IR 05000237/1979022
| ML17174A364 | |
| Person / Time | |
|---|---|
| Site: | Dresden, Quad Cities, Zion  |
| Issue date: | 11/30/1979 |
| From: | Gallagher E, Hayes D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML17174A361 | List: |
| References | |
| 50-237-79-22, 50-249-79-20, 50-254-79-24, 50-265-79-21, 50-295-79-21, 50-304-79-20, NUDOCS 8001160271 | |
| Download: ML17174A364 (16) | |
Text
U.S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT
REGION III
Report No. 50-237/79-22; 50-249/79-20 50-295/79-21; 50-304/79-20 50-254/79-24; 50-265/79-21 Docket No. 50-237; 50-249 50-295; 50-304 50-254; 50-265 Licensee:
Commonwealth Edison Company Post Office Box 767 Chicago, IL 60690 License No. DPR-19; DPR-25 DPR-39; DPR-48 DPR-29; DPR-30 Facility Names:
Dresden Nuclear Power Station, Units 2 and 3 Zion Nuclear Power Station, Units 1 and 2 Quad-Cities Nuclear Power Station, Units 1 and 2 Inspection At:
Dresden Site, Morris, IL Zion Site, Zion, IL Quad-Cities Site, Cordova, IL Inspection Conducted:
September 26-27, October 3-4, 22-23 and November 7-9, 1979 Inspector:
E. J. Gallagher ~~
Approved By:..Jbn. W. Hayes, Chief ~ ~
Engineering Support Section 1 Inspection Summary Inspection on September 26-27 October 3-4, 22-23 and November 7-9, 1979 (Report No. 50-237/79-22; 50-249/79-20; 50-295/79-21; 50-304/79-20; 50-254/
79-24; 50-265/79-21)
Areas Inspected:
Follow up to IE Bulletin No. 79-02, pipe support base plate designs using concrete expansion anchor bolts; review of test program and pro-cedures; observation of testing anchor bolts; and review of quality record The inspection involved a total of 68 inspector-hours onsite by one NRG inspecto Results:
No items of noncompliance were identified in the areas inspecte soo11602.11
DETAILS Persons Contacted Commonwealth Edison Company (Dresden Site) September 26-27 and October 22-23, 1979
- B. Stephenson, Plant Superintendent
- B. Shelton, Administrative Assistant Superintendent
- R. Rybak, Technical Staff
- E. Wilmere, QA Coordinator
- R. Ragan, Operations Assistant Superintendent
- P. Holland, Technical Staff United Engineers and Constructors
- D. Morris, Project Superintendent NRC Resident
- J. Barker Commonwealth Edison (Zion Site) October 3-4, 1979
- N. E. Wandke, Plant Superintendent
- L. G. Soth, Assistant Superintendent
- J. Marianyi, Technical Staff Supervisor
- C. E. Schumann, Operation Assistant Supervisor
- E. Murach, Maintenance Assistant Superintendent
- T. Luken, QC Supervisor
- D. B. Wozniak, Station Nuclear Engineering Department
- J. Montgomery, Maintenance Staff
- J. Gilmore, Technical Staff
- R. Rostkowski, QA Inspector
- B. E. Harl, QA Coordinator Sargent & Lundy Engineers
- R. W. Hooks, Phillips Getschow Company
- M. Pietrzak, Site Manager NRC Resident
- J. E. Kohler
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Commonwealth Edison Company (Quad Cities Site) November 7-9, 1979
- N. Kalivianakis, Plant Superintendent
- K. Graesser, Assistant Superintendent
- F. Geiger, Staff Engineer
- D. Wozniak, Staff Engineer
- D. Thayer, Senior QA Inspector
- W. Burknamper, Quality Control Sargent & Lundy
- T. McKenna, Structural Project Engineer NRC Resident
- N. J. Chrissotimos
- Denotes those in attendance at above exit meeting NRG/Commonwealth Edison Meeting - November 13, 1979, RIII Office CECo Personnel D. 1. Peoples, Licensing Manager R. Janecek, Staff D. Wozniak, Staff N. Wandke, Zion Superintendent E. Murach, Zion Staff G. Plimil, Staff R. Rybak, Dresden Staff W. F. Naughton, Staff Sargent & Lundy Engineers T. McKenna NRC Region III R. L. Spessard, Section Chief, Operations Branch E. J. Gallagher, Reactor Inspector, Construction Branch Functional or Program Areas Inspected Inspections were performed at the Dresden Nuclear Station, Units 2 and 3, Zion Nuclear Station, Units 1 and 2 and Quad-Cities Nuclear Station, Units 1 and 2 in order to followup on the licensee's actions regarding IE Bulletin No. 79-02, pipe support base plate design and installations using concrete expansion anchor Status of Licensee's Program to Inspect Pipe Support Base Plates IE Bulletin 79-02 was originally issued on March 8, I979 and later revised on July I, I979 as a result of various inquiries by licensee The original bulletin required that "all holders of operating licenses for power reactor facilities are required to complete Item I through 4 within I20 days... "
On July 5, I979, Commonwealth Edison responded to the subject bulleti The licensee was responsive to Items I, 2 and 3, however, Item 4 which required field testing and inspection of the expansion anchors installed on support plates at all facilities on a system by system basis was not adequately addresse At that time, only ten anchors at the Zion facility had been inspecte This was considered an inadequate number at Zio No inspections had been performed at Dresden 2 and 3 or Quad-Cities I and 2 as of July 5, 197 Commonwealth Edison Company indicated in the response that an inte-grated program for inspection and testing at all operating facilities was being developed and would be implemented by August I5, I979 for accessible supports while inaccessible supports would be inspected during the next refueling outag A meeting in Region III NRC office was held on September 10, 1979 to discuss the scheduled completion ot the inspection program and the contents of the field inspection and test progra Commonwealth Edison Company letter dated September II, 1979 (Mr. D. L. Peoples to Mr. J. G. Keppler, NRC RIII, Director) indi-cated the next refueling outages for Dresden 2 and 3, Quad-Cities 1 and 2 and Zion 1 and A second letter from Commonwealth Edison Company dated September Il, I979 also gave a status report relative to inspections on IE Bulletin 79-0 The completion schedule for Zion I and 2 for all accessible anchors was indicated as December 1, 1979; for Dresden 2 and 3 and Quad-Cities I and 2 the completion date was indicated as November 15, I979 for accessible anchor Inaccessible anchors would be inspected during the next refueling outage The NRC responded to Commonwealth Edison Company on October 4, I979 and indicated that we expected the inspections to be completed in accordance with the schedule presented in their correspondence and as stated abov As of thes*e inspections, Commonwealth Edison Company had fully imple-mented the field inspection and test program of pipe support base plates designs and installations using concrete expansion anchor The systems included in the test program are listed in Attachment IA (Dresden 2 and 3),
Attachment lB (Zion I and 2).and Attachment IC (Quad-Cities I and 2). Dresden Unit 2 and 3 Status - At the time of this inspection, Dresden was in the early stages of implementing the field test progra On Unit 2, approximately 23 supports of 250 had been
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inspected while in Unit 3, some 27 supports of 250 had been inspecte CECo committed that by November 15, 1979, all required accessible supports would be inspected, including repairs and resolution Zion Unit 1 and 2 Status - As of this inspection, Zion was also in the early stages of implementing the field inspection progra Each unit has approximately 1600 support Unit 1 has had some 300 supports inspected while none on Unit 2 have been inspected at this poin Inspection of inaccessible supports inside contain-ment are to be performe Quad-Cities Unit 1 and 2 Status - As of the inspection, Quad-Cities has fully implemented a program for inspectio Each unit has approximately 250 support A total of some 175 had been complete Subsequent to the above inspection, a meeting was again held with Commonwealth Edison Company at the Region III, NRC office in Glen Ellyn, Illinois on November 13, 1979 to review the results and findings to dat CECo presented the summary of the expansion anchor pipe support inspections at Zion, Quad-Cities and Dresden facilitie This presentation is included as Attachment 2 to this report. It was agreed at this meeting that CECo would review on a system by system basis the results of the inspections rather than on a total plant basi This information is to be presented in a subsequent meetin.
Review of Inspection, and Test Program for Concrete Expansion Anchors The inspector reviewed specifications for the inspection and testing of concrete expansion anchor bolt The specifications encompassed the requirements as stated in IE Bulletin 79-02 as follows: Form CEAI-1, Revision 5, dated September 18, 1979, Revision 6, October 16, 1979 and Revision 8, November 6, 1979 entitled,
"Field Inspections of Expansion Anchors" for Dresden Nuclear Power Station, Units 2 and 3, Quad-Cities Station, Units 1 and 2, and Zion Station, Units 1 and Specification No. T-3291, dated September 7, 1979, "Certification of Specification for Torque Versus Preload Testing for Self-Drilling Anchors."
The following comments were made relative to the above procedure:
(1)
CEAI-1 to Revision 3 stated, "where plate washers are used because of oversized holes in the plate, the plate washers shall be welded to the base plate in accordance with Form 1701."
Revision 4 deleted this requirement to weld plate washers to base plat The inspector requested the licensee to evaluate
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shear forces on the base plat If shear forces exist and oversized (flame cut) holes are present, the support becomes unrestrained to shear load On October 11, 1979, the licensee's representative called the NRC to comment that plate washers would be welded to the base plates while inside the containment at Zion during the refueling outages and that this requirement would be applied to all other supports subjected to shear load It is the NRC's understanding that either the plate should be replaced or the plate washer welded to the base plate when oversized bolt holes exist in order to develop shear capacity distributed to the bolt (2)
CEAI-1 to Revision 3 stated, "If it is found that the expansion plug has not been properly set on the bolt inspected, then it will be necessary to repeat the requirements of Article 6.1 and 6.2 for each bolt within the assembly."
This requirement was deleted on Revision The inspector informed the licensee that the bulletin permitted inspecting only one bolt per plate, how-ever, if that bolt was not properly set or had some discrepancy, then it was required to also inspect each bolt on that suppor The licensee indicated that although the anchor was not fully set, it was tested to design loa The licensee committed to evaluate the specification require-ments which were used. to identify anchors not fully set ( the dimension from the top of the shell to the top of the expansion plug).
(3)
CEAI-1 Section 6.2.4 stated, "If the specified inspection torque cannot be attained or if anchor slip is greater than 1/16", then the.
requirements of Articles 6.1 and shall be repeated for each bolt within the plate assembl At the Zion Station, the above requirement was misinterpreted by the contracto If the first anchor failed but was able to be reset, no other bolts were inspecte The licensee committed to reinspect all other bolts on supports where the first anchor faile The results of this re-inspection should be factored into system operabilit (4)
The results of the torque vs. tension correlation were reviewed and determined to be acceptabl The test included the use of lubricated bolts and a load cell to determine the actual load developed on the anchor while application of torque to the bolt hea *
3.
No items of noncompliance were identified in the above area.
Observation of Inspection and Testing of Concrete Expansion Anchors Zion Unit 1 - Observation of licensee inspection on support SWRS-1118 and 1118-A was performe The licensee contractor performed the inspec-tion per the current procedur Flame cut (oversized) holes were present on this support, plate washers were installe In addition, two of the four bolts did not pass torque inspection and were repaired using wedge type anchors per the procedur Torque wrenches being used were calibrate Dresden Unit 2 - Inspection on support 1403-6-209 (core spray line) in Unit 2 torus was observe The contractor performed the inspection per current procedur Torque inspection meets specification requirement Quad Cities Unit 1 - Observed in-process inspections on support R-16 At the request of the NRC inspector, a reinspection of completed torque tests was performed on support R-16 All bolts meet specification requirement Tension test on support SBGT-12170 was observe The anchor tested was able to support 2700# of tensile load as per requirement It was verified that at ~11 three facilities, the shell type expansion anchor was used during the original constructio No established pro-cedures or inspection requirements were used during original constructio No items of noncompliance were identified in the above are.
Review of Quality Records for Inspection and Testing of Concrete Expansion Anchors Zion Station - Quality records were reviewed and found satisfactory according to documentation requirement Records were reviewed for completeness, disposition of open items and resolution of discrepancie S&L is reviewing each completed inspection package and comparing them to design requirment Quad Cities - Licensee event reports (LER's) for support SBGT-R149, R165 and R164 were reviewe These supports were identified as having a factor of safety of less than two and therefore identified as inoperabl Procedures required these supports to be modified such that the factor of safety is increased to greater than fiv This was accomplished within the 24 hour2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> time perio During the inspection, three more supports were identified with a factor of safety less than two, RHR H83, H87 and SBGT-R19 Modifications were in progress during this inspectio Licensee reported these under LER requirement Dresden Station - Quality records were reviewed and found acceptable according to documentation requirement Similarly, S&L is reviewing the completed inspection results and dispositioning the findings according to design requirement No items of noncompliance were identified in the above are.
Other Bulletin 79-02 Items Anchors Used in Concrete Block Walls - Licensee indicated that concrete expansion anchors were not utilized in concrete block walls for support of piping system Pipe Supports With Anchors Using Structural Shapes - The licensee indicated that piping supports used base plate supports rather than structural shape attached directly to concrete surfac Anchor Bolt Preload - The licensee's consultant, Sargent & Lundy's position is that the lack of preload will not effect the cyclic capacity on shell type anchor S&L is in the process of performing cyclic tests with varying degrees of preload and without preload to demonstrate the effect Results will be transmitted to the NRC for review when complete No items of noncompliance were identified in the above area Exit Interviews The inspector met with licensee and construction representatives (denoted in Persons Contacted) at the conclusion of each inspection and summarized the inspection scope and finding The licensee acknowledged the finding Attachments: Attachments lA through lC Attachment 2
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- ' Core S1:J1' rcPI L"f1CI Dresden Units 2 and 3 I so Li. *U_on C0:1 c1:-nsG1' crrn s.:*r:*._;n Snb~;ystP.:n F
SU-.. 1~1~by Lir1uicl Cont:i*ol Di.cs:::l G... ~11er:-~t.cn* Cooli.ng l SLHl Ll.JJY (> s 'f i*,_: ~~ t:r.c*nt Attachment 1 A Pri:;,~i:i.*y Co11tn..ii::N~nt I' lpj ill; (Jn el lF'lr:s only portionn ot tlv~ fpl l::..~*.*:in r;; syst:cr \\':td.ch a.rr; p:1.i*t of P.d.rna1*y Cont::i innK:nt })j_plilg) Dry".vell Snmp.
Clc::-:n D2rn1.ncra.l:i.:t~cr RBCCW Inlet and Outlet
- P:.i.*c.-:ssllrC Supp:rcssion Core Sp1*;-;,y (Tn-st Rctu1*n) LPCI (Test Return) JlPCI (Stc;:rn Exl1a.ust) FPC1 Pp 1'l i.i1. }"'l0w I ystc;11::> \\':1-:::ic.h a:i..*R I'art o:C the Pl'i1,*,ary l"rc-~::sm:e J.3ou~Hhry and Tlicrc.lore, hn V8 Sc:ismic Portions A.,
?.Ini.n Ster:.m :!,cod1-..*a ter ncactor Rccirculntion Reactor W~tcr CJ.canup Slnt.tck'*,*m Cooling Hmid Spn.1-y crm Il Sys"Lc:r::s wll:i.t~h h~~ve Sections th[!t rorm a Ernmt'i.:Ll"Y of a 8ci.~;1;*,:i.c Sys*tcm Fecu*.*:.-::.ter nuactor Water Clennup
Attachment lB The following systems are classified as nuclear safety related at Zion Station:
BS - Steam Generator Blowdown CC - Component Cooling CS - Containment Spray DO - Diesel Fuel Oil DT - Reactor Coolant Drains FW - Steam Generator Feedwater IA - Instrument Air IW - Isolation Valve Seal Water MS - Main Steam PP - Penetration Pressurization RC - Reactor Coolant RH - Residual Heat Removal SF - Spent Fuel Pit Cooling SI - Safety Injection SS - Nuclear Sample VC - Chemical and Volume Control
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Attachment 1C Quad Cities Units 1 and 2
- ~~c~:i.~_;mie Core Spray LPCI (HHR) JlPCI CED Scra.m Subsystem Standby Liquid Control Diesel Generator Cooling Standby Ga.s Trcr1. trn2nt I Pcinnry Contairnr.::nt Pipinz (.Incl udcs only portj ons of the followin~ systc:ns whic.h are part of Primary Contn.inrnent Piljin~;) Drywcll Srn11ps Clean D8~inaralizor RDCCW Inlet and Outlet Pressure Suppression Cure SprrLy (Test Rctu:cn) IX*CI (Tnst Return) IJPCI (St earn E::h::tust) JJPCI I'-::.:> Min. }'low Con tainmc::nt Cooling Service Water
I Systc:1:1s which are Part o:r the Primary Prcssu1*c DowH1ary and, Therefore, have Seismic Portions Main Steam J Fcec1wa t er Reactor Hccircu*Jation Reactor Y7:i ter Cleanup HC CRD II Systems whj ch have Sections that Form a J3crnnclary of a Seismic System F8edwa tcr
Service is safety related but not seismic
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Attachment 2.(5 S\\.\\E.E.\\<S;.'j As OF NovEhBER 9~ 1979 EXPANSION f1NCHORED PI.I'f_HANGER I NSPECTI Otl. SLWMARY *
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ZION UNIT 1 FACTORS OF SAFETY CAS COMPARED WITH LILTIMf1TE CAPACITIES~OF SELF-.
DRILLING TYPE EXPANSION ANCHORS)
TOTAL NUMBER OF HAUGERS TO BE INSPECTEfl.
1388 HANGERS WITH P. FACTOR OF SAFETY OF 20 OR MORE--851 (61%)
HANGERS WITH A FACTOR OF SAFETY* OF 10 OR MORE BUT LESS THP.N 20
--216 C16%)
HANGERS WITH A FP.CTOR OF SAFETY OF LESS THAN 10
- --137 C10%)
-
HANGERS WHERE NO LOAD AVAILABLE
--124 C9%)
HANGERS WHERE AWAITING FIELD INFORMATION
-- 60- (4%)
TOTAL HANGERS INSPECTED TO-DATE NUMBER OF HANGERS INSPECTED.
. 552.
ANCHORS REVIEWED WHICH.WERE LOAD.TESTED NUMBER OF ANCHORS LOAD TESTED
---~------- 242
NUMBER OF EXISTING ANCHORS.REPLACED HITU
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HEDGE-TYPE EXPANSION ANCHORS BECAUSE OF.FAILED LOAD TEST
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J
TOTAL NUilDEH OF ASSD'!BIJES P.EVIEWEl)
SHEEl 2)
TOTAL NUMBER OF HOLES REVIEWED 110 ur 1*.ovi:.: *.pch
~*,.
.J..:..,.1
~)
CFROfi D~JA NUMBER OF HOLES WITH F.L;CTGRS OF SAFETY GRE/\\TER THN\\l 2
./.,'
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EACJQljS OLSAEETY EDJUXl:illlS~Ll'JWED_£1££ HIHJGEBS <AS COB£b.BE!LlQJlL.IJllfil.LCA2hfJJ I ES C 1F SELF-DRILLING TYPE. EXP1JlSION ANfTClRS)
Z I C'N UN IL TOTAL NLJr'1BER OF HA!JGE~S TO BE I l'~SPECIED
ll~.93 NrnmER OF HANGERS WITH A Ff\\CTOR OF SAFETY GREATER THAt*l OR EQUAL TO 10
--11£7 C78%)
NUMBER OF HANGERS WITH A FP.CTOR OF Sft.FETY LESS THAN 10
-- 101 C7%)
NUMBER OF HANGERS WHERE NO LADD IS AVAlL~.BtE-- 192 C13%)
NUMBER OF HANGERS \\'!HERE AWAITING FIELD IIJFORMATION
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33 (2%)
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EXPf\\NS I ON NKl*lO_BED Pi PE llANGER *I NSP(J~I I OM SUViMP;RY QllAJ) CITIES UNITS 1 g I
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SAFETY. <AS COMPARED \\'!ITH ULTIMATE C~.PACITIES OF SELF-DRILLING TYPE EXPAMSION Al'!CHORS)
TOTAL NLJrlBER OF HANGERS TO BE INSPECTED.
HANGERS WITH A FACTOR OF SAFETY OF_lO OR MORE HANGERS WITH A FACTOR OF SAFETY OF LESS THAN 10 TOTAL HANGERS INSPECTED IO-DATE
.
.
NUMBER OF HANGERS REVIEWED
. ANCHORS REVIE\\'JED WHICH HAVE BEEN LOAD. IESTEll-NUMBER OF ANCHORS LOAD TESTED NUMBER OF EXISTING ANCHORS REPLACED WITH WEDGE -TYPE EXPANSION l\\NCHORS *BECAUSE OF FAILED LOAD TEST
528
--362 (68%)
. --166 (32%)
125
EXPM~si"oN A!
1!CllORED PJPE HANGER JNSPECTlflN Sll[*~MARY DRESlli:]~ llN ITS "2 & 3
- oRS OF SAFETY <AS COMPARED HJTH ULTIMATE CAPACITitS OF SELE-DRI LLH~G TYPE EXPANSION ANCHORS)
TOTAL NUMBER OF llANGERS TO BE INSPECTED I
.
500 I
ESTIMATED TOTAL NUMBER WITH HANGERS WITH DRAWINGS*
*--. 264 HANGERS WiTll /\\ FP\\CTOR OF SAFETY OF 10 OR fiORE ~-127 (ll8%)
HAt~GERS WITH A FACTOR OF SAFETY OF LESS THAN 10
-- 43 (16%)
HANGERS WHERE NO LOAD AVAILABLE
. HANGERS HH~RE A\\*J~ITING FIELD INFORMATION TOTAL HANGERS IlfSPECTETJ TO-DATE NUMBER OF HANGERS INSPECTED *
(\\
108S REVIEWED ~Hl[H WERE lDAD TESTED TO~DATE NUMBER OF ANCHORS LOAD TESTED NUMBER OF EXISTING ANCHORS REPLACED WITH WEDGE-TYPE EXPANSION ANCHORS BECAUSE OF FAILEP LOAD TEST PLATE HOLE SIZE MEASUREMENTS TOTAL NUMBER OF ASSEMBLIES REVIEWED <FROM DATA
-- 88 (33%)
6 (3%)
144
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SHEET 2)
~--- 167 TOTAL NUMBER OF HOLES REVIEWED
355 NUMBER OF HOLES HITH FACTORS OF SAFETY GREATER THAN 2
355
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