ML20151A521

Insp Repts 50-498/88-36 & 50-499/88-36 on 880516-0617. Violations Noted.Major Areas Inspected:Preservice Insp of Components & Component Supports

ML20151A521
Person / Time
Site:	South Texas
Issue date:	07/05/1988
From:	Barnes I, Gilbert L, Mcneill W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV)
To:
Shared Package
ML20151A512	List: ML20151A508 ML20151A513 ML20151A521
References
50-498-88-36, 50-499-88-36, NUDOCS 8807200025
Download: ML20151A521 (8)

See also: IR 05000498/1988036

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APPENDIX B

. U.S.-NUCLEAR REGULATORY COMMISSION

REGION IV

NRC Inspection Report: 50-498/88-36 Operating License: HPF-76

50-499/88-36: Construction Permit: CPPR-129

Dockets: 50-498

50-499

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

P.O. Box 1700

Houston, Texas 77001

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

Inspection At: STP, Matagorda County, Texas

Inspection Conducted: May 16 through June 17, 1988

Inspectors: 8w> 7 - 5 -- P P -

g@< L. D. Gilbert, Reactor Inspector, Materials Date

and Quality Programs Section, Division of

Reactor Safety

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W. M. McNdill, Reactor Inspector, Materials

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and Quality Programs Section, Division of

Reactor Safety .,

Approved: es 7-I-FF

1. Barnes, Chief, Materials and Quality Date

Programs Section, Division of Reactor

Safety

Inspection Summary

Inspection Conducted May 16 through June 17, 1988 (Report 50-498/88-36)

Areas Inspected: No inspection of Unit I was conducted.

Inspection Conducted May 16 through June 17, 1988 (Report 50-499/88-36)

8807200025 88070s

PDR ADOCK 05000498

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! Areas I.ispected: Routine, unannounced inspection of preservice inspection'of

- comprnents and component supports.-

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

promptly identify nonconformances, paragraph 2.d)~. Two unresolved items are

identified in paragraphs 2.c and 2.d.

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DETAILS

1. Persons Contacted'

HL&P

• J. T. Westermeier, Project Manager

• J. E. Geiger, General Manager, Nuclear Assurance

• L. Giles, Operations Manager', Unit 2

• D.- R. Keating, Quality Engineering Manager

• M. A. McBurnett, Operations Support Licensing Manager

• R. L. Beverly, PSI /ISI Supervising Engineer

• J. Haning, Systems Engineering Group, Senior _ Engineer

M. Stewart, PSI Coordinator-Supports

W. Isereau, Operations Quality Assurance Supervisor

D. Murdock, ISI Coordinator-Piping-

Bechtel Engineering Corporation (BEC)

• R. W. Miller, Project Quality Assurance Manager

• R. H. Medina, Quality Assurance Supervisor

F. Almeida, Engineering ABR Group Supervisor

Southwest Research Institute (SwRI)

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R. A. Fougerousse, PSI Project Engineer

J. C. Younger, Research Engineer

Kemper Group

B. R. Russell, Authorized Nuclear Inservice Inspector (ANII)

The NRC inspectors also interviewed other contractor personnel during

the inspection.

• Indicates the personnel that attended the exit meeting.

2. Preservice Inspection.

a. Review of Program (73051)

The NRC inspectors reviewed the licensee's program pertaining to the

preserviceinspection(PSI). The following documents were reviewed

for conformance with the requirements of 10 CFR Part 50.55a(g) and

Section XI of the ASME Boiler and Pressure Vessel Code.

• Interdepartmental Procedure No. 3.04Q, Revision 0, "Preservice

and Inservice Inspection Program."

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Operations Engineering Procedure No. 9.04Q, Revision 0,

"Personnel Certification Procedure for Visual Examination per

ASME B&PV Code,Section XI."

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Unit 2 PSI Weld Examination Plan, ST-HL-AE-2178, dated May_14,

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1987, with changes 1 through 14.

PSI Examination Plan for Component Supports-Unit 2,

ST-HL-AE-2514, dated March 9, 1988.

PSI Examination Plar, for Steam Generator Tubes (Unit 2),

ST-HL-AE-2020, dated April 13, 1987.

Mechanized Scan Plan for PSI of Unit 2 RPV, ST-HL-AE-2274, dated

June 23, 1987.

SwRI Plan 84-HLP-STP-1-1-0, Revision 0 Change 5, "Project Plan

for the Preservice Examination of South Texas Project Electrical

Generating Station, Units 1 and 2."

SwRI Project 17-1480, "Examination _ Plan for the Preservice

Inspection of Selected Class 1 and Class 2 Components of the

South Texas Project Electric Generating Station, Unit 2."

SwRI Nuclear Quality Assurance Program Manual, Revision 2,

Change 13.

Interdepartmental Procedure No. 3.07Q, Revision 3, "ASME

Section XI Repair / Replacement Program."

Specification No. SUO36JS0002, Revision 0, "Specification for

Preservice Inspection of Component Supports of South Texas

Project Electric Generating Station-Unit 2."

Records of licensee Quality Assurance (QA) audit and surveillance of

PSI activities were reviewed by the NRC inspectors. From this

review, the NRC inspectors found that the vendor (Conam) for eddy

current testing of steam generators had been audited (Audit Report

No.88-122) and the vendor (SwRI) for PSI of vessels and piping had

been subjected to QA surveillance (Surveillance Report No. 87-08).

The NRC inspectors also ascertained that com)onent supports PSI for

Unit 2, which is performed by the licensee, lad not been the subject

of audits or surveillances. Licensee personnel informed the NRC

inspectors that it was planned to perform such after hot functional

testing. The NRC inspectors observed that approximately 75 percent

of the component supports had been already inspected and that the

post hot functional testing inspection would be limited to

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observation for damage. The licensee agree 6 to review this

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information and assure itself that PSI of component supports would

indeed be the tubject of surveillance or audit.

No violations or deviations were identified.

'b. Review of Procedures (73052)

The NRC inspectors reviewed the following procedures:

Mechanized Ultrasonic Inside Surface Examination of Ferritic

Vessels Greater Than 2.0 Inches In Thickness. SwRI-NDT-800-120

Revision 0.

Manual Ultrasonic Examination of Austenitic Thin Wall Pioing

Welds, SwRI-NDT-800-36, Revision 37.

Dry Powder Magnetic Particle Examination, SwRI-NDT-300-1,

Revision 33.

Solvent-Removable Liquid Penetrant Color Contrast Examination,

SwRI-NDT-200, Revision 69.

Visual Examination of Nuclear Plant Components, SwRI-NDT-900-7,

Revision 11.

VT-3 Visual Examination of Component Supports, OEP-9.05Q,

Revision 1.

VT-4 Visual Examination of Component Supports, OEP-9.06Q,

Revision 1.

Multifrequency Eddy Current Drocedure Westinghouse Series E2

Steam Generator Tubing MIZ-18 Digital Eddy Current System South

Texas Project, Conam-42-EC-153, Revision 0.

Motorized Rotating Probe Procedure for Westinghouse Series E2

Steam Generator Tubing Expansion MIZ-18 Digital Eddy Current

System South Texas Project, Conam-42-EC-156, Revision 0.

• Guidelines for Data Analysis of MIZ-18 Data Utilizing DDA-4

Digital Data Analysis System Bobbin Coil Examination Sot.th Texas

Project, Conam-42-DA-011, Revision 2.

• Guidelines for Data Analysis of MIZ-18 Data Utilizing DDA-4

Digital Data Analysis System Motorized Rotational Probe Exam of

Support Plate Expansions South Texas Project, Conam-42-DA-014,

Revision 0.

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The procedures were reviewed for their conformance to the

requirements of ASME Code and the established plans. The ANII log

was inspected to verify his review of the procedures.

-No violations or deviations were identified,

c. Observation of Work Activities (73053)

The NRC inspectors reviewed the PSI plans to ascertain whether the

licensee's PSI program met the Safety Analysis Report for number of

items to be inspected, methods of examination, and extent of

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The qualifications and certifications of 2 Level I, 21 Level II, and

1 Level III examination personnel were reviewed by the NRC inspectors

A which included personnel for visual, liquid penetrant, ultrasonic,

and eddy current examinations.

The NRC inspectors observed the following examinations that were

performed as required by the Unit 2 PSI examination plans for .

components and component supports. l

Liquid penetrant examination of Weld Exam 28 on Line 16-SI-2101,

a reactor containment sump suction line for the safety injection

piping system.

Visual examination, augmented PSI VT-3 and VT-4, of component

support SI-2301-SS05 for the safety injection piping system.

Visual examination, augmented PSI VT-3, of component support

SI-2306-HL5012 for the safety injection piping system.

• Visual examination, PSI VT-3, of component supports SGCIA.

SGC2A, SGC3A, and SGC4A for steam generator "A."

• Visual examination, PSI and augumented PSI VT-3 and VT-4, of

component support CC-2105-HL5004 for the component cooling

piping system.

In the areas inspected, the examinations were performed in accordarca

with the examination procedure by certified Level 11 examiners.

However, the NRC inspectors determined that the visual examiners were

not consistent in interpreting the examination boundary where the

support selected for examination was part of a multiple support and

the building connection was not shown on the support drawing but

reference was made to another support for the connection. The visual

examiners were reinstructed to clarify that the examination boundary

for performing a VT-3 examination, as stated in Procedure OEP-9.050,

is from the component to the building structure. The licensee

initiated a review of the supports which had been completed to assure

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that all supports with this type of design included examination of

the. building connection. This subject is an unresolved item pending

the licensee's review of completed examinations for drawings that

reference other support drawings for the building connection

(4s9/8836-01).

No violations or deviations were identified.

'd.. Review of Records (73055)

(1) Component Supports

The following records for completed examinations on seven

component supports were reviewed:

Exam Number Method

CS-2303-HL5001 VT-3

AF-2012-HL5018 VT-3 and VT-4

CC-2106-RH12 VT-3

CV-2121-HS5008 VT-3

RC-2125-HL5003 VT-3

RH-2204-HL5002 VT-3

SI-2102-HL5016 VT-3

(2) Components

The following records for completed examinations on components

were reviewed:

Exam Number Method

SG-28-TR12 PT

SG-28-FW10-IR UT

6-SI-2108-BB1-3 PT and UT

10-RH-2108-BB1-3A PT and UT

(3) Pechanized Examinations

The NRL inspectors reviewed the "Eddy Current Examination

Houston Lighting & Power Co. South Texas Electrical Generating

Station Unit 2 Steam Generators A, B, C, and D April, May, and

September 1987." NonconformanceReport(NCR)Nos.AN-03389,

3365, 3366, and 3388 were examined which documented

nonconformances identified during the inspection by Conam. It

was noted that three tubes were reworked and one tube was

plugged as a result of the PSI inspection. The NRC review

verified the use of qualified personnel and properly calibrated

equipment as well as compliance to the ASME Code and the

approved procedures. The eddy current testing records of Steam

Generator No. A were reviewed in detail. During the NRC review,

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one' nonconforming condition (i.e., bulge) was found in the

initial inspection by Conam; this. nonconforming condition had

not been identified on an NCR for Westinghouse evaluatier.. The

licensee initiated an NCR (No. SN-03778) and reviewed the Conam

data in detail. The licensee's review found four additional

nonconforming tubes (i.e., overexpansions) which had not been

previously identified in NCRs. Again the licensee initiated an

NCR (No. SN-03780) for these additional tubes. Unit I data

which was collected by a different vendor is also under review

presently. The failure to appropriately document nonconforming

conditionsisanapparentviolation(499/6836-02).

The records of mechanized ultrasonic examination of the reactor

vessel were reviewed by the NRC inspe, tors. Only very minor

rework, blending gouges, was perforrad as a result of the PSI.

One intermediate shell longitudina". weld (2-101-124) was

reviewed in detail. From the rev',ew, the NRC inspectors found

that Examination Sheet No. 05001 dated June 24, 1987, referenced

a Resolution Record No. 31034 in regard to a reportable

indication. This resolution record was not available. There

was, however, on the weld's Examination Sumary Record Sheet

No. 001300 a reference to another resolution record which was in

the data and appeared _to address the indication in question. ,

SwRI contended that Resolution Record No. 310154 had been

voided, replaced by the one which was in the package, and the

examination sheet had not been updated to reflect the

replacement record. This subject is considered an unresolved

item pending SwRI furnishing a basis for whid is the correct

resolutionsheet(499/8836-03).

3. Unresolved Item

Unresolved items are matters about which more information is required in

order to ascertain whether or not the items are acceptable, violations,

or deviations. The following two unresolved items were discussed in

this report:

Paragraph Item Subject

2.c 499/8836-01 Review drawings of multiple supports

to assure PSI examination completed

2.d 499/8836-03 Missing PSI examination resolution

sheet

4. _E_xj_t Interview

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The NRC inspectors reet with the licensee representatives denoted in

paragraph 1 on June 17, 1988, and summarized the inspection scope and

findings.

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