IR 05000445/1980007
| ML19309G096 | |
| Person / Time | |
|---|---|
| Site: | Comanche Peak  |
| Issue date: | 03/13/1980 |
| From: | Beach A, Crossman W, Martin L NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19309G095 | List: |
| References | |
| 50-445-80-07, 50-445-80-7, 50-446-80-07, 50-446-80-7, IEB-79-02, IEB-79-14, IEB-79-2, IEB-79-2-R2, NUDOCS 8005020346 | |
| Download: ML19309G096 (7) | |
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8006020348
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U. S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT
REGION IV
Report No. 50-445/80-07; 50-446/80-07 Docket No. 50-445; 50-446 Category A2 Licensee: Texas Utilities Generating Company 2001 Bryan Tower Dallas, Texas 75201 Facility Name:
Comanche Peak, Units 1 and 2 Inspection at:
Comanche Peak Steam Electric Station, Glen Rose, Texas Inspection conducted: February 25-28, 1980 e
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Inspectors:
.s L. E. Martin, Reactor Inspector, Projects
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Section (Paragraphs 1, 2, 3, & 6)
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. L mdo 3Az/m A. B. ' Beach, Reactor Inspector, Engineering Date Support Section (Paragraphs 4 & 5)
(February 25-27, 1980 only)
4ty 3//.7/fo Approved:
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W. A. Crossman, ChVef, Projects Section Date
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R. E. Hall, Chief, Engineering Support Section
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Inspection Summary:
Inspection on February 25-28, 1980 (Report No. 50-445/80-07; 50-446/80-07)
Areas Inspected:
Routine, unannounced inspection of safety-related construc-tion activities pertaining to installation and inspection of instrumenta-tion; instrument QC inspector training; instrumentation tubing and valves receiving records; and procedures, records, and observation of wark associated I
with NRC IE Bulletins 79-02, Rev. 2 and 79-14.
The inspection involved fifty-l four inspector-hours by two inspectors.
l Results: No items of noncompliance or deviations were identifie *
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DETAILS 1.
Persons Contacted Principal Licensee Personnel
- R. G. Tolson, TUGCO, Site QA Supervisor J. V. Hawkins, TUGC0/G&H, Senior QC Supervisor D. H. Wade, TUSI, Field Mechanical Engineering Supervisor
- J. Merrit, TUSI, Engineering and Construction Manager
- J. B. George, TUSI, Project General Manager Other Personnel R. E. Holloway, Supervisor Technical Services, B&R B. J. Murray, Mechanical Engineer, Technical Services, B&R J. Henline, Instrumentation QC Supervisor, B&R J. Williams, Instrumentation QC Lead Inspector, B&R R. Estes, Instrumentation Engineer, B&R The IE inspectors also interviewed other licensee and contractor personnel during the course of the inspection.
- Denotes those attending the exit interviews held on February 27 and 28, 1980.
- Denotes those attending the exit interview on February 27, 1980 only.
2.
Site Tour The IE inspectors walked through Unit 1 Reactor and Auxiliary Buildings to observe construction activities in progress and to inspect house-keeping.
No items of noncompliance or deviations were identified.
3.
Instrumentatior_locoonents and Systems a.
Review of Procedures i
The IE inspe reviewed the following procedures and change authorizations zor compliance with 10 CFR 50, FSAR, and applicable industry standards.
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(1) 35-1195-ICP-4, Rev. 3. " Instrument and Tubing Installation and Inspection" (2)
35-1195-ICP-5, Rev. O, " Control of Issue of Permanent Plant Instrumentation" (3)
35-1195-MCP-10, Rev. 4, " Storage and Storage Maintenance of Mechanical and Electrical Equipment" (4) 35-1195-ACP-3, Rev. 7, " Material Receiving, Storage and Handling"
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(5) 35-1195-IFP-4, Rev. O, " Instrument Installation Inspection" (6)
35-1195-ICP-9, Rev. 1, " Instrument Support Installation" (7)
CP-QP-11.8, Rev. 1, " Instrumentation and Control Inspection Activities" (8)
QI-QP-11.8-1, Rev. 3, " Instrument Tubing and Fittings Inspection" (9)
QI-QP-11.8-2, Rev. 3, " Instrument Supports and Rack Assembly Inspection" (10)
QI-QP-11.8-3, Rev. 1, " Instrument Installation Inspection" (11)
QI-QP-11.8-4, Rev. O, " Inspection of Welded Instrumentation Support Systems" (12)
Interim Change Notice ICN-3 to 35-1195-ACP-3 (13) Design Change Authorization DCA 4372 (14) Design Change Authorization DCA 6288 No items of noncompliance or deviations were identified.
b.
Observation of Work and Records Review The IE inspector examined the following installed instruments and reviewed the Manufacturing Record Sheets (MRS) including QC signoff for compliance with FSAR and applicable installation and quality procedures:
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1 PIS 4522 1 PIS 4518 1 PIS 5951 1 PIS 4519 1 PIS 5948 1 PIS 5349 1 PIS 5954 1 FIS 4599 in process The IE inspector also reviewed the DCAs and revision level of the drawings referenced on the MRSs for the above instruments to determine that the installations were accomplished in accordance with the latest drawings.
The following purchase orders (P.O.), Material Receiving Recorda (MRR), and Receiving Inspection Records (RIR) including Certificates of Compliances and Material Certification Test Reports for instru-ment tubing, fittings, and valves were reviewed. These records were reviewed for completeness, accuracy, traceability to records
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previously reviewed and applicability.
P.O. 35-1195-15800 MRR 60807 and 77180 RIR 6002 and 9389 P.O. 35-1195-15783 MRR 96274 and 93982 RIR 13470 and 13244 P.O. 35-1195-18604 MRR 82333 RIR 10109 The IE inspector reviewed the training records for three of the eleven instrumentation QC personnel.
i No items of noncompliance or deviations were identified.
4.
Licensee Actions Taken in Response to IE Bulletin 79-02, Revision 2 The IE inspector reviewed the licensee's reponse to IE Bulletin 79-02, Rev. 2, " Pipe Support Base Plate Designs Using Concrete Expansion i
Anchor 2 nits."
From this review and from discussions with licensee and contractor personnel, it was determined that base plate flexibility is now being incorporated into the design of pipe support base plates which use concrete expansion bolts in Seismic Category I systems.
Of the two organizations involved in this pipe support base plate design, only ITT Grinnell considered base plate flexibility in their original design.
NPS Industries assumed, in their original design, that the base plates were, in fact, rigid. To satisfy the requirements
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of the Bulletin, NPS Industries conducted a finite element analysis to incorporate base plate flexibility into their design of approximately 157 applicable supports.
At present, all field modifications and changes in the field to the pipe support base plates are subject to review by each of the respective organizction's home office. A TI-59 computer program is being developed for a consistent means for flexibility analysis at the site for these field modifications.
This field computer program is similar to the ITT Grinnell FUBI program. Also, a contract is being negotiated with an independent consulting firm to perform, on a case-by-case basis, a finite element analysis on those base plates or anchor bolts which do not meet the requirements of the more conservative TI-59 romputer program.
The IE inspector reviewed procedura 35-1195-CEI-20, Rev. 5,
" Installation of Hilti Drilled-In Bolts." All concrete expansion bolts, in use at the Comanche Peak facility, are the Hilti wedge type anchor bolts, with a minimum factor of safety of five between the bolt design load and the ultimate capacity of the bolt. Additionally, the maximum support load includes twice the operating basis earthquake (2 x OBE) in its seismic calculation.
Procedure CEI-20 includes the construction installation procedure as well as torquing verification program to assure the anchor bolts are preloaded above the design load.
The bolt torquing requirements were established from on-site test data, dated May 5, l
1978, and are as follows:
Bolt Diameter (Inches)
Torque (Ft. Lbs.)
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3/8
1/2
5/8 120 3/4 150
230 1-1/4 400 The torque and tension correlation data available at the site were in accordance with the manufacturer's specifications. Additional
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testing is to be performed for other-sized diameter bolts utilized on the project. Discussion with contractor and licensee personnel indicated that additional testing would not be performed on those anchor bolts utilized whose embedment length varied from the embedment length of the original bolt tested, but whose diameter
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was the same as that diameter of the bolt qualified by on-site testing.
This has been acceptable as long as there is not a large differential in the design capacity of the bolts in relation to their length.
Proc edural requirements were addressed for verification by inspection that the concrete expansion anchors are properly installed in accordance with the requirements of the Bulletin.
Inspection procedures reviewed were as follows:
CP-QP-11.2, Rev. O, " Surveillance and Inspection of Concrete Anchor Bolt Installations" QI-QP-11.2-1, Rev. O, " Concrete Anchor Bolt Installation" QI-QP-11.2-3, Rev. O, " Torquing of Concrete Anchor Bolts" QI-QP-11.2-4, Rev. O, " Inspection of Hilti Super Kwik Bolts" In conjunction with this procedural review, work packages for the following hanger support base plates were selected:
CS-1-018-22-S5'R CS-1-018-017-S52K CH-1-002-003-S52R CC-1-011-020-S53R A work package consisted of the following:
Construction Operation Traveler Bill of Materials Drawings (Support Number and Sketch)
l Multiple Weld Data Card for Hanger Installation Weld Filler Material Log Component Modification Card and/or Pipe Support Base Plate "As-Built" Record Instruction I
i Manufacturing Record Sheet
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Each of the above base plates were reviewed in the field with the appropriate documents in each of the work packages to confirm that all of the inspection attributes required by the inspection procedures were being met.
Inspection attributes included proper type and size of bolt, proper embedment depth, adequate anchor bolt spacing, actual verification and documentation of "as built" installation, and torquing verification of at least one anchor bolt per base plate.
All activities observed and documentation reviewed met the requirements of the constru-tion and inspection procedures.
7uring the review of the licensee's response to IE Bulletin 79-02, Rev. 2, aad a field review of structural shapes as addressed by the Bulletin, there were numerous structural shapes attached to the structure with Richmond inserts as stated in the licensee's response. However, there were numerous cases where the structural shapes were attached to the structure with concrete anchors and base plates.
The IE inspector emphasized, in his discussions with the licensee and contractor, that these, too, must be analyzed for flexibility, just as base plates with concrete anchors for pipe supports, or justification must be provided for a rigid assumption, as required by the Bulletin.
No items of noncompliance or deviations were identified.
5.
Licensee Actions Taken in Response to IE Bulletin 79-14 The IE inspector reviewed hanger and base plate installation procedures relative to IE Bulletin 79-14, " Seismic Analysis for As-Built Safety-Related Piping Systems." However, the procedure addressed in the licensee's response to the Bulletin was, at the time of this inspection, in the review cycle and had not yet been issued for implementation.
Therefore, the entire program initiated in response to the Bulletin will be reviewed in a subsequent inspection.
6.
Exit Interviews Mr. A. B. Beach, IE inspector, and R. G. Taylor (NRC Resident Ir.spector)
met with licensee representatives (dencted in paragraph 1) at the conclusion of the portion of the inspection covering NRC IE Bulletins 79-02 and 79-14 on February 27, 1980.
Mr. L. E. Martin and R. G. Taylor met with licensee representatives at the conclusion of the inspection on February 28, 1980.
The IE inspectors summarized the purpose, scope, and findings of the inspection.
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