IR 05000445/1989026
| ML20247C283 | |
| Person / Time | |
|---|---|
| Site: | Comanche Peak  |
| Issue date: | 05/16/1989 |
| From: | Livermore H, Runyan M Office of Nuclear Reactor Regulation |
| To: | |
| Shared Package | |
| ML20247C266 | List: |
| References | |
| 50-445-89-26, 50-446-89-26, NUDOCS 8905240387 | |
| Download: ML20247C283 (18) | |
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APPENDIX B U.
S. NUCLEAR rtEGULATORY COMMISSION-OFFICE OF NUCLEAR REACTOR REGULATION NRC Inspection Report:
50-445/89-26 Permits: CPPR-126 50-446/89-26 CPPR-127 Dockets: 50-445 Category: A2 50-446 Construction Permit Expiration Dates:
Unit 1: August 1, 1991 Unit 2: August 1, 1992 Applicant:
TU Electric Skyway Tower 400 North Olive Street Lock Box 81 Dallas, Texas 75201 Facility Name:
Comanche Peak Steam Electric Station (CPSES),
Units 1 & 2 Inspection At:
Comanche Peak Site, Glen Rose, Texas Inspection conducted:
April 5 through May 2, 1989 Inspector:
I'Ih~89-hn_
M.
F7 Runyad, Resident Inspector, Date Civil Structural (paragraphs 2, 3, 4)
Consultants: W. Richins, Parameter (paragraphs 2, 5, 6)
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J. Dale, EG&G (paragraphs 2, 5)
b /b"OO Reviewed by:
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tAAW /49 s H. H. Livermore, Lead Senior Inspector Date 8905240387 890516 PDR ADOCK 05000445 O
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Inspection Summary:
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Inspection Conducted:
May-5 through April 2, 1989 (Report
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50-445/89-26; 50-446/89-26)
E Areas Inspected: Unannounced, resident safety inspection of.
applicant's actions on previous inspection findings, follow-up on
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l; violations / deviations, actionJon 10 CFR Part 50.55(e) deficiencies l'
' identified by the applicant, Post-Construction Hardware Validation I
' Program (PCHVP), and plant tours.
Results:
Within the areas inspected, no programmatic strengths or-L weaknesses were identified.- A violation was identified regarding the closure of two NCRs without correction of all identified discrepancies (paragraph-2.c).
Another violation was identified regarding inadequate PCHVP inspections of structural steel platforms (paragraph 2.e).
Another violation was identified regarding the failure of procedures to require verification of configuration following a construction. activity (paragraph _2.f).
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DETAILS 1.
. Persons Contacted
- R.
W. Ackley, Jr., Director, CECO
- G.
K. Afflerbach, ASM Startup, TU Electric
- M.
Axelrad, Newman and Holtzinger
- J.
L. Barker, Manager, Engineering Assurance, TU Electric
- D.
P. Barry, Senior Manager, Engineering, Stone and Webster Engineering Corporation (SWEC)
- J.
W.
Beck, Vice President, Nuclear Engineering, TU Electric
- O.
Bhatty, Issue Interface Coordinator, TU Eles~ric
- M.
R. Blevins, Manager, Technical Support, TU Electric
- H.
D. Bruner, Senior Vice President, TU Electric
- J. H. Buck, Senior Review Team, IAG
'*J. T. Conly, APE-Licensing, SWEC H. M. Crocket, Engineering, TU Electric
- R.
J. Daly, Manager, Startup, TU Electric
- J.
W.
Donahue, Operations Manager, TU Electric
- D.
E. Deviney, Deputy Director, Quality Assurance (QA),
TU Electric
- D, M. Ehat, Consultant, TU Electric
- J.
C.
Finneran, Jr., Manager, Civil Engineering, TU Electric
- C.
A.
Fonseca, Deputy Director, CECO
- W.
G.
Guldemond, Manager of Site Licensing, TU Electric
- P.
E. Halstead, QC Manager, TU Electric N. D. Hammett, Engineering Assurance, Brown and Root (B&R)
- T.
L. Heatherly, Licensing Compliance Engineer, TU Electric
- C.
B. Hogg, Engineering Manager, TU Electric
- T.
A. Hope, Licensing, TU Electric
- A.
Husain, Director, Reactor Engineering, TU Electric
- R.
T. Jenkins, Manager, Mechanical Engineering, TU Electric
- J.
J. Kelley, Manager, Plant Operations, TU Electric
- O. W. Lowe, Director of Engineering, TU Electric
- F.
W. Madden, Mechanical Engineering Manager, TU Electric
- D.
M. McAfee, Manager, QA, TU Electric
- S.
G. McBee, NRC Interface, TU Electric
- J. W. Muffett, Manager of Engineering, TU Electric D. Noss, Licensing, Daniel
- E.
F. Ottney, Program Manager, CASE
- S.
S.
Palmer, Project Manager, TU Electric
- P.
W.
Pellette, Operations, TU Electric
- D.
M. Reynerson, Director of Construction, TU Electric
- A.
H.
Saunders, EA Evaluations Manager, TU Electric
- A.
B. Scott, Vice President, Nuclear Operations, TU Electric
- B.
J.
Sewell, TU Materials Coordinator Manager, TU Electric
- J.
C.
Smith, Plant Operations Staff, TU Electric
- R.
L.
Spence, TU/QA Senior Advisor, TU Electric
- M.
D. Skaggs, CPE, Mechanical, TU Electric
- P.
B.
Stevens, Manager, Electrical Engineering, TU Electric
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- J.
F. Streeter, Director, QA, TU Electric
- C, L. Terry, Unit 1 Project Manager, TU Electric
- M.
A. Thero, CASE Intern
- 0.
L. Thero, QTC Consultant to CASE
- T.
G.
Tyler, Director of Projects, TU Electric
- R.
D. Walker, Manager of Nuclear Licensing, TU Electric
- R.
G. Withrow, EA Systems Manager, TU Electric The NRC inspectors also interviewed other applicant employees during this inspection period.
- Denotes personnel present at the May 2, 1989, exit meeting.
2.
Applicant Action on Previous Inspection Findings (92701, 55150, 50073)
a.
(Closed) Open Item (445/8516-0-49):
This item addressed potential deviations regarding the location of a capture
plate and anchor bolt washers and/or nuts that did not i
have full bearing for pipe whip restraint CP1-SISSMR-08.
These conditions were identified by CPRT during an inspection of Verification Package I-S-PWRE-053 witnessed
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by the NRC inspector, dn-Rmented in CPRT Deviation Reports (DRs) I-S-PWRE-053-DR1, -DR2, -DR3, and -DR4, and incorporated into Nonconformance Report (NCR) M-23364N, j
Revision 2.
This NCR was subsequently dispositioned j
"use-as-is" for DR I-S-PWRE-053-DR1 (location of the capture plate) due to a change in the location toleraLce.
For DRs I-S-PWRE-053-DR2, -DR3, and -DR4, NCR M-23364N was dispositioned rework by loosening nuts and bolts, chipping i
excess grout, and cleaning all bearing surfaces prior to j
reinstallation of the bolts.
The NRC inspector verified i
by documentation review that the work has been completed and inspected.
This item is closed.
b.
(closed) Unresolved Item (445/8713-U-03):
The NRC inspector had questioned paragraph 5 (Homogeneity Justification) of the work process / attribute memorandum for heating, ventilating and air-conditioning equipment installation (HVIN) dated June 28, 1987, which states, in part, "All the work activities (attributes) for this work process were performed by the same contractor.
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However, it was the NRC inspector's understanding that both Bahnson Service Company and Brown and Root, Inc.
(B&R) had performed work in the HVIN work activity.
TU Electric responded with the following information:
"One of the bases used to establish homogeneity for the HVIN population was that all the work activities (attributes) for this work process were performed by the l
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same contractor 'Bahnson Service Company).
Heating, ventilation, and air-conditioning (HVAC) equipment installed on foundations or structural steel were excluded from the population as these items were installed by B&R.
Any item selected in this category was removed from the sample list and a new sample item was chosen.
This selection process ensured that all HVIN items were installed by Bahnson Service Company.
"HVAC equipment set on equipment foundations or structural steel were included in the mechanical equipment installation population (MEIN).
There were 128 items of HVAC equipment that were installed by B&R; these items were obtained from the HVIN population list.
" Complete coverage of HVAC equipment was provided by putting each item of HVAC equipment in either the HVIN or MEIN population based on the contractor (Bahnson or B&R)
responsible for installation".
The NRC inspector has reviewed the HVIN and MEIN population item lista and agrees with TU Electric that there existed a clear and concise division between which company actually installed the equipment in question.
This item is closed, c.
(Closed) Unresolved Item (445/8875-U-02):
During an inspection of duct segments in the diesel generator building the NRC inspector identified several wolds on 6 duct segments that had not been coated with zinc rich paint.
This was considered an unresolved item.
TU Electric initiated two NCRs, 88-19673 and 88-18905, which directed the craft to regalvanize the affected areas in accordance with TU Electric Procedure CHV-101, Revision 6.
These NCRs were signed off complete on January 25, 1989, and January 26, 1989, respectively.
However, the NRC inspectcr reinspected the duct segments in question and found that although the work had been
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signed off as complete, bare welds and ducts still exist that had been identified to the applicant during the original inspection.
The discrepant weld coatings were noted on the north face of duct segments B-1-658-028,
-041, -043, -045, and -047.
Raw exposed edges of structural components were noted in one duct segment.
The unresolved item is closed and the information changed to a violation (445/8926-V-01).
d.
(Closed) Unresolved Item (445/8881-U-03):
This item addressed an apparent discrepancy in the Fluor / Daniel (F/D) filler material control Procedure CHV-104.
This j
procedure requires that the weld material control room (
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(WMCR) stationary rod issue ovens maintain a minimum l
temperature of 250 degrees and that the ovens be checked daily for this.
However, the same procedure only required that portable rod ovens be checked once a month.
During the NRC's inspection of F/D's WMCR, the NRC inspector identified one portable rod oven full of E-308-16 weld rods that were being used as a main issue oven.
Further,
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it was determined that temperature checks were only being
taken once a month and that the portable rod oven in t
question would not melt a 250 degree temperature stick.
F/D committed to revise their filler material control
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procedure (CHV-104) to address the use of portable rod ovens as primary issue ovens.
On November 11, 1988, F/D revised Procedure CHV-104, paragraph 6.1.6, to require a daily check of portable rod ovens if they are being used for primary electrode issue.
Further, the discrepant rod oven in question was removed from service for repair.
The NRC inspector reviewed F/D Procedure CHV-104, Revision 1, reinspected the rod room in question and is satisfied that the identified conditions'have been corrected.
This item is closed.
e.
(Closed) Unresolved Item (445/8905-U-02):
This item addressed concerns identified in NRC Inspection Reports 50-445/89-05, 50-446/80-05; 50-445/89-11, 50-446/89-11; and 50-445/89-19, 50-446/89-19 regarding the adequacy of QC inspection of structural steel platforms for the Post-Construction Hardware Validation Program (PCHVP).
Additional concerns are addressed in this report for platforms FB-0271B-01 and AB-206-01.
The NRC inspector discussed these concerns with the applicant and subsequently resolved the following concerns:
Platform AB-0241-01 (50-445/89-05; 50-446/89-05)
A 3" x 4" angle shown in Section C-C, page 5 of DCA 62581, Revision 0, appeared to be installed incorrectly.
A similar section on page 19 of the DCA shows the angle as installed.
This inconsistency was subsequently identified on Deficiency Report (DR) C-89-00160 and has been corrected by issuing Revision 1 of DCA 62581.
Platform FB-271B-01 (50-445/89-19; 50-446/89-19)
(1)
The spacing between two Hilti bolts on the baseplate shown in Section A-A on Drawing MFB-0803-DCA, Sheet 2, Revision 1, was specified to be 14 inches (1 2 inches).
DCA 9835 allows the Hilti bolts to be relocated in any direction a maximum of 2 inches.
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i Thus, the installed spacing of 11 3/8 inches is
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adequate.
(2)
The weld type and size for the installed toe boards was not specified; however, the toe boards are not considered a safety-related portion of the platform and were not part of the inspection.
Criterion X of Appendix B to 10 CFR Part 50, as implemented by Section 10, Revision 0, of the TU Electric
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Quality Assurance Manual requires that inspection activities affecting quality be executed to verify conformance with drawings.
The following inspection concerns were not identified by the QC inspector and are in violation of this criterion (445/8926-V-02):
Platform AB-0241-01 (50-445/89-05; 50-446/89-05)
A 6" x 3 1/2" angle shown in Section F-F, page 14 of DCA 62581 is specified to be 3 feet 9 inches in length.
The actual length is 3 feet 10 inches.
Platform SG1-77N-01 (50-445/89-05; 50-446/89-05)
The NRC inspector requested QC to verify dimensions on Section 1-1 of drawing 2323-S1-0637.
The QC inspector determined that an error had been made in one dimension and issued an NCR to address the condition.
i Platform AB-113-01 (50-445/89-11; 50-446/89-11)
(1)
Page 5 of DCA 1508, Revision 7, shows a typical brace connection with 1 1/2 inch (1 1/4 inch) spacing between the center line of a 3/4-inch A-325 bolt and the end of a 4" x 4" x 1/4" angle.
On the east face of the southwest column, the spacing is 2 1/16 inches.
(2)
Page 7 of DCA 1508, Revision 7, shows a minimum edge distance of 1 1/4 inch for a 3/4-inch Hilti bolt on i
the southeast baseplate.
The actual distance is l
1 1/16 inches.
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Platform FB-271B-01 (this report period)
A 3" x 3" x 1/4" angle, MK C-12 on drawing MFB-0803-DCA, Sheet 2, Revision 1, is shown to be 36 5/16 inches in length.
The installed length is 42 3/4 inches.
Also note that with the exception of weld location, the specific details of the unsatisfactory conditions identified by the PCHVP QC inspector are not provided on NCR 88-11162 or the corresponding inspection reports.
The NRC inspector,
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therefore, could not verify the location of the unsatisfactory conditions.
Platform AB-206-01 (this report period)
(1)
DCA 5465, Revision 9, page 5, Section 5-5, calls for single bevel groove welds.
Near side and far side fillet welds were installed.
(2)
DCA 5465, Revision 9, page 7, Section AA, calls for single bevel groove welds.
Fillet welds were installed.
(3)
Drawing figure 706-001, Revision 1, shows 3 1/2" x 3 1/2" x 1/2" angles, members 6-Y1, to be 7 feet 4 3/16 inches in length.
The installed length is 8 feet 7 1/4 inches.
Also, the angles are shown welded using 3/8 inch single bevel groove welds.
Ti.ese welds are undersized.
The unresolved item is closed and has been replaced with a violation (445/8926-V-02).
f.
(Closed) Unresolved Item (445/8911-U-01):
This item addressed events leading to the condition where the valve i
stem of valve ICC-692 was not positioned within the
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required i 5 degrees of the 13 degree angle depicted on isometric drawing BRP-CC-1-RB-003.
This requirement is stated in Specification 2323-MS-100, Revision 9.
The discrepancy was first thought to indicate a failure of the
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QC inspector to identify the condition during the PCHVP walkdown of the above referenced isometric.
However, as documented in NRC Inspection Report 50-445/89-19; 50-446/89-19, the valve stem angle was altered during the i
process of applying a seal weld to the adjacent threaded
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spool piece.
This activity occurred between the time of the original PCHVP inspection and the discovery of the discrepant valve angle by the NRC inspector.
Therefore, the apparent cause of the out-of-specification valve angle is an unsatisfactory fit-up or post-maintenance inspection.
The NRC inspector reviewed documentation pursuant to the seal weld application, including Traveler CC-1-RB-003, weld data card 001065 (weld No. TUX-FW-49),
and Inspection Report CC-1-RB-003 dated December 5, 1988.
The applicant stated that the QC inspector assigned this activity was required to verify the valve stem orientation in accordance with Procedure AQP-11.2, " Fabrication and Installation Inspection of Pipe and Equipment," and document the result on weld data card 001065 under the line item for fit-up.
The applicant's position was that the QC inspector's failure to perform this required measurement resulted in the undocumented field l
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discrepancy.
The applicant provided QC surveillance results showing that the subject QC inspector had an excellent performance record, thereby suggesting this to be an isolated mistake.
The NRC. inspector concluded that the QC inspector was not procedurally required to inspect the stem orientation of valve ICC-692 and considered the issue to be procedural rather than one of personnel error.
Section 6.8.4.5 of Procedure AQP 11.2, entitled, " Threaded Connections Requiring Seal Welding," delineates QC weld inspection requirements, but does not include a requirement to check valve stem orientation.
The only mention of valve stem orientation within Procedure AQP 11.2 is in Section 6.8.3,
" Valve Installation," but this' matter does not involve valve installation.
The only other portion of Procedure AQP 11.2 relevant to this matter'is found under Section 6.9.4,
"Fitup Requirements."
In Section 6.9.4.1,
" Tack Welds," the QC inspector is required to " verify that the correct configuration is maintained and verify weld marking adjacent to the weld."
By context of the procedure, " configuration" refers to the welding configuration.
It should also be noted the.t the traveler did not include any requirements to verify valve orientation prior to or following the work.
The NRC inspector concluded-that the discrepant valve stem orientation resulted from a procedural failure to require an in-process or post-maintenance inspection verifying that the valve stem angle was positioned within 1 5 degrees of the angle specified on the isometric.
The unresolved item is closed and changed to a violation (445/8926-V-03).
3.
Follow-up on Violations / Deviations (92702, 46071)
(Closed) Violation (445/8836-V-01):
This violation addressed the inadequate embedment of two 3/8-inch diameter Hilti bolts into structural concrete on conduit support C02012055-07.
In response to the Notice of Violation (TXX-88552, July 18, 1988),
the applicant stated that the engineer who developed the as-built drawing did not identify the existence of grout topping on the concrete pedestal on which the Hilti bolts were anchored.
As a result the bolts were only embedded in the grout.
NCR 88-09714 was issued and dispositioned "use-as-is" based on engineering Calculation 12055, Revision 2, for the two bolts cited in the violation.
The applicant reviewed applicable procedures and concluded that similar conditions
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should not exist in verifications of Hilti bolt embedment for l
commodities other than conduit supports since instructions for other grout applications were adequate.
The applicant
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committed to visually examine equipment pads in Category I l
structures to identify commodities attached to concrete l
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pedestals with Hilti bolts.
This effort is now complete for Unit 1 and common areas and is documented in interoffice correspondence C-1978 dated March 28, 1989.
The applicant evaluated all safety-related installations and resolved unsatisfactory conditions through NCRs.
Although 20 additional unsatisfactory Hilti bolt embedments were identified, no modifications were deemed necessary.
The NRC inspector reviewed NCR 88-09714 and interoffice correspondence C-1978 and concluded that the applicant had taken adequate corrective action to resolve this matter.
This item is closed.
4.
Action on 10 CFR Part 50.55(e) Deficiencies Identified by the Applicant (92700)
(Closed} Construction Deficiency (SDAR CP-82-13):
" Auxiliary Building Concrete Floor Slabs."
By Letter TXX-3589 dated October 29, 1982, the applicant informed the NRC that the discovery of embedded debris in an auxiliary building concrete floor slab did not constitute a reportable item.
The debris, found when drilling holes for the installation of anchor bolts, was first thought to be misplaced rotafoam and plywood.
Additional chipping and reference to mechanical plumbing drawings revealed that the assumed plywood was actually an embedded stainless steel floor drain pipe wrapped in Ethafoam No. 220.
Therefore, a discrepant concrete condition did not exist.
The NRC inspector reviewed documentation related to the repair of the pipe and concluded that the applicant had satisfactorily addressed the perceived discrepancy.
This SDAR is closed.
5.
Post-Construction Hardware Validation Program (PCHVP) (48051, 48053, 48055, 50100)
a.
Structural and Miscellaneous Steel (CPE-SWEC-FVM-EE/ME/IC/CS-086 and CPE-SWEC-FVM-ME/EE/IC/CS-090)
FB-271B-01, platform, fuel building, Unit 1:
The NRC
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inspector reviewed the PCHVP package and inspected the platform during a previous report period (see NRC Inspection Report 50-445/89-19; 50-446/89-19).
An additional concern was identified by the NRC inspector during this report period.
A 3" x 3" x 1/4" angle, MK C-12 on Drawing MFB-0803-DCA, Sheet 2, Revision 1, is shown to be 36 5/16 inches in length.
The installed length is 42 3/4 inches.
AB-206-01, platform, fuel building, Unit 1:
The NRC inspector reviewed the PCHVP package and inspected the Class I platform.
The QC inspector had previously identified unsatisfactory conditions related to:
(1) item i
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size and length, (2) item location and orientation, (3) alterations, and (4) weld' size, length, and location.
These conditions were identified on NCRs 88-10972, Revision 0, and 88-10973, Revision O.
NCR 88-10972 has not been dispositioned.
NCR 88-10973 has been dispositioned "use-as-is" based on Calculation 16345-CS(B)-178, Revision 2.
The NRC inspector concurred with the disposition of NCR 88-10973 and the identification of the above unsatisfactory conditions.
The NRC inspector identified the following concerns:
(1)
DCA 5465, Revision 9, page 5, Section 5-5 calls for single bevel groove welds.
Near side and far side fillet welds were installed.
(2)
DCA 5465, Revision 9, page 7, Section AA calls for i
single bevel groove welds.
Fillet welds were l
installed.
(3)
Drawing 79-170-01, Revision 1, shows 3 1/2" x 3 1/2" x 1/2" angles, members 6-Y1, to be 7 feet 4 3/16 inches in length.
The installed length is 8 feet 7 1/4 inches.
Also, the angles are shown welded using 3/8-inch single bevel groove welds.
These welds are undersized.
These conditions are incorporated into Violation 445/8926-V-02 in paragraph 2.e of this report (See closure of 445/8905-U-02).
b.
Heating, Ventilation, and Air-Conditioning (HVAC)
(CPE-EB-FVM-CS-029)
The NRC inspector performed field inspections and documentation reviews of the following documentation packages generated as a result of construction, engineering, and inspection activities related to PCHVP.
Seismic Duct Hangers Unit Room DH-1-792-1N-1G
124
CH-1-792-1N-WP9
124 Duct Segments Unit Room B-1-751-158
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B-1-751-161
125 B-1-751-162
125 B-1-751-163
113 B-1-751-165
113 B-1-751-166
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No violations or deviations were identified.
6.
plant Tours (42051C, 46053)
The NRC inspectors made frequent tours of Unit 1, Unit 2, and common areas of the f acility to observe iten.s such as in-process work activities, equipment protection, and housekeeping activities.
The NRC inspectors observed work in progress for the closure of temporary access openings used for cleaning and removal of debris from the seismic air gap.
The access openings were approximately 8' x 8'
in the auxiliary building outer wall.
The NRC inspectors observed work being performed under Traveler CCE-88-1239-8404A, packages 02C-8904A-1855-3 (Room 182) and 02C-8904A-1855-4 (Room 176).
The work included installation of concrete forms, concrete pouring, and concrete curing in Room 182 and final QC inspection of rebar and cad-welding in Room 176.
The closure of these access openings appeared to follow appropriate procedures and design documents.
The NRC inspector will review concrete data sheets during a subsequent inspection period.
No violations or deviations were identified.
7.
Exit Meeting (30703)
l An exit meeting was conducted May 2, 1989, with the applicant's representatives identified in paragraph 1 of this report.
No written material was provided to the applicant by the inspectors during this reporting period.
The applicant did not l
identify as proprietary any of the materials provided to or reviewed by the inspectors during this inspection.
During this meeting, the NRC inspectors summarized the scope and findings of the inspection.
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- Functional areas for Construction and Operations CRITERIA FOR DETERMINING CATEGORY RATING 1.
Management Involvement in Assuring Quality.
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Responsiveness to WRC Initiatives.
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Enforcement History.
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. RATING KEY: (For Categories 2 - Declining and 3, provide narrative basis for
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Category 1 Category 2 - Declining
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