IR 05000455/1986025
| ML20214P677 | |
| Person / Time | |
|---|---|
| Site: | Byron  |
| Issue date: | 09/18/1986 |
| From: | Danielson D, Liu W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML20214P667 | List: |
| References | |
| 50-455-86-25, NUDOCS 8609240015 | |
| Download: ML20214P677 (8) | |
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U. S. NUCLEAR REGULATORY COMMISSION
REGION III
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Report No. 50-455/86025(DRS)
Docket No. 50-455 License No. CPPR-131 Licensee: Comonwealth Edison Company Post Office Box 767 Chicago, IL 60690 Facility Name: Byron Station, Unit 2 Inspection At: Byron Site, Byron, IL Inspection Conducted: August 12-14 and August 26-28, 1986 h
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Inspector-W. C. Liu Date
Approved By:
D. I. Danielson, Chief
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Materials and Process Section Date Inspection Sumary Inspection on August 12-14 and August 26-28, 1986 (Report No. 50-455/86025(DRS))
Areas Inspected: Routine safety inspection of the verification of as-built conditions associated with structural installations (37051) and of onsite design activities (37055).
Results: No violations or deviations were identified.
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8609240015 860918 PDR ADOCK 05000455 G
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DETAILS
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1.
' Persons Contacted
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Commonwealth Edison Company (CECO)
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- R. Moravec, Assistant Construction Superintendent
-*E.-Martin,-Quality Assurance Superintendent
- D. Pyatt, Engineer, Plant Construction' Department
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R. Klinger, Project QC Supervisor J. Harchut, Engineer, Plant Construction Department S_a nent and Lundy Engineers (S&L)
- J Meister, Overall Field Coordinator -
- K.' 'Kloecker, Structural Field Coordinator I
- B. Dankevala,- Senior Structural Engineer Westinghouse Electric Corporation (W)
- M. Pitluk, Manager, Structural Analysis Mobile Unit (SAMU)
D. Bhowmick, Engineer, SAMU G. Orlowski, Engineer, SAMU
'Blount Brothers Corporation (BBC)
S. Hess, Engineer
.R. Gibson, QC Inspector Hunter Corporation
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M. Somsag,lQA Supervisor
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NRC Inspector
- J. Malloy, Resident Inspector
- Denotes those attending the final exit interview on August 28, 1986.
2.
Verification of As-Builts (370S1)
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a.
Document and Procedure Review (1) Blount Brothers. Corporation General Structures Procedures:
QA/QC Work Procedure No. 1, Document Control, Revision 13,
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December 30, 1983.
QA/QC Work Procedure No. 1A, QA/QC Records / Systems
Turnover, Revision 2, March 2, 1984.
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QA/QC Work Procedure No. 11, Welding, Revision 19,
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QA/QC Work Procedure No. 21, Structural Steel Fabrication
and Erection, Revision 17, November 13, 1985.
(2) Sargent & Lundy Project Instructions:
PI-BB-08, Processing of Commonwealth Edison Site
Non-Conformance Reports, On-site Contractors Non-Conformance Reports, Sargent & Lundy Engineering Change Notices and Advance Design Changes, Revision 12, June 4, 1986.
PI-BB-13, Procedure for Processing Commonwealth Edison
Company Field Change Requests (FCR's), Revision 13, June 30. 1986.
Standard Specification for Fabrication of Structural
Steel, May 10, 1973.
General Structures Work Section 5-2, Miscellaneous
Metalwork, Structural Steelwork and Embedded Work, Revision 31, December 27, 1983.
The NRC inspector reviewed the relevant portions of the above documents and procedures pertaining to as-built structural installations to determine whether appropriate procedures have been established and whether they comply with NRC requirements and licensee commitments.
The NRC inspector noted that the utilization of the aforementioned procedures and instructions appeared to be acceptable in terms of performing structural activities associated with installation and inspection.
b.
Field Inspection of Structural Members The NRC inspector randomly selected the following steel beams and columns for a verification inspection to determine whether the as-built configurations are consistent with the design documents.
I Containment Building:
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Beam Nos. 43003, 43202, 52209, 52907, 53325, 54025, 63802, L
92205
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Column Nos. R32 at Elev, 404.0'
l R33 at Elev, 404.0'
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Auxiliary Building:
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Beam Nos. 3.6ABIN-2, 3.6AB9N-13, 4AB46N, 4AB70N, 4AB74N, 4.3AB15N, SAB105N, 5AB106N l
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Column Nos. S.7-23 at Elev. 453'-6"-
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V-23.3 at Elev. 453'-6"
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The above structural steel beams and columns were inspected with respect to the applicable design 'rawings for d
configuration,~ identification, location, connection, member size, weld size,_and damage / protection.
In general, the appearance of the structures was good and the structural members were installed in accordance with design documents.
c.
As-Built Structures Versus Final Load Check Program During the inspection, the NRC inspector noted that many structural
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_ members had been modified or redesigned as a result of the
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licensee's implementation of the final load check proJram.
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containment building for example, a total of 1423 structural members which include beams, columns and braces were used in the
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installation.
One hundred and seventy members had been modified to the latest design loads.
There were 2846 structural connections in the structural systems,'of which 1012 connections had been-
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modified to the latest design drawings.
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I Within the areas inspected, no violations or deviations were identified.
3.
Onsite Desian Activities (37055)
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Functional Responsibilities for Onsite Design Sargent & Lundy and Westinghouse Electric are the two major organizations responsible for onsite design activities associated
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with the construction of the Byron facility. _ Currently, S&L has 34 engineering personnel involving various design activities in the areas of piping stress analysis, pipe support design, and
i civil / structural modifications. Westinghouse has 14 engineering personnel performing design activities in conjunction with piping i
stress analysis and pipe support design.
There are 11,877 pipe I
hangers for the Unit 2 facility, of which 7,170 are safety-related pipe' hangers.
Seven thousand nine hundred and thirty-five are small bore pipe hangers while 3,942 are large bore pipe hangers. At the time of this inspection, only 303 pipe hangers needed to be installed in the Unit 2 facility.
b.
Desian Procedure Review (1) Sargent & Lundy Procedures and Instructions DC-ST-03-BY/BR, Structural Project
Design Criteria, Section 8, Codes, Standards, References, Design Reports, and Procedures, Revision 18, July 22, 1985
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Structural Project Design Criteria, Section 10,
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Project Loads and Load Combinations, Revision 18,
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July 22, 1985
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Structural Project Design Criteria, Section 37,
Mechanical Component Support Design Criteria, Revision 18, July 22, 1986 I~
Project Instruction PI-BB-25, Activities of the On-Site Structural Design Group, Revision 2, June 4, 1986 Project Instruction PI-BB-28, Activities of the Byron
Station Mechanical Engineering, Piping Design, Support Design, Analysis and HVAC Systems Field Personnel, Revision 7, June 4, 1986 Project Instruction PI-BB-29, Distribution and Control of
Design Documents for S&L Field Personnel at the Byron Station, Revision 3, December 5, 1985
(2) Westinghouse Electric Corporation Procedures Byron Procedures and Guidelines Manual,_ Volume 2,
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Support Design and Reconciliation, Revision 1, August 1985 PED-B-1.2, Byron Unit 1 and Unit 2 Engineering Change
Notices, Revision 0, April 1, 1985 The NRC inspector reviewed the relevant portions of the above procedures and instructions associated with onsite design activities to determine whether appropriate procedures / instructions have been established and whether they comply with NRC requirements and licensee commitments.
The NRC inspector found that the utilization of the aforementioned procedures / instructions in performing onsite design activities appeared to be acceptable.
c.
Design Process Review
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(1) S&L Onsite Design Activities (a) New Design Calculations
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Engineering Change Notice (ECN) No.
Pipe Hanger No.
21372 2SD21037X, Revision A 21426 2SD23084G, Revision A 21443 2SD21041G, Revision A 21446 2SD24031G, Revision A 21448 2SD23089V, Revision A
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(b) Engineering Change Notices Pertaining to Hanger Field Problems 21428 Hanger No. 2FW47001G, Revision A
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21438 Hanger No. 2RH02A002X, Revision A 21442 Hanger No. 2SD21016V, Revision B 21450 Hanger No. 2SD23060R, Revision B 21456 Hanger No. 2AF03005R, Revision D
.(c) Field Change Requests (FCR) Pertaining to Structural Field Problems FCR No.
Resolution 44408 Structural Modifications 54041 Structural Modifications
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54060 To Provide Structural Tolerance 54067 Anchor Bolt Size Revision 54132 To Facilitate Construction (d) Release of Latest Drawings To Contractors Structural Drawing No.
Location S-2115, Revision F Containment Building S-2125, Revision AL Containment Building S-2135, Revision AL Containment Building
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S-2149, Revision E Auxiliary Building S-2158, Revision K Auxiliary Building Pipe Hanger Drawing No.
Pipe System 2AF08025G, Revision C Auxiliary Feedwater 2AF09008R, Revision C Auxiliary Feedwater 2CC04005R, Revision C Component Cooling 2CS01025R, Revision B Containment Spray 2CS01038R, Revision B Containment Spray (2) Westinghouse Onsite Design Activities (a) Engineering Change Notices Pertaining to Field Problems ENC No.
Pipe Hanger No.
245000 2CS0400SX, Revision B 245255 2CC20025X, Revision A 245800 2SD11016X, Revision A 246177 2SI13015X, Revision A 246481 2SX09003X, Revision C
- 248484 2CV42048X, Revision A 248514 2CV05003X, Revision C
- 248795 2CV30001X, Revision A 251214 2SIO5030X, Revision C
- 251522 2RH04006X, Revision D
- Minor discrepancies were identified during the review.
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(b) Field Change Requests Associated With Field Problems
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FCR No.
Resolution
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35753 Pipe Line Dimension Change 35793 Reroute Pipe Line Resulting From Interference 36042 Valve Number Designation Correction 36981 Offset Pipe Line To Facility Support Installation 37103 Relocation of Pipe Line and Valve (c) Release of Latest Drawings to Installation Contractor Pipe Hanger Drawing No.
Piping System 2CC22008X, Revision C Component Cooling 2CC22025X, Revision B Component Cooling 2CV11005X, Revision B Chemical & Volume Control 2RC30015X, Revision B Reactor Coolant 2SIO6208X, Revision B Safety Injection The NRC inspector randomly selected the aforementioned S&L's ECNs in conjunction with the new pipe hanger designs, ECNs pertaining to pipe hanger field problems, FCRs pertaining to structural field problems, and the latest structural / pipe hanger drawings released to the construction contractors.
In addition, the NRC inspector also randomly selected the above Westinghouse's ECNs in conjunction with pipe hanger evaluations, FCRs associated with field problems, and the latest pipe hanger drawings released to the construction contractor. The NRC inspector reviewed the relevant portions of the above identified ECNs, FCRs with respect to the applicable procedures, instructions, criteria, NRC requirements, and licensee commitments.
Further, the NRC inspector verified the aforementioned latest structural and pipe hanger drawings issued by the S&L and
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Westinghouse design organizations with the respective construction contractors to determine whether the onsite organizations used the same latest drawings to perform their work activities in accordance with procedural requirements.
Results of the above review indicated that, in general, onsite design activities were implemented in accordance with the established procedures and instructions. Minor discrepancies were identified during the review of the Westinghouse ECNs (ECN Nos. 248484, 248795, and 251522 contained engineering evaluations that were not updated to the corresponding ECN numbers).
These minor discrepancies were discussed with licensee's representatives and were also presented to the licensee during the exit interview such that the licensee's attention in this area should be increased.
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d.
Review of Licensee's QA Audit Reports
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During the inspection, the NRC inspector reviewed four audit reports
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which were prepared by the licensee in accordance with its QA program. The QA audits were conducted by the licensee between March 1986 to August 1986 to determine whether the onsite design organizations were adequately performing their work activities in
.accordance with the QA program. The scope of the audits included:
design control; document control; inspections; nonconforming
. materials, parts, or components; corrective actions; organization;
'QA program; QA records; instructions, procedures, and drawings; hanger field problems; contractor nonconformances; FCR activities; conduit system design review; and disposition of contractor nonconformance reports. Results of the licensee's audits revealed that the onsite design organizations were effectively implementing their QA program in the areas covered by the audits.
Within the areas inspected, no violations or deviations were identified.
4.
Exit Interview The inspector met with site representatives (denoted in Persons. Contacted paragraph) at the conclusion of the inspection. The inspector summarized the scope and findings of the inspection noted in this report. The inspector also discussed the likely informational content of the inspection report with regard to documents or processes reviewed by the
. inspector during the inspection. -The licensee did not identify any such documents / processes as proprietary.
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