IR 05000498/1982009

IE Insp Repts 50-498/82-09 & 50-499/82-09 on 820501-31.No Noncompliance Noted.Major Areas Inspected:Const Activities Re Transfer of Engineering & Const Mgt Functions from Brown & Root to Bechtel Power Corp

ML20054M526
Person / Time
Site:	South Texas
Issue date:	07/02/1982
From:	Boardman J, Breaux D, Crossman W, Hill W, Hubacek W, Oberg C NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV)
To:
Shared Package
ML20054M520	List: IR 05000498/1982009 ML20054M519
References
50-498-82-09, 50-498-82-9, 50-499-82-09, 50-499-82-9, NUDOCS 8207130550
Download: ML20054M526 (21)

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APPENDIX l

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I U.S. NUCLEAR REGULATORY COMMISSION

REGION IV

NRC Inspection Report: 50-498/82-09 50-499/82-09 Dockets: 50-498/50-499 Category A2 Licensee: Houston Lighting and Power Company P. O. Box 1700 Houston, Texas 77001 j

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Facility Name: South Texas Project, Units I and 2

Inspection at: South Texas Project, Matagorda County, Houston, Texas, l San Francisco and Campbell, California i Inspection Conducted: May 1982-Inspectors: M eh - 7/2/82-

/),41. M. Hill, Resident Reactor Inspector Date

'O Details Section A, paras. 1, 2, 3, 4, 5, 7, & 8 d A dMa<v 7///c 2-C. R. Oberg, Inspedtion Specialist, Details Date Section B l

0 mk0 llo-,' 7hku D. G.grJaux, Reside 5t/Ir$pector, Details Gate' "

Section C

' j dokwon R. Boardman, Reactor Inspector, Reactor yhhv Date '

Project Section B, Details Section A, par. 6 Reviewed: /W e ' +-- [p[f T -

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W. G. Hubacek, Consultant STP Approved: rc e -

W. A. Crossman, Chief, Reactor Project Section 8 Date 8207130550 82070s

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hDRADOCK 05000498 PDR

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C%d ,00 C. J. Q , Cliief, Reactor System Section 7/u Date n'

Inspection Summary Inspection Conducted During the Period of May 1982 (Report 50-498/82-09; 50-499/82-09)

Areas Inspected: Construction activities related to the transfer of engineering and construction mana0ement functions frc'n Brown & Root (B&R)

to Bechtel Power Corporation (Bechtel) including: Bechtel review of the existing design; assessment of the Quadrex Report findings; site caretaking and maintenance activities; material procurement, control, and procurement documentation. The inspection involved 283 inspector hours by four NRC inspector Results: No violatio is or deviations were identifie _ - _ _ _ _ _ _ _ _ _ _ _ _ _ - _ _ _ - - _ _ - _ _ _ _ .

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DETAILS SECTION A Persons Contacted Principal Licensee Employees D. G. Barker, Project Manager

• J. E. Geiger, Project QA Manager

• D. R. Keating, Project QA General Supervisor T. J. Jordan, Project QA Supervisor, Design / Procurement

• J. W. Williams, Project Site Manager S. M. Dew, Engineering Manager

• P. Morrow, Construction Superintendent

• F. Bednarczyk, Project QA Supervisor, Civil J. N. Bailey, Supervising Project Engineer, Special Coordinator Other Personnel B. L. Lex, Project Manager, Bechtel Power Corporation (Bechtel)

• L. W. Hurst, Project QA Manager, Bechtel K. R. Dotterer, Project QA Engineer, Bechtel

• A. W. Stenersen, Deputy Project QA Manager, Bechtel E. Rumbaugh, Assistant Project Manager, Bechtel B. R. McCullough, Construction Manager, Bechtel J. R. Downs, Deputy Construction Manager, Bechtel S. T. Cozzens, Project Quality Engineer, Bechtel W. Straight, Quality Engineer, Bechtel

• J. Crnich, Construction Manager, Ebasco Service, Inc. (Ebasco)

• C. L. Hawn, Quality Program Site Manger, Ebasco R. Cummings, QA Site Supervisor, Ebasco The NRC inspectors also interviewed other licensee and contractor personnel including members of the engineering and QA/QC staff * Denotes those persons attending one or more management meetings during May 198 . Site Tour Routine tours of the site were conducted by the Senior Resident Inspector to observe housekeeping activities; general cleanliness; protection and preservation of equipment and material; personnel access control; and plant status. Areas observed included: Units 1 and 2 Reactor containment buildings, mechanical-electrical auxiliary buildings, fuel handling buildings, and diesel generator building .

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2 Site-Reservoir, essential cooling pond, and storage areas, including the warehouses, laydown areas, and the welding fabrication sho With regard to the above areas, the inspector confirmed the following:

Safety related and storage areas were free from accumulations of trash, refuse, and debri Work areas were clean and orderl Tools, equipment, and material were returned to their proper storage locations when no longer in us No unsatisfactory conditions were identifie . Site Transition Relative to contractor documentation of plant status, the NRC inspector reviewed the following drawings and supporting documentation packages: Cable Trays FSHE-AX1-079 Structural - Cable Tray Hanger; Section Between Elev. 60'1" and 74'0", Electrical Auxiliary Building-Unit 1 - Sheet 12 of 13 FSHE-AX1-082 Structural - Cable Tray Hangers; Miscellaneous Details, Electrical Auxiliary Building - Unit 1 -

Sheet 1 of 1 FSHE-AX1-034 Structural - Cable Tray Hangers; Section Between Elev. 10'0" and 35'0", Electrical Auxiliary Building - Unit 1 FSHE-AX1-077 Structural - Cable Tray Hanger; Section and Detail, Electrical Auxiliary Building - Unit 1 - Sheet 5 of 10 FSHE-AX1-211-4 Tray Hangers (CM-102-1-N-12-001)

FSHE-FH1-009-0 Tray Hangers (CM-102-1-F-12-001)

FSHE-AX1-066-10 Tray Hangers (CM-102-1-M-12-001) Duct Banks 5-E-10-0-E-2100 Electrical Underground Duct Banks (CM-102-0-B-10-001)

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The NRC inspector reviewed the Field Verification Reports which itemized comments made by the QC engineers during the walkdown inspection Comments generally ranged from incomplete installation, material deficiencies, inadequate separations between channels and insufficient room to permit future cable installation by craft personnel. Generally, the drawings which were "Hi-Lited" with different colors and contained written comments by the engineers indicated that efforts to document the construction status of cable tray supports were effectiv Comments relative to documentation review for cable tray supports generally indicated installations were incomplete, and subsequent inspections had not been performed. This was acceptable to the NRC inspector provided that cable tray support welds and related documentation were examined through another portion of the transition program. This item is unresolved pending fur-ther review of welds and documentation for cable tray supports (8209-01).

The NRC inspector reviewed a draft copy of "The Plan for the Change of Responsibility for ASME Section III Components, Component Supports, and Appurtenances on the South Texas Project." The formal copy of this procedure / plan was in routing for review and concurrence. This document supplements Bechtel Procedure No. 5, "As-Built Verification of Safety-Related Installed NSS Components, Rotating / Stationary Mechanical / Nuclear Equipment During the Transition Phase." The purpose of the plan is to identify the ASME Code responsibility for each of the organizations identified therein and prepare documentation that describes the ASME Section III installation status of all components, component supports, and appurtenances, with the exception of piping systems and reactor coolant loop pipin The plan requires the Code Status Report (CSR) and supporting documentation to become part of the project's permanent records stored in a central location and shall include, as applicable: Weld Data Card or suitable alternative completed to the point of fabricatio Applicable Manufacturer's Data Reports, Certified Material Test Reports (CMTR's), and/or Certificates of Compliance (C of C's) for piping materials, filler metal, et Welding Procedure Specifications (WPS's) and Procedure Qualification Records (PQR's) that support the activities noted on the Weld Data Car Welder /NDE personnel qualification Installation or mark-up drawings that provide identification and locatio Drawings are filed with the CS ___ _ _ _ _

4 NDE report Operational travelers, as applicabl This plan is very similar to the plan for the change of responsibility for ASME Section III piping systems. Both plans require a descrip-tion of incomplete items and concurrence of the Authorized Nuclear Inspector (ANI).

NRC review of the CSR's for ASME Section III components, component supports, and appurtenances will be performed following formal approval of this procedure and preparation of the reports.

4. Construction Activities (Restart)

By correspondence dated May 15, 1982, the licensee outlined their program for restart of safety-related construction activities. Milestones were scheduled for the remainder of 1982. A detailed schedule was provided for the Essential Cooling Water (ECW) System, the first safety-related system for which actual field construction effort is anticipate The NRC inspector confirmed during discussion with a licensee QA representative that a checkoff list was being developed. This list contained areas (outstanding items) that must be examined and determined to be accept-able before construction would resume on the ECW system. The licensee representative stated that a similar list was being developed by the construction manager. Review of these lists for adequacy and exam-ination of these areas will be accomplished in subsequent NRC inspections. This item is unresolved pending completion of this review (8209-02).

The inspector reviewed the following ASME Section III piping packages for the ECW system:

--3M361P-EW-1202-WT3 (Intake structure to MEAB)

--3M361P-EW-1205-WT3 (Return line)

The NRC inspector confirmed that the isometric drawings reflected the status of the field installation, supporting documentation was included in the packages, and rework and reinspection requirements from previous NCR's were included as part of the Certification of Code Statu The NRC inspector had no further questions relative to the status of the ECW syste :

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5. Storage and Maintenance The NRC inspector observed activities in several warehouses and other designated storage areas with particular attention paid to the following:

. Equipment in various storage areas was segregrated and classified as levels A through D to provide appropriate storage and environmental control for various types of equipmen . Storage areas were not being used to store food, drink, or sal . An active program was in effect to control rodents and small animals.

1 . Racks, crates, and cribbing were carrying the full weight without

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component distortio . All items were labeled and stored in a manner that allowed access for inspectio . Fire protection systems and equipment were available for us . Sufficient dunnage was available to protect materials and components in storag . Canvas or plastic covering was available for weather protection, as required.

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. Protective covers and seals were properly attache . Personnel access to the storage locations was adequately controlle ,

l The RRI reviewed the maintenance records for the following safety-related l equipment:

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l Card N Equipment V-10958 3-inch automatic operated gate valve 1500#

V-0188 3-inch motor operated flex wedge valve l l

V-0185 4-inch motor operated stop check valve 700# l

V-0783 3-inch motor operated flex wedge gate valve 150#

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V-1391 3-inch motor operated gate valve 150#

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V-1584 3-inch air operated globe valve 1500#

V-1628 1-inch air operated globe valve 1500#

V-1629 Air operated valve (SS)

V-2346 16-inch butterfly control valve (CS) with appendages V-2348 16-inch butterfly control valve (CS) with appendage V-2417 1-inch air operated globe valve 150# (CS)

V-2420 1-inch air operated valve (SS)

V-2927 Safety valve (SS)

V-2429 Safety valve (SS)

E-0778 800 HP motor for ECW pump #21 E-0314 * 125 Volt class 1E battery charger E-0131 4160 Volt Switchgear El E-0111 Dry type transformer for load center #251 E-1051 200 HP Spent Fuel Pit pump motor E-1032 CRD motor generator set E-1031 CRD motor generator set E-0780 800 HP motor for ECW pump #23 E-0779 800 HP motor for ECW pump #22 E-0751 1000 HP motor for HH (high head) SI pump A E-0743 300 HP motor for RHR pump E-0741 1000 HP motor for HH SI pump C

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E-0740 1000 HP motor for HH SI pump B

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• Maintenance record E-0314 for the 125 volt Class 1E battery charger contained a copy of Missed Maintenance Evaluation No. 35, dated May 19, 1982. This form documented the failure to perform scheduled maintenance items B (heat check) and H (protective cover) and required an engineering evaluation to determine any supplemental, corrective, or other maintenance actions that may be required due to failure to perform the scheduled maintenance. The maintenance record contained documentation recording satisfactory performance of these maintenance requirements immediately following identification of this item. The inspector confirmed that the maintenance program identified and documented any scheduled maintenance which was not performed. Appropriate action was initiated to correct the situation. Although closeout of the evaluation by the engineering depart-ment remains, the NRC inspector did not expect any deleterious effects on the battery charger due to the nature of the items and the environmental control in the storage warehouses. The NRC inspector considers the followup action to be within the purview of the engineering department. Since the maintenance program receives continuing review by the NRC resident inspector, no further review of this item is necessar The NRC inspector observed the performance of electrical checks (megger, heat check, and shaft rotation) on several electric motors by electri-cians. The NRC inspector confirmed that the electricians were qualified to perform the assigned maintenance; procedures were approved and in use; and, any discrepanci a were corrected on the spot or documented for further actio The NRC inspector had no further questions relative to equipment maintenance.

! Material Procurement, Material Control, and Procurement Documentation Vendor Control Program (VCP) Review i

The licensee, in its letter to the Director of Region IV, dated October 31,

1980, ST-HL-AE-570, SFN

V-0530-Subject: South Texas Project Units 1 & 2, Docket Nos. STN 50-498, STN 50-499, " Third Interim Report Concerning the Breakdown in the Quality Program - Procurement Cycle of Purchased Material,"

Section 3.2.3, Investigation and Verification, states the following:

" Brown & Root has engaged the services of the NUS Corporation (NUS) for the purpose of performing an independent, third party investigation and verification of the procurement cycle for all safety-related materials and equipment."

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On May 18, 1982, the NRC inspector discussed with licensee personnel, the fact that both B&R and NUS are apparently part of the Halliburton Co.,

and whether the licensee considered that relationship compatible with their definition of an " independent, third party investigation and verification."

Licensee personnel, on May 21, 1982, confirmed to the NRC inspec+or that the joint ownership of B&R and NUS by the Halliburton Co., did no' affect their definition of an independent third part Steam Generator Support Column Anchor Bolts The NRC inspector reviewed a sample of vendor Certified Material Test Reports (CMTR's) for steam generator support column anchor bolts on licensee's Purchase Order 4033/8033 with the following findings:

. The size of the anchor bolts, nuts, and jam nuts is 3 inche The nuts are described as " heavy hex". The B&R specification is 1C1195503 . CMTR's show that the nuts and jam nuts were fabricated of Crucible Steel, heat 134951. The nuts are of traceability code C580 which includes 340 pieces in two sublots (#1 and #2).

The Crucible Steel CMTR provided is for a 3-inch bar from which the nuts coulg not be fabricated. CMTR's for code C58D do not show the +10 F Charpy Tests required by ASTM A540. It was also noted that the Nondestructive Test (NDT) report for

" Lots 1 and 2" of heat 134951 are not traceable to code C58D and show 378 pieces in lieu of the 340 which are in code C58D as indicated by mechanical property test report ,

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Similarly, the CMTRfs for jam nuts identified by code C570, do not include the +10 F Charpy Tests required by ASTM A540, and the NDT report is not traceable to code C57D and covers 257 pieces in lieu of the 230 pieces reflected by the CMTR for heat treatment and mechanical propertie . There was not specific identification in vendor documentation to the heat of material used for fabrication of the anchor bolts, but CMTR's .ere provided for 11985 pounds of 3-inch diameter bar, heat 8060986, from Republic Steel and 3 3/4-inch diameter bar from Copperweld Steel Company, heat 6337 . For the bar of heat 8060986, the CMTR's are mill test reports whigh reflect all required mechanical tests, including bothgthe

+10 Charpy V notch Tests required by ASTM A540 and the +60 F Charpy Tests required by ASME (NF 2333-1). Vendor documentation indicates, however, that the anchor bolts were fabricated by

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rolling the threads in lieu of cuttin Thread rolling significantly cold works the bar and can result in mechanical properties significantly different from those values reported, those required by ASTM A540, and those used as the basis for the design of the anchor bolt .

Heat 63373 (41 pcs) was machined from 3 3/4-inch diameter tg 3 1/2-inch bar and then heat treated. Subsequently the +60 F Charpy Test required by the ASME code was performed. After heat treating, the mill CMTR's on mechanical properties were no longer valid,gutonlyoneretestwasperformedwhichdidnotinclude the +10 F Charpy Test required by ASTM AS4 In addition, rolling of the threads would have cold worked the bar severely since there was apparently a reduction in diameter from 3 1/2 inches to 3 inches in the process of rolling the thread . The NRC inspector also noted that no design specification (such as Handbook H-28) was indicated by B&R for these fastener This will renain an unresolved item (8209-03) pending further review by the NRC inspecto b. Structural Plates and Bars and Flat Washers for Reactor Coolant

, System (RCS) Support The STP FSAR, Section 3.8.3.6.5.1, specifies the materials for RCS supports structural shapes, plates, and bars as being ASTM A588 corrosion resistant, high strength, low alloy stee B&R Specification IC11955035E/DCN 6-2-77, provided to the NRC inspector as being the latest revision, in Section 3.1.1 specifies the use of ASTM A36 carbon steel structural plates and bars, 32ksi minimum yield stress, for thickness greater than 8 inches, not ASTM A58 The STP FSAR, Section 3.8.3.6.5.1, also specifies for washers, the use of quenched and tempered carbon steel. B&R Specification 1C11955035E/DCN 6-2-77 also allows " material as specified in ASME materials specification for the bolting materia ASTM A325 is acceptable" which is not covered by the FSAR.

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The licensee's Vendor Control Program (VCP) Task Force Purchase Order Closure Report, Revision 2, for P0 #35-1197-4033 does not identify the above anomalies, but does reference B&R specification IC1195S035- (

This will remain an unresolved item (8209-05), pending NRC inspector review of B&R Specification 1C11955035- c. Licensee Control of Galvanizing The licensee FSAR, Section 3.8.3.6.4.1, states that galvanizing of structural and miscellaneous steel conforms to ASTM A123-7 ASTM A123-73, Section 7.2, states that galvanizing of bolts and similar threaded fasteners shall be in accordance with spec-ification A153, for zinc coating (hot dip) on iron and steel hardwar Both ASTM A123 and A153 specify verification of the purity of the galvanizing bath and reference ASTM A143 " Standard Recommended Practice for Safegarding Against Embrittlement of Hot-Dip Galvanized Structural Steel Products and Procedure for Detect-ing Embrittlement." Based on ASTM A143, galvanized fasteners to ASTM A490 would be candidates for hydrogen embrittlement (tensile strength in excess of 150,000 psi). The NRC inspector found 4637 ASTM A490 bolts electro-zinc plated to ASTM A164 (not permitted by FSAR), or with no specification indicated on Mosher Steel Orders HM-540, 608, 628, 794, 1004, arid 1337 which were for bolts ordered for nonsafety-related applications, but were used for safety-related applications as previously reported by the licensee under 10 CFR 50.55(e). The NRC inspector could find no evidence of

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the invoking or performance of tests to verify the freedom of these fasteners from hydrogen embrittlement, even though ASTM A164-71, Section 5.1, states that after plating and any subsequent oper-ations (such as baking to remove embrittlement), the steel shall be free from the detrimental effects of hydrogen embrittlement and that the test methods, and their evaluation for freedom from hydrogen embrittlement shall be agreed upon by the manufacturer and the purchase Similarly, the NRC inspector could find no evidence that the licensee, or B&R, including the VCP reviews, had verified the accomplishment of the chemical analyses required by ASTM A123 and A153 to determine impurities in the plating bath, although the licensee had committed in his QA program to control of special processes as set forth in 10 CFR 50, Appendix B, Criterion I .. ____ - _____________-___ _-__

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This will remain an unresolved item (8209-05) pending further review by the NRC inspector . Welding of ASTM A193 Anchor Bolts The licensee previously reported a construction deficiency related to the fabrication of safety-related anchor bolts from improper material. In reviewing this matter, the NRC inspector ascertained that the B&R design drawing for anchor bolts for STP, drawings 5-A-01, until Revision 2, dated March 8, 1977, required welding of Type VI (ASTM A193) anchor bolts to-their anchor plates. Neither the NRC inspector nor licensee personnel were able to identify a B&R welding procedure for these weld This will remain an unresolved item (8209-06) pending determination of the existing installed welded A193 anchor bolts and the related approved welding procedur Female Threaded Couplings to ASTM A194 ASTM A194 " Specification for Carbon and Alloy Steel Nuts for Bolts for High Pressure and High Temperature Service" covers the requirements for nuts, which are not loaded in tensio Licensee Purchase Order 35-1197-24191 ordered 783 couplings, 2-inch diameter x 9 inches long to ASTM A194, Grade ZH. The form of the couplings (heavy or finished) was not specifie Licensee personnel were unable to provide information to the NRC inspector regarding the desired form of these couplings and verify the adequacy of these couplings for their seismic load. Since this fastener form and loading is not covered by ASTM A194, the NRC inspector questioned why final product testing, to prove design adequacy, was not performe This will remain an unresoved item (8209-07) pending verification by the licensee for design adequacy and final product acceptability of the subject coupling Self Locking Nuts to ASTM A307 ASTM A307 " Standard Specification for Carbon Steel Externally and Internally Threaded Standard Fasteners" does not cover self-locking nuts, nor does the STP FSAR, Section 3.8.3.6. Licensee Purchase Order 35-1197-19775 ordered 375 1-inch x 4-inch black bolts with self-locking nuts and washers to ASTM A307. No design requirements (breakaway torque, etc.) were given for the self-locking nuts.

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The vendor CMTR and accompanying data show the fasteners to be

"ANC0 nuts," but do not indicate that the fasteners were proof '

tested. The test reports provided are typical for bolts and nut This will remain an unresolved item (8209-08), pending verification of design requirements of the self-locking nuts and the compliance of the bolts and nuts with the requirements of ASTM A30 g. Vendor Documentation The NRC inspector reviewed licensee's records of site procurement of safety related material for regulatory requirements, licensee commitments, invoked B&R specifications and applicable ASTM standard designations. Apparent deficiencies were identified in vendor documentation for material accepted by site personnel as indicated below:

. Material supplied under purchase order 35-1197-12030 for 120 1 1/2-inch diameter heavy hex nuts, ASTM A540 Grade B23, Class 3; and 32 2-inch diameter heavy hex jam nuts, ASTM A540 Grade B23, Class 3 was not provided with the required vendor test report In the case of both sizes and types of nuts, the manufacturer reported only one tension test and no Charpy impact tests. ASTM AS40 requires two tension tests and two Charpy impact tests with each test consisting of three Charpy V-notch specimen . The invoked B&R Specification 3A010SS026-E, " Category I Miscellaneous Steel", specifies ASTM A540 material for anchor bolt material (bolts, nuts, washers) only, and requires MT (or PT) for all size The vendor's test reports for both sizes and types of nuts show no MT or PT was performe This remains an unresolved item (8209-09) pending determination of installation or use of the subject material at the time of this inspectio h. Material Control of Structural Steel Bolts The licensee, in letter dated April 16, 1981, serial ST-HL-AE-655, SFN: V-0530, G. W. Oprea, Jr. , to Karl Seyfrit, Subject:

South Texas Project Units 1 & 2, Docket Nos. STN 50-498 and STN 50-499, Final Report on Material Control of Structural Steel Bolts, states the following:

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"Mosher Steel; supplied structcral bolts (A325 & A490) under a Non-Category I specification. Documentation received consists of CMTR's and C of C's accompanied by a statement from the structural bolt supplier to the effect that all bolts were manufactured to the quality standards set forth by the respective ASTM standards."

The NRC inspector reviewed the subject Mosher Steel CMTR's and discovered that approximately 13,000 1-inch and 1 1/8-inch diameter bolts to ASTM A490 did not have documentation of performance of the proof load (or alternate proof load) as required by Section 5.3 of ASTM A-490-75 to wnich the bolts were certified on purchase orders HM-1004, HM-628, HM-1868, AMJ-2281, DM-1262, HM-540, HM-608, DM-628, HM-794, HM-1377, AMJ-2281, HM-1262, HM-1377, HM-4365, AMJ-2279, HM-1829, and AJM-228 The NRC inspector noted that while material control of structural steel bolts was apparently corrected, the subject of such control of the mating nuts was not addressed. The NRC inspector also noted that licer:see personnel stated that the subcontractors supplying the nonsafety-related bolts and nuts used in safety-related applications, have never been surveyed to determine compliance with requirements of 10 CFR 50 Appendix B or ANSI N45.2 and daughter standards, and are not included in the licensee's Vendor Control Program (VCP) revie This will remain an unresolved item (8209-10) pending further review by the NRC inspecto . Unresolved Items Unresolved items are matters about which more information is required in order to ascertain whether they are acceptable items, violations, or deviations. Ten unresolved items, disclosed ouring the inspection, are discussed in paragraphs 3, 4, and . Management Meetings Meetings were held with management personnel periodically during the course of the inspection to discuss inspection scope and findings.

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DETAILS SECTION 8 Persons Contacted Houston Lighting and Power Company (HL&P)

• 1. +J. White, Special Coordinator, Engineering

1. +G. Robertson, Manager, Nuclear Licensing Department

• J. Molleda, Supervising Engineer Bechtel Power Corporation (Bechtel)

• 1. +J. Gormly, Project Manager for Licensing

• R. Scott, Licensing Engineer (EN-617 Coordinator)

1. R. Ashley, Licensing Manager, San Francisco Office Quadrex Corporation (Quadrex)

+L. Stanley, Group Manager, Licensing & System Analyses

• Participated in May 11-13, 1982, meeting # Participated in May 24, 1982, meetin + Participated in May 25, 1982, meetin . Status of HL&P and Bechtel Review of Quadrex Report The status of the resolution of Quadrex Report issues was reviewed with HL&P and Bechtel personnel (indicated in paragraph 1 above) during the period May 11-13, 1982. The NRC inspector determined that the list of Quadrex Report issues is based on the Quadrex Report findings (Volume I). The list also includes any significant items from Volumes II and III. Work package EN-619, Quadrex Issue Resolution Summary, is being prepared. A tentative format has been established for the work package and includes identification and resolution informatio The report is now due to be issued as a final work package, approved by HL&P on July 19, 1982. Inspection of the Quadrex, issued by NRC inspectors, will commence after this dat . Visit to Bechtel - San Francisco Offices On May 24, 1982, a visit was made to Bechtel offices in San Francisc The reason for the visit was to obtain answers to questions concerning a report entitled, "An Assessment of the Findings in the Quadrex Corporation Report," dated May 1982. This report was issued on March 15, 1982, for HL&P, and was prepared by a Bechtel Task Force, I

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independent of STP, as a qualitative assessment of the findings l identified in the Quadrex Report. Questions asked of the task force l director by the NRC inspector were questions of clarification onl No assessment or conclusions regarding any findings were made by the NRC inspector. All questions were answered satisfactoril . Visit to Quadrex - Campbell, California Office On May 25, 1982, a visit was made to Quadre The NRC inspector met with Quadrex and licensee representatives, (identified in paragraph 1, above)

in order to obtain clarification of items noted during the NRC inoffice review of the Quadrex Report. No conclusions on the Quadrex Report items were made during the visit. Additional questions regarding the Quadrex Report will be submitted through HL&P. All questions were answered satisfactoril e

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l DETAILS SECTION C ,

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1. Persons Contacted l J. L. Hurley, Assistant Project Engine 2 ring Manager, Bechtel H. Friend, Project Manager, Bechtel K. R. Dotterer, Project QA Engineer, Bechtel J. McBride, Quality Engineer, Bechtel R. L. Rogers, Project Engineering Manager, Bechtel J. L. Quinnelly, Quality Engineer, Bechtel T. C. Smith, Records Manager, Bechtel B. Robertson, Purchasing Manager, Bechtel W. Melton, Project Engineering Coordinator, Bechtel D. Krisha, Project QA Manager, Bechtel S. Cozzens, Project Quality Engineer, Bechtel B. L. Lex, Project Manager, Bechtel J. L. Blau, Supervising Project Engineer, HL&P S. M. Dew, Manager Engineering, HL&P T. J. Jordan, Project QA Supervisor, HL&P J. M. LeBlanc, Records Manager, HL&P 2. Design Engineering Transition This section of the report details NRC activites with respect to surveillance / inspection of the Bechtel/B&R transition process. To assess the overall transition program and to keep track of exact status of the Bechtel review and assessment of the existing B&R engineering design and associated data; a NRC Region IV inspector was placed at the A/E facility on a full-time basis (Bechtel, Houston). For background information on transition activities prior to this report, refer to the details section of previous monthly report Phase A of the Bechtel/B&R transition process is the review and assessment of the South Texas Project design. This task has been broken down to discretely defined systems which are defined as work packages. As the initial Bechtel review and assessment of a certain work pa: age is complete, a draft final report is sent to HL&P for their review and comment. The HL&P comments are then incorporated into the generation of the work package final report. When all of the final reports have been completed for the designated work packages, Phase A of the transition will be complete Some Phase B activities are scheduled to commence prior to the completion of Phase A of the transitio .

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The following draft final reports have been sent to HL&P for review and comment:

• EE-200 *EN-612 EJ-306 EJ-303 *EM-511

• EE-215 *EE-208 *EM-558 *EN-606 EC-150

• EE-202 *EJ-300 EJ-314 *EA-006 *EC-151

• EE-210 *EN-610 *EJ-361 *EJ-318 EM-410

• EJ-316 *EJ-364 *EA-002 EA-003 EJ-315

• EJ-310 *EN-609 *EE-205 EM-515 EJ-352

• EE-209 *EE-220 EN-605 EC-11 *EJ-366

• EA-007 *EJ-313 *EE-206 EJ-351 EC-155

• EM-557 *EE-214 *EC-174 EJ-369 EC-142

• EN-608 *EJ-362 *EM-506 *EJ-360 EE-219 EC-165 EJ-367 EA-005 *EM-455 EE-212 EN-607 EJ-301 EJ-358 EM-405 EJ-370 EJ-365 EM-452 EM-504 EC-104 EM-509 EC-186 EJ-317 EP-700 EN-603 EN-604 EE-216

• Final report sent to HL&P The present status of design documentation transmitted by B&R and received by Bechtel is as follows:

B&R Subpackages Total Scheduled Scheduled to date Received Engineering 872 872 833 Procurement 1538 1538 1446

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B&R transmitted a general assessment of the Quadrex Report to HL& l HL&P seemed to be unaware that B&R was conducting this assessmen The NRC inspector's initial review of the report indicated that B&R detailed the circumstances and background to the assessment of certain Quadrex concerns. There are differing opinions between B&R and Quadrex on the report finding . Findings As the NRC inspector reviewed work packages final reports, it was observed that in the commercial assessment done by Bechtel Purchasing, there were items listed that could be viewed as open or followup item Bechtel was questioned as to how these items would be listed

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for future followu These items will be closed under normal procurement activitie As defined in the Engineering Transition Procedures, only items that diverge from normal scheduled project activities will be tracked on an action item syste HL&P conducted a corporate audit of Bechtel's Engineering and QA activities for the transition phase during this mont The NRC inspector participated as an observer during this audit. The NRC inspector was briefed on the preparation and scope of the audi Audit checklists were reviewed to assure that the procedural scope was of a detailed nature as to assure proper implementation of procedural commitments. No major findings were identified during the audit, although some minor implementation discrepancies were foun These items were corrected promptly by Bechte During this month, the NRC inspector observed that the generation of work package draft final reports had declined. Allocation of Bechtel Engineering personnel for Phase B construction restart activities was cited as the cause. Reemphasizing to Bechtel Engineering personnel the importance of the orderly completion of Phase A activi-ties was made by Bechtel asanagemen In a letter dated May 14, 1982, transmitted from HL&P to the NRC Region IV office, HL&P provided the NRC with a program and schedule for resuming safety-related work. The NRC inspector was notified that construction of the ECW system piping is scheduled to begin in mid-Jul As the NRC inspector began reviewing the status of the Phase A assessment of critical ECW design documents, it became apparent that the Review Package Final Report was scheduled to b9. finished after the safety-related construction had resume HL&P had committed on May 14, 1982, that the related work package final reports would be issued prior to initiation of safety-related constructio Bechtel management informed the NRC inspector that they had rationalized one of three options: Generating an internal auditable subpackage for only the ECW buried service water documents that were critical for this construction restar Break EM-406 essential " Cooling Water System" into two package Step-up review activities of EM-406 and finish the final report prior to construction restar ..

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From the review of Bechtel procedures relating to the South Texas Project transition activities, the NRC inspector found that the procedures adequately reflected the transition phase of design responsibility from B&R to Bechtel. Transitional activities are being implemented properly to Bechtel procedural commitment t