IR 05000315/1979012
| ML17317B377 | |
| Person / Time | |
|---|---|
| Site: | Cook  |
| Issue date: | 06/13/1979 |
| From: | Gallagher E, Hayes D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML17317B376 | List: |
| References | |
| 50-315-79-12, NUDOCS 7907310206 | |
| Download: ML17317B377 (9) | |
Text
U.S. - NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT
REGION III
Report No. 50-315/79-12 Docket No. 50-315 I.icense No. DPR-58 Licensee:
American Electric Power Service Corporation Indiana and Michigan Power Company 2 Broadway New York, NY 10004 Facility Name:
Donald C.
Cook Nuclear Power Plant, Unit
Inspection At:
Donald C.
Cook Site, Bridgman, Michigan Inspection Conducted:
June 5-6, 1979 Inspector:
E. J. Gallagher gfe~~~ / Dl Approved By:
D.
W. Hayes, Chief Engineering Support Section
Ins ection Summar Ins ection on June 5-6 1979 (Re ort No. 50-315/79-12)
Areas Ins ected:
Followup to IE No.Bulletin 79-02, pipe support base plate designs using concrete expansion anchor bolts; review of test program and procedure; observation of testing anchor bolts and review of quality records (Unit 1).
The inspection involved a total of 15 inspector hours by one NRC inspector.
Results.
No items of noncompliance were identified in the areas inspecte DETAILS Persons Contacted Indiana and Michi an Power Com an-D. V. Shaller, Plant Manager-J.
D. Gore, Construction Manager
"B. A. Svensson, Assistant Plant Manager J. F. Stietzel, gA Supervisor American Electric Power Service Co oration Stelle, Chief, Civil Engineering Division K. Paleos, Head Structural Engineering Section Brittan, equality Assurance J. Trippy, Site equality Assurance Coordinator Puckett, Field Construction
'NRC-D. H. Danielson, Chief, Engineering Support Section
-"R. E. Masse, Region III Resident Inspector
"Denotes those in attendance at the exit meeting.
- - unctional or Pro ram Areas Ins ected An inspection was performed at the Donald C.
Cook Nuclear Plant in order to followup on the licensee actions regarding the IE Bulletin Nc. 79-02, pipe support base plate designs using concrete expansion anchor bolts.
1.
Status of Licensee's Test Pro ram of Pi e Su ort Base Plates As of the inspection, the licensee had fully implemented a
major review and test program of pipe support base plate designs and installations using concrete expansion anchors.
The systems included in the test program are listed in Attachment 1 to the report.
Items brought to the attention of the NRC inspector are as follows:
a.
Each system is planned to be 100'f, tested in order to assure system by system operability.
b.
Deficient bolt installations will be replaced, modified by design or analyzed to verify existing conditions'
P
~
c ~
Self-drilling or shell type anchors are not being utilized for load capability except for shear conditions.
Wedge type anchors will replace the shell type for tensile load capacity.
An ultrasonic test will be performed on shell type to verify embedment in the shell.
d.
Before 100'j test program was initiated, random tests were performed to determine existing preload by using strain measurements.
It was determined that the existing bolt setting prior to the test program was not adequate; a 100$
reinspection and setting of the bolts was initiated.
e.
Original bolts were installed without any procedure, inspection or quality control documentation.
As of June 5-6, 1979, the following work had been completed on Unit 1:
~Buildin Containment:
A~uxiliar Turbine:
Total Anchor Bolts to be Tested 1685 1138 126 No. of Bolts 100/
Com lete 1256 755 126 Statistical numbers on the rate of failure had not been developed at this time.
g.
Unit 1 had been shut down for refueling as of April 6, 1979.
The anchor bolt test program began on May 9, 1979; completion is expected by June 15, 1979.
The licensee has expended extensive effort which has included approximately 200 craft, QC and construction personnel and approximately 25 design engineers onsite 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> per day, 7 days per week.
Subcontractors include Southwest Research (QC function),
EDS (design review) an/ Power Systems Incorporated (providing manpower).
The licensee indicated that, although Unit 2 has also been shut down since May 19, 1979, no anchor bolt testing was being planned.
The inspector informed the licensee a
supplement to IE Bulletin No. 79-02 was being developed.
It was expected to require tests on otherwise inaccessible supports be performed during an extended outage within the bulletin time frame,
2.
Review Procedure for Ex ansion Anchor Bolt Test Pro ram (Unit 1)
The inspector reviewed specifications for the anchor bolt test program.
The specifications encompassed the requirements for inspection of expansion anchor bolts as stated in IE Bulletin No. 79-02 as follows:
a.
DCCE-135-gCN, Rev. 5, dated May 30, 1979,
"Procedure for Field Inspection and Testing of Pipe Support Base Plate Concrete Expansion Anchors."
b.
DCCE-135-$ CN, Rev. 5, Addendum A, dated June 1,
1979, including the use of spring washers for testing inacces-sible bolts.
c.
DCCE-136-gCN, Rev. 2, dated May 18, 1979,
"Expansion Anchors Repair Procedure."
d.
DCCE-136-gCN, Rev.
2, Addendum A, dated June 4, 1979, including repair of grouted base plates.
3.
Observation of Testin Concrete Ex ansion Anchors (Unit 1)
The inspector observed selected work activities including tensile testing, ultrasonic testing for determining bolt embeded length, use of spring washers to setting inaccessible bolts and repair of identified deficient anchor bolts.
The following specific items were observed:
1-CCW-L238 - observed (1) ultrasonic testing to determine bolt embedment length using both a digital readout and pulse echo UT device, and (2) tensile test bolt "A" using hydraulic ram to specified test load according to procedure DCCE-135, Rev. 5, Table 1.
Specified test load is equal to 4 times the design load (i.e. 3/4" bolt at 6000 lb.
tensile load).
b.
1-GFW-V803 - observed (1) ultrasonic testing using both digital readout and pulse echo UT device, and (2) tensile testing bolt "A" to specified 4 times design load (i.e.
5/8" bolt at 2750 lbs. tensile load).
C.
1-GMS-R808 - the NRC inspector requested a UT examination of the four bolts on this hanger base plate assembly.
Bolt "C" over all length was determined to be only 2" while the projection from the concrete surface was also measured to be 2".
The inspector requested the licensee to remove the plate assembly to further investigate this condition.
At the time of original installation a craftsman had tack welded a threaded bolt stub to a bolt which had been driven incorrectly into the drilled hole.
The licensee identified this condition on the data sheet for corrective action.
d.
1-GCCW-R107 - the bolts on the hanger were determined to be of an incorrect size.
The hanger detail required a
3/4" diameter bolt while the installed bolts were 1/2" diameter.
It was determined after an engineering review that a repair would be required to reinstall the correct diameter bolt to meet the design conditions.
Work was observed according to repair procedure DCCE-136, Rev. 2.
e.
1-CCW-L293 - observed setting of expansion bolt using Schnon spring washers according to procedure DCCE-135, Rev. 5, Addendum A.
It was ascertained that the testing program being performed of the Donald C.
Cook plant was in accordance with established procedure using calibrated testing equipment, under adequate supervison and quality control inspection measures.
4.
Review of gualit Records for Testin Anchor Bolts (Unit 1)
A review of base plate support inspection data sheets was made as listed in Paragraph 3 of this report.
The sheets included all appropriate information to document inspection findings.
Where deficiencies were found, an engineering review was performed to resolve them.
Resolutions included replacing the bolts, designing a structural modification or performing an analysis for acceptability.
The calibration tests run on the Schnon spring washers being used to preload the inaccessible anchor bolts was reviewed.
Results indicated the force required to flatten the washers was conservative since values obtained during the test were higher than manufacturer's published values.
5.
Other Items in IE Bulletin 79-02 a
~
The bulletin requires verification that pipe support base plate flexibilitywas accounted for in the calculation of anchor bolt loads.
The licensee.indicated that criteria set forth in the bulletin for base plate flexibilitywas
"5-
not being used.
Instead, they were awaiting the results of Teledyne's analysis and experiments to address plate flexibility.
b.
The bulletin requires a description of the design requirements for anchor bolts to withstand cyclic loads; the licensee is awaiting the Teledyne study.
This information will be included in the bulletin response.
Exit Interview The inspector met with site staff representatives (denoted in the Persons Contacted paragraph)
at the conclusion of the inspection on June 7, 1979.
The inspector summarized the scope and findings of the inspection.
The licensee acknowledged the findings.
Attachment:
List of Systems in Test Program
Attachment
List of S stems in Test Pro ram 1.
Blowdown Line 2.
Condensate Line 3.
Control Air 4 ~
Component Cooling Water 5.
Chemical Volume Control 6.
Diesel Generator 8.
Essential Service Water 9.
Fuel Oil I,ine 10.
Feed Water Line ll.
Hydrogen Skimmer 12.
Jacket Water 13.
tube Oil 14.
Main Steam 15.
Nitrogen Line 16.
Nonessential Service Water 17.
Ice Cond. Refrig.
18.
Reactor Cool 19.
Residual Heat 20.
Spent Fuel 21.
Safety Injection 22.
Vent Water 23.
Waste Drain 24.
Miscellaneous Snubbers Attachment
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