ML20199G179
| ML20199G179 | |
| Person / Time | |
|---|---|
| Site: | Comanche Peak, 05000000 |
| Issue date: | 06/11/1986 |
| From: | Livermore H NRC |
| To: | NRC |
| Shared Package | |
| ML20197J178 | List:
|
| References | |
| FOIA-85-59 NUDOCS 8606250114 | |
| Download: ML20199G179 (79) | |
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- d YiY g 9 13 -15 Texas Utf11 ties Electric Company A -
In Reply Refer To: DRAFT j Docket: 50-445/85-03
- i 50-446/85-02 f g' W c.
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, mY Texas Utilities Electric Company .
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- ATTN
- M. D. Spence, President, TUGC0 m g,eweg _ M / G &
o 8 Dallas, Texas 75201 bl e
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Gentlemen: ( , [,
'i This refers to the inspection conducted under the Res$ dent Inspection Program 3 by Mr. J. E. Cumins and others of this office during the period December 19, 1984, th' rough March 31, 1985, of activities authorized by NRC Construction 7%-[
Permits CPPR-125 and CPPR-126 for the Comanche Peak facility, Units I and 2, and to the discussion of our findings with Mr. J. T. Merritt of your staff at r' the conclusion of the inspection. ~$
Areas examined during the inspection included plant status, action on previous findings, action on applicant identified design / construction deficiencies l
(10 CFR Part 50.55(e) reports), review of purchase order and related documentation for fuel building liner plates, followup on 10 CFR Part 21 [. --
i report, Inspection and Enforcement Bulletin followup, action on Special Review Team (SRT) identified deficiencies, special plant tours, followup on alleged improper construction practices involving CPSES main condensers, review of
}- concrete placement procedures, and observations and reviews of reinforcing steel splices. Within-these areas, the inspection consisted of selective i
examination of procedures and representative records, interviews with personnel, and observations by the inspectors. These findings are documented in the enclosed inspection report.
i Within the scope of the inspection, no violations or deviations were j identified.
!s FO)A-85-59 1
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- ---------______n _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
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Texas Utilities Electric Company Should you have any questions concerning this inspection, we will.be pleased to discuss them with you. -
Sincerely, f
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Dorwin R. Hunter, Chief Reactor Project Branch 2
Enclosures:
(, Appendix - NRC Inspection Report 50-445/85-03 50-445/85-02
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{ cc w/ enclosures:
Texas Utilities Electric Company ATTN: B. R. Clements, Vice President, Nuclear Skyway Tower i 400 North Olive Street i Lock Box 81 Dallas, Texas 75201 l Texas Utilities Electric Company j ATTN: J. W. Beck, Manager, L Licensing j Skyway Tower g 400 North Olive Street y Lock Box 81 Dallas, Texas 75201
] Texas Radiation Control Program Director t
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_ _ _ . - .. ._ L e
fi -
- - APPENDIX U. S. NUCLEAR REGULATORY COMMISSION !
REGION IV i '
i i NRC Inspection Report: 50-445/85-03 Permit: CPPR-126 I 50-446/85-02 CPPR-127 Docket: 50-445; 50-446 Category: A2 1 -
Appplicant: Texas Utilities Electric Company (TVEC)
Skyway Tower i 400 North Olive Street t
i Lcck Box 81 l Dallas, Texas 75201 l1 i Facility Name: Comanche Peak Steam Electric Station (CPSES), Units 1 and 2 1
5 Int.pection At: Glen Rose, Texas
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Inspection Conducted: December 19, 1984 through March 31, 1985 l
b j Inspectors:
J. E. Cummins, Senior Resident Reactor Date i
Inspector (paragraphs 2, 3, 4, 5, 7, 10, 11, and 13) l H. 5. Phillips, Senior Resident Reactor Date f
l~
Inspector (paragraphs 11 and 13) j
,/ .
b J. I. Tapia, Reactor Inspector, Project Date Section B (paragraph 8) j _
1>
l 8-D. M. Hunnicutt, Chief, I Reactor Project Section B f (paragraphs 6, 9, and 12) f
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- . - .----;. J. ._ __ L
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S Approved: Date D. M. Hunnicutt, Chief.
Reactor Project Section B (paragraphs 6, 9, and 12)
) i Inspection Sumary i Inspection Conducted: December 29, 1984 through March 31, 1985 j .
i, (Report 50-445/85-03)
Areas Inspected: Routine announced inspection of plant status, action on i previous findings, action on applicant identified design / construction deficiencies (10 CFR 50.55(e) reports), review of Afco Steel purchase order J (PO) for fuel building liner plates, followup of a 10 CFR Part 21 report, Inspection and Enforcement Bulletin (IEB) followup, action on previous NRC inspection findings, NRC Region IV followup on Special Review Team (SRT) identified deficiencies, special plant tours, alleged improper The construction inspection practices involving CPSES main condensers, and plant tours.
involved 162 inspector-hours onsite by four NRC inspectors.
Results: Within the ten areas inspected, no violations or deviations were identified.
1' Inspection Conducted: December 19, 1984 through March 31, 1985 (Report 50-446/85-02)
Areas Inspected: Routine announced inspection of plant status, action on j applicant identified design / construction deficiencies (10 CFR 50.55(e) a reports) IEB followup, concrete placement procedure review, reinforcing steel splices review and observations, review of Afco Steel PO for fuel building j liner plates and plant tours. The inspection involved 26 inspector-hours onsite by three NRC inspectors.
Results: Within the seven areas inspected, no violations or deviations were f p identifieg g
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b DETAILS
- 1. Persons Contacted Applicant Personnel
- J. T. Merritt, Assistant Project General Manager, Texas Utilities *
} Generating Company (TUGCO)
C. H. Welch, Quality Assurance (QA) Supervisor l! T. Jackson, QA Staff Member, TUGC0 D. Eddie, QA Staff Member, TUGC0 G. Sigler, QA Staff Member, TUGC0 P. Mills, QA Staff Member, TUGC0 B. Cromeans, TUGC0 Lab and Civil Supervisor, TUGC0 f The NRC inspectors also contacted other plant personnel during this inspection period.
J 3
- Denotes those present at exit interview.
q j 2. Plant Status i
i At the end of this inspection period, the construction of Unit I was lj 99 percent complete and Unit 2 was 72 percent complete.
- 3. Action on Previous NRC Insnection Findings (Unit 1) y
- a. (Closed) Severity Level V Violation 445/8440-01: Unique Identifier Assigned to two Different 10 CFR Part 50.55(e) Items The NRC inspector p(eviewed the applicants 10 CFR Part b 50.559 e an isolated incident. Procedure CP-QP-16.1 has been revised to specifically state that numbers assigned to 3 voided (10 CFR significant deficiency)
Part 50.55(e) reportsanalysis shall notreports be reused. This 1
j item is closed.
p
- b. (0 pen) Severity Level IV Violation 445/8400-02: Unit 1 Main
> Coolant System Crossover Leg Restraints j The applicant initially responded to this violation in a g
letter (TXX-4271)datedAugust 23, 1984, and submitted a k
supplemental response in a letter (TXX-4294) dated
{ September 7, 1984. Based on information furnished in these two letters, Region IV requested additional information in e
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L a letter dated November 2, 1984. The applicant responded in a letter (TXX-4370) dated November 28, 1984 to the request for additional information and delineated the
/ corrective action that had been taken. The applicant reinspected the crossover leg restraint installation for ,
fj elevation, location, levelness, anchor bolt tightness and correct material. This reinspection of the crossover leg J
1 - restraints was documented in NCR M84-100281 and '
Construction Operation travelers CE-84-131-8902,
) CE-84-132-8902, CE-84-133-8902 and CE-84-134-8902. The NRC f inspector's review of this documentation determined that i
j the corrective action and reinspection resolved this
! specific issue. However, the review of the generic 7 3
implications regarding computer certification reouires~ "t)
! further evaluation. This item remains open.
- c. (Closed) Unresolved Item 445/8410-01: Sealino of Penetrations in the Cable Spread Room
]
The NRC inspector verified that the penetrations in the
) cable spread room wall and fire door E-29 frame had been .
1- sealed. The NRC inspector also reviewed documentation that identified the location and type of seal used for each penetration. Documents were made available to the NRC j inspector that verified that each type seal used had been certified by testing to meet the fire barrier requirements.
j This item is closed.
3 If
- d. (Closed) Severity Level V Violation 445/8422-01: Failure to
)) Maintain a Positive pressure on Electrical Penetrations Applicant personnel took immediate action to repressurize
! the electrical penetrations. The NRC inspector verified I that the pressure gauge readings were as specified in the procedure. The nitrogen pressure on the electrical f'.. penetrations is now checked each shift as required by procedure 0WI-104, Revision 2 " Operations Department ,
' Logkeeping and Equipment Inspections," dated November 15, d 1984. The shift supervisors were instructed by the operations supervisor to be aware of all plant alarm conditions. This item is closed.
- e. (0 pen) -
Severity Level IV Violation 445/8434-01: Su ) port Inst 111ation Nonconfonnances Not Identified )y Inspection The incorrectly installed support and the snubber were reworked and reinspected. Procedure QI-QAP-11.1-28A,
" Installation Inspections of ASME Class 1, 2, and 3 L
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Snubber", was deleted and the snubber inspectio'ns incorporated into Procedure QI-QAP-11.1-28 " Fabrication and Installation Inspection of ASME Component Supports, Class 1, 2, and 3." Revision 24 to QI-QAP-11.1-28 was
, issued to clarify the requirements for snubber and sway g strut installations and. appropriate inspection personnel l
a were retrained in the correct configuration for snubber and "j
sway strut installations. The generic implications of this '
H issue require further review. This matter remains open.
9
- 4. Action on Applicant Identified Design / Construction Deficiencies (10 CFR
{ Part 50.55(e) Reports) (Units 1 and 2) j ij The 10 CFR Part 50.55(e) reports discussed below were reviewed by the NRC inspector and closed. The reports were reviewed for content, compliance
] with NRC requirements for reporting, appropriate applicant evaluation, and
?
d adequacy and implementation of corrective action. Each report is
? identified and tracked by the unique, applicant assigned number.
- a. CP84-02 Applicant's letter (TXX-4108) dated February 8, 1984, J reported to the NRC that linear indications had been found 1 on the emergency diesel generator engine push rods. The
.d applicant has replaced the push rods in both of the Unit I diesel generators and will replace them in the Unit 2 diesel generators prior to operation of Unit 2.
NRC inspector observations during the teardown, inspection
- and reassembly of the Unit 1 emergency diesel generators was reported in NRC Inspection Reports 50-445/84-17 and 7
50-445/84-20.
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- b. CP84-04 The applicant reported by letter (TXX-4109) dated February 13, 1984, that three of the four Unit 1 f safety-related inverter ferroresonant output transfomers g
had failed. This 10 CFR 50.55(e) report to the NRC was discussed in NRC Inspection Report No. 50-445/84-22; 50-446/84-07. The transfomers have been modified by the c
vendor to correct the defect.
1 The 10 CFR Part 50.55(e) report was initiated by the J
- c. CP84-33
' applicant based on a 10 CFR Part 21 report made by Brown Boveri. The 10 CFR Part 21 reported that voltage balance relays (Model ITE-60) were found that operated outside .
specified operating times. Brown Boveri notified the applicant by letter dated November 13, 1984, that the problem did not exist for the Brown Boveri (ITE) i switch-gear furnished to the applicant. The applicant also perfomed a review and determined that the questionable relays were not used at CPSES. The applicant reported by ,
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- letter (TXX-4376) dated December 10, 1984, that this item was not reportable.
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- 5. Inspection and Enforcement Bulletin (IEB) Followuo (Units 1 and 2)
The NRC inspectors reviewed the applicant's file for the IEB discussed j below and perfomed inspections as necessary to verify that the applicant had conducted an adequate review to detemine if the IEB was applicable to
- the.CPSES facility, and to verify that the applicant had taken the action required by the IEB.
IEB 84-03: Refueling Cavity Water Seals This bulletin identified a potential loss of water from the refueling cavity and spent fuel pool due to the failure of the refueling cavity seal during._ refueling operations. The bulletin l
was issued because an incident of this type occurred at the Haddam Neck Nuclear Plant. As directed by the bulletin, the applicant evaluated the potential for and consequences of a refueling cavity water seal failure at the CPSES site. The applicant's response letter (TXX-4373) dated December 4, 1984 J reported that the refueling cavity water seal at CPSES is a 1 different design from the seals used at Haddam Neck. The I refueling cavity water seal at CPSES is a stainless steel ring L that is permanently welded in place and does not require the use i
of any pneumatic type device.- The CPSES refueling cavity water
! seal design is less likely to experience a gross failure than f seal designs utilizing pneumatic seals or gaskets. The
! applicant determined from the evaluation that level alams located in the containment building sump and the spent fuel pool
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would detect leakage from the refueling cavity or spent fuel i pool and that makeup water sources would be available in the event that there was a leak. Prior to the first refueling, the applicant will revise applicable procedures to check the
- refueling cavity for leakage and to explicitly address a leak in j the refueling cavity seal. The NRC review of the refueling 5 cavity leakage check and refueling cavity seal leak procedures during a subsequent inspection is an open item (445/8503-01; 446/8502-01).
f 6. Review of Afco Steel Purchase Order Package for Fuel Building Liner Plates 5 (Unit 1 and 2)
L In response to an allegation, the NRC inspector reviewed the Afco Steel package for PO No. 35-1195-14911 (Job No. a.1d Accot.nt 35-1195-1-0-1312-193703-002) from Brown & Root, Inc. (B&R) to Afco Steel, Little Rock, Arkansas, Change Orders, letters of approval, and related r
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correspondence to this PO to detennine whether B&R had improperly cancelled their contract with Afco Steel.
1 The P0 was let by B&R to Afco Steel on July 6, 1977, for stainless steel i liners (S/SL) and gates for the two spent fuel pools, the S/SL transfer h canal, and the S/SL wet cask loading pit. The PO requirements were .
specified by Gibbs and Hill (G&H) (Specification 2323-55-18, Revision 2; 2323-55-7, Revision 1; 2323-S5-20, Revision 4; and drawings M1-0014 *"
Revision E; M1-0015. Revision E; S-0831. Revision 1; S-0832, Revision 1; l 5-0833, Revision 1: S-0834, Revision 1, and S1-0560, Revision 3). The PO-specified that " Safety Related QA was Required."
f -
l During the course of the contract, B&R processed twelve Change Orders l
between the dates of August 5, 1977, and July 31, 1978. These change orders were required to incorporate changes in scope of work with 1' l drawings, tolerance requirements, method of transmittal of documents,
< material additions required, ar.endments related to monetary conditions, I and reductions in materials required. ,
AB&Rletter(BRF-8550),datedJuly 13, 1978, stated in part ". . . please find a Change Order request from Afco Steel on PO 35-1195-14911 in which they supplied the stainless steel liner for the Fuel Building. . . ." '
This letter also stated that B&R felt the listed monetary credits were 4
reasonable and justified.
} The NRC inspector's review of the documentation revealed no apparent i
j discrepancies regarding the contract between B&R and Afco Steel.
No violations or deviations were identified.
- 7. Followup of 10 CFR Part 21 Report (Unit 1)
The NRC inspector reviewed documents related to a potential 10 CFR Part 21 t report from RTE Delta. RTE Delta reported via letter dated April 3, 1984,
[ to the Director of NRC Region IV that Texas Utilities Services A Incorporated (TUSI) (the responsible organization name was later changed to Texas Utilities Generating Company), had possibly violated 10 CFR Part 21 requirements by actions TUSI had taken in replacing type CFD differential relays in the diesel generator control panels. The NRC inspector reviewed the following documents:
- a. RTE Delta letter to the Director, NRC Region IV, dated April 3, 1984.
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l b. Transamerica Delaval (TDI) letter to TUSI dated April 12, 1984.
, c. Texas Utilities letter to TDI dated August 24, 1983.
- d. Comanche Peak Deficiency Review Report (DRR) No. 046.
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- e. Construction Operation Travelers Z-2485 and Z-2486.
- f. Qualification Report NES 26291-1TR, IEEE Qualification Report for Generator Control Panel.
- g. TUGC0 P0 CPF-11509-5
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- h. TUGC0 Receipt Inspection Report (RIR) 24286 .
The NRC inspector determined from review of these documents and q
discussions with appropriate applicant personnel that the CFD relays were /
replaced by the applicant with prequalified General Electric type IJD52-A l relays. The applicant also revised Qualification Report NES 262991-1TR, IEEE Qualification Report for Generator Control Panel (G8H Specification 2323-MS-34, Revision 1) to reflect the change in these relays. General Electric documentation that verified the relay qualification was attached to the qualification report for the diesel generator control panels.
TUSI provided TDI with specifics of the replacement relay type IJD 52-A by letter dated August 24, 1983. When notified by letter dated April 12, 1984, from TDI of the possible 10 CFR Part 21 violation reported by RTE Delta, the applicant initiated a review (documented on DRR No. 046) to evaluate the situation. The conclusion of the TUSI evaluation was that TUSI was responsible for onsite revisions or modifications and that the activities related to the relay change had been adequately documented.
No violations or deviations were identified.
M
/'
- 8. Concrete Placement (Unit 2)
The NRC inspector reviewed quality related procedures relative to the i proposed placement of the Unit 2 containment building construction opening structural concrete. The review was conducted to ascertain whether these l procedures reflected proposed work accomplishment co1sistent with NRC requirements and Safety Analysis Report commitments. The following procedures for the proposed concrete placement in the Unit 2 containment L wall were reviewed:
B&R Procedures i No. 35-1193-CCP-12, Rev. 4. " Concrete Petching, Finishing and Preparation f of Construction Joints" h No. 35-1195-CEI-24, Rev. O, "Rebar Prepour Inspection for Containment #2 j Exterior Only" 9
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[ No. 35-1195-CCP-14. Rev. 4, " Concrete Prepour Inspection and Pour Card Sign Off" ll Nu. 35-1195-CCP-10, Rev. 5. " Concrete Batch Plant Operations" No. 35-1195-CCP-11, Rev. 0, "C'oncrete Placement" 1 No. 35-1195-CCP-13, Rev. 3. " Concrete Curing" -
l TUGC0 Procedures g
i No. CP-QP-11.0, Rev. 4, " Civil Inspection Activities" -
1
- No. QI-QP-11.0-3, Rev. 5. " Concrete or Mortar Placement Inspection" j No. QI-QP-11.0-2, Rev. 4 " Reinforcing Steel, Miscellaneous Steel and 1 Embedded Item Placement Inspection" t
i No. QI-QP-11.0-1, Rev. 5, "Cadweld Inspection Activities" -
u No. QI-QP-11.0-8,'Rev. 2, " Concrete Production Inspection" I
No. QI-QP-11.0-4, Rev. 4. "Sunner Concrete or Mortar Curing Inspection" jl The procedures were found to comply with NRC requirements and Safety
- Analysis Report connitments. Specifically, the applicable portions of the
- following documents were found to have been incorporated in the review procedures
l j American Concrete Institute Documents
) No. 318-71, " Building Requirements for Reinforced Concrete" !
LI No. 301-72, " Specification for Structural Concrete for Buildings" i
No. 614-59, "Reconnended Practice for Measuring, Mixing, Transporting, and Placing Concrete" No. 308-71, "Reconnended Practice for Curing Concrete" h -
Although a specific concrete placement plan had not been developed for the construction opening, discussions were held with the engineers responsible for its generation. Since the actual plan was not expected for another six weeks, a similar placement plan previously used in the auxiliary g
building was presented to show those attributes to be considered. The proposed placement plan contents were also found to consider those admonitions from the American Concrete Institute which, when employed, f will yield satisfactory concrete placements. i j
- 0 No vio1ations or deviations were identified.
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- 9. Reinforcing Steel Splices (Unit 2) l a. Records Review of Crew Qualifications l The NRC inspector reviewed the qualifications records of 16 cadweld
- personnel. Applicable experience and education for each person was j included in the qualification records. The records indicated that each person had prepared two qualification splices for each of the
- three cadweld splice positions (horizontal, vertical, and dia
- The cadweld splices were made using No. 18 reinforcingrebar). bars (gonal).
l Each cadweld splice met the requirements specified in Regulatory Guide 1.10. " Mechanical (cadweld) Splices in Reinforcing Bars of l Category I Concrete Structures" and G8H Specification No. 2323-SS-11, j
Revision 2.
Each cadweld crew member had been instructed by a representative of the manufacturer in the preparation of cadweld splices for each of
, the three splice positions. Each cadwelder had been assigned a
!, unique identification number (symbol) consisting of two letters.
i l
- b. Observations of Cadwelding of Rebar l The NRC inspector observed five preparations for cadwelding rebar j splices on five different days and observed the following:
(1) the ends of the rebar were cut reasonably square, were clean and free from slag or adhered weld splatter or rust scale, and a j reference line had been marked on each rebar; I (2) the rebar ends and the cadweld splice sleeve were checked for location (centering);
(3) the fiberglass roce was properly inserted into the spaces between the splice sleeve and the rebar; (4) the cadweld carbon receptacle which acts as a receiver for the cadweld powder and a carbon funnel to channel the molten metal into the sleeve volume to fonn a splice between the two rebar ends and the splice sleeve was properly and securely attached prior to loading the cadweld powder;
. (5) after each cadweld splice had been completed and permitted to l cool, the weld surface area was cleaned and inspected; f
!. (6) the acceptance standards for visually inspected cadweld splices
- were in accordance with American Weld Society (AWS) D1.1-72, f ,
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. i Section 8.15. Regulatory Guide 1.1 and G&H Specification No. 2323-SS-11 Revision 2; and l (7) rejected (unacceptable) cadweld splices were rencved in 1 accordance with AWS 01.1-72, Section 3.7. -
j -
- i c. Nonconfomance Report (NCR) on Rebar Due to Longitudinal Seams
! A No. 18 rebar was tagged with an NCR (C-85-200-210) due to j longitudinal seams identified during visual inspection. A representative from the rebar fabricating company inspected this rebar and otner rebar with visually observed seams. The l representative evaluated the seams and submitted a letter discussing
. rebar seams. The letter, dated March 14, 1985, and supporting test
? results indicated that longitudinal tensile tests on rebar with se6ms
} in excess of 3/4" have been perfomed. The test results indicated that no propagations or failures in full section (the cross sectional ll area is 4 square inches) testing occurred in tests performed in i accordance with Specification ASTM A-615 which is designed for tensile testing in the longitudinal direction. 4 gf g gJ
- d. Rebar Certifications M .
a
( Material Specifications
. The NRC inspector reviewed the certifications for No.18 rebar.
t Those certifications indicated that the rebar conformed to the
- i requirements of ASTM A-615-72, Grade 60. The certified minimum yield i strength is 60,000 psi. The minimum certified ultimate strength is
.i 90,000 psi. The minimum certified elongation is 7 percent in 8 inches.
1 i No violations or deviations were identified.
l1
- 10. NRC Region IV Followup on Special Review Team (SRT) Identified Deficiencies (Unit 1) ,
}
During the period from April 3, 1984, to April 13, 1984, the NRC SRT conducted a review at the CPSES site, of activities related to construction, inspection and testing. Details of the SRT review were documented in a report that was transmitted to the applicant via letter dated July 13, 1984. In Section E.b.(8), page 36, of the report the NRC SRT inspectors noted 14 deficiencies in pipe supports that were identified i during a field walkdown in the Unit 1 containment building. Two of these deficiencies (Supports CC-1-295-005-C53R and MS-1-151-025-C52K) were
$ considered to be a potential enforcement item and the details of the t Region IV followup action for these two supports were reported in NRC Inspection Report No. 50-445/84-34; 50-446/84-13. The NRC inspector I
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verified that the applicant had taken adequate action to correct nine of the remaining deficiencies by reviewing the applicant's documentation, discussions with cognizant applicant personnel, and field inspections as necessary. The nine SRT deficiencies inspected during this report period are listed below. The applicant's NCR that documented the corrective-action is also listed. The generic i T 49 +4aac of these deficiencies i will be followed up during review of the Comanche Peak Response Team - L g )
Action Plan. *'
Status NCR Support No.
Snubber connection cotter keys missing M-13377 l CC-1-218-012-C53K Snubber connection cotter keys missing M-13380 CT-1-038-436-C62K No washers in rear bracket Snubber connection cotter key missing M-13383 CT-1-117-405-C62K Snubber safety wire broken M-13382 CT-1-117-415-C62K The south snubber was installed M-13376 CT-1-053-444-C62K
- improperly Snubber cotter keys missing M-84-01113 DD-1-046-020-C65R Snubber safety wire broken M-13381 FW-1-096-705-C62K Snubber cotter key missing; needs M-13379 FW-1-102-002-C62K relative adjustment on snubber s
Snubber cotter keys not bent M-13378 FW-1-102-003-C62R l
i No violations or deviations were identified. ~
I
- 11. Special Plant Tours (Unit 1)
[
On January 10, 1985, the NRC inspector conducted a tour of selected areas I of Unit I andReview Technical Unit 2. Team The (TRT) group consisted of two NRC inspectors, ar L allegers (who were brought to the site to specifically With locate hardware h
which had previously been alleged to be deficient). the allegers' 5
consent a tape recorder was used to note locations and describe any ,
) alleged deficiencies. The TRT is analyzing this information and will j decide what action should be taken.
l -
During this plant tour a portable welding rod oven was observed to be 3
empty and was without paperwork. The NRC inspector discussed this with a t
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j B&R supervisor to determine how long the welding rod had been outside the heated oven. The welding supervisor did not know who had checked out the oven and welding rod; did not know what procedure controlled welding rods; did not know.the general content of the procedure which controls welding
- rod material; and could not find the procedure in his work area. The NRC f inspector further determined that 13 welders worked for this supervisor and that the welding oven in question belonged to this supervisor. He was
- asked how he knew his men were following procedures, if he did not know the requirements of the procedure. He replied that he relied on his men and the training they had received.
The NRC inspector discussed this matter with TUGC0 Assistant Project General Manager and as a result 73 welding supervisors were retrained and tested on CPM 6.93 " Weld Filler Material Control." One of 73 failed the test after receiving training. In addition, training was administered to welding supervisors concerning other welding procedures depending on their scope of responsibility. The following are the results:
Procedures No. Persons Test Failures WES 29 (Welding Structural Steel) 43 3 CP-CPM 9.10 (Welding ASME Hangers) 36 0
! CP-CPM 6.90 (Welding Piping and 37 6 Components)
A B&R Memo (28140) dated January 15, 1985, indicated that after additional training was given all passed the test. This memo indicated thr.t the j
reason for the failure was the fact that the individuals only occasionally used or needed to refer to a specific type item. One failure was attributed to a supervisor having no welding related responsibilities.
The NRC inspector considers this itam e :: clued nanding the review of M#
four concerns: (1) the survey was confined only to welding supervisors I g~ ~ ' ', 4, /
even though 6 of 37 failed to pass the test on welding piping and ' '
components (i.e., what about electrical, civil, startup, and operations);NO $
(2) QA surveillance was performed after instruction and testing, not before; (3) the action, which was confined only to welding supervisors, appears to be a failure to take generic corrective action; and (4) a surveillance was not completed to detennine craft knowledge on CPM 6.93 even though one of three craftsmen failed the test given by the site surveillance group on January 11, 1985.
I On February 5, 1985, the NRC inspector conducted a plant tour with the NRC f Contention Panel 5 members.- The purpose of the tour was to observe the i quality of construction in Unit 1 and to observe some of the deficiencies I
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g identified by the NRC to TUEC management in a series of meetings between the NRC TRT members and TUEC management, staff, and consultants.
On February 25, 1985, the NRC inspector conducted a tour for a number of NRC licensing personnel and NRC consultants to observe mechanical hangers, restraints, and snubbers throughout Unit-1.
l On March 7,1985, the NRC inspector and a TRT member from NRR conducted an
! inspection of selected areas in Unit 1. The purpose of this inspection I was to allow an alleger to physically identify areas that were alleged to j be deficient. Several NRC consultant personnel, who were members of the i TRT and who had followed up on specific allegations, went along to I evaluate specific deficiencies that were to be pointed out. With the j consent of the alleger, a tape recorder was used to note locations and describe the alleger's concerns. This inspection centered on visually inspecting the stainless steel liner plate in Units 1 and 2 reactor refueling cavities and the copper-nickel tubes in the condenser. The TRT I ijs analyzing this infonnation and will decide what action should be taken. /
l No violations or deviations were identified.
j 12. Alleged Improper Construction Practices Involving CPSES Main Condensers
- (Unit 1)
I i A potential safety concern from an alleger was forwarded to TUEC by an NRC l letter dated June 19, 1984. The allegation had been expressed during an
' interview conducted on August 24, 1983, by members of the NRC Office of i Investigation (OI) Field Office. The allegation concerns were assessed by j the TRT and were documented in NUREG-0797, Supplement No. 8, pages K-111
- through K-113.
l The NRC inspector reviewed the applicant's July 9, 1984, response to the 1 NRC June 19, 1984, letter. NRC inspectors perfonned inspection activities
! during the scheduled Mini-Hot Functional Testing (Mini-HFT) Program during
? late 1984. NRC inspection observations and a review of NCR 84-0229 1 determined that the condenser was of acceptable cleanliness insnediately J prior to and during the Mini-HFT test period. NCR 84-0229 and Revision 1
!j to NCR 84-0229 indicated that following HFT during the period between p January 1983 and May 1983 debris collected in the condensers as a result j of various work activities perfonned between mid-1983 and mid-1984; however, the debris was removed prior to the start of the Mini-HFT. The Unit 1 condenser is clean and closed at the present time. Surveillance of the condenser cleanliness.will be determined by the applicant through water sampling and analyses. The water analyses will determine water purity (quality) as required by Procedure STA-610 " Secondary Water l Chemistry Control Program," Revision 2. The water will be analyzed for chlorides, dissolved oxygen, silicone, and other chemical compounds to e
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i determine the purity of the water and assure that deleterious chemicals j do not remain in the water for the secondary side of the steam generators.
1 i No violations or deviations were identified.
- 13. Routine Plant Tours (Units 1 and 2) ,
t '
l At various times during the inspection period, the NRC inspector conducted general tours of the reactor building, fuel building, safeguards building,
? electrical and control building, and the turbine building. During the j tours, the NRC inspector observed housekeeping practices, preventive i maintenance on installed equipment, ongoing construction work, and discussed various subjects with personnel engaged in work activities.
No violations or deviations were identified.
, 14. Exit Interviews l
i The NRC inspectors met with members of the TUEC staff (denoted in
~
- paragraph 1) at various times during the course of the inspection. The scope and findings of the inspection were discussed. The applicant j acknowledged the findings.
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PROCEDURE ISSUE REVISION PAGE NUMBER DATE TEXAS UTIUTIES GENERATING CO CPSES CP-Q P-17.0 4 APR 2 7 m ,I f2
' A 4 PREPARED W/
U;#/Me w I ~
COR9ECTIVE ACTION ATE 4
1
[
APPROVED BY: / 8/W M
['0 ATE I-
1.0 REFERENCES
J 1-A CP-QP-15.7, " Tracking of Audi t Reports / Corrective Action 4 Reports"
]
2.0 GENERAL C 0" C R 0'_'_ D C 0 3 Y 2.1 PURPOSE AND SCOPE CONTROL No. PIM-o'R This procedure describes the methods utilized by TUGC0 .-
QA in reviewing _ construction deficiencies and -- c' -
! nonconfomances for the purpose of providing corrective g .yg action to preclude repetition of significant conditions ,
~
adverse to quality. The scope of this procedure encompasses safe ty-r_ elated construction activities , at CFSES that are identified as deficient or nonconforming and which any require corrective action.
2.2 RESPONSIBILITY The Quality Assurance Supervisor and the Quality Engineering Supervisor are responsible for the evaluation of the need a
j jh M / ,for corrective action in a systematic, timely and ef fective manner, as described herein, within their area of f
yesponsibili ty p g 7f,p fraye c y, ,y . i 3.0 PROCEDURE 3.1 BASIC ACTIVITIES l Quali ty Assu rance/ Quality EA/fineering personnel are l routinely involved in the follovfag basic activities:
l 1
i F01A-85-59 acn.p. AnfrAg y yY 9}o,f f TUGeo CA
%y e
I ,. e _, m _ _ __ -
=
4 t
& 'o PROCEDURE REWSION NUMBER E PAGE TEXAS UTILITIES GENERATING CO.
1 CPSES CP-QP-17.0 4 APR 2 7 @ 2 of 2 f c
]
)b y .
- a. Review of nonconfomances and unsatisfactory conditions documented on Nonconformance Reports, Inspection i i g Reports, and QC Deficiency Reports.
l t
- b. Frequent discussions with cognizant personnel.
j c. Moni toring/ Surveillance Activities.
of Cons truction l l
1 'h* d. Review of Field Design Changes / Deviations.
{ *l I
j' u The results of these activities fonn the basic background data for evaluating conditions which may require corrective .
action. Wh a ible, the evaluation results are tracked <3 l
d7 '
using tren analysis echniques as an objective method of ~1 ascertaining the need for corrective action.
J, q
- 3.2 REPORTING q 3.2.1 Quarterly Trend Analysis Reports u) '
gh J Each cale iar quarter a trend analys.is report ' pre]ared i) for the _QE Supervi sor. 1his trend analysis g i ed ? 7 j f
- on he review of deficiencies reported on Inspection rts,I g 1 9
1 e( <le Deficiency, Reports, and Nonconfomance Reports and A yj j t f
The Site QA Manager :
J g will issut/ Corrective Action Requests per Paragraph 3.2.2 Mfp/, g) }w for field trendsdest (saschanges and deviations.
identified adverse to quality. '
a g me 3.2.2 Corrective Action Request .Ovk{3,7 I -
x, k g #
M When are identified through
/
o/ the conditions activities adverse in Paragraphto quality 3.1 / that, due to their W I g
significance and/or repeti tive na tu re, requi re immediate M. #
attention the Site QA Manager shall islue a Corrective I
! ,q Tiition Request _ (CAR) in a fomal letter to appropriate f l 2 personnel . The CA hall specify a date by l;
J hga
-d (,C 7 h,;7 m 3 management w4 which wrl .en response is Impleuen from tne addre
'on of stated corrective action shali De Wr Nsse N N by Site 44, this verification will be documented and the % g
- k responsible manager notified as to the acceptability of h/ 4
%M' corrective action by memo from the Site QA Manager. :
he gJh of open CAR's will be in accordance with g C Meterence 1-A. '
Tllitf*n O4
[ m ._ _---my.-._ . , _
- m. . -- --
_-_-__-,-. ________7-.- --._
^ ^ ^ ^
, . . . . - ...., y miimresiiimsw_ -
PROCEDURE REVISION ISSUE I NUMBER DATE PAGE LITIES GENERATING CO l CPSES '
CP-Q P- 17. 0 4 1- f 2
- APh 2 7 W {
A -
PREPAR2D -
1)
- ~
f S/Ag W CORRECTIVE ACTION- ATE l
APPROVED BY: / g//W M u '
['0 ATE I l
1.0 REFERENCES
~
1-A CP-QP-15.7, " Tracking of Audi t Reports / Corr 6ctive Action l Reports" 2.0 GENERAL C 0 m 0'__ D C 0 3 Y 2.1 PtJRPOSE AND SCOPE CONTROL No. PlM-N l
- This procedure describes the methods utilized by TUGC0 ,
J QA in revieking _ construction deficiencies and MgE' nonconformances for the purpose of providing corrective action to preclude repetition of significant conditions g/?d'.~
.; adverse to quality. The scope of this procedure encompasses I safe ty-rela ted construction ac.tivities at CFSES that are i q identified as deficient or nonconforming and which nay I
- 3 require corrective action.
B j 2.2 RESPONSIBILITY The Quality Assurance Supervisor and the Quality Engineering l of the need I Li
, jh Mj /
[ Supervisor manner, are responsible
, for carrective as for the evaluation action in a systematic, timely and ef fective described herein r within their area of l
d /" responsibili ty gp f,.y 3',g. f,ty .
y,1 1 3.0 PROCEDURE 3.1 BASIC ACTIVITIES f
l Quali ty Assu rance/Quali ty Eat neering i personnel are f routinely involved in the follovfag basic activities:
3 u
I !
mg Tuoco cA !
l
a
.m. . - - . . ,
PROCEDURE REVISION ISSUE PAGE NUMBER DATE l iflES GENERATING CO.
, uSES 4 -2 of 2 CP-QP-17.0 APR 2 7 198a 5 l
- a. Review of nonconfonnances and unsatisfactory conditions i documented on Nonconformance Reports, Inspection j 4
g /, Reports, and QC Deficiency Reports. j l
j b. Frequent discussions with cognizant personnel.
j Li c. Monitoring / Surveillance of Cons truction i
}j Activities.
~
i gf d. Review of Field Design Changes / Deviations'.
l .
\ The results of these activities fonn the basic background
] data for evaluating conditions which may require corrective. ,
1 action. Wh s%1e, the evaluation results are tracked .
g'l i
j d7 '
using tren analysis echniques as an objective method of ascertaining the need for corrective action. ,
i 7
3.'2 REPORTING 3 g 3.2.1 Quarterly Trend Analysis Reports u.)
' Each c_ ale iar currter a trend analys,is report els; preaared i d fo r the QE Supt rvi sor. Inis trend analysis i 7 on he review of. ceficiencies reported on Inspection R/eports #s yed,3? li ?
et </8 Deficiency, fieports, and Nonconfonnance Reports and (certy 4l
!,j j / q [wur field desifs changes and deviations. The Site QA Manager .
f will issut/ Corrective Action Requests per Paragraph 3.2.2 7 for trends identified as advers'e to quality.
y j 3.2.2 Corrective Action Request , (VA ft s
'd5 k '
When conditions adverse re identified through j
, ,' o/ the activities in Paragraph 3.1 to quali ty / that, significance and/or repeti tive na tu re, require _immediate attention the Site QA . Manager shall issue a Correctiv6 due to their ; i l
, 'Alition Request _ (CAR) in a fonnal letter to aporopriate , i m '2
- management personnel . The CAR shall specify a date by h_J[ b^7 which wr/p.en response is uirTfrom the addressee _f M b' C
] g jp,; e 4 Implement 4 don of stated e corr @ctive action shali De veritied @
. by Site 4, this verification will be documented and the g f.,
4 , ,
responsib(le manager notified as to the acceptability of 7j"f O corrective action by memo from the Site QA Manager.
3 *< i.
es ;
Tracking of open CAR's will be in accordance with g d ' g/ Y. e erence 1-A.
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,. PROCEDURE REVISION ISSUE l PAGE UTILITIES GENERATING CO NUMBER DATE t j C SES CP.QP.15. 7 2 ' 1 of 4 "
y JUL 2 61983 26 s.
e 7 PREPARED BY: h A.> d'Ad dJ d4 7 5~ 13 W -*
TRACKING b c DATE '
AUDITREPORT]S/
RRECTIVE ACTION 1r- REPORTS q/f
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j' ' APPROVED BY: , .
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1.0 REFERENCES
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[i 2.0 GENERAL C0n0__D CO?Y
{ - CONTROL No ~PM-coa 2.1
~
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- PURPOSE
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The purpose ofethis procedure is to describe the method r -
- trackino_ Audit Report / Corrective Action (Report (CAR j findings from the time of receipt of the report until fo rmal i closure of each item.
'i 2.2 RESPONSIBILITY AND AUTHORITY .
. ft,t3 N '7 - The Site QA Supervisor has overall responsibility for
! cc3 r a' 4 timely responses to Audit _ Report / Corrective Action Report j findings. The g.ASME QA SupervT soDhall be responsible g/w)]I g.p_ M for implementing the tracking system described in this M k
'geb k sh -procedure and to ensure timely response to Audit Report / l
] {q Corrective Action Report findings. (
, f p p o 3.0 PROCEDURE 7 ; j 3.1 RESPONSE ASSIGNMENT g y,w, 1 4 1 Upon receipt of the Audit Report / Corrective Action Report,
. personnel shall be assigned the responsibility to respond
/
udi-t---Report %ve Action Report findings. .T.he Q on.ASME QA Supe,r. visor '; hall--make _the_ assignment . .of . ,(
m,* i, personnel to respond to a finding. , s
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INSTRUCTION REVISION ISSUE N ER NE PAGE 3 UTILITIES GENERATING CO.
CPSES 6-
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CP.QP.15.7 2 JUL 2 6 1933 2 of 4 ;
7 7
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3.2 ASSIGNED RESPONSES f, 7
- g. ko!
The reports shall be transmitted to the individual assigned '
the responsibility .to provide a response. The transmittal
.I i shall show a requi A response date. Nomally the required f i
response shall be from the date of the transmittal.q h, Extensions to response dates may be made upon written) 4 o
/f pf justification to the Non.ASME QA Supervi sor. When rg extensions exceed the response due date of the report, the <
(lJW
- Site QA Supervi sor shall formally request an extension. g 4 "* '
7 3.3 OPEN ITDiS REPORT . t
~
- Ar ort shall be generater providing a brief status of each M e ort.
pub Thi s report (Attachments 1 and 2) shall be Individuals assigned a response due date!
]i s 4
7 which falls ed urmg the week when the report is issued shall hhj ,/'[.
p t be verbally reminded that the response is due.
response is not received before the due da te , a fomal t If a g is9f 'fj -
J+ ,-
request for the response shall be responsible individual, requesting immediate action.
delivered to the Any fhQ .[g,,,'i.,
response overdue more than two (2) days, without an approved f. ' j f p' <.
extension, shall be brought to the attention of the Non-ASME -.r'4 QA Supervisor for resolution. Items shall remain on the gh .<h.
report until such time the Non ASME QA Supervisor _ is p ('g' h,;~ .sf
notified the report has been closed. 7 gjg af ,; f, j 3.5 RESPONSE REVIEW l
1 After receipt of the response, the Non-ASME QA Supervisor j shall review the draft response for adequacy and upon 1 approval, shall forward the response to the Site QA
] Supervi sor for review and forwarding to the proper _ .
individual.
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i PROCEDURE ISSUE l REVISION PAGE TEXAS UTILITIES GENERATING CO NUMBER DATE CPSES s CP,QP.15.7 2 1 t4
-JUI. 2 6 1983 l 7 PREPARED BY: h dd4dA 7 5 13 DATE'
- i. TRACKING OF e
[ AUDIT REPORTS /
{ RRECTIVE AC ON e
/)
/f(,
[
REPORTS APPROVED BY:
- f OATE l
j
1.0 REFERENCES
2'0 GENERAL con 0__D CO?Y '
L CONTROL No. PM-ooA -
2.1
~
PURPOSE '
f' A The purpose of this procedure is to describe the method -
r tracki na_ Audit Report / Corrective Action (Report (CAR findings from the time of receipt of the report until formal closure of each item.
I 2.2 RESPONSIBILITY AND AUTHORITY .
' hil gund M "(- The Site QA Supervisor has overall responsibility for timely responses to Audit Report / Corrective Action Report M findings. The n ASME 0ATpervisoDhall be responsible g/w)Ig Q for implementi the tracking system escribed in this d / b g N rd procedure and to ensure timely response to Audit Report '
h,6 g Corrective Action Report findings.
l w
g .O o 3.0 PROCEDURE 7
?( j
\
l k k95 .> -. lf) 3.1 ni RESPONSE ASSIGNMENT
'il Upon receipt of the Audit Report / Corrective Action Report, g s personnel shall be assigned the responsibility to respond
+0 Audit "cpe rt/Cerrect,ive i Action Report findings. The i on.ASME 1A. Supervise --shall ma ke.- _the_a s signment_._of-.7 a Apersonnel to respond to a finding. , s
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INSTRUCTION ISSUE PAGE REVISION UA f -
TEXAS UTILITIES GENERATING CO.
, CP.QP.15.7 2 JE 2 6 1983 2 of 4 e
? .
3.2 ASSIGNED RESPONSES 7 The reports shall be transmitted to the individual assigned g 4 the responsibility to provide a response. The transmittal shall show a requ _ response date. Normally the required r h- response shall be ' from the date of the transmittal.
j l
Extensions to response justification to the dates may be made upon written k Non.ASME QA Supervi sor. WhenI f( #
[
( 9 I- extensions exceed the response due date of the report, the l Site QA Supervi sor shall formally request an extension. y k' 3.3 OPEN ITDiS REPORT t Ar ort shall be generated roviding a brief status of each
,M e ort. This report (Attachments 1 and 2) shall be ed wee Individuals assigned a response due date!
j s 4
7 pub which fal uring the week when the report is issued shall 37'[' 0 ,
{
-L be verbally reminded that the response is due. If a I [
i Y response is not received before the due da te , a fonnal t ,
.t/ the response shall be delivered to the l
i ' '
request for responsible individual, requesting immediate action. Any g/g. ,
} response overdue more than two (2) days, without an approved j extension, shall be brought to the attention of the Non ASME h, ,
- QA Supervi sor for resolution. Items shall remain on the report until such time the Non.ASME QA Supervisor, is (
notified the report has been closed.
gf g g -g, '
j 3.5 RESPONSE REVIEW After receipt of the response, the Non ASME QA Supervisor j shall review the draft response for adequacy and upon approval, shall forward the response to the Site QA Supervisor for review and forwarding to the proper _ "
individua .
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__ DT PROCEDURE REVISION ISSUE PAGE NUMBER DATE TE'(AS UTit.lTIES GENERATING CO.
s CPSES g
CP-QP-15.7 2 JUL 2 6 138, 3 of 4 6 .
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ATTACHMENT 1 g
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AUnti REPURTS opEn
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" .P- 56 kROJECT TRA!N!NG & Responded 12/21/H2 (SC5) *oriCONFORMANCE5 j
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- .-_ , 1 PROCEDURE REVISION ISSUE PAGE NUMBER DATE y TEXAS UTILITIES GENERATING CO.
i CPSES CP-QP-15.7 4 Of 4 2 R 2 6 M3
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ATTACHMENT 2 1
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CORRECTIVE ACTION REPUMTS OPE'.
l j **R 012 Jncontrolled ' Jrawing !!/4/32 receives r.34ponse 4 (JSG) l CAR-313 Rejection Rate of Cable 11/16/32 received response (J5G) Tray Hangers l
GR-014 Storage of Electrical !?/b/s.' reseiv.ed r nponse
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