ML20093M746
| ML20093M746 | |
| Person / Time | |
|---|---|
| Site: | Comanche Peak  |
| Issue date: | 10/19/1984 |
| From: | Thornton P ISHAM, LINCOLN & BEALE, OLIVER B. CANNON & SON, INC. |
| To: | Atomic Safety and Licensing Board Panel |
| Shared Package | |
| ML20093M744 | List: |
| References | |
| OL-2, NUDOCS 8410230222 | |
| Download: ML20093M746 (75) | |
Text
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bMb!E61@DM UNITED STATES OF AMERICA NUCLEAR REGULATORY COMMISSION C0CKETED BEFORETHEATOMICSAFETYANDLICENSINGkb[b In the Matter of )
)-
TEXAS UTILITIES ELECTRIC ) u COMPANY, et al. ) DocketNd.f[5%((45-2and t$ JB-2"
) .
(Comanche Peak Steam Electric ) (Application for
. Station, Units 1 and 2) ) Operating Licenses)
MOTION FOR LEAVE TO FILE OUT OF TIME Oliver . B. Cannon & Son, Inc., by its attorneys, Isham, Lincoln & Beale, moves the Atomic Safety and Licensing Board for leave to file the enclosed documents out of time. In support of this motion, movant states as follows:
- 1. The enclosed documents are being produced I pursuant.to the subpoenas issued to movant in this proceeding.
Under the terms of the subpoenas, the documents were to have been produced by October 18, 1984..
- 2. In complying with these subpoenas, counsel for l-l movant was obliged to. examine a large number of documents to determine whether-the assertion of privilege was appropriate I with respect to any of them. Mr. Lipinsky's diary notes took some time to review for this purpose and counsel was unable to complete this task in-time to produce them on October 18.
- 3. The other- three documents enclosed were inadvertently omitted from the materials produced on October
Y
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- (
' December 14 ', 1983, a memorandum of Ralph A. Trallo dated
' October'8, 1982 attaching a Three Mile Island Damage Report,
- anda M,ay 23,.1984 letter from Richard L. Bangart attaching a Region IV Interim . Report on-Protective Coatings prepared by Brookhaven National Laboratory.
t.
j- 4. The delay of less than 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> in the filing of these documents caused by the circumstances described above ishould not prejudice any party.
' WHEREFORE, for the reasons' shown, movant requests
- that - it. be given leave to file the enclosed documents out of time.
t Res ectfully submitted,
.M Peter Thornton
~
Counsel to Oliver B. Cannon
& Son, Inc.'
ISHAM, LINCOLN & BEALE 1120 Connecticut Avenue, N.W.
Suite 840 Washington, D.C. 20036
-(202)-833-9730 Dated: -October 19, 1984 f
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JJLs I have talked with McNeill Watkins of Bishop, Liberman, Cook Purcell and Reynolds, and I thought this call would have been cancelled by suw. I would prefer not to have any conversations on thl's e 8 , matter, again not that I do not want to cooperate with you, but I feel that an informal conversation would ret provide as much
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- SKs I had the rnessage to call Watkins tiut did ret return the call.
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Voll, suppose I call him (MW) then and we try to talk to yoi, sone s other time if it turns out that we can. We will try to get back
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JJLs Please don't take my attitude as hostile, but I would prefer that
- you talk to Watkins and coordinate through him.
SKs You do not want to auke a move 'that he doesn't thirik is right?
's JJL I n uld not say that. tiowever, I think it would be best that you
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SKs Perhaps we can reschedule it at a later time. I will try to call
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OLIVliR 13.l CANNON & SON, INC. fi'
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@TED g0RRE.SP,0J4DENCE DEPARTMENTAL CORREGPONDENCE
; f; o
, g g ctober 8. MS2 StiRC Threc Mile Island Damye Report f8 JECT
- starr .M M 22 R2:16 g
._~_ecc, Ralph A. Trollo _
f0M' hfcWiimu&'ilt SRt.MCH Attached'_is a presentation summary on the cause of coating damage within the Three Mile Island Unit Containment. The Summary was prepared by EPRI (Electric Power Research Institute) _ which is sponsoring several investigations of materials performance at t f-
...- Three Mile Island.
The last paragraph is.of utmost importance to Cannon. I have requested at set _of slides taken'within the Three Mile Island Colitainment. N p kRajph e. Trallo RAT:ja .
/ Attachments e
b!
m a tr11 bit MCl7-E MM ME hp 2 st )
' IM ' ' # 0 .
.PENTEK .
PENTEK =
=
- . .i F F EStif f AT ICH 5'.*W ARY on 31.7* elevation) were esposed to the spray salution. Igul p aie nt s ci 305* elevation were t rotected by the 30* . etevation s'cor stati.
- with chernical spray due to seme drainage through the 347* den the plates and via recis c ulation of the reactor buildin g ' air by ~
tr3? 13 spenseelag several In v e s' a g a tion s into the performance air handling units. rf c.e<%eveal g o v er.ee ns aeC the be%avtor of materials in response As part of these ,,,g. la e *,e T*.ee id ts e Island l'a i t Twa accident. Despite the harsh immediate environments and she longer tern hyr. vera.es, s t ve ienaary in v e s t ig a t ion s are being undertaken with h u rr.idit y i;on d is ton s, the prot ectiv e c e n t u.g s applieJ . in Three 84 te seer.et eo reims and pro *ecitwe costings, Island t!nse Two perforr.e4 e x c epie cr.a tt y well it,a se d upor. wisual . piservation) p:ep,,s for very localised grees. 1he Init.al da-age e-ec .a nisas in the reacter containment building
- e ,
. -e er.aes;a'ir the sesv ' cf a hydrogen burn caused by the.
i , , ee .e P ,dec-e . gas gener ated as a r e s ult cf catensive cere damage. 9,;.<-. t,en creased a .2!t F5tG l.1 pressure spike in the - e tMei e em b u tid e.ig w h it 's en turn automiatic a ty initiated .the it. .
. e r. s a . - e ,e op ae s y stem. a "sSew e r" system designed to condense (The .*
- e-:...e of s t e a -i ei sne eeert of a er sjer pipe break. *
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t .e, is . . totead ( n. Two accident did not in volve any ma jor *, g .; e s.gets.' A side e!!cet of t* e spray initi a t ion fthe s ys tect
- was eCy a c t.v a'ed br fi.e or sie n.inutes t.ef ore isolated by the . . . '
- egereses. was t%as the spray c e r t a ir.e d a corrosive solution of
- 5,*.ceede and breic acid to remove to d e r.e isotope s and *
,-.*.., respectively. ..t Ur I . . .
a dditice.a ? t e e rtar sSsidosn c a p alstlit y, . .,. .. . ic ter.ife
, , . . . , e . e nt el a napr gire break. The longer term effects of , , , , *
.. a i .I
...e dwe en =cey he r,5 Isaluestedl humidity conditions . i. , ,
c .. e se. i
.*.e per ineed in' she c an t a is'- e n t tvildin2 for fif teen months . .
w'se. ti e arcieeat until the fir st rur ging was allowed. , dama ge was due to hot gsses and localtred high F r ee*
- y s'en, . . ', ..
se revenween tree the hy er gen twee=, <ctresive effects of the spray - .j, , .y,. ,,
. t.;
- z b s e . . :.- .c . . , g ,
eased air.csphere for a long period
- a. ..e rr . a. d ee -ee sic . in a sa* s c' *-e tot s's s'd te a-.es snet the c or.t s t r.n.e nt buildtr.g basement , * ,
, 2*.,..o',,..., , . . / , ,
ce..re. e4 e..a.ly no e feet of hig%'y contaminated water for almost
,s s g .
s '.e ee staes s'ter the artsfentl. *.it'. . , .*p . . i .. . . . Ta r damage rath 1.e g a n 4.s s '. e ba se nent (252' elevationI. where 3 ,
* . . ***' .***3*'T' ' . *
- t. . '
- r g. n was f ee s, r e'.e a sed the e nts the reactor coolant system e p i' r o p .e eu p e a ' ed up stairwells -and elevator re' e' ric e. 1 s.e containing n ' .' s is it, i ieve dia'e elevat ens (305* elevation
- ea . e . : .. . e - e n and as, h e ad t .e.e units; 347' elevaston - refueling . . , . , , ,
8,.. As** e t c. .s in - g. i e r crane platform), and eventually to It is 3 e* s- e t h t p h s.oin t at UJ' elevation).
' ", esaverr t,weldir a Se..esed eSe burn was initiated by equiper.er t in t h'c upper ele- 'S ,
'8
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....:-s. sed since a hydregen fiame t e r.d s ts propcgate upward.- **,
!* e - o pt .e v of d e- a ge dwe diretely W**
- t i t.etor the e areburn andneoverpressure as yet pho:ographs
- re s.. .n the v,,g e r e le = a t .cn s. '. i c' "e t a se-eat area sinc e it has been triacce ssible due to high e e9 ai a. and the sute ergecte ef e luipment.) ,,
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Spray snatission oc cur re d at the spray headers loc ated in the ' 8.
- tractor de rne . 5s-iply stated, all eq .aspreent located directly in
- t%e pain of spray l principally the ps!a r crane and compone nts 1
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D EP A R"'.',tCC AL C O R R E.~.P ON D CIC E OATE I Of.'14 C__!-Q 231 t[ flu CI C JLU JLIR05._fC flCIT.IJac o - CCDlQllCICn LL1per - THI s As noted.!:c1cv , 't
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I rcccived a copy today of Bob Noore's letter to
- Al Roebuck, re the ASTtt 0-33 Commi t tec, in which he quotes the recent trade and nces release on tire inspection of the Containment Liner coating at .
T.H. I . , Uni t #2. , The liner plate was the Carboline #368 Phenolic Epoxy. k'c sandblated the plates on the ground and first coated, then touched up welds and finish coated in place. Concretc and masonry surfaces.in Containment were Kccler 6 Long Epoxy. , , 1 Unit 2 work would be five to six years old, so I
~
feel oc have gotten a nice testimonial.
'9
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F,. D. R th '
/1 To: R. R. Kerns ,
J. II. !!cycr
.J. D. Lauck R. J. Dodner '
p.I!cl:,on
/S. R.1/i neman T. f. Ilogers ,
J. J. l! orris . O I -
t '* ., 9^ February 4, 1981 9 Dr. Al II. nec5uck, chatrus AStt Ccm!ttr.a D-33 , y]uor Co ;inects 6 Constructors Inc. 3333 !!!cheloon Drive ' Irvine, Calif. 92730 , Pear A1: - Itappy 1 ce Year! In enco any ASnt or U':CWC ecebers 3 cr non-mec6ers , wonder if all the DM, radiation and decontat..ination qualification testina :, at ORNL is northwhil 1, picace note the following execrpt fro;; the l'hilndelp_hia Incui rer of 12/28/80, reporting on the condition of the n:I-2
- contatiwcut interior:
, "An casier cicanup job in czpected becauco 'cpecial cpexy paints through-out the interior have managed to weather the severo temperatures and taoicture extrcooly voll. IIcVey (Calc Iloveyl chief engineer) said that if they had cracked or flaked, cicanir4: vould have ccant painotakingly peeling off all the
(~ paint. Eccause the epoxy resin held up,1:ct Ed ucrkera have rcInti.voly cmooth { surfacco to acrub c1can." . Theco cpery coatings ucrc cenufactured by Carbolino and Keeler & Long, . and applied by O.D. Cannon & Sen of Phila. , all of uhem deservo much credit. (UE!4 vna the constructor of D!I Units 1 & 2). Certainly, tho til-2(%.,d!/G,) Containment temperatures and radiation icvels muut have exceeded anj DBA tect' exposure of cpexy coated pancia, cither performed or conceived. . Ao dor D33 nectings, Prc:: ton 1:cabec will repreocnt un at Phoenix, and I plan to attend the 1cu Oricana meeting. Sco you at UORRCSION/81 in Toronto. Sin cr91v
/ 11-(M. wtc/
Robert E. liocre Supervicina Engineer Corrosion 1:ncincaring RD:/dbm " CC: tr. Albert 1:. Levy 7 E-.i.]
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f' o l s ,. e lll,Gv7,, 90b.5 Ll% 'in 1.ull,llll . . s per nour. I closten A sfeci door an the entry "In all, radittion esch arc about icel that was a::parcr.t:v blow n open four or five times towcr in .:cc t*ntt 2 :o N etiv DV the bla.t ts crusned. t! an we ortetnally ricuic:cd." tud ws c.:2 betuten the heavy pipes it
~ Gale iloscy, fr.c M*:uv. dark hatred b.it. The moutn cf an sicvator who.c chief cngneer in char.;e of c!can:n.: mrs coe ver:::;. . half the dcor up Linit 2. "The prcdic:mns are al'. shocs down. halt up) suffers from most a!wa)s conservative.so we kind malocclusion - the upper half of Ihe of expected to find actual rcadings door protrudes several inches over much lowcr than ' hat." the lower half. Se..ac cmpty stcci lloveY himself tookPart in the last drums were dented and crushed like Met Ed 5.ntry.on Dec.11, when a Ib soda cans. Tc!cphones, wirina and member crew sta)cd inside Unit 2low.tumperaturefnr other instruments fashioned plastics were melt. $ut of 45 minutes The color vidcotapes ed and deformed.
they made d::rtng that and a previ. ous entry show a casernous interior "Still, the overall impression is with little stsibh: d .orgc. despite a that the c.splosion caused littic or no hydrogen gas expirsta.. en the first serious structural damage." !!ovey day of the acek';nt 1:.:.. would have said."The lid to the reactor vcssel. up destroyed a smi.i bu:!dtng. Surisces on the operating level. shows no have corroded from the inoisture _ structuraldama tc at aU." and from botng spra)cd on the first day of the accider.t with the corro.y An cancr
,.because c!canup spceial epoxy job paints is expceted sive chemicals of Unit 2's fire control 'throughout the interior nave m'an-system. aged to weather the severc tempera-There is some evidence of the ex.j (Continued on next page)
{ s x -
. . . Gil Berle SCe??e, Continued fram preceding page expected to be ready for use in April, tures and monture extremely well. but it has not yet been approved by Hovey said th:t if they had cracked the Nuclear Itegulatory Commiss:on or flaked cleanino " wnuld ' have (NitCL ff the NitC s:a:t opts for a dif.
meant pain 3 takingly pecting oif all lerent method of cleanint; up the the paint. tiecause the epmy resin containment building Ilcod. those hcid up, hiet Ed workers have rela, j milhons already spent m!! he lut, tively smooth surfaces to scrub de and the cleanup will be further de. __ _ J la);ed.
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So although another sho : entry Lower thar expected radiation into l' nit 2 is scheduled for late.f anu-readings mean that Alet Ed workers ary, actual cicanup operations are at will be able to stav in.ude, w hen the a standsull Other than s me final cleanup begini, for longer stretches moppine up in the auxilt iry hulld. before being "biirr.ed cut? Ilut no ing. the low, more conventional cleanup v.ork will proceed instde strusture abutting the containment linit 2 untti the basement pool 15 w hich houses. support e uipment. cleaned and reatosed; that is the pipin;: and machinery. linit 2 will next big ster llavey and his ciew continue to sit. face.
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May 23.-1984 00(.EEijb us E Dockets: 50-445 - 50-446 g $ 22 R236
.- 4 Texas Utilities Electric Company . N,,.c c: u c:.m ATTN: M. D. Spence, President, TUGC0 T*.g af. '
l Skyway Tower
-400 North Olive Street "
,. Lock Box 81 Dallas, Texas 75201
. Gentlemen:
In January 1984, the,NRC. Region IV office began a special inspection of the coatings program at the Comanche Peak-Steam Electric Station in response to allegations that had been received regarding .the adequacy of the coatings. To assist us in this inspection, we have contracted with Brookhaven National . Laboratory (BNL) for assistance in the onsite inspection program.
. The principal purpose of this special inspection is .toI examine the adequacy
. of the applied protective coatings. Our contractors have now completed three
) trips to the Comanche Peak Steam Electric Station to review your procedures and practices for the application and inspection of protective. coatings. -.In order to complete our review, we require additional information, as identified in Section III of the enclosed " Interim Report on Protective Coatings" prepared by Brookhaven National Laboratory," dated April 25, 1984. We request that you provide this to us within 30 days from your receipt of this letter.
As documented in the interim BNL report, our contractor has identified two ' general areas of concern wich are summarized as items 2 and 3 of interim ; report Section V. Also within 30 days from the date of this letter, please respond to this office with your evaluation of the safety significance of ~ l
.these findings. Your response should' address the specific concerns identified -
in the interim report and for each concern provide: (1) information that supports your position as to the safety significance of the concern, (2) a
- description of corrective. actions that will be taken to alleviate safety l questions associated with each significant concern, and (3) a description of actions that will be taken to prevent any safety significant concerns from recurring in the remaining coatings progrant ' work. Your response should also describe the actions that will be taken to ' modify the backfit, program so that its conclusions will address the adequacy of applied coatings as far as the
! total coatings system is concerned, i . r O
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Texas Utilities Electric Company May 23, 1984
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A copy of the' April 25, 1984, interim BNL report has been filed with the ASLB and parties to the hearing. , The responses directed by this letter are not subject to the clearance procedures of the. Office of Management and Budget as required by the Paperwork Reduction Act of 1980, PL 96-511. Should you have any questions regarding this matter, please contact Mr. D. M. Hunnicutt at 817/860-8137 or me at 817/860-8248. !- .'. Sincerely,
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Richard l'.. Bangart, Director Region IV Comanche Peak Task Force
Enclosure:
As stated cc w/enclosura: I ' Texas Utilities Electric Company
)- ATTN: B. R. Clements,'Vice President, Nuclear Skyway Tower 400 North Olive Street Lock Box 81 Dallas, Texas .75201 Texas Utilities Electric Company -
ATTN: H. C. Schmidt, Manager .
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l Nuclear Services l Skyway Tower - l 400 North Olive Street .. , Lock Box 81 ! Dallas, Texas 75201 l i l t . e , , i l .
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r ASSOCIATED UNIVERSITIES, INC. 5p
. f l [.a C L e . Upton, Long is!cnd. NewYork 11973 (516)282N 7005 peporrrnent of Nuclear Energy FTS 666' April 25, 1984
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Mr. Eric H. Johnson U.S. Nuclear Regulatory Commission
. Region IV
, 611 Ryan Plaza Drive, Suite 1000 Arlington, Texas 76011 . s ..
Dear Eric:
Enclosed is Brookhaven National Laboratory's (BNL) report titled " Interim
- Report on Protective Coatings" for Comanche Peak Steam Electric Station (CPSES).
The NRC comments in the draft report dated April 19, 1984 have been incorporat-ed. This report also includes the requested information needed to assess the O. adequacy of applied coatings at CPSES. We are currently in the process of. preparing an additional report that will address each of the 60 allegation:, We anticipate issuing this second report on or about April 30, 1984. Yours truly, W - John Tay1 r, Group Leader Plant Systems & Equipment Analysis Group VL:JHT/ar cc: R.= Bari
=R. Hall F. Hawkins (NRC Reg. III)
D. Hunnicutt (NRC Reg. IV) - W. Kato _ _ . , . , H. Xouts V. Lettieri J. Oechsle
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. OFFICE OF INSPECTION AND ENFORCE' MENT '
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INTERIM REPORT ON PROTECTIVE C0ATINGS
.9 ,..
f/J k ~ . PREPARED BY BROOKHAVEN NATIONAL LABORATORY s ..
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LICENSEE: Texas UtilitiescGenerating Company
. ; . . ). 2001 Bryan Tower G '
Dallas, Texas 75201 ..
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m rr FACILITY:' .. Comanche Peak, Units 1&2. ., 0 1 o Ova 4. G1en Rose, Texas
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HNICAL SPECIALISTS: Vincent Lettieri sf k (date)
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b f 4 l7 1 5. donn Decnsle* ,, (date) t s
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O' APPRdVED: M . /2 s-MV John H. .Ta'ylor - (date) t . t. - t i a) . < , q ') f p ' Vj j ,') '
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- Stephen G. Pin'ney and Associates .
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CONTENTS
). .
Pace -
- 1. INTRODUCTION ..................................................... 1 II. BACKGROUND ....................................................... 1 III. INFORMATION REQUIRED TO DETERMINE ADEQUACY OF APPLIED PROTECTIVE
., COATINGS THROUGH THE BACKF IT PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 I V. FINDINGS RELATED TO THE ADEQUACY OF APPLIED PROTECTIVE COATINGS ......................................................... 4 V.
SUMMARY
AND CONCLUSIONS .......................................... 7 e e
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INTRODUCTION -ycy .w =. . 7; This is an interim report in response to an NRC Region IV request- to item-
-- ' ize the information that is necessary to assess the adequacy.of the Applied
- Protective Coatings Backfit Program at Comanche Peak Steam Electric Station (CPSES), Units 1 & 2. That information is contained in Section III of this report. - -
The remainder of the report is organized as follows: Sectior. II: Provides histor,ical background related to CPSES and BNL'.s work to date . Section III: Outlined above
~
,~.
Section . IV: Summary of findings to date
, Section V:' Conclusions The major portion of.BNL's effort to date has been in evaluating approx-imately 60 allegatibas. A report on this subject is due April 30, 1984.
II. BACKGROUND There are two major reasons for applying protective coatings inside the reactor containment building. The first reason is to protect exposed carbon / ., ' The second reason is to provide for easier steel surfaces from corrosion. decontamination, which also reduces the level of occupational radiation expo-
) sure.
If coatings are not properly applied and subsequently fail, they can have an adverse safety impact by clogging pump strainers, spray nozzles, and fan filters which can degrade safety equipment operation.
-~ .This is more than a theoretical concern since a number of For protective example:
. coatings failures have occurred at nuclear power stations.
o Beaver Valley (1975) - During construction, the coatings failed on the-containment dome.
~
o Brunswick 2 (1980) - During operation, coatings failure occurred below the torus water line.
~
o Dresden 2 (1971) - During operation, Torus coatings failure occurred. o Peach Bottom 2 (1971, 1973) - During preoperational testing, torus coatings fa,ilure occurred. l I E '
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IV of the NRC conducted an inspection"of protective coat-ings at Comanche Peak.. As a result of this inspection, (Inspection Report
' ~
I L s #81-15), a Notice-of Violation was issued regarding failure to follow quality
-.) assurance procedures for the inspection of protective coatings. From late L
.. September.1979 through October 1981, documentation for protective coatings was not naintained or was incomplete. As a result of this Notice of Violation, Comanche Peak instituted a Backfit Program to verify that the applied protec-tive coatings were themselves adequate even though' adeq'uate documentation did not exist. .
Starting ~in 1983, numerous , individuals have made allegations concerning the adequacy of the applied protective coatings at Comanche Peak. Brookhaven National Laboratory (BNL) was contracted to provide technical
~
assistance in performing on-si.te inspections of the protective coatings 7 program at Comanche Peak. The work, as stated in the contract, is to " Provide
, , technical assistance in performing an inspection of the protective coatings
~
program at the specified NTOL nuclear power plant. This inspection will include the examination of site procedures and verification of the adequacy of these procedures against standards and FSAR commitments, the adequacy of 4- applied coatings, the adequacy of rework,- and the procedures governing rework, the_ adequacy of verification tasting, and the adequacy of completed quality
-records. Also included in the scope of this tcsk will be the followup on specific technical questions contained in sworn testimony from persons making '
allegations of .the adequacy of the protective coatings program." The responsibility for reviewing the statistical adequacy of the licen-
)~
see's Backfit Program, (i.e. , sampling techniques, acceptance criteria, etc.) has been assigned to the NRC Auxiliary Systems Branch. With the concurrence of NRC Region IV, a meeting was held between ASB and BNL on April 2,1984.
.The outcome of this meeting was that additional statistical information is requi red. This information has ben incorporated into Section III of this report.
L III. INFORMATION REQUIRED TO DETERMINE ADEOUACY OF APPLIED PROTECTIVE l COATINGS THROUGH THE BACKFIT PROGRAM Brsed on interviews with various personnel on the licensee's staff, it is BNL's vaderstanding that the Backfit Program is limited to the primer coatings
- l. applied prior to the NRC's issuing Notice of Violation, Inspection Report No.
8I-15. That .is to say,'no statistical analysis 'of Elcometer adhesion pull tests and Tooke Scratch tests was performed for coatings applied since the NRC issued its violation and for the top coat that has been applied since the coatings application first began. Therefore, if this understanding is accu-rate, BNL does not believe that the Backfit Program will be useful in deter-mining the adequacy of applied coatings as far as total coating system is concerned. It is understood that in some if not all cases, the testing may have been performed for the total system. However, the licensee chose to perform a statistical analysis only in regard to the primer coat, and does not address the statistical significance of test results for the tota} coatings system. This will be resolved when the required information is supplied by the licensee.
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- Note: The information requested in this section should be provided in review-able form to BNL or made available at the site. ,' A. Programmatic -
1 1. Provide the document or series of documents that explains the Backfit Program in its e,ntirety. 1 2. What is the estimated . total square footage of applied coatings. in k Unit I containment? What portion of the total applied coatings 2 - represents coatings applied to concrete surfaces, miscellaneous steel y and containment liner plate? i 3. Provide the location and boundaries and define all areas that have
- been exempted from the Backfit Program. Also provide the justifica- - tion for the exemption. . .- 4. - Provide the percentage of the three major areas (see Question 2),
- g. .that was4ncluded/ exempted in the Backfit Program.
4^ Training B.
- 5. Provide the operating procedure for instruments used during the Backfit Program.
- n. .
x Provide indoctrination'and training records that demonstrate that p 6.
- ') those individuals performing testing for the Backfit Program were~
)- - ~ ~~
quali fied.
- 7. . Provide procedure reference for field checking of instruments during the Backfit Program. -
f C. Instrumentation and Testing
- 8. Provide instrument history / calibration records of each instrument h- used in the Backfit Program.
Provide the method used to evaluate and account for instruments found 4 9. to be out of calibration during the Backfit Program. How was and is the deviation incorporated in reporting E1cometer Adhesion Test results? h Additionally, for an instrument found out of calibration, provide
'; documentation that shows that all tests done with that instrument since its last calibration were invalidated. Al so, provide the y procedure used to handle those inspection reports written after the i e instrument went out of calibration.
di If not provided in the answers to Questions 7 and 8, provide the "- 10. total number of instruments used in the Backfit Program. Provide the
) type and serial number of each instrument.
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' ': / .3 11. - Provide the total number of individual pull tests performed and a-6,;.:J number of individual pull tests that failed for each of the threi) h;yj;,E . major areas (see Question 2). g.,4.0.> e.,9
- 12. Provide the final calculations for each of the three major areas
-W-IET (see Question 2) that demonstrate t'he es'timated failure rate wit 4 .its associated confidence limits, for each of the three major art {
;;,+#s2;.
i individually.
~
f.sr.4.- ' p.7.n)ly. IV. FINDINGS RELATED TO T"HE ADEOUACY OF APPLIED PROTECTIVE COATINGS.
. r~ . . .
2.w.h.h.h. A. Testino ,
.n <. :. 2 , . .. ~ " p;.j;p;;. , ' ' 1. BNL has performed independent tests on the protective coatings at f(.g.+:. 4 site. On a random basis, 6 areas of approximately one hundred (100). squar; Oc9 feet were chosen at various elevations and various azimuths. Two areas W.2.M ~ ~ represented liner plate, two areas represented miscellaneous steel and two R. areas represented . concrete surfaces. In each area, five (5) test dollies .
Y.' 7 !:.%,?.pf
- approximately.1/2 square-inch were glued to the protective coatings and a .
- - of 250 psi was applied to the test. dollies. If a dolly separated from the V, surface, the force that caused the separation was recorded. If the dolly G not pull off the surface at 250 psi, a reading of 250 psi was recorded and p dolly was knocked off of the surface after the instrument had been returne@
a reading of zero and removed. T, . ,?. . For the liner plate, a failure rate was exhibited' of 4 out of 10, or 4a
~
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. Failures occurred in both test areas with corrected readings of 156, 186,
, Jr, '186, and.186. For miscellaneous steel, no failures were recorded in ten -( t
' .[ ,IF. . , tests,' and for concrete surfaces, a failure of the concrete was experiencee
-l.,T.y a corrected reading of 156 psi for one test and no failures of the protecti c
;p.<M.4
. coatings in nine (9) tests. -
>.3 .A l d'.O.I In addition to Elcometer adhesion pull tests, 30 Tooke (scratch) tests
?; were performed adjacent to the pull tests. No "out of specification" condt
! .@f@9.- lj - tions were recorded in the dry fim thicknesses testing. i ','-:i 4 BNL's observed failure rate for the liner plate is unacceptable. Al the
. .'.". .P. ;.' . it was limited in scope, it raises questions about the adequacy of the Bach .;Q.';;,i.; Program for the liner plate. . MAU
- 2. During the week of March 18, 1984, BNL observed an area at approxic
!' $ih YE.y/jf . mately elevation 860 and azimuth 175 of the liner plate that was being , C V.', repaired because of recent unacceptable adhesion test readings and visible ! k.(
i f,$b deterioration. This same area had acceptable adhesion test readings during initial backfit testing'in December 1982. This again raises doubts about t {.}, adequacy of the Backfit Program for the liner plate. .-
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B. Procedural. ?. . i - .
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.' 3. Contrary to good industry practice, solvent has been u::ed excessively to wipe cown primed surfaces: prior to the top coat application. Excessive
'.. solvent retention will inhibit the curing of inorganic films and can lead to 4: coatings failure under operating conditions. The licensee's procedures do not g provide direction or caution on solvent use, nor is there evidence of proper training to this effect. In three areas of coating' system failures on the
[% containment. liner plate, BNL observed a solvent odor that was far in excess of g:; :what .would be considered no~rmal. $.7 4. Contrary to CPSES FSAR Section IA(B), Regulatory Guide 1.58, and @ LANSI/ASME_N45.2.6-1978, Section 4 and Table 1, Level 1 Coatings QC Inspectors [.C. have been making judgments 'and evaluations that they are not qualified to r , make. e-g. g, Examples of this were evident in procedures where level I inspectcrs were: a) evaluating surface preparation without instruments or approved visual f$f: .,' : standards, b) evaluating the . adequacy of coatings materials when its " pot (N life" had_ been. exceeded, and c) evaluating the acceptable extent of overlap-Q : ping dry spray 4eyond the specific areas to be coated. QC r.J 5. Contrary to Gibbs & Hill, Inc., Protective Coatings Specification b' No. 2323-AS-31, Revision 1-March 15,1978 for CPSES, Section 6.1 b and Brown and Root, Inc. letter BRV-12605, dated May 7,1981 to Tim Dolen, Carboline iy Company from D. C. Frankum, Project Manager, proper surface preparation was
- -F -- not achieved. Instruction Number QI-QP-11.4-5 ' allows 80 grit " flapper wheels"
' ..j - versus the 60 grit " flapper. wheels" used to qualify surface preparation.
~
,,j; 6. BNL has identified numerous piocedural deficiencies. A summary of h,.- - some of the more serious deficiencies follows: a) Contrary to good industry practice and 10 CFR Part 50, Appendix B, W Criterion V; M ~,.
- 1) The procedures are not " stand-alone" documents, acceptance g)i d criteria are found in other referenced documents.
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- 2) Procedures such as Instruction Number QI-QP-11.4-1, and QI-QP-11.4-5 requires a flashlight to be held perpendicular to the inspection surface only. Proper inspection technique would require a light to be positioned parallel to the surface to
% locate certain types of defects. Additionally, the minimum M light required is not specified.
h-6 3) Procedure QI-QP-11.4-1,' paragraph 3.1.2, states that for abra-sives "... All grease, oil, and deleterious material is unac- >J.i ka ' ceptable", and.yet provides no methods to determine if these materials are present. The procedure also does not define deleterious material. 9 Wa. - g ws If g'g 4, . , ~
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g,, . b);' Contrary to 10 CFR 50 Appendix B Criterion V and CPSES FSAR, par.-- graph 17.1.1.5, the final coatings walkdown procedure contained
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acceptance criteria and did not contain appropriate instructions ffe ,k.'. . regarding hiding. quality, cracking, delamination, peeling, exces2 d.4Ns. . . overspray, excessive roughness, flaking, blistering, or crackinga f..$hj; conjunction with inadequate inspection procedures, this could all acceptance of inadequate coatings. ,
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%($$i c) l Contrary to CPSES FSAR, page IA(B)-22; R. G.1.54, and ANSI
.M . N101.4-1972, paragraph 4.4.3, CPSES coatings procedures allow wel 4.@.6 u- splatter to rema.in on. metal surfaces. This could contribute to
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, -ccatings failure.
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i.'f ,l' d) Contrary to CPSES FSAR, page IA(B)-2?; R. G.1.54, and ANSI
? M. N101.4-1972, paragraph 5.2.2, CPSES coatings procedures provide ?
[h[ph,.' ',' the writing and approval of special . coatings procedures, without
.- approval of the coating manufacturers. . g%5: ,if.4. 'lhy; .
0 %2 - e) Contrary to CPSES FSAR, paragraph 6.18.2 and ANSI N.101.2, coatin [. ' ' applied over "drypack" concrete repairs were not DBA-qualified.
.g,, - Additionally, the "drypack" does not appear to meet paragraph 6.6 f.ru.,.gf of ANSI N101.2-1972.
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J.~"*/ 7) Based on a brief review of Design Change Authorizations (DCA's) Q - "d- written in the coatings- area, it does not appear as though Qualit I. j ~,- Assurance is included in the review and approval chain, as would
.?... required by 10 CFR 50 Appendix B, Criterion III. Also, there is -
g3. ,, . . formal mechanism to ensure that users of controlled copies of the
.- Coating Specification have received and are aware of all applicab
- u. DCAs. Finally, there is no requirement for specification revision-
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after DCA's have been issued against it, either based on time or gMft$ number of DCA's. Additional review in this area is needed to l 3; g i determine how quality is assured in the DCA program.
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ll[ E_i, - 8) Contrary to FSAR Section 6.1B.2, ANSI N101.2, Section 4, a number q , .t J coatings systems have been specified and used that have not been [i qualified. After identification of this by BNL, the licensee has lE[_'R: .-.5 committed to submitting these ' coatings systems to the appropriate ! t
- D'*} testing.
t a- :- LM.h. Contrary to FSAR Section 1A(B), Regulatory Guide 1.54 Section C.4 i 9) M.dh,;s ,.
"STAF Hospital Spray Disinfectant", an aerosol containing chloride
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was used by painters inside containment where stainless steel is
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' #.M .T%p,4,: i 10) A number of the 6.0 allegations against CPSES's protective coatingt ! 5'.7:W have been substantiated and additional allegations may be substand ' T!.?i'- tiated. The status of all 60 all'egations will be stated in a foll up report due April 30, 1984. t g:O.jrf"[$ 4. b L I',-a it . .Q - p'6..~
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SUMMARY
AND CONCLUSIONS. .
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-3 1. An adequately conceived and properly implemented Backfit Program will permit an evaluation of the applied coatings at Comanche Peak. The informa-
.. tion requested in Section III of thi.s report will permit an assessment of the licensee's Backfit Program. -
- 2. As demonstrated in Sections IV B and C, th'e coatings procedures and design control for coatings at CPSES appear to be inadequate to assure the specification of proper coatings systems and the application of coatings, once they are specified. As such, no determination can t,e made as to the adequacy of coating for the following applications: a) any repair work completed subsequent to the backfit testing, b) coating applications not included in the scope of the Backfit Program, and c) all coating work for Unit No. 2.
As stated in Section IV A, and further reinforced by conclusion 3.
. number 2, the liner plate coating appears to be inadequate.
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