months or
          when "y" unincorporated design changes are outstanding.
          Attachment C, sheet 2 of the study indicates, for example, that
          a total of 25,320 Drawing Change Notices, 27,120 Field Change
          Requests, and 4,113 Field Change Notices have been issued for
          the South Texas Project through October, 1985. Attachments H,
          sheets 1, 2 and 5, indicate that approximately 90 percent of
          the change documents tracked since the beginning of 1985
          have been processed in accordance with the governing number and
          time constraints.
  c. Conclusions
    The controls for posting unincorporated design changes on design
    documents were not adequately implemented at Station B49. However,.
    for the sample inspected, the availability of design documents and
    approved design change documents for users is generally adequate.
  2. Preparation of Document Packages
    The use of design documents and design change documents in the
    preparation of work packages and inspection packages was inspected.
                                VII-4
 
  a.  Inspection Scope
      (1) The following procedures primarily related to the preparation
            and use of work packages and inspection packages and were
            reviewed to establish the inspection criteria for this portion
            of the inspection:
            *
                South Texas Project Standard Site Procedure (SSP) No. 36,
                " Work Package Control," Rev. O, dated September 16, 1985.
            *
                Bechtel QCP-10.16, " Inspection of Electrical Raceways,"
                Rev. 4, dated May 1, 1985.
            *
              Bechtel PED-027, " Civil / Structural Directive for the
                Review of Pipe Support Drawings," Rev. 1, dated March 13,
              1985.
            *
              Bechtel Specification 3A010SS0012 for Category I Structural
              Steel, Rev. 2, dated January 21, 1984.
            *
              Bechtel Specification 3A010SS0026 for Category I
              Miscellaneous. Steel, Rev. 6, dated August 27, 1985.
            *
              Ebasco QCP-9.5, " Weld Inspection (AWS)," Rev. 6, dated
              October 10, 1985.
          *
              Ebasco QCP-10.5, " Inspection of Structural Steel Erection
              and Bolting," Rev. 5, dated July 19, 1985.
          *
              Ebasco QCP-10.7, " Miscellaneous Metal Fabrication," Rev.
              6, no rev. date.
          *
              Ebasco QCP-10.12 " Component Support Fabrication and
              Installation Inspection," Rev. 4, dated June 17, 1985.
          *
              Ebasco QCP-10.19, " Inspection of Anchoring Devices
              Installed Within Concrete Structures," Rev. 6, dated
              February 28, 1985.
          *
              Ebasco QCP-10.31, " Inspection of Configuration Control
              Packages," Rev.1, dated July 11, 1985.
          *
              Ebasco Procedure Construction Site Procedure (CSP) 43,
              " Installation of Electrical and Associated Hangers,"
              Rev. 5, dated September 30, 1985.
    (2) Bechtel, Ebasco and HL&P document control, engineering,
          construction and QC personnel were interviewed concerning
          the use of design documents and design change documents.
                                  VII-5
-
 
                                                                            -
.
  b. -Inspection Findings
      (1) Ten samples of installed structural _ steel installation docu-
            ments and QC inspection records provided by Ebasco civil /
            structural site engineering were reviewed. Table VII-2
            summarizes the NRC CAT findings for this review, which was
            performed to confirm that Ebasco used the correct drawings,
            change documents, procedures and specifications to install and
            inspect the structural. steel. Four of the ten samples were
            found_to have deficiencies. The most significant. finding from
            this review was that work done under a Field Change Request
            (FCR) dated September 14, 1984 had not been QC. inspected.
            When a QC inspection was performed, a nonconformance was
            identified (Item 1, Table VII-2).
            Structural steel is installed and inspected based on design
            drawings and approved design changes (i.e., there is no
            procedural requirement at STP for a structural steel work
            package) and the related QC inspection activities are performed
            on an area basis, with no easily auditable tracking of. records
            for specific joints, members, etc. In a number of instances,
            the team encountered difficulty in identifying the specific-
            installed steel that had been QC inspected. As a consequence,
            some installed or modified structural steel may not be QC.
            inspected or inspected in a timely manner.
            On September 20, 1985, HL&P notified NRC Region IV of a
            potentially reportable. item ccncerning inspection of installed
            structural steel. The lack of an accurate detailed location
            description for structural steel is one of the identified
            deficiencies currently under review by NRC Region IV. The
            licensee is conducting an investigation to determine the
            extent of the documentation deficiencies in regard to
            structural steel erection. A thorough review of inspection
            documentation on structural steel erection is currently
            being performed. The licensee's review should also address
            the above identified NRC CAT finding.
      (2) A sample of installation documents and QC inspection records
            for the ten electrical cable tray supports listed in Table
            VII-3A was reviewed to verify that Ebasco used the correct
            drawings, change documents, procedures and specifications to
            install and inspect the cable tray hangers. Table VII-38-
            summarizes the NRC CAT findings for this review. Minor docu-
            mentation deficiencies were identified in seven of the ten
            samples.
            There is no requirement at South Texas Project to provide an
          - as-built record of an installed cable tray support.    In addi-
            tion, a given cable tray support detail drawing defines a
            design envelope rather than a unique hanger configuration. As
            a consequence, physical inspection is required to verify the
            specific configuration of an installed cable tray support.
            NRC CAT inspectors verified another sample of 14 cable tray
            supports, and concluded that the installed hanger configurations
                                  VII-6
 
          conformed to the hanger detail drawings.    NRC CAT review of
          this sample is documented in Section II, Electrical and
          Instrumentation Construction, of this report.
c. Conclusions
  The use of design documents and design change documents in prepara-
  tion of work packages and inspection packages appears generally
  adequate.    However, during this review a deficiency in inspection
  of structural steel was identified. The licensee needs to determine
  whether this deficiency will be addressed in his overall evaluation
  of the inspection of structural steel pursuant to his notification
  to NRC Region IV of similar problems with the inspection and iden-
  tification of structural steel.
3. Control of Design Changes
  The specific aspects of the control of changes to design inspected
  by the NRC CAT were the change control systems for Field Change
  Notices (FCNs), Field Change Requests (FCRs) and Drawing Change
  Notices (DCNs) and implementation and verification of the changes.
a. Inspection Scope
  (1) The following procedures relating primarily to the control of
        design changes were reviewed to establish the acceptance
        criteria for this portion of the inspection:
        *
            South Texas Project Site Instruction 2.17, " Requests for
            Engineering Assistance," Rev. 2, dated July 31, 1985.
        *
            Bechtel Procedure No. WPP-QCI 20.0, " Field Change Request,"
            Rev. 15, dated August 20, 1985.
        *
            Bechtel Procedure No. WPP 20.1, " Field Change Notice,"
            Rev. 5, dated May 21, 1985.
        *
            Bechtel Procedure No. WPP 22.0, " Configuration Control
            Package (CCP)/(Design Change Package - DCP)," Rev. 2,
            dated November 4, 1985.
        *
            Bechtel Procedure No. WFP-QCI 34.0, " Organization and
            Responsibilities," Rev. 8, dated June 10, 1985.
        '*
            Bechtel EDP-2.13, " South Texas Project Engineering Team
            Organization and Responsibilities," Rev. 4 STP, dated
            June 1, 1984.
        *
            Bechtel EDP-4.26, " Interdisciplinary Design Review,"
            Rev. O, dated December 2, 1977.
        *
            Bechtel EDP-4.27, " Design Verification," Rev. 2 STP,
            dated July 31, 1984.
                              VII-7
                                                                          _ _ _ _ _ _
 
              *
                Bechtel EDP-4.33, "On-Project Design Review," Rev. 3 STP,
                dated December 31, 1984.
              *
                Bechtel EDP-4.34, "Off-Project Design Review (Design
                Control Check List and Design Review Notice)," Rev. 2 STP,
                dated December 15, 1983.
              *
                Bechtel EDP-4.37, " Design Calculations," Rev. 4 STP,
                dated August 7, 1984.
              *
                Bechtel EDP-4.47, " Drawing Change Notice," Rev. 4 STP,
                dated February 6, 1985.
            *
                Bechtel EDP-4.62, " Field Change Request / Field Change
                Notice," Rev. 5 STP, dated March 26, 1985.
            *
                Bechtel EDP-4.72, " Configuration Control Package,"
                Rev. 3 STP, dated September 5, 1985.
            *
                Bechtel EDP-4.73, " Design Change Management Procedure
                (Design Change Approval Request - DCAR - Process),"
                Rev. 2 STP,. dated May 23, 1984.
            *
                Ebasco Procedure No. ASP-7, " Field Change Notice Procedure,"
                Rev. 4, dated August 1, 1985.
  -
            *
                Ebasco Procedure No. ASP-11 " Field Change Request," Rev. 4,
                dated July 29, 1985.
            *
                Ebasco Procedure No. ASP-17, " Configuration Control Package
                (CCP)/ Design Change Package (DCP)," Rev. 2, dated October
                28, 1985.
      (2)' Bechtel and Ebasco QA audit and surveillance reports
            concerning design changes were reviewed for findings, trends
            and~ corrective actions.
      (3) Interviews were conducted with personnel from Bechtel, Ebasco
            and HL&P concerning initiation (organization) review, approval
            and implementation of design changes.
    b. Inspection Findings
      (1) The Bechtel Site Engineering Organization (SE0) currently
            employs approximately 150 office personnel and 120 field
            personnel on site. The functions of Bechtel SE0 are described
            in Bechtel procedure.WPP-QCI 34.0, subsection 5.6.      The
            functions of Bechtel project engineering personnel assigned to
            the site are described in Bechtel procedure EDP 2.13,
l            subsection 5.6. Bechtel project engineering personnel
            assigned to the job-site take the lead in responding to field
,            change requests, provide engineering dispositions on noncon-
L
'
            formance reports, and monitor Ebasco field change' notices for
            compliance to Ebasco and Bechtel requirements.
l
                                  VII-8
<
 
  (2) The NRC CAT reviewed a sample of 55 Bechtel and Ebasco FCNs,      l
        FCRs and DCNs.  These change documents                        ,
      were selected from the civil / structural and pipe support
        disciplines. Table VII-4 summarizes the NRC CAT findings
      derived from this review, which was performed to confirm that
        change documents had been correctly incorporated into the
        referenced drawings. .NRC CAT review of an additional sample
      of design change documents is discussed in Section
      VII.B.3.b.(7), below.
      Discrepancies were observed in the incorporation of 8 of
      the 55 change documents into the design documents. In
      seven cases, the team found that either the technical content
      or the scope of some change documents had been modified upon'
        incorporation into the referenced design drawings.    Six of
      these. cases involved modification of FCRs or FCNs. Neither
      Bechtel procedure WPP-QCI 20.0, " Field Change Request,"
      subsection 5.4.3, nor Ebasco procedure ASP-11, " Field Change
      Request," subsection 8.0.6, permits the modification of Field
      Change Requests.    Bechtel procedure EDP 4.47, " Drawing Change
      Notice," subsection 3.6 permits the modification of a Drawing
      Change Notice upon incorporation into a design drawing, if
      notification is included in the drawing revision block.
'
      However, the change documents are not annotated to indicate the
      modified version of the technical content or scope that has
      been incorporated.
      Change documents originally restricted to k 2ilation in
      either Unit 1 or Unit 2 have been modified upon incorporation
      into the. referenced drawing for installation in both Units.
      Since many drawings are applicable to both Units 1 and 2 by
      default, and since the change documents are not reviewed to
      reflect the incorporated modification, it is not possible to
      determine if any error of omission has occurred or a conscious
      design decision has been made.
  (3) The NRC CAT reviewed selected audits in the area of design
      control (Table VII-5) that had been conducted either by
      Bechtel or Ebasco, or by teams composed of Bechtel, Ebasco
      and HL&P personnel. The modification of some field change
      requests upon incorporation into the design drawings does
      not appear to have been an identified concern, although
      Bechtel explicitly audited this attribute in the latter part
      of 1984 (audit No. ESI-14-84, page 45, audit item 47).
      The team also reviewed audit findings with respect to the
      Bechtel/ Westinghouse interface. Audit M24-501 was conducted on
      March 11-25, 1984 to assess the programmatic adequacy and the
      proper procedural implementation of the Westinghouse NSSS
      program on site. The audit summary noted that the corporate
      Westinghouse program was being adequately implemented, but
      concluded that' site specific procedures and instructions had
      not been developed to control. activities affecting quality
      which were being performed by Westinghouse site personnel.
                            VII-9
    _                                        -
 
-
        The audit summary considered this a significant deficiency
        which could have an impact on the overall South Texas Project
        quality program. Audits S15-501, D08-501, G42-501 and S23-501
        also address aspects of the Bechtel/ Westinghouse design
        interface. The deficiencies identified in Section II,
        Electrical and Instrumentation Construction, of this report
        with respect to the installation of Westinghouse motor
        operated valves indicate that the concerns identified in
        previous audit reports at the Bechtel/ Westinghouse design
        interface require vigorous corrective action to assure a
        controlled A/E-NSSS design interface at South Texas Project.
  (4) The NRC CAT documented conflicting definitions for confi-
        guration control package revisions in the governing Bechtel
        and Ebasco procedures: Bechtel EDP 4.72, subsections 7.3-4;
        Bechtel WPP-22.0, subsection 4.9.1, and Ebasco ASP-17, subsec-
        tion 8.0.4. One definition notes that each revision of a
        configuration control package supersedes all previous revi-
        sions, and includes all previously issued design information.
        Another definition notes that each revision of a configuration
        control package supplements the previous revisions, and that
        all revisions are necessary to determine the intended final
        installed configuration. Design documents contained in a
        specific configuration control package may be revised upon
        completion of the physical work associated with that package.
        The team notes that the Bechtel field document control center
        has recently upgraded -the field revision list to identify con-
        figuration control packages as a function of a given drawing.
        However, the NRC CAT is concerned that drawings incorporated
        into multiple configuration control packages prior to this
        upgrade may have been subject to conflicting modifications.
  (5) The NRC CAT requested the Bechtel structural calculations
        for ten civil / structural change _ documents which added (or
        modified) equipment support steel to the Bechtel structural
        drawings. Table VII-6 summarizes the NRC CAT findings for
        this review, which was perfonned to confirm that appropriate
        calculations had been performed to substantiate design changes
        to project drawings. The team found seven of the ten Bechtel
        calculations acceptable.
        Three of the changes . reviewed were found to have inadequate
      . calculational bases. A calculation for a nonsafety support in
        the seismically designed Fuel Handling Building had been
        performed, but not checked or signed off by a group leader
        (Table VII-6, item 1). Four bays of floor steel had not been
        verified by calculation, or by documented engineering judgment
        (Table VII-6, item'2), and some existing steel that was
        recently checked for the first time showed relatively high
        stress ratios (Table VII-6, item 3).
        The NRC CAT is concerned that structural calculations or other
        adequate documentation of design bases may be lacking for some
        structural steel in safety related and nonsafety seismic
        structures. All structural steel should be explicitly or
                                VII-10
 
                                                                                  1
              generically qualified, and this analytical qualification
              should be documented.      ANSI N45.2.11-1974 Section 4.2, Design
              Analyses, notes in-part that " Analyses shall be sufficiently
              detailed as to purpose, method, assumptions, design input,
              references and units such that a person technically qualified
              in the subject can review and understand the analyses and
              verify the adequacy of the results without recourse to the
              originator."
        (6) The NRC CAT reviewed three pipe support calculations to verify
              that supplementary steel had been properly ~ modeled, and that
              calculated weld sizes had been noted on the pipe support
              drawings. Although no concerns were identified, the team had
              become concerned during the course of the inspection that pipe
              support supplementary steel and supporting steel was not always
              being evaluated for possible addition of beam stiffener plates.
              However, the NRC CAT was informed that a pipe support review
              team has already been established within the Bechtel pipe
              support group to review all ASME and seismic II/I supports
              for various pipe support design attributes. Both new as well
              as existing pipe support designs will be reviewed under this
              program, in accordance with Rev. 3 to Bechtel PED 023.
        (7) Inspectors in each NRC CAT discipline checked the design con-
              trol process at South Texas Project by evaluating compliance
              of a sample of installed and inspected hardware with respect
              to the applicable design drawings and their approved design
              change documents (Table VII-7A-C). In most instances,.the
              installed hardware conformed to the design documentation.
            .0f the 87 hardware samples reviewed for compliance with the
              governing design change documents, only 2 discrepancies were
              noted.  However, because the NRC CAT is concerned that the
              design control process at South Texas Project may not be
              adequately controlled in some areas, i.e. , motor-operated
              valves (Section II.B.3.b(8)), the licensee needs to assess the
1
              impact that these deficiencies may have on the associated
              hardware.
    c. Conclusions
      Control of the design change process is generally adequate for
      the sample inspected. However, additional management attention is
      needed to: (1) preclude further modification of design changes
      during incorporation into their referenced drawings, particularly
      unit specific changes, (2) control the design interface between
      Bechtel and Westinghouse, (3) ensure that documented calculations
      exist to demonstrate both the bases and adequacy of design drawings
      and design changes, and (4) to ensure that the conflicting defi-
      nitions for configuration control packages have not resulted in
      the improper use or as-building of these change documents.
                                  VII-11
  ,                      -            ._.
                                                    _--        -    -  -
 
                                                                              I
                            TABLE VII-1A
                                                                              ;
                REVIEW 0F POSTING OF DESIGN CHANGES
                  PROCEDURES / SPECIFICATIONS SAMPLE
                        Reference Station A02
      Document.                              Observation
  Ebasco Procedure                a) Table of contents does not list ICP
  ASP-11                              (interim change to a procedure) No. 1;
                                  b) Procedure pages not correctly numbered
  Ebasco Procedure                Table of contents does not list PCR
  QCP-10.7                        (procedure change report) No. 7
  Bechtel Specification          a) Table of contents and appendices
  SA010PS002                          misfiled;
                                  b) Total number of pages per appendix
                                      not tabulated.
  Bechtel Specification          Total number of pages per appendix not
  3A010SS0030                    tabulated
,
                              VII-12
 
--
                                              TABLE VII-1B
                                  REVIEW 0F POSTING OF DESIGN CHANGES
                        BECHTEL LARGE AND SMALL BORE PIPING ISOMETRIC SAMPLE
                                          Reference Station A02
                                                      Total Active                  Superseded
                                                    Change Documents Active CDs Not CDs Posted
          Drawing      Sheet No.    Rev. No.    ,
                                                          (CDs)    Posted on dwo    On dwa
      '8M369 PIA 239      A08          4              5                -            -
      8M369 PIA 239      A13          4              4                -            -
    -
      8M369 PIA 239      A17          4              4                -            -
      8M369 PIA 239        A24          3              4                -            -
      8M369 PIA 239        A29          4                3                -            -
      3M369PCC207          2          4              17                -            -
      SM369PCC207'          S          3                5                -            -
      SM369PCC207            7-        4              14                1            -
      4M369PCC207          9          5              14                -            -
      5M369PCC207          10          4              18                -            -
      3M369 PEW 229        18          0              40                1            -
  -50369 PEW 329          5          1              18                -
                                                                                      2
      3C01951542            -
                                        4                6                -
                                                                                      1
      3C019S1600            -
                                        5                2                -            -
      3C01951603            -
                                        3                3                1            -
                  TOTAL                              F                  3-          3
                                                VII-13
 
_-
                                          TABLE VII-1C
                              REVIEW OF POSTING OF DESIGN CHANGES
                                BECHTEL ELECTRICAL DRAWING SAMPLE
                                      Reference Station A02
                                                  Total Active                  Superseded
                                              Change Documents Active CDs Not-  CDs Posted
        Drawing      Sheet No.    Rev. No.            (CDs)      Posted on dwg    On dwg
  -3E560E55127*        -1          1              21                '-              -
    -3E359E58001'        1        11              7                -
                                                                                      3
    3E359E58001          4          6              4                -
                                                                                      1
    3E359E58001        -5          7              4                  --
                                                                                      1
    3E359E58001          7          4              7                  -
                                                                                      4
    3E359E58001-        2          9              2                    -
                                                                                      1
    -3E359E58002          1          0              3                -              -
    SE209E01638          2          9              5                -              -
    SE209E1631-        ~
                          5          8              3                -              -
  .9E0VNAV.-            1          3              6                -              -
    9EEWO101-            1          2              5                -
                                                                                      li
    9E0HE21              1          2              2                -              -
    SE549EL5031          -
                                    8              15                -              --
    ~3E209E2825          -
                                    8              16                -              -
    3E209E56009          -
                                    9              7          >      -              -
    9E0ANO3              2          2              1                -              -
    6E100E02130-        -
                                    .7              6                -              -
    SE030E0100          3        14              4                -              -
    9E00AAB              1          5              1                -              -
    .5E030E0100.          3A        3              4                -              -
    -9E0HC09              1          2              2                -              -
    SE500E00103        .3          22              9                2              -
    9E0VCAB              1          3              5                -              -
    9E0VCAG              1          2              3                1              -
    9EOFP08              1          3              -4                -          --
  -9EOPMAL              1          5              3                -              -
    OEOSW10 -            1          1              2                -              -
    3E209E56104          -
                                    5              6                -              -
    9EOPFCF              1          3              2                -              -
    1EPFCC01'            1          3              1                -              -
              TOTAL                              T6T                  3          T
    (*) There were approximately 35 not to be incorporated (N/I) CDs posted on
          this drawing that were subsequently tabulated on sheet 1A of the drawing
          and should have been deleted from sheet 1.
    (!) Incorrect CD No.-posted.
                                            VII-14
 
                                          TA8LE VII-1D-
                              REVIEW OF POSTING OF DESIGN CHANGES
                              BECHTEL ELECTRICAL DRAWING SAMPLE
                                      Reference Station B49
                                                  Total Active                            Superseiled
                                                Change Documents Active CDs Not            CDs Posted
      Drawing      Sheet No.    Rev. No.            (CDs)    Posted on dwg              On dwg
    3E359E58317          1          5              14                3                      5
- -3E359E58191          1          3              4                1                      6
    3E359E58020          1        10              15                9                      4
    3E359E58029        1            6              7                2                      5
    3E359E58260          1          6              6                -                      -
    6E210E02564        2            4              6                -
                                                                                              1
    3E359E58042        1          11                9                1                      2
    3E359E58140        1            4              7                -                      -
    9E560E50021        -
                                    3              4                -
                                                                                              1
    3E359E58901        1            1              5                -
                                                                                              it
    3E359E58067        1          '5              7                2-                      -
    3E560E55127        l'          1              21                -                      -
    3E560E55127        1A          2              3.              -                        -
    3E359E58822        1            4              13                -
                                                                                              1
  -3E359E58072        1            6              5                -                      -
    3E359E58041        1            9              10                1                      1
    SL49T60002        '
                        -
                                  16              44                16                      1
    3E560E55045        -
                                  12              15                -                      -
  .3E560E55046        -
                                    -9              22                -
                                                                                              1
            TOTAL                                717~              20                    -'2T
    (1) Incorrect CD posted
    (9) 1 CD posted on drawing.twice
.                                            VII-15
                                                                            _ , . _ - _ _        ._  ,
 
.
                                        TABLE VII-1E
                            REVIEW 0F POSTING OF DESIGN CHANGES
.                            BECHTEL ELECTRICAL DRAWING SAMPLE
                          Field Document Control Center (FDCC)
                                                Total Active                  Superseded
                                              Change Documents' Active CDs Not. CDs Posted
      Drawing      Sheet No.    Rev. No.            (CDs)    Posted on dwa    On dwg
  .3E359E58317*      1            5              14                lt
                                                                                  -
  3E359E58191*      1            3                4                -            -
  3E359E58020*      1-          10              15                1            -
  3E359E58029*      1            6                7                -            -
  3E359E58041*      1            9              10                -            -
  3E359E58140*      1-          4                7                -            -
  3E359E58148        1            6                3                -            -
  3E359E58169-      1            5                3                -            -
  3E359E58238        1            3                3                -            -
  3E359E58093        1            4                4                1            -
  3E359E58260*      1            6                6                -            -
  3E359E58268        1            2                3                -            --      '
  3E359E58048        1            8                3                -            -
  3E359E58057        1            4-              3                -
                                                                                  1
  3E359E58901        1            1                5                -            -
  3E359E58831        1            1                2                -            -
  3E359E58042*      1          11                9                -            -
  .30359E58067*      1            5                7                -            -
  3E359E58073        1A          5                4                -            -
  3E359E58072*      1            6                5                -            -
  -3E359E58822*      1            4              13                -
                                                                                  1
          TOTAL                                  130                3            2
.
  (*) Drawings reviewed at Reference Station B49
  ( ) 1 CD number transposed
                                            VII-16
                                          .            __  -.                -      ._.
 
                . _ . . _        _      .                    ._  . . _ _      _
  ,
        -
          7
                                                    TABLE VII-2
                                  REVIEW OF WORK PACKAGES AND INSPECTION REPORTS
                                              STRUCTURAL STEEL SAMPLE
'
        ITEM-                                OBSERVATION -
              1
    <
            1              Field Change Request (FCR) No. CC-0414W was issued on September
                            14, 1984-against Bechtel drawings No. 3C01-9-S-1506, Rev.:5,
;                          3C01-9-S-1508, Rev. 3, and 3C01-9-S-1510, Rev. 2. The.FCR
;                          .specified the coping of radial and circumferential steel at three
:                            different elevations in containment. Coping the beam.
,
'
                            flanges provides access to enable welding of the containment liner
                            plate at the construction hatch opening. -However, at the time of
                            the CAT inspection, the steel rework had not been QC inspected.
                            Subsequent Ebasco-QC inspection is documented on miscellaneous
,                          metal fabrication inspection report 3461F1 dated October 28,
                            1985. Nonconformance Report Number CC-03133 was also issued on
                                                                                ~
f'
                            October 28, 1985 to document coping of beam flanges in excess of
,7
                            the dimensions specified in the FCR.
i
            2              Drawing Change Notice (DCN) No. 3 was issued on January _25,1985
,                          against Bechtel drawing No. 3F01-9-S-3001, Rev.1, in order to
,
*
                          . provide support details for Fuel liandling Building Sump Tank No.1
                            Sump Pumps 9Q061/2NPA113A.      Field Change Notice (FCN) 1-C-0329
                            provides the fabrication details for the new steel.      However,
                            there are discrepancies in the bolt hole diameters specified for-
,_                          the beam clip angles. The DCN and the drawing sp?cify 15/16 in.
.                          diameter bolt holes for 3/4 in. diameter bolts,:while the FCN-
r-                          specifies 13/16 in. diameter bolt holes. The Bechtel civil /
;                          structural site engineering organization issued DCN No. 5 on
                            Octobe'r 30, 1985 to correct DCN.No. 3.
.          3                FCR BC-01544 was issued on December 24, 1984 against Bechtel
.                          drawing No. 3F01-9-S-3005, Rev.1.1 The FCR detailed modifica-
                                ~
i
                            tions to'HVAC plenum No. 9V121VXV021 perimeter grating and
u                          support steel to provide an air-tight seal.      However, Ebasco QC
                          AWS D1.1 structural welding inspection report No. 1-00865,-dated
{.                        Narch 7, 1985, incorrectly references Rev. 1 of the Bechtel
                          drawing. Rev. 2 of the drawing, dated December 18, 1984, was
                            the correct drawing of record. The inspection report was
,
                          corrected on October.30, 1985.
                                            -
t
          4              The not to be incorporated (N/I) amendment list for Bechtel
                          drawing .3M01-9-S-4043, Rev. 3, dated July 15, 1985, incorrectly
                          references FCN 1C-0265, dated February 21, 1985, as a FCR.
L                          Rev. 4 of the drawing, issued on November 5, 1985, correctly
!
                          references the FCN.
:
i.
l
                                                    VII-17
      ,
[
 
                            TABLE VII-3A
              LISTING OF ELECTRICAL CABLE TRAY SUPPORTS
~ Support No.                            Location Drawing No.
    H64-                              3-E-20-9-E-56004, Rev. 3
    H117                              3-E-20-1-E-56004, Rev. 5
    H2                                3-E-35-9-E-56008, Rev. 8
    H153                              3-E-20-9-E-56004, Rev. 3
    H139                              3-E-35-9-E-56008, Rev. 5
    H115                              3-E-20-9-E-56004, Rev. 3
    H84                                3-E-20-1-E-56004, Rev. 5
    H136                              3-E-35-9-E-56008, Rev. 3
    H102                              3-E-35-9-E-56008, Rev. 5
    H100                              3-E-35-9-E-56008, Rev. 8
                                            .
                              VII-18                          j
                                                                l
                                                                :
 
:
                                TABLE VII-3B
            REVIEW 0F WORK PACKAGES AND INSPECTION REPORTS
                  ELECTRICAL CABLE TRAY SUPPORT SAMPLE
  -ITEM                  OBSERVATION
    1  Page 2 of the electrical' raceway hanger inspection
        record / traveler for hanger No.1-004-H64 does not reference
        Bechtel drawing No. 3-E-35-9-E-58140, sheet 1, Rev. 2
        AWS D1.1 structural welding inspection report No. 02630 for hanger
        No. 1-004-H64 does not reference the cable tray hanger connection
        detail drawings, and references incorrect detail numbers 22 and 23
        for the installed cable tray. ~The correct details are 42 and 70.
        The inspection report was corrected on November 11, 1985.
    2  Bechtel drawing No. 3-E-20-1-E-56004, Rev. 5, is incorrectly
        referenced on page 3 of the electrical raceway hanger inspection
        record / traveler for hanger No. 1-004-H117. The inspection
        report was corrected on November 11, 1985.
    3  Page 2 of the electrical raceway hanger inspection record /
        traveler for hanger No.1-004-H153 does not reference
        Bechtel drawing No. 3-E-35-9-E-58148, sheet 2, Rev. 4.
        AWS D1.1 structural welding inspection report No. 02407 for
        hanger No.1-004-H153 references Rev. 2 of Bechtel drawing
        3-E-20-9-E-56004. Rev.-3 of the drawing, dated September 16,
        1983, was the drawing of record at the time of inspection on
        October 20, 1983. The inspection report was corrected on
        November 11, 1985.
        AWS D1.1 structural welding inspection report No. 02407 does not
        reference the cable tray hanger connection detail drawings.
    4  Page 2 of the electrical raceway hanger inspection record / traveler
        for hanger No. 1-008-H139 does not reference Bechtel drawing No.
        3-E-35-9-E-58029, sheet 4, Rev. 4.
    5  The line diagram for the cable tray support shown on page 2 of the
        electrical raceway hanger inspection record / traveler for hanger
        No. 1-004-H115 shows one more G58HD12A tray support than the
        installed cable tray.
        Page 1 of the traveler (item 5) does not reference Bechtel drawing
        No. 3-E-35-9-E-58117, sheet 3, Rev. 5. The inspection report was
        corrected on November 11, 1985.
        Page 2 of the traveler (item 5) does not reference Bechtel drawing
        No. 3-E-35-9-E-58117, sheet 3, Rev. 3.
                                  VII-19
 
                        _                        _ . . _ . .  . _ _ -            _ ._    .    .-              .-    _-
#
    ,.;                                      TABLE VII-3B - (Continued)
9                                  REVIEW OF WORK PACKAGES AND INSPECTION REPORTS
j                                        ELECTRICAL-CABLE TRAY SUPPORT SAMPLE                                            ,
1
                  ITEM                        OBSERVATION
j.                          AWS D1.1-structural welding inspection report No. 02630 for hanger
                            No. -1-004-H115 does not reference the cable tray hanger connection
*
  .                        ~ detail drawings. The inspection report was corrected on November
                          'll', 1985.                                                                                    :
].
,
*
                    6      Page 2 of electrical raceway-hanger inspection record / traveler-
                            1-004-H84, prepared on December 19,-1983, was not updated to
                            reference Field' Change Request (FCR) CE-02312, dated April 24, .
,                          1984. The construction supervisor signed off on page 2 on June
                            23, 1985.
'
                    7-    Page 2 of the electrical raceway hanger inspection recor'd / traveler-
:                          for hanger No.1-008-H136 references Field Change Notice (FCN)
                            CE-00831.      The change document is actually a FCR. Ebasco voided
-
                            this FCR on January 6, 1984. The construction supervisor signed
>
                            off page 2 on August 4, 1984.
                            FCR CE-00923 is referenced on the traveler (item 7). However,
                            this FCR was superseded by FCR CE-01089 on November 4,1983.
    -
                            FCR CE-01089 is referenced on page 2 of the traveler, but does
                            not appear to be applicable to hanger 1-008-H136.
-
                            FCR~CE-00578 is referenced on the traveler (item 7), but this
                            FCR was superseded by FCR CE-00828 on September 27, 1983, which
                            is not referenced on the traveler.
                            FCR'CE-01133 is referenced on the traveler (item 7) but this FCR
-
                            was superseded by FCR CE-01287 on December 6, 1983, which is not
,
                            referenced on the traveler.
                            Page 5 of electrical raceway hanger inspection record / traveler No.
                            1-008-H136 does not reference Bechtel drawing 3-E-35-9-E-58042,
'
.
                            sheet 5; Rev. 0.            The inspection report was corrected on November
                            11, 1985.
                                                                                                                          ,
*
                                                                                                                            l
                                                              VII-20                                                      l
                                                                                                                            1
i                                                                                                                          1
      - . _ . _ _ . ._._      -____            . _ . _          _ _ _ . _ _ . - .                _ . _ . _ . _ _ . _
 
                              TABLE VII-4                                    I
                REVIEW OF DESIGN CHANGE DOCUMENTS FOR
                INCORPORATION INTO DESIGN DOCUMENTS
                                                                            j
ITEM                  OBSERVATION
1    Field Change Request (FCR) BC-01202 was issued on June 13, 1984
      against Rev. 2 of Bechtel drawing 3M01-9-C-4312. The FCR was
      issued to reduce an oversized HVAC opening. A modified version of
    'the FCR (as noted.in the drawing revision block) was incorporated
      into revision 3 of the Bechtel drawing, which was issued on
      October 4, 1984. As shown on the drawing, the detail is now
      applicable to both Units 1 and 2.    It appears that the penetration
      was reworked ~in accordance with the FCR, so that the as-built
      configuration is not in agreement with the design drawing. The
      Bechtel civil / structural site engineering organization indicates
      that FCR BC-01202 was incorrectly incorporated into Rev. 3 of the
      Bechtel drawing, and issued Drawing Change Notice (DCN) No. 3 on
      November 16, 1985 to correct the drawing.
2    FCR CC-03426.was issued on June 23, 1984 against Rev. 7 of Bechtel
      drawing 3M35-9S-37417.    The FCR was issued to shift a piece of
      supplementary steel in plan to provide support for a hanger for
      Unit 1 only. The FCR was incorporated into Rev. 8 of the Bechtel
      drawing, but this detail is now applicable to both Units 1 and 2.
      The drawing revision block does not indicate that the FCR was
      modified upon incorporation into the drawing. The Bechtel civil /
      structural site engineering organization indicates that the
      decision was made to shift the steel for Unit 2 as well, at the
      time the FCR was incorporated into the drawing.
3    DCN No. 7 was issued on September 26, 1984 against Rev. 1 of
      Bechtel drawing 3C01-9-S-1600. The DCN was issued to provide
      support details for.RHR pumps A, B and C in Unit 1 containment.
      The DCN was modified upon incorporation into Rev. 2 of the
      Bechtel drawing, as noted on the drawing revision block, to be
      applicable to both Units 1 and 2.
4    FCR CC-04949 was issued on December 22, 1984 against Rev. 3 of
      Bechtel drawing 7G-22-9-S-2002. The FC9 revised support details
      for relay racks ERR 126 (nonsafety) in Units 1 and 2. The FCR
    was modified upon incorporation into Rev. 3 of the Bechtel
      drawing, as noted in the drawing revision block, and as detailed
      on the drawing. However, the location of the revised steel in
    plan was not clouded, and the 13/16 in. bolt holes for the
      support channel were not transferred onto the drawing. The
    Bechtel civil / structural site engineering organization has
    verified that the support was installed as detailed on the
    drawing, and issued DCN No. 18 on November 18, 1985 to correct
      the drafting error.
                              VII-21
 
                                                                          -
                      TABLE VII-4 - (Continu;d)
              . REVIEW OF DESIGN CHANGE DOCUMENTS FOR
                  INCORPORATION INTO DESIGN DOCUMENTS
ITEM                    OBSERVATION
5    FCR BC-01279 was issued on July 24, 1984 against Rev. 1 of
      Bechtel_ drawing 7G22-9S-2010. The FCR adds a supplementary
      steel beam to provide support for exhaust fans 8V321(2)VFN013
      and _4 (nonsafety) in the turbine generator building. The
      addition of the supplementary steel is required because of
      interference _ with a concrete block wall. FCR BC-01279 was
      superseded by FCR CC-04461, which restricted the identical
      support detail for installation in Unit 1 only.      FCR-04461 was
      modified upon incorporation into Rev. 3 of the Bechtel drawing,
      as noted in the drawing revision block, for installation in Units
      1 and 2. The Bechtel civil / structural site engineering organi-
      zation issued DCN No. 4 on November 18, 1985 to restrict the
      application of FCR CC-04461 to Unit 1 only.
6    DCN No. 2.was issued on October 6, 1984 against Rev. 1 of
      Bechtel drawing 3C01-9-S-1603. The DCN.provided construction
      details for the carbon unit A and B fan supports in containment
      for Units 1 and 2. The DCN was correctly incorporated into
      Rev. 3 of the Bechtel drawing, except for.a minor drafting
      error involving failure to dimension a steel connection plate.
    The Bechtel civil / structural site engineering organization
      issued DCN No. 3 on November 15, 1985 to correct the drawing.
7    FCN BS-1-0194 was issued on July 9, 1984 against Bechtel drawing
      CV-9010-GU0006, Rev. 1.      The FCN revised the bill of materials    <
      for a pipe support configuration to allow the installation of a
      rigid sway strut from bulk stock for-Unit 1 only.      The FCN also
      specified the center-to-center dimensions for the Unit 1 struts.
    However, the drawing did not properly specify the different            ,
    center-to-center (C-C) dimensions required ~for the struts.      The
    C-C dimensions for the Unit 2 struts were listed in the bill of
    materials (apparently past practice) while the C-C dimensions
      for the Unit 1 struts were dimensioned on the drawing. However,
      the drawing did not restrict the use of these strut C-C dimensions
    to the Unit 1 struts. The Bechtel pipe support group site              i
    engineering organization issued DCN No.1 on November 18, 1985
    to correct the drawing.
8  FCN BS-1-0235 was issued on August 5, 1984 against Rev. 2 of
    Bechtel drawing CC-9215-RR0005. The FCN was incorporated into          1
    Rev. 3 of.the Bechtel drawing on March 12, 1985. The team              !
    reviewed the drawing, which details separate pipe supports for
    Units 1 and 2. The supporting steel for these supports appeared
    to require stiffeners, and the team then reviewed the pipe
    support calculation. Rev. 1 of calculation JC-CC-92-15-RR0005,
    dated September 30, 1985, does require beam stiffeners for both
    the pipe support supplementary steel and the support.ng framing
                                VII-22
 
                                      TABLE VII-4 - (Continued)
                      REVIEW OF DESIGN CHANGE DOCUMENTS FOR
                        INCORPORATION INTO DESIGN DOCUMENTS
  ITEM                                OBSERVATION
            . steel. Bechtel~ issued two separate configuration control packages
            on October 30, 1985 to add beam stiffeners to the pipe support
            steel, CCD-1-M-ST-0066-00 and 2-M-ST-0067-00; however, the beam    ;
            stiffeners to be added to the supplementary steel for the Unit 2
            pipe support were not clouded on the pipe support drawing. The
            Bechtel pipe support group site engineering organization issued
            FCR XEJ-00371 on November 18, 1985 to correct the configuration
            control package for Unit 2.
                                                      VII-23
--    -. .-    , .-. .    , . . . - , -  . - - - - .        .. -- .- .. . -
 
                          TABLE VII-5
              SOUTH TEXAS PROJECT AUDIT SAMPLE
Audit-No. Audit Date                  Audit Subject
EQA-123  12/07/84            Document Control / Instructions and
                              Procedures, FCNs
ESI-14-84 11/26/84            Evaluation of Design Control Operations
BEC-6-84  05/24/84            Document Control - Field Control of
                              Design Documents (Unscheduled Audit)
BEC-7-84  07/18/84            Evaluation of Quality Program for-
                              Procurement Document Control
BEC-8-84  08/14/84            Evaluation of Quality Program for
                              QA Records
BEC-10-84 09/28/84            Evaluation of Compliance to Quality
                              Program Requirements for Design Control
                              and Project Engineering-Design Interface
                              Activities
BEC-11-84 10/31/84            Evaluation of Quality Program for
                              Evaluation of' Compliance to Quality
                              Program Requirements for Preparation,
                              Review, Approval and Control of Procedures
C14-501  02/06/85            Ebasco Structural Steel Installation
                              Activities
G35-501  02/06/85            HL&P-RMS Site Records Retrieval
G39-501  03/13/85            HL&P/Bechtel/Ebasco-Quality Records
M24-501  04/18/85            Westinghouse - Site Activities
S15-501  04/15/85            Bechtel Control of Westinghouse Design
                              Disclosure Documents
D08-501  04/23/85            Bechtel Design Control (Houston & Site)
G42-501  06/06/85            Bechtel/Ebasco Document Control
M16-501  07/25/85            Ebasco Valve & Pipe Installation
008-502  10/22/85            Bechtel Design Control (Houston & Site)
S23-501  10/16/85            Bechtel Document Control of Ebasco and
                              Westinghouse Documents
                            VII-24
 
                            TABLE VII-6
                      REVIEW 0F CALCULATIONS
                          STRUCTURAL SAMPLE
ITEM                .0BSERVATION
  1-  Drawing Change Notice (DCN) No. 5 issued on August 9, 1983
      against Bechtel drawing No. 3F01-9-S-3005, 'added support details
      for Fuel Handling Building heating coils 8V121VHX001 and -002 at
      two plan elevations.    Bechtel had performed a calculation for the
      support steel for this non-safety equipment but the calculation
      had not been checked or signed by the group leader at the time of
      the inspection. Bechtel did not assign a number to this
      calculation, and does not plan to formalize this calculation.
2    Bechtel' drawing No. 3M01-9-S-4043, issued on November 5,1984,      1
      revised the structural steel floor plan in the Mechanical and
      Electrical Auxiliary Building between column lines 30 and 32, and
      column lines M8 and H, at plan elevation 69 ft.-6 in. Field
      Change Notice (FCN) 1-C-0265, issued on March 6, 1985, provides
    .the fabrication details for the structural steel adjacent to a
      pair of HVAC openings located in the southeast corner of the floor
      plan. The CAT team requested the calculations for the structural
      steel detailed on the FCN. Bechtel indicates that engineering
      judgment was used to size the installed steel. However, this
      engineering judgment was not documented. The Bechtel civil /
      structural site organization has verbally indicated that calcula-
      tions could not be retrieved for any of the four above-referenced
      bays of structural steel in the Mechanical and Electrical
      Auxiliary Building.
3    DCN No. 5, issued on October 24, 1985 against Bechtel drawing
      No. 3M01-9-S-4069 Rev. 4, added a transverse stiffener beam
      between two existing parallel beams which support pipe hangers.
      The beam was added to increase the torsional stiffness of the
      existing beams. The added steel is located in the Mechanical
      and Electrical Auxiliary Building. The team requested the
      structural calculation for the added steel beam. Bechtel
      provided a recently completed calculation which verified the
      adequacy of the added beam (Rev. 1 to Bechtel calculation No.
      CC-6043, dated November 13, 1985).    Each of the existing steel
      beams was also checked in this calculation. The stress in one
      of the beams is 86 percent of. allowable load capacity. The
      stress in the other beam is 109 percent of allowable load
      capacity. These beams were subjected to generic dead and live
      distributed loads, a concentrated live load, and peak vertical
      and horizontal seismic spectra (i.e., the loads that would
      normally have been used to size this steel initially). It
      appears, however, that this is the first formal check of this
      steel.
                              VII-25
 
                                    TABLE Vl"-7A
            ELECTRICAL-AND INSTRUMENTATION CONSTRUCTION HARDWARE SAMPLE
                                Change Document
                                FCR DE-00274
                                FCR CE-04476
                                FCR CE-04475*
                                FCR CE-05252
                                FCR CE-05302
                                FCR BE-00536
                                FCR CE-05294
                                FCR CE-04881
                                DCN No. 8 (Dwg. 3D019-S-5002)
                                FCR CC-D5635
                                FCR XDE-00055
                                FCR CE-04284
                                FCR BE-00674
                                FCR BM-00225
                                FCN TGXM-10585, A, B, C*
(*) Refer to Section II, Electrical and Instrumentation Construction, for a-
    discussion of the deficiencies noted with the implementation of these
    design change documents.
                                        VII-26
 
                                TABLE VII-7B
                  MECHANICAL CONSTRUCTION. HARDWARE SAMPLE
                            Change Document
  A. Piping                FCR DP-451
                            FCR DP-541
                          FCR DP-57-1
                          FCR DP-503
                          FCR DP-690
                          FCR DP-748'
                          FCR DP-662
                          FCR DP-669
                          FCN IP-1125
                          FCN IP-1074
                          FCN IP-1069
                          'FCN IP-1067                                      '
                          FCR DP-269W
                          FCR DP-614
                          FCR DP-916-
                          FCR DP-14W
                          DCN Nos. 14 & 15 (Dwg. 5M369PCC207, Sh. 10, R.1)
                          FCN IP-1384
                          FCR DP-939W
                          .FCR DP-918
                          .FCR DP-772
                          FCR DP-751
                          FCR DP-739
                          FCR DP-718
                          FCN IP-1081
                          FCN IP-1106
                          FCN IP-0836
<
  B. Pipe Supports        FCN IP-0981
                          FCR DJ-00248
                          FCR XEJ-00185
                          FCN J-0919
                          FCR DJ-00368
                          FCR DJ-00306
                          FCR DJ-00374
                          FCR DJ-00648
                          FCR DJ-00440
                          FCN J-0967
                          FCN J-0968
                          NCR BS-00212
                                  VII-27
 
                                    TABLE VII-7B - (Continued)
                            MECHANICAL CONSTRUCTION HARDWARE SAMPLE
                                      Change Document
    C..  Concrete Expansion      _
                                      FCR CM-02181W
        -Anchors and Base Plates    NCR CM-00587
                                      NCR CS-00802
                                      NCR CS-03103
                                      NCR CS-01014
                                      FCR DJ-00787
              '
                                      FCR DJ-00994
                                      FCR DJ-00894
                                      FCR EJ-00289                                          1
          '
                                    -FCR J-0983
:                                    DCN No.1 (Dwg. CC9317-HL5006)
                                      FCR DJ-00763
    D.  HVAC                        FCR BH-00827
                                      FCR CH-01546
                                      FCR BH-00559
                                      FCR CH-00845
                                      FCR CH-01800
                                      FCR DL-00152W
    3                                FCR CH-02181W
                                      FCR EAB-314
                                      FCR BH-01844
                                      FCR BH-01142
4
                                        .
1
            \
4
                                              VII-28
  ,              .              ..
                                              . . - . . - . . - . - . . , , - - - . ,. .. .
 
  . .. .          .  -  _
                                  . . - .    -        _. .-    . , - . _ . .,      .
                                          ..
                            TABLE VII-7C
          CIVIL / STRUCTURAL CONSTRUCTION HARDWARE SAMPLE
                      Change Document
                      FCR EC-00318
                      FCN 2C-0450-
                      FCR EC-00321
                      FCR EC-00098
                      FCR EC-00318
                      FCR CM-00194
                      FCR CC-02180
                      Dwg. No. 3C01-9-S-1633, Rev. 10
                                                                                            ,
                                                                                            '
,
                                                                                            t
i
i
                                                                                            f
                                                                                            f
g.
                              VII-29
i                                              _ _ _ _ _ . _ .          ._,  _ . . . - . _
 
                                                      __                    _ - - -
                                                                                    - - _ _ - . .
,
  VIII. CORRECTIVE ACTION SYSTEMS
          A. Objective
              The objective of this portion of the NRC CAT inspection was to verify
              through selected samples, whether measures were established and
              implemented to assure that nonconformances and other conditions adverse
              to quality were promptly identified and corrected.
                                                                                                  r
          B.  Discussion
              An examination was made of the licensee's program for identification
i
              and control of nonconformances and corrective actions, including review
              of documents and inspection of some material / equipment for verification
              of actual corrective actions in the plant. Items such as the following
              were reviewed:
              * Quality assurance programs
                Procedures and organizational interfaces
                Trend analyses
              * Audits and surveillance reports
            '* Nonconformance reports
r                Deviation reports
(            * Inspection reports
(            * Corrective action reports
              * Control of actual material / equipment corrections in the plant
              * Control of open nonconformances at turnover for testing or operation
              Table VIII-1, " Corrective Action Samples," contains a list of samples
              that were randomly selected.
              The following manuals and procedures of on-site organizations were
              found in place, and applicable portions pertaining to corrective action
              provide the background infonnation and acceptance criteria for this
              inspection.
              Houston Lighting and Power Company (HL&P)
              * Quality Assurance Program Description for the Design and Construction
                Phases of the South Texas Project, Rev. 11
                Project Quality Assurance Plan, Rev. 7
                South Texas Project Quality- Assurance Procedures, Rev. 46
                Standard Quality Assurance Procedures:
                SQAP-01 General Control of Standard QA Procedures, Rev.1
                SQAP-02 Deficiency Reporting, Rev.1
                SQAP-03 Project Audits, Rev.1
                SQAP-04 Project Surveillances, Rev. 1
                PSQP-16.3 Trend Analysis, Rev. 3
                SSP-8 Nonconformance Reporting, Res. 0
                                            VIII-1
                                                      - _ _ _ _ _ _ _ _ _ _
 
    OPGP03-ZM-0002 Preventive Maintenance Program, Rev. O
  Bechtel Power Corporation (Bechtel)
    Project Quality Program Manual, South Texas Project, Rev. 11
    WPF/QCI.-4.0 Receiving Inspection, Rev. 11
  * WPP/QCI-5.0 Nonconforming Materials,. Parts and Components, Rev. 14
    WPP/QCI-28.0 Maintenance of Materials and Equipment, Rev.11
    SQAP-04 Project Surveillances, Rev. 1
  Ebasco Services Incorporated (Ebasco)
    _ETR-1001 Nuclear Quality Assurance Program Manual, Rev. 11
    QAI-11 Corrective Action and Stop Work Authority, Rev. 7
    QCP-10.9 General Inspection (G series), Rev. 2
  * QCP-10.30 Inspection of Installation and Fabrication of Electrical
      Cable Tray Hangers, Conduit Supports and Auxiliary Steel, Rev.1
  * QCP-10.11 Mechanical Equipment Installation Inspection, Rev. 5
  Westinghouse Construction Services (Westinghouse)
  * Quality Assurance Program Manual (QAPM) for ASME Code Section III,
      Division I
    QAPM Addenda for South Texas' Project (yellow pages)
  * QAPM Addenda, Section 15.0 Nonconformances, Rev. 9
    QAPM Addenda, Section 16.0 Corrective Action, Rev. 7
  * STP Project Quality Plan, Rev. 4
  Pittsburgh DesMoines St' eel Company (PDM)
    Corporate Quality Assurance Manual (CQAM) ASME Section III, 1981
    Edition, Rev. 8
    CQAM Appendix 202 (for STP), Section 12, Nonconformances and
    Corrective Action
  Richmond Engineering Company (RECO)
    Quality Assurance Manual, South Texas Project, Rev. 3
  Intermach Company (Intermach)
    Quality Assurance Manual (The Bahnson Co.), Rev. 9
                                VIII-2
.
-
                                                              -.
 
m      .
  J
      * QFP-15.001 Nonconfonning Items, Rev. 4
      * QFP-16.001 Corrective Action, Rev.1
      * QFP-8.001 Identification and Control of Materials, Parts and
      .
                        '
          Components, Rev. 3
      * QFP-9.001 Control of Welding Processes, Rev. 3
    - * QCI-013 Control of Nonconforming Items, Rev. 2
      Prescon Corp. (Prescon)
      * Quality Assurance Program, Rev. 10
      Champion, Inc. (Champion)
      * Quality Assurance Manual, Rev. 26
      Pittsburgh' Testing Laboratory-(PTL)
      * Quality Assurance Manual, Rev. 8
      1.  Corrective Action Measures
      a.  Inspection Scope
          A review was performed of applicable portions of the Quality
          Assurance (QA) program and procedures.    In addition to QA manuals
          and procedures, a total of 439 samples of corrective action docu-
          ments were reviewed. . Also,'16. samples-of closed nonconformances
          involving material / equipment were inspected for verification of
          corrective actions in the plant.    In' addition, 58 samples of open
          nonconfonnances were selected for verification of " HOLD" status.
      b.  Inspection Findings
          In general, it was found that satisfactory procedures were in place
          for corrective action systems to identify and control the
          correction of conditions adverse to quality at the site. Except
          for concerns discussed below, the corrective action systems and
          implementing measures were found to be acceptable. The 16
          material / equipment samples requiring rework in the plant were
          inspected, and corrective action control was verified.
          (1)' Fastener Materials
                Numerous problems with fastener material discrepancies on large
                vendor-supplied ASME pump / motor assemblies and other vendor
                equipment were found by the NRC CAT inspectors for which
                effective corrective actions were not previously evident.
                See Section VI.B for details. These problems indicate a
                lack of attention by vendors to ensure that fasteners of
                required materials are specified and provided with delivered
                items, a lack of effective quality control at vendors'
                                    VIII-3
1
 
  '
    .
                            ~
              plants, and also a lack of vendor surveillance by the licensee
              wi_th ' attention to' verification of proper fasteners prior to
              shipment.
          '
      (2) Preventive Maitenance (PM)
              Review of the PM program revealed that numerous problems have
              been encountered, including overlubrication and contamination
              due to commingling of lubricants.. Seven fan motors, after
          - turnover to Startup, .were _later found to have been
              overlubricated.
              Review of PM history of four Auxiliary Feedwater Pumps (three
              motor: driven and one turbine driven) revealed repeated
              corrosion problems. One unit seized and could not be
              rotated. Rotating . elements of the four_ units had to be
              returned to the ' vendor for repairs.
              .The NRC Resident Inspection Office has issued inspection
              reports (85-08 and 85 11) on PM deficiencies. Also, Ebasco
              issued a Management Corrective Action Report .MCAR-13 dated
              February 23, 1985 which contains a list of 106 deficiencies and
              resulted in a major review and reorgnization of the PM program.
              Of parti _cular concern is the current practice of the' licensee _
              accepting turnover packages and preparing operational
              maintenance programs assuming that the past PM history is
              good without assessing potential for damage to the equipment
              due to past PM deficiencies. The potential long term effects
              of' the lack of proper maintenance-has not been addressed and
              documented, and it does not appear that measures-(reference:
              OPGP03-ZM-0002 Preventive Maintenance Program, Rev. O, dated
              5-15-85) were in place to. provide for damage assessment and.
'
              evaluation.
      (3) Nondestructive Examination (NDE)/ Radiographic Testing (RT)
              Audits; Records Retrieval
              Review of'the total .of 21 prior audits of welding /NDE revealed
              only two audits that addressed RT records packages and
              retrievability (audits M11-301 and G35-502). These two audits
              included three weld joints for one audit and six weld joints
              for the other. The total of 9 weld joints (of approximately
              25,000 field weld joints) is a very small sample to have been
              audited. NRC CAT examination of the radiographs for'two of the
              three welds for audit M11-301 found them to have deficiencies,
            ' indicating that the audits.were limited in scope and depth
              (see Section IV.B 'for details).
              None of the 21 prior audits covered vendor NDE/RT records.
              Requests for information to identify vendors that were
              required to supply radf ographs were not'readily answered.
              Some radiographs from vendors involving plant equipment were
              not made available to the NRC CAT inspectors, and in some
                                    VIII-4
 
          cases could not be located. A method for identifying vendors,
          equipment and related radiographs was not available at the
          start of the CAT inspection (see Section IV.B for details).
          The required records retrieval for RT film was not evident
          during this inspection, and raises questions regarding the
          ability of the licensee to verify the required product quality,
          if records are not readily available.
  '(4),, Significant Deficient Corrective Actions for Certain Electrical
          Items: Motor Operated Valves (MOVs) and Motor Control Centers MCC)
          Corrective action deficiencies related to unauthorized
          electrical wiring of MOVs furnished by Westinghouse were noted
          by the NRC CAT inspectors (see Section II.8). Questionable
          QA and corrective action activities involving design change
          control, field modification and inspection were indicated.      It
          was noted that no audits or surveillances of Westinghouse
          activities related to MOVs had been conducted. However, one
          HL&P audit report, S26-501 dated September 24, 1985 addr(ssed
          field wiring changes by Westinghouse on other electrical equip-
          ment inspected and accepted at the site without prior written
          authorization for the changes. The response by Westinghouse
          noted a procedure change for accelerated Field Change Notice
          (FCN) work to require written authorization prior to the work.
          Also, a project team audit S15-501 dated April 15, 1985
          referenced a prior HL&P audit M24-501 of Westinghouse which
          addressed deficiencies in the electrical area. It appears that
          the generic aspects of these audit results were not applied by
          Westinghouse to the MOV~ work.
          Also, corrective action deficiencies related to faulty bus
          extensions of circuit breakers in MCCs procured by Bechtel
          were noted by the NRC CAT inspectors (see Section II.B).
    (5) Open Nonconformances " HOLD" Status Control
          Open Nonconformance Reports (NCRs) and related equipment
          requiring " HOLD" tags for 58 items were reviewed for
          verification.    " HOLD" tags for 13 items (22%) were missing or
          improperly controlled.
          Since " HOLD" tags are required to be used as a means of
          controlling quality, attention and action are required to
          assure proper application and maintenance of "H0LD" tags on
          nonconforming material and equipment. As a result of this NRC
          CAT finding, Bechtel issued General Surveillance Report SB 727
          to document incorrect " HOLD" tag control,
c.  Conclusions
    The licensee's corrective action program was found to be generally
    acceptable, except for the following concerns:
                                VIII-5
 
r-
  (1) Failure to assure that fasteners of required materials were
        furnished with vendor supplied equipment.
  (2)  Failure for Operations to assess and evaluate damage to
        equipment due to past PM deficiencies and incorporate such
        considerations into operational maintenance programs.
  (3) Failure to conduct a reasonable quantity of audits of actual
        radiographs of both field welds and vendor supplied welds.
        Also, failure'to assure that vendors required to supply
        radiographs were readily identified and that the location of
        radiographs / records were known and readily retrievable as
        required.
  (4) Failure to identify the need for effective corrective action
        activities for certain electrical items: MOVs and MCCs.
  (5) Failure to properly apply and control " HOLD" tags on
        nonconforming material and equipment.
  (6) There appears to be a need for more ~ attention to generic and
        lessons-learned aspects of the corrective action program to
        help reduce deficiencies and avoid recurrence.
                            VIII-6
 
C
L
r _      , , - -
    .~ l        r
                  ,
p          .
L~
j;;
                        ,
                                                          -TABLE VIII-1
p                                                    CORRECTIVE' ACTION SAMPLES
[
          >
                    JItems/ Reports                                    Quantity Examined
L                                              HLP  BEC    EBA'    WES    PDM    -REC    INT  PTL-    TOTAL
L                    . Trend                  3*    *-    *      ~3    -        -            -
                                                                                                              6
                - . Audit'                    41*    *      *        6    3        '--  -1      -
                                                                                                            51
;
                    : Nonconformance          17    61    69        6    5        5  .12      5        180
l-                        ~
                      Deviation                --    -      -
                                                                    10    8        -
                                                                                          .15      -
                                                                                                            33.
''
                      Inspe'ct' ion
                                                                                                    -
                                                -
                                                      5    18        -    -        -    4      -
                                                                                                            27
l-                  . Surveilla'nce          -14    19    12        -    -        -    -      -
                                                                                                            45
i
"
                    : Corrective Action        9    18    12        -    -        -    -      -
                                                                                                            39
L
!
                      Deficiency Eval.        10    10      -        -    -        -    -      -
                                                                                                            .20
i                    :Mgt. Corrective          -    -
                                                            4        -    -        -    -      -
                                                                                                              4
l
              ,
                        . Action-
                      Inspection              9    -      -        -    -        -    -    ~ -:        9
r.                          Efficiency-
l
L
                    /Stop Work ~              3    -
                                                            1        -    -        -      .
                                                                                                        -
                                                                                                              '4
                      Turnover. Packages      20    -      -        -      -        -    --
                                                                                                      .    20
p
                                                                                  -T
      ~
                                      TOTA'l TE6    TIT    IT6      Y5    T6            72    - !i.    . TJB
                                '
L_                    HLP = Houston' Lighting and Power Company
                      BEC = Bechtel Power-Corporation
=
',
.                    EBA = Ebasco Services Incorporated
L                    . WES =. Westinghouse. Construction Services
D                      PDM = Pittsburgh DesMoines Steel. Company
                      REC = Richmond Engineering Company
  .''
                      INT.= Intermach Company
                      PTL = Pittsburgh.. Testing Laboratories
                                                                                                                -
v
                      * Joint (HLP,. BEC, and EBA) trend and audit program samples listed under' HLP,          ,
'                                                                                                                l
                                                                                                                l
                                                                                                                l
                                                                                                                l
                                                                                                                l
                                                                VIII-7-
                                                                                                                1
L___'
 
                                      _
                                                                ATTACHMENT A
  A. PERSONS CONTACTED
    The following list identifies 1 censee representatives and NRC personne1'
                                        4
    present at the exit meeting, and licensee discipline coordinators and key
      individuals-contacted during the inspection for each area.
    1.    Exit Meeting
    Houston Lighting and Power Company
    F. L. Alkov                G. Goldberg              T. H. McGriff
    J. Bevins                  S. Head                  R. C. Munter
    P. F. Boyle                R. Hernandez              A. G. Peterson
    D. P. Bradley              S. R. Hubbard            G. B. Rogers
    R. J. Daly                  M. F. Hutcheson          M. T. Sweigart
    S. Dew                      T. J. Jordan              W. Trujille
    F. Dotson                  D. R. Keating            J. Westermeier
    J. E. Geiger                W. H. Kinsey, Jr.        W. R. Whitley
                                                          M. R. Wisenburg
    Bechtel Energy Corporation
    R. D. Bryan                L. W. Hurst              -R. L. Rogers
    J. L. Hurley                D. R. Quattrochiocchi    R. Wilkerson
    Ebasco Services, Incorporated
    A. M. Cutrona              W. Taylor                R. W. Zaist
    R. A. Harrington
    Westinghouse Ele-tric Corporation
    D. M. Bokesch              C. W. Rowland            F. J. Twogood
    H. L. Hogarth              S. R. Spiegelman          R. J. Von Osinski
    NRC and Consultants
    S.' Baron            D. Garrison          T. McLellan          W. Sperko
    D. Carpenter          G. Georgiev          0. Mallon            S. Stein
    L. Constable          R. Heishman          E. Martindale        R. Taylor
    R. Compton            C. Johnson          J. Nemoto            R. Vollmer
    A. DuBouchet          R. Kadambi          M. Peranich
    D. Ford              J. McCormack        H. Phillips
                                          AA-1
.                                                            .-
 
'~
      .  ~                                                                                          .
                '
            r.-
        ,
                          2.    Licensee Coordinators and Contacts'
                                      Area'                                      Contact
                                = Team-Leader-                              R. Hernandez
  -
                                                                            W. Trujillo
                                : Electrical and Instrumentation            D. Bradley-
                                                                            D.-Richter
                                                                            J. Bagley
                                Mechanical                                M. Hutchesan.
                                                                            S.' Hubbard
                                                                            J. Bagley
                                                                            C. Brewer
                                                                            A. Benyo
    ~
                                Welding and NDE                            S. Hubbard
                                                                            R. Abel-
                                                                            R.. Lewis
                                Civil and Structural                      'T. McGriff
                                                                            J.-Stevens
                                                                                                    .
                                Material. Traceability                    F. Alkov
                                                                            J. Senecal
                                                                          ~~R. Fish
                                Corrective Action Systems                  E..Luder
                                                                          -J. Hansen
                                Design Change. Controls -                  K. McNeal
                        .In addition to the above personnel, numerous other inspectors, engineers-
                          and supervisors were also contacted.
                  ~ B.  DOCUMENTS REVIEWED.
                          The types of documents listed below were-reviewed by the NRC CAT members-
                          to the extent necessary to satisfy ~the inspection objectives stated in.
                        'Section I of this report. There are' additional references within the
                          body of.the report to' specific procedures, instructions, specifications
                          and drawings.
                          1.    F.inal Safety Analysis Report and. Safety Evaluation Report
                                                          .
                          2.  lQualityassurancemanual
                        '3.    ' Quality assurance procedures and instructions
                          4.  ' Quality control procedures and instructions
                          5.    Administrative procedures
                          6.    General. electrical installation precedures and specifications
                                                              AA-2
 
        .-
;_ . .
                                    .
,
      _
            7.    General instrumentation . installation procedures and specifications.
            - 8.r : General piping and pipe support installation procedures and
                    specifications
                                          ~~
            9.    General mechanical equipment . installation procedures and
                    specifications-
                                            '
:c                                                                                        ,
            !10. -General concrete specifications                                          !
            11. As-built. drawings
            12.. Welding and NDE procedures
            .13.    Personne1~ qualification records
            14.    Material traceability procedures
            15. ---Procedures for processing design changes
            16. .-Procedures for document control
            -17. . Procedures for controlling as-built drawings
            18. . Procedures for processing nonconformances
se
                                                AA-3
 
    , <
              ,
        . . .
                                                                                                                      ~ ATTACHMENT B
                                                        GLOSSARY OF ABBREVIATIONS.
      _        .
                        A/E        - Architect-engineer
                    'AISC.        - American Institute of Steel Construction
                        ANSI      '- American National Standards Institute
                                      '
                        ASME      - American Society of Mechanical Engineers
                      ' ASTM            .American Society for Testing and Materials
                        AWG        - American Wire Gage
                        AWS      --American Welding Society
                    'ATWS'        - Anticipated transient without scram
                        BBC-      -TBlount Brothers Company
                        BEC_    ' -~Bechtel Engineering Corporation
                    -BR-          - Brown & Root, Inc.
  ,                  . CAR-      - Corrective Action Report
                        CAT      - Construction _ Appraisal. Team (NRC)
                                    '
                        CB&I.    - Chicago Bridge and Iron Company
                        CCP      - Configuration Control Package
                        C of C    - Certificate of Conformance
                        CEA      - Concrete expansion anchor
      ,                CMTR-  ~- Certified material test report
                        CPS            -Construction Process Sheet
                        CSP      - Construction Site Procedure
                    .DCN                Drawing Change Notice
                        DEF      - Deficiency Evaluation Form
                        DER      - Deficiency Evaluation Report
          -
                      DR      ' - Deviation Report
                        ECN          : Engineering Change Notice
                                  - Essential Cooling Water
                              ~
                                      '
                        ECW
  ,                    EDP-      - Engineering Department Procedure
  '
                      .ERSA      - Engineering Request for Site Action
                  'FCN          '- Field Change. Notice
                      FCR        - Field Change Request
                      FDCC              Field Document' Control Center
                    -FRLL        - Field Revision List
.                      FSAR      - Final Safety Analysis Report
                      HEco      - Hatfield Electric Company
I
                      HL&P      - Houston Lighting and Power Company
'
                      Hunter-  - Hunter Corporation
*
                  .HVAC        - Heating, ventilating and air conditioning
:                      IE        - Office of Inspection and Enforcement (MC)
*
                  'IEEE
                    -
                                - Institute of Electrical and Electronic Engineers
L                      IPCEA    - Insulated Power Cable Engineers Association
'
                      LP --    - Liquid penetrant inspection
                      LOCA      - Loss-of-coolant accident
                      MCC.      - Motor Control Center
                      MCM        - Thousand circular mils
                      MIC        - Midway Industrial Company.
                      MOV      - Motor operated valve
!-                    NCR      - Nonconformance Report
j3                    NDE      - Nondestructive examination
                                                                  AB-1
    --
                                                                        - . - . . . . - - - . - . _ . - . - . . . - . - . - - - - _ . - -
 
                      ,
    NISCo  - Nuclear Installation Service Company
                  ' Nuclear Power Service, Inc.
          ~
    NPS'
    NRR    - Office'of Nuclear Reactor Regulation (NRC)
    NRC        .U.S. Nuclear Regulatory Commission-
                '
  .NSSS.    - Nuclear. steam system supplier
    PAP    - Powers-Azco-Pope
  . PDM    - Pittsburgh Des Moines Corporation
    PED          Project Engineering Directive-
    PSAR        . Preliminary Safety Evaluation Report''
    PSI  - Preservice inspection
    PTL'  - Pittsburgh Testing Laboratories'
    QA    - Quality assurance
    QAI    - Quality Assurance Instruction
    QAM'  - Quality Assurance Manual.
    QC    - Quality Control-
    QCP    - Quality-Control Procedure
                                  ~
    QR    - Quality Requirement
    RG'    - Regulatory Guide (NRC)
    RHR    - Residual Heat Removal System
    RSM    - Reliable Sheet Metal Works, Inc.
    RTD -- - Resistance Temperature Detector
  .SAR    - Safety Analysis Report
    SDR    -. Standard Deficiency Report
    SEO.  - Site Engineering Organization
    SIP    - Site Implementation Procedure
    SSP    - Standard Site. Procedure
    STP    - South Texas Project
    SWI    - Site Work Instruction
    SWR-  - Startup Work Request
    UT    - Ultrasonic inspection
    V      - Volt
    VT. -  - Visual inspection
          - Westinghouse Electric Corporation
              '
    W.
i
                                              AB-2
                                                          __ _
 
  ._. _.
        _
                                                                                                -,
              _7
        NRC Form 8-C
              (4-79)
            NRCM 0240
          o
                                  COVER SHEET FOR CORRESPONDENCE
                      Use this Cover Sheet to Protect Originals of Multi-Page Correspondence.
                                                                                              >
                                                                                                  d
L
 
                                                                                                                                                                                                                        ;q
                                                                                                                                                                                            -
                                                                                                                                    .
                                                                                                                                                                =                                        r
  re                                  ~,, ~;
                                                                                            -
                                                                                                            .
                                                                                                                                                                                                              _
                                                                                                              ,        _
                                                                                                                                                                                              _ ,      ,
                                                                                                                                                                                                                      ,
                                                                                                                                                                                                                          ,
                                      y;, ' "
                                                                                                                                                                                          ,
                                                                                                                                                                                                                                  '
        _. ..
                    ~
                                                                              :'.'.: '          _
                                                                                                                          ,
                                                                                                        >
      :r;                                    -
                                                          .
                                                                      ,.
                                                                                                            ,
                                                    .j -                                                                      ,
                                                                                                                                                                                                                    t
                            '
  ' w' f ~ .~j                                                                                                    m ,
          =                                                                              ,
              4                          *
            3,.
                                          9    = '-
      __ t7e .g. ;                                                                                                                                                                                                                j
                  t                                                                                                                                                                                                              .
              A
                            _*.                                  g
                          i i'                  I'                                                                                                                                                                            _
                                  * ' ,
                                            , :;s .
                      >                  >      a    s
                                                          ,                                                                                                                                                            ~ >      ,
                                                                                                                                                                                                    -
                                                            ~
      ?
                                                                                                                                                              i.
                                                                                                                                                              -
                                                                                                                                      ..l
                                                                                                                                                    -
                s
                                                                                                                                                            ,
                                                                                                                                                  9                  .
        #
                                      ,
                                                                        '
                                                                                                                                          [.              i.
                                                                                                                                                                        ,'
                                                                                            .
                                                                                                                                      :*.                f? ~
                                                                                                                                  I.          -
                                                                                                                                                                    #'                                                    "
                                                                                                                            ({p't.
                                                                                                                                - . )y f0, igf ..3p    ,
                                                                                                                              (        ,. I , .                    ,. [;(          r
                                                                                                                .                                                      ,.    i.                              .
                                    '''
                                    -
                                                                t                                        ..
                                                                                                            '
                                                                                                                                &.                [f
                                                                                                                                                                                  '
            s
                                                                - -
                                                                                                    w
                                                                                                      .c                          -- p, . r,a    ,
                                                                                                                                                                                      )
  ~                            ..
                                                                                      , . -
                                                                                        .s
                                                                                              .s . .
                                                                                                                                              ..
                                                                                                                                            .2
                                                                                                                                                                    . .> o
                                                        '
                                                                                      W 3---
          ,
                                  '              ~                                                                                      l?!d, _ t, _            :                                                    e
                                                                          : it ,. .                                                  .A,q . , *.. . .
                                                                                                                                                                                                                              ~;
                                                                                                                                                                                                                              .
                                                                                                                                          _
                                                                                                                                                                  ,
                      -
                                                                                                                                                                                                                  c
                                                              py
                                                                                                                                                                                      .,
                                                                    g                                                  .
                                                                                                                                            p j ;p+,y'                        p#      :
                                                                                                                                                                                                                            ,
                                                                                                                                                                                                                        -- '
          ,
                                                                                                                                                            ' *. ..          A
                                                                                                                                                                                    '
                                                                                                                                                      l a $* . -f W} .y'    -
                                                                                                                                                    ,- 4                    ;
                                                                                                                                                                                _
                                                                                                                                                                ,o
                                                                                                                                                ..-  /.$.
                                                                                                                                                      '/i  4
                                                                                                                                                                    h^
                                                                                                                                                          d
                          .                                                            ;
                                                                                                                                                                                                      i
                                                                                                                                                                                                            1
                                                              %
                                                                                                                                                                                                          k
    .
t-
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                      /
$
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      -                          .
g.
# '
      -
                                                                    4
+fj;  4                            ,
F
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,-
                    . .
                                                                                                      _
        I
j-                                                                                                                                                                                                s
t.
t.
!
,
f
              #
                        1
                                      : 4
, .                      .,.
r
                            I
hJ                                                        _ v6
m-
                                                                                                                                                          .g
  ,o                                              .-____-.___;.,____-_..-_-_--
}}

Latest revision as of 01:33, 18 December 2020

Const Appraisal Team Insp Repts 50-498/85-21 & 50-499/85-19 on 851021-1101 & 12-22.Potential Enforcement Action Noted: Failure to Provide Adequate Interface Between Design Organizations (A/E) & NSSS
ML20151V035
Person / Time
Site: South Texas  STP Nuclear Operating Company icon.png
Issue date: 01/17/1986
From: Garrison D, Georgiev G, Heishman R, Mclellan T, Nemoto J, Peranich M, Phillips H, Phillips H, Stein S
NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV), NRC OFFICE OF INSPECTION & ENFORCEMENT (IE)
To:
Shared Package
ML20151V027 List:
References
50-498-85-21, 50-499-85-19, NUDOCS 8602110181
Download: ML20151V035 (200)
v • d • e


See also: IR 05000498/1985021

Text

UNITED STATES NUCLEAR REGULATORY COMISSION

OFFICE OF INSPECTION AND ENFORCEMENT

DIVISION OF INSPECTION PROGRAMS

REACTOR CONSTRUCTION PROGRAMS BRANCH

Report No.: 50-498/85-21,499/85-19

Docket No.: 50-498, 50-499

Licensee: Houston Lighting and Power Company

Facility Name: South Texas Project

Inspection At: Matagorda County, Texas

Inspection Conducted: October 21-November 1 and November 12-22, 1985

Inspectors: / M '#

M. W. Peranich, Chief Construction Programs /

/////74

Date 51gned

CAT Section, Team Leader

W hr /

'Inspedtor

h (Region IV)

Y'/fC

D&te' Signed

<D.L.Garytson,feside

N. 4. 5 /\lm LE& /f/0 86

)rgiev, Sr. Retctor Co truction Engineer Date S4gned

/G.B.Ge

I r Y Y?Yk

T. K. McLellan, Reactor Construction Engineer

///r/d4

D4te' Signed

L ll ///O/86

gmoto, Reac Construction Engineer Ddte S'igned

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M. W. P ipips, Reactor struction Engineer

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Date Signed

. ' {&J.'Jn -

'

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' S. R. Stein, Riactor Construction Engineer

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Date Signed

Consultants: S. L. Baron, A. V. duBouchet, D. C. Ford,

J. B. McCormack, O. P. Mallon, E. Y. Martindale

W. J. Sperko, Jr. , D. G. Whatley,

/,

Approved By: / _

Robert F. Heishman, Chief 0(te' Signed

Reactor Construction Programs Branch

0602110101 06020S ,-

  • R. !!. Compton was inadvertently omitted PDR ADOCK 0500 0

from the list of consultants. O

._. _ _ -_ _ - _ - _ _ - _ _ _ _ _ _ _ _ _ _ _ _ - - _ _ _ - - _ _ _ -

_ _ _ _ _ _ _ _ _ _ _ _ _ _

TABLE OF CONTENTS

TOPIC SECTION

INSPECTION SCOPE AND OBJECTIVES............................... I

ELECTRICAL AND INSTRUMENTATION CONSTRUCTION................... II

MECHANICAL CONSTRUCTION....................................... III

WELDING AND NONDESTRUCTIVE EXAMINATION........................ IV

CIVIL AND STRUCTURAL CONSTRUCTION............................. V

MATERIAL TRACEABILITY AND CONTR0L............................. VI

DESIGN CHANGE CONTR0L......................................... VII

CORRECTIVE ACTION SYSTEMS..................................... VIII

ATTACHMENT A - PERSONS CONTACTED AND DOCUMENTS REVIEWED

ATTACHMENT B - GLOSSARY OF ABBREVIATIONS

l

I

_ _ _ . _ _ _ . _ _ _ _ . _ . _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ .

. _ _ _ . _ _ . _ ._ _. . _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

I. INSPECTION SCOPE AND OBJECTIVES

The objective of this inspection was to evaluate the adequacy of

construction at the South Texas Project site. This objective was

accomplished through review of the construction program, evaluation nf  ;

project construction controls, and review of selected portions of the i

Quality Assurance Program, with emphasis on the installed hardware in the i

field. The scope and significance of identified problems were also i

determined. '

F

Within the areas examined, the inspection consisted of a detailed

examination of selected hardware subsequent to quality control

inspections, a selective examination of procedures and representative

records, and limited observation of in process work.

For each of the areas inspected, the following was determined: )

Were project construction controls adequate to assure quality i

construction?

Was the hardware or product fabricated or installed as designed?

r

Were quality verifications performed during the work process with

applicable hold points?

Was there adequate documentation to determine the acceptability of

installed hardware or product?  !

Are systems turned over to the startup organization in operable

condition and are they being properly maintained?

,

i

,

&

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(

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1

1-1

_ _____ __-__- - _ _ - - _ _ _ _ _ _ - - - - - _ _ _ - - _ _ _ _

W

II. ELECTRICAL AND INSTRUMENTATION CONSTRUCTION

i

A. Objective

The primary objective of the appraisal of electrical and

instrumentation construction was to determine whether safety-related

components and systems were installed in accordance with regulatory

. requirements, Safety Analysis Report commitments, and approved vendor

and construction specifications and drawings. Additional objectives

were to determine whether procedures, instructions, and drawings used

to accomplish construction activities were adequate and whether

quality-related records accurately reflect the completed work.

B. Discussion

Within the broad categories of electrical and instrumentation

construction, attention was given to several specific areas. These

included electrical cable, raceways and raceway supports, electrical

equipment, and instrumentation tubing and components. Additionally, a

review as made of a selected number of documents associated with design

change control and nonconformance reporting.

A number of documents were generated by the applicant to record

individual observations of the NRC Construction Appraisal Team (CAT)

inspectors, and are referenced directly in the discussions that follow.

1. Electrical Raceway Installation

a. Inspection Scope

Seventy-two segments of installed Class 1E cable tray, representing

a total length of about 1,000 feet, were selected from various

plant areas for detailed examination by the NRC CAT. These

segments were inspected for compliance to requirements relative to

routing, location, separation, support spacing and configuration,

identification, protection, and physical loading. Additionally, 28

runs of installed conduit, with an aggregate length of about 1,600

feet, were inspected for compliance to specified requirements such

as routing, location, separation, bend radii, support spacing, and

associated fittings.

Twenty-eight raceway supports were examined in detail for such items

as location, material, anchor spacing, weld quality, bolt torque, and

installed configuration.

See Table 11-1 for a listing of cable tray, conduit, and raceway

support samples.

The following documents provided the basic acceptance criteria for

the inspection:

Bechtel Specification 3E189ES1000, " Conduit and Tray Supports,"

Rev. 6

11-1

-

___ __________-____-___ _ _ _ _ _ _

Ebasco Quality Control Procedure (QCP) 10.16, " Inspection of

Electrical Raceways," Rev. 4

Ebasco QCP-10.30, " Inspection of Installation and Fabrication of

Electrical Cable Tray Hangers, Conduit Supports and Auxiliary

Steel," Rev. 1

Ebasco Construction Site Procedure (CSP) 40, "EE580 Electrical

Installation," Rev. 4

b. Inspection Findings

In the area of electrical raceway the NRC CAT inspectors observed

that, in general, Class 1E raceway installations were in accordance

with applicable design criteria. Quality attributes such as

material type, location, identification, and installed

configuration were found to be as shown on approved construction

drawings. However, several deficiencies in design or construction

or both were identified and are discussed below.

(1) Raceway Separation

The South Texas Project (STP) Final Safety Analysis Report

l (FSAR) section 8.3.1.4, entitled " Separation of Redundant

'

Systems," provides the basic criteria for acceptable Class 1E

circuit and electrical raceway installations. This FSAR

section describes commitments for physical arrangement of

raceways which pertain to the requirements of Regulatory Guide

(RG) 1.75 for independence of redundant systems. In general,

these FSAR criteria specify the physical separation which must

be maintained between components of redundant electrical

divisions. Additionally, physical separation is required

between components performing Class 1E and non-Class 1E

functions.

During the examination of the selected raceway sample, NRC CAT

inspectors observed that a number of installations were not in

accordance with the FSAR requirements. Deficiencies were

identified in several areas of the plant but were most common

in the Mechanical / Electrical Auxiliary building. In this area

'

numerous Class 1E raceway components had been installed

without the required physical separation. See Table Il-2 for

a listing of the identified raceway segments that violated

separation criteria.

NRC CAT inspectors discussed this issue with licensee personnel

and reviewed relevant inspection procedures, design drawings

and plant historical records to determine why those deficien-

cies exist. The review indicates that the licensee had

identified problems in the area of electrical separation as

'

early as 1984. Corrective Action Report (CAR) G-434, dated

May 8, 1984, details specific violations of relevant FSAR

l criteria. Additionally, other site initiated documents such

l as the " Final Report for STP Pre-CAT Verification," dated July

j 18, 1985, highlight deficiencies in this area.

1

Il-2

_ _ _ _ - _ _ _ _

In reviewing these documents NRC CAT inspectors expressed

i

concerns with regard to actions taken to correct existing

deficiencies. As an example, in response to the deficiencies

identified in CAR G-434 the licensee elected to postpone the

inspaction of raceway division separation until the time of

area turnover. Relevant inspection and construction procedures

were then revised to reflect this decision by eliminating the

attribute of division separation from inspection of cable tray

and conduit. Discussions with licensee personnel indicate that

>

this decision was made based upon the fact that construction

activities are ongoing and thus it is not prudent to identify

separation violations prior to completion of any given area.

At the time of area turnover, a walkdown of each area is

planned by Ebasco engineering to identify violations in

separation and determine the course of action necessary to

alleviate those problems. Additionally, Ebasco Quality

Control (QC) personnel will perform an inspection after the

installation of required barriers in accordance with the

applicable Quality Control Procedure.

NRC CAT inspectors noted that many of the deficiencies identi-

fled during the examination of the raceway sample involved

i components which were part of a system turned over to Houston

!

Lighting and Power Company (HL&P) Startup. Consequently,

component modification or installation of barriers which may

result from future inspection activities may adversely affect

plant systems which have been turned over and accepted.

Several aspects of the licensee's proposed inspection and

engineering walkdown programs were evaluated, including a

review of Standard Site Procedure SSP-45. This procedure,

issued on October 25, 1985 during the NRC CAT inspection,

provides the basic acceptance criteria which will be used for

future inspection of separation between electrical components.

The procedure content appears thorough, but because inspection

activity has not commenced an evaluation of program effec-

tiveness could not be made.

In summary, while it is clear that the licensee is aware of

existing separation deficiencies, the implementation and

effectiveness of actions planned to correct these and other

currently unidentified deficiencies requires further evalua-

tion.

NRC CAT inspectors also observed several raceway installations

in which redundant divisional cable tray or conduit had been

attached to a common raceway support. NRC CAT inspectors

expressed concern that this configuration does not meet the

intent of RG 1.75 position C.3 which states that "In general,

locating redundant circuits and equipment in separate safety

class structures affords a greater degree of assurance that a

'

single event will not affect redundant systems. This method of

separation should be used whenever practicable and where its

use does not conflict with other safety objectives."

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This concern,.and its relationship to plant missile protec-

tion, was discussed with licensee personnel. With regard to

the common support of redundant raceways, it.is postulated that

a single event (i.e., missile impact) could adversely affect

the function of redundant divisional circuits.

NRC CAT inspectors reviewed section 3.5 of the STP FSAR. This

section and its Table 3.5-1 contain criteria for missile

protection for South Texas Project. Specific attention was

given to the FSAR discussion under the heading Internally

Generated Missiles Outside of Containment, ar.d the protective

measures required by the referenced table. NRC CAT inspectors

also reviewed Bechtel Project Engineering Directive PED-039

entitled " Engineering Evaluation Walkdowns" and the Systems

Interaction Design Guide PED-016 entitled " Internally Generated

Missiles."

One area of concern was identified during this review and was

discussed with licensee personnel. FSAR Table 3.5-1 describes

safety class systems and components and seismic category I

structures which require missile protection. The table appears

to provide exclusions for the categories of cable raceway

l systems and electrical supports based on component redundancy.

i However. as previously discussed the NRC CAT inspectors noted

I

that redundant raceway installations that are attached to a

common support would be equally affected by missile impact.

As a result of this observation the licensee has issued FSAR

l Change Notice 779 to more appropriately reflect the intent of

!

Table 3.5-1 to include raceways and raceway supports in missile

protection evaluations. This resolves the NRC CAT concern in

this area.

(2) Electrical Conduit

'

With exception of the specific deficiencies listed below, the

conduit sample inspected conformed to applicable design and

installation requirements relative to such attributes as size,

routing, identification and proper supports.

l Conduit C1XM3ER5204'was found to have a support distance

violation between two supports, and conduit AIXE2ARY102 was not

identified with its safety division marking at the required 15

i feet intervals. These two isolated deficiencies were sub- ,

sequently recorded on Nonconformance Reports (NCRs) CE-03207

'

l

and CE-03213 by the licensee.

The strap bolts for eight QC accepted conduits did not exihibit

l

torque seal as required by project instructions. QCP-10.30

requires QC to verify the torque on at least one bolt from each

connection and requires the verified bolt to be marked with

! torque seal. Discussion with the licensee indicates that the

l lack of or partial application of torque seal for QC accepted

l conduits is due to removal and reinstallation without reinspec-

l tion by QC. NRC CAT inspectors concluded that the licensee's

l ccentrol of QC accepted conduit installation is not completely

II-4

l

effective. The inadequate torque sealing was subsequently

recorded on NCR CE-03213 by the licensee.

(3) Raceway Supports

The examination of raceway supports included conduit and cable

tray supports. Attributes such as location, material type and

size, anchor spacing and embedded length, welds (location, size

and general quality), and installed configuration were found to

be in accordance with design requirements. However, several

isolated hardware deficiencies and one documentation deficiency

were identified.'

It was noted by the NRC CAT inspectors that the traveler

package for cable tray hanger 2-002-H3 included the inspection

report for a different hanger. The licensee's subsequent

investigation revealed a number of documentation errors and

omissions attributable to hangers inspected by the same QC

inspector. The licensee has issued Standard Deficiency

Reports (SDRs) E-361 and E-362 to document and correct these

deficiencies.

The torque of approximately 150 bolts and 50 concrete anchors

of various sizes on raceway supports was verified by the NRC

CAT inspectors. Three cable tray supports, 2-103-H61,

1-010-H84 and 1-024-H52, each contained several 1/2-inch strut

bolts which did not meet minimum torque requirements. These

deficiencies were documented on NCRs CK-03111, and CE-03229.

Independent of the bolt torque sample, hanger 1-065-H11 was

also found to contain several loose 1/2-inch strut bolts even

though the bolts were marked with torque seal. In addition,

the embedded lengths of 17 concrete anchors were verified using

an ultrasonic inspection method with no items of concern noted.

It was noted by the NRC CAT inspectors that virtually all the

1/2-inch strut bolts had no markings on the bolt heads making

identification of the material indeterminate. Beginning with

Rev. 3 in 1983, Bechtel specification 3E189ES1000 requires

these strut bolts to be from material conforming to American

Society for Testing and Materials (ASTM) A-307, Grade B, but

specifically negates the ASTM requirement for manufacturers'

markings. The use of ASTM A307 bolting materials without

manufacturer's identification marks is also discussed in

Section VI, Material Traceability and Control, of this report.

Other than the indeterminate traceability of bolt material, the

documentation and hardware discrepancies identified by the NRC

CAT in this area are considered isolated cases,

c. Conclusions

Except as noted, raceway systems have been installed in accordance

l

'

with applicable design and installation requirements. However,

numerous installations have not naintained the physical separation

required by the licensee's commitment in the FSAR. In this area, it

i

II-5

l

was determined that pertinent procedural.and administrative controls

have only recently been developed. As such, the adequacy of

electrical raceway separation after implementation of these controls

at South Texas Project will require further evaluation by the

licensee and NRC personnel.

The number of reworked conduit installations that were found lacking

QC reinspection of bolt torque indicate that rework of QC accepted

conduit installations requires increased control.

2. Electrical Cable Installation

a. Inspection Scope i

The NRC CAT inspectors selected a sample of installed Class 1E

cable runs that had been previously accepted by QC inspectors. The

sample included medium and low voltage power, control, and instru-

mentation cabling. For each of the cable runs, physical inspection

was made to ascertain compliance with applicable design criteria

relative to size, type, location, routing, bend radii, protection,

separation, identification, and support.

Additionally, the NRC CAT inspectors selected approximately 108 l

cable ends for examination of terminations. These were inspected to l

applicable design and installation documents for items such as lug

i size and type, proper terminal point configuration, correct identi-

l fication of cable and conductors, proper crimping of lugs or

connectors, and absence of irmulation or jacket damage. See Table

l II-3 for a listing of cable terminations examined.

The following medium and low voltage power cable totaling about

1,700 feet were selected from different systems, electrical

trains, and locations:

Cable Type

'

AIDJAKC1LA 1/C No. 4 AWG

B1CSABC1EA 1/C 250 MCM

I

B1CHABC2LB 3/C No. 6 AWG

BIRHADC1LE 3/C No. 10 AWG

C1PKACC1GA 3-1/C 750 MCM

D1VAABC1HB 3/C No. 4 AWG

D1DJABC1LE 1/C 750 MCM

The.following control cables totaling approximately 1,100 feet were

selected from different systems, electrical trains, and locations:

Cable Type

A1FWO7CISC 5/C No. 12 AWG

A1JWO2C1SA 7/C No. 12 AWG

C1PK01C3SK 3/C No. 16 AWG

01VA10C25A 7/C No. 12 AWG

II-6

_ __ ____ _______-____ __ __

. _ _

The following instrument cable totaling approximately 1,000 feet

were selected from different systems, electrical trains, and

locations:

Cable Type

AIDG04CIPA 2/C No. 16 Shielded

AIDG04C1PC 2/C No. 16 Shielded

A11114CAXF 2/C No. 16 Shielded

BIRH03C2WD 2/C No. 16 Shielded

D1VA10C2XA 2/C No. 16 Shielded

D1DJ10C4XC 2/C No. 16 Shielded

The following documents provided the basic acceptance criteria for

the inspection:

  • Bechtel Specification SE189ES1007, " Cable Installation In Trays,

Conduits and Ductbanks," Rev. 5

  • Bechtel Specification SE189ES1004, " Cable Splicing, Termination,

and Supports," Rev. 5

  • Bechtel Specification 5A230ES1008, " Installation of Electrical

Cable, Raceway, and Equipment Identification," Rev. 6

  • Ebasco QCP-10.17, " Electrical Cable Installation Inspection,"

Rev. 2

  • Ebasco CSP-19, " Safety and Non-Safety-Related Cable Pulling,"

Rev. 4

  • Ebasco CSP-8, " Cable Termination and Splices," Rev. I

b. Inspection Findings

(1) Routing

In general, the routing of Class 1E cables through design

designated raceway systems was found to be in accordance with

specified criteria. Each of the Class 1E cables examined by

NRC CAT inspectors had been installed in accordance with the

routing detailed on the EE580 pull cards.

The examination of Class 1E cables did disclose an

apparent deficiency-in the routing of medium voltage cables

into cable spreading areas. NRC CAT inspectors observed

that these installations do not meet the requirements of IEEE

384-1974 section 5.1.3 which limits cable installation in a

cable spreading room to circuits which perform control and

instrumentation functions.

Subsequent discussions with licensee personnel disclosed that

the " cable spreading areas" were inaccurately defined on

drawing SE-03-0E-0100 sheet 6AA Rev. O. Consequently, the

medium voltage cables identified by NRC CAT inspectors were

11-7

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.

e

acceptably installed outside of actual cable spreading areas

and were in accordance with IEEE-384 and RG 1.75. As a result

of this observation the licensee has issued Design Change

Notice (DCN) I to revi'se and clarify the referenced drawing.

(2) Separation

In general, the separation of Class 1E cables was found to be

in accordance with requirements.

NRC CAT inspectors did identify a number of Class 1E cable

installations which exhibit inadequate separation at the

entrance to Class 1E equipment. However, these deficiencies

were the subject of Bechtel Deficiency Evaluation Report (DER)85-034 issued September 10, 1985, which was subsequently

determined to be potentially reportable pursuant to 10 CFR

50.55(e). Evaluation of actions taken to correct existing

deficiencies are in.accordance with this process and as such,

NRC CAT inspectors have no additional observations in this

area.

In~ general, the separation of Class 1E cables located inside

of electrical equipment was found to conform with requirements.

One area where a deficiency was identified is in cubicle 3 of

4160V switchgear 3E151ESCOE1C. The physical separation between

a non-Class 1E pull out~ fuse block and Class 1E wiring was less

than the required six inches. As a result of this observation

the licensee has issued NCR SE-03233 to identify and correct

this condition.

No other deficiencies were observed in this area.

(3) Power Cable Spacing and Derating

STP po.ter cable installations have been designed in accordance

with Insulated Power Cable Engineers Association (IPCEA)

publication P-46-426, 1963 " Power Cable Ampacities - Volume I

- Copper Conductors" and P-54-440, 1972 "Ampacities - Cables

in Open Top Trays." The STP FSAR further requires that SkV

and 15kV cables in tray be installed with spacing maintained

at 1/4 of the cable bundle diameterc In general, the installa-

tion of Class IE power cables was found to comply with these

requirements. However, spacing had not been maintained in tray

segments B1XE3FTEAE, B1XE3FTEAF and B1XE3FTEAJ. Deficiencies

in cable tie down requirements were also observed in these tray

segments. As a result of these observations the licensee has

issued NCR CE-3211.

No other deficiencies were identified in this area.

(4) Cable Damage

Although no damaged cable was found, two situations with'the

potential for cable damage were identified by the NRC CAT

inspectors. A number of cable tray segments above equipment

II-8

were found to be missing required edge softeners where cable

breaks out of the tray over the. tray side rail into the equip-

ment. Numerous examples were noted in the switchgear rooms.

Based on this observation, the licensee documented an

individual occurrence on NCR CE-03210 and addressed the generic

issue with a procedure change. The change will add a visual

check for the presence of edge softeners to QCP-10.32,

"Walkdown/ Turnover of Safety-Related Systems, Sub-Systems,

Areas, or Components."

The second situation involves vertically run free air cable

between-spreading rooms on elevations 60 ft. and 74 ft. The

cables run through flame cut holes in metal decking with no

protection provided for the cut edges. This item was

subsequently documented on NCR CE-03256 for evaluation.

In addition, the quantity of Class 1E cable coiled throughout

the plant is of concern in that the potential for damage is

increased whenever cable coils are exposed to general construc-

tion activities. As a result of an NRC CAT observation, the

licensee issued NCR CE-03310 to document minimum bend radius

violations and other workmanship problems with cable

temporarily coiled in panel C1PNZLP803.

The area of cable protection merits continued licensee atten-

tion.

(5) Cable Identification.

In general, the identification of Class 1E cable installations

was found to be in accordance with applicable design criteria.

In connection with an issue which had been previously identi-

fied in both licensee and Region IV inspection reports, NRC CAT

inspectors noted that the color coding of numerous Class 1E

cables had faded due to weathering, aging or both. In some

installations fading had resulted in cable coloring which did

not accurately represent the functional division of the instal-

led cable. For example a purple cable (Division A) had faded

to blue (Division B).

Discussions with licensee personnel and the review of the

response to a previously issued nonconformance report indicates

that, although color fading of Class 1E cabling does cause some

confusion during performance of a visual inspection, a detailed

examination of any particular cable will confirm proper routing

and divisional separation based upon the divisional code

applied to each cable jacket. In addition, the cable identi-

fication at termination ends indicates the cable's safety

division.

NRC CAT inspectors conf % ed this during the field examination

of Class 1E cables but - ed that the divisional code had not

been applied to cable supplied by Rockbestos. However, no

examples of color fading in Rockbestos cable were identified

by the NRC CAT inspectors or site inspection personnel.

II-9

No other concerns were identified in this area.

-

(6) Terminations

In general, cable termination activities performed by

construction personnel conformed to requirements. However,

several isolated construction deficiencies and one procedure

conflict were identified by the NRC CAT inspectors.

  • Cable B1DJACC1LL, the power feed from the safety Division

B battery, is trained such that it is in contact'with the

battery rack. This observation was subsequently recorded

on NCR SE-03241 by the licensee.

  • Terminal block 200 in panel A1SIABC1HH has a broken separator

'

between the positive and negative terminal points for cable

A1SPAAC1SA. This was subsequently documented on NCR

CE-03222 by the licensee.

  • Cables A1SPIABCICA and A1SIABC1HH-are terminated on their

respective breakers in reverse order to the specification

requirements. The specification requires black,. red, orange

terminated top to bottom and the cables.are terminated black,

red, orange bottom to top. This was subsequently recorded

-

on NCR CE-03258.

  • During the inspection of control cable terminations, several

adjacent cable conductors were found to violate the. require-

ment for minimum bend radius. The cables involved are.

A1SP25CBSC and A1SP25CBSE in panel A1PNETCA04, and cable

A1SP21 COSH in panel A1PNETCA02. Based on this observation

the cables were documented on NCR CE-03205 by the licensee.

QCP-10.13 Section 5.2.2.1 requires inspection for nicked or

missing conductor strands. This characteristic is required

for and is being recorded acceptable on inspection records

for post termination inspections where the conductor strands ,

are inaccessable for-inspection.

c. Conclusions

With the exception of concerns or deficiencies identified in the

areas of cable identification and cable damage, and the apparently

isolated deficiencies identified with terminations, the installation

of Class 1E circuits and wiring was found to be in accordance with

applicable design requirements' .

3. Electrical Equipment Installation

a. Inspection Scope

Over 40 pieces of installed or partially installed electrical

equipment and associated hardware items from the various safety

divisions were inspected.

11-10

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.

The following specific electrical components were inspected in

detail:

(1) Motors

The installation of ten motors and associated hardware was

inspected for such items as location, anchoring, grounding,

identification and protection. The motors inspected were:

Essential Cooling Water Pump Motor 3R281NPA101A

Essential Cooling Water Pump Motor 3R281NPA101B

Containment Spray Pump Motor 2N101NPA101A

Containment Spray Pump Motor 2N101NPA101B

Containment Spray Pump Motor 2N101NPA101C

Safety Injaction Pump Motor 2N121NPA101C

Essential Lnilled Water Pump Motor 3111VPA004

Reactor Makeup Water Pump Motor 3R271NPA101A

EAB Air Handling Unit Fan Motor 3V111VFN014

EAB Air Handling Unit Fan Motor 3V111VFN016

(2) Electrical Penetration Assemblies

.The following containment penetration assemblies were

inspected:

C1PHEP046 Instrumentation

C1PHEP054 480V Power

B1PHEP028 Instrumentation

A1PHEP018 Control

B1PHEP032 Control

B1PHEP036 480V Power

The location, type, mounting, identification, and maintenance

of these penetrations were compared with the installation

drawings and vendor manuals.

(3) Circuit Breakers

Circuit breakers for the following Class 1E motors were

examined to determine compsiance with design and installation

documents for size, type, system interface, and maintenance:

Containment Spray

Safety Injection

(4) .Switchgear and Motor Control Centers

The following switchgear and motor control centers were

inspected:

II-11

. - - - . .

Motor Control Center B1PMMCEB1

Motor Control Center C1PMMCEC3

Motor Control Center A1PMMCEA2

Motor Control Center A1PMMCEA3

Motor Contro1~ Center A1PMMCEA4

4160V Switchgear B1PKSG0ElB

4160V Switchgear AIPKSG0E1A

(5) Station Batteries and Racks

The 125V battery rooms including the installed batteries,

battery racks and associated equipment were inspected. .The

location, mounting, maintenance and environmental control for

installation of the batteries were compared with the

applicable requirements and quality records.

125VDC Battery C1DJBT045D

125VDC Battery AIDJBT045A

(6) 125VDC System Equipment

The following equipment comprising portions of the 125Vdc

systems were inspected for compliance to design documents for

such items as location, mounting (welds, concrete anchors and

bolting) and proper configuration:

Battery Charger B1DJBC047E

Battery Charger AIDJBC047B

Battery Charger AIDJBC047A

Distribution Panel A1VADP1201

Distribution Panel B1DJPLO39B

Distribution Panel C1DJPLO39C

Static Inverter A1VAIV1201

Inverter / Rectifier A1VAIV001

(7) Control Panels

A number of safety-related electrical control panels were

inspected for compliance to requirements for items such as

location, mounting and type. The panels inspected were:

Diesel Generator Control Panel A1PNZLP101

Diesel Generator Control Panel B1PNZLP103

Remote Shutdown Panel A1PNZLP100 B1PNZLP100

C1PNZLP100 D1PNZLP100

Main Control Boards (2)

(8) Motor Operated Valves

The following 16 motor operated valves were examined in detail:

11-12

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i

l

CICVMOV01128 B1SIMOV0001B

B1CVM0V0113A CISIMOV00016

A1RCMOV0001A A1SIMOV0004A

B1RCMOV0001B B1SIMOV0004A

B1SIMOV0016B CISIMOV0016C

B1SIMOV0018B CISIMOV0018C

C1RHMOV0061B A1RHMOV0061C

C1CCMOV0209 CICCMOV0199

The following documents provided the basic acceptance criteria

for the inspections:

Bechtel Specification 3E319ES1040, " Class 1E' Induction

Motors (250HP and Below)," Rev. 0

Bechtel Specification 4A479ES1018, " Environmental

Qualification of Safety-Related Electrical and

Mechanical Equipment," Rev. 2

Bechtel Specification 3E159ES0012, "5KV Class IE Metal-Clad

Switchgear," Rev. 2

Bechtel Specification 3E269ES1091, "Special Electrical

Penetration Assemblies," Rev. 2

Bechtel Specification 5A230ES1008, " Installation of

Electrical Cable, Raceway and Equipment Identification,"

Rev. 6

Bechtel Specification SE329ES1002, " Valve Electric Motor

Actuators," Rev. 3

Bechtel Procurement Appendix G, "Large AC Induction Motors

for Class 1E Service (250 HP and Larger)," no revision

Ebasco QCP-10.15, " Electrical Equipment Installation

Inspection," Rev. 4

Ebasco QCP-10.20, " Electrical Penetration Installation

Inspection," Rev. 3

Ebasco SP-2, " Installation of Permanent Electrical and

Mechanical Plant Equipment," Rev. 4

Ebasco CSP-44, " Installation of Electrical Penetration

Assemblies," Rev. 3

Ebasco Construction Maintenance Instruction CMI-1, " Caring

and Maintenance of Permanent Plant Items," Rev. 7

Applicable design drawings and design change documents

II-13

__

b. Inspection Findings

. (1) Motors

In general, the Class 1E motors inspected were found to conform

with applicable design documents. The motors examir, d were of

the type, size, and configuration specified. A limited review

of maintenance records indicated that construction maintenance

had been performed in accordance with approved procedures.

However, several specification deficiencies were found with-

several 480V motors and mounting deficiencies were noted with

several 4160V motors.

Bechtel specification 3E319ES1040 requires motors under 250

horse power (HP) rating to have vendor installed terminal lugs

on the motor leads. The two air handling unit fan motors

inspected, 3V111FN014 and FN016, did not have the required

terminal lugs. The braided jackets on the fan motor leads were

also found to be frayed. A third fan motor, FN002, identified

by the NRC CAT mechanical inspectors was also found in this

condition. Although these are not considered significant

hardware deficiencies by the NRC CAT, the appropriate terminal

lugs need to be installed when the fan motors are terminated to

their permanent power source. Fans FN014 and FN016 were

subsequently documented on NCR BE-03335 and fan FN002 on NCR

BE-03334.

The Bechtel specification also requires motors under 250 HP

rating to have an insulation rating of Class F (135*C) or H

(150*C). The nameplate and vendor manual for the reactor make

-up water pump motor 3R271NPA101A indicate the motor insulation

is only Class B (110*C). This requires evaluation by the

licensee to assure the motor is adequate for its intended

service environment.

Approximately half of the motor hold down bolts for containment

~

spray pumps 2N101NPA101B and C and high head safety injection

pump 2N121NPA101C were unmarked ana of indeterminate material.

The remainder of the' bolts were marked as ASTM A-449 in lieu of

the required A-193, Grade B7. These and other pump motor hold

down bolt-discrepancies were subsequently dotumented on NCR-

CM-03078. These are discussed further in Se.ctions III,-

Mechanical Construction, and VI, Material Traceability and

Contt01, of this report.

In an isolated finding, containment spray pump motor

2N101NPA101A did not have a sight glass for the upper bearing

oil reservoir although the maintenance records indicated

adequate oil level. The missing sight glass was subsequently

documented by the licensee on Deficiency Report (DR) 1-505M.

(2) Electrical Penetrations

The penetrations examined were found to have been installed in

<

accordance with the applicable design documents. A review of

II-14

. -.

~

relevant maintenance records indicates that a number of

maintenance discrepancies such as 0 psi pressure and no

internal heaters were documented and adequately dispositioned

on Maintenance Discrepancy forms or determined to be unneces-

sary by the equipment vendor.

No deficiencies were observed in this area.

(3) CircuitBreakers

'

Thi. examination of the selected circuit breakers for the

containment spray and safety injection pump motors indicated

that they had been purchased, installed and maintained in

accordance with the applicable design documents. Important

installation attributes such as proper alignment, main contact

penetration, and safety interlocks were verified by physical

inspection and review of construction and test records.

Maintenance records were also reviewed and indicate that

appropriate activities had been performed.

Circuit breakers which serve various 480V motor control

centers were also examined and are discussed in Section

II.B.3.b.4, below.

No deficiencies were observed in this area.

(4) Switchgear and Motor Control Centers

The examination of Class 1E motor control centers disclosed

several deficiencies with regard to installation of circuit

protection devices. NRC CAT inspectors observed that load-side

terminal extensions on ITE type HE molded case circuit breakers

had been attached using connecting screws which lack sufficient

thread engagement to achieve and maintain a tight connection.

Additionally, insulating barriers installed between the

terminal extensions were found to be loose or missing. As a

~

result of this condition two concerns were noted and discussed

with licensee personnel.

(a) Potential for Inadvertent Circuit Interruption

Actual measurements indicate that terminal connecting

screws have an engagement of less than 1/4 inch into the

circuit breaker housing. This engagement was found not to

be adequate to assure that a tight connection will be

maintained between the terminal and circuit breaker in a

number of these installations. Many of the circuit

breakers examined, including QC accepted and turnover

items,. exhibited terminal extensions which were loose as

received from the vendor or due to normal construction

activity; i.e. , attachment of field cables or work in

adjacent cubicles and wireways. The potential for

inadvertent circuit interruption exists in that terminal

II-15

}

. - - . - - . .

connecting screws may work' loose during construction or

startup activities or due to the vibrations typically

experienced during plant operation.

(b) Phase to Phase Faultina

As detailed in (a), above, many of the Class IE circuit

breakers examined contained loose terminal extensions.

The' length and spacing of these extensions was such.that

phase to phase contact is possible. . Additionally, many of

the insulating barriers installed between terminals were

loose or missing due to inadequate vendor-installation or

construction or startup damage. As a result, the potential

for phase to phase faulting exists.

_

, These concerns were. discussed with licensee personnel in an

attempt to determine the reason for use of load terminal

'

extensions on molded case circuit breakers at South Texas

Project, and why the previously mentioned deficiencies had not

been identified by site inspection or source surveillance

personnel.

These discussions and a review of the relevant Bechtel purchase

specification, 3E179ES1054, indicate that although the specifica-

tion does detail a requirement for breaker terminals which can

accomodate attachment. of a two hole termination lug, no

specific renuest for use of terminal extensions had been made

.

by the licensee to the motor control center vendor. It was

also observed that load terminal extensions were not-detailed

on any of the applicable. design and vendor documents available

for review.- Additionally, based upon review of relevant vendor ,

documentation and the equipment seismic qualification report it

could not be determined whether the Class 1E motor control

centers had been tested with circuit breakers in this ~

configuration. As a result of this observation and at the

request of NRC CAT inspectors, Bechtel engineering issued

~

letter ST-YB-00-74 to the motor control center vendor

(Telenecanique) requesting additional information on this

subject. No response had been received from the vendor during

the NRC CAT inspection.

During meetings with the licensee regarding the possible

reasons for use of the terminal extensions, the licensee's

criteria for cable sizing were discussed. At the request of

the-NRC CAT, the licensee evaluated the cable sizes and

limiting factors for the Unit 1 circuits connected to

breakers'with terminal extensions. Their evaluation showed

that although the cables for several circuits were one size

larger than required, all the circuits but one could be

terminated directly to their breakers. The one circuit with

terminal lugs too large for direct connection to its breaker

(MCC E1A4, cubicle F3L) was size limited for ampacity and not

voltage drop. Prior to the NRC CAT inspection, the licensee

had identified one circuit with a cable size limited due to

II-16

1

voltage drop (MCC E1C2, cubicle H2R) and has since re-routed

the circuit eliminating the voltage drop problem.

As a result of deficiencies identified in this area the

licensee has issued NCRs BE-03208 and SE-03201 to document and

identify the extent of this problem. Preliminary reviews

indicate that approximately 30 Unit 1 Class 1E circuit

breakers exhibit this configuration with an equal. number

existing in Unit 2. See Table 11-4 for a listing of motor

control centers, breakers, and safety-related loads affected by

this condition.

On November 18, 1985, the licensee notified NRC Region IV that

this issue is potentially reportable pursuant to 10 CFR

50.55(e).

In general, the installation of Class 1E 4160V switchgear was

found to be in accordance with requirements. Attributes.such

as location, mounting and installed configuration were as

specified by. approved design documents. However, several

specification deficiencies were identified.

Appendix C of Bechtel specification 3E159E50012 establishes

requirements for control wiring within SkV metal-clad

switchgear.

Subsection E states in part..."The preferred terminal

blocks are G.E. Catalog CR-151B2, connection U2 or

connection NU2. Each terminal block shall have no less

than 12 points." Contrary to this requirement NRC CAT

inspectors identified severai cubicles of the 4160V

'tchgear which contain terminal blocks with less than

t'w 12 points specified.

section Q states in part'.." Adequate space shall be

.

t c .ded on both sides of the terminal blocks for connect-

ing wires and wire markers. To allow for stripping and

bending on incoming cables, terminal strips shall be

located a minimum of 8-inches away from cable entrances

either at top or bottom." Contrary to this requirement

NRC CAT inspectors observed the location of terminal strips

to be less than 8 inches from cable entrances in several

switchgear cubicles.

These specification deviations were observed in several

cubicles of 4160V switchgear.

As a result of this observation the licensee has issued NCR

SE-03225 and initiated Specification Change Notice SCN-3 to

document and correct this condition.

No other deficiencies were identified with 4160V switchgear.

II-17

--- - - .- - - - --.

(5) Station Batteries and Racks

The condition of the battery rooms was found to be in good

order and clean and free of debris. . Ventilation systems were

installed and in operation. Access to these areas was

controlled by keyed entry, and the appropriate danger signs had

been posted to prohibit smoking or open flames.-

The 125V batteries were examined and found to be in good

condition. Maintenance _ activities were reviewed, and in

general, had been performed in accordance with requirements.

The inspection of the 125V battery-racks disclosed that

indeterminate bolting materials had been used in the assembly

process. This issue is discussed in detail in Section VI,

Material Traceability and Control, of this report.

(6) 125VDC System

In' general, the examination of components which comprise

portions of the 125Vdc system indicates that construction

activities had been accomplished in accordance with the

applicable procedures and design documents. However,

deficiencies in the area of equipment mounting and product

quality were identified on several pieces of Class IE

equipment.

The examination of distribution panels B10JPLO39B and

C1DJPLO39L disclosed a weld configuration which does not

match the mounting details specified by applicable design

documents. Field Change Request (FCR) CE-04475 specifies a

1/4 inch fillet weld of 4 inches length on 6 inches centers

to be installed on two sides of the equipment and a

continuous 1/4 inch fillet weld on the front. Actual

field conditions exhibited a 1/4 inch fillet weld on 8

inches centers on both front and sides of the panels.

Relevant inspection records which indicate acceptable

irstallations do not account for this discrepancy.

As a result of this observation the licensee has issued

NCR SE-03325 to document and correct this condition.-

Each of the three Class 1E battery chargers examined by

the NRC CAT exhibited loose soldered connections on the

equipment " firing boards." Inadequate solder joints were

observed at both pin-to-conductor and pin-to-circuit board

connections. Discussions with licensee personnel revealed

that this condition had been identified and evaluated on

Startup Work Request (SWR) 01757, and that, pending

delivery of qualified solder material, approved corrective

action would be implemented.

No other deficiencies were identified in this area.

II-18

i

l

,

(7) Control Panels

In general,-the installation of Class 1E control panels was

found to be in accordance with applicable requirements.

Mounting, location, and installed configuration were as

specified. Several discrepancies were identified with regard

to fastening materials used in the assembly of some panels.

This issue is discussed in detail in Section VI, Material.

Traceability and Control, of this report.

~

The NRC CAT inspectors also noted several non-Class 1E equip-

ments with identification tags color-coded as Class IE equip-

ment. Ten nonsafety relay panels had white identification tags

which indicate safety Division D 'and the nonsafety heater in an

emergency diesel generator high voltage panel had a blue tag

indicating safety Division B. The licensee .bsequently

documented the relay panels o'n DR E-0632 and all three diesel

generator high voltage panels on NCR BE-03300 for corrective

action.

(8) Motor Operated Valves

The NRC CAT -inspected 16 valve operators for installation to

the latest design requirements and identified deficiencies in

all 16 operatort examined. In addition, discrepancies were

found in the control and execution of design changes to certain

motor operated valves (MOVs) supplied by Westinghouse

Corporation (W).

Several deficiencies were noted in virtually all of the MOVs

inspected. These included loose vendor terminations,-jumper

wires containing bend radius violations, and the use of No. 16

AWG wire in lieu of No. 14. In addition, the licensee was

unable to provide the NRC CAT with evidence of qualification

for the No.16 wire. Other deficiencies were noted in one or

more operators and included more than two wires on one terminal

point, duct seal melted onto terminal points, unidentified

terminal points, Raychem wire installed in lieu of the required

Fire Wall III wire , a cracked terminal lug, and damaged

conductors. The damaged conductors and several of the minimum

bend radius violations appear to be generic to Limitorque model

SMB operators due to the minimal clearance between the cover

anr1 the rotor. Table II-5 lists the MOVs inspected and the

ficiencies found with each. The licensee subsequently issued

hCR BE-03209 to document the deficiencies observed by the NRC

CAT in valve motor operators.

During the first week of inspection the NRC CAT inspectors

observed in process field wiring changes in motor operated

valves and attempted to verify their field installation. A

number of problems ~ arose resulting in the investigation

continuing through the final weeks of the NRC CAT inspection.

The sequence of events is as follows:

II-19

  • NRC CAT inspectors observed design changes being performed

during implementation of Configuration Control Package (CCP)

'1-N-WN-0021 by Westinghouse.

-

  • NRC CAT's field. verification of.CCP 0021 resulted in the

identification of numerous hardware deficiencies as discussed

above.

~

  • NRC CAT inspectors requested CCPs for ongoing design changes

with MOVs and were provided CCPs 1-E-EM-0243.and 1-E-ST-0339.

The subsequent NRC CAT evaluations of these packages resulted

"

in the identification of conflicts with CCP 0021.

  • Based on NRC CAT observations and licensee reviews of the

identified problems for MOVs, the licensee issued a

voluntary stop work order.

  • No further documentation was provided to the NRC CAT, pending

the completion of a review of the overall MOV problem by the

licensee.

  • The licensee. informed NRC Region IV of a potentially

reportable deficiency relating to the wiring of MOVs.

CCPs-0021 and 0339 were initiated by W FCNs to modify valve

closure indications and bypass an unqualified terminal block

respectively. CCP 0243 was initiated by Bechtel to brirg the

valve operators up to Bechtel's current design. -W was per-

fonning the work and QC inspection under CCP 0021 while .

Ebasco was making the design changes under CCPs 0339 and 0243.

While performing the wiring changes under CCP 0021, W added

additional jumpers outside the stated scope of the CEP. The

NRC CAT review indicated that these jumpers were the same as

several jumpers being removed by Ebasco under CCP 0243. The

review also showed that one of the required jumpers of CCP

0021 was being deleted by CCP 0339. In addition, jumpers had

been added to several MOVs such that a continuous close indica--

-tion would be displayed regardless of the actual valve posi-

tion.- These jumpers were required by and installed in

accordance with the site's EE-580 field wiring program. These

NRC CAT observations indicate that there was a lack of coordi-

nation for the sequence of work for'the CCPs and between the '

CCPs.and the ongoing EE-580 program. This also indicated

inadequate control of wiring changes for the MOVs and the

potential for installed wiring not conforming to design.

When an earlier wiring discrepancy in a motor operator was identified

by Ebasco under CCP 0243, Bechtel issued Engineering Request

for Site Action (ERSA) 0121-E in September 1985 to determine,

the actual wiring configuration of 58 W MOVs.

Discussions with the licensee and Bechtel at the site and

Bechtel's Houston office regarding the design changes being  !

made to the W MOVs indicated several items:

1

l

II-20 '

_

..

  • The status of QC . inspection for the design changes is

indeterminate.

  • The licensee was unable to specifically identify the

original wiring diagram which represented the configura-

tion of the MOVs as they were received and upon which

design changes were being based.

  • Bechtel changes to MOV wiring were not appropriately reviewed

by W'or provided for incorporation into W design drawings.

A similar problem in another area was identified in a licensee

audit report S15-501 dated April 15, 1985. This is discussed

further in Section VII, Design Change Control, of this

report.

  • Bechtel verification of the ERSA as-built wiring details

revealed discrepancies between the reported configuration and

the actual configuration of the MOVs. As a resu'.t of these

observations the licensee has initiated a walkdown to .

establish the current wiring configuration of Class 1E MOVs.

Further discussions with the. licensee revealed that an MOV

inspection program was being planned because of a history of

problems reported by vendors, other sites, and the NRC.

However, the documents provided to the NRC CAT, specifically

Bechtel Interoffice Memorandum 10M-3885S dated October 21,

1985,.with the subject " Problems Associated with Limitorque

Valve Operators," propo w d a sample surveillance of only

warehoused valves. Such a program would not have identified

all the problems found with the installed MOVs.

As a result of the continued problems witn the valve motor

operators, the constructor instituted a r luntary stop work

order on November 13, 1985, and the licensee informed NRC

Region IV on November 19, 1985 of a potentially reportable item

under 10 CFR 50.55(e).

The interface for design between the A/E and NSSS is further

discussed in Section VII, Design Change Control, of this

report.

In summary, numerous hardware deficiencies were found with the

MOVs inspected. In addition, a lack of effective design

change control for the wiring of W supplied valve motor

operators has resulted in the licensee not being certain as to

their wiring baseline or current configuration. Corrective

action by the licensee is required to assure that all

safety-related MOVs meet their required design configuration.

An ancillary concern was rais*.( by the NRC CAT inspectors

during discussions with the licensee regarding the control of

design documents for MOV wiring. It was noted that Bechtel's

elementary wiring diagrams, wnich are the controlled design

documents, did not provide point-to point wiring information.

II-21

The NRC CAT inspectors were concerned that HL&P startup and

operations personnel would need point-to-point information for

perfoming tests, troubleshooting and modifications. The

discussions with Bechtel indicated that they would review this

issue,

c. Conclusions

In general, the installation of Class IE equipment conforms to

design requirements. However, of concern were the hardware

deficiencies identified in Class 1E motor control centers and

motor operated valves, and the specification c'eviations identified

in Class IE switchgear and motors.

The examination of ITE type HE molded case circuit breakers

disclosed deficiencies with regard to attachment of load-side

terminal extensions. Consequently, installations which exhibit

this configuration have the potential for inadvertent circuit

interruption or phase to phase faulting.

Numerous hardware deficiencies were identified in the wiring of

V0Vs. A lack of effective design control for the MOV wiring has'

resulted in the inability to correlate their actual configuration

to the required design.

Several cubicles of Sky switchgear were found to deviate from the

applicable specification requirements for the location of terminal

strips and the minimum number of teminal block points. Four

motors were also found to deviate from their applicable

specification. Three air handling unit fan motors did not have the

required vendor installed terminal lugs, and the insulation of a

reactor makeup water pump motor is Class B in lieu of the required

Class F or H.

4. Instrumentation Installation

a. Inspection Scope

The NRC CAT inspectors selected a sample of 10 installed and

inspected instruments for examination to requirements for location,

mounting details, and instrument type and range. The instrument

tubing for these instruments were also examined to specification,

procedure, and isometric drawing requirements. A total of 16

supports from these runs were also inspected. Table II-6 details

the inspection sample for the instrumentation installation.

In addition, the internal wiring configuration of an

instrumentation process panel was verified.

The following documents provided the acceptance criteria for the

inspection:

II-22

  • Bechtel Specification 4Z519ZS1040, " Instrument Installation

Seismic Category 1," Rev. 3

Ebasco QCP-10.13, " Mechanical Instrument Installation

luspection," Rev. 4

  • Fbasco CSP-47, " Instrument Installation," Rev. 4

b. Findings

The sample of instruments inspected by the NRC CAT represents half

of all the instruments the licensee had inspected, accepted and

turned over to the startup organization at the time of the NRC CAT

inspection. The limited sample examined revealed numerous

construction deficiencies and several program weaknesses.

Deficiencies were found in the installation of the instrument-or

tubing in eight of the ten instr 2ments inspected. .The deficien-

cies found with more than' one installation included out of tolerance

dimensions, and loose conduit fittings._ Other deficiencies which

appear isolated to individual installations included a hanger weld

not meeting the drawing configuration, the actual instrument identi-

fication not corresponding to the drawing, a missing tubing clamp,

and a loose pressure transmitter. Two weaknesses were also identi-

fied through the installation inspections. These were QC inspec-

tions performed with drawing revisions other than the latest

revision, and existing supports used without the required engi-

neering approval. The deficiencies were subsequently recorded

on nonconformance documents by the licensee. Table II-7 details the

findings for the eight instrtnent instellations with deficiencies.

Discussions with the licensee indicated that a sample surveillance

of. instrument installation was being performed under their QC

Effectiveness Inspection Program. Two of the five instruments.

A1EWFT6854 and C1EWFT6873, inspected by the Effectiveness Program

coincided with the NRC CAT sample. Although the Effectiveness

Program has identified installation deficiencies similar to those

found by the NRC CAT, they failed to identify the out of tolerance

dimensions found with the installation of C1EWFT6873.

The NRC CAT inspectors verified wiring changes conducted under

CCP 1-N-WN-0083 (W FCN TGXM-10585 Revs. A, B, C) to instrument

process panel 3Z121ZRR018. Attributes such as circuit board

changes, point-to-point wiring changes, wire type and size, and

contrasting wire color met'the CCP requirements. However, the

jumper locations on two circuit cards were not as required. The

jumpers on the circuit cards in locations C3-247 and 248 are in

the "high" position while the CCP requires them to be in the " low"

~

position. This discrepancy was subsequently documented on NCR

SE-03341. In additon, HL&P's Station Procedure OPCP03-ZM-0011

" Plant Instrumentation Scaling Program" has provisions for document-

ing the configuration of circuit cards with jumpers or plug-in

components for use in calibrating.and testing process instrumenta-

tion by plant staff.

II-23

c. Conclusions

The number of construction deficiencies found in the limited sample

~o f. instrumentation indicates that the licensee's inspection and

surveillance programs are not completely effective. In addition,

weaknesses were identified in the use of latest drawing revisions

.for i.nspections and obtaining required engineering approval for

additional attachments to existing supports. This area requires

additional management attention.

!

II-24

i

l

TABLE II-1

RACEWAY INSPECTION SAMPLE

Cable Tray:

B1XC4ATHAP B1XC4ATHAG B1XC4ATHAF B1XC4ATHAE

B1XC4ATHAD B1XC4ATHAC B1XC4ATHAB B1XC4ATHAA

B1XC4BTHAA B1XC4BTHAB B1XC4BTHAC AIXE1HTTAM

AIXE1HTTAG AIXE1HTTAH AIXE1DTTBH AIXE1DTTBG

A1XE1DTTBF AIXE1DTTBE AIXE1DTTBD AIXE1DTTBC

AIXE1DTTBJ A1XE1DTTBK AIXV1ATSAA AIXVIATSAB

B1XE3FTHAN B1XE3FTHAP B1XE3FTHAR B1XE3FTHAS

B1XE3FTHAT B1XE3FTHAU B1XE3FTHAF B1XE3FTHAE

B1XE3FTHAD B1XE3FTHAC .B1XE3FTHAB B1XE3FTHAA

B1XE4GTHAA B1XE4GTHAB -AIXFIBTJAG AIXF1BTJAF

AIXF1BTJAE AIXF1BTJAB A1XF1BTJAA AIXF1BTJAH

A1XF1BTJAV AIXF5AKTVA AIXF5AKTAB A1XF5ATTAA

A1XF5ATJAA AIXM4KTJAC AIXM4KTJAB AIXM4KTJAA

A1XM4JTJAB AIXM4JTJAA AIXM4DTJAS A1XM4CTJAB

AIXM4CTJAA A1XM4BTJAC AIXM4BTJAB AIXM4BTJAA

C1XG1ATSAN C1XG1ATSAM C1XG1ATSAG C1XG1ATSAF

C1XG1ATSAE C1XG1ATSAD C1XG1ATSAC C1XGIATSAB

C1XG1ATSAA

Cable Tray Supports:

1-019-H109 1-106-H4 2-103-H23

1-100-H51 1-019-H704 2-002-H3

1-105-H30 2-103-H41 2-002-H47

1-105-H702 2-103-H92 2-002-H23

1-152-H109 2-103-H61

Conduits:

Number Length (Feet) Number Length (Feet)

~A1XC4DRJ004 100- B1XE2ARY005 79

AIXC4DRT005 100 B1XE2ARY006 79

A1XE1FRS006 32 B1XF1BRS008 89

A1XE1FRH001 35 B1XM2ER5073 48

A1XElGRLO33 49 B1XM3ERJ068 33

AIXElGRLO32 44 C1XF1ARH004 55

A1XE2ARY102 51 C1XF1ARS004 67

AIXE2BRX004 39 C1XFIARS010 63

'A1XF1BRF001 64 C1XF1FRS009 45

AIXF1BRF002 58 C1XM3ERS204 39

A1XF1BRF003 49 D1XElGR2037 15

A1YC4 DRY 003 95 D1XElGRX002 30

B1XE2ARY003 79 D1XE2BRX004 84

B1XE2ARY004 79 D1XE2CRS081 32

II-25

1

TABLE II-1 - (Continued)

RACEWAY INSPECTION SAMPLE

. Conduit Supports:

~ 1120005 1532512 1625783

1120008 1541547 1651000B

'1134931 1613130 1651001

1134932 1613132 1654548

1153322 1625779

i

,

Y

l'

'II-26

L

TABLE II-2

SEPARATION FINDINGS

Raceway segments listed in the A columns do.not maintain required separation from

the corresponding raceway segments in the B columns. The (*) indicates physical

separation of less than one inch between the two raceway segments.

Column A Column B Column A Column B

AIXE1HTTAM NIXE1HTTAD AIXE1DTSBB N1XE1DTSAA

D1XE1HTXAJ N1XE1HTYAH AIXE1DTXBB N1XE1DTCAA

AIXE1DTHBH- N1XE1DTJAV A1XE1DTXBS N1XE1DTCAC

AIXE1DTXBB N1XE1DTYAA AIXE1DTXBC NIXE1DTXAE

A1XE1DTXJB N1XE1DTHBF A1XE1DTHBK N1YE1DTHAX

AIXM4KTYAC N1XM4KTYAC AIXF1BTFAF * N1XF1BRJ011

A1XM4JTYAA N1XM4JTTAA AIXM4JTJAA N1XM4JTYAA

A1XM4CTYAA N1XMiCTYAA A1XM4BTJAC NIXM4BTSAE

AIXM4BTJAC N1XM4BTJAE AIXM4BTYAF N1XM4BTYAC

AIXM4BTFAB NIXM4BTHAC AIXM4BTFAB NIXM4BTTAC

B1XC4ATHAJ NIXC4ATAAJ AIXM4BTFAB * N1XM48R031

B1XC4ATHAP N1XC4ATHAJ B1XC4BTJAE * N1XC1BRX278

B1XC4BTXAF N1XC4BTHBA B1XCABRT852 * N1XC1BRX278

B1XE4GTHAB N1XE4GTHBA AIXE2ARY102 * C1XE2ARY103

B1XM1ERYO48 AIXM1MTYAB

II-27

TABLE II-3

TCPMINATIONS

Location Termination Description

A1B52RR014 A1BSAAC23B Control Cabinet

A1BS2RR014 A1SP12C1XA2 Control Cabinet Plug

A1CCMOV0050 A1CC04C1WA2 MOV

A1MB2CP1822 A1AM10C1XA2 Control Panel

A1PMMCEA152 A1AF01C1WA1 MCC EIA1

A1PMMCEA1G1 A1RH03C1WD1 MCC E1A1

A1PMMCEA1V42 A151AAC1HJ2 MCC ElAl

A1PMMCEA2F3 A1SP23CASC2 MCC E1A2

A1PMMCEA2J3 A1SP23 CASA 2 MCC EIA2

A1PMMCEA2R2 A151ABCILA MCC E1A2

A1PMMCEA2R3 A1S1ABC1HH1 MCC ElA2

'A1PMMCEAA2E1 A1CC04C1WC1 MCC E1A2

A1PMMCEAE1 A1CC04CID1 MCC E1A2

A1PN2LP10052 A1AF01C1WE2 Control Panel

A1PN2LP100S2 A1AF0361WF2 Control Panel

AIPN2LP659 A1AF01C1SA2 Control Cabinet

A1PN2LP700 A1AP02C1WB1 Control Panel

A1PN2LP700 A1AP02C1WA2 Control Panel

A1PN2LP801 A1AF01C1WF2 Control Panel

A1PNERR118A A1AF05C1WA2 Control Panel

A1PNERR130A A1AF08C1WA1 Control Panel

A1PNERR130A A1CC2VC1WA1 Control Panel

A1PZRR002-2 A1SP17CCSA1 Control Cabinet

A1502R0011 A1SP12C1XC1 Control Cabinet Plug

A1502RR008I A1SP12C2XA1 Control Cabinet Plug

A1S12RR051 A15129C1XB2 Control Panel

A1SP2RR001I A1SP12C1XB1 Control Cabinent Plug

A1SP2RR002-1 A1SP27CCSC1 Control Cabinet

A1SP2RR002-2 'A1SP17CHSB2 Control Cabinet

A1SP2RR0081 A1SP12C2XB1 Control Cabinet Plug

A1SP2RR002-1 A1SP27CCSB1 Control Cabinet

A1SP7RR002-2 A1SP17CDSA1 Control Cabinet

B10SPLO37C7 B1PKACCILA1 DC Switchgear

B1852RR017 BIBSABC26A2 Control Cabinet

B1B52RR018 B1HC30C1XB-1 Control Cabinet

81DJBC047E B1DJACCILG1 Charger / Inverter

B1DJBC047F B1DJACC1LH1 Charger / Inverter

B1DJBT045LN B1DJACCILL2 Battery

-B10NERR137 B1HC18C1SD2 Control Cabinet

B1FMMCEB1J1 B1HC20C2SC1 MCC E181 I

B1MB2CP22T11 B1HC18C1SC2 Control Panel

BlMB2CP4T30 BlMB04C1501 Control Panel

B1MB2CP4T30 BlMB04C1SS1 Control Panel

B1M82CP4T30 B1MB04CIST1 Control Panel

B1PK2GD0E183 B1SP22CUSB2 MCC E182

B1PKSG0E187 B1EW01C2WH1 4160V Switchgear EIB

B1PMMCEB122 BlAF03C2WC1 MCC E181

B1PMMCEB1F1 B1CCADC1LC1 MCC ElB1

B1PMMCEB1F3 B1HC18CISE1 MCC E181

II-28

TABLE II-3 - (Continued)

TERMINATIONS

Location Termination Description

B1PMMCEB1LIL B1CCADL1LK1 MCC ElB1

B1PMMCEB1P3 B1CCADC1LM1 MCC E181

B1PMMCEBIR2 B1AF03C2WA1 MCC E181

B1PMMCEBIT1 B1CC1C1WA1 MCC ElB1

B1PMMCEB203 B1CC0525El MCC ElB2

B1PMMCEB253 B1CHABC2LB1 Distribution Panel

B1PMMCEB2F3 B1CC642WD1 MCC E182

B1PMMCEB2F3 B1CC04C2WC1 MCC ElB2

B1PMMCEB2G B1C006C2SB1 MCC E182

B1PMMCEB2G1 B1CC06C2SC1 MCC ElB2

B1PN2LP654 B1AF01C2WD1 Control Panel

B1PN2LP660 B1CC06C2SA2 Control Cabinet

B1PN2LP678 B15129C1XB1 Control Panel

B1PN2LP678 B1HC30C1XB2 Control Panel

B1PN2LP678 B1B509C1XA2 Control Panel

B1PN2LP802 B1CC01C2WB2 Control Panel

B1PNERR1208 B1C010CBSB Control Panel

B1PNERR121B B1CC01C2WA2 Control Panel

B1PNTB678 BlAMABC2SR1 Termination Box

B1512RR052 B1S129C1XC1 Control Panel

BISP2RR004-1 B1SP22CMSD Control Cabinet

B1SP2RR004-1 B1SP24CASD1 Control Cabinet

81SP2RR004-1 B1SP24CASB1 Control Cabinet

81SP2RR004-2 B1SP22CUSA1 Control Cabinet

B1SP2RR004-2 B1SP22CVSD1 Control Cabinet

B1VA1V1203 B1VAACCILA2 Charger / Inverter

C1BS2BR019 C1FW11C2PA1 Control Cabinet

C1BS2RR019 C1CV10C5PA2 Control Cabinet

C1BS2RR019 CIRC 10C7PB1 Control Cabinet

C1DN2LP679-1 C1FW23C9XC2 Control Panel

ClMB2CD4T50 C1MB04C1SF1 Control Panel

ClMB2CP1T35 C1B504C1XA2 Control Panel

C1MB2CP1T35 C1MB01C1SC1 Control Panel

ClMB2CP3T45 C1MB03C15El Control Panel

C1MB2CP3T45 C1MB031SE1 Control Panel

C1MB2CP4T50 ClMB04CISG1 Control Panel

ClMB2CP4T50 C1MB04CISH1 Control Panel

C1PN2LP10055 C1AMACG1SC2 Control Panel

C1PN2LP679 CIAMACCISG2 Control Panel

C1PN2LP679 C1RA13C1XB2 Control Panel

C1PN2LP679 C1RA13C1XH2 Control Panel

C1PNETCC01 ClMB04C1SH2 Control Cabinet

C1PNTB679 C1AMACC15G1 Termination Box

D1DJBC047D D1DJABCILG1 Charger / Inverter

01DJBC047G D1DJABC1LB1 DC Switchgear

D1DJPLO37813 D1AF09C1SL1 DC Switchgear

D1DJPLO37B3 D1DJABC1LG2 DC Switchgear

D1DJPLO37B4 D1VAABC1LA1 DC Switchgear

11-29

"

i

TABLE II-3 - (Continued)

'TERNINATIONS.

~ Location Termination Description  !

D1DNERR141 D1PNAEC3SA2 Control Cabinet

D1M82CP1817 D1CC17CISA2 . Control Panel

01PNERR1240 01CC17C1SB1 Control Panel

DIPMERR124P DIPN10CNA2 Control Panel

DISP 2RR0011 DISP 12C1XC1 Control Cabinet Plug

DISP 2RR008I DISP 12C2XA1 Control Cabinet Plug i

DISP 2RR0081- DISPT2C2VB1 Control Cabinet Plug.

,

DISP 2RR008I DISP 12C2XC Control Cabinet Plug  :

' DISP 2RR008I- Control Cabinet

'

DISPABCISB2

01VADP1202 D1BSA8CISA1 Distribution Panel

D1VATV11202 D1VAABC1LA2 Charger / Inverter

V

i

l

6

l

l

I

l-

l

>

.

'

l

!

1

II-30

-

>

L

l

- . . , . . . - - . . . . . . . - . . ..- , . . . - - - . - , - - . . . -,- , -. ,.. , , -.- -_-..-..- - , ~. -

m

TABLE'II-4

UNIT l' CLASS 1E E0UIPMENT AND LOADS AFFECTED BY

MOLDED CASE CIECUIT BREAKER DEFICIENCIES

.

Motor Control Center: 3E171MCE1A2

Cubicle / Breaker Type: A4L/HE3-8050

Class 1E Load: Distribution-Panel Transformer

Motor Control Center: 3E171EMCE1A4

Cubicle / Breaker Type: C1R/HE3-8015

Class 1E Load: Containment Hydrogen Monitoring Panel

Cubicle / Breaker Type: C1L/HE3-8015

Class 1E Load: 120Vac Distribution Panel Inverter Channel II

Cubicle / Breaker Type: C3R/HE3-B030

Class 1E-Load: -Spare

Cubicle / Breaker Type: C3L/HE3-B015

Class 1E Load: Battery Room Reheat Coil

Cubicle / Breaker Type: EIR/HE3-8040

Class 1E Load: Accumulator 1A Discharge Isolation MOV

Cubicle / Breaker Type: E1L/HE3-B015

Class 1E Load: Containment Cubicle Exhaust Fan

Cubicle / Breaker Type: F3R/HE3-8050

-

Class 1E Load: Voltage Regulating Transformer

Cubicle / Breaker Type: F3L/HE3-B100

Class 1E Load: Battery Room Charger

Cubicle / Breaker Type: H3R/HE3-B030

Class 1E Load: Spare

Cubicle / Breaker Type: H3L/HE3-8015

Class 1E Load: Battery Room Reheat Coil

Cubicle / Breaker Type: J2R/HE3-8050

Class 1E Load: Distribution Panel Transformer

Cubicle / Breaker Type: J2L/HE3-B015

Class 1E Load: Starter for Chiller Oil Lamp

II-31

--

TABLE II-4 (Continued)

UNIT'l CLASS 1E EOUIPMENT AND LOADS AFFECTED BY

HOLDED CASE CIRCUIT BREAKER DEFICIENCIES

.

- Motor Control Center: 3E171EMCE184

Cubicle / Breaker Type: B2R/HE3-B015

Class 1E Load: Starter for Chiller Oil Pump

Cubicle / Breaker Type: B3R/HE3-8015

Class 1E Load: Spare

Cubicle / Breaker Type: B3L/HE3-8015

Class 1E Load: Containment Cubicle Exhaust Fan

Cubicle / Breaker Type: C2L/HE3-B015

Class 1E Load: Battery Room Reheat Coil

Cubicle / Breaker Type: C2R/HE3-8030

Class 1E Load: Spare

Cubicle / Breaker Type: C3R/HE3-8030

Class 1E Load: EAB Main Area Heating Coil

Cubicle / Breaker Type: C3L/HE3-8030

Class 1E Load: Spare

Cubicle / Breaker Type: E4R/HE3-8020

Class 1E Load: Spare

Motor Control Center: 3E171EMCEIC.!

Cubicle / Breaker Type: H2R/HE3-B050

Class 1E Load: Heat Tracing Transfomer

~~

l Motor Control Center: 3E171EMCE1C4

Cubicle /Breater Type: C3R/HE3-8040

Class 1E Load: Accumulator 1C Discharge Isolation MOV

Cubicle / Breaker Type: C3L/HE3-8015'

Class 1E Load: Containment Cubicle Exhaust Fan

l Cubicle / Breaker Type: D1R/HE3-8015

l

Class 1E Load: 120Vac Distribution Panel Inverter

'

Cubicle / Breaker Type: D1L/HE3-8050

Class IE Load: Power Distribution Panel Transformer

l

l

-

( II-32

L

. _

TABLE II-4 (Continued)

. UNIT 1 CLASS 1E EQUIPMENT AND LOADS AFFECTED BY

MOLDED CASE CIECUIT BREAKER DEFICIENCIES

Cubicle / Breaker Type: D3R/HE3-B015

Class 1E Load: ' Spare

Cubicle / Breaker Type: D3L/HE3-8015

Class 1E Load: Containment Hydrogen Monitoring Panel

Cubicle / Breaker Type: LElR/HE3-8015

Class 1E Load: Starter for Chiller Oil Pump

Cubicle / Breaker Type: E1L/HE3-8015

Class 1E Load: Battery Room Reheat Coil

11-33

_ _ - - _ _ _ _ - _ _ - - - _ _ - - - _ - _ _ - _ _ _ _ _ - _ _ _ _ _

-

_.

TABLE II-5

VALVE MOTOR OPERATOR DEFICIENCIES

Motor Operated Valve CICVMOV0112B:*

a. Jumper wires contain bend radius violations. ,

i

b. Loose vendor terminations on the power terminal block, heater coils, and l

torque switch points 24, 25, 26, and 27. .'

c. No. 16 AWG wire is installed in lieu of No. 14 AWG wire on the limit

switch between points 22 and 37 and between points 11 and 36.

d. More than two-wires terminated under one terminal point.

Motor Operated Valve B1CVMOV113A:*

a. Loose vendor terminations on the terminal blocks, heaters, and limit

switches.

b. No. 16 AWG wire used in lieu of No. 14 AWG wire.

c. Jumper wires contain bend radius violations.

d. More than two wires terminated under one terminal point.

Motor Operated Valve A1RCMOV0001A:*

a. Loose vendor terminations'on the terminal blocks, craters, and limit

switches.

b. No. 16 AWG wire is installed in lieu of No. 14 AWG wire.

c. Jumper wires contain bend radius violations.

l d. More than two wires terminated under one terminal point.

Motor Opreated Valve BIRCMOV0001B:*

a. Loose vendor terminations on the terminal blocks, heaters, and limit

!

switches.

b. No. 16 AWG wire is installed in lieu of No. 14 AWG wire.

c. Jumper wires contain bend radius violations.

d. 'More than two wires tenninated under one terminal point.

II-34

_ _ _ _ _ _ _ _ _ - _ _ _ _ _

TABLE II-5 - (Continued)

VALVE MOTOR OPERATOR DEFICIENCIES

Motor Operated Valve B1SIMOV00018:*

a. Loose vendor terminations on the terminal blocks, heaters, and limit

switches.

b. Lug at terminal point 26 was cracked and then broke off during

inspection.

c. Jumper wires contain bend radius violations.

d. More than two wires terminated under one terminal point.

Motor Operated Valve CISIMOV0001C:*

a. Jumper wires cont'ain bend radius violations.

b. Loose vendor terminations on the power terminal block, heater coil

and torque switch points 24, 25, 26, and 27.

c. More than two wires terminated under one terminal point.

Motor Operated Valve A1SIMOV0004A:*

a. . Loose vendor terminations on the terminal blocks, heaters, and limit

switches.

b. An additional jumper was installed which was not on drawing 9-E-SI13,

sheet 1 DSP.

c. Jumper wires contain bend radius violations.

d. More than two wires terminated under one terminal point.

Motor Operated Valve B1SIM0V0004B:*

a. Loose vendor terminations on the terminal blocks, heaters, and limit

. switches.

b. Duct seal used to cover temporary power cabic opening has melted onto

the termination points.

c. Jumper wires contain bend radius violations.

d. More than two wires terminated under one terminal point.

II-35

.

'

,

TABLE II-5 - (Continued)'

' VALVE MOTOR OPERATOR DEFICIENCIES-

.

Motor Operated Valve B1SIMOV0016B:*

a .' Loose 1 vendor terminations on the terminal blocks, heaters,:and limit  ;

switches. '

.b. Jumper wires contain bend radius violations.

c. More than two wires terminated under one terminal point.

I

MotorL0perated Valve CISIMOV0016C:*

a. Loose vendor terminations on the terminal blocks, heaters, and limit

switches.

C

b. Jumper wires contain bend radius violations.

c. -Terminal point 10 is not identified.

.

d. .More than two wires-terminated under one terminal point. .{

Motor Operated. Valve B1SIMOV00188:

i

a. Loose vendor terminations on the terminal blocks, heaters, and limit

switches.

b. Temporary power cable is shorting against the MOV housing and the

vendor wires.to'the heater have been deformed by the cover installation. j

c. Jung r wires contain bend radius violations.

' d. No. 16 AWG wire in lieu of No. 14 AWG wire is installed between-

points 22 and 37.  ;

-

e. More than two wires terminated under one terminal point.

Motor Operated Valve CISIMOV0018C:*

a. Loose vendor terminations on the terminal blocks, heaters, and limit

switches.

b. Numerous jumper wires contain bend radius violations.  ;

c .- . Wire manufactured by Raychem was installed on site instead of '

Firewall III as required.

11-36

,

. .

s

'

. TABLE II-5 - (Continued)

VALVE MOTOR OPERATOR ~ DEFICIENCIES

fd. (Jumperwirescontainbendradiusviolations.

-

- e. .More than two wires. terminated under one terminal' point.

~

MotorOperatedValveN1RHMOV0061C:*-

a. Loose vendor terminations'on.the terminal blocks, heaters, and. limit

. switches.

- b. -No. 16 AWG wire'is installed in lieu of No. 14 AWG wire.

c. " A jumper between point 35 and 36 has been installed that is not

identified on the scheme drawing; 9-E-RH02, sheet 1.

' d. Jumper. wires contain bend radius violations.

e. ' More than two wires terminated under one terminal point.

-Motor Operated Valve C1CCMOV0209:

a '. Damaged conductors.from. removal /re-insta11ation of motor-operated valve

cover. -(This appears to be a generic problem due to lack of cover / rotor

clearance'on limitorque SMB models).

b. Jumper wires contain bend radius violations.

Motor Operated Valve CICCMOV0199:

~

a. Insufficient motor operated valve cover clearance with wires on top'of

rotors. (Similar to problem with CICCMOV0209).

b. Jumper wires contain bend radius violations.

N'TES:

O

  • Def.iciencies for these valves were subsequently recorded on NCR BE-03209 by

.the licensee.

'

.

l II-37

E

TABLE II-6

INSTRUMENTATION INSPECTION SAMPLE

Hangers:

Field Sketch Hanger Field Sketch Harger

-IC-EW-02 A IC-EW-03 F

IC-EW-02 B IC-EW-03 G

IC-EW-02 'C IC-EW-03 H

IC-EW-03 A IC-EW-03. I

IC-EW-03 B IC-EW-03 J

IC-EW-03 C -IC-EW-05 A

IC-EW-03- D IC-EW-12 A

IC-EW-03 E IC-EW-12 C

Tubing:

Field Sketch Field Sketch

IC-CC-22 IC-EW-09

IC-EW-02' IC-EW-10

IC-EW-03 IC-EW-11

IC-EW-04 IC-EW-12

IC-EW-05 IC-EW-13

Instruments:

A1EWFT6854 CICCFT4522

A1EWFT6856 C1EWFT6873

A1EWFT6904 .C1EWFT6874

B1EWFT6864 C1EWFT6876

B1EWFT6866 CIEWFT6906

II-38

e

l TABLE II-7

L -

INSTRUMENTATION INSPECTION DEFICIENCIES

,

-Field Sketch Instrument Findines

IC-EW-12, Rev. 2 A1EWFT6856 1. Har.ger C welded at one end only.

Drawing 4201-9-2-45080 Sheet 126,

, Detail A requires both ends welded.

2. Hanger A not installed in accordance

with the correct drawing detail.

IC-EW-10, Rev. 3 C1EWFT6906 1. Seven dimensions outside'of

tolerance.

'

2. Sketch identifies instruments as

FT-9606 and FI-9606.

3. Loose conduit fittings at FT-6906.

4. Inspected and accepted to ICEW-10,

Rev. O. Rev. 3 in effect at time

of inspection.

IC-EW-02, Rev. 3 A1EWFT6904 1. Two dimensions outside of tolerance.

2. Loose conduit fitting at FT-6904.

3. Inspected and accepted to IC-EW-02,

Rev. O. Rev. 2 in affect at time

of inspection.

! IC-EW-09, Rev. 3 C1EWFT6874 1. Missing clamp east of hanger E.

i

2. Hanger E 17 inches east of sketch

location.

l 3. Hangers A and B attached to existing

'

.

support without required engineering

concurrence.

4. Inspected and accepted to IC-EW-09,

, Rev. O. Rev. 3 was in effect at

time of inspection.

IC-EW-03, Rev. 3 A1EWFT6854 1. Conduit fittings loose at FT-6854.

2. Flow transmitter loose at base

plate.

3. One dimension outside of tolerance.

,

IC-EW-04, Rev. 2 C1EWFT6873 1. Five dimensions outside of tolerance.

IC-EW-05, Rev. 2 B1EWFT6864 1. Hanger B attached to existing support

i

without required engineering

concurrence.

2. Conduit fitting loose at FT-6864.

IC-CC-22, Rev. 5 CICGFT4522 1. Three dimensions outside of tolerance.

I

II-39

~III. MECHANICAL CONSTRUCTION

A. Objective

The~ objective of the appraisal of mechanical construction was to

determine if the installed and Quality Control (QC) accepted mechanical

items conformed to engineering design, regulatory requirements and

licensee commitments.

B. Discussion

The specific areas of mechanical construction evaluated were piping,

pipe supports / restraints, concrete expansion anchors, mechanical

equipment, and heating, ventilating and air conditioning (HVAC)

systems. To accomplish the above objective, a field inspection of a

sample of QC~ accepted hardware was performed in each arec. In

addition, certain programs, procedures'and documentation were reviewed

as required to support or clarify hardware inspection findings.

1. Piping

a. Inspection Scope

Piping depicted on the sixteen Bechtel isometric drawings listed in

Tabe III-1 was inspected by the NRC CAT. Approximately 140 feet of

2 inch diameter and smaller. piping, and approximately 1680 feet of

greater than 2 inch diameter piping, which had previously been

accepted by Ebasco QC, was inspected. The inspection sample

included piping located in the Unit 1 Reactor Containment Building

(RCB), the Mechanical and Electrical Auxiliary Building (MEAB), the

Fuel Handling Building (FHB), and the Diesel Generator Building

(DGB); the~ Unit 2 MEAB; and the Essential Cooling Water structure.

Piping sizes ranged from 3/4 inch to 30 inches and pipe classifi-

cations were ASME 1, 2 and 3. Attributes inspected included

configuration (component orientation and dimensions), component

locations and types, valve operator orientations, clearances,

flanged joints (gasketing, bolting material, proper makeup), and

hydrostatic testing. In addition, site construction practices were

observ.ed.

As identified in Table III-1,'six of the piping isometrics included

in the NRC CAT inspection sample had been walked down for turnover

to the Houston Light and Power (HL&P) Startup organization, for

flushing and hydro-testing in accordance with Ebasco Quality

Control Procedures (QCP) 10.14. One piping isometric included

piping which had been hydrostatically tested. The h3 Jro-test

documentation package was also reviewed.

Verification of installations in accordance with current design

change documents were also selectively examined for the sixteen

piping isometric drawings, involving 28 design change documents

including Design Change Notices (DCN), Field Change Notices (FCN),

and Field Change Requests (FCR), as listed by Section VII, Table

VII-78.

III-1

The NRC CAT inspectors reviewed, and discussed with responsible

inspectors and engineers the execution of the following procedures

related to final walkdown inspections and engineering reconciliation

of as-built conditions, developed to meet the requirements of IE

Bulletin 79-14, " Seismic Analysis for As-Built Safety-Related Piping

Systems."

Ebasco QCP-10.14, Rev. 3, " System / Subsystem Walkdown Inspection"

Standard Site Procedure (SSP) -34, Rev. 0, " Technical Requirements

and Walkdown Procedure for As-Building of Piping Systems"

-SSP-39, Rev. 0, " Engineering Procedure for As-Built Reconciliation

of Safety-Related Piping Systems and Associated Pipe Supports"

The following documents provided the acceptance criteria and

background .information for the NRC ' CAT inspection:

Bechtel Specification, 5A010PS002, Rev. 7, " Piping Erection and

Field Fabrication"

Bechtel Specification, SL019PS004, Rev. 8, " Criteria for Piping

Design"

Bechtel Specification, 4UO10PS007, Rev. 6, " Pre-service and

In-Service Inspection"

Ebasco Construction Site Procedure, CSP-16, Rev. 5, " Piping

Installation Procedure"

.

  • Ebasco Construction Site Procedure, CSP-17,'Rev. 4, " Hydrostatic

and Pneumatic Testing"

Ebasco Construction Site Procedure, CSP-22, Rev.~3, " Valve / Pump

Work"

  • Ebasco Quality Control Procedure, QCP-9.1, Rev. 6, " Weld

Inspection ASME"

Ebasco Quality Control Procedtre, QCP-10.11, Rev. 5, " Mechanical

Equipment Installation Inspection"

Ebasco Quality Control Procedure, QCP-10.14, Rev. 3,

" System / Subsystem Walkdown Inspection"

Ebasco Quality Control. Procedure, QCP-11.1, Rev. 4, " Hydrostatic

and Pneumatic Pressure Test Inspection"

In addition. the NRC CAT inspection included observation of the

modificatio, of Unit 1 Reactor Coolant Piping by Westinghouse

Construction in accordance with Westinghouse traveller T-TGX-059.

This modification involving Fast Response RTD's was accomplished

under a Westinghouse Field Change Notice (FCN).

III-2

e

b. Inspection Findings

NRC CAT inspections associated with specific piping isometric

drawings are listed in. Table III-1. In general, piping conformed to

design aid procedural requirements. However, several deficiencies

were identified.

On six lugged wafer valves. in the Unit 1 Essential Cooling Water

System (EW-0016, 0019, 0052, 0055, 0089, and 0092), the hex-head

cap screws in the flange-to-valve joints were determined through

ultrasonic testing (UT) to be shorter than required by the asso -

ciated isometric-drawing and bill of materials, reducing thread

engagement in several locations to less than one-half bolt diameter.

Licensee and NRC CAT inspectors subsequently performed a physical

verification for the six lugged wafer valves, resulting in a con-

firmation of the UT findings. In a number of other installations of

~

this type of valve in Unit 1, hex-head cap screws have been substi-

tuted for threaded studs and nuts, without appropriate changes to

the isometric drawing and/or bill of materials. In addition, the

applicable Ebasco inspection procedure, QCP-10.11, does not require

verification or documentation of the length of headed bolts used in

assembly of bolted flange connections. Thus, the bolt length in

lugged wafer valves installed with hex-head cap screws (in place of

studs) is currently indeterminate, and based on NRC CAT findings,

are likely to be incorrect. A Nonconformance Report (NCR CM-03068)

was initiated to disposition the first valve found with unauthorized

substitution of cap screws for studs. Standard. Deficiency Reports

(SDR E-353 and -354) were initiated to evaluate the extent of the

construction deficiency and the inspection procedure deficiency. A

Deficiency Evaluation Report (DER 85-057) was also initiated to '

evaluate the reportability of this-deficiency.

Undersize socket weld fillets were found on twelve of the thirty QC

accepted field welds on isometric 4C369PCV417, SH. A02 for 2 inch

Schedule 160 pipe fittings. During the NRC CAT inspection, a

Nonconformance Report (NCR CP-03139) was issued to disposition

the undersize welds. This deficiency is discussed in more detail

in Section IV of this report.

Two Annubar flow probe mounting flanges on isometric 3M369 PEW 229

Sh. 18, were mislocated with respect to the distance from the pipe.

outer wall, based on the installation dimensions supplied by the

vendor. However, these probes were located within the field piping

erection tolerances provided in Bechtel Specification 5A010PS002.

There are 33 such installations in the Essential Cooling Water,

Component Cooling Water, and Chilled Water Systems. After discus-

sions between Bechtel and the vendor to determine the extent to

which these tolerances could be relaxed, Nonconformance Reports (NCR

SJ-3008 and -3111) were initiated to rework the seven Annubar

mounting flanges which did not meet the relaxed installation

tolerance. A Deficiency Evaluation Form (DEF 85-80) was initiated

to determine if field installation tolerances may impact other

unspecified installation tolerances for vendor supplied pipe mounted

instrumentation.

III-3

At several locations on the support columns for Unit 1 steam genera-

tors, the NRC CAT inspection noted zero clearance to steel work

platform supports. A Nonconformance Report NCR BC-03193 was

initiated. In a number of locations, piping exhibited zero or very

small (less than 1/2 inch) clearance to adjacent components and

structures. A further discussion of this issue is contained in

paragraph III.B.2.b below.

The NRC CAT inspectors considered the procedures related to final

system walkdown inspections and engineering reconciliation of

as-built conditions to meet IE Bulletin 79-14 requirements, to be

thorough and well written. Responsible personnel were

knowledgeable of requirements and responsibilities.

No prcblems were noted in the inspected hydro-test packages or in

the implementation of design. change documents.

c. Conclusions

' Piping was found generally to conform to design documents. However,

the improper flange bolting on lugged wafer valves indicates impro-

per documentation / control of hardware changes and inadequate proce-

dures and inspection effort for bolted joint makeup. The Annubar

flow probe installation criteria deficiency indicates a design

error, which requires resolution by engineering.

2. Pipe Supports / Restraints

a. Inspection Scope

Thirty-two ASME Class 1, 2 and 3 supports / restraints which

represented a variety of types, sizes, systems and locations were

selected for detailed inspection. As a result of the licensee's

Pre-CAT inspection performed earlier this year, the basic support /

restraint inspection program was revised and previously accepted

hardware was subjected to a reinspection for many attributes. The ,

sample selected by the NRC CAT included ten that had been through l

the reinspection program and 22 that had been QC accepted under the

new inspection criteria. These supports / restraints were inspected

for proper configuration, clearances, member size, location, weld

size, fasteners, expansion anchor installation and damage. See

Table III-2 for a listing of the inspection sample.

Documentation packages for five of the inspected supports /

l restraints were examined for completeness, accuracy, and conformance

to procedural requirements. The Field implementation of seven

Field Change Requests (FCRs), four Field Change Notices (FCNs) and

one Nonconformance Report (NCR) applicable to the inspected hard-

ware were also inspected. See Section VII, Table VII-78.

Acceptance criteria for the above described inspections were

contained in the following documents:

  • Bechtel Construction Specification SL340JS1002, Rev. 7, SCN

24, " Pipe Support Field Fabrication and Installation"

III-4

t

  • Ebasco Construction Site Procedure (CSP) 7, Rev. 5, ICP 4, " Pipe

Support Installation"

  • Bechtel Work Plan Procedure / Quality Control Instruction (WPP/QCI)

23, Rev. 6, " Fabrication and Furnishing Pipe Support Items"

Ebasco Quality Control Procedure (QCP) 10.12, Rev. 4, " Component

Support Fabrication and Installation Inspection"

  • Applicable design drawings and change documents

b. Inspection Findings

At the time of the CAT inspection, of the approximately 9,000 ASME

pipe supports / restraints to~be installed in Unit 1 and common

systems, approximately 1200 had been QC accepted. Approximately 500

had been accepted under the revised inspection program and 700 had

been previously accepted and reinspected to the new criteria by

retrained inspectors. A review'of the licensee's Pre-CAT

inspection report indicated a thorough study of pipe supports /

restraints. Improvements in specifications, procedures and person-

nel training were implemented and reinspections performed as

required.

Discrepancies were noted on seven of the 32 supports / restraints

inspected by the NRC CAT. Discrepancies included out of tolerance

angularity of a strut and a restraint brace member, undersized /

missing welds (two supports), undersized U-strap restraint, improper

expansion anchor embedment and an oversized spacer plate installed

that could have decreased support capacity. With the exception of

the undersized U-strap, the discrepancies were not a major concern

from a structural integrity standpoint although they were items.that

should have been identified by QC during the inspection / reinspection

process. In addition,- conditions were noted on several installa-

tions relating to unclear criteria and/or work control.

Restraint SI-9106-HL5009 consisted of a pipe clamp with welded lugs

restraining the pipe laterally in a box frame. However, the ears

of the pipe clamp were only about 3/8 inch from the horizontal

members of the box frame. The construction specification allowed a

1/2 inch tolerance on clearances in the unrestrained direction. As

no clearance in the unrestrained direction was specified on this

drawing, it was not clear what was acceptable in this situation.

The following actions were taken as a result of the NRC CAT inspec-

tion findings: A change to the specification was issued to provide

a tolerance on the installation of the pipe clamp for this type of

configuration; a drawing review by engineering identified 47

restraints of this design including 11 that could still have

potential interference due to thermal or seismic movement (including

.four that had previously been QC accepted); nonconformance reports

were issued to provide for reinspection of the four supports and

Design Change Notices (DCNs) were issued to specify the necessary

clearance on the remaining seven.

III-5

.

A temporary hanger for a 30 inch pipe had been welded to support

EW-9406-HL5001. Although the installation of this temporary support

was specified on a Request for Conditional Release form and a

Startup Work Request (SWR), the only reference to removal was a note

on the installation sketch. The NRC CAT inspectors consider that a

more formal method of control is warranted with at least an

inspection signature that the temporary support has been removed.

~The inspector notes that this is a programmatic issue and that in

this case the temporary support would most likely have been removed

and system walkdowns should identify ~this type of oversight if left

installed.

A large number of potential or actual interferences u e observed.

during inspection by the NRC CAT, between piping, supports /

restraints and other hardware, and installation and inspection

criteria for this attribute did not appear to be adequate. It was

determined that this issue had been identified months earlier by an

INPO evaluation and had been reported to Region IV pursuant to 10

CFR 50.55(e). Although a program to address this concern has been

developed, it has not yet been' implemented. More aggressive and

timely action to provide craft and QC with acceptance criteria

is warranted.

After identification of the undersize (under capacity) U-strap on

restraint SI-9118-HL5009 the NRC CAT inspector selected and

examined ten additional restraints that had heavy duty U-straps

specified on the drawing. All were found to have the correct

material installed.

The NRC CAT inspector noted two large (1500 pounds each) air

operated valves on a three inch diameter Safety Injection line

(SI-1117) in a high traffic area that were not supported, were

visibly leaning and could easily be moved by hand. This was

questioned by the inspector. Although not considered required by

Bechtel site engineering, temporary supports were installed on these

valve operators and installation of the permanent' designed supports

was initiated.

The change documents associated with the supports / restraints

inspected had all been properly implemented and closed out. No

problems were noted in the documentation packages reviewed.

See Table III-3 for a summary of inspection observations.

c. Conclusions

In general, pipe support / restraints were found to be installed in

accordance with drawing, design change and procedural requirements.

However, due to the one undersized U-strap and number of other

discrepancies noted, it appears that further improvement by craft

and QC in attention to detail is required. Also, improved controls

for the installation and removal of temporary supports is warranted.

III-6

. . . -.

3. Concrete Expansion Anchors

a. Inspection Scope

Fifty-six concrete expansion anchors (CEAs) on 12 pipe

supportshestraints and 97 CEAs on 17 HVAC supports were inspected

in detail. Inspection attributes included length, marking,

embedment, spacing, edge distance, damage, angularity and residual

torque. In addition, the CEAs on pipe' supports were verified to be

the proper length by ultrasonic testing (UT). Various systems,

sizes, and locations were included in the anchor sample. Table

III-4 provides a listing of the anchors inspected. Anchors were

torqued to the designer specified test torques which were 70% of

minimum installation torques.

Seven FCRs, four NCRs and one DCN related to expansion anchors

were inspected for conformance to as-built conditions. See Section

VII, Table VII-78.

Acceptance criteria for these field inspections were contained in

the following. documents:

Bechtel Construction Specification 5A010SS1000, Rev. 7,

" Installation of Expansion Anchors, Rock Bolts, Grouted Anchor

Bolts, and Core Drilling"

Bechtel Construction Specification SL340JS1002, " Pipe

Support Field Fabrication and Installation"

"

. * Ebasco CSP-41, Rev. 6, " Installation of Expansion Type Anchors" -

  • Ebasco CQP 10.19, Rev. 7, " Inspection of Anchoring Devices

Installed Within Concrete Structures"

"

Applicable design drawings and change documents

b. Inspection Findings

Nut rotation at test torque or less was observed on approximately

20 of the 153 CEAs tested and most turned very close to the test

torque value. Only one anchor took as much a one turn to achieve

minimum installation torque. Only one anchor was determined to

have less than the specified embedment (on pipe-support

EW-1329-HL5001) although many were at the exact minimum and many

had been previously identified by QC as not meeting original

specifications and were dispositioned by FCR or NCR. During the

NRC CAT's inspection of pipe supports / restraints and mechanical

equipment several cases of CEAs with out of tolerance embedment and

anchor to concrete edge distances were identified. Other attri-

butes were within design tolerances or had been previously identi-

, fied and dispositioned by engineering. The FCRs, NCRs and DCNs were

verified as being acceptably implemented.

l

III-7

-_

See Section-V.B.4.b (Civil / Structural) for a discussion of qualifi-

cation testing and other design aspects of the concrete expansion

anchor program at STP.

c. Conclusions

Generally with the exception ~of minor deficiencies as noted above, the

-

concrete expansion anchors for pipe supports / restraints and HVAC

supports were installed and inspected in accordance with design and

procedural requirements.

4. Mechanical Equipment

a. Inspection Scope

Twelve pieces of mechanical equipment including six HVAC mechanical

components which are part of the STP's equipment specification, five

ASME pumps, and one ASME tank were inspected for conformance to

design and procedural requirements. In addition the insertion of a

Roto-lock reactor vessel stud insert (#35) in the Unit I vessel was

observed.

The installation documentation for the inspected equipment was

examined and the process control and QC verification documentation

for assembly of the Unit I reactor vessel upper internals by

Westinghouse Construction was also reviewed. Table III-5 provides

a listing of the mechanical equipment inspection sample.

The following documents provided the acceptance criteria and

background information for the NRC CAT inspection:

Bechtel Specification 4C1195S1008, Rev. 2, " Reactor Coolant System

Component Supports and Other NF Steel Items"

  • Ebasco CSP-22, Rev. 3, ICP-1, " Valve / Pump Work"
  • Ebasco CSP-2, Rev. 4, ICP-5, " Installation of Permanent Electrical

and Mechanical Plant Equipment"

Ebasco SSP-24, Rev. O, " Disassembly / Reassembly of Safety and

Non-Safety Related Valves"

Ebasco QCP-10.11, Rev. 4, PCR-5, " Mechanical Equipment Installation

Inspection"

Ebasco QCP-9.1, Rev. 6, " Weld Inspection ASME"

  • Bechtel Drawing 3A01-0-C-0010, " Concrete Standard Details-Embedded

Plates-Misc. Supports"

  • Bechtel Drawing 3A01-0-C-0012, " Concrete Standard Details-Embedded

Plates-Misc. Supports"

  • Applicable design drawings, vendor technical manual and drawings.

l

[

III-8

1

b. Inspection Findings

Discrepancies were noted on most of the mechanical equipment

installations examined by.the NRC CAT inspectors. Programmatic /

procedural weaknesses as well as inadequate QC inspection are of

concern.

The discrepancies listed below were noted in the reassembly of

the following Unit 1 pumps; Containment Spray (CS) pump B, Low Head

Safety In.jection (LHSI) pump B, and High Head Safety Injection

(HHSI) pump 8:

  • Fasteners installed for bolting the motor stand to the motor and

the motor stand to the foundation were of various material types

or were unmarked. Washers specified for the motor stand to motor

connections were missing. These installations had been accepted

by QC and the joints sealed with " torque seal". Refer to Section

VI, Material Traceabil'ty and Control, for further discussion of

this concern.

Although the process control sheet referred to the vendor manual,

which required installation of new 0-rings, the old 0-rings were

reinstalled.

Although the applicable construction procedure, CSP-22, requires

bagging of fasteners and small parts, disassembled fasteners -from

the pump-motor couplings were observed stacked on the pumps

and pump flange fasteners were observed scattered on the floor,

and the QC inspector involved with the pump work was unaware of

the bagging requirement.

Discrepancies noted on four of the six mechanical equipment HVAC

components inspected, included missing and undersize welds,

unshimmed foundations, backed off foundation mounting nuts, improper

concrete expansion anchor embedment and spacing to concrete cored

holes, attachment welding to edge of embedment in possible violation

of structural drawing requirements, damage, and support bracing that

did not conform dimensionally to design. The current site program

for inspecting non-ASME equipment does not provide for inspection of

equipment support configuration dimensions etc. Based on a review

of structural drawings 3A01-0-C-0010 and 3A01-0-C-0012 and discus-

sions with pipe support and mechanical equipment QC inspectors it

was apparent that the design requirements for welding near the edge

of embedded plates was not clearly delineated. Site engineering

. committed to evaluation of existing criteria and revising drawings

and retraining inspectors as required.

On the Reactor Water Make-up Tank the NRC CAT inspectors found that

a design specified ring of cushion material (Flexcell) had been

removed after QC acceptance of the tank installation. The tank

mounting flange was in contact with the concrete floor at some

locations and had more than a one inch gap at others. At the time

of the inspection the tank was partially filled with water for

flushing operations. The licensee was unable to provide evidence

that formal documentation and/or controls existed to identify,

III-9

track and restore the installation of the tank to design require-

ments. At the request of the NRC CAT inspectors the licensee agreed

to perform the following actions:

  • Determine the nature and distribution of the remaining

cushion material and other sandy material under the tank.

Evaluate the activities related to removal (and eventual

replacement) of the cushion material.

  • Evaluate the stresses imposed on the tank due to loading the

tank with the existing gaps around the foundation.

During the NRC CAT inspection of piping it_was noted that vendor

assembled piping spool flanges on Diesel Generator 1A had been

disconnected, apparently to facilitate the installation of an

adjacent field installed expansion joint. There was no documenta-

tion authorizing this disassembly as required per QCP 10.27. During

t

the course of this inspection these joints were remade, apparently

to eliminate leakage during testing, again without authorization or

control / documentation of proper joint makeup. A Procedure Violation

Notification (M-17) was initiated to address this problem.

During the observation of the installation of the Roto-lock insert,

it was observea that a case of Molycote 505 anti-seize lubricant,

which is no longer recommende~d by Westinghouse for nuclear-

applications (Westinghouse letter DL-82-01 and WCAP-9464, 1979),

had been requisitioned and delivered to the reactor vessel flanga

area. However, Ebasco personnel did use a recommended lubricant

and the 1%tAe :etete rmined unopened. The Molycote was

removed and NCR BN-03021 was initiated. The Inspectors note that

the installation traveler for the RHR pumps listed as an acceptable

lubricant FEL PRO N1000, whic- is . iso on the Westinghouse "not

recommended" list. Again a .aeck of installation records indicated

that an approved lubricant 'nd been used on the RHR pumps. However,

it appears that additional .ittention to ensure control and use of

approved lubricants is we ranted.

On RHR pumps A and C, the construction process sheet (CPS) specifies

as sequencing step 1 the installation of the pump supports per the

vendor manual and drawing 3C01-9-S-1600. This is checked in the CPS

column for " work sequence installation" as a prerequisite step to

pump and motor installation. A QC HOLD point was not specifici.

Subsequent steps of the CPS had been completed including machin.ng

and leveling of the pump feet and support pads to a precise.0.00z

inch tolerance. However, the ASME Equipment Support Checklist used

in conjunction with the CPS, indicated that the torquing of the pump

support foundation bolts had not yet been performed. The condition

was considered acceptable based on the engineering response that

the pump had not been accepted for levelness and location, nor had

the pump alignment been performed. However, as the RHR pump instal-

lation is still in progress, it appears that specific sequence

requirements of the CPS should have been more clearly controlled

with the review of exceptions taken to an intended prerequisite

appropriately documented prior to completing subsequent work steps to

III-10

<

ensure that leveling during subsequent torquing of foundation

bolting is not degraded.

It should be noted that the installation of the lugged wafer valves

with the fastener control problems previously discussed in the

piping section of this report was under the control of the

mechanical equipment installation program and the valves were

inspected by mechanical equipment inspectors.

No problems were identified during the review of reactor vessel

upper internal installation documentation.

Table III-5 provides a number of NRC CAT observations for the

mechanical equipment items inspected.

c. Conclusions

Significant deficiencies were noted in regard to mechanical

equipment installation. A lack of attention to detail by craft and

QC inspators was apparent. Programmatic / procedural weaknesses

regarding control and documentation of bolting activities, lubri-

cants, inspection of non-ASME equipment support framework, and

acceptance criteria for location of attachments to embedded plates

was also apparent.

Licensee action is necessary in areas of mechanical equipment

installation to provide assurance'that hardware is installed and

inspected in accordance with design and procedural requirements.

Subsequent rework activities must be controlled, documented and

provide for QC reverification of hardware acceptability.

5. Heating, Ventilating and Air Conditioning (HVAC)

a. Inspection Scope

Fifteen HVAC seismic supports / restraints, forty-seven duct sections,

and five fire-dampers were selected from both Units 1 and 2 at

random and inspected in detail.

The supports / restraints were inspected for location, configuration,

member size, weld size and connection details. Duct sections and

fire dampers were examined for proper configuration, companion angle

size, joint make-up and free operation of fire dampers.

In addition, adjacent HVAC hardware, including approximately 20 other

HVAC supports / restraints, 25 duct sections, and 10 dampers was

observed at random for the following attributes: loose or missing

fasteners, joint makeup, improper clearances or angularity,

disassembled, and damaged items.

Ten Field Change Requests (FCR) associated with the NRC CAT HVAC

hardware samples were verified for conformance to as-built

conditions. Also, twenty-four construction traveler packages were

reviewed for completeness and accuracy.

III-11

Acceptance criteria for these field inspections were contained in

the following documents:

Bechtel Specification SV279VS1003, Rev. 5. " Installation

of Safety Class and Non-Safety Class HVAC Equipment and Duct

Work."

Bechtel Specification 3V279VS1000, Rev. 8, " Safety Class

HVAC Duct-Work Fabrication."~

Ebasco Procedure CSP-6, Rev. 4, " Installation of HVAC Duct

Hangers and Equipment klangers."

Ebasco Procedure CSP-9, Rev. 4, " Inspection of Duct and

Duct Accessories."

Ebasco Procedure CSP-95, Rev. 2, " General Welding Requirements

for HVAC."

Bechtel Procedure QCP-10.21, Rev. 5, "HVAC/ DUCT / HANGER

Installation Inspection."

pplicable Duct Support / Restraint and Layout Drawings.

-b. Inspection Findings

Approximately 39 percent of the seismic supports, 22 percent of

the duct sections, and 9 percent of the fire dampers had been QC

accepted by Ebasco at the time of the NRC CAT inspection. During

the inspection by the NRC CAT, workmanship appeared to~be good and

no installation deficiencies were found for HVAC hardware (supports,

. duct sections, and fire dampers). However, during the observation

of adjacent HVAC hardware, QC accepted tornado damper number

3V11V0A0302 was'found installed upside down. This apparent isolated

case of questionable. installation was subsequently dispositioned

"use-as-is" by Bechtel Engineering on NCR BH-03037.

Ten " Field Change Requests" (FCR) associated with the HVAC hardware

inspected were reviewed and found to conform to the as-built condi-

tion. See Section VII, Table VII-78.

The NRC CAT was informed of an reinspection program under

" Deficiency Evaluation Report (DER 85-031) conducted by Ebasco QC

for direct attachment welds and expansion anchor bolt / base plate

installation. During the inspection of HVAC supports the NRC CAT

did not observe weld attachment discrepancies as described in

DER-031.

Six of the twenty-four " construction traveler packages" reviewed by

,

the NRC CAT for completeness and accuracy, were noted to have

documentation omissions on the " Construction Cover Sheet" (Form

'

CS-AD-852). A Standard Deficiency Report (SDR) was subsequently

issued by the licensee to Construction (SDR E-350) and to Quality

Control (SDR E-351) to prevent the recurrence of these deficien-

cies.

.

! III-12

- _.

--

.

c. Conclusions

.HVAC safety related support / restraints, duct sections, and fire

.

, dampers conformed to design and procedural requirements. More

attention to the review of documentation is required to ensure

completeness and accuracy of the construction traveler packages.

,

9

4 ,

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III-13

TABLE III-1

PIPING IhSPECTION SAMPLE AND OBSERVATIONS

Isometric Diameter

(Note 1) (Inches) Class Notes Observations

2C369PAF402 6, 8 2 None

.Sh. 01, Rev. 3

~2C369PCV417 4 2 -

Clearance to hanger

Sh. 03, Rev. 2

2M369PRH259 8 2 2, 4 Deficient ISI prep (NCR

Sh. 02, Rev. 2- SP-03152)

3M369 PEW 229 . 6, 8 3 2, 4 Annubar flow probe mounting

Sh. 18, Rev. 0 10, 30 flange (NCR SJ-03008 & 03111)

3M369PRM263 4, 6 3 2, 4 Broken flex conduit

Sh. 03, Rev. 4 (SWR-01921)

3Y361 PEW 729 3, 24, 30 3 2 None

Sh. 03, Rev. 3

4C369PCV417' 2 2 4 Undersize socket welds (NCR

SH. A02, Rev. 4 CP-03139, SDR E-349 DER 85-049)

4C369PCC407 16 2 2, 4 Luggedwafervalvebbiting(NCR

SH. 34, Rev. 3 NCR CM-03068, SDR E-353

& -354, DER 85-057)

Uncapped MOV housing. (Main-

tenance Discrepancy MD 1-0868)

4C369PRC457 3/4, 2 1, 2 -

Only partially inspected

SH. A06, Rev. 4 during CAT. Reviewed hydro-

test records.

3/32" saw-cut in coupling

4C369PRH459 4, 12 1, 2 -

Masking tape on pipe.

Sh. 04, Rev. 6 Uncapped opening

SD369 PEW 329 4, 6, 10 3 2 Broken temperature probe.

Sh. 01, Rev. 1

SD369 PEW 329 4, 6, 10 3 4 Valve reversed and handle

Sh. 03, Rev. 1 blocked (NCR SP-03148)

III-14

_ - _ - _ _ _ _ _ .

_ _ _ _ . _____ __ __ - -

.

TABLE III-1 - (Continued)

PIPING INSPECTION SAMPLE AND OBSERVATIONS

-Isometric Diameter

(Note 1)- (Inches) Class Notes Observations

SD369 PEW 329 4, 10 3 -

Clearance to support

SH._04, Rev. 1

Wood blocking

50369 PEW 329 4, 6, 10 3 -

.None.

SH. 06, Rev. 1

SF369PFC530 4, 10, 20 3 -

None

SH. 04, Rev. 4

5M369PCC207 14, 20 3 3 No gaskets on temporary

Sh. 10, Rev. 4 flange assembly (poor

construction practice)

Notes

1. Letter in second position of isometric drawing number

identifies pipe location.

"

C = RCB

M = MEAB

Y.= Yard (Essential Cooling Water Intake Building)

2 0 = DGB '

F = FHB.

2. This isometric had been walked-down in accordance with Ebasco QCP-10.14,

and turned over to HL&P Startup for flushing and hydro-testing.

3. All isometrics are Unit 1 except SM369PCC207

4. HL&P and Ebasco discrepancy reports are a result of NRC CAT observations

and are shown in parentheses ( ).

III-15

_ _ _ - - . - - - - - - _ - - - - - - - - - - - - - _ _ _ _ _

7_

TA8LE III-2-

PIPE SUPPORT / RESTRAINT' INSPECTION SAMPLE

Support / Restraint .

ASME

Number M (Inches)- Location (1) Class

.RH-9215-HL5004 (2)- Strut 8 C 2

-SI-9105-RR0031 (2) Strut 8 C 2

CC-9105-HL5007 (2)- Strut 16 C 3

SI-9106-HL5009 (2) Box 6 C 2

.

SI-9105-RR0038 (2) Box 8 C 2

RH-9206-HL5006 (2) ' Strut 8 C 2

RH-9102-SH0001(2) Spring 12 C 2

CC-9426-SH0001 Sprir.g 12 FHB 3

SI-9102-RH0007 Strut 8 FHB 2

CC-9427-HL5005 Strut 12 FHB 3

CC-9427-HL5004 Strut 12 FHB 3

EW-9406-HL5001 (3) Strap 3 EWPH 3

SI-9102-HL5001 Strut 8 FHB 2

EW-9113-HS5001.(3) Anchor 2 MAB 3

EW-9383-HL5001 (3) Box 10 MAB 3

EW-9283-HL5001 Box 10 MAB 3

SI-9117-RR0004 Strut 3 MAB 2

SI-9118-HL5009 (3) Strap 6 MAB 2

EW-9102-HL5001 Strut 30 MAB 3

EW-9205-HL5008 Strut 4 MAB 3

EW-9102-HL5003 (3) Strut 30 MAB 3

EW-9202-HL5001 Strut 30 MAB 3

RH-9205-HL5011 Box 8 MAB ' 2

RH-9205-HL5001 Box 8 MAB 2

SI-9118-RH0011 Strap 6 MAB 2

III-16

_ _ _ _ _

e

! -TABLE III-2 - (Continued)

PIPE SUPPORT / RESTRAINT INSPECTION SAMPLE

Support / Restraint ASME

Number Type (Inches) location (1) Class

RH-9205-HL5009 Box 8 'MAB 2

CH-9203-HL5004 (2) Box 6 EAB 3

SI-9337-HF5005 (2) U-Bolt 2 FHB '2

CV-9032-H15015 (2) Box 4 MAB 3

l CC-9413-GU1004 Unit 2 Strap 4 MAB 3

CC-9413-HL5002 Unit 2 Strap 4 MAB 3

SI-9201-HL5009 . Strut 12 FHB 2

NOTES:

, (1) C = Containment Bldg.

!

'FHB = Fuel Handling Bldg.

EWPH = Essential Service Water Pump House

MAB = Mechanical Auxiliary Bldg. ,

EAB = Electrical Auxiliary Bldg.

(2) Through licensee reinspection program

l (3)' Document package reviewed

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III-17

. _ _ _ _ _ _ _ _ - _ - _ _ _ _ . -

y

TABLE III-3

PIPE SUPPORT / RESTRAINT INSPECTION OBSERVATIONS

Support / Restraint Observations (1)

SI-9105-RR031 Strut angularity exceeds tolerance by 4

degrees (NCR CS-3181)

SI-9106-HL5009 Minimal clearance between pipe attachment

and support structure in unrestrained

direction (NCR CS-03314)

~ SI-9105-RR0038 Undersize skewed fillet welds (NCR CS-00875)

RH-9102-SH001 1/2. inch clearance to adjacent support'

EW-9406-HL5001 Temporary support attached

SI-9118-HL5009 undersize U-strap installed (NCS CS-3189)

EW-9102-HL5003 Three expansion anchors with less than

specified embedment (NCR CS-3182)

EW-9202-HL5001 Oversized plate installed but not properly.

documented / evaluated. (NCR 55-3227)

CC-9413-HL5002 *

Missing flare bevel fillet cap weld

(Unit 2) -(NCR CS-03263)

SI-9201-HL5009 Brace angle exceeds design' tolerance

(NCR CS-03228)

NOTE:

(1) Ebasco NCR issued as a result of the NRC CAT

observation (s) shown in parentheses.

f

III-18

TABLE III-4

CONCRETE EXPANSION ANCHOR INSPECTION SAMPLE AND OBSERVATIONS

Number / Diameter

(Inches)

of Anchors

Support / Restraint Inspected Observations

Pipe S/R's:

CC-9318-HL5002 8 - 3/4

CC-1317-HL5006 4 - 1/2

CC-1317-RR13 4 - 3/4

CC-1114-GU19 4 - 3/4

CC-1317-HL5001 4 - 1 1/4

CC-1428-HL5016 4 - 3/4

CV-1006-HL5017 4-1

CC-9422-HL5005 4 - 3/4

CC-1414-HL5010 4 - 3/4 *(One CEA)

CC-1424-HL5004 4 - 3/4

CC-1301-HL5002 8-1

EW-1329-HL5001 4 - 1/2 Embedment violation on

one CEA: 3 3/16 actual

vs. 3 1/2 required (NCR

SS-03264)

HVAC S/R's:

1-6-0144-5012 4 - 3/4

1-6-0144-S016 12 - 1/2 *(Four CEA's)

1-6-0144-5046 -

3 - 5/8 *(One CEA)

1-6-0144-5017 12 - 1/2 *(FourCEA's)

1-6-0144-5019 16 - 1/2 *(Eight CEA's)

1-6-0144-S037 4 - 3/4

1-6-065-5045 4 - 1/2, 4 - 1 1/4

III-19

- - - - _ - - _ _

7_ _

.. ..

-

TABLE III-4 --(Continued)

CONCRETE EXPANSION ANCHOR INSPECTION SAMPLE AND OBSERVATIONS

Number / Diameter

(Inches)

of Anchors

Support / Restraint Inspected Observations

HVAC S/Rs: I

1-6-0065-5025 4 - 5/8

1-6-0065-5075 4 - 3/4, 3 - 1

1-6-065-S008' 2 - 3/4, 2 - 1 *(One CEA)

1-6-0144-5083 6 - 1 1/4

1-6-0128-5083 8 - 1/2, 4 - 1 1/4 *(Two CEA's)

1-6-0128-5002 2 - 3/4

1-6-0128-S058 4 - 3/4 *(Two CEA's)

  • Nut turned at or below torque value but minimum installation torque acbieved

in less than 1 full additional turn of the nut.  ;

,

.

III-20

p--

'

TABLE III-5

MECHANICAL EQUIPMENT SAMPLE AND OBSERVATIONS

Equipment (All Unit 1) Observations

Reactor Water Makeup Tank Alteration to tank foundation configura-

tion without proper documentation / control.

Containment Spray Pump B 1. Incorrect /indeterminant fastener material.

Low Head Safety'Injecton Pump B 2. 0-ring reused when technical manual

High Head Safety Injection Pump B specified replacement.

3. Fasteners not controlled.

RHR Pumps A and C Torquing of foundation bolts not completed

. prior to leveling and setup of critical

support framing.

Charging Pump Supply Cooler- One mounting pad not shimmed as required

3V101VAH010 and damage to flange of foundation beam.

(NCR CM-03087).

EAB Return Air Fan-3V111VFN002 1. Gusset plate welded to edge of embed

exceeding tolerance.

2. Undersize attachment weld.

3. Missing welds on 4 gusset plates.

4. Damage frame member on fan.

5. Notches in bracing not shown on drawing.

6. Bolt hole locations in brace gusset

plates'not per drawing. (NCR CM-3092)

Control Room Return Fan - None

3V111VFN026

MEAB HVAC Chiller - 3V111VCH001 None

Charging Pump Supply Cooler - 1. North end of attachment welds 1/16 to

3V101VAH004 1/8 inch undersize entire length.

2. Attachment welds to edge of embed

plate violates drawing requirement.

3. Two maxibolts to cored holes in concrete

violate minimum spacing requirements.

(12 1/2 inch required, 5 inch actual)

4. Nut is tight on foundation stud but

is 1/4 inch from mating with contact

surface. (NCR CM-03091)

i Fuel Handling Building Filter 1. Undersize unit to embed fillet welds.

l Train-3V121VXV003 2. Expansion anchors violate minimum

i spacing to cored holes.

3. Expansion anchors do not have required

embedment.

i

r

NOTE: Ebasco NCR's generated as a result of the NRC CAT observation (s) shown in

, parenthesis.

l

,

III-21

l

I

. - _ _ - _ _ - _ _ _ - - _ _ _

,-

TABLE III-6

HVAC INSPECTION SAMPLES AND OBSERVATIONS

(Supports / Restraints)

Inspection

Support Duct. ~FCR Traveler

Number Size In. Unit' Building 1 Review Reviewed Observation

1-1-0083-S014 8 dia. 1 RCB None Yes None

1-1-0083-S039 16 dia. 1 RCB BH-00827 Yes None

1-1-0083-5040 16 dia. 1 RCB CH-01546 Yes None

1-1-0083-5046 8 dia. 1 RCB BH-00559 Yes None

1-1-0083-5048 16 dia. 1 RCB CH-00845 Yes None

1-1-0083-5049 16 dia. 1 RCB None Yes None

1-1-0087-5-004 14x10 1 RCB CH-01800 Yes- None

1-6-0143-5016 30x72 1 EAB DL-00152W - Yes None

1-6-0144-5017 12x12 1 EAB CH-02181W Yes None

1-6-0144-5019 12x12 1 EAB EAB-314 Yes None

2-6-0050-S033 14x16 2 EAB None Yes Document

discrepancies

on content

sheet of

construction

traveler.

2-6-0051-5007 24x20 2 EAB None Yes Document

discrepancies

on content sheet

of construction

traveler.

.

III-22

._ _ _ _ ______ _ _ _ - ____-_ - _ ___- _ __ - __ _ - -_ _ _~

TABLE III-6 (Continued)

HVAC INSPECTION SAMPLES AND OBSERVATIONS

(Supports / Restraints)

Inspection

Support Duct FCR Traveler

Number ' Size In. Unit Building 1 Review Reviewed Observation

2-6-0124-5003 20x18 2 EAB None Yes Document i

discrepancies

on content

sheet of

construction

traveler.

2-6-0124-S066 22x22 2 EAB None Yes Document

discrepancies

on content

sheet of

construction

traveler.

2-6-0125-S005 20x18 2 EAB BH-01844 Yes Document

discrepancies

on cover sheet

of construction

traveler.

'RCB = Reactor Containment Building

EAB = Electrical Auxiliary Building

III-23

--

_ _ _ _ _ _ _ _ _

,

TABLE III-6 (Continued)

HVAC INSPECTION SAMPLES AND OBSERVATIONS

(HVAC Sections)

Inspection

-Orawing Number FCR Traveler

& Duct Sections Unit Building 1 Reviewed Reviewed Observations

5-V-14-1-V- 1 RCB None None None

0083-A-10

Rev. 5

HVAC Section Nos.

P-005 thru P-019

5-V-14-1-V- 1 RCB None None None

0083-B-1D

Rev. 5

HVAC Section Nos.

P-101 thru P-114

5-V-11-1V- 1 EAB BH-01142 Yes None

0144-A-1D (P-011,

Rev. 0 012, 015,

HVAC Section Nos. 016, 021,

P-011 thru P-025, and P-025)

P-027, P-028

2RCB = Reactor Containment Building

EAB = Electrical Auxiliary Building

III-24

. -

TABLE III-6 (Continued)

HVAC INSPECTION SAMPLES AND OBSERVATIONS

(Fire Dampers)

Inspection

Drawing Fire Damper FCR Traveler

Number Number Unit Building 1 Reviewed Reviewed Observations

5-V-11-1-V- FF-01 1 EAB None No None

065-A-ID,

Rev. 4

FF-04 1 EAB None No None

5-V-11-1-V- FF-319 1 EAB None Yes None

0128-A-ID

Rev. 3

FF-320 1 EAB None Yes None

FF-321 1 EAB None Yes None

IRCB = Reactor Containment Building

EAB = Electrical Auxiliary Building

.

III-25

_ _ - _ _ _ - _ - _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ - _ - - _ _ _ _ _ _ _ _ _ _ __ _______ __ _. _ _ _ - _ _ . - _ - _ - _ _ _ - _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ -

IV. WELDING AND NONDESTRUCTIVE EXAMINATION

A. Objective

The objective of the appraisal of welding and nondestructive examination

(NDE) was to determine if Quality Control accepted work related to

welding and NDE activities was controlled and performed in accordance

with design requirements, Safety Analysis Report commitments, and

applicable codes and specifications.

An additional objective was to determine if personnel involved in

welding and NDE activities were trained and qualified in accordance

with established performance standards and applicable code

requirements.

B. Discussion

To accomplish the above objectives; welds and welding details for

piping; pipe supports /retraints; field and shop fabricated tanks;

structural steel installations; heating, ventilating and air condition-

ing (HVAC) installations; electrical supports; and instrumentation

control tubing and supports were inspected. The inspected welds were

selected to provide a representative sample of the applicant's

contractor welding activities in terms of welding processes used,

materials welded and existing weld-joint configurations. Considera-

tions such as physical location, difficulty of welding and limited

accessibility were also used in sample selection. Design changes

related to welding such as increase or decrease of weld sizes and a

change from one welding process or procedure to another welding process

or procedure were also reviewed for technical adequacy and

implementation.

NDE activities were appraised through the review of radiographs for

both field and vendor fabricated welds, the review of NDE procedures

and personnel qualifications, the inspection of the calibration status

of NDE equipment and the witnessing of in process NDE activities. The

NRC construction assessment team (CAT) inspectors reviewed a sample of

radiographic film in final storage in the vault of the licensee's

facility. In addition, a sample of NDE documentation was requested for

review which was stored by the Nuclear Steam System Supplier,

Westinghouse and was not yet transmitted to the licensee.

During the inspection of structural welds in the pipe supports' area,

the NRC Construction Appraisal Team (CAT) identified welds which did

not meet the weld size requirements specified by the Architect Engineer,

Bechtel Power Corporation (Bechtel). Undersized socket welds were also

identified in 2 inch schedule 160 piping spools. Some undersized weld

reinforcements were also found in nozzle to shell joints (ASME Code

Category D Joints) on tanks and heat exchangers. A detailed discussion

concerning these welds is included later in this section.

In the area of NDE, the NRC CAT inspectors reviewed. film for field and

shop fabricated pipe welds, film involving equipment and hardware

supplied under the Westinghouse (NSSS) scope of supply and film supplied

by various vendors and contractors for the balance of plant.

IV-1

.

!

l

l

A relatively small number of deficiencies were found in the reviewed

sample of radiographs. However, in the area of NDE documentation,

with the exception of the Westinghouse file, the team encountered

difficulties in establishing the number of NDE vendors and suppliers.

The inspectors also observed that in general the project has difficul-

ties in identifying existence and location of film and documentation

related to the balance of plant suppliers. For equipment and hardware

supplied under the NSSS scope of supply the licensee has instituted a

program in which, Westinghouse is required, to submit monthly reports

identifying the current status of film and NDE documentation. The

program was instituted in May 1985 after the project identified missing

radiographs of the reactor head supplied by Combustion Engineering. The

NRC CAT believes that some similar program is needed for the balance of

plant suppliers, to insure film and documentation could be readily

identified. A detailed discussion concerning NDE deficiencies,

retrievability and availability of film and documentation is provided

later in this section.

The welding and NDE activities were examined in order to ascertain

compliance with the governing construction codes and specifications.

This effort involved the review and inspection of the following

contractors:

Field Activities

1. Bechtel Power Corporation: architect engineer.

2. Ebasco Services Inc.: piping installation and piping supports /

restraints, fire protection system fabrication and installation,

electrical, instrumentation, HVAC installation and structural steel

erection.

3. Pittsburgh Des Moines Corp. (PDM): containment liner and contain-

ment penetration fabrication and installation, reactor and spent

fuel liner fabrication.

4. Westinghouse: reactor internals-modification and installation.

5. Babcock and Wilcox: Steam Generator Eddy current preservice

inspection and examination.

Shop Fabrication

1. Southwest Fabricating & Welding Company, Inc.: shop fabricated

piping spools.

2. Copes-Vulcan: valve manufacturer.

3. Westinghouse: nuclear steam supply system.

4. Anchor / Darling Valve Company: valve manufacturer.

5. Teledyne Brown: steam generator supports fabricator.

IV-2

6. Esco Corporation: material supplier.

7. Sandansky F&M Company: material supplier.

8. Brown Minneapolis Tank Manufacturers: tank fabricator.

9. RECO industries: tank fabricators.

10. Fisher Controls: valve manufacturer.

11. Joseph Oat Corporation: heat exchanger manufacturer.

12.~TRW Mission Manufacturing Co.: material supplier.

13. Richmond Engineering: tank fabricators.

14. Pacific Pumps: pump manufacturer.

15. Pacific Valve: valve manufacturer.

16. Master Craftsman Inc.: ' heat exchangers suppliers.

17. Pall Trinity Micro. Corporation: cartridge filters supplier.

18. Lamco Industries: tank fabricators.

19. Quaker Ally Casting Co.: castings supplier.

20. Wollaston Alloys: material supplier.

21. McJunkih Corporation: material suppliers.

22. Combustion Engineering: reactor vessel fabricator.

23. Sabine Steel: tank fabricators.

24. GW Energy Product Corp.: tank fabricators.

25. Atlas Industrial manufacturing: heat exchangers manufacturer.

26. Struthers Wells Inc.: heat exchanger manufacturer.

27. PDM - tank fabricators.

The results of the inspection activities involving each of these

areas and contractors are documented as follows:

IV-3

1. Pipe and Pipe Support Fabrication

a. Inspection Scope

(1) Welding Activities

The NRC CAT inspectors reviewed activities relating to fabrica-

tion contracts in the areas of piping system welds, support /.

restraint welds, welding procedures, welder qualifications, NDE

procedures, personnel qualifications, and the review of radio-

graphic film for shop and field fabricated welds. Field

welding involving pipe fabrication was performed by Ebasco. .

Southwest Fabricating and Welding supplied the shop fabricated

piping spools.

The NRC CAT inspected 41 pipe supports / restraints involving

approximately 450 welds to verify conformance of welding to

drawing requirements, and to confirm the visual acceptability

of welds. Thirty-four of the pipe supports had been inspected

by QC inspectors, 4 supports were "in process" and were not yet

inspected by QC, and 3 supports were identified as Class 7

supports which does not require QC inspection except on a

random basis. The "in process" and Class 7 pipe supports were

inspected in order to verify the initial quality of work

performed by craft personnel. See Table IV-1 for a listing of

supports subjected to detailed inspection. Additionally,

another 14 supports / restraints involving 150 welds were-

visually inspected to verify the quality of the completed

welds. See Table IV-2.for a listing of supports inspected. '

The NRC CAT inspectors also inspected the welds on the upper

and lower lateral supports.for two steam generators. The

steam generator supports were fabricated by Teledyne Brown.

Three sets of Bechtel calculations for the design of skewed

welded supports were also reviewed for adequacy.

The NRC CAT inspection of piping welds consisted of visual

inspection during walkdown of piping systems and inspection of

pipe welds located near the supports restraints being inspected.

Approximately 62 piping spools involving 1200 American Society

of Mechanical Engineers (ASME) Class 1,.2 and 3 welds were

inspected. Four of those piping spools were subjected to

detailed inspection which included the review of pertinent QC

documentation while the remaining 58 spools were only visually

inspected. Both field and shop welds were inspected in order

to assure compliance with the requirements of the ASME Cooe.

See Tables IV-3 and IV-4 for listings of piping spools

inspected. In addition, 60 welding filler metal test reports,

27 welder qualification test _ records and 6 welding procedures

were reviewed for' compliance with applicable specifications,

procedures and the ASME Code requirements.

IV-4

. . . .. . . . - - _ . . . . . . .- ~, .- .

'

,

~

'

(2) Nondestructive Examination Activities.

J-

JThe NRC CAT inspection of NDE activities in the pipe fabri-

cation area included the review of 46 shop and 145 field

fabricated welds which involved 1,905' film. The-field welds

were fabricated by Brown and Root (SR) and-Ebasco and the shop

fabricated pipe spools were supplied by Southwest Fabricating

i and Welding. _In addition, 6 NDE procedures and 4 NDE personnel

' qualification records were reviewed in order to verify compli-

~

ance with the governing codes and specifications. Three NDE ,

I technicians were observed while performing in process inspec- '

tions and were evaluated for their ability to follow the .

,

applicable inspection procedures. Twenty pieces _of NDE equip- "

, ' ment were inspected for calibration and one NDE procedure was.

reviewed for adequacy.

1

,

I

. b. Inspection Findings  !

(1) In general, the inspected pipe and pipe supports / restraints

welding activities were found to comply with' governing codes

and specifications. However, discrepancies were identified

l involving undersized welds'in pipe supports / restraints.

Specifically, eight QC accepted skewed welds were found to be.

undersized and two other-skewed welds were located on the acute

side of the joint instead of the obtuse side as required on the' '

drawing. Ten nonskewed welds were also found to be undersized

with~ respect to.the specified acceptance criteria. As a result

~

4

'of these findings-the licensee issued nonconformance reports

and the deficient' welds will be reviewed and evaluated by~

Bechtel.

,

In the area of "in process"-and class 7 pipe supports inspec-

-tions, the NRC CAT inspectors also identified welds which did
not conformed to the specified acceptance criteria. Twelve

"in process" welds were found'to be undersized and two gusset

plates were missing in one of the inspected supports. 10 of

,

the inspected welds in class 7 supports were also found to be  ;

undersized. As a result of this finding Ebasco and HL&P

indicated that they will conduct additional training for both  ;

L craft and inspection personnel.  ;

,

One of the three sets of calculations reviewed for the design l

of supports having skewed joints.did.not have any calculations

for the welds in the skewed connections. The calculations

also did not provide compensation for the loss of weld throat ,

thickness in. skewed welds. '

.

The lack of calculations for skewed joints had been previously-

identified on a number of supports.during a third party design

assessment performed in March and April 1985. The project'has

committed to review the design calculation and such review was

i underway during the time of the NRC CAT inspection.

1

.I

i

IV-5

-

.._. ~ . , . . . _ . . . . . . . . _ _ . . . , _ , _ . - - . _ - . - . _ _ _ . . . . , , . , _ _ , _ . - , _ _ _ . , , _ . , , . -

Undersized reinforcing fillets on groove welds and undersize

fillet welds were found on the upper and lower steam generator

lateral supports. NRC CS-03201 was written against this

finding. Ebasco performed additional inspection consisting of

mapping out the undersized conditions, which were evaluated and

accepted by Bechtel without rework.

During the inspection of pipe welds the NRC cal inspectors

identified undersized socket welds in 2 inch schedule 160 pipe

spools. As a result of this finding the licensee issued NCR

CP-03139. A Standard Deficiency Report (SDR E-349) was issued

to determine the extent of the undersize condition in other

small-bore socket welds, and a Deficiency Evaluation Report

(DER 85-049) was issued to evaluate the reportability of the

condition. Results of the reinspection conducted by Ebasco

QC indicated that the undersized condition is limited to

2 inch Sch.160 socket welds fabricated in the field (not the

site fabrication shop). Of the approximately 200 QC accepted

field welds of this type, at least 15 percent were reported

to be undersize. No undersized socket welds were found in

other pipe schedules and sizes by the_NRC CAT inspectors or

the Ebasco reinspection effort.

The NRC CAT inspectors also visually inspected ~55 socket welds

for proper fitup and gap. In addition, 7 socket welds ~were

radiographed to determine that the required gap exist between

the pipe and the fitting. No discrepancies were identified

during the visual and RT inspections. Two of the-100 inspected

" weld-o-let" pipe branch connections were found to have inade-~

quate weld sizes. NCR HP-3238 and NCR HP-03164 were written to

document this condition.

During the review of Welding Procedure Specifications,_one of

the supporting qualification records for WP-89 was found to

violate ASME Code requirements regarding the size of tensile

specimens which were in effect at the time the qualification

tests were performed. Ebasco Welding Engineering performed a

review of the applicable qualification record against current

code requirements, which had deleted the tensile specimen

restriction, and it was found acceptable.

During review of the Material Test Reports for welding filler

metal, it was observed that the purchasing specifications and

test reports did not specifically address the requirements of

ASME Section III regarding the cooling rate of post weld heat

treatment to be followed during welding of the test coupons.

Bechtel agreed to add the cooling rate requirements to the

purchasing specification, as well as the specific tensile

strength requirements for material tested in the heat treated

condition. Based on review of 60 welding filler metal test

reports, this discrepancy has no consequence on hardware.

IV-6

(2) Nondestructive Examination Activities

In general, the inspected NDE activities were found to comply

with the applicable codes and specifications. No deficiencies

were identified with the inspected shop fabricated pipe welds.

However, during the review of the radiographic film for field

fabricated welds some deficiencies were identified which

involved the following four welds:

  • Weld EW 1202 - FW 0027 was found to have low weld thickness.
  • Weld EW 1205 - FW 14 had a linear. indication adjacent to a

repair area.

  • Weld EW 2205 - FW 0009 had a penetrameter shim extending into

the area of interest; one repair-view indicated that the

complete area repaired had not been covered; and one view

exhibited porosity with a crack extending from_it. NCR

  1. BP-03221 was written to document this deficiency.
  • During the review of circumferential weld C52007 - FWOO6

the adjacent area of the logitudinal weld seam showed a crack

.like indication in the seam. The licensee indicated that the

crack like indication may be caused by microbiological

induced corrosion (MIC) attack which has taken place during

the storage of the pipe. The licensee committed to investi-

gate further the cause and nature of this indication.

It should be noted that weld EW1202 - FW0027 and weld EW1205 -

FW14 identified above have been reviewed during HP&L audit

  1. M11-301 of the radiographic activities prior to the NRC CAT

inspection.

The HP&L audit did not ideritify any deficiencies with those

two welds which indicates that the audits were not effective.

See Section VIII'of this report for additional details

concerning project audits and corrective actio~ns.

c. Conclusion

(1) Welding Activities

In general, the inspected welding activities were found to

comply with the requirements of_the applicable codes and

specifications. However, the NRC CAT found structural welds on

pipe supports / restraints which did not meet the weld specifi-

cations. Skewed connections did not meet drawing requirements

.for size and location and some were not supported by calculations.

In addition, undersized socket welds were found in 2 inch

schedule 160 piping spools.

IV-7

.

_. ..

(2) Nondestructive Examination

In general, the inspected NDE~ activities were found to comply

with the requirements of the governing codes and specifica-

tions. However, the NRC CAT found some welds which had linear

indications and another weld which had low weld thickness. In

addition, the reviewed NDE audits were found to be ineffective.

2. Reactor Internals Modification and Installation

a. Inspection Scope

Approximately 30 tack welds on the bottom mounted Instrumentation

(BMI) locking caps were~ visually inspected. The documentation

packages for the welds on the Core Barrel Assembly and tie plates

for the lower internals were reviewed. The documentation package

for the welds on the Energy Absorber Installation was also reviewed.

In addition, one welding procedure and the qualification test

records for two welders were also reviewed for adequacy. The

modification work was performed by Westinghouse.

b. Inspection Findings and Conclusions

No problems were identified in the area of irispected welding

activities. Activities were found to meet the specified acceptance

criteria.

3. Preservice Inspection (PSI)

a. Inspection Scope

Approximately 30 steam generator tubes requiring preservice and

inservice inspections were witnessed while performing Eddy current

inspections in order to verify compliance with the requirements of

Section XI of the ASME Code. In addition, the qualification test

records for four Eddy current technicians were reviewed and 2

technicians were observed while performing Eddy current inspections.

The NDE procedure and 10 data records, were reviewed for adequacy.

b. Inspection findings and Conclusions

No problems were identified in the inspected preservice inspection

activities. Activities were found to comply with the requirements

of the governing codes and specifications.

4. Electrical Installation and Electrical Supports

a. Inspectior Scope

The NRC CAT inspected approximately 110 welds in the area of

electrical installation. This involved the inspection of welds on 6

cable tray -supports, 2 junction ' box supports, 9 conduit supports

and the installation welds for 3 electrical panels. Two welding

procedures and the qualification test records for five welders were

reviewed. In addition, the personnel qualification test records for

IV-8

_ _ . _ -

___ - . _ _ _ _ _ _ - _ _ _ _

four welding inspectors were also reviewed and two inspectors were

observed and evaluated for their ability to follow the visual I

inspection procedures. The welding activities in the electrical

'

area were performed by EBASCO.

b. Inspection Findings

During the inspection of Electrical supports 1-016-H99 and

1-016-H100 it was established that those supports were QC accepted

-for integrity and tightness of technical connections on September

15, 1984. Since that date, two bolted connections on support H-100

have been changed to welded connections without obtaining the

required Modification / Removal Form prior to installation of the

welded connections. As a result of this finding a Quality Control

. Notification of Procedural. Violation #C-8 was generated and the

connections will be inspected by QC to determine the acceptability

of the welded connections.

c. Conclusions

No major problems were identified in~the area of inspected welding

activities. With the exception of the uncontrolled modification

discrepancies, all inspected activities were found to comply with

the applicable construction codes and specifications.

5. Instrumentation Tubing Installation and Instrumentation Supports

a. Inspection Scope

Approximately 80 welds involving 10 instrumentatic.. supports were

visually inspected to ascertain compliance with_the specified

acceptance criteria. Two welding procedures and qualification test

records for four welders were reviewed. The qualification records

for five NDE inspectors were also reviewed. Two visual welding

inspectors were observed and evaluated for their ability to follow

the applicable inspection procedures. The radiographs for one

instrumentation tubing weld was also reviewed for adequacy. The

welding in the instrumentation area was performed by Ebasco.

b. Inspection Findings

During the review of documentation of instrument stand EWR~#A03134

it was discovered that the stand has been fabricated and installed

without the welds being inspected as required by QC procedure QCP-95

paragraph 5.2.1. As a result of this finding the licensee issued

NCR C503004. The paint was removed from the welded areas and the

welds were inspected as required by the inspection procedures and no

other problems were noted.

During the inspection of supports.for instrument #N2ED-FT-7822A it

was noted that a double type globe strut (G5812A strut) was used

instead of.the required single type globe strut. As a result of

this finding Ebasco generated Deficiency Report (DR) I-0021 and all *

IV-9

double type globe strut (G-5812-A) will be removed. The construc- l

tion personnel was instructed in the correct use of the G-5812-A  ;

strut.

l

C. Conclusions

No major problems were identified in the area of inspected welding

activities. With the exception of the globe strut installation

discrepancies, all inspected activities were found to comply with

the applicable construction codes and specifications.

6. Heating, Ventilating and Air Conditioning

Installation and Supports

a. Inspection Scope

Approximately 120. welds involving 16 supports were inspected for

compliance with the specified acceptance criteria. Two welding

procedures and the qualification test records for five welders were

~

reviewed. In addition, four personnel qualification test records

were also reviewed and two welding inspectors were observed and

evaluated for their ability to follow the visual inspection

procedures. The welds on four duct pieces, two air blowers and two

dampers were also included in this inspection. The welding in the

HVAC area was performed by Ebasco.

b. Inspection Findings and Conclusions

No problems were identified in the area o.f inspected welding activi-

ties. Activities were found to comply with the applicable construc-

tion codes and specifications.

7. Structural Steel Fabrication, Erection and Modification

a. Inspection Scope

Approximately 120 welds comprising 70 field and 50 shop welds

involving 16 structural beams and columns.were visually inspected in

order to ascertain compliance with the specified acceptance

criteria.

Two welding procedures and the qualification test records for five -

welders were revie, sed. Visual inspection procedures and the quali-

fication records for four inspectors were also reviewed. Four

welding inspectors were observed and evaluated for their ability

to follow the visual inspection procedures. The structural steel

field welding was performed by Ebasco. American Bridge Steel-

Company supplied the structural steel to the project.

b. Inspection Findings

No problems were identified in the area of inspected field welding

activities.- However, several original welds involving clip to beam

web connection welds were found to be deficient. Specifically, the

design drawings required fillet welds all around, while the connec-

IV-10

. . . .

r

tion was seal welded on the top and bottom of the clip. As a result

of this finding the licensee issued NCR #HC-03182, HC03183 and

HC-03184. The welded connections were evaluated by Architect

Engineer, accepted "as is" and determined to be adequate for the

intended application.

c. Conclusions

In general, the . inspected welding activities were found to comply

with the governing Code and Specifications. With the exception

of the deficient undersized clip to web welds, which required.

engineering evaluation, the inspected welding activities were

found to comply with the specified requirements.

8. Refueling Cavity and Spent fuel pool Liner Fabrication

a. Inspection Scope

The NRC CAT visually inspected approximately 80 feet of welded seam

on the spent fuel pool and the Reactor Pool Liner. The attachment

welds for four brackets and the welds' on two erriedment plates were

also inspected in order ~to ascertain compliance with the specified

acceptance criteria. One welding procedure was also reviewed for

adequacy. In the area of NDE, the NRC CAT reviewed the NDE docu-

mentation for the required vacuum box testing of the inspected

welds. The Refueling Cavity and spent fuel pool Liner fabrication

was performed by PDM.

b. Inspection and Findings and Conclusion

No problems were identified in the areas of inspected welding and

NDE activities. Activities were found.to comply with the applicable

construction codes and specifications.

9. Containment Liner and Containment Penetration Installation

a. Inspection Scope

The NRC CAT visually inspected approximately 60 feet of liner seam,

the welds on two incert plates, four welded plugs, the welds on one

construction opening, and the attachment welds for two mechanical

and two electrical penetrations. Two welding procedures and the

qualification test records for four welders were also reviewed. In

the area of NDE, the NRC CAT reviewed the radiographs for 41 welded

seams which involved 674 films. One radiographic examination

procedure was also reviewed as a part of this inspection. The

containment liner and penetrations were installed by PDM.

b. Inspection Findings and Conclusions

No problems were identified in the area of inspected welding and

NDE activities. Activities were found to comply with the require-

ments of the governing codes and specifications.

IV-11

-10. LVendors-and Shop Fabricators Other Than Those Previously Addressed

-a. Inspection Scope

.The NRC CAT visually inspected nine vendor supplied tanks and heat

exchangers. See Table IV-5 for inspected vendor supplied equipment.

-In addition to'the welds inspected and listed in Table IV-5, the NRC

CAT inspectors reviewed radiographs related.to work performed by 25

vendors which have supplied various equipment and hardware to the

South Texas Power-Station project. .A total of 2,271 feet'of welded-

sean involving 3,168 radiographs and 20 welds involving 145 film

were. reviewed. The radiographs for 74 valves, pumps and castings

involving 1,170 film, and the radiographs-for 105 spot welds

involving 105 film were also~ reviewed for compliance.with the

-

governingLcodes and specifications.

b. Inspection Findings

-

During the inspection of tanks and heat exchanges supplied by the

vendors-listed in.T%1e IV-5, the NRC CAT found that the size of

the nozzle and manway weld reinforcement did not meet the require--

.ments stated in the' vendor drawings. In addition, the welds on some

of the inspected supports-were also found to be undersized. A total

of seven tanks an~d heat exchangers'were found to deviate from the

required drawing sizes. See Table IV-5 for details. -The NRC has

issued.Information Notice 85-33 on the subject of undersized weld

reinforcement in ASME Code nozzle to shell joints. The project has

not performed any. inspection of tanksLand heat exchangers prior to

-the NRC CAT inspection, indicating the licensee may not have

performed an adequate review of the content.of this notice for

applicability to the South Texas = site.

In the area of NDE the NRC CAT inspectors identified disorganized

reports, . linear indications and yellow film in radiographs and NDE

documentation supplied by vendors. See Table IV-6 for details.

Prior to the NRC CAT inspection the NRC requested that the project

provide a list of. vendors which have supplied radiographs in

conjunction with vendor supplied equipment and hardware. Such a

list was still unavailable at the end of the first two weeks of

the NRC CAT inspection.

At the beginning of the second.two week period, film from several

vendors picked at random was requested. This list included; Guyon

Alloys, Rockwell, Lonergan, Target Rick, Valtek, Yarway, Clow, and

Posi-Seal, among others. A computer search failed to locate any

record of. film for these vendors. Furthermore, there appears to be

no way to readily determine whether film is required or not required

for these purchase orders. If the film is required for any of these

orders, there seems to be no convenient method to determine where

the. film is located, or even if it exists.

A document search for four of the above vendors was conducted using

only one purchase order per vendor and the following results were

obtained: Target Rock-P.O. 4050 included some 8 inch ASME III

IV-12

.

valves which probably would require radiographs. Further search

is~necessary to determine this. Valteck-0.0. 4409 includes many

valves requiring weld end radiographs. A search for these radio-

-

graphs has been started by the applicant. Yarway-P.O. 6455 includes

ASME III Valves which, if cast would require weld end radiographs.

Clow-P.O.6452, as above, if the valves are castings, weld end

radiographs probably would be. required.

Early in the first week of the inspection the NRC CAT requested the

radiographs for three Component Cooling Water (CCW) heat exchangers

fabricated by Struthers Wells. In the third week another request

was made for film based on P.O. No. 4018, FID NO. P0610 and PID N05.

3R201NMX101A, 3S201NMZ101B and 3R201NMX101C. The computer found no

film. Also no information could be obtained as to whether the film

existed or where it could be found. A document search.found that

the film had been reviewed by the vendor, that verification of the

review had been made, but no indication of a request for the film to

be sent to the site was found.

During the last two weeks much effort was expended to come up with

a computer program which would expedite retrieval of information-

concerning the radiography program. A program was developed that

does improve accessibility of information concerning radiographs in

the film storage vault. However, the ability to determine if a

verdor should have performed radiography is still a tedious and time

cons 1 ming task. After a brief scan of the vendor list the

possibility that there could be in excess of 60 vendor purchase

ordera that may require radiography and for which there is no

program for expeditious retrieval of this information.

It should be noted that the Code of Federal Regulation 10 CFR 50

Appendix B, Criterion VII requires that documentary evidence that

the material and equipment conform to the procurement requirements

be available at the site prior to installation or use of the

material and equipment. The documentary evidence is to be retained

at the site and shal1 be sufficient to identify the specific

requirements, such as codes, standards or specifications met by the

purchased material and equipment. Since the NDE requirements are

<

specified by the ASME code, the NRC CAT team believes that the

project should have instituted a program to identify location and

'

existence of NDE film and documentation for the Balance of Plant

vendors and suppliers.

~

The NRC CAT also reviewed NDE documentation and film which was under

the Westinghouse scope of supply and in general the retrievability

and availability of NDE documentation was found to be satisfactory.

It should be noted that the project has instituted a program

requiring Westinghouse to suomit monthly reports concerning status-

and availability of NDE film and documentation. This program was

instituted after missing radiographs were identified for the reactor

vessel head. The NRC CAT inspectors believe that the project

should have instituted the program to cover both, the Westinghouse

i,

suppliers and the balance of plant suppliers so that the existence

and location NDE film and documentation could be promptly

identified.

IV-13

.- _ -- - ._

-

c. Conclusions

In general, the inspected welding and NDE activities'were found to

comply with the requirements for the governing codes and specifi-

cations. However, seven tanks and heat exchangers were found to

deviate from the requirements stated in the applicable drawings and

specifications. In the are of NDE, several radiographs and NDE

documentation supplied by vendors were found to be deficient with

respect to the_ required quality. In addition, difficulties were

encountered in retrievability, availability and location of NDE film

and documentation for the balance of plant suppliers which indicated

that the licensee had performed inadequate corrective action after

the discovery of missing radiographs for the reactor vessel head in

May 1985.

The difficulties encountered in retrievability, availability and

location of NDE film and documentation pertaining to the Balance

of Plant Scope of supplied equipment, indicates a need for a formal

program to identify requirements, location and existence of NDE

film and documentation.

IV-14

- --

_

.

TABLE IV-1

LIST OF SUPPORTS WHICH WERE INSPECTED AGAINST DRAWING REQUIREMENTS

SA-1756-HF5025 (1) CC-1318-HL5002 'CC-1403-HL5001

FW-10160-HL5001- .CC-1402-RR3002 FW-1018HL5001 (4)

CC-1401-HL-5003 CS1001-RR0029 (2) .CC-1106-HL5016

CV-1209-RR002 (5) FP-1560-GUO412 CV-1046-GU1001 (6)

CC-1106-HL5015 RH-1201-RR0004 CC-1504-RR0013

CC-1412-HL5001 FC1016-HL5001 EW-1285-HL5001

'BA-1003-HF5005 CH-1203-HL5017 CS-1001-RR0012 (2)

'EW-1383-HL5006 CS-1001-HL5007 CV-1088-RR0019

CC-1474-GU01. CV-1047-RR1004 (7) CC-1317-HL5006 (3)

EW-1383-HL5007. CC-1480-RR0011.(8) SI-1201-HL5015 (11)

.SI-1301-HL5010 (9) CC-1103-HL5003 SI-1201-HL5009 (10)

CC-1210-SS01 (12) 'CC-1101-HL5001 (13)'CC-1209-HL5004

- RH-1205-HL5002 (14)- CC-1210-HL5001 CC-13-3-HL5003 (15)

SIl05-RR0038 (16) CV-1046-RR1002

(1)7 of 14 fillet welds undersized. Class 7 item. Item still

'"in process".

-

(2) Two undersized skewed fillet welds and two undersized

fillet welds. Item still "in process".

(3) Fillet' weld from spring can to base plate undersized. NCR-CS-3215.

(4) 'Two fillets un'dersized.

~

NCR-CS-03205. Item still "in process".

(5) Seven fillet welds undersized. NCR-CS-03198.

(6) One' undersized fillet. Class 7. Engineering accepted "as-is"

during' audit.

(7) Two fillet welds undersized. Class;7. NCR-CP-03147.

(8) Three of four skewed fillet welds undersized. NCR-CS-03200.

(9) One skewed fillet welds undersized. NCR-CS-03199.

(10) Two skewed welds specified as groove welds were actually seal

welds. NCR-CS-00840.

(11) Four skewed fillet welds undersized, two gusset plates missing.

Item still "in process".

(12)~W8X31 section bent through the web. NCR-CS-03197.

'(13) Two undersized fil.lets. Item still "in process".

(14) Two welds located on the accute side of a skewed joint instead

of'the obtuse side as specified on the drawing.- NCR-CS-03169.

(15) One skewed fillet weld undersized on throat. Two fillet welds

undersized. NCR-CS-03201.

.(16) One skewed fillet weld undersized. NCR-CS-00875.

IV-15

}

=

-TABLE IV-2

SUPPORTS WHICH WERE VISUALLY INSPECTED

DW-1501-HF5005 DW-1501-HF5006 DW-1501-HF5004

SI-2205-HL5020 CC-2317-RR0012 CC-2115-RR0006-

' CC-2115-RR0005 CV-2088-HL-5006 CV-2086-HL5010-

CC-2209-RH0009 CC-2209-RH008 CC-2109-RR0009

CC-2109-RR0008 CV-1214-HL5002

4

IV-16  ;

. _ . - . _ __ _ ,

. ._ . . .. . .._ _ . _ _ . . __

TABLE IV-3

LIST OF PIPING'WHICH WAS VISUALLY INSPECTED

'

ITEM DESCRIPTION. PIPE' SIZE (IN.) MATERIAL

,

'

CC-2116. ' Component Cooling '10 Carbon Steel

CC-2114 Component Cooling '10 Carbon Steel

CC-2117L Component Cooling 14 Carbon Steel

CC-2317 Component Cooling 10- Carbon Steel

CC-2115 Component Cooling 10 Carbon Steel

.BA-2001 Breathing Air. 2 Stainless Steel

CV-2086 ' Chemical / Volume Control 4- Stainless Steel

CV-2088 Chemical / Volume Control 4 Stainless Steel

CV-2006' Chemical / Volume Control 4 Stainless Steel  ;

CV-2092 Chemical / Volume Control 4 Stainless Steel  !

-CC-2109 Component. Cooling 12, 24 Carbon Steel

-CC-2209 -Component Cooling 30 Carbon Steel

CC-2410 _ Component Cooling 12 Carbon Steel

CC-2110 Component Cooling 24 Carbon Steel

CC-2109 Component Cooling 20 Carbon Steel

EW-2202. Essential Service Water 30 Aluminum Bronze

CV-1111 Chemical / Volume Control 2 Stainless Steel

.CV-1112 Chemical / Volume Control 2 Stainless Steel

CV-1209 Chemical / Volume Control 2 Stainless Steel

.CV-1106 Chemical / Volume Control 2 -Stainless Steel

CV-1205 Chemical / Volume Control 2 Stainless Steel-

.CC-1515 Component Cooling 2 Carbon Steel

CC-1479 Component Cooling 2 Carbon Steel

CC-1401: Component Cooling 3 Carbon Steel

CC-1402 Component Cooling 3 Carbon Steel:

CC-1403- -Component Cooling 3 Carbon Steel

SA-1756 Station Air l' Carbon Steel

FP-1506 Fire Protection 4 Carbon Steel.

'

CC-1106 Component Cooling 16- Carbon Steel

FC-1016 _ Fuel Pool Cooling 10 Stainless Steel

~CC-1504 Component Cooling 6 Carbon Steel

CS-1002 Containment Spray 8 Stainless Steel

.CC-1417 Component Cooling 14 Carbon Steel. '

FW-1016 Feedwater 18 Carbon Steel

FW-1018 Feedwater 18 Carbon Steel

RH-1201 Residual Heat Removal 12 Stainless Steel

CC-1474 Component Cooling 6 Carbon Steel

CC-1318 ' Component Cooling 14 Carbon Steel

'

CS-1001 Containment Spray 8 Stainless Steel

EW-1285 Essential Service Water 30 Aluminum Bronze

EW-1383 Essential Service Water 30, 10 Aluminum Bronze

CV-1088 Chemical / Volume Control 4 Stainless Steel

CV-1047 Chemical / Volume Control 4 Stainless Steel.

CC-1480 Component Cooling 8 Carbon Steel

CC-1103 Component Cooling 16 Carbon _ Steel

~CC-1201 Component Cooling 24 Carbon Steel

SI-1201 ' Safety Injection 12, 16 Stainless Steel

.SI-1301 Safety Injection 12 Stainless Steel

.CC-1412 Component Cooling 4 Carbon Steel

i

IV-17

-

__

l

. . ._ . _ _ . _ . _ ._ . _ . . --

TABLE IV-3 .(Continued)

LIST OF PIPING WHICH WAS VISUALLY INSPECTED

ITEM- DESCRIPTION PIPE SIZE (IN.-) MATERIAL

CC-1209' Component Cooling 20 Carbon Steel

' CC-1309 Component Cooling 20 Carbon Steel

4

CC-1203- Component. Cooling 20 Carbon Steel

CC-1209. Component Cooling 20 Carbon Steel

CC-1527 Component Cooling 12 Carbon Steel

CH-1029; Chilled Water 12 Carbon Steel

CH-1053- Chilled Water 12 Carbon Steel

CC-1425 Component Cooling 4 Carbon Steel'

- RH-1102 Residual Heat Removal 12 Stainless Steel

.

I

. -

?

1

IV-18

. -. . _ _ - _ . _ __ _ - _ . , , ,

TABLE IV-4

PORTIONS OF' PIPING SYSTEMS VISUALLY EXAMINED AND

FOR WHICH DOCUMENTATION WAS REVIEWED

ITEM DESCRIPTION PIPE SIZE (IN.) MATERIAL

MS-1004 -Main Steam 30 Carbon Steel

FW-1014- Feedwater. 18 Carbon Steel

FW-1012 Feedwater. 18 Carbon Steel

SI-1201 Safety Injection 16 Stainless Steel

i.

1

IV-19

-

TABLE IV-5

TANKS PRESSURE VESSELS AND HEAT EXCHANGERS

WHICH WERE VISUALLY INSPECTED

ITEM MANUFACTURER NOTES

Accumulator. Tank SIATAT-02 Southwest Fabricating and Welding (1)

CCW Surge Tank 3R201NTS101A Brown-Minneapolis Tank (2)

CCW Heat Exchanger 3R201NHX101A Struthers-Wells, Inc (3)

RHR Exchanger 2R161NHX101B Jcseph Oat Corporation (4)

Dimineralizer' Tank 3R171NDM102A Westinghouse Pensacola

Spray Additive Tank.TGXSIATSA-03 RECO Industries, Inc. (5)

DFO. Storage Tank 3Q15MTF0337TK21 Brown-Minneapolis Tank (6)

Volume Control Tank'TGXCSATVC-01 RECO Industries, Inc. (7)

Fuel Pool Cooling HXTXSFAHSF-02 Atlas' Industrial Manufacturing

-(1) Bolting ring fillet welds intermittently undersized on one leg.

NCR HM-03081

(2) Reinforcing fillet weld at various nozzles, manway neck to flange fillet

weld and support fillet welds undersized.- NCR HM-03075.

(3) Fillet weld from nozzle reinforcing pad to shell undersized. One reinforcing

fillet weld at a 1" nozzle to shell weld undersized. NCR HNO3074.

(4) Reinforcing fillet at three nozzle to shell welds intermittently undersized.

NCR HN-03029.

(5) -Arc strike on vessel shell. NCR HM-03088.

(6) Shell access hole re'inforcing fillet at nozzle to shell and fillet at

flange face undersized. Manway to shell reinforcing fillet undersized.

Roof vent nozzle to roof reinforcing fillet weld undersized. One fillet

weld undersized. NCR~HM-03094.

(7) Manway nozzle fabricated as a nozzle with reinforcing pad instead of

integrally reinforced butt welding fitting as required by drawing.

Stiffening ring to vessel shell fillet welds undersized. .NCR HM-03095.

IV-20

TABLE IV-6

VENDOR RADIOGRAPHS-REVIEWED

Castings

Valve. Spot Feet of

Contractor Welds Pumps Welds Welds Film Notes

G&W Energy 4 8

-Products

TRW Mission 2 8 (1)

Manufacturing

Anchor Darling 56 775

Pacific Valve 1 4

Quaker Alloy. 6 42

Teledyne~ Brown 8 8

Pall: Trinity 8 72

Sandusky.Fo6ndry 39 169

Master Craftsman- 16 16

Lanco 46 46

Joseph Oat 114 114

Richmond Engineering 206 206 (2)

Brown Minneapolis 508 508 (3)

Westinghouse 1041 1436 (4)

PDM 100 '200

Southwest Fabricating 149. 260 (5)

Copes-Vulcan 4 98

Esco 1 88

Reco Industries 8 65

Pacific Pumps 8 67

-Wollaston Alloys- 1 22

McJunkin Corp. 18 18

IV-21

. TABLE IV-6 --(Continued)

VENDOR RADIOGRAPHS REVIEWED

Castings .

.

._ . Valve Spot Feet of

Contractor' _ Welds Pumps' _Welds. Welds Film Notes

Combustion Eng. 80' 182

Fisher Controls 3 133

Sabine Steel- 43 43 (6)

NOTES:

(1) Reader sheet was not found in the. package. The sheets were later found and

film was reviewed and no further problems were identified.

(2) Yellow film was found in the film packages for the Volume Control tank and

Lthe Pressure Relief Tank. The licensee issued SDR #-192 to cover this

deficiency.

~(3)' Microbiological Induced attack was found to have occurred during the storage

-

'

-

period of the tanks. However, '.he-licensee has rework all BMT supplied tank

-and the final condition of the tanks is considered acceptable.

_( 4) Linear-indications found in the backing ring welds in the demineralizer tank

serial #37740. Yellow film was found in a.16 inch surge line, however the

line was deleted by a design change. NCR #AN-03028 and AN-0329.

(5) Cylinder P4131, weld W-K-H-69 showed no evidence of retakes although the

reader sheet indicates some were shot. Cylinder _4133, weld W-K showed a

linear indication 3/4 of an inch long at interval no. 2. This appears on

the films for intervals 1-2 and 2-3.

.(6) Problem areas included questionable film,. disorganized reports, some pages

were unreadable due to light copy, it was therefore unable to coordinate

film-with data sheets. Also some repair _ film for rejects seemed to be

unavailable. After some time HL&P determined that the light data sheets were

apparently duplicates of other readable data' sheets. Also it was determined

that the apparently missing film areas-were covered by film shot by Ebasco

after.they had. repaired the questionable areas. The film was reviewed and

- no further problems were identified.

IV-22

-

V. -CIVIL AND STRUCTURAL CONSTRUCTION

A. Objective

The objective of-the appraisal of civil and structural construction

was to determine by evaluation and review of Quality Control (QC)

accepted work and documentation whether civil and structural construc-

tion areas were completed in accordance with regulatory requirements,

Safety Analysis Report commitments, and project specifications,

drawings and procedures.

B. Discussion

The specific areas of civil and structural construction evaluated

included: reinforced concrete construction including mechanical

splices, and concrete pour packages; structural steel installation

including high strength bolting for structural steel friction and

sliding connections; backfill and earthwork construction; the concrete

expansion anchor bolts; and the containment post tensioned system.

This evaluation included hardware and selected documentation.

This portion of the NRC CAT inspection of concrete expansion anchors

was limited to the review of the qualification test report. The

inspection of installed concrete expansion anchors was performed by

NRC CAT electrical and mechanical groups (see Sections II and III).

Parts of the above hardware inspection included verification of

hardware to a sample of design change documents. The documents

reviewed are listed in Section VII, Table 7C.

1. Reinforced Concrete Construction

a. . Inspection Scope

Reinforced concrete construction ~ areas inspected by the NRC

Construction Appraisal Team (CAT) included reinforcing steel

configuration, activities for two concrete placements, in-process

mechanical splicing, Quality Control (QC) documentation for -

mechanical splices and concrete placement, and general concrete

surface quality.

The reinforcing steel for three concrete placements were inspected

for proper bar diameter, spacing and length. Embedded plates and

anchor bolts which were part of the concrete placements were

inspected for proper size and spacing.

Activities for two concrete placements were observed by the NRC

CAT. Activities observed were batch plant mixing operations,

concrete placement, tests for slump, air content and unit weight,

length of time required. for concrete placement from truck mixers,

and preparation of concrete cylinder test specimens. For one of

V-1

. _ . . _ _ _ _ _ _ _ . _ _ _ _ _ _ . . _ .__

,

k

the two concrete placements, the general surface quality after

the forswork had been removed was_ inspected. In process mechanical

i splicing activities were observed by the NRC CAT. QC documentation

~

and appropriate field procedures were reviewed for. concrete

placements and mechanical.' splices completed by Ebasco Constructors.

A review of the licensee's Phase A statusing of_QC documentation

_

for concrete placements and mechanical splices was performed. The

purpose of the licensee's Phase A statusing was to determine the -l

status of construction and QC documentation of work performed by '

Brown and. Root at the time when engineering and construction

services were turned over to Bechtel Engineering and Ebasco ,

i Constructors. In addition, the qualification records for four

cadwelders were reviewed. ~

$' Concrete placement. records reviewed included concrete pour

pre placement checklist, in process concrete pour placement

'c checklist, concrete pour curing and post placement checklist,

and concrete compressive strength test. report. The reviews

checked the forms for' adequate completion by the QC inspectors,

existence of senior QC inspectors' signature for evaluation of

completed forms when necessary, and acceptable coverage of various

, inspection attributes.

'Cadweld QC documentation reviewed by the NRC CAT included the 5

j cadwelder test record report, the tension test report of cadweld

rebar splices, the cadwelder qualification report, and the cadweld

(visual) inspection report. This review also verified whether or

i not the forms had been adequately completed by the QC inspectors,

.' had been signed off by a senior QC inspector, and had acceptable- *

] coverage of various inspection attributes.

, By a general walkdown, the surface' quality of completed concrete

work was observed by the NRC CAT. -

1

The requirements and acceptance criteria for reinforced concrete

construction were obtained from the drawings listed in Table

i V-1 and the following specifications and procedures:

i

  • Bechtel Construction Specification 2A010CS1004, Rev. 2, "Spect-

. fication for Mechanical Splicing of Reinforcing Bars,"

January 18, 1985

  • Bechtel Construction Specification 2A010CS1009, Rev. 4, "Speci ,

fication for Forming,.P13cing, Finishing, and Curing of Concrete,"

.

,

-

< March 28, 1985

4

  • Ebasco CSP-4, Rev. 5, " Concrete Placement," June 28, 1985
  • Ebasco QCP-10.1, Rev. 5, "Cadweld Inspection," September 20,

,

1985

i

i * Ebasco QCP-10.2, Rev. 5, "Preplacement Concrete Inspection,"

August 14, 1985

i

[ V-2

!

- - - - - . - . - . - - - . - , - . . - - - . - . - - - -

.- . - - -.- - -.- . . - -

,

4

  • Ebasco QCP-10.3, Rev. 5, " Concrete Placement Inspection,"

August 12,-1985

b. Inspection Findings

<

The inspection of installed reinforcing steel for the two

concrete placements found no hardware deficiencies.

Activities observed for the two concrete placements as well as

in process mechanical splicing of reinforcing steel were found

to be adequate.

The licensee's Phase A statusing for concrete pour packages and

grouting packages reviewed a list of documents for 100 percent .

of the activities. This list was. developed from the requirements.

in Brown and Root Procedure CCP-25. A concrete document checklist

~

, had been prepared by the licensee for Phase A statusing of concrete

pour packages to-identify existing and missing (if any) QC documen-

tation. The NRC CAT sampled one concrete pour package including

six sets of associated QC documentation to verify if the contents

in the concrete pour package matched those indicated on the

concrete document checklist. No concerns were identified.

The licensee's Phase A statusing for mechanical splice QC docu-

mentation reviewed the documentation of cadwelds made by Brown and

>

Root. Two forms, a cadwelder qualification and testing report

and a cadweld walkdcwn and documentation checklist, were prepared

<

by the. licensee for Phase A statusing to identify existing and

. any missing records related to mechanical splices. The NRC CAT

reviewed the Phase A statusing work by sampling one cadwelder and

one cadweld.' One concern was identified with the cadwelder

., qualification and testing report for cadwelder No. 43. The space

. box for the "two in ea. subsequent 100" column of the " horizontal-

requalification" row had been marked "S" for satisfactory.

However, it should have been marked "U" for unsatisfactory. The ,

NRC CAT was informed that cadwelder No. 43 was the only Brown and

. Root cadwelder requalified. Based on the information that no other

cadwelder was requalified and that the error was only with the

tensile testing frequency implemented after cadwelder No. 43 was

'

e requalified, the NRC CAT feels the error to be an isolated one.

Nonconformance Report (NCR) No. GC03199 was issued to address the

concern. Also, the dates listed in the " Dates Qualified To" spaces

for the " vertical qualification" and " horizontal qualification"

parts of the cadwelder qualification summary were found to be

E reversed. The licensee subsequently documented this concern.

The NRC CAT found no concern with the cadweld sample checked

against the contents of the cadweld walkdown and documentation

checklist.

During a general walkdown, the NRC CAT identified a crack in the ,.

Unit 2 azimuth 304* tendon access wall at elevation (-)13 ft. 3

inches. This area was subsequently chipped out. It was then

identified that the 3 inch seismic joint material had not been

installed as required by drawing 3M01-9-C-4230R0 between the l

Reactor Containment Building mat and the tendon access wall.

V-3

._ u - ,_ , - - - . - - . - . _ . - - - - - - - - . . - - . . . - - -

-

"Y

~Bechtel Engineering (BEC) issued NCR HCO3170.and state'd that-the

~

disposition-of. this' NCR would be to use as is. The stated basis of

- ;the disposition was that all settlements had taken place, the

bearing surface area was small, and the -vertical seismic movements

would be small at this location.

The NRC CAT's review of this issue found that BEC's disposition did

not adequately address the seismic movement of the mat and the

'previously predicted unfavorable relative heaves of the two

adjoining buildings once the dewatering system is discontinued.

Whether predicted unfavorable soil heave between the Reactor

Containment Building and the Mechanical and Electrical Auxiliary

Building could. create added unacceptable forces on the tendon

access wall r.eeds to be addressed.

, c. Conclusion

-

In general, reinforced concrete construction appeared to be

adequate. The review work performed for Phase A statusing on the

Brown and Root concrete pour and mechanical splicing QC documenta-

tion appear ~ed to be thorough. The documentation concerns with the

mechanical splice QC records did not appear to affect the hardware.

Under certain conditions the omission of the seismic joint between

adjacent concrete structures could cause significant structural

damage.

2. Structural Steel Inspection

. a. Inspection Scope

Installed and QC accepted structural steel members and connections

were-inspected by the NRC CAT. Attributes ' inspected were member

size, configuration, and bolted connections. For bolted connec-

tions, both friction and sliding connections were tested by using a

,. calibrated torque wrench to detemine whether the bolts had proper

L pretension. In addition, the bolts were inspected for proper

. material and nut engagement on the bolt.

The 1, ample used in the structural steel verification for correct

? member size and configuration is described in Table V-2. A total

of 93 structural steel members and 39. connections were inspected.

The location, bolt size and material type, and number of ~ friction

and sliding type connections which were checked for proper pre-

tension are shown in Tables V-3 and.V-4 respectively. These

bolts were sampled from structural steel connections although both

samples are separate from those nentioned above as inspected for

configuration. Test torque v0 ns were obtained by using a

Skidmore Whilhelm tension testm to establish the proper torque-

tension relationship.

The requirements and acceptance criteria for structural steel

installation are included in the drawings listed in Table V-5

and in the following specifications and procedures:

.

V-4

_ _ _ ___ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

-_

. _ _

  • Bechtsi Construction Specification 3A010SS0012, Rev. 3,

F " Category I Structural Steel," December 4, 1984

~

  • Bechtel Construction Specification 3A010SS0030, Rev. 5,

" Erection of Structural Steel and Miscellaneous Steel,"

July 26, 1985

  • Ebasco CSP-10, Rev. 6, " Erection and Boltup of Structural-

Steel," September 19,'1985

  • Ebasco QCP-10.5, Rev. 5, " Inspection of Structural Steel

Erection and Bolting," July 19, 1985

b. Inspection Findings

Of the-93 structural steel members and 39 connections inspected

for correct member size and configuration, only one hardware

configuration deficiency was identified. This deficiency involved

~

.one column base connection being installed without nuts on one of

its anchor bolts. Deficiency Notice 2-510-C was issued to repair

the condition.

A total of 648 7/8 inch diameter A325 high strength bolts were

checked _ for proper installed torque for structural steel friction

type _ connections.-- The installed torque values of twenty-three

(approximately 4 percent) of the 648 7/8 inch diameter A325 bolts

were significantly below the inspection torque of 450 ft-lbs. . Four

of the 23 were found to be installed loose. NCRs CC03132 and

CC03134 were written to repair the improperly installed bolts. All

twenty-three bolts were to be properly tightened. The remaining

625 bolts were determined to be acceptable.

Thirty-two 7/8 inch diameter A490 high strength bolts were checked

for proper installed torque. The sampled bolts were installed

above the inspection torque value of 550 ft-lbs and determined to

be acceptable.

'

For the sliding type structural steel connections, a total of.

68>7/8 inch diameter A325 high strength bolts were inspected for

proper installation torque. Forty-three of the 68 A325 bolts were

installed at torque values greater than the inspection torque

value of 150 ft-lbs. Twenty-five of the 43 'over-tightened bolts

were installed at torque values greater than 500 ft-lbs. NCR-

CC03190 was written to document and disposition the deficiency.

All of the sampled ' sliding connections had inspection markirgs

indicating that they had been inspected. The inspection criteria

for sliding connections states that the bolts be installed snug

tight. : Snug tight is defined as the full force of a man on a

~

spud wrench. Based.on such a vague inspection criteria, neither

the NRC. CAT'nor the licensee was able to. determine how these _

connections could have been inspected. The NRC CAT finding

indicates that more specific inspection criteria is necessary to

V-5

- _ _ - _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ -- A

..

inspect the sliding connections adequately. The licensee has

committed to write adequate inspection criteria in the current

specifications and to reinspect all sliding. connections.

It was found that project specifications allow welding across the

flanges on fully loaded structural steel members. The NRC CAT

asked if an engineering evaluation had been performed (similar to

that indicated in AWS D.1.1, Section 7.5.1) to determine, due to

extent of cross-section heating, whether or not a member is permit-

ted to carry a live-load stress while welding on it. No specific

analytical evaluation of whether the welding across the flange

could weaken the affected structural steel member was provided to

the NRC CAT. BEC ju'stified the specifications based on general

engineering judgement and historical knowledge. This engineering

response, without the supporting evaluation, is considered

inadequate.

c. Conclusion

In general,-utructural steel members and connections for size and

configuration verification were .found to be installed properly.

The high strength A325 and A490 bolts for friction type structural

steel connections were generally determined to be installed

adequately. The lack of adequate inspection cri_teria for sliding

connections resulted in the acceptance of a deficient installation.

All sliding connections should meet the new inspection criteria

when established by the licensee.

An evaluation should be conducted. showing that the practice of

cross flange welding has not and will not overstress loaded

members.

3. Backfill and Earthwork Construction

a. Inspection Scope

The daily reports and backfill compaction records'for the

Essential Cooling Water (ECW) pipe trench backfill were

reviewed. The backfill compaction work activities and in situ

sand cone tests in area II40, northeast of the Unit 1 Diesel

Generator Building, were witnessed by the NRC CAT.

The requirements and acceptance criteria are contained in the

following specifications:

  • Bechtel Construction Specification SY069YS0043, Rev. 12,

" Structural Excavation and Backfill".

  • Bechtel Construction Specification 2Y060YS0044, Rev. 5, " Field

and Laboratory Testing of Earthwork Construction".

V-6

. __ ._ . . -_. . _ . __ _ _ _ . .__ .._ __ - . _

d

t

Inspection Findings

{ b.

The daily. reports and backfill compaction records appeared _to

3 be complete'and in accordance with the project specifications.

J The backfill work activities observed by the NRC CAT northeast

'

of the Unit'l Diesel Generator Building at elevation +26.0 was

L properly placed and compacted.

2

F -The NRC CAT inspectors-identified a potential problem which may

, not.have been addressed by the licensee. The ECW pipe trench is

i

. supported on a highly plastic A 2 clay layer. This clay layer

will shrink when dried and expand as the clay particles absorb

'

_

-

water. Since 1975 the. site dewatering system has been in operation

and the ground water level has fallen below the A2 clay layer. -+

,

During this dewatering period the clay layer could have lost

'

i

significant moisture. The site dewatering system is scheduled to

be discontinued prior to plant operation. When this occurs, the. s

<

ground water level will be re-established to about-its pre-1975

level. If,the moisture. content of the clay layer during the

1 dewatering period has been reduced significantly and then the

, dewatering system is discontinued, the clay layer when exposed to

, the returned ground water is expected to expand. The issue _of

whether this clay layer will expand and whether.the expansion will

-

occur uniformily_ appears not to have been properly considered to

date. This along with other data on the thickness of the clay

,

, layer, the placticity index of the clay, the confining pressure and

, 'the quantity of water absorbed by'the clay particles, and the in

situ moisture content of several points at various levels in the

'

' clay layer during the dewatering period will also need to be

,

considered. The concern is whether the expansion of the underlying ,

- and adjacent clay could cause differential-displacements of the ECW  ;

pipes. Also, whether.this potential.for ground movement could

'

cause the ECW pipes to become overstressed. The licensee was not

able to provide information on such.a review during the NRC

inspection.

c. Conclusions

1

The structural backfill compaction records and the structural

backfill reviewed by the NRC CAT inspectors were generally _found

'

-

l to be acceptable.

The licensee should investigate the potential of the expansive

. clays to swell upon return of ground water to normal levels and

the potential affect of this swelling on the ECW piping.

4

4. Concrete Expansion Anchor Bolt Qualification Test Report

,

a. Inspection Scope "

i-

'

The qualification test report for the wedge type concrete expansion

anchors was reviewed for technical adequacy, conformance to

.

project specifications and demonstration of satisfactory anchor

performance.

L

i

-

V-7

,

  • &

'

,-w ey,=. < , ,,w,,,,- - .

,.,,e y,,,,_,w,y .-.r_.my, .-, ,--,.g ..

.,,my, ,

<

The following qualification test report was reviewed:

  • Wiss, Janey, Elster and Associates, Rev. 2, " Tension, Shear and

Relaxation Testing of Expansion Anchors at the South Texas

Project, Bay: City Texas", May 29, 1981

The requirements and acceptance criteria are contained in the

following documents:

  • Bechtel Construction Specification 5A010SS1000, Rev. 7,

" Installation of Expansion Anchors, Rock Bolts, Grouted

Anchor Bolts, and Core Drilling"

Ebasco CSP-41, Rev. 6, " Installation of Expansion Type Anchors"

  • Ebasco QCP 10.19, Rev. 7, " Inspection of Anchoring Devices

Installed Within Concrete Structures"

b. Inspection Findings

The allowable loads used in the design of concrete expansion bolts

(CEAs) was based on the average results of the tests divided by

a factor of safety of 4. For the 1/4 inch diameter CEAs with

1-1/8 inch embedment the average maximum load for 4070 psi concrete

is 890 lbs. The allowable tensile load is 250 lbs. This allowable

load does not meet the factor of safety of 4 criteria specified in

Inspection and Enforcement Bulletin 79-02.

For the 1-1/4 inch diameter CEAs, the anchor slip at the design

tension loads is greater than 1/16 inch for 8-1/2 inch embedment

and 3/16 inch for 10-1/2 inch embedment. The shear tests show

similar results. The licensee has stated that the 3/16 inch

movement at the design loads was unacceptable and that the

allowable loads will be reduced. The licensee stated that for

the 1/16 inch slip, the current design load is acceptable.

The-NRC CAT finds the licensee's response for the 1/16 inch slip

at the current design loads to be inadequate. The results in the

test program for anchor bolts are for one time loading. However,

reliance solely on the referenced test program without considering,

in actuality, that within the plant the maximum design load may

be applied more than one time, is considered inadequate. Since

most of the slip is likely to be permanent, these deflections will

tend to accumulate with each load application. Also, the 1/16 inch

deflection in shear and tension may be considered unacceptable in

many piping analysis.

c. Conclusion

The licensee should reevaluate the~ allowable design loads used for

concrete expansion anchors. This reevaluation should take into

account the magnitude of anchor slip at the design load and

consider the shear, tension, deflections, and the piping systems

that are supported.

V-8

1

_-

5. Containment Post-Tensioned System

a. Inspection Scope

The installation records of 8 Unit 1 prestressed tendons were

reviewed. The NRC CAT also observed.various stages of tendon

installation work activities which include the pulling, button-

heading, stressing, and greasing of the tendons.

The requirements and acceptance criteria were included in the

following specification and procedures.

  • Bechtel Construction Specification 2C239CS0003, Rev. 4,

" Containment Post Tensioning System," July 15, 1985

  • FIM-STP-01, Rev. O, " Procedure for Cleaning and Checking-

Post Tensioning Embedded Items," August 8,1984

  • FIM-STP-H-1, Rev. 1A, " Installation, Buttonheading, Stressing

and Greasing of Horizontal Tendson," August 29, 1985

  • FIM-STP-V-1, Rev. 3A, " Installation, Buttonheading, Stressing

and Greasing of Vertical Tendons," August 29, 1985

  • FIM-VCP-01, Rev. 2, " Tendon Void Clearing Procedure," May 22,

1985

FQCP-STP-03, Rev. 3, " Quality. Control Procedures - Vertical

and Horizontal Tendons," July 9, 1985

  • STP-FTP-1, Rev. 4, " Friction Test Procedures," August 13, 1985

b. Inspection Findings

. ,

The review of installation records and the observation of various

stages of tendon installation work activities indicated that the

post-tensioned system was being installed in accordance with

the specifications and procedures.

c. Conclusions

The installation of the containment post tensioned system was found

to be in accordance with applicable instructions and specifications.

V-9

_

.- . . - - ~. .. . _ - _ _ -

b

_

TABLE V-1

DRAWINGS USED FOR REINFOR'C D CONCRETE CONSTRUCTION INSPECTION

[DrawingNo. Rev. Title

t

193AB- -B (Shop Drawing)

t 193BC C. (Shop Drawing)

] 193C A (Shop Drawing)

-2C22-9-S-1012 1 Steel Reactor Containment Building Dome Liner - Plans -

-and Sections and Details

,

2C22-9-C-1033 5 -Concrete-Reactor Containment Building Dome Reinforce- '

,

'

ment.- Plan

2C22-9-C-1034 2 Concrete Reactor Containment Building Dome Shell"-

i Sections and Details

2C22-9-C-1036 0 Concrete Reactor Containment Building Dome Tendon - i

Anchorage Location

j J2C23-9-C-1021 1 Concrete Reactor Containment Building Post Tensioning

System

'

3A01-0-C-0001 20 -Concrete Structural St'andards General Notes

3A01-0-C-0011 14 Concrete Structural Standards General Notes-

3M01-2-C-4026 9. Concrete Mechanical & Electrical Auxiliary Building

, Floor Plan 9 E1. 41'..-0"

i

3M01-9-C-4241 2 Concrete Mechanical & Electrical Auxiliary-Building =

Std.: Wall Reinf._ Details E1. 29'-0" to Roof (U.N.0.)

p'

3M01-9-C-4242 1 Concrete Mechanical and Electrical Auxiliary Building

Miscellaneous Details .i

j 3M01-9-C-4309 3 ' Concrete Mechanical and Electrical Auxiliary Building i

d

Miscellaneous Sections-and Details

-

3M05-9-C-4009 5 Concrete Mechanical and Electrical Auxiliary Building

j. Foundation Plan 9 El. 10'-0"

i

J

Y'.

.

,

J

V-10

.-. - -. -

. . - . . . - _ _ - . . .. a .-. - . - - . . . . . . - . - ...-.;-. . . - - - -.

- - . - . . .. . - . . _ . - -. .. .

-

.

j

. TABLE V-2

INSTALLED STRUCTURAL-STEEL INSPECTION SAMPLE

i. i

Unit ~ Number Approximate Truss

. and Building- Elevation Comments

Beans Braces Columns Connection @ @ers

.

Unit 1- 68 ft 14 -

2 3 -

'

Reactor .

'

- Containment 52 ft 5 .1 - - -

,

37 ft 2 - --

.- -

-2 ft 2 -

1 3 -

Unit 11 118 ft 5 - -

8 11 Sample Taken

Fuel Handling-. From Roof

Trusses and

Framing -'

Unit-1 69 ft ~5- - -

5 3

, Mechanical'& and

Electrical 6 inches

t . Auxiliary

.

74 ft 3 -

3 3 -

_ _ _ _ _

Total 36 1 6 22 14

'

,

1

t

L

4

e

$-

t

,

k

r

V-11

,

4

,. , ..

-

~,__,.._.,,-_,-w,,,,,,,_ , _ . . _ _ . . _ , . , - . , ,,_,,_.r, _._,,_m.,. _ . . ~ . , . . , . . , . , . . , . . _ , . _ , , ..,,.%

. - . - - - - . _ . . .. . . - - - . .-

1

-TABLE V-2 (Continued)

,

INSTALLED STRUCTURAL STEEL INSPECTION SAMPLE

~

Unit Number- Approximate

and Building Elevation Beams Columns Connections Comments

Unit 2 .

10 ft - -

1 Deficiency Notice

. Mechanical & 2-510-C was issued

Electrical to repair the

Auxiliary anchor bolts of

column base

connections.

20 ft 5 2 6

35 ft 3 2 3

.

58 ft 8 3 5

Unit 2 52 ft 5 -

1

Reactor

Containment 68 ft 8 -

1

_ _ _

-

Total 29 7 17

.

.t

i

I

4

v

'

V-12

- - . .. . .. - . _ . . - - - - -

. . _ . - - - _ - _ . - . - - . - _ _ . - . .

. .

,

I

TABLE V-3

HIGH STRENGTH BOLTING FOR FRICTION CONNECTION INSPECTION SAMPLE

Number of Number of

Number of Bolts Checked Bolts Installed

Unit Number- Bolt Size Friction for Proper Below Inspection

!

-and Building and Type- Connections * Installation-Torque

-

Torque Comments

Unit 1 7/8 inch .15 144 5 See note 1

Reactor dia. A325

Containment

Unit 1 7/8 8- 77 8

Mechanical & dia. A325

Electrical

Auxiliary

Unit 2 7/8 inch 12 172 0

Reactor dia. A325

Containment

Unit 2 7/8 inch 20 255 13

Mechanical & dia. A325'

. Electrical

Auxil'iary

Unit 2 7/8 inch 1 32 0 See note 2

Reactor dia. A490

Containment

Note 1: The inspection torque value for 7/8 inch dia. A325 bolts was 450 ft. lbs.

Note 2: The inspection torque value for 7/8 inch dia. A490 bolts was 550 ft. lbs.

  • The connections sampled are separate from the structural steel connections

inspected in Table V-2.

V-13

-

TABLE V-4

HIGH STRENGTH BOLTING FOR SLIDING CONNECTION

INSPECTION SAMPLE

Number of Bolts

Number of Bolts Installed Above

_ Number of Checked for Inspection Torque

Unit Number Sliding Proper Installation and the Installed

and Building Connections * Torque Torque Range Comments

Unit 1 1 10 67 10 installed between All bolts were

R; actor

160 and 200 ft-lbs 7/8 inch dia.

A325. Approxi-

5 installed between 'mately 63% were

200 and 250 ft-lbs found to be

installed

28 installed above overtorqued.

300 ft-lbs

"The connections sampled are separate from the connections inspected in Table

Table V-2 and V-3.

V-14

, :. :

TABLE V-5

DRAWINGS USED FOR STRUCTURAL STEEL INSTALLATION INSPECTION

American Bridge Detail Drawings

Order No. Sheet No. Revision No.

K-7023 E12 8

610AD .A-

~6100 -

'K-7024 E2 C

E5 F

E18 G

E20 E

E22- G

E301- E

E302 G

123 B

176 C

506 A

526 -

,

K-7025 E4 D

E12 H

E702 A

718 -

K-7029 E17 C

E22 C

405 -

413 -

,

508 B

516 C

K-7030 'El -

E2 -

E6 B

E7 A

E9 0

102 A

106 A

V-15

TABLE V-5 (Continued)

DRAWINGS USED FOR STRUCTURAL STEEL INSTALLATION INSPECTION

Bechtel Design Drawings

Drawing No. Rev. Title

1C01-9-S-1532 4 Reactor Containment Building Steam Generator,

R.C. Pump Vertical and Pressurizer Lateral Support

IC01-9-S-150 5 Reactor Containment Building Internal-Steel Framing

Plan @ E1. 68-0"

3A01-05-0001 12 Steel Structures Standards General Notes

3C01-9-S-1502 8 Reactor Containment Building Internal - Steel Framing i

Plan 9 El. (-)2'-0"

3C01-9-5-1505 4. Reactor Containment Building Internal - Steel Framing

Plan @ El. 37'-3"

3C01-9-S-1508 5 Reactor Containment Building Internal - Steel Framing

Plan 9 El. 52'-0'

3C01-9-S-1509 4 Reactor Containment Building Internal - Steel Framing

Plan @ El. 68'-0"

3C01-9-S-1510 5 Reactor Containment Building Internal - Steel Framing

Plan 9 El. 68'-0"

3C01-9-S-1511 1 Reactor Containment Building Coluc.n Schedule and Details

3C01-9-S-1528 8 Reactor Containment Building Internal Sections and Details

3C01-9-S-1539 2 Reactor Containment Building Internal - Miscellaneous

Plan Sections and Details

3C01-9-S-1619 6 Reactor Containment Building Internal - Steel Alterations

@ El. (-)2'-0"

3C01-9-S-1621 5 Reactor Containment Building Internal - Steel Alterations

0 E1. 37'-3"

3C01-9-S-1622 3 Reactor Containment Building Internal - Steel Alterations

O El. 52'-0"

3C01-9-S-1623 3 Reactor Containment Building Internal - Steel Alterations

9 E1. 68'-0"

3C01-9-S-1624 6 Reactor Containment Building Internal - Steel Alterations

Details and Tables

3C01-9-S-1625 2 Reactor Containment Building Internal - Steel Alterations

Details and Tables

3C01-9-S-1629 6 Reactor Containment Interal - Steel Alterations

Details and Tables

3F01-9-S-3003 3 Fuel Handling Building Roof Framing Plan (Plan - Roof

Truss 9 Top Chord and Roof Truss MK-TI)

3M01-9-S-4043 3 Mechanical and Electrical Auxiliary Building Framing

in HVAC Areas El. 69'-6" U.N.

3M01-9-S-4060 4 Mechanical and Electrical Auxiliary Building Framing

Plan @ Els. 21'-0" and 23'-0"

V-16

,

TABLE V-5 (Continued)

DRAWINGS USED FOR STRUCTURAL STEEL INSTALLATION INSPECTION

Bechtel Design Drawings

Drawing No. Rev. Title

'3M01-9-S-4065 4 Mechanical ~and Electrical Auxiliary Building Framing

Plan 9 El. 35'-0"

3M01-9-S-4071 1 Mechanical and Electrical Auxiliary Building Framing

Plan 9 El. 60'-0"

3M01-9-S-4082 4 Mechanical and Electrical Auxiliary Building Framing

Plan 9 El. 72'-0", 74'-0" and 76'-0"

3M01-9-S-4090 4 Mechanical and Electrical Auxiliary Building Coluns

Schedule and Standard Details

-

4

i

W

V-17

,_. - .. ,_ -_ - . , _ _ _ . _ -. -_- - _ .

VI. MATERIAL TRACEABILITY AND CONTROL

A. Objective

This part of the inspection effort was to verify that the identifi-

cation and marking of materials and equipment used in the fabrication

and construction processes have been maintained, and that the docu-

mentation required to support traceability, to both the. design

drawings / specifications and to the material sources, was retrievable

and met regulatory requirements, PSAR commitments, and applicable

codes and standards.

B. Discussion

A total of 219 items were selected at random and identified as samples

for the inspection. The items inspected were located in the storage

yards, laydown areas, storage warehouses, outlying buildings, and

various elevations and rooms in the reactor containment, auxiliary

building, diesel building, and fuel handling building for both Unit

1 and Unit 2. Some items inspected were in storage and others

were being installed. Some had been installed and were in a storage

mode, and others had been installed and turned over to the operations

group.

Tables VI-1 through VI-8 indicate the areas where material / equipment

samples were selected, and adequacy of the identification, trace-

ability and documentation. The applicable reference documents

reviewed and used during the inspection included the following:

Site Final Safety Analysis Report.

  • Specification 4A010GS1009, Safety Related Non-ASME Bolting

Materials, Rev. 1.

  • Specification 5A010GS1007, Civil / Structural Construction

Materials, Rev. 3.

  • Specification 3E189ES1000, Conduct and Tray Supports, Rev. 6.
  • Procedure SSP-13, Material Control, Rev. O.
  • Procedure ASP-5, Material Control, Rev. 8.
  • Procedure WPP/QCI-12.4, Material Identi*ication and Marking

Requirements, Rev. 10.

  • Procedure QCP-9.4, Verification of Weld Filler Material

Control, Rev. 3.

  • Procedure WPP/QCI-18.0, EE580 Cable and Raceway Tracking

Procedure, Rev. 12..

  • Procedure QCP-10.22, Receipt Inspection, Rev. 12.
  • Engineer and Constructor ASME Procedure.

VI-1

' * American Society for Testing Materials standards.

Equipment and components were inspected in order to verify that

required identification codes were maintained on items such as civil

construction materials, electrical cable and equipment, welding

supplies, vendor supplied equipment assemblies, structural and

mechanical items.

1. Material Traceability

a. Inspection Scope

Two hundred nineteen samples were examined to determine if the

identification and markings were traceable to the applicable

specification, drawing, purchase. order, code data package, mill

test report or a combination thereof. The licensee's records

management group. retrieved the requested documentation which was

analyzed and compared to site requirements and field notes by the

NRC CAT inspector.

b. Inspection Findings

During the inspection it was determined that a program for

. identification of materials and retrievability and adequacy of

documentation was generally in place and functioning.

(1) The following were found to be satisfactory:

(a) The records management group uses a computer assisted

program for retrieval of most documents that are

considered complete. In process records are processed

manually or by using sub programs (i.e., electrical

EE580 program for. routing, terminations, cable type,

etc.)

(b) Eighteen samples of different types of welding

consumables as noted'in Table VI-1 were examined for

markings, retrievability of documentation and adequacy

of the documentation.

(c) Fourteen samples of different types and sizes of

electrical cables were inspected for identification,

documentation and qualification requirements. These

results were satisfactory as shown in Table VI-2.

(d) Civil / Construction materials were inspected for

compliance to the specification requirements. Thirty-

one items were sampled and were found to meet the

specification requirements as shown in Table VI-3.

(e) Anchor bolts and embedded items were not a part of the

traceability program due to the fact that a major

program in this area was previously undertaken by the

licensee and is awaiting review by the NRC. The NRC CAT

inspector reviewed the structural bolting for an

VI-2

=

{

Accumulator and Residual Heat Removal Heat Exchanger and

noted that both were included in the licensee's report.

(f) Table VI-4 summarizes materials and equipment that was

inspected and is used in the Heating, Ventilating and

Air Conditioning (HVAC) discipline including fans,

motors and dampers. Tracability was.found to be

satisfactory.

(2) Significant' weaknesses in the program were found in the

following areas:

(a) The action taken for the disposition of FCR BE-00088 on

the clarification of bolting material requirements for

cable tray.and conduit supports was not effective in

that it allowed the option of not .aposing the manufac-

tures marking requirements of the specified national

bolting standard without appropriate consideration of

the measures needed to maintain the traceability and

control of unmarked fasteners throughout the plant.

(b) Verification of markings / traceability of bolting

materials used in the fabrication of large vendor

supplied skid mounted equipment and used by the

construction crafts in the fabrication and installation

of electrical equipment.

(3) The following' observations were made by the NRC CAT inspector

and found to be unsatisfactory:

(a) Code data packages for the' Unit 1 Radwaste Holdup' Tank

7R32IXTS101A and Reactor Internals Disconnecting Device

Pressure Housing, Board #18288 could not be_ located. As

a result of the NRC CAT finding, the licensee issued

Nonconformance Report BN-03015 to document the

deficiency of Board #18288 and provide for appropriate

corrective action. No written corrective action was

noted during the NRC CAT inspection concerning the'

Radwaste Holdup Tank.

The code data package for an ASME 8-inch check valve was

incomplete and a corrected copy of the certificate of

welding was generated. As a result of the NRC' CAT

finding, the licensee issued a Document Deficiency

Notice QC-RN-150.1. The material type'as indicated on a

code data report for an ASME 8 inch Safety Injection

Check Valve Bonnet (valve #V1423) was different than

that indicated on the mill test report. As a result of

the NRC CAT finding, the licensee initiated NCR BN-03013

to document this discrepancy for corrective action.

These and other ASME code data packages inspected are

indicated in Table VI-5.

VI-3

(b) Some documents that were requested to confirm bolting

traceability of certain selected equipment samples

summarized in Table VI-6 were not located and furnished

for review by the NRC CAT inspector prior to the end of

the inspection. Licensee representatives stated that

actions would be. continued to locate applicable

documentation and review bolting traceability.

(c) It was found by the NRC CAT inspectors that the specific

requirement of the national standard ASTM A307 Grade B

for marking of fasteners has been deleted by engineering

from a specification for electrical raceway supports,

~

L

without requiring adequate on-site material control

during their installation (Reference FCR BE-00088 and

Specification 3E189ES1000 for conduit and tray supports).

The deletion of marking / identification requirements for

electrical equipment bolting has resulted in the

uncontrolled distribution of bulk quantities of these

items throughout the plant. This condition may have

resulted in the indiscriminate use of the unmarked

fasteners in other types of equipment installations

because the bolting is readily available and presumed to

be adequate.

Based on the above observations, the NRC inspector could

not ascertain the appropriate use and traceability of

the unmarked fasteners for the various electrical

installations of the NRC CAT sample, and thus the

quality of the fasteners is considered indeterminate.

(d) The bolting in 10 of 11 samples of electrical equipment

was not found to be traceable when inspected for

conformance to specifications or seismic reports.

~

Bolting used in fabrication and/or installation of the

ten samples were not marked or had mixed markings. The

results are tabulated in Table VI-7.

(e) Two sections of 2 inch schedule 160 stainless piping in

storage were found to be mismarked. As a result of the

NRC CAT finding,.QCI report G1649 was issued by the

licensee to scrap the pieces.

(f) Mechanical material and equipment was inspected to the

specification requirements. Regarding bolting, several

items were found to be of the correct type, identified

and traceable. However, traceability deficiencies were

found in 14 of 20 samples of bolting for large mechani-

cal installations listed in Table VI-8. The following

are five examples of such deficiencies:

VI-4

  • Mounting bolts for the Essential-Coo. ling Water Wash

Screen (3R281NPA102A) Motor were unmarked. These are-

required to be ASTM A193-87. As a result of the NRC

CAT finding, the utility has issued NCR AM-03072

documenting the discrepancy for corrective action.

  1. 13 were identified as~ ASTM A193-B7 and were required'

to be ASTM A307. The licensee, during the NRC CAT

inspection, did not issue documentation to record this

-discrepancy for corrective action.

Injection and Low Head Safety Injection Pumps, motors

and transition pieces Nos lA, 2A, 3A, IB, 2B, 3B and

IC, 2C, 3C were observed to be either unmarked, A307,

A325 or A449. The correct bolting for these units is

~ ASTM A193-B7. As a result'of the NRC CAT finding, the

licensee issued NCR'CM-03078 to document this

discrepancy for corrective action.

bolting to the base was not identified or marked.

This material is required to be SA193-B7. As a result

of the NRC CAT finding, NCR BM-03076 was issued to '

document this item for' corrective action.

  • Bolting on the Essential Cooling Water Strainer Flange

.(3R281NSP101A) by drawing was required to be cadmium

plated. The specification allowed for cadmium or zinc

plating, and the sample appeared to be zinc plated.

As a result of the NRC CAT finding, the licensee

issued Field Change Request BP-00891 to change the

drawings to include zinc ~ plating.

c. Conclusions

In general, the material traceability and control program was

considered to be satisfactory. However, lack of traceability was

found for fastener materials for certain large sendor supplied

4

mechanical / electrical equipment assemblies mounted on skids and

for certain electrical equipment and cable tray / conduit supports.

Also, documentation to permit verification of traceability of

fasteners for certain equipment was not located by the licensee

,' during the inspection.

VI-5

i

L

TABLE VI-1-

WELDING CONSUMABLES

.. ITEM LOCATION COMPLIANCE

3/32 E7018 Test Shop Satisfactory

.093 E6010 Test Shop Satisfactory

'3/32 E7018 Test Shop Satisfactory

1/8 E6010 RCB II Satisfactory

1/8 308L-16 RCB II Satisfactory

3/32 308-16 RCB II Satisfactory

1/8 316-16 RCB I Satisfactory

.045 ERNICR-3 RCB I Satisfactory

1/8 E12018-M RCB I Satisfactory

5/32-308-16 RECO Satisfactory

5/32 308-16 RECO Satisfactory

3/16 309-16 RECO ' Satisfactory

3/32 E7018 DG Caddy Satisfactory

3/32 E7018 MEAB Caddy Satisfactory

5/32 E7018 MEAB I Caddy Satisfactory

5/32 E7018 MEAB I Room Satisfactory

.035 wire MEAB I Room Satisfactory

1/8 308-16 MEAB I Room Satisfactory

VI-6

._ - .. _ _ _ _ .

'

TABLE VI-2

ELECTRICAL CABLE

ITEM LOCATION COMPLIANCE

3/c #12

'

Reel yard Satisfactory

7/c #12 . Reel yard Satisfactory

3/c #12 ECW Structure Satisfactory

'2/c #16 Unit I laydown Satisfactory

-

1/c 500MCM Unit I laydown

~

Satisfactory

3/c #8 Unit I laydown Satisfactory

5/c #12 Unit I RCB El 68 Satisfactory

9/c #12 Unit I RCB El 50 Satisfactory

3/c #8 Unit I RCB El 24 Satisfactory

3/c #10 Unit I FHB El 73' Satisfactory

i 2/c #12 Unit I MEAB El 65 Satisfactory

3/c #12 Unit I MEAB Satisfactory

5/c #12 Unit I MEAB El 35 Satisfactory-

7/c #12 Unit I MEAB El 10 Satisfactory

i

1

1

,

VI-7

- _ _ _ , . . . . . . _ . . . _ _ _ - _ . . _ . - . _ _ . . _ , _ - _ . _ _ _.

TABLE VI-3

CIVIL / CONSTRUCTION MATERIALS

Item Identifier Location Compliance

  1. 9 Rebar T5-6275 Laydown Satisfactory
  1. 10 Rebar S-16741 Laydown Satisfactory
  1. 11 Rebar S-25074 Laydown Satisfactory

Cadweld Powder N-7178 Storage warehouse Satisfactory

Cadweld Powder D-24409 Storage warehouse Satisfactory

Cadweld Sleeve S-2068 Storage warehouse Satisfactory

Cadweld Sleeve S-1901 Storage warehouse Satisfactory

W.R. Admixture B-12120-09W Batch plant Satisfactory

A.R. Admixture B-11293-09V Batch plant Satisfactory

Cement Grind #13 Batch plant Satisfactory

Paint 111488 Paint warehouse Satisfactory

Paint Cure 108220B Paint warehouse Satisfactory

Paint Mix 112389 Paint warehouse Satisfactory

Paint Powder 112260 Paint warehouse Satisfactory

Cadweld Sleeve S-1798 Unit II RCB springline Satisfactory

Cadweld Sleeve S-2082 Unit II RCB springline Satisfactory

Structural Seam J72499 Unit II El 72 RCB Satisfactory

Wall Embed 70479 Unit II El 45 RCB Satisfactory

Structural Nuts 2H Unit II stairwell RCB Satisfactory

Steel Column K7029 . Unit II RCB Satisfactory

Floor Embed 2907 Unit'II El 35 control Room Satisfactory

Threaded Rod NA Unit II MEAB El 10 Satisfactory

Nuts DH Unit II MEAB El 10 Satisfactory

Stainless Plate -13721 Condensate Tank Unit I Satisfactory

C.S. Plate 401C7601 Condensate Tank Unit I Satisfactory

3" Shim 680015 Unit I FHB roof Satisfactory

Wall Embed 52028 Unit I RCB El 60 Satisfactory

Liner Plate 2425 Unit 1 RCB El 57 Satisfactory

Anchor Bolts NA Unit I RCB El 2 Satisfactory

Anchor Bolts NA Unit I RCB El 32 Satisfactory

Floor Plate 3E1846 Unit 1 RCB Refuel Pool Satisfactory

i

a

VI-8

__ - -

F 1

TABLE VI-4

HEATING, VENTILATING AND AIR CONDITIONING

Item Identifier Location Compliance

Joy Fan 3V112VFN003 Warehouse C Satisfactory

Bolts TB- Unit II MEAB El 60 Satisfactory

Bolts STB. Unit II MEAB El 60 Satisfactory

Hanger. 2-6-0052-S056-RSI-28075 Unit II MEAB El 35 Satisfactory

Damper 8V141VDA-043 Unit I RCB El 5 Satisfactory

Ventilation Fan 8V141VFN-023 Unit I RCB El 6 . Satisfactory

Cooling Coil 8V141VHX-004 Unit I RCB El 6 Satisfactory

Fire Damper 1-3-0073-VD-101 Unit I.FHB El 47 Satisfactory

VI-9

._

-

_ l

3 ,

. ,

[ TABLE VI-5'

ASME CODE DATA PACKAGES REVIEWED

Item Location' Compliance

8". Check Valve: Warehouse D -Unsatisfactory-

16" Gate' Valve  : Warehouse D Satirfactory

-

Instrument- Valve - -Unit II RCB Satisfactory

Component Support - Unit II RCB Satisfactory-

12" Pipe and Flange Unit II FHB- Satisfactory

Spent Fuel Pool Heat Exchanger Unit II FHB- Satisfactory

10" Gate Valve. Unit II FHB Satisfactory

Ball Valve Unit II MEAB El 10" Satisfactory

6" Bronze Pipe ECW Building Satisfactory

24" Bronze Pipe

-

ECW Building Satisfactory-

2" Pipe and Elbow -

Unit I FHB Satisfactory

8" Containment Spray Ring Pipe Unit I FHB Satisfactory
2" Globe Valve Unit I FHB Satisfactory

Reactor' Internal Disconnect Device Housing Unit I RCB Not Retrievable

'30" Main Steam Pipe Unit I RC8 El 65 Satisfactory

~30" Main. Steam Pipe Unit I RCB El 35 Satisfactory

Pipe'Pentration Unit I RCB Satisfactory

-

RHR Heat Exchanger Unit I RC8 Rm 306 . Satisfactory _

Flexible Instrument Line- Unit I RC8 El'35' Satisfactory

-24". Gate. Valve ~ Unit I RCB El 24 Satisfactory

31" Crossunder Pipe- Unit I RCB El 2 Satisfactory

8" Safety Injection Check Valve Unit I RC8 El 6 Unsatisfactory

Pressure Sensor Unit I RCB E1 32 Satisfactory

2": Solenoid Valve . ' Unit I DG8 El 32' ~ Satisfactory

Spent Fuel Pool Heat Exchanger Unit I FH6 El 4 Satisfactory

Spent Fuel Cooling' Pump Unit 1 FHB El 35 Satisfactory

14" Fabricated Pipe Unit I FH8 El 17 Satisfactory

3" Plug Valve . Unit I MEAB El 74 Satisfactory

Component Cooling Water Surge Tank Unit I MEA 8 El 65 Satisfactory

Recycle Evaporator Condensate Tank Unit I MEA 8 El 56 Satisfactory

Waste Evaporator Condensate Tank Unit I HEA8 El 56 Satisfactory

FTD Filter Unit I MEAB El 65 Satisfactory

2" Valvc Unit I MEAB El 65 Satisfactory-

Radwaste Holdup Tank Unit I MEAB El 57- Not Retrievable

Chemical & Volume Control Tank Unit.I MEA 8 El 46 Satisfactory

Component Cooling Heat Exchanger Unit I MEA 8 El 29 Satisfactory

Seal Water Heat Exchanger Unit I MCAB El 10 Satisfactory

VI-10

t -

TABLE VI-6

TRACEABILITY DOCUMENTATION FOR BOLTING NOT FURNISHED

Item Location Compliance

Chilled Water Pumps Unit II MEAB El 10 Not Retrieved

Centrifugal Charging Pump Unit II MEAB El 10 Not Retrieved

Fire Pumps Fire Pump house Not Retrieved

Reactor Internals Disconnect Device * Unit I RCB .Not Retrieved

Feedwater Booster Pump Motor Unit I TGB Not Retrieved

Feedwater Booster Pump Unit I TGB Not Retrieved

Steam Generator Feed Pump Unit I TGB Not Retrieved

Diesel Generator Unit I DGB Not Retrieved

Spent Fuel Pool Skimmer Unit I FHB El 27 Not Retrieved

Load Center E1C-1 Unit I MEAB El 65 Not Retrieved

Chemical and Volume Control Monitor Unit I MEAB El 35 Not Retrieved

Relay Cabinets Unit I MEAB El 35 Not Retrieved

Pressurizer Heater Controller Unit I MEAB El 35 Not Retrieved

'2" Carbon Steel Pipe Spoo1* Unit I MEAB El 46 Not Retrieved

Radwaste Holdup Tank * Unit I MEAB El 57 Not Retrieved

Load Center Transformers Unit I MEAB El 10 Not Retrieved

Liquid Waste Pumps Unit I MEAB El 10 Not Retrieved

Essential Cooling Water Pump Unit I MEAB El 10 Not Retrieved

"Except for those items indicated by an asterisk, the NRC CAT inspector requested

documentation to determine bolting requirements. Since documentation was not

provided, traceability was not verified.

VI-11

TABLE VI-7

.

ELECTRICAL EQUIPMENT BOLTING

!

Item Location- Compliance

Relay' Rack Cabinets Unit I MEA 8 El 35 Unsatisfactory

Computer Unit I MEAB El 35 Satisfactory

'

Pressurizer Heater-Controller Unit I MEAB El 35 Unsatisfactory

Load Center Transformers Unit I MEAB El 10 Unsatisfactory

Battery Racks Unit I MEAB El 10 Unsatisf actory

Battery Racks Unit I MEAB El 35 Unsatisfactory

Battery Racks Unit I MEAB El 65 Unsatisfactory

C&VC Control Board Monitor Unit I MEAB El 35 Unsatisfactory

Bi-Stable Status Control Board Monitor Unit I MEAB El 35 Unsatisfactory

Load Center Transformers Unit I MEAB El 65 Unsatisfactory

Diesel Generator. Control Panels Unit I DGB El 35 Unsatisfactory

l

!

i

< VI-12

l

l

k.

=-

,

TABLE VI-8

MECHANICAL BOLTING

Item Location Compliance

Chilled Water Pump Unit II MEAB El 10 Unsatisfactory

Centrifugal Charging Pump Unit II MEAB El 10 Satisfactory

Charging Pump Gearbox Unit II MEAB El 10 Unsatisfactory

Positive Displacement Charging Pump Unit II MEAB El 10 Satisfactory

Recycle Evaporator Feed Pump Unit II MEAB El 10 Satisfactory

ECW Wash Screen Pump ECW Building Satisfactory

ECW Wash Screen Motor ECW Building Unsatisfactory

FCW Motor ECW Building Satisfactory

Fire Pumps. Fire Pump House Unsatisfactory

RHR Pump Support Unit 1 RCB El 3 Satisfactory

Feedwater Booster Pump Unit 1 TBG Unsatisfactory

Steam Generator Feed Pump Unit 1 TGB Unsatisfactory

Auxiliary Feedwater Pump Unit I Valve Cubicle 1 ' Satisfactory

Auxiliary Feedwater Motor Unit I Valve Cubicle 1 Unsatisfactory

Diesel Air Compressor Unit I DGB Unsatisfactory

Fire Protection Actuators Unit I Deluge House #12 Unsatisfactory

Spent Fuel Cooling Pump Unit I FHB El 35 Satisfactory

HHSI, LHSI & Containment Spray Pumps (9) Unit I FHB El 15 Unsatisfactory

HHSI, LHSI & Containment Spray Motors (9) Unit.I FHB El 15 Unsatisfactory

Spent Fuel Pool Skimmer Unit I FHB El 27 Unsatisfactory

Liquid Waste Pump Unit I MEAB El 10 Unsatisfactory

ECW Turbine Driver Unit I Valve Cubicle 4 Unsatisfactory

VI-13

VII. DESIGN CHANGE CONTROL

'

A. Objective

The primary objective of the appraisal of design change control was to

determine whether design change activities were conducted in compliance

with regulatory requirements, Safety Analysis Report commitments and

approved licensee, engineer, constructor and vendor procedures. An

additional objective was to determine that the changes.to structures

and hardware prescribed in a sample of design change documents were

accurately completed.

B. Discussion

10 CFR 50 Appendix B, Criterion III " Design Control" and Criterion VI

" Document Control" establish the overall regulatory requirements for

design change control. These requirements are elaborated in Regulatory

Guide (RG) 1.64 Rev. 2, June 1976, " Quality Assurance Requirements for

the Design of Nuclear Power Plants," which endorses American National

Standards Institute (ANSI) Standard N45.2.11-1974 " Quality Assurance

Requirements for the Design of Nuclear Power Plants." The licensee's

commitments to comply with RG 1.64 is stated in Chapter 17 of the South

Texas Project (STP) Final Safety Analysis Report (FSAR).

The areas of design change control evaluated by the NRC Construction

Appraisal Team (CAT) inspectors were control of changes to design

documents and control of design changes. In each of these areas,

interviews were conducted with persor.nel responsible for the control of

activities, procedures were reviewed, and a sample of the controlled

documents was reviewed. In addition, a sample of the completed

structures and hardware which had been inspected and accepted by on-

site contractor quality control (QC) personnel was inspected by the NRC

CAT inspectors. These evaluations were performed on an interdiscipline

basis.

1. Control of Design Documents

The specific aspects of the control of design documents inspected

were the availability to the users of the latest approved design

documents and design change documents, and the methods of assuring

that approved changes not yet incorporated into design documents

are provided to the users prior to work being performed,

a. Inspection Scope

(1) The following general quality assurance (QA) program manuals

and procedures primarily related to distribution and control

of design documents and design change documents were reviewed

to establish the acceptance criteria for this portion of the

inspection:

'

Houston Lighting and Power Company (HL&P) Project Quality

Assurance Plan for South Texas Project, Rev. 7, dated

August 7, 1985.

VII-1

]

Bechtel South Texas Project Quality Program Manual, Rev. 3,

dated July 15, 1985.

Ebasco Nuclear Quality Assurance Program Manual ETR-1001

for South Texas Project, Rev. 12, dated July 26, 1985.

South Texas Project Procedure No. RMSP 1.02, " General

Operating Description-RMS," Rev. 3, dated August 1, 1985.

South Texas Project Procedure No. RMSP 2.03, " Design

Drawing and Drawing Change Notice Control," Rev. 3,

dated June 14, 1984.

South Texas Project Procedure No. RMSP 2.05, " Specifications,

Specification Change Notices and Procurement Document Control,"

Rev. 4, s ted March 14, 1984.

South Texas Project Procedure No. RMSP 3.16, " Quality

Records," Rev. 6, dated May 20, 1985. '

Bechtel Procedure No. WPP 3.0, " Field Control of Design

' Documents," Rev. 17, dated November 13, 1985.

Bechtel . Procedure No. WPP 3.2, " Field Supplier Document

Control," Rev. 3, dated March 29, 1983.

Bechtel Procedure No. WPP-QCI 6.0, " Control, Review and

Processing of Quality Records," Rev. 9, dated March 25, 1985.

! Bechtel Engineering Department Procedure (EDP) No. 4.46,

" Project Drawings," Rev. 8 STP, dated March 6, 1985.

Bechtel EDP 4.49, " Project Specifications," Rev. 6 STP,

dated January 23, 1985.

l Ebasco Quality Assurance Instruction (QAI) No. 019,

l " Review, Processing and Turnover of Quality Records,"

Rev. 2, dated March 25, 1985.

'

Ebasco Quality Control' Procedure (QCP) No. 6.2, " Document

Control," Rev.1, dated January 21, 1985.

t

Ebasco QCP No. 17.1, " Quality Assurance Records," Rev. 3,

dated March 8, 1985.

Ebasco Procedure No. ASP-6, " Document Control," Rev. 7,

dated May 17, 1985.

(2) Bechtel, Ebssco and HL&P QA audit and surveillance reports

concerning det.ign document control were reviewed for findings,

trends and corrective actions.

VII-2

_ _ - _ _ _ _ _ _ _ _ _ _ _ _ _ - _ _ _ _ _ _ _ _ _

. . . -- -.- _- - . - . - - . -_ - -..- - . - . - -

1

4

' (3) Bechtel, Ebasco and HL&P document control, engineering,

1 construction and QA personnel were interviewed concerning

design document and design change document distribution and

control.

i..

b. -Inspection Findings

i

(1) Design documents and design change documents are issued by  :

Bechtel; issue at the site is through the Bechtel Field  !

Document Control Center (FDCC) to various satellite document

stations in accordance with a distribution matrix. The

satellite stations are also controlled by Bechtel. A.compu-

i

terized Field Revision List (FRL) is the data base which gives i

the current design document revision and lists the unincor- f

i

'

porated design changes; a " historical" version of the FRL' ,

showing each revision of design documents and the change

'

documents written against each revision is also available.

The unincorporated design changes are posted on the design

documents in the reference stations to relieve the users of

i the need to review the FRL.

. i

(2) The NRC CAT inspectors reviewed against the latest FRL a series

of procedures, specifications and drawings at the Bechtel FDCC,

at Bechtel Reference Station A02 (located in the Unit 1 con-

struction office, Building 10), and at Bechtel Reference

Station B49 (located in the Unit 2 construction office,

Building 16). Tables VII-1A through IE summarize the NRC ,

CAT findings for this review, which was performed to check  :

that documents were being distributed, posted and otherwise

~

controlled in accordance with Bechtel Procedure WPP 3.0,

" Field Control of Design Documents, and other applicable

requirements.

The team reviewed eleven Bechtel and Ebasco procedures and

five Bechtel specifications against the latest FRL at Reference

- Station A02. Four of the sixteen documents had deficiencies

(i.e. , did not accurately reflect all approved changes) as

recorded in Table VII-1A.

<

Fifteen Bechtel large and small bore piping' isometric drawings '

'

.

were reviewed at Reference Station A02. The active change

documents listed in the field revision log for these drawings

were posted on the drawings with minor exception, and only a

few superseded change documents were found posted on the

drawings (Table VII-1B).

.

4 A total of 49'Bechtel electrical drawings.were reviewed

. against the latest FRL at Reference Stations A02 and B49

i (Tables VII-1C-D). Four of the nineteen drawings reviewed at

Reference Station B49 exhibited an unacceptably high rate of '

discrepancies (Bechtel drawings 3E359E58020, -029, -191 and

,

-317, Table VII-10). The NRC CAT inspectors are particularly

concerned about the active change documents not posted on the

drawings, since this information is lost to the users. These

drawings were all cable tray support detail " cookbook"

'

<

VII-3

L

4

+ --m,,,m+-----e-. ,-e, , , - - , , m-,r- * -.-- - ~ + -.m., ,--y , + - - ew -

F

drawings. The cable tray support " cookbook" drawings posted

in the reference stations are maintained by reference station

personnel for reference use only. However, FDCC maintains the

master copies of these drawings, and issues bound sets of these

detail drawings at five-day intervals to check-out-stations

where their issuance for use by the construction craft is

also controlled.

In order to determine if incorrect information was being issued

to the construction crafts, the team reviewed 21 electrical

drawings at the Bechtel FDCC against the latest field revision

log, including 11'of the detail drawings reviewed at Reference

Station B49. The team found these drawings to be properly

controlled (Table VII-1E).

(3) The NRC CAT reviewed a sample of ten pipe support detail

drawings for large and small bore safety class pipe. The

latest issue of each pipe support drawing was checked to

confirm that any change documents issued against the previous

revision to the drawing had been properly incorporated. No

discrepancies were observed.

(4) A Bechtel in-house study entitled " Overview of the Design

Change Control Program" was prepared at the request of the

NRC CAT inspectors and issued on November 11, 1985. This study

describes the scope and trends of change documents issued for

the South Texas Project, as well as compliance with respect to

the number and time constraints detailed in existing site

procedures; i.e., documents must be revised every "x" months or

when "y" unincorporated design changes are outstanding.

Attachment C, sheet 2 of the study indicates, for example, that

a total of 25,320 Drawing Change Notices, 27,120 Field Change

Requests, and 4,113 Field Change Notices have been issued for

the South Texas Project through October, 1985. Attachments H,

sheets 1, 2 and 5, indicate that approximately 90 percent of

the change documents tracked since the beginning of 1985

have been processed in accordance with the governing number and

time constraints.

c. Conclusions

The controls for posting unincorporated design changes on design

documents were not adequately implemented at Station B49. However,.

for the sample inspected, the availability of design documents and

approved design change documents for users is generally adequate.

2. Preparation of Document Packages

The use of design documents and design change documents in the

preparation of work packages and inspection packages was inspected.

VII-4

a. Inspection Scope

(1) The following procedures primarily related to the preparation

and use of work packages and inspection packages and were

reviewed to establish the inspection criteria for this portion

of the inspection:

South Texas Project Standard Site Procedure (SSP) No. 36,

" Work Package Control," Rev. O, dated September 16, 1985.

Bechtel QCP-10.16, " Inspection of Electrical Raceways,"

Rev. 4, dated May 1, 1985.

Bechtel PED-027, " Civil / Structural Directive for the

Review of Pipe Support Drawings," Rev. 1, dated March 13,

1985.

Bechtel Specification 3A010SS0012 for Category I Structural

Steel, Rev. 2, dated January 21, 1984.

Bechtel Specification 3A010SS0026 for Category I

Miscellaneous. Steel, Rev. 6, dated August 27, 1985.

Ebasco QCP-9.5, " Weld Inspection (AWS)," Rev. 6, dated

October 10, 1985.

Ebasco QCP-10.5, " Inspection of Structural Steel Erection

and Bolting," Rev. 5, dated July 19, 1985.

Ebasco QCP-10.7, " Miscellaneous Metal Fabrication," Rev.

6, no rev. date.

Ebasco QCP-10.12 " Component Support Fabrication and

Installation Inspection," Rev. 4, dated June 17, 1985.

Ebasco QCP-10.19, " Inspection of Anchoring Devices

Installed Within Concrete Structures," Rev. 6, dated

February 28, 1985.

Ebasco QCP-10.31, " Inspection of Configuration Control

Packages," Rev.1, dated July 11, 1985.

Ebasco Procedure Construction Site Procedure (CSP) 43,

" Installation of Electrical and Associated Hangers,"

Rev. 5, dated September 30, 1985.

(2) Bechtel, Ebasco and HL&P document control, engineering,

construction and QC personnel were interviewed concerning

the use of design documents and design change documents.

VII-5

-

-

.

b. -Inspection Findings

(1) Ten samples of installed structural _ steel installation docu-

ments and QC inspection records provided by Ebasco civil /

structural site engineering were reviewed. Table VII-2

summarizes the NRC CAT findings for this review, which was

performed to confirm that Ebasco used the correct drawings,

change documents, procedures and specifications to install and

inspect the structural. steel. Four of the ten samples were

found_to have deficiencies. The most significant. finding from

this review was that work done under a Field Change Request

(FCR) dated September 14, 1984 had not been QC. inspected.

When a QC inspection was performed, a nonconformance was

identified (Item 1, Table VII-2).

Structural steel is installed and inspected based on design

drawings and approved design changes (i.e., there is no

procedural requirement at STP for a structural steel work

package) and the related QC inspection activities are performed

on an area basis, with no easily auditable tracking of. records

for specific joints, members, etc. In a number of instances,

the team encountered difficulty in identifying the specific-

installed steel that had been QC inspected. As a consequence,

some installed or modified structural steel may not be QC.

inspected or inspected in a timely manner.

On September 20, 1985, HL&P notified NRC Region IV of a

potentially reportable. item ccncerning inspection of installed

structural steel. The lack of an accurate detailed location

description for structural steel is one of the identified

deficiencies currently under review by NRC Region IV. The

licensee is conducting an investigation to determine the

extent of the documentation deficiencies in regard to

structural steel erection. A thorough review of inspection

documentation on structural steel erection is currently

being performed. The licensee's review should also address

the above identified NRC CAT finding.

(2) A sample of installation documents and QC inspection records

for the ten electrical cable tray supports listed in Table

VII-3A was reviewed to verify that Ebasco used the correct

drawings, change documents, procedures and specifications to

install and inspect the cable tray hangers. Table VII-38-

summarizes the NRC CAT findings for this review. Minor docu-

mentation deficiencies were identified in seven of the ten

samples.

There is no requirement at South Texas Project to provide an

- as-built record of an installed cable tray support. In addi-

tion, a given cable tray support detail drawing defines a

design envelope rather than a unique hanger configuration. As

a consequence, physical inspection is required to verify the

specific configuration of an installed cable tray support.

NRC CAT inspectors verified another sample of 14 cable tray

supports, and concluded that the installed hanger configurations

VII-6

conformed to the hanger detail drawings. NRC CAT review of

this sample is documented in Section II, Electrical and

Instrumentation Construction, of this report.

c. Conclusions

The use of design documents and design change documents in prepara-

tion of work packages and inspection packages appears generally

adequate. However, during this review a deficiency in inspection

of structural steel was identified. The licensee needs to determine

whether this deficiency will be addressed in his overall evaluation

of the inspection of structural steel pursuant to his notification

to NRC Region IV of similar problems with the inspection and iden-

tification of structural steel.

3. Control of Design Changes

The specific aspects of the control of changes to design inspected

by the NRC CAT were the change control systems for Field Change

Notices (FCNs), Field Change Requests (FCRs) and Drawing Change

Notices (DCNs) and implementation and verification of the changes.

a. Inspection Scope

(1) The following procedures relating primarily to the control of

design changes were reviewed to establish the acceptance

criteria for this portion of the inspection:

South Texas Project Site Instruction 2.17, " Requests for

Engineering Assistance," Rev. 2, dated July 31, 1985.

Bechtel Procedure No. WPP-QCI 20.0, " Field Change Request,"

Rev. 15, dated August 20, 1985.

Bechtel Procedure No. WPP 20.1, " Field Change Notice,"

Rev. 5, dated May 21, 1985.

Bechtel Procedure No. WPP 22.0, " Configuration Control

Package (CCP)/(Design Change Package - DCP)," Rev. 2,

dated November 4, 1985.

Bechtel Procedure No. WFP-QCI 34.0, " Organization and

Responsibilities," Rev. 8, dated June 10, 1985.

'*

Bechtel EDP-2.13, " South Texas Project Engineering Team

Organization and Responsibilities," Rev. 4 STP, dated

June 1, 1984.

Bechtel EDP-4.26, " Interdisciplinary Design Review,"

Rev. O, dated December 2, 1977.

Bechtel EDP-4.27, " Design Verification," Rev. 2 STP,

dated July 31, 1984.

VII-7

_ _ _ _ _ _

Bechtel EDP-4.33, "On-Project Design Review," Rev. 3 STP,

dated December 31, 1984.

Bechtel EDP-4.34, "Off-Project Design Review (Design

Control Check List and Design Review Notice)," Rev. 2 STP,

dated December 15, 1983.

Bechtel EDP-4.37, " Design Calculations," Rev. 4 STP,

dated August 7, 1984.

Bechtel EDP-4.47, " Drawing Change Notice," Rev. 4 STP,

dated February 6, 1985.

Bechtel EDP-4.62, " Field Change Request / Field Change

Notice," Rev. 5 STP, dated March 26, 1985.

Bechtel EDP-4.72, " Configuration Control Package,"

Rev. 3 STP, dated September 5, 1985.

Bechtel EDP-4.73, " Design Change Management Procedure

(Design Change Approval Request - DCAR - Process),"

Rev. 2 STP,. dated May 23, 1984.

Ebasco Procedure No. ASP-7, " Field Change Notice Procedure,"

Rev. 4, dated August 1, 1985.

-

Ebasco Procedure No. ASP-11 " Field Change Request," Rev. 4,

dated July 29, 1985.

Ebasco Procedure No. ASP-17, " Configuration Control Package

(CCP)/ Design Change Package (DCP)," Rev. 2, dated October

28, 1985.

(2)' Bechtel and Ebasco QA audit and surveillance reports

concerning design changes were reviewed for findings, trends

and~ corrective actions.

(3) Interviews were conducted with personnel from Bechtel, Ebasco

and HL&P concerning initiation (organization) review, approval

and implementation of design changes.

b. Inspection Findings

(1) The Bechtel Site Engineering Organization (SE0) currently

employs approximately 150 office personnel and 120 field

personnel on site. The functions of Bechtel SE0 are described

in Bechtel procedure.WPP-QCI 34.0, subsection 5.6. The

functions of Bechtel project engineering personnel assigned to

the site are described in Bechtel procedure EDP 2.13,

l subsection 5.6. Bechtel project engineering personnel

assigned to the job-site take the lead in responding to field

, change requests, provide engineering dispositions on noncon-

L

'

formance reports, and monitor Ebasco field change' notices for

compliance to Ebasco and Bechtel requirements.

l

VII-8

<

(2) The NRC CAT reviewed a sample of 55 Bechtel and Ebasco FCNs, l

FCRs and DCNs. These change documents ,

were selected from the civil / structural and pipe support

disciplines. Table VII-4 summarizes the NRC CAT findings

derived from this review, which was performed to confirm that

change documents had been correctly incorporated into the

referenced drawings. .NRC CAT review of an additional sample

of design change documents is discussed in Section

VII.B.3.b.(7), below.

Discrepancies were observed in the incorporation of 8 of

the 55 change documents into the design documents. In

seven cases, the team found that either the technical content

or the scope of some change documents had been modified upon'

incorporation into the referenced design drawings. Six of

these. cases involved modification of FCRs or FCNs. Neither

Bechtel procedure WPP-QCI 20.0, " Field Change Request,"

subsection 5.4.3, nor Ebasco procedure ASP-11, " Field Change

Request," subsection 8.0.6, permits the modification of Field

Change Requests. Bechtel procedure EDP 4.47, " Drawing Change

Notice," subsection 3.6 permits the modification of a Drawing

Change Notice upon incorporation into a design drawing, if

notification is included in the drawing revision block.

'

However, the change documents are not annotated to indicate the

modified version of the technical content or scope that has

been incorporated.

Change documents originally restricted to k 2ilation in

either Unit 1 or Unit 2 have been modified upon incorporation

into the. referenced drawing for installation in both Units.

Since many drawings are applicable to both Units 1 and 2 by

default, and since the change documents are not reviewed to

reflect the incorporated modification, it is not possible to

determine if any error of omission has occurred or a conscious

design decision has been made.

(3) The NRC CAT reviewed selected audits in the area of design

control (Table VII-5) that had been conducted either by

Bechtel or Ebasco, or by teams composed of Bechtel, Ebasco

and HL&P personnel. The modification of some field change

requests upon incorporation into the design drawings does

not appear to have been an identified concern, although

Bechtel explicitly audited this attribute in the latter part

of 1984 (audit No. ESI-14-84, page 45, audit item 47).

The team also reviewed audit findings with respect to the

Bechtel/ Westinghouse interface. Audit M24-501 was conducted on

March 11-25, 1984 to assess the programmatic adequacy and the

proper procedural implementation of the Westinghouse NSSS

program on site. The audit summary noted that the corporate

Westinghouse program was being adequately implemented, but

concluded that' site specific procedures and instructions had

not been developed to control. activities affecting quality

which were being performed by Westinghouse site personnel.

VII-9

_ -

-

The audit summary considered this a significant deficiency

which could have an impact on the overall South Texas Project

quality program. Audits S15-501, D08-501, G42-501 and S23-501

also address aspects of the Bechtel/ Westinghouse design

interface. The deficiencies identified in Section II,

Electrical and Instrumentation Construction, of this report

with respect to the installation of Westinghouse motor

operated valves indicate that the concerns identified in

previous audit reports at the Bechtel/ Westinghouse design

interface require vigorous corrective action to assure a

controlled A/E-NSSS design interface at South Texas Project.

(4) The NRC CAT documented conflicting definitions for confi-

guration control package revisions in the governing Bechtel

and Ebasco procedures: Bechtel EDP 4.72, subsections 7.3-4;

Bechtel WPP-22.0, subsection 4.9.1, and Ebasco ASP-17, subsec-

tion 8.0.4. One definition notes that each revision of a

configuration control package supersedes all previous revi-

sions, and includes all previously issued design information.

Another definition notes that each revision of a configuration

control package supplements the previous revisions, and that

all revisions are necessary to determine the intended final

installed configuration. Design documents contained in a

specific configuration control package may be revised upon

completion of the physical work associated with that package.

The team notes that the Bechtel field document control center

has recently upgraded -the field revision list to identify con-

figuration control packages as a function of a given drawing.

However, the NRC CAT is concerned that drawings incorporated

into multiple configuration control packages prior to this

upgrade may have been subject to conflicting modifications.

(5) The NRC CAT requested the Bechtel structural calculations

for ten civil / structural change _ documents which added (or

modified) equipment support steel to the Bechtel structural

drawings. Table VII-6 summarizes the NRC CAT findings for

this review, which was perfonned to confirm that appropriate

calculations had been performed to substantiate design changes

to project drawings. The team found seven of the ten Bechtel

calculations acceptable.

Three of the changes . reviewed were found to have inadequate

. calculational bases. A calculation for a nonsafety support in

the seismically designed Fuel Handling Building had been

performed, but not checked or signed off by a group leader

(Table VII-6, item 1). Four bays of floor steel had not been

verified by calculation, or by documented engineering judgment

(Table VII-6, item'2), and some existing steel that was

recently checked for the first time showed relatively high

stress ratios (Table VII-6, item 3).

The NRC CAT is concerned that structural calculations or other

adequate documentation of design bases may be lacking for some

structural steel in safety related and nonsafety seismic

structures. All structural steel should be explicitly or

VII-10

1

generically qualified, and this analytical qualification

should be documented. ANSI N45.2.11-1974 Section 4.2, Design

Analyses, notes in-part that " Analyses shall be sufficiently

detailed as to purpose, method, assumptions, design input,

references and units such that a person technically qualified

in the subject can review and understand the analyses and

verify the adequacy of the results without recourse to the

originator."

(6) The NRC CAT reviewed three pipe support calculations to verify

that supplementary steel had been properly ~ modeled, and that

calculated weld sizes had been noted on the pipe support

drawings. Although no concerns were identified, the team had

become concerned during the course of the inspection that pipe

support supplementary steel and supporting steel was not always

being evaluated for possible addition of beam stiffener plates.

However, the NRC CAT was informed that a pipe support review

team has already been established within the Bechtel pipe

support group to review all ASME and seismic II/I supports

for various pipe support design attributes. Both new as well

as existing pipe support designs will be reviewed under this

program, in accordance with Rev. 3 to Bechtel PED 023.

(7) Inspectors in each NRC CAT discipline checked the design con-

trol process at South Texas Project by evaluating compliance

of a sample of installed and inspected hardware with respect

to the applicable design drawings and their approved design

change documents (Table VII-7A-C). In most instances,.the

installed hardware conformed to the design documentation.

.0f the 87 hardware samples reviewed for compliance with the

governing design change documents, only 2 discrepancies were

noted. However, because the NRC CAT is concerned that the

design control process at South Texas Project may not be

adequately controlled in some areas, i.e. , motor-operated

valves (Section II.B.3.b(8)), the licensee needs to assess the

1

impact that these deficiencies may have on the associated

hardware.

c. Conclusions

Control of the design change process is generally adequate for

the sample inspected. However, additional management attention is

needed to: (1) preclude further modification of design changes

during incorporation into their referenced drawings, particularly

unit specific changes, (2) control the design interface between

Bechtel and Westinghouse, (3) ensure that documented calculations

exist to demonstrate both the bases and adequacy of design drawings

and design changes, and (4) to ensure that the conflicting defi-

nitions for configuration control packages have not resulted in

the improper use or as-building of these change documents.

VII-11

, - ._.

_-- - - -

I

TABLE VII-1A

REVIEW 0F POSTING OF DESIGN CHANGES

PROCEDURES / SPECIFICATIONS SAMPLE

Reference Station A02

Document. Observation

Ebasco Procedure a) Table of contents does not list ICP

ASP-11 (interim change to a procedure) No. 1;

b) Procedure pages not correctly numbered

Ebasco Procedure Table of contents does not list PCR

QCP-10.7 (procedure change report) No. 7

Bechtel Specification a) Table of contents and appendices

SA010PS002 misfiled;

b) Total number of pages per appendix

not tabulated.

Bechtel Specification Total number of pages per appendix not

3A010SS0030 tabulated

,

VII-12

--

TABLE VII-1B

REVIEW 0F POSTING OF DESIGN CHANGES

BECHTEL LARGE AND SMALL BORE PIPING ISOMETRIC SAMPLE

Reference Station A02

Total Active Superseded

Change Documents Active CDs Not CDs Posted

Drawing Sheet No. Rev. No. ,

(CDs) Posted on dwo On dwa

'8M369 PIA 239 A08 4 5 - -

8M369 PIA 239 A13 4 4 - -

-

8M369 PIA 239 A17 4 4 - -

8M369 PIA 239 A24 3 4 - -

8M369 PIA 239 A29 4 3 - -

3M369PCC207 2 4 17 - -

SM369PCC207' S 3 5 - -

SM369PCC207 7- 4 14 1 -

4M369PCC207 9 5 14 - -

5M369PCC207 10 4 18 - -

3M369 PEW 229 18 0 40 1 -

-50369 PEW 329 5 1 18 -

2

3C01951542 -

4 6 -

1

3C019S1600 -

5 2 - -

3C01951603 -

3 3 1 -

TOTAL F 3- 3

VII-13

_-

TABLE VII-1C

REVIEW OF POSTING OF DESIGN CHANGES

BECHTEL ELECTRICAL DRAWING SAMPLE

Reference Station A02

Total Active Superseded

Change Documents Active CDs Not- CDs Posted

Drawing Sheet No. Rev. No. (CDs) Posted on dwg On dwg

-3E560E55127* -1 1 21 '- -

-3E359E58001' 1 11 7 -

3

3E359E58001 4 6 4 -

1

3E359E58001 -5 7 4 --

1

3E359E58001 7 4 7 -

4

3E359E58001- 2 9 2 -

1

-3E359E58002 1 0 3 - -

SE209E01638 2 9 5 - -

SE209E1631- ~

5 8 3 - -

.9E0VNAV.- 1 3 6 - -

9EEWO101- 1 2 5 -

li

9E0HE21 1 2 2 - -

SE549EL5031 -

8 15 - --

~3E209E2825 -

8 16 - -

3E209E56009 -

9 7 > - -

9E0ANO3 2 2 1 - -

6E100E02130- -

.7 6 - -

SE030E0100 3 14 4 - -

9E00AAB 1 5 1 - -

.5E030E0100. 3A 3 4 - -

-9E0HC09 1 2 2 - -

SE500E00103 .3 22 9 2 -

9E0VCAB 1 3 5 - -

9E0VCAG 1 2 3 1 -

9EOFP08 1 3 -4 - --

-9EOPMAL 1 5 3 - -

OEOSW10 - 1 1 2 - -

3E209E56104 -

5 6 - -

9EOPFCF 1 3 2 - -

1EPFCC01' 1 3 1 - -

TOTAL T6T 3 T

(*) There were approximately 35 not to be incorporated (N/I) CDs posted on

this drawing that were subsequently tabulated on sheet 1A of the drawing

and should have been deleted from sheet 1.

(!) Incorrect CD No.-posted.

VII-14

TA8LE VII-1D-

REVIEW OF POSTING OF DESIGN CHANGES

BECHTEL ELECTRICAL DRAWING SAMPLE

Reference Station B49

Total Active Superseiled

Change Documents Active CDs Not CDs Posted

Drawing Sheet No. Rev. No. (CDs) Posted on dwg On dwg

3E359E58317 1 5 14 3 5

- -3E359E58191 1 3 4 1 6

3E359E58020 1 10 15 9 4

3E359E58029 1 6 7 2 5

3E359E58260 1 6 6 - -

6E210E02564 2 4 6 -

1

3E359E58042 1 11 9 1 2

3E359E58140 1 4 7 - -

9E560E50021 -

3 4 -

1

3E359E58901 1 1 5 -

it

3E359E58067 1 '5 7 2- -

3E560E55127 l' 1 21 - -

3E560E55127 1A 2 3. - -

3E359E58822 1 4 13 -

1

-3E359E58072 1 6 5 - -

3E359E58041 1 9 10 1 1

SL49T60002 '

-

16 44 16 1

3E560E55045 -

12 15 - -

.3E560E55046 -

-9 22 -

1

TOTAL 717~ 20 -'2T

(1) Incorrect CD posted

(9) 1 CD posted on drawing.twice

. VII-15

_ , . _ - _ _ ._ ,

.

TABLE VII-1E

REVIEW 0F POSTING OF DESIGN CHANGES

. BECHTEL ELECTRICAL DRAWING SAMPLE

Field Document Control Center (FDCC)

Total Active Superseded

Change Documents' Active CDs Not. CDs Posted

Drawing Sheet No. Rev. No. (CDs) Posted on dwa On dwg

.3E359E58317* 1 5 14 lt

-

3E359E58191* 1 3 4 - -

3E359E58020* 1- 10 15 1 -

3E359E58029* 1 6 7 - -

3E359E58041* 1 9 10 - -

3E359E58140* 1- 4 7 - -

3E359E58148 1 6 3 - -

3E359E58169- 1 5 3 - -

3E359E58238 1 3 3 - -

3E359E58093 1 4 4 1 -

3E359E58260* 1 6 6 - -

3E359E58268 1 2 3 - -- '

3E359E58048 1 8 3 - -

3E359E58057 1 4- 3 -

1

3E359E58901 1 1 5 - -

3E359E58831 1 1 2 - -

3E359E58042* 1 11 9 - -

.30359E58067* 1 5 7 - -

3E359E58073 1A 5 4 - -

3E359E58072* 1 6 5 - -

-3E359E58822* 1 4 13 -

1

TOTAL 130 3 2

.

(*) Drawings reviewed at Reference Station B49

( ) 1 CD number transposed

VII-16

. __ -. - ._.

. _ . . _ _ . ._ . . _ _ _

,

-

7

TABLE VII-2

REVIEW OF WORK PACKAGES AND INSPECTION REPORTS

STRUCTURAL STEEL SAMPLE

'

ITEM- OBSERVATION -

1

<

1 Field Change Request (FCR) No. CC-0414W was issued on September

14, 1984-against Bechtel drawings No. 3C01-9-S-1506, Rev.:5,

3C01-9-S-1508, Rev. 3, and 3C01-9-S-1510, Rev. 2. The.FCR
.specified the coping of radial and circumferential steel at three
different elevations in containment. Coping the beam.

,

'

flanges provides access to enable welding of the containment liner

plate at the construction hatch opening. -However, at the time of

the CAT inspection, the steel rework had not been QC inspected.

Subsequent Ebasco-QC inspection is documented on miscellaneous

, metal fabrication inspection report 3461F1 dated October 28,

1985. Nonconformance Report Number CC-03133 was also issued on

~

f'

October 28, 1985 to document coping of beam flanges in excess of

,7

the dimensions specified in the FCR.

i

2 Drawing Change Notice (DCN) No. 3 was issued on January _25,1985

, against Bechtel drawing No. 3F01-9-S-3001, Rev.1, in order to

,

. provide support details for Fuel liandling Building Sump Tank No.1

Sump Pumps 9Q061/2NPA113A. Field Change Notice (FCN) 1-C-0329

provides the fabrication details for the new steel. However,

there are discrepancies in the bolt hole diameters specified for-

,_ the beam clip angles. The DCN and the drawing sp?cify 15/16 in.

. diameter bolt holes for 3/4 in. diameter bolts,:while the FCN-

r- specifies 13/16 in. diameter bolt holes. The Bechtel civil /

structural site engineering organization issued DCN No. 5 on

Octobe'r 30, 1985 to correct DCN.No. 3.

. 3 FCR BC-01544 was issued on December 24, 1984 against Bechtel

. drawing No. 3F01-9-S-3005, Rev.1.1 The FCR detailed modifica-

~

i

tions to'HVAC plenum No. 9V121VXV021 perimeter grating and

u support steel to provide an air-tight seal. However, Ebasco QC

AWS D1.1 structural welding inspection report No. 1-00865,-dated

{. Narch 7, 1985, incorrectly references Rev. 1 of the Bechtel

drawing. Rev. 2 of the drawing, dated December 18, 1984, was

the correct drawing of record. The inspection report was

,

corrected on October.30, 1985.

-

t

4 The not to be incorporated (N/I) amendment list for Bechtel

drawing .3M01-9-S-4043, Rev. 3, dated July 15, 1985, incorrectly

references FCN 1C-0265, dated February 21, 1985, as a FCR.

L Rev. 4 of the drawing, issued on November 5, 1985, correctly

!

references the FCN.

i.

l

VII-17

,

[

TABLE VII-3A

LISTING OF ELECTRICAL CABLE TRAY SUPPORTS

~ Support No. Location Drawing No.

H64- 3-E-20-9-E-56004, Rev. 3

H117 3-E-20-1-E-56004, Rev. 5

H2 3-E-35-9-E-56008, Rev. 8

H153 3-E-20-9-E-56004, Rev. 3

H139 3-E-35-9-E-56008, Rev. 5

H115 3-E-20-9-E-56004, Rev. 3

H84 3-E-20-1-E-56004, Rev. 5

H136 3-E-35-9-E-56008, Rev. 3

H102 3-E-35-9-E-56008, Rev. 5

H100 3-E-35-9-E-56008, Rev. 8

.

VII-18 j

l

TABLE VII-3B

REVIEW 0F WORK PACKAGES AND INSPECTION REPORTS

ELECTRICAL CABLE TRAY SUPPORT SAMPLE

-ITEM OBSERVATION

1 Page 2 of the electrical' raceway hanger inspection

record / traveler for hanger No.1-004-H64 does not reference

Bechtel drawing No. 3-E-35-9-E-58140, sheet 1, Rev. 2

AWS D1.1 structural welding inspection report No. 02630 for hanger

No. 1-004-H64 does not reference the cable tray hanger connection

detail drawings, and references incorrect detail numbers 22 and 23

for the installed cable tray. ~The correct details are 42 and 70.

The inspection report was corrected on November 11, 1985.

2 Bechtel drawing No. 3-E-20-1-E-56004, Rev. 5, is incorrectly

referenced on page 3 of the electrical raceway hanger inspection

record / traveler for hanger No. 1-004-H117. The inspection

report was corrected on November 11, 1985.

3 Page 2 of the electrical raceway hanger inspection record /

traveler for hanger No.1-004-H153 does not reference

Bechtel drawing No. 3-E-35-9-E-58148, sheet 2, Rev. 4.

AWS D1.1 structural welding inspection report No. 02407 for

hanger No.1-004-H153 references Rev. 2 of Bechtel drawing

3-E-20-9-E-56004. Rev.-3 of the drawing, dated September 16,

1983, was the drawing of record at the time of inspection on

October 20, 1983. The inspection report was corrected on

November 11, 1985.

AWS D1.1 structural welding inspection report No. 02407 does not

reference the cable tray hanger connection detail drawings.

4 Page 2 of the electrical raceway hanger inspection record / traveler

for hanger No. 1-008-H139 does not reference Bechtel drawing No.

3-E-35-9-E-58029, sheet 4, Rev. 4.

5 The line diagram for the cable tray support shown on page 2 of the

electrical raceway hanger inspection record / traveler for hanger

No. 1-004-H115 shows one more G58HD12A tray support than the

installed cable tray.

Page 1 of the traveler (item 5) does not reference Bechtel drawing

No. 3-E-35-9-E-58117, sheet 3, Rev. 5. The inspection report was

corrected on November 11, 1985.

Page 2 of the traveler (item 5) does not reference Bechtel drawing

No. 3-E-35-9-E-58117, sheet 3, Rev. 3.

VII-19

_ _ . . _ . . . _ _ - _ ._ . .- .- _-

,.; TABLE VII-3B - (Continued)

9 REVIEW OF WORK PACKAGES AND INSPECTION REPORTS

j ELECTRICAL-CABLE TRAY SUPPORT SAMPLE ,

1

ITEM OBSERVATION

j. AWS D1.1-structural welding inspection report No. 02630 for hanger

No. -1-004-H115 does not reference the cable tray hanger connection

. ~ detail drawings. The inspection report was corrected on November

'll', 1985.  :

].

,

6 Page 2 of electrical raceway-hanger inspection record / traveler-

1-004-H84, prepared on December 19,-1983, was not updated to

reference Field' Change Request (FCR) CE-02312, dated April 24, .

, 1984. The construction supervisor signed off on page 2 on June

23, 1985.

'

7- Page 2 of the electrical raceway hanger inspection recor'd / traveler-

for hanger No.1-008-H136 references Field Change Notice (FCN)

CE-00831. The change document is actually a FCR. Ebasco voided

-

this FCR on January 6, 1984. The construction supervisor signed

>

off page 2 on August 4, 1984.

FCR CE-00923 is referenced on the traveler (item 7). However,

this FCR was superseded by FCR CE-01089 on November 4,1983.

-

FCR CE-01089 is referenced on page 2 of the traveler, but does

not appear to be applicable to hanger 1-008-H136.

-

FCR~CE-00578 is referenced on the traveler (item 7), but this

FCR was superseded by FCR CE-00828 on September 27, 1983, which

is not referenced on the traveler.

FCR'CE-01133 is referenced on the traveler (item 7) but this FCR

-

was superseded by FCR CE-01287 on December 6, 1983, which is not

,

referenced on the traveler.

Page 5 of electrical raceway hanger inspection record / traveler No.

1-008-H136 does not reference Bechtel drawing 3-E-35-9-E-58042,

'

.

sheet 5; Rev. 0. The inspection report was corrected on November

11, 1985.

,

l

VII-20 l

1

i 1

- . _ . _ _ . ._._ -____ . _ . _ _ _ _ . _ _ . - . _ . _ . _ . _ _ . _

TABLE VII-4 I

REVIEW OF DESIGN CHANGE DOCUMENTS FOR

INCORPORATION INTO DESIGN DOCUMENTS

j

ITEM OBSERVATION

1 Field Change Request (FCR) BC-01202 was issued on June 13, 1984

against Rev. 2 of Bechtel drawing 3M01-9-C-4312. The FCR was

issued to reduce an oversized HVAC opening. A modified version of

'the FCR (as noted.in the drawing revision block) was incorporated

into revision 3 of the Bechtel drawing, which was issued on

October 4, 1984. As shown on the drawing, the detail is now

applicable to both Units 1 and 2. It appears that the penetration

was reworked ~in accordance with the FCR, so that the as-built

configuration is not in agreement with the design drawing. The

Bechtel civil / structural site engineering organization indicates

that FCR BC-01202 was incorrectly incorporated into Rev. 3 of the

Bechtel drawing, and issued Drawing Change Notice (DCN) No. 3 on

November 16, 1985 to correct the drawing.

2 FCR CC-03426.was issued on June 23, 1984 against Rev. 7 of Bechtel

drawing 3M35-9S-37417. The FCR was issued to shift a piece of

supplementary steel in plan to provide support for a hanger for

Unit 1 only. The FCR was incorporated into Rev. 8 of the Bechtel

drawing, but this detail is now applicable to both Units 1 and 2.

The drawing revision block does not indicate that the FCR was

modified upon incorporation into the drawing. The Bechtel civil /

structural site engineering organization indicates that the

decision was made to shift the steel for Unit 2 as well, at the

time the FCR was incorporated into the drawing.

3 DCN No. 7 was issued on September 26, 1984 against Rev. 1 of

Bechtel drawing 3C01-9-S-1600. The DCN was issued to provide

support details for.RHR pumps A, B and C in Unit 1 containment.

The DCN was modified upon incorporation into Rev. 2 of the

Bechtel drawing, as noted on the drawing revision block, to be

applicable to both Units 1 and 2.

4 FCR CC-04949 was issued on December 22, 1984 against Rev. 3 of

Bechtel drawing 7G-22-9-S-2002. The FC9 revised support details

for relay racks ERR 126 (nonsafety) in Units 1 and 2. The FCR

was modified upon incorporation into Rev. 3 of the Bechtel

drawing, as noted in the drawing revision block, and as detailed

on the drawing. However, the location of the revised steel in

plan was not clouded, and the 13/16 in. bolt holes for the

support channel were not transferred onto the drawing. The

Bechtel civil / structural site engineering organization has

verified that the support was installed as detailed on the

drawing, and issued DCN No. 18 on November 18, 1985 to correct

the drafting error.

VII-21

-

TABLE VII-4 - (Continu;d)

. REVIEW OF DESIGN CHANGE DOCUMENTS FOR

INCORPORATION INTO DESIGN DOCUMENTS

ITEM OBSERVATION

5 FCR BC-01279 was issued on July 24, 1984 against Rev. 1 of

Bechtel_ drawing 7G22-9S-2010. The FCR adds a supplementary

steel beam to provide support for exhaust fans 8V321(2)VFN013

and _4 (nonsafety) in the turbine generator building. The

addition of the supplementary steel is required because of

interference _ with a concrete block wall. FCR BC-01279 was

superseded by FCR CC-04461, which restricted the identical

support detail for installation in Unit 1 only. FCR-04461 was

modified upon incorporation into Rev. 3 of the Bechtel drawing,

as noted in the drawing revision block, for installation in Units

1 and 2. The Bechtel civil / structural site engineering organi-

zation issued DCN No. 4 on November 18, 1985 to restrict the

application of FCR CC-04461 to Unit 1 only.

6 DCN No. 2.was issued on October 6, 1984 against Rev. 1 of

Bechtel drawing 3C01-9-S-1603. The DCN.provided construction

details for the carbon unit A and B fan supports in containment

for Units 1 and 2. The DCN was correctly incorporated into

Rev. 3 of the Bechtel drawing, except for.a minor drafting

error involving failure to dimension a steel connection plate.

The Bechtel civil / structural site engineering organization

issued DCN No. 3 on November 15, 1985 to correct the drawing.

7 FCN BS-1-0194 was issued on July 9, 1984 against Bechtel drawing

CV-9010-GU0006, Rev. 1. The FCN revised the bill of materials <

for a pipe support configuration to allow the installation of a

rigid sway strut from bulk stock for-Unit 1 only. The FCN also

specified the center-to-center dimensions for the Unit 1 struts.

However, the drawing did not properly specify the different ,

center-to-center (C-C) dimensions required ~for the struts. The

C-C dimensions for the Unit 2 struts were listed in the bill of

materials (apparently past practice) while the C-C dimensions

for the Unit 1 struts were dimensioned on the drawing. However,

the drawing did not restrict the use of these strut C-C dimensions

to the Unit 1 struts. The Bechtel pipe support group site i

engineering organization issued DCN No.1 on November 18, 1985

to correct the drawing.

8 FCN BS-1-0235 was issued on August 5, 1984 against Rev. 2 of

Bechtel drawing CC-9215-RR0005. The FCN was incorporated into 1

Rev. 3 of.the Bechtel drawing on March 12, 1985. The team  !

reviewed the drawing, which details separate pipe supports for

Units 1 and 2. The supporting steel for these supports appeared

to require stiffeners, and the team then reviewed the pipe

support calculation. Rev. 1 of calculation JC-CC-92-15-RR0005,

dated September 30, 1985, does require beam stiffeners for both

the pipe support supplementary steel and the support.ng framing

VII-22

TABLE VII-4 - (Continued)

REVIEW OF DESIGN CHANGE DOCUMENTS FOR

INCORPORATION INTO DESIGN DOCUMENTS

ITEM OBSERVATION

. steel. Bechtel~ issued two separate configuration control packages

on October 30, 1985 to add beam stiffeners to the pipe support

steel, CCD-1-M-ST-0066-00 and 2-M-ST-0067-00; however, the beam  ;

stiffeners to be added to the supplementary steel for the Unit 2

pipe support were not clouded on the pipe support drawing. The

Bechtel pipe support group site engineering organization issued

FCR XEJ-00371 on November 18, 1985 to correct the configuration

control package for Unit 2.

VII-23

-- -. .- , .-. . , . . . - , - . - - - - . .. -- .- .. . -

TABLE VII-5

SOUTH TEXAS PROJECT AUDIT SAMPLE

Audit-No. Audit Date Audit Subject

EQA-123 12/07/84 Document Control / Instructions and

Procedures, FCNs

ESI-14-84 11/26/84 Evaluation of Design Control Operations

BEC-6-84 05/24/84 Document Control - Field Control of

Design Documents (Unscheduled Audit)

BEC-7-84 07/18/84 Evaluation of Quality Program for-

Procurement Document Control

BEC-8-84 08/14/84 Evaluation of Quality Program for

QA Records

BEC-10-84 09/28/84 Evaluation of Compliance to Quality

Program Requirements for Design Control

and Project Engineering-Design Interface

Activities

BEC-11-84 10/31/84 Evaluation of Quality Program for

Evaluation of' Compliance to Quality

Program Requirements for Preparation,

Review, Approval and Control of Procedures

C14-501 02/06/85 Ebasco Structural Steel Installation

Activities

G35-501 02/06/85 HL&P-RMS Site Records Retrieval

G39-501 03/13/85 HL&P/Bechtel/Ebasco-Quality Records

M24-501 04/18/85 Westinghouse - Site Activities

S15-501 04/15/85 Bechtel Control of Westinghouse Design

Disclosure Documents

D08-501 04/23/85 Bechtel Design Control (Houston & Site)

G42-501 06/06/85 Bechtel/Ebasco Document Control

M16-501 07/25/85 Ebasco Valve & Pipe Installation

008-502 10/22/85 Bechtel Design Control (Houston & Site)

S23-501 10/16/85 Bechtel Document Control of Ebasco and

Westinghouse Documents

VII-24

TABLE VII-6

REVIEW 0F CALCULATIONS

STRUCTURAL SAMPLE

ITEM .0BSERVATION

1- Drawing Change Notice (DCN) No. 5 issued on August 9, 1983

against Bechtel drawing No. 3F01-9-S-3005, 'added support details

for Fuel Handling Building heating coils 8V121VHX001 and -002 at

two plan elevations. Bechtel had performed a calculation for the

support steel for this non-safety equipment but the calculation

had not been checked or signed by the group leader at the time of

the inspection. Bechtel did not assign a number to this

calculation, and does not plan to formalize this calculation.

2 Bechtel' drawing No. 3M01-9-S-4043, issued on November 5,1984, 1

revised the structural steel floor plan in the Mechanical and

Electrical Auxiliary Building between column lines 30 and 32, and

column lines M8 and H, at plan elevation 69 ft.-6 in. Field

Change Notice (FCN) 1-C-0265, issued on March 6, 1985, provides

.the fabrication details for the structural steel adjacent to a

pair of HVAC openings located in the southeast corner of the floor

plan. The CAT team requested the calculations for the structural

steel detailed on the FCN. Bechtel indicates that engineering

judgment was used to size the installed steel. However, this

engineering judgment was not documented. The Bechtel civil /

structural site organization has verbally indicated that calcula-

tions could not be retrieved for any of the four above-referenced

bays of structural steel in the Mechanical and Electrical

Auxiliary Building.

3 DCN No. 5, issued on October 24, 1985 against Bechtel drawing

No. 3M01-9-S-4069 Rev. 4, added a transverse stiffener beam

between two existing parallel beams which support pipe hangers.

The beam was added to increase the torsional stiffness of the

existing beams. The added steel is located in the Mechanical

and Electrical Auxiliary Building. The team requested the

structural calculation for the added steel beam. Bechtel

provided a recently completed calculation which verified the

adequacy of the added beam (Rev. 1 to Bechtel calculation No.

CC-6043, dated November 13, 1985). Each of the existing steel

beams was also checked in this calculation. The stress in one

of the beams is 86 percent of. allowable load capacity. The

stress in the other beam is 109 percent of allowable load

capacity. These beams were subjected to generic dead and live

distributed loads, a concentrated live load, and peak vertical

and horizontal seismic spectra (i.e., the loads that would

normally have been used to size this steel initially). It

appears, however, that this is the first formal check of this

steel.

VII-25

TABLE Vl"-7A

ELECTRICAL-AND INSTRUMENTATION CONSTRUCTION HARDWARE SAMPLE

Change Document

FCR DE-00274

FCR CE-04476

FCR CE-04475*

FCR CE-05252

FCR CE-05302

FCR BE-00536

FCR CE-05294

FCR CE-04881

DCN No. 8 (Dwg. 3D019-S-5002)

FCR CC-D5635

FCR XDE-00055

FCR CE-04284

FCR BE-00674

FCR BM-00225

FCN TGXM-10585, A, B, C*

(*) Refer to Section II, Electrical and Instrumentation Construction, for a-

discussion of the deficiencies noted with the implementation of these

design change documents.

VII-26

TABLE VII-7B

MECHANICAL CONSTRUCTION. HARDWARE SAMPLE

Change Document

A. Piping FCR DP-451

FCR DP-541

FCR DP-57-1

FCR DP-503

FCR DP-690

FCR DP-748'

FCR DP-662

FCR DP-669

FCN IP-1125

FCN IP-1074

FCN IP-1069

'FCN IP-1067 '

FCR DP-269W

FCR DP-614

FCR DP-916-

FCR DP-14W

DCN Nos. 14 & 15 (Dwg. 5M369PCC207, Sh. 10, R.1)

FCN IP-1384

FCR DP-939W

.FCR DP-918

.FCR DP-772

FCR DP-751

FCR DP-739

FCR DP-718

FCN IP-1081

FCN IP-1106

FCN IP-0836

<

B. Pipe Supports FCN IP-0981

FCR DJ-00248

FCR XEJ-00185

FCN J-0919

FCR DJ-00368

FCR DJ-00306

FCR DJ-00374

FCR DJ-00648

FCR DJ-00440

FCN J-0967

FCN J-0968

NCR BS-00212

VII-27

TABLE VII-7B - (Continued)

MECHANICAL CONSTRUCTION HARDWARE SAMPLE

Change Document

C.. Concrete Expansion _

FCR CM-02181W

-Anchors and Base Plates NCR CM-00587

NCR CS-00802

NCR CS-03103

NCR CS-01014

FCR DJ-00787

'

FCR DJ-00994

FCR DJ-00894

FCR EJ-00289 1

'

-FCR J-0983

DCN No.1 (Dwg. CC9317-HL5006)

FCR DJ-00763

D. HVAC FCR BH-00827

FCR CH-01546

FCR BH-00559

FCR CH-00845

FCR CH-01800

FCR DL-00152W

3 FCR CH-02181W

FCR EAB-314

FCR BH-01844

FCR BH-01142

4

.

1

\

4

VII-28

, . ..

. . - . . - . . - . - . . , , - - - . ,. .. .

. .. . . - _

. . - . - _. .- . , - . _ . ., .

..

TABLE VII-7C

CIVIL / STRUCTURAL CONSTRUCTION HARDWARE SAMPLE

Change Document

FCR EC-00318

FCN 2C-0450-

FCR EC-00321

FCR EC-00098

FCR EC-00318

FCR CM-00194

FCR CC-02180

Dwg. No. 3C01-9-S-1633, Rev. 10

,

'

,

t

i

i

f

f

g.

VII-29

i _ _ _ _ _ . _ . ._, _ . . . - . _

__ _ - - -

- - _ _ - . .

,

VIII. CORRECTIVE ACTION SYSTEMS

A. Objective

The objective of this portion of the NRC CAT inspection was to verify

through selected samples, whether measures were established and

implemented to assure that nonconformances and other conditions adverse

to quality were promptly identified and corrected.

r

B. Discussion

An examination was made of the licensee's program for identification

i

and control of nonconformances and corrective actions, including review

of documents and inspection of some material / equipment for verification

of actual corrective actions in the plant. Items such as the following

were reviewed:

  • Quality assurance programs

Procedures and organizational interfaces

Trend analyses

  • Audits and surveillance reports

'* Nonconformance reports

r Deviation reports

( * Inspection reports

( * Corrective action reports

  • Control of actual material / equipment corrections in the plant
  • Control of open nonconformances at turnover for testing or operation

Table VIII-1, " Corrective Action Samples," contains a list of samples

that were randomly selected.

The following manuals and procedures of on-site organizations were

found in place, and applicable portions pertaining to corrective action

provide the background infonnation and acceptance criteria for this

inspection.

Houston Lighting and Power Company (HL&P)

  • Quality Assurance Program Description for the Design and Construction

Phases of the South Texas Project, Rev. 11

Project Quality Assurance Plan, Rev. 7

South Texas Project Quality- Assurance Procedures, Rev. 46

Standard Quality Assurance Procedures:

SQAP-01 General Control of Standard QA Procedures, Rev.1

SQAP-02 Deficiency Reporting, Rev.1

SQAP-03 Project Audits, Rev.1

SQAP-04 Project Surveillances, Rev. 1

PSQP-16.3 Trend Analysis, Rev. 3

SSP-8 Nonconformance Reporting, Res. 0

VIII-1

- _ _ _ _ _ _ _ _ _ _

OPGP03-ZM-0002 Preventive Maintenance Program, Rev. O

Bechtel Power Corporation (Bechtel)

Project Quality Program Manual, South Texas Project, Rev. 11

WPF/QCI.-4.0 Receiving Inspection, Rev. 11

  • WPP/QCI-5.0 Nonconforming Materials,. Parts and Components, Rev. 14

WPP/QCI-28.0 Maintenance of Materials and Equipment, Rev.11

SQAP-04 Project Surveillances, Rev. 1

Ebasco Services Incorporated (Ebasco)

_ETR-1001 Nuclear Quality Assurance Program Manual, Rev. 11

QAI-11 Corrective Action and Stop Work Authority, Rev. 7

QCP-10.9 General Inspection (G series), Rev. 2

  • QCP-10.30 Inspection of Installation and Fabrication of Electrical

Cable Tray Hangers, Conduit Supports and Auxiliary Steel, Rev.1

  • QCP-10.11 Mechanical Equipment Installation Inspection, Rev. 5

Westinghouse Construction Services (Westinghouse)

  • Quality Assurance Program Manual (QAPM) for ASME Code Section III,

Division I

QAPM Addenda for South Texas' Project (yellow pages)

  • QAPM Addenda, Section 15.0 Nonconformances, Rev. 9

QAPM Addenda, Section 16.0 Corrective Action, Rev. 7

  • STP Project Quality Plan, Rev. 4

Pittsburgh DesMoines St' eel Company (PDM)

Corporate Quality Assurance Manual (CQAM) ASME Section III, 1981

Edition, Rev. 8

CQAM Appendix 202 (for STP), Section 12, Nonconformances and

Corrective Action

Richmond Engineering Company (RECO)

Quality Assurance Manual, South Texas Project, Rev. 3

Intermach Company (Intermach)

Quality Assurance Manual (The Bahnson Co.), Rev. 9

VIII-2

.

-

-.

m .

J

  • QFP-15.001 Nonconfonning Items, Rev. 4
  • QFP-16.001 Corrective Action, Rev.1
  • QFP-8.001 Identification and Control of Materials, Parts and

.

'

Components, Rev. 3

  • QFP-9.001 Control of Welding Processes, Rev. 3

- * QCI-013 Control of Nonconforming Items, Rev. 2

Prescon Corp. (Prescon)

  • Quality Assurance Program, Rev. 10

Champion, Inc. (Champion)

  • Quality Assurance Manual, Rev. 26

Pittsburgh' Testing Laboratory-(PTL)

  • Quality Assurance Manual, Rev. 8

1. Corrective Action Measures

a. Inspection Scope

A review was performed of applicable portions of the Quality

Assurance (QA) program and procedures. In addition to QA manuals

and procedures, a total of 439 samples of corrective action docu-

ments were reviewed. . Also,'16. samples-of closed nonconformances

involving material / equipment were inspected for verification of

corrective actions in the plant. In' addition, 58 samples of open

nonconfonnances were selected for verification of " HOLD" status.

b. Inspection Findings

In general, it was found that satisfactory procedures were in place

for corrective action systems to identify and control the

correction of conditions adverse to quality at the site. Except

for concerns discussed below, the corrective action systems and

implementing measures were found to be acceptable. The 16

material / equipment samples requiring rework in the plant were

inspected, and corrective action control was verified.

(1)' Fastener Materials

Numerous problems with fastener material discrepancies on large

vendor-supplied ASME pump / motor assemblies and other vendor

equipment were found by the NRC CAT inspectors for which

effective corrective actions were not previously evident.

See Section VI.B for details. These problems indicate a

lack of attention by vendors to ensure that fasteners of

required materials are specified and provided with delivered

items, a lack of effective quality control at vendors'

VIII-3

1

'

.

~

plants, and also a lack of vendor surveillance by the licensee

wi_th ' attention to' verification of proper fasteners prior to

shipment.

'

(2) Preventive Maitenance (PM)

Review of the PM program revealed that numerous problems have

been encountered, including overlubrication and contamination

due to commingling of lubricants.. Seven fan motors, after

- turnover to Startup, .were _later found to have been

overlubricated.

Review of PM history of four Auxiliary Feedwater Pumps (three

motor: driven and one turbine driven) revealed repeated

corrosion problems. One unit seized and could not be

rotated. Rotating . elements of the four_ units had to be

returned to the ' vendor for repairs.

.The NRC Resident Inspection Office has issued inspection

reports (85-08 and 85 11) on PM deficiencies. Also, Ebasco

issued a Management Corrective Action Report .MCAR-13 dated

February 23, 1985 which contains a list of 106 deficiencies and

resulted in a major review and reorgnization of the PM program.

Of parti _cular concern is the current practice of the' licensee _

accepting turnover packages and preparing operational

maintenance programs assuming that the past PM history is

good without assessing potential for damage to the equipment

due to past PM deficiencies. The potential long term effects

of' the lack of proper maintenance-has not been addressed and

documented, and it does not appear that measures-(reference:

OPGP03-ZM-0002 Preventive Maintenance Program, Rev. O, dated

5-15-85) were in place to. provide for damage assessment and.

'

evaluation.

(3) Nondestructive Examination (NDE)/ Radiographic Testing (RT)

Audits; Records Retrieval

Review of'the total .of 21 prior audits of welding /NDE revealed

only two audits that addressed RT records packages and

retrievability (audits M11-301 and G35-502). These two audits

included three weld joints for one audit and six weld joints

for the other. The total of 9 weld joints (of approximately

25,000 field weld joints) is a very small sample to have been

audited. NRC CAT examination of the radiographs for'two of the

three welds for audit M11-301 found them to have deficiencies,

' indicating that the audits.were limited in scope and depth

(see Section IV.B 'for details).

None of the 21 prior audits covered vendor NDE/RT records.

Requests for information to identify vendors that were

required to supply radf ographs were not'readily answered.

Some radiographs from vendors involving plant equipment were

not made available to the NRC CAT inspectors, and in some

VIII-4

cases could not be located. A method for identifying vendors,

equipment and related radiographs was not available at the

start of the CAT inspection (see Section IV.B for details).

The required records retrieval for RT film was not evident

during this inspection, and raises questions regarding the

ability of the licensee to verify the required product quality,

if records are not readily available.

'(4),, Significant Deficient Corrective Actions for Certain Electrical

Items: Motor Operated Valves (MOVs) and Motor Control Centers MCC)

Corrective action deficiencies related to unauthorized

electrical wiring of MOVs furnished by Westinghouse were noted

by the NRC CAT inspectors (see Section II.8). Questionable

QA and corrective action activities involving design change

control, field modification and inspection were indicated. It

was noted that no audits or surveillances of Westinghouse

activities related to MOVs had been conducted. However, one

HL&P audit report, S26-501 dated September 24, 1985 addr(ssed

field wiring changes by Westinghouse on other electrical equip-

ment inspected and accepted at the site without prior written

authorization for the changes. The response by Westinghouse

noted a procedure change for accelerated Field Change Notice

(FCN) work to require written authorization prior to the work.

Also, a project team audit S15-501 dated April 15, 1985

referenced a prior HL&P audit M24-501 of Westinghouse which

addressed deficiencies in the electrical area. It appears that

the generic aspects of these audit results were not applied by

Westinghouse to the MOV~ work.

Also, corrective action deficiencies related to faulty bus

extensions of circuit breakers in MCCs procured by Bechtel

were noted by the NRC CAT inspectors (see Section II.B).

(5) Open Nonconformances " HOLD" Status Control

Open Nonconformance Reports (NCRs) and related equipment

requiring " HOLD" tags for 58 items were reviewed for

verification. " HOLD" tags for 13 items (22%) were missing or

improperly controlled.

Since " HOLD" tags are required to be used as a means of

controlling quality, attention and action are required to

assure proper application and maintenance of "H0LD" tags on

nonconforming material and equipment. As a result of this NRC

CAT finding, Bechtel issued General Surveillance Report SB 727

to document incorrect " HOLD" tag control,

c. Conclusions

The licensee's corrective action program was found to be generally

acceptable, except for the following concerns:

VIII-5

r-

(1) Failure to assure that fasteners of required materials were

furnished with vendor supplied equipment.

(2) Failure for Operations to assess and evaluate damage to

equipment due to past PM deficiencies and incorporate such

considerations into operational maintenance programs.

(3) Failure to conduct a reasonable quantity of audits of actual

radiographs of both field welds and vendor supplied welds.

Also, failure'to assure that vendors required to supply

radiographs were readily identified and that the location of

radiographs / records were known and readily retrievable as

required.

(4) Failure to identify the need for effective corrective action

activities for certain electrical items: MOVs and MCCs.

(5) Failure to properly apply and control " HOLD" tags on

nonconforming material and equipment.

(6) There appears to be a need for more ~ attention to generic and

lessons-learned aspects of the corrective action program to

help reduce deficiencies and avoid recurrence.

VIII-6

C

L

r _ , , - -

.~ l r

,

p .

L~

j;;

,

-TABLE VIII-1

p CORRECTIVE' ACTION SAMPLES

[

>

JItems/ Reports Quantity Examined

L HLP BEC EBA' WES PDM -REC INT PTL- TOTAL

L . Trend 3* *- * ~3 - - -

6

- . Audit' 41* * * 6 3 '-- -1 -

51

Nonconformance 17 61 69 6 5 5 .12 5 180

l- ~

Deviation -- - -

10 8 -

.15 -

33.

Inspe'ct' ion

-

-

5 18 - - - 4 -

27

l- . Surveilla'nce -14 19 12 - - - - -

45

i

"

Corrective Action 9 18 12 - - - - -

39

L

!

Deficiency Eval. 10 10 - - - - - -

.20

i :Mgt. Corrective - -

4 - - - - -

4

l

,

. Action-

Inspection 9 - - - - - - ~ -: 9

r. Efficiency-

l

L

/Stop Work ~ 3 -

1 - - - .

-

'4

Turnover. Packages 20 - - - - - --

. 20

p

-T

~

TOTA'l TE6 TIT IT6 Y5 T6 72 - !i. . TJB

'

L_ HLP = Houston' Lighting and Power Company

BEC = Bechtel Power-Corporation

=

',

. EBA = Ebasco Services Incorporated

L . WES =. Westinghouse. Construction Services

D PDM = Pittsburgh DesMoines Steel. Company

REC = Richmond Engineering Company

.

INT.= Intermach Company

PTL = Pittsburgh.. Testing Laboratories

-

v

  • Joint (HLP,. BEC, and EBA) trend and audit program samples listed under' HLP, ,

' l

l

l

l

l

VIII-7-

1

L___'

_

ATTACHMENT A

A. PERSONS CONTACTED

The following list identifies 1 censee representatives and NRC personne1'

4

present at the exit meeting, and licensee discipline coordinators and key

individuals-contacted during the inspection for each area.

1. Exit Meeting

Houston Lighting and Power Company

F. L. Alkov G. Goldberg T. H. McGriff

J. Bevins S. Head R. C. Munter

P. F. Boyle R. Hernandez A. G. Peterson

D. P. Bradley S. R. Hubbard G. B. Rogers

R. J. Daly M. F. Hutcheson M. T. Sweigart

S. Dew T. J. Jordan W. Trujille

F. Dotson D. R. Keating J. Westermeier

J. E. Geiger W. H. Kinsey, Jr. W. R. Whitley

M. R. Wisenburg

Bechtel Energy Corporation

R. D. Bryan L. W. Hurst -R. L. Rogers

J. L. Hurley D. R. Quattrochiocchi R. Wilkerson

Ebasco Services, Incorporated

A. M. Cutrona W. Taylor R. W. Zaist

R. A. Harrington

Westinghouse Ele-tric Corporation

D. M. Bokesch C. W. Rowland F. J. Twogood

H. L. Hogarth S. R. Spiegelman R. J. Von Osinski

NRC and Consultants

S.' Baron D. Garrison T. McLellan W. Sperko

D. Carpenter G. Georgiev 0. Mallon S. Stein

L. Constable R. Heishman E. Martindale R. Taylor

R. Compton C. Johnson J. Nemoto R. Vollmer

A. DuBouchet R. Kadambi M. Peranich

D. Ford J. McCormack H. Phillips

AA-1

. .-

'~

. ~ .

'

r.-

,

2. Licensee Coordinators and Contacts'

Area' Contact

= Team-Leader- R. Hernandez

-

W. Trujillo

Electrical and Instrumentation D. Bradley-

D.-Richter

J. Bagley

Mechanical M. Hutchesan.

S.' Hubbard

J. Bagley

C. Brewer

A. Benyo

~

Welding and NDE S. Hubbard

R. Abel-

R.. Lewis

Civil and Structural 'T. McGriff

J.-Stevens

.

Material. Traceability F. Alkov

J. Senecal

~~R. Fish

Corrective Action Systems E..Luder

-J. Hansen

Design Change. Controls - K. McNeal

.In addition to the above personnel, numerous other inspectors, engineers-

and supervisors were also contacted.

~ B. DOCUMENTS REVIEWED.

The types of documents listed below were-reviewed by the NRC CAT members-

to the extent necessary to satisfy ~the inspection objectives stated in.

'Section I of this report. There are' additional references within the

body of.the report to' specific procedures, instructions, specifications

and drawings.

1. F.inal Safety Analysis Report and. Safety Evaluation Report

.

2. lQualityassurancemanual

'3. ' Quality assurance procedures and instructions

4. ' Quality control procedures and instructions

5. Administrative procedures

6. General. electrical installation precedures and specifications

AA-2

.-

_ . .

.

,

_

7. General instrumentation . installation procedures and specifications.

- 8.r : General piping and pipe support installation procedures and

specifications

~~

9. General mechanical equipment . installation procedures and

specifications-

'

c ,

!10. -General concrete specifications  !

11. As-built. drawings

12.. Welding and NDE procedures

.13. Personne1~ qualification records

14. Material traceability procedures

15. ---Procedures for processing design changes

16. .-Procedures for document control

-17. . Procedures for controlling as-built drawings

18. . Procedures for processing nonconformances

se

AA-3

, <

,

. . .

~ ATTACHMENT B

GLOSSARY OF ABBREVIATIONS.

_ .

A/E - Architect-engineer

'AISC. - American Institute of Steel Construction

ANSI '- American National Standards Institute

'

ASME - American Society of Mechanical Engineers

' ASTM .American Society for Testing and Materials

AWG - American Wire Gage

AWS --American Welding Society

'ATWS' - Anticipated transient without scram

BBC- -TBlount Brothers Company

BEC_ ' -~Bechtel Engineering Corporation

-BR- - Brown & Root, Inc.

, . CAR- - Corrective Action Report

CAT - Construction _ Appraisal. Team (NRC)

'

CB&I. - Chicago Bridge and Iron Company

CCP - Configuration Control Package

C of C - Certificate of Conformance

CEA - Concrete expansion anchor

, CMTR- ~- Certified material test report

CPS -Construction Process Sheet

CSP - Construction Site Procedure

.DCN Drawing Change Notice

DEF - Deficiency Evaluation Form

DER - Deficiency Evaluation Report

-

DR ' - Deviation Report

ECN  : Engineering Change Notice

- Essential Cooling Water

~

'

ECW

, EDP- - Engineering Department Procedure

'

.ERSA - Engineering Request for Site Action

'FCN '- Field Change. Notice

FCR - Field Change Request

FDCC Field Document' Control Center

-FRLL - Field Revision List

. FSAR - Final Safety Analysis Report

HEco - Hatfield Electric Company

I

HL&P - Houston Lighting and Power Company

'

Hunter- - Hunter Corporation

.HVAC - Heating, ventilating and air conditioning

IE - Office of Inspection and Enforcement (MC)

'IEEE

-

- Institute of Electrical and Electronic Engineers

L IPCEA - Insulated Power Cable Engineers Association

'

LP -- - Liquid penetrant inspection

LOCA - Loss-of-coolant accident

MCC. - Motor Control Center

MCM - Thousand circular mils

MIC - Midway Industrial Company.

MOV - Motor operated valve

!- NCR - Nonconformance Report

j3 NDE - Nondestructive examination

AB-1

--

- . - . . . . - - - . - . _ . - . - . . . - . - . - - - - _ . - -

,

NISCo - Nuclear Installation Service Company

' Nuclear Power Service, Inc.

~

NPS'

NRR - Office'of Nuclear Reactor Regulation (NRC)

NRC .U.S. Nuclear Regulatory Commission-

'

.NSSS. - Nuclear. steam system supplier

PAP - Powers-Azco-Pope

. PDM - Pittsburgh Des Moines Corporation

PED Project Engineering Directive-

PSAR . Preliminary Safety Evaluation Report

PSI - Preservice inspection

PTL' - Pittsburgh Testing Laboratories'

QA - Quality assurance

QAI - Quality Assurance Instruction

QAM' - Quality Assurance Manual.

QC - Quality Control-

QCP - Quality-Control Procedure

~

QR - Quality Requirement

RG' - Regulatory Guide (NRC)

RHR - Residual Heat Removal System

RSM - Reliable Sheet Metal Works, Inc.

RTD -- - Resistance Temperature Detector

.SAR - Safety Analysis Report

SDR -. Standard Deficiency Report

SEO. - Site Engineering Organization

SIP - Site Implementation Procedure

SSP - Standard Site. Procedure

STP - South Texas Project

SWI - Site Work Instruction

SWR- - Startup Work Request

UT - Ultrasonic inspection

V - Volt

VT. - - Visual inspection

- Westinghouse Electric Corporation

'

W.

i

AB-2

__ _

._. _.

_

-,

_7

NRC Form 8-C

(4-79)

NRCM 0240

o

COVER SHEET FOR CORRESPONDENCE

Use this Cover Sheet to Protect Originals of Multi-Page Correspondence.

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