IR 05000259/1992001
| ML18036A524 | |
| Person / Time | |
|---|---|
| Site: | Browns Ferry  |
| Issue date: | 02/10/1992 |
| From: | Blake J, Chou R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML18036A523 | List: |
| References | |
| 50-259-92-01, 50-259-92-1, 50-260-92-01, 50-260-92-1, 50-296-92-01, 50-296-92-1, NUDOCS 9202260090 | |
| Download: ML18036A524 (12) | |
Text
gag REGII, (4
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UNITED STATES NUCLEAR REGULATORY COMMISSION
REGION II
101 MARIETTASTREET, N.W.
ATLANTA,GEORGIA 30323 Report Nos.:
50-259/92-01, 50-260/92-01, and 50-296/92-01 Licensee:
Tennessee Valley Authority 6N 38A Lookout Place 1101 Market Street Chattanooga, TN 37402-2801 Docket Nos.:
50-259, 50-260 and 50-296 License Nos.:
DPR-33, DPR-52, and DPR-68 Facility Name:
Browns Ferry 1, 2, and
Inspection Conducted:
January 6-10, 1992 Inspector:
C.
R.
Approved by:
J. J.
la e, Section Chief te ials and Process Section iv sion of Reactor Safety Date Signed Date Signed SUMMARY Scope:
This routine, unannounced inspection was conducted in the areas of piping systems and civil structures, and previous open item for Units 2 and 3.
Results:
In the areas inspected, violations or deviations were not identified.
The design calculations of Control Rod Drive (CRD) piping supports for Unit 2 performed by Bechtel Power Corporation appeared to meet the requirements of the American Iron and Steel Institute (AISI)
Code and Unistrut Corporation Specification (Manufacturer).
9202260090 920214 PDR ADOCK OS0002S9
REPORT DETAILS Persons Contacted Licensee Employees R. Baird, Unit 3 Civil Engineer
- M. Bajestani, Technical Support Manager
- R. Baron, Licensing Manager
- C. Crane, Maintenance Manager
"R. Cutsinger, Lead Civil Engineer
- M. Herre11, Plant Operations Manager
- J. McCarthy, Restart Licensing Manager
- N. Nelson, Unit 2 Project Management
"P.
Osborne, Civil Engineer
- P. Salas, Compliance Licensing Manager
- J. Scalice, Plant Manager
- J. Schlessel, Maintenance Manager
- J. Swindell, Unit 3 Plant Operation Manager
- G. Turner, guality Assurance (gA) Manager
- J. Valente, Restart Engineer Supervisor Other licensee employees contacted during this inspection included craftsmen, engineer, mechanics, technicians, and administrative personnel.
NRC Resident Inspectors
- C. Patterson, Senior Resident Inspector
- M. Bearden, Resident Inspector E. Christnot, Resident Inspector
"Attended exit interview Instrument Tubing Malkdown - Unit 3 (50090)
The licensee has completed the walkdown of three instrument tubing lines Five other tubing lines were walked down together with the small bore piping.
Procedure No.
BC-012, Rev.
2, "Engineering Attribute Malkdown Instructions For Seismic Class I Small Bore Piping, Tubing, and Associated Supports" was used for the tubing walkdown.
The main purpose of the walkdown is to gather information and to check certain attributes listed in the procedure, to be used for engineering evaluation and analysis.
The attributes to be checked are the tubing, the support adequacy, support span, support type and damage.
The inspector selected three lines with supports which had previously been walked down by the licensee walkdown team which consisted of one support design engineer and one stress analysts engineer.
The drawings and packages used by the NRC inspector for the walkdown reinspection were the drawings and.checklist generated and compiled by Bechtel Power Corporation after their walkdown inspection.
The walkdown reinspection was completed with assistance from Bechtel's
walkdown inspectors who were a
lead tubing inspector (stress analysis engineering)
and a lead support inspector (support design engineer).
The tubing was checked for configuration identification, dimension, tubing size, fitting, support location, tubirg span, support type, and inter-ference.
The supports were checked for configuration, identification, fastener installation, bolt diameter, and dimensions.
The tubing and
'supports reinspected durino the current inspection are listed below.
Table I Walkdown Reins ection Tubin Item No.
Isomatric No.
Inspected
~Lee th Total Tubing 'omments/
I NI-332-51R 6 ft.
2 NI-332-58R 6 ft.
3 NI-376-51R 70 ft.
The licensee field walkdown, packages, and information collected appeared to be acceptable.
Only minor discrepancies were found.
During the walkdown reinspection, the inspector found that the portion of the tubing lay on top of angle steel, called tubing track, and was fastened by clips.
The tubing track is not a part of tubing systems such as tubing or tubing supports, and will have a separate as-built walkdown and analyses by Bechtel Civil Design Group.
The tubing track walkdown will be started after the majority of the tubing system walkdown has been completed.
The tubing track walkdown and analyses will be reviewed later when it becomes available.
No violations or deviations were identified.
3.
Corrosion Control and Plant Maintenance During the last inspection of the small bore piping and supports in Unit 3, recorded in Inspection Report No. 91-42, the inspector found that two large pipes had heavy rust.
In order to understand the licensee
'orrosion control and plant maintenance, the inspector discussed this problem with the licensee engineers and coating foreman.
The licensee has four procedures, either from TVA headquarters or Browns Ferry Nuclear Plant, for the specification or application of corrosion control (coating) for plant maintenance.
The four procedures are listed below:
Procedure No.
Rev.
No.
Title G-14 G-55 Selecting, Specifying, Applying and Inspecting Paint and Coating Technical Requirements for Protective Coating Program for TYA Nuclear Plants
t
'
Procedure No.
cont d)
NIA"930 Rev.
No.
Title Special Protective Coating Systems Approved for Use in Coating Service Levels I and II and Corrosive Environments SSP-12.7 Housekeeping/Temporary Equipment Control Procedure G-14 is currently used for Balance-of-Plant and cannot be used for nuclear coating work.
This general construction specification manual describes (1) surface prepar ation, (2) coating systems, (3) application procedures, (4) materials, and (5) inspection procedures for use in the
'reparation of coating specifications for specific surfaces and environments.
This manual also includes coating systems, material indexes, selection guides, and coating suppliers.
The coating systems are classified by their area of use as Architectural Coating System, Industrial Coating System, and Nuclear Coating System.
Procedure G-55 is a general engineering specification which defines the engineering requirements for protective coating work in nuclear applications (Coating Service Levels I
and II) and for corrosive environments, including verification and testing requirements.
Coating Service Level I (CSL I) is an area in which failure of the coating system producing solid debris (as paint chips)
could compromise the intended function of a safety-related system.
Coating Service Level I applies to coatings inside primary containment that are subject to nuclear exposure and design basis accident (OBA) environment.
Coating Service Level II (CSL II) applies to those areas outside the primary containment that are subject to nuclear exposures such as radiation and contamination.
The primary function of Level II coatings is to provide corrosion protection
.
and/or decontaminability for ALARA consideration.
A painter must be certified prior to application in CSL I areas.
CSL Material shall be procured with a Manufacturer's Product Identify Certification Record (PICR) for each batch of each product in the shipment.
CSL II material shall be procured with a certificate from the manufacturer which certifies that the material was manufactured under a TYA approved gA program and has the same chemical and physical properties as was originally tested and qualified in accordance with American National Standards Institute (ANSI)
N5. 12, Section 4,
"Oecontamination Factors" and Section 6,
"Adhesion."
All CSL I coating materials shall be stored in accordance with ANSI N45.2.2, Level B with the temperatures under control based on the manufacturer data.
The minimum and maximum storage temperatures shall be recorded daily, and the record maintained for the shelf life of the material.
Procedure NIA-930 is a plant construction specification for each individual coating system number.
Each coating system number will include:
the approved service level I or II; material to be served such
as steel, concrete, wood, etc.;
location; type of materials for primer, surfacer, intermediate, or finish coats; maximum operating temperature; minimum surface preparation; manufacturer; product name and code; dry film thickness (mils);
number of coats; and total dry film thickness (min.
and max. ).
Procedure SSP-12.7 delineates the housekeeping, material conditions, and temporary equipment control.
This standard practice prescribes the activities required to comply with requirements for general housekeeping and cleanliness of buildings, facilities and area that can affect the quality of the nuclear plant.
This standard practice encompasses the inspections, initiation of corrective actions, documentation and assignment of responsibilities for all structures, facilities, equipment, and appurtenances housekeeping in all the areas of the plant, inside and outside of the security fence.
Appendix C lists the deficiency examples such as trash, tool, chemical materials, equipment, paint requirements, leakage, etc.
There are
zones listed in SSP-12.7.
Each zone will be assigned an inspector and will be inspected, at least, once a week.
The inspection result or any deficiencies will be documented.
The outside areas which are not assigned to a zone wi 11 be inspected once a month.
Currently, TVA's practice on corrosion control and plant maintenance such as checking or identifying leakage, loose parts, rust, damage on materials, ect.,
is based on inspection reports generated per Procedure SSP-12.7 or anybody reporting the deficiency to gA or plant maintenance.
After the associated department reviews the deficiency report, they issue a Work Request (WR) to fix the problem or send it to another department such as engineering for resolution.
For corrosion control, if the rust is light on piping, support parts, or components, the maintenance department may clean the surface with sand paper and paint with coatings.
If the rust is heavy, the maintenance department will request that the engineering department study the problem, check the structural capacity, and find a special treatment or solution.
The licensee is currently developing a maintenance procedure for the periodic inspection on rust, loose part, leakage, damage, etc.
This procedure will concentrate on mechanical maintenance, rather than just material control or housekeeping.
The licensee has just started to divide the Unit 3 plant into zones for housekeeping, based on Procedure SSP-12.7.
The examples of heavy rust found on two pipes lines during the last inspection were in Unit 3.
But, the licensee has not had time to take care of them.
In order to review the licensee coating work, material storage, and paint shop, the inspector walked down Unit 2, the second storage room for coating materials, and the paint shop.
The coatings were applied or will be applied to all materials from the floor up to about 7 ft., including wall.
The coatings are required per CSL II for balance-of-plant, in case of contaminatio (
=
gV
During the inspection in the second coating storage room, the inspector found that there was no personnel assigned to control or attend this room and to record the room temperature for coating materials to be used in CSL I.
Since alii painters were laid off in March 1991, no coatings have been applied to Unit 2 or 3 for CSL I.
The licensee agreed to remove all coatings from this second coating storage room and downgrade them to be used only in balance-of-plant, since CSL I coating materials required temperature control.
No violations or deviations were identified in this area.
CRD Piping - Unit 2 During the las inspection of CRD piping in Unit 3, the inspector was told that all CRD piping supports, for control rod insert and withdrawal lines of 1" and 3/4" diameters, will be removed arid the unistrut will be replaced with tube steel, as was done in Unit 2.
Since the CRD piping support design for Unit 3 will follow the design criteria used in Unit 2, the inspector plans to review the adequacy of CRD piping support design as it applies to Unit 3.
For Unit 2, the licensee modified the existing unistrut members by adding plates to reinforce the unistr ut to qualify as the design criteria were changed.
The licensee became tired of making changes each time that the design criteria changed and decided to use heavy tube steel members to replace the unistrut and reduce the modification cost for Unit 3.
The design criteria for CRD piping supports are contained in General Design Criteria No.
BFN-50-C-7107, Design of Class I Seismic Pipe and Tubing Supports.
The CRD piping supports for the control rod drive insert and withdrawal lines at 1"
and 3/4" diameters are frames to support multiple lines.
The multiplication factor is a load reduction factor for an individual load applied to a frame which supports the multiple lines.
In normal case, the total load applying to a frame from multiple lines is the summation of the individual load with a load factor of 1.0.
The multiplication factor was used for CRD piping supports and described in footnote 6 to Table 1.4.2.1 of BFN-50-C-7101, Rev.
5.
The factor is defined as 1.00 for applications involving between I and 8 loads (or 8 pipes),
0.75 for applications involving between 9 and 22 loads, and 0.50 for 23 and more loads.
The above multiplication factor was accepted by The Office of Nuclear Reactor Regulation (NRR) of NRC per NUREG-1232, Volume 3,
Supplementory 2,
Safety Evaluation Report on Browns Ferry Nuclear Plant, dated January 1991.
The inspector randomly selected CRD support No. 47W2468-108 (or Frame No.
108)
and walked down the lines to partially check the as-built drawing against the as-installed condition.
The support was checked for configuration, identification, fastener/anchor installation, plate size, weld sizes, dimensions, part numbers, maintenance, and damage protection.
While some minor dimension discrepancies were found, the as-installed conditior, was acceptabl ~I
Design Calculation No.
CD-f2085-883931, Rev.
3 for CRD Support No.
47W2468-107 was selected for review.
The review included the code requirement, multiplication factor, load input, member allowable capacity, member stresses, interaction ratio, etc.
Per Section 1.4.2. 11 of BFN-50-C-7107, P1000 series Unistrut shall be qualified to the provisions of American Iron and Steel Institute (AISI) in accordance with American Institute of Steel Construction (AISC).
Six main references were used in this calculation which were listed below:
1.
2.
Reference Reference 5.
Reference Reference 3.
Reference 2, Unistrut General Engineering Catalog No.
3, Design of Unistrut and B-Line Clamps for Piping and Tubing DS-C1.6.14, Revision
5, BFN-50-C-7107, Revision 3, General Design Criteria
"Design of Class I Seismic Pipe and Tubing Supports" 16, American Iron and Steel Institute Specification (AISI)
25, Calculation No. CD-f2085-88050, Revision 6 for gualification of CRDH Piping Support Frame H-119 (Support No. 47W2468-119)
Reference 25 was a prime and basic validation calculation to use MCODE for all CRD pipe support calculations.
Reference 25 contains the MCODE computer program which checks that support members meet AISC or AISI Codes.
In Section 6, Theory, of Reference 25, Equation 1 is used to check the interaction ratio of direct tension stresses and tension stresses due tn bending moments for AISC and AISI Codes.
Equation 2 is used to check the interaction ratio of tension stresses due to bending moments and total shear stresses due to the direct shear stresses and torsional shear stresses.
The Equation 2 is specified for AISI Code checking for Unistrut.
In addition, Section 6, Theory of Reference 25 also provides a
graph extracted from Reference 2, which is used to reduce the unistrut allowable capacity based on the total length.
The yield strength of 42 ksi for Unistrut was an input in MCODE for checking.
The use of 42 ksi yield strength for Unistrut was permitted and signed by Unistrut Corporation per Bechtel Telecon Record, dated March 9, 1989.
The yield strength increase for ASTM Material A-570 with a normal yield strength of 33 ksi was permitted per Section 3. 1. 1 of AISI Specification due to a
strength increase from the Cold Work of Forming.
Therefore, the design calculation No. CD-f2085-883931 for CRD Support No. 47W2468-107 was based on Reference
and Reference
(AISI Code)
and was acceptable.
No violations or deviations were identified in this area.
Exit Interview The inspection scope and results were summarized on January 10, 1992, with those persons indicated in paragraph 2.
The inspector described the areas inspected and discussed in detail the inspection results.
Proprietary
";nformation is not contained in this report.
Dissenting comments were not received from the licensee.