IR 05000336/1986027

Insp Rept 50-336/86-27 on 861209-12.No Violation Noted.Major Areas Inspected:Licensee Response & Subsequent Analysis & Mods of Masonry Walls Per IE Bulletin 80-11 Re Masonry Wall Design

ML20210G885
Person / Time
Site:	Millstone
Issue date:	01/12/1987
From:	Strosnider J, Varela A NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I)
To:
Shared Package
ML20210G859	List: IR 05000336/1986027 ML20210G853
References
50-336-86-27, IEB-80-11, NUDOCS 8702110344
Download: ML20210G885 (12)

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U.S. NUCLEAR REGULATORY COMMISSION

REGION I

Report N /86-27 Docket N License No. DPR-65 Category C Licensee: Northeast o Nuclear Energy Company P. O. Box 270 Hartford, Connecticut 06141-0270 Facility Name: Millstone Nuclear Power Station, Unit 2 Inspection At: Berlin and Waterford, Connecticut Inspection Conduc ed: December'9-12, 1986 Inspectors: f,i k5 k DAN. 6, /ib/

A. A.' Varsla,' Lead Reactor Engineer date NRC Contact Personnel: M. E. Nitzel, EG&G, Idaho

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V. B. Call, EG&G Idaho

! / //87 Approvedby:h.R.Strosnider, Chief,Materialsand date Processes Section, EB, DRS Inspection Summary: Inspection on December 9-12, 1986 (Inspection Report Number 50-336/86-27).

Areas Inspected: A special announced inspection by a regional-based inspector and two contractor personnel was conducted at the licensee's engineering office and the Millstone 2 plant site. The inspection encompassed review of licensee responses and subsequent analysis and modifications of masonry ~ walls related to IE Bulletin 80-11, Masonry Wall Design. The inspection included a walkdown of existing walls affecting safety related equipment, a review of design analyses and a review of work packages on wall modification Results: No violations were identifie &2110344 G ADOCM o

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DETAILS 1.0 Persons Contacted Northeast Utilities (NU)

J. Bergin, Plant Engineer

• J. Briggs, Supervisor, Generation Engineering W. Frisbie, Quality Assurance Engineer

• G. L. Johnson, Director, Generation Engineering Design

• D. Robinson, Senior Engineer

• R. N. Smart, Manager, Civil Engineering

• R. P. Werner, Vice President, Generation Engineering Construction Bechtel Power Division (BPD) Gaithersburg, MA P. Carrato, Senior Engineer NRC Contractor EG&G Idaho In *V. B. Call, Senior Engineer

• E. Nitzel, Engineer Specialist

• Attendees at exit meeting on December 12, 1986

2.0 Inspection Purpose And Scope The purpose of this inspection was to review with cognizant and responsi-ble licensee representatives at the corporate office and the plant the completeness of their responses to NRC/IE Bulletin 80-11, Masonry Wall Design. The scope of the inspection included a review of engineering design and quality assurance documentation relating to inspection, test-ing, analysis and modifications satisfying requirements and licensee commitments with respect to the bulletin. A walkdown inspection of the plant was conducted to verify the acceptability of repairs and/or modifi-cations relating to the bulleti .0 Review Criteria The latest revision of the bulletin was used to define required actions by the utilit In addition, Temporary Instruction (TI) 2515/37 was used to further define inspection requirements. Applicable sections of the Code of Federal Regulations (10 CFR 50) were use .0 Review Of Licensee Responses The inspection team reviewed bulletin responses available from NRC files prior to the inspection. These responses included reports addressing the reevaluation methodoloav, acceptance criteria, wall configurations and

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functions, structural adequacy, proposed modification plans, and modifica-tion schedules. Table 1 lists those documents reviewed prior to the inspection. Any items of noncompliance or those requiring further discus-sion were noted as items to be addressed while at the corporate office or l plant site. Questions relating to licensee responses were forwarded to licensee in advance of the inspection as a preliminary agenda for discus-sio The inspection team reviewed additional material provided by the licensee during the inspection. This material consisted of procedures governing the original wall survey and reevaluation activities, reevaluation calcu-lations, structural adequacy of wall modifications, construction packages for wall modifications, and QA/QC documentation. The documents reviewed are listed in Tables 2 and .1 Findings It was determined from the review of the documentation described above that, in general, all aspects of the work done in response to the subject bulletin were acceptable. However, two unresolved items were identified. Further details regarding these items are given belo IEB 80-11 required the inspection and reevaluation of safety related masonry walls to assure structural adequacy. In order to assure continued compliance with bulletin requirements, physical conditions such as absence of mortar cracking and assumed boundary conditions must be maintained. The licensee was asked to provide a surveillance plan for routine inspection of masonry walls subject to bulletin action to demonstrate continued compliance. No formal plan for routine surveillance currently exists. However, the licensee did produce a draft for a procedure that would govern periodic surveil-lance of the subject walls at the licensee's Haddam Neck plant. The licensee representatives noted that it was their intention to use this procedure to govern continuing masonry wall surveillance activi-ties at all their nuclear power plants. The licensee stated that work was still in progress in formalizing the procedure. This item is unresolved pending completion of the procedure and review by the NRC. This is unresolved item number (50-336/86-27-01).

The procedurd control over mortar joint repair work was reviewed by the inspector. The only procedural controls over mortar joint repairs, were those accomplished in conjunction with another wall modificatio . .

The licensee stated that a mortar joint repair procedure that would govern any repair activities required by the continued periodic surveillance program was being developed. It was stated that this procedure would incorporate research into the latest materials avail-able for use in this type of repair. This item is unresolved pending completion of the procedures and review by the NR This is unresolved item number (50-336/86-27-02).

The licensee representatives acknowledged the unresolved items and agreed to respond by submitting to the NRC a draft of the surveil-lance plan procedure by December 31, 1986. The licensee representa-tives also agreed to submit a draft copy of the mortar joint repair procedure for NRC review. This procedure would be submitted prior to the end of February,1987. Formalization of both procedures would then be completed prior to the beginning of the next refueling outage (approximately June, 1987).

5.0 Verification Walkdown Inspection A physical inspection of certain masonry walls subject to bulletin action was conducted. The walls included in this sample were chosen by the inspection team. The purpose of this walkdown was to verify samples of inspections and/or modifications required by the bulletin. The walls listed in Table 4 were examine .1 Findings During the walkdown inspection, it was noted that eight masonry walls out of the 29 sampled had incurred cracks not shown on the wall survey sheet or differing from that shown on the survey sheets: Walls 3.6, 3.18, 3.29, 4.18, and 9.35 were found to contain cracks at one or both side boundaries extending the full height of the wal . Wall 7.5 was found to contain mortar and through block cracking on the west face of the wall near cabinet MUX- Wall 1.21 was found to contain mortar cracking on the north face of the wall in addition to that originally noted on the south face during the original survey. This appeared to be a through wall crac . The original survey of wall 7.8 noted a hairline crack at the east boundar During this walkdown inspection, it was noted that the crack extended the full length of the wall and included a large separation (approximately one inch or larger). Although this wall does not affect safety related equipment, the changing nature of the crack and the magnitude of displacement further indicate the desirability for continued surveillance of those walls that are in the safety-related categor . .

Further review of the reevaluation calculations and additional evalu-ations indicated that none of the cracks noted above would pose an immediate hazard to the structural adequacy of the subject wall The probable causes of the cracks noted above could not be determined at the time of the inspection. As noted under the findings described in paragraph 4, the licensee is currently developing a continuing surveillance and repair plan. The observations made during the walk-down inspection emphasize the need for the licensee to ensure that the procedures currently being developed include appropriate measures to: Provide an analysis of the probable cause of any newly discov-ered crack . Perform an evaluation of the structural adequacy of the subject walls taking into account the effects of the cracks or any other degraded physical conditio . Provide for the timely repair of any masonry wall for which the structural adequacy cannot be assure .0 Licensee Administrative Controls And Assurance Of Quality To determine the adequacy of administrative controls for assuring quality work, the inspector examined records of inspection / verification and materials control. The inspector also verified the availability and retrievability of pertinent documents, and reviewed procedures that established those requirements. The pertinent documents examined are identified in Table Based on the above examination and review, the inspector determined that the administrative controls were adequate and effective to assure quality. Sufficient inspections and verifications were performed to assure conformance of the masonry wall surveys and modifications to established requirements, specifications, and drawing Findings No violations were identified, Based on the results of this inspection IEB 80-11 is close .0 Definition Of Unresolved Items Unresolved items are matters about which more information is required in order to ascertain whether they are acceptable, violations, or deviations relative to the bulletin requirements. Unresolved items identified during this inspection are discussed in paragraphs 4.0 and 5.0 abov l

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8.0 Exit Meeting

! The' exit meeting was conducted by the NRC inspector. The NRC contractor i personnel and licensee representatives (denoted in paragraph 1) were in attendance. The NRC inspector summarized the inspection findings and the licensee acknowledge these comments. No written material, other than that described in paragraph 4.0 (preliminary agenda for discussion) was provi-ded to licensee personne !

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TABLE 1 DOCUMENTATION REVIEWED PRIOR TO INSPECTION Document Description

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W. G. Counsil (NUSCO) letter to B. H. Grier (USNRC) dated 07/07/80 forwarding licensee's 60 day response to IEB 80-1 W. G. Counsil letter to B. H. Grier dated 11/04/80 transmitting licensee's 180 day response to IEB 80-1 W. G. Counsil letter to B. H. Grier dated 03/03/81 providing status of IEB 80-11 activities and requesting schedule extensio R. A. Clark (NRC) letter to W. G. Counsil dated 09/28/82 requesting additional information regarding responses to IEB 80-1 W. G. Counsil letter to R. A. Clark dated 12/03/82 forwarding additional information regarding IEB 80-11 activitie G. Lear (NRC) memo to J. Miller (NRC) dated 02/13/84 forwarding results of a review of licensee submittals and requesting additional informatio J. Miller letter to W. G. Counsil dated 02/24/84 requesting additional information regarding IEB 80-11 activitie W. G. Counsil letter to J. R. Miller dated 05/11/84 forwarding partial response to the 02/24/84 request for additional information regarding IEB 80-1 W. G. Counsil letter to J. R. Miller dated 11/02/84 forwarding additional responses to the 02/24/84 request for additional information regarding IEB 80-1 W. G. Counsil letter to J. R. Miller dated 01/04/85 forwarding additional responses to the 02/24/84 request for additional information regarding IEB 80-1 R. Besnak (NRC) memo G. Lainas (NRC) dated 03/28/85 forwarding results of the review of licensee submittals and a Safety Evaluation Report (SER).

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J. Miller letter to W. G. Counsil dated 04/17/85 transmitting the SER regarding IEB 80-11 actions taken at Millstone 2. Followup information requeste . .

TABLE 1 2 Document Description

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J. F. Opeka letter to J. R. Miller dated 05/22/85 providing commitment and schedule for the reevaluation of masonry ,

walls qualified by inelastic method '

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J. F. Opeka letter to E. J. Butcher dated 10/28/85 transmitting results of the reevaluation of masonry walls originally qualified by inelastic method D. B. Osborne (NRC) letter to J. F. Opeka dated 10/20/85 forwarding supplemental SE . -.

TABLE 2 DOCUMENTATION REVIEWED DURING THE INSPECTION Document Description

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Masonry wall locations plans shown on drawings 25203-59024 through 5903 Revision 5 of Bechtel masonry wall survey procedur Letter from Thames Permacrete Co. to Bechtel regarding masonry wall mortar propertie A-1 Bechtel specification for furnishing, delivery, and erection of masonr EDP-4.37 Bechtel engineering procedure governing preparation and documentation of design calculation .1 Bechtel calculation for the justification of the use of averaged response spectr GPD Bechtel civil design aid for the calculation of the inelastic behavior of masonry wall Bechtel specification for the reevaluation of concrete masonry wall PD-2.29 Bechtel plant design group calculation of wall loads for masonry wall 2.2 Bechtel evaluation procedure for determining loads on masonry walls.

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8011-001 Bechtel calculation of Millstone Unit 2 auxiliary building response spectr Mercury Co. block wall structural modification procedure.

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NUSCO draft of block wall surveillance and repair procedure.

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Original survey sheets, log sheets, and modification l drawings for walls 1.13, 1.12, 2.29, 2.21, 2.24, 2.17, 2.71, 3.6, 3.18, 3.25, 3.29 4.16, 4.18, 4.21, 5.10, 5.11, 7.5,

7.12, 7.13, 9.3, and 10.3.

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Modification construction packages for walls 1.13, 1.12, j 2.21, 2.24, 2.17, 3.18, 3.25, 7.5, 7.12, 7.13, and . .

.e TABLE 3 CALCULATION PACKAGES REVIEWED Calc. N Wall

8011-1.13 1.13 (no mod.)

8011-1.12 1.12 (no mod.)

8011-2.29 2.29 (pipe support removed, no mod. to wall)

80-11-2.21 2.21 80-11-2.24 2.24 80-11-2.17 2.17 80-11-2.71 2.71 80-11- .6 80-11-3.18 3.18 80-11-3.25 3.25 80-11-3.29 3.29 80-11-4.16 4.16 80-11-4.18 4.18 80-11-4.21 4.21 80-11-5.10 5.10 80-11-5.11 5.11

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80-11- .5 80-11-7.12 7.12 80-11-7.13 7.13 80-11- .3 80-11-1 .3 Note: Calculation packages listed above included the associated modification calculations unless otherwise note :

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TABLE 4 MASONRY WALLS FIELD VERIFIE Wall Elevation (ft) Location 1.11 38'-6" Warehouse 1.13 38'-6" Warehouse 1.12 38'-6" Warehouse 1.16 38'-6" Warehouse 1.21 38'-6" Auxiliary 1.32 38'-6" Auxiliary 1.48 38'-6" Auxiliary 1.51 38'-6" Auxiliary 1.59 38'-6" Auxiliary 2.29 14'-6" Auxiliary 2.21 14'-6" Auxiliary '-6" Auxiliary '-6" Auxiliary 2.24 14'-6" Auxiliary 2.17 14'-6" Auxiliary 2.71 14'-6" Auxiliary '-6" Auxiliary 3.18 -5'-6" Auxiliary 3.25 -5'-6" Auxiliary 3.29 -5'-6" Auxiliary 4.16 -25'-6" Auxiliary 4.18 -25'-6" Auxiliary '-6" Turbine '-6" Turbine 7.12 31'-6" Turbine 7.13 31'-6" Turbine '-6" Turbine 9.35 14'-6" Turbine 1 '-0" Turbine

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TABLE 5 DOCUMENTATION REVIEWED OF LICENSEE ADMINISTRATIVE CONTROLS Document Description QM-2666 December 18-20, 1979 NUSC0/ Nuclear Audit and Testing Company, Inc. (HATC0) audit of Bechtel, Gaithersburg Power Division (GPD) to assess BC quality system for work in compliance to NRC/IE Bulletin QM2-677 NUSCO acceptance March 10, 1980 of BC corrective actions to findings identified in QM2-66 File A01274 NUSCO annual supplier evaluation reports of GPD supplemented by NRC Region IV vendor inspection report numbers 81-01, 03, 81-04, and 82-0 QAF 80-1 GPDQA audits of BC procedure and plant surveys of QAF 80-2 as-built masonry walls / jeopardized safety related QAF 80-3 equipment in response to IEB 80-11 July 2, 1980 and August 8, 1980. Corrective actions completed / verification close out of above findings and turnover to GPD for design, dated December 12, 198 QL2-G-80 NUSCO construction QA audit A-40712 of Mercury February 11, 1982 Company (masonry wall modification contracter) QA Program conducted December 29, 1981 through January 8, 1982 identified a finding QL2-G-84 Mercury responses to above dated January 28, 1982, March 16, 1982 February 11, 1982, March 10, 1982, and NUSCO surveillance reports and verification of corrective actions undertaken by Mercur QL2-G-83 NUSCO QA audit A-40675, Turnover Documentation of Februa ry 19, 1982 Mercury and 2 finding March 10, 1982 Mercury response to above findings and corrective action QL2-G-82 NUSCO verification and close out of A-4067 March 18, 1982

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