ML20100L342

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Illinois Power Co Overinsp Program
ML20100L342
Person / Time
Site: Clinton Constellation icon.png
Issue date: 10/25/1984
From:
ILLINOIS POWER CO.
To:
Shared Package
ML20100L309 List:
References
PROC-841025, NUDOCS 8412110537
Download: ML20100L342 (29)
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Text

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.,. ATTACHMENT 1 s

ILLINOIS POWER COMPANY i .

4 OVERINSPECTION PROGRAM 1

-t l PREPARED FOR:

l U.S. NUCLEAR REGULATORY COMMISSION OCTOBER 25, 1984 GLEN ELLYN, ILLINOIS i

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8412110537 841121 DR ADOCK 05000461 l PDR i

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10/25/84

OVERINSPECTION PROGRAM t INTRODUCTION I.

II. PROGRAM OBJECTIVES III. PROGRAM COMMITMENTS IV. PROGRAM STATUS V. PROGRAM RESULTS A. GENERAL B. SPECIFIC i

VI. PROGRAM MANAGEMENT ACTIONS A. STRUCTURAL STEEL

! B. PIPING & PIPE SUPPORTS C. ELECTRICAL HANGERS D. OTHER COMMODITIES SUPPLEMENTARY INFORMATION i

I. SUPPORTING VERIFICATION PROGRAM - PIPING g II. SUPPORTING VERIFICATION PROGRAM - PIPE SUPPORTS 4

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10/25/84 I. -INTRODUCTION D A. ILLINOIS POWER COMPANY. QUALITY IMPROVEMENTS (1982)

1. IMPROVED PROJECT MANAGEMENT i
2. . ENHANCEMENTS IN PROJECT QUALITY ASSURANCE i
3. ENHANCEMENTS IN THE CONTROL OF NONCONFORMANCE AND THE CORRECTIVE ACTION PROGRAM
4. ENHANCEMENTS IN THE CONTROLS FOR CONSTRUCTION AND INSPECTION ACTIVITIES
5. OVERINSPECTION PROGRAM
6. RECORD VERIFICATION PROGRAM
7. OTHER ACTIVITIES WHICH VERIFY QUALITY a) THIRD PARTY AUDITS AND EVALUATIONS ,

b) SPECIAL PROGRAMS LO u 79-14 WitRw WN PROGRAM

2) SEISMIC INTERACTION ANALYSIS PROGRAM
3) ELECTRICAL SEPARATION PROGRAM
4) FIRE PROTECTION PROGRAM
5) 50.55 (e) AND PART 21 EVALUATIONS
  • c) CONFIGURATION MANAGEMENT PROGRAM l d) TURNOVER PROGRAM AND STARTUP TESTING PROGRAM i
1) SYSTEM / SUBSYSTEM TURNOVER PROGRAM I i

i

2) STARTUP TESTING PROGRAM
1 i e) INDEPENDENT DESIGN REVIEW B. THIS PRESENTATION EMPHASISES THE OVERINSPECTION PROGRAM AND THOSE OTHER RECOVERY EFFORTS WHICH SUPPORT OR o

! ENHANCE ITS RESULTS O

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O II .- OVERINSPECTION PROGRAM OBJECTIVE PROVE THAT THE STRUCTURES, SYSTEMS, AND COMPONENTS AT CLINTON POWER STATION ARE PROPERLY INSTALLED TO ASS'URE SAFETY OF OPERATIONS.

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III. OVERINSPECTION PROGRAM COMMITMENTS .

COMMITMENT PROGRESS ON COMMITMENTS I. CONDUCT THREE PHASE OVERINSPECTION PROGRAM

  • I - REVIEW U.S. TESTING OVERINSPECTION ACTIVITY
  • COMPLETE
  • II - BA FIELD VERIFICATION OF OLD AND NEW WORK *0NGOING
  • III - IP OVERINSPECTION OF OLD AND NEW WORK
  • ONGOING II. ADDRESS SAFETY-RELATED, AUGMENTED CLASS D (RADWASTE) ALL COMMODITIES HAVE PROTECTION SYSTEMS, AS FOLLOWS: BEEN OVERINSPECTED TO
  • LARGE BORE PIPING VARYING DEGREES
  • MECHANICAL EQUIPMENT
  • STRUCTURAL STEEL
  • HEATING, VENTILATING AND AIR CONDITIONING (HVAC)
  • ELECTRICAL HANGERS
  • ELECl?ICAL CONDUIT RACEWAY
  • ELECTRICAL TERMINATION
  • ELECTRICAL EQUIPMENT
  • INSTRUMENTATION - ELECTRICAL / MECHANICAL 5

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COMMITMENTS PROGRESS ON COMMITMENTS III. ADDRESS BOTH OLD AND NEW WORK SUBSTANTIAL AMOUNTS OF BOTH (WORK PERFORMED BEFORE AND AFTER JULY 26, 1982) OLD AND NEW WORK HAVE BEEN OVERINSPECTED IV. CONDUCT PROGRAM BASED ON 95/5 SAMPLE PLAN THE MAJORITY OF WORK TO DATE HAS BEEN 100%

INSPECTED 95/5 HAS BEEN APPLIED WHEN SAMPLING WAS USED V.

V- EVALUATE PROGRAM FOR: PROGRAM EVALUATIONS HAVE BEEN MADE .

DECREASING SAMPLE BY CATEGORY OR CHARACTERISTIC

  • ADJ'USTMENTS HAVE BEEN MADE TO INSPECTION PROGRAM TERMINATION OF INSPECTIONS BY CATEGORY
  • NONE ROOT CAUSE DETERMINATIONS AND CORRECTIVE ACTION
  • ROOT CAUSE DETERMINATIONS HAVE BEEN MADE VI. CONTINUE THE PROGRAM IN THE FUTURE PROGRAM IS CONTINUING 6 -. .. . - _ _ _ _ _ - _ _ _ -

10/25/84 s

IV. OVERINSPECTION PROGRAM STATUS l

0 EFFECTIVE JULY 31, 1984 FIELD VERIFICATION HAD INSPECTED 6,762 TRAVELERS RESULTING IN 647,295 ATTRIBUTE INSPECTIONS AND

., HAD IDENTIFIED 28,208 NONCONFORMING ATTRIBUTES FOR AN OVERALL FV NONCONFORMANCE RATE OF 4.4%. OVERINSPECTION ADDITIONALLY

. INSPECTED 3,915 TRAVELERS'RESULTING IN 477,156 ATTRIBUTE INSPECTIONS AND IDENTIFIED 6,690 NONCONFORMING ATTRIBUTES FOR AN j OVERALL OI NONCONFORMANCE RATE OF 1.4%.

t i NUMBER OF ATTRIBUTES INSPECTED BY

..l j' BA AND IP UNDER THE OVERINSPECTION PROCRAM NUMBER OF ATTRIBUTES INSPECTED BY BA FV 647,295 l NUMBER OF ATTRIBUTES INSPECTED BY IP OI 477,156 i.

TOTAL NUMBER OF INSPECTIONS 1,124,451

! NUMBER- 0F ATTRIBUTES INSPECTED BY BOTH '

i BA FV AND IP-0I 285,448 TOTAL KUMBER OF DIFFERENT ATTRIBUTES INSPECTED 839,003

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10/25/84 OVERINSPECTION PROGRAM RESULTS GENERAL RESULTS

  • IP INITIATED A REVIEW OF THE RESULTS OF THE OVERINSPECTION PROGRAM ON JULY 23, 1984.

ASSESS RESULTS IN TERMS OF PLANT QUALITY.

PROVIDE INFORMATION FOR PROGRAM MANAGEMENT ACTION.

  • THE FIRST EVALUATION REPORT WAS COMPLETED AND REVIEWED BY IP, BA AND S&L ON OCTOBER 19, 1984.

OVERALL PLANT QUALITY IS GOOD.

SOME AREAS HAVE NOT ACCUMULATED A SUFFICIENT AMOUNT OF INFORMATION TO ALLOW CONCLUSIVE EVALUATION.

OTHER AREAS HAVE ACCUMULATED SUFFICIENT INFORMATION TO ALLOW CONCLUSIVE EVALUATION. S MANAGEMENT ACTION MAY BE TAKEN IN SOME AREAS WITH HIGH CONFIDENCE LEVELS.

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_o . OVERINSPECTIGI PROGUM p\J'

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< SPECIFIC RESLLTS

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,- IG030GHH2 RATES BY G2iS11tlXTIGI DT13CIPLINE

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4- " NGEER OF IGBER OF NON00tG G HANCE TYPE OF x ATIPlBLIFFJ NON00tGUHMING RATEG)

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s. AINSIEHON M. k INCPEC11D ATIRIBUIES

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,s 223,651 -

12,890 5.8 s_

- ELECIRICAL/INSIRGENTATION 177,527 5,627 3.2

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-?"t P2ING/MEGANICAL s 226 8,855 3.9

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.c , , o u 'IttfAL ~ - ;647,295 28,208 4.4 e '

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SIBUCITPAL

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86,367 >'2,563 3.0 s -

3. INSPECTION ELECTRICAL / INS'IRGENTATION 52,495 543 1.0 e  % '. .

PIPY /MEDIANICAL, 52,846 734 1.4

' .. PRIOR 10 W s,

HVAC \, . , - - - 0 - -

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,'IUTAL' 191,708 3,840 2.0 a s -

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i o x OI 's., STRICTIRAL 155,031" 2,465 1.6

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s!NSPECTIWS ILEGIRICAL/INSIRINERG" ION '49,041 161 0.3 s ys , . . . c y, AFIER W ' 'D dtPING/MEGANICAL' \h,0,350 219 0.3 s s ,, .,

1 44  % 4

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11.026 5 0.0 O

O 'IUTAL 285,44 8

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o o NWCWmRMANCE RATES BY TIPE W IIEM 8 " -

W OI ATIRIBUIES NWOONHRIING NONO3GOBMANCE ATIRIBUIES NON00N mRMING N WOW mHMANCE ITEM INSPECTED ATIRIRTIES RATE (%) INSPECIED ATIRIRTIES RA'IE (%)

BEAMS AND STRUCIURAL STEEL 223,651 12,890 5.8 241,398 5,028 2.1

, CABLE 5,80 8 88 1.5 2,639 16 0.6 CABLE TERMINATIW 31,883 101 0.3 18,087 20 0.1 Cot 0UIT 3,269 54 1.7 511 0 0 CABLE 'IRAYS 649 24 3.7 0 - -

ELECIRICAL BOXES 195 13 6.7 10 2 20.0 ELECIRICAL HANGERS 90,170 4,873 5.4 67,834 572 0.8 1 7,142 0.9 ELECTRICAL EQUIIMNr 11,785 187 1.6 66 INSIRINENTATION 153 0 0.0 102 0 0.0 INSIRINENT PIPE 9,770 136 1.4 2,170 12 0.6 INSIRINENT SUPERT 23,845 151 0.6 3,041 16 0.5 IARGE BORE PIPE 27,062 2,850 10.5 13,583 182 1.3 SMALL BORE PIPE 42,223 2,086 4.9 48,221 313 0.6 2 2,11 6 245 11.6 473 11 2.3 WDIANICAL HNIIMNr 3 154,713 3,67 4 2.4 60,919 447 0.7 WDIANICAL SUPIORIS HVAC DUCT 9,007 495 5.5 5,391 0 0.0 HVAC HANGERS 10,996 341 3.1 5,635 5 0.1 TorAL 647,295 28,208 4.4 477,156 6,690 1.4 1

INnninFS ELECIRICAL PANELS AND SWITGEAR INCLUIES CWPRESSORS, PLNPS, VALVES, AND MISCELIJEOUS EQUIIMNr 3 INCLUDES ANCEOR PLATES, EXPANSION ANCHORS AND HANGERS 10

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10/25/84 O NUMBER OF NONCONF0aMix ES Er TTPE Or iTrRIaUTE TYPE OF ATTRIBUTE NUMBER OF PERCENT OF NONCONFU15ENCES TN, OF

NONCONFDYMANCES ARCSTRIKE/SPAbER 8,544 24.5 FUSION /0VERLAP/ UNDERCUT 6,298 18.0

. -WELD SIZE / PROFILE 6,275 18.0 INSTALLATION P3R DESIGN 4,631 13.3 IDENTIFICATION ~ 3,769 10.8 TOLERANCE 1,958 5.6 DAMAGE , 1,262 3.6 SLAG 606 1.7 LOCATION 606 1.7 ALL OTHERS 954 2.7 TOTAL 34,898 100.0%

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, NONCONFORMANCE RATES FOR OLD WORK AND NEW WORK FV INSPECTIONS NUMBER OF NiJMBER OF ATTRIBUTES NONCONFORMING NONCONFORMANCE '

DISCIPLINE . TYPE OF WORK INSPECTED ATTRIBUTES Rate (%)

N OLD 223,651 12,890 5.8 NEW N/A - -

ELECTRICAL / OLD 87,166 3,721 4.3 INSTRUMENTATION NEW 90,361 1,906 2.1 PIPING / OLD 48,587 4 ,44 2 9.1 MECHANICAL NEW 177,527 4,413 2.5 HVAC OLD N/A - -

NEW 20,003 836 4.2

. TOTAL OLD 359,404 21,053 5.9 . ,

l NEW 287,891 7,155 2.5 OVERINSPECTIONS

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NUMBER OF NUMBER OF ATIRIBUTES NONCONFORMING NONCONFORMANCE DISCIPLINE TYPE OF WORK INSPECTED ATTRIBUTES RATE (%)

NTIMCTUIEC OLD 241,398 5,028 2.1 NEW N/A - -

ELECTRICAL / OLD 79,987 465 0.6.

INSTRUMENTATION NEW 21,549 239 1.1 PIPING / OLD 83,741 639 0.8 .

MECHANICAL NEW 39,455 314 0.8 HVAC OLD~ N/A - -

NEW 11,026 5 0.0 TOTAL OLD 405,126 6,132 1.5 .

NEW 72,030 558 0.8 12

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10/25/84 O~

VI. OVERINSPECTION PROGRAM MANAGEMENT ACTION O

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10/25/84 F

STRUCTURAL STEEL 1 i

  • THE OVERALL~NONCONFORMANCE RATES FOR STRUCTURAL STEEL ARE NOT EXCESSIVELY HIGH FIELD VERIFICATION 5.8%

OVERINSPECTION (BEFORE FV) 3.0%

OVERINSPECTION (AFTER FV) 1.6%

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  • THE NONCONFORMANCES' REPORTED ARE NOT, IN GENERAL, SERIOUS WITH RESPECT TO PLANT SAFETY

,

  • HOWEVER, ONE NONCONFORMANCE REPORT (NCR) WAS BEING' GENERATED FOR NEARLY EVERY' STRUCTURAL STEEL BEAM INSPECTED.
  • WITH AT LEAST ONE NCR PER BEAM, SAMPLING, INSPECTION WILL NOT BE ACHIEVABLE.

PROGRAM MANAGEMENT ACTION

  • INSTITUTED 100%~ REINSPECTION BY THE IP OVERINSPECTION GROUP OF ,

STRUCTURAL STEEL BEAMS ON OCTOBER 1, 1984.

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. 10/25/84 PIPING AND PIPE SUPPORTS

  • BASED ON INITIAL EVALUATION, HARDWARE QUALITY IS ADEQUATE TO ASSURE SAFE,' RELIABLE OPERATION OF CPS' FV NON00NFORMANCE RATES FOR CED PIPING /MEGANICAL W)RK NINBER OF NLNBER OF NLNBER OF NON00tGGMANCE ATIRIRHES NWCDNEGMDC ABC STRIKES RATE EK(2.UDING ITEM INSPECTED ATIRIBUTES & WLD SPATIER ARC STRIKES IARGE BORE PIPE 12,298 2,269 1,681 4.8 SMALL BORE PIPE 17,203 1,251 922 1.9 1

MECHANICAL EQUIPMENT 913 71 24 5.2 2 18,173 MECHANICAL SUPPOEtrS 851 398 2.6 i

TOIAL 48,587 . 4 ,44 2 3,025 3.0 1 l

1 INCL 11IES (XNPRES. ORS, PtNPS, VALVES, AND MISCELIANEDUS O EQUIRENT 2

I! nim ANC10R FIATES, EXPANSION ANCHNS, AND HANGERS L

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- ACTIONS TO BE TAKEN

-REMOVE LARGE AND SMALL BORE PIPE AND MECHANICAL SUPPORTS FROM OVERINSPECTION PROGRAM INSTITUTE TASK FORCE FOR ARC STRIKES ON THESE COMMODITIES EVALUATE ARC STRIKE RESULTS FOR SIGNIFICANCE - POTENTIALLY REDUCE SCOPE OF PROGRAM t

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-10/25/84 ELECTRICAL HANGERS _

COMMITMENTS PROGRESS'ON COMMITMENTS

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  • COMPLETE FOR OLD WORK INSrECTION BY BA QUALITY CONTROL
  • 100% REINSPECTION LY BA QUALITY-
  • ONGOING .

AND TECHNICAL-SERVICES OF OLD WORK

  • RANDOM SAMPLE VERIFICATION BY BA
  • ONGOING FIELD VERIFICATION
  • RANDOM SAMPLE VERIFICATION BY IP
  • ONGOING OVERINSPECTION 4

FIELD VERIFICATION NONCONFORMANCE RATES FOR OLD WORK

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NUMBER OF NUMBER OF NUMBER OF NONCONFORMANCE ATTRIBUTES NONCONFORMING ARC STRIKES & RATE EXCLUDING INSPECTED ATTRIBUTES. WELD SPATTER . ARC STRIKES 61,127 3,66 5 1 ,28 5 3.9 REQUESTED NRC ACTION EVALUATE ANSWER PROVIDED TO ILLINOIS POWER COMPANY IN NRC LETTER J. G.-KEPPLER (RIII) TO W. C. GERSTNER, 9-17-84: "BA FIELD .

VERIFICATION /IPC OVERINSPECTION" REGARDING"THE NECESSITY TO CONTINUE OVERINSPECTION PROGRAM ACTIVITIES FOR ELECTRICAL'

. HANGERS.

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10/25/84 OTHER COMMODITIES

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  • HVAC (DUCT & HANGERS)
  • CONDUIT AND ELECTRICAL BOXES
  • CONDUIT HANGERS
  • CABLE
  • CABLE TERMINATIONS
  • ELECTRICAL EQUIPMENT
  • INSTRUMENT SUPPORTS
  • INSTRUMENT PIPING
  • INSTRUMENTATION
  • MECHANICAL EQUIPMENT O

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y b ATTACHMENT 2 10/25/84 ILLINOIS POWER COMPANY OVERINSPECTION PROGRAMS SUPPORTING VERIFICATION PROGRAMS ,

PIPING A. DESIGN INPUT VERIFICATION

  • 55-82 PIPE MINIMUM WALL VIOLATIONS S&L REVIEWED STRESS ANALYSIS INPUT REQUIREMENTS S&L VERIFIED PIPE LINE LIST l

S&L REVIEWED ALL LARGE BORE, IS0 METRICS FOR CORRECT INFORMATION DATA IS EVALUATED FOR IMPACT ON CALCULATION / SAFETY B. DESIGN CALCULATION REVIEW / VERIFICATION 4

  • 53-82-09: REVIEW OF SMALL BORE, INSTRUMENTATION AND CONDUIT CALCULATIONS a

0 REVIEW / VERIFICATION OF S&L METH'DS/ SUBSTANTIATION OF SIMPLIFIED ANALYSES METHODOLOGIES S&W ENGINEERS REVIEWED S&L SMALL BORE PROCEDURE NSED. ENGINEERS REVIEWED A PERCENTAGE OF S&L SMALL BORE CALCULATIONS CALCULATIONS WERE REVISED AND CORRECTED WHERE _

NECESSARY S&L PROVIDED ADDITIONAL TRAINING / SUPERVISION TO DESIGNERS

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10/25/84

  • IP/NSED REVIEW OF S&L LARGE BORE CALCULATIONS CONTINUOUS EVALUATION OF S&L CALCULATIONS BY NSED (TRAINING PROVIDED TO NSED)

S&L REVISES CALCULATIONS WHEN NECESSARY NSED DOES SAMPLE STRESS CALCULATIONS ON THE PROGRAM -

NUPIPE TO VERIFY / CHECK S&L RESULTS INPO FINDING ON CLASS I ANALYSIS HAD INDEPENDENT REVIEW BY S&W ENGINEERS ON S&L METHODS. S&L FORMALIZED THE METHODS AND CALCULATION FORMATS FOR 2 CLASS I ANALYSIS NSED FOLLOWS STRESS ANALYSIS THROUGH TO THE PIPE SUPPORT DESIGN CALCULATIONS TO ASSURE THE INFORMATION TRANSFER IS CORRECT AND CURRENT AS-BUILTS ARE DRAWN FOR STRESS RECONCILIATION (I&E 79-14 )

C. FABRICATION VERIFICATION

  • 55-82 -10: APPROVED ISOMETRICS ARE USED TO VERIFY FABRICATION
  • 55-83-07: SOUTHWEST FABRICATION RADIOGRAPH REVIEW REREAD ALL RADIOGRAPHS FOR PIPE SUPPLIED TO BA BY SWF: 3,000 WELDS; 19,000 PIECES OF FILM REPAIR 104 WELDS HAD INDEPENDENT AUDITS OF THE FILM REVIEW 2

. _ . . . __ _ - _ . _ . . _ . _ . _ ~ . _ - , _ _ . ~ _ - . . _ _ _ _ _ _ _ _ _ _ _ _ _ _ . - - . _ - _ _ _ . _ . . . _ _ _ _ _ . . -

10/25/84

  • 55-84-05: INCORRECT MATERIAL SUBSTITUTION REVIEW BY BA RESIDENT ENGINEER OF APPROVED IS0 METRICS FOR MATERIAL ADDED BY BA WHEN MODIFYING SWF SPOOLS VERIFY MATERIAL ADDED THRU P.O./RIR/CMTR REVIEW S&L REVIEWED ALL DEFICIENCIES FOR SAFETY. SOME REWORK REQUIRED BUT NO ADVERSE CONDITIONS IDENTIFIED PROCEDURE CHANGES TO VERIFY PIPE AT RELEASE FROM STORAGE
  • 55-84 -04 : HEAVY FITTING SUBSTITUTION REVIEW ALL SWF ISOMETRIC / SPOOL DRAWINGS FOR SUBSTITUTION OF FITTINGS HEAVIER THAN SPECIFIED S&L REVIEWS ALL SUBSTITUTIONS FOR IMPACT ON STRESS ANALYSIS AND SAFETY SIGNIFICANCE (NO ADVERSE CONDITIONS IDENTIFIED) k 3

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10/25/84

  • 55-83-02: _ COUNTERBORE OF SAFETY RELATED PIPE

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REVIEW ALL IS0 METRICS AND IDENTIFY JOINTS WITH NOMINAL I.D. MISMATCH GREATER THAN 1/16'AND WHICH MAY REQUIRE.COUNTERBORE/I.D. GRINDING 4

S&L AND ANI CONCUR WITH METHODS USED TO IDENTIFY SUSPECT JOINTS DEVELOP PROCEDURE WITH VARIABLE ULTRASONIC TEST (UT) PROBE TO DETERMINE ANGLE OF INCLINE OF i

i~ FINISHED JOINTS i *- DEMONSTRATE THE METHOD ON KNOWN COUPONS TO THE ANI, QA, NRC, S&L S&L APPROVED THE PROCEDURE AND ANI CONCURRED QUALIFY UT OPERATORS ON TEST COUPONS PRIOR TO PERFORMING PRODUCTION WELDS

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INSPECT 515-JOINTS'AND REWORK 95 D. AS-BUILT PROGRAM:

  • AS-BUILTS ARE PREPARED TO GIVE INFORMATION TO S&L FOR STRESS ANALYSIS RECONCILIATION AND COMPLIANCE WITH I&E 79-14 REQUIREMENTS AND ASME N-5 SIGN-OFF.
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10/25/84 E. MATERIAL VERIFICATION / DOCUMENT REVIEW EFFORT

  • 55-84111: UNCERTIFIED FLANGES INSTALLED IN ASME SYSTEMS SEARCH OF RECORDS AND TRAVELERS FOR FLANGES PURCHASED l 1

WITHOUT PROPER ASME CERTIFICATION FROM THE VENDOR I 77 WERE IDENTIFIED AND WERE REMOVED FROM THE PLANT

  • 55-84-02: MATERIAL TRACEABILITY I

NO MATERIAL HAS BEEN FOUND THAT DOES NOT MEET THE SPECIFICATION REQUESTED UNIQUE TRACEABILITY IS NOW PROVIDED BY HEAT NUMBER OR BA RECEIVING IDENTIFICATION NUMBER -

MATERIAL TEST PROGRAM UNDERWAY k

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  • '55-84-09: CERTIFICATION OF PENETRATION HEAD FITTINGS - i I

FIND AND REPLACE AND/OR TEST PLATE STEEL WITHOUT PROPER ASME CERTIFICATION USED IN CONTAINMENT HEAD FITTINGS I&E BULLETIN 83-01: RAY MILLER CO. FRAUDULENTLY SUPPLIED l MATERIAL. NO MATERIAL FOUND AT CPS FROM RAY MILLER CO. ,

I&E BULLETIN 83-06 : TUBE LINE NONCONFORMING MATERIAL.

IP IS~STILL EVALUATING THE MATERIAL RECEIVED AT CPS FROM TUBELINE i

G.E. LETTER PRC-84-18: G.E. SUPPLIED PIPE:

MICROFISSURING OF 316NG RECIRCULATION PIPE. CPS DID NOT I

RECEIVE THE TYPE OF MATERIAL / PIPING PIECES DESCRIBED I&E BULLETIN 83-02: STRESS CORROSION CRACKING IN STAINLESS STEEL RECIRCULATION PIPING. IP HAS TAKEN STEPS l i TO PREVENT THIS PROBLEM.

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F.- DOCUMENT REVIEW GROUP:

  • REVIEW SAFETY-RELATED TRAVELERS FOR REQUIREMENTS OF MATERIAL, ETC. , AND VERIFY THROUGH THE REVIEW OF PURCHASE ORDERSS, RECEIVING INSPECTION REPORTS, CERTIFIED MATERIAL TEST REPORTS AND QUALIFICATION RECORDS THAT WHAT IS REQUIRED BY THE DESIGN IS INSTALLED IN THE PLANT. (PIPE, FITTINGS , VALVES , WELD ROD, OTHER MATERIAL, ETC.)
  • DOCUMENT EXCEPTION LIST ITEMS WRITTEN TO OBTAIN ENGINEERING,

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QA RESOLUTION

  • NCRs WRITTEN FOR NONCONFORMING CONDITIONS AND ENGINEERING EVALUATIONS l

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10/25/84 ILLINOIS POWER COMPANY _

SUPPORTING VERIFICATION PROGRAMS-L- PIPE SUPPORTS 4

A. 55-82-11: INCORRECT WELD PROCEDURE MATERIAL I.D. ON PIPING HANGER

- TRAVELERS REVIEWED 10,000 TRAVELERS FOR PROPER MATERIAL IDENTIFICATION SO THAT THE CORRECT WELDING PROCEDURES WOULD BE ASSIGNED REWORKED SEVERAL HANGERS - S&L EVALUATED SAFETY SIGNIFICANCE WITH NO ADVERSE CONDITIONS BEING IDENTIFIED 4

B. 55-82-12: BINDING OF SWAY STRUT / SNUBBER PIPING COMPONENT SUPPORTS

  • REVIEWED / MEASURED GREATER THAN 3000-STRUTS AND SNUBBERS TO ASSURE PROPER CLEARANCE IS PRESENT IN THE END BRACKETS AND PIPE CLAMPS TO ASSURE NO BINDING WHEN THE PIPE GROWS THERMALLY
  • REWORKED GREATER THAN 800 HANGERS t

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10/25/84 C. 10CFR21: INVESTIGATION OF GE PIPE CLAMPS FOR CONTROL ROD DRIVE INSERT AND WITHDRAW PIPING

  • IDENTIFIED THAT THE CLAMPS SUPPLIED BY GE ON THE INSERT AND WITHDRAW PIPING WERE NOT ASME SUBSECTION NF QUALIFIED AND DID NOT HAVE DESIGN CAPACITY TO WITHSTAND THE PIPING LOADS
  • DESIGNED NEW CLAMP AND REPLACED ALL OF THOSE SUPPLIED BY GE D. 55-84-02: MATERIAL TRACEABILITY
  • . NO MATERIAL HAS BEEN FOUND THAT DOES NOT MEET THE SPECIFICATION REQUESTED UNIQUE TRACEABILITY IS NOW PROVIDED BY HEAT NUMBER OR BA RECEIVING IDENTIFICATION NUMBER ,
  • MATERIAL TEST PROGRAM UNDER WAY I

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10/25/84 E. 55-84-03: CONCRETE EXPANSION ANCHORS

  • ~ VERIFIED HILTI EXPANSION ANCHORS USED IN PIPE SUPPORTS, INSTRUMENTATION SUPPORTS., et.al, WILL PERFORM DESIbN FUNCTIONS (ALSO NON-SAFETY INSTALLATIONS)
  • TESTED A SAMPLE OF 290 PIPING HANGER INSTALLATIONS AND FOUND l

NO CONDITIONS ADVERSE TO SAFETY AFTER S&L REVIEW l

  • CHANGED PROCEDURES AND TRAINED CRAFT FOR PROPER INSTALLATION AND QC PERSONNEL FOR PROPER INSPECTION

\

  • ALL HILTI EXPANSION ANCHORS ARE END STAMPED FOR LENGTH VERIFICATION AND WILL ONLY BE ISSUED TO CRAFT PERSONNEL WHO

'ARE QUALIFIED TO INSTALL-THEM.

F. 55-84 -12 : CONCRETE EXPANSION ANCHORS IN FINISHING SLABS

  • AS-BUILT ALL HANGERS WITH HILTI- EXPANSION ANCHORS EMBEDDED IN FINISHING SLABS
  • S&L WILL EVALUATE THESE FOR THEIR ABILITY TO PERFORM DESIGN FUNCTIONS 3

1

c 10/25/84

-G. NSED REVIEW OF HANGER CALCULATIONS l

- 1

-l

  • NSED PERSONNEL REVIEWED S&L LARGE BORE PIPE STRESS l CALCULATIONS AND VERIFIED THE LOADS GENERATED AND TYPE OF l HANGER REQUIRED BY THE STRESS REPORT ARE ACTUALLY USED AND DESIGNED PROP 5RLY H. OTHER ISSUES EXPLORED
  • SITE THREADING OF ROD STOCK FOR PIPE SUPPORTS NO SIGNIFICANT ISSUES
  • ASME SUBSECTION NF BOUNDRY STILL UNDER INVESTIGATION
  • - THREADS OF BOLTS IN PIPE CLAMPS BEING INCLUDED IN THE SHEAR PLANE NO SIGNIFICANT PROBLEMS i.

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