ML20106D529
| ML20106D529 | |
| Person / Time | |
|---|---|
| Site: | Palo Verde  |
| Issue date: | 10/15/1984 |
| From: | Van Brunt E ARIZONA PUBLIC SERVICE CO. (FORMERLY ARIZONA NUCLEAR |
| To: | Bishop T NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V) |
| References | |
| ANPP-30852-TDS, DER-83-53, NUDOCS 8410260025 | |
| Download: ML20106D529 (10) | |
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- nECEWEb ur.c Arizona Public Service Company 19 OCT 22 13; 10 5 i 9MKN Y!'E October 15, 1984 ANPP-30852-TDS/'IRB U. S.. Nuclear Regulatory Commission Region V~
Creekside Oaks Office -Park 1450 Maria Lane - Suite 210 Walnut Creek; California 94596-5368 Attention: Mr. T. W. Bishop;' Director Division of Reactor Safety and Projects
Subject:
' Final Report - DER 83-53 A 50.55(e) Reportable Condition Relating To Unit 3 Embed Plates Do Not Meet Specification Of WPP/QCI Requirements.
File: 84-019-026;-D.4.33.2
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Ref erence: A) Telephone Conversation between P. Narbut and R. Tucker on August 1, 1983 B) ANPP-27597, dated August 26; 1983 (Interim Report)
C) ANPP-28323, dated November 30, 1983 (Interim Report)
D) ANPP-28799; dated February 6; 1984 (Interim Report)
E) ANPP-29532;' dated May 17; 1984 (Time Extension)
Dear Sir:
Attached is' our final written report of the Reportable Deficiency under 10CFR50.55(e), ref erenced above.
Very truly yours; CULL.,
>\\ L A
E E. E. Van Brunt, Jr.
APS Vice President Nuclear Production ANPP Project Director
-EEVB/TRB/nj Attachment cc: See Page Two L
8410260025 841015
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v s-Mr. T.,W. ' Bishop -
! DER:83-53 Page Two' cc:'
Richard DeYoung, Director.
Office 'of Inspection and Enforcement U. S. Nuclear Regulatory: Commission -
Washington, D. C.
20555 s
Th.G. Woods, Jr; D. B. Karner W. E. Ide D. B. Fasnacht A. C. Rogers L. A. Souza
,D. E. Fowler T. D. Shriver C.. N.- Russo J. Vorses
- J. 'R. Bynum J. M. Allen JA.1% Gehr
.W. J. Stubblefield-W. G.. Bingham R. L.~Patterson R. W. Welcher H. D. Foster D. R. Hawkinson R. P. Zimmerman -
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L. Clyde M. Woods "C
T. J. Bloom i:
-D. N. Stover J. D. Houchen J. E. Kirby.
D. Canady
-Records Center Institute of Nuclear Power Operations 1100 Circle 75 Parkway, Suite 1500 Atlanta, GA 30339
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1 FINAL REPORT - DER 83-53 i
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DEFICIENCY EVALUATION 50.55(e) i
' ARIZONA PUBLIC. SERVICE -COMPANY ( APS)
- PVNGS UNITS 1, 2, 3 I escription of -Deficiency
- I '. -
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= DuringL the removal of a damaged beam in the Unit 3 Containment Building, as documented on'Nonconformance Report (NCR)
CC-4043, it was discovered that two type N wall embed plates were installed without any anchor. bolts.- This finding was
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documentedJon NCR CC-4201.'.
Evaluation
. As a result 'of ' the findings :in Unit ' 3, a field walkdown
-program.was initiated to inspect all accessible wall embed plates f or all Unit 3 buildings.. The decision to inspect wall embed plates was based on the construction practice employed of inserting threaded anchor bolts in the plate af ter attachment of the plate to the form. This ' practice makes it
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.more difficult torverify complete thread engagement of anchor U
bolts, prior to. concrete placement. Verification of thread engagement is accomplished af ter the concrete forms are removed. Embed' plates placed in other areas, such as slabs, are generally placed with. anchor bolts already inserted.
Approximately 20,000 plates with. 190,000 bolts were inspected
- in Unit 3 and NCRs were. issued to document missing bolts, bolts having thread engagement less than required by
. Specification 13-CM-308,. and bolts covered by. attachments on 4
plates which did not have a post-concrete placement inspection. The results of the Unit 3 inspection are summarized in Table I.
. As a precautionary measure, approximately 10% of wall embed plates in Units 1 ~and 2 'were randomly selected by Engineering at each level of.each building for field inspection. During inspection, the walkdown personnel inspected an additional number of plates in areas adjacent to those plates selected in F'
the original 10%. The number of additional pictes inspected was approximately 30% in Unit 1 and 40% in Unit 2.
Only those additional plates with nonconformities were reported.
Furthermore, ~ due to a finding in the Unit 2 Auxiliary Building of one plate with all 10 anchor bolts missing, all wall embed plates.in the Unit 2 Auxilia:f Building which support heavier loading were also inspected. The results of the Unit 1 and Unit 2 inspection are summarized in Tables II and III respectively.
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? DER ' 83-53 4.Page-Two=
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1 TABLE I INSPECTION RESULTS'- UNIT 3 (100%* - APPRCXIMATELY 20,000 Plates) 1s0. OF EMBED PLATES TOTAL WITH NO. OF NO. OF NO. OF NO.
TOTAL BOLTS BOLTS' BOLTS PLATES i
EMBED NO.
COVERED COVERED REQUIRING
'WITH.
NO. OF
- FLATES OF BY-BY PLUG
' MISSING BOLTS
- BLDG.
NCR NO.
- REPORTED BOLTS ATTACH.
ATTACH.
WELD BOLTS _ MISSING Diesel / Gen CG-4259 78
.774 8
9 181 1
2
. Fuel:
CF-4260 557 3442
. '441
. 976
'194-0 0
Control' CJ-4261 180 1182 17 25 345 i
1 Containment CC-4262-80
'796 7 -
29 106 99-1 1
' Containment-CC-4263
'39 321 39 74-0 0
0 Tunnels CY-4264 11 126 4
7 11 0
0
. Containment-. CC-4265 65 516 9
16 120 0
0 Containment-CC-4266 196 1898 42 146 347 0
0 Auiliary CA-4267 168 1682 13 33 236 4
11 Turbine-CT-4286 88 715 85 249 9
1 10 Radwaste.
CR-4 310 1
1 0
0 0
1 1
~ Auxiliary _
CA-4460 38 324 2
2 52 0
0
- TOTALS.
1,501
-11,776 689 1,643 1,594 9
26
- 100% of accessible wall embed plates e
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. DER 83-53' Page Three TABLE II INSPECTION RESULTS - UNIT 1 (NCR CX-4563)
INITIAL 10% - APPROXIMATELY 2,000 PLATES Y
N0.' OF EMBED PLATES
, TOTAL; WITH NO. OF NO. OF NO. OF NO.-
. TOTAL-BOLTS BOLTS BOLTS PLATES
. EMBED
'NO..
. COVERED-. COVERED REQUIRING WITH NO OF
' PLATES:
OF' BY BY PLUG MISSING BOLTS BLDG.
-REPORTED BOLTS ATTACH. ATTACH.
WELD BOLTS MISSING Fuel' 4
32 1
1 5
0 0
Diesel / Gen
'4 42 1
1 5
0 0
' Control 7
63' 0
0 10 0
0 MSSS 14 144 6
20 21 0
0 Tunnels-1 12 0
0 1
0
.0 Containment 6
58 2
5 15 1
2
' Auxiliary 28 270 5
6 32 1
1 Turbine 5
32 1
1 10 0
0 Radwaste 3
30
=1 2
3 0
0 TOTALS 72 683 17 36 102 2
3 ADDITIONAL 30% - APPROXIMATELY 6,000 PLATES Fuel 3-26 1
1 3
0 0
. Diesel / Gen 5
50 1
2 8
0 0
Control 2.
8 1
1 3
0 0
'MSSS 12 113 4
19 35 0
0 Tunnels 7
70 2
3 9
0 0
Containment 8
67 2
2 9
2 3
Auxiliary 85 805 15 25 101 2
4 Turbine 3
18 1
2 6
0 0
Radwaste 5
50 0
0 7
0 0
TOTALS 130 1,207 27 55 181 4
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DER 8F53.
Page'Four
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TABLE III INSPECTION RESULTS UNIT 2 (NCR CX-4564)
~ INITIAL 10% - APPROXIMATELY 2,000 PLATES NO. OF EMBED
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PLATES TOTAL WITH NO. OF NO. OF NO. OF NO.'
~ TOTAL BOLTS BOLTS ROLTS PLATES EMBED
.NO.
COVERED COVERED REQUIIING WITH NO. OF PLATES OF BY BY PLUG MISSING BOLTS BLDG.
REPORTED BOLTS ATTACH. ATTACH.
WELD BOLTS MISSING s
Fuel.
6
'54 1
1 10 0
.0 Diesel / Gen 2
20' O-0 2-0 0
Control.
13 94 0
0 13 1
1 MSSS
'2 19 0
0 5
0 0
Tunnels 1
12 1
3 1
0 0
Containment 3
29 1
4
-3 0
0 Auxiliary-36-
'329-6 10
'40 1
1
= Turbine
~4 34 0
0 8
0 0
-'Radweste 10-94 2
3 11 0
0' TOTALS:
,TT 685 11 21 93 2
2 ADDITIONAL 40% - APPROXIMATELY 8,000 PLATES Fuel 7
54 1
2 8
0-0 Diesel / Gen-
.3 24 0
0 2
1
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-Contro1 ~
4 34 1
1 4
0 0
. MSSS.
7 64-2 4
12
-1 2
L Tunnels
.1 10 0
0 2
0' O
containment:
5 20 0
0 10 0
0 72 646 7
9 93 2
11*
3.f. Auxiliary __
2 14 1
2 2
0 0
Turbine Radwaste
. 3 30 1
1 4
0 0
TOTALS.
T5T T9T TI TF TIT T
- Includes one' plate with all 10 bolts missing.
ALL HEAVILY LOADED PLATES IN AUXILIARY BLDG.
1 (APPROXIMATELY 1,050 PLATES INSPECTED) l
Auxiliary-25 262 13 18 29 2
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DER _83-53
' 1 Page Five r.4 The inspection revealed plates.which had missing bolts, bolts
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having thread engagement less than required by Specification -
13-CM-308, and -bolts covered by attachment which did not. have a _ post-concrete placement inspection. With the exception of
' four plates found with 'all anchor -bolts missing, all reported conditions have been evaluated to be acceptable f or the actual
. loading conditions. Based on this evaluation, only plates found with all anchor bolts missing are considered to be Edefective and not able to perf orm the intended function.
The table below gives the estimated number of plates inspected-
= in Units 1, 2, and 3 and the number of plates found to have all bolts missing. These plates are considered defective and the' appropriate corrective action was taken as_ prescribed in the NCR disposition.
Number of Embed Number of Unit No.
Plates Examined Defective Plates (a)
'l 8,058 (est) 0 2
11,193 (est) 1 3
20,000 (est) 3 TOTALS 38,251 4'
(a) All anchor bolts missing The f requency of occurrence of defective plates, as illustrated by 'the above data, is such that these cases can be considered isolated and not indicative'of any deficiency in the overall construction or quality verification programs.
The root cause is attributed to the failure of craf tsmen to install plates per design drawings plus the f ailure of QC to detect the craf tsman's error. Nonconformances related to thread engagement of anchor bolts are believed to be a result of the technique used to inspect bolt recess f rom the f ace of the' embed plate.
Project Work Plan Procedure WPP/QCI 54-0, Revision 11, 'which was in effect at the time this work was 1.
done, lacked specific definition of how to perform the inspection utilizing the appropriate tools and only required visual inspection for proper anchor bolt thread engagement.
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- Page'Six-1 l
II..
Analysis of Safety' Implications-
- The lack of adequate' anchorage for'an embed. plate could cause c the' plate to f ail.when subjected to its design load. - Failure of.the embed plate could damage safety-related systems and/or
- equipment.- Therefore, the condition-reported herein is 4
considered safety significant and _ is evaluated as reportable r-1
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under the requirements of.10CFR50.55(e). This condition is
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evaluated as not reportable:under the' requirements of 10CFR
'Part:21 since it does not involve a defect in a basic component.
III.'
-Corrective Action The following corrective actions have been implemented by Engineering:
A. U_ nit 3
- 1. The two defective Type N embed plates in the Unit 3 Containment Building, documented in NCR CC-4201, were replaced by new plates attached to the concrete with Maxi-bolts in accordance with Specification No.
13-CM-307.
- 2. The anchor bolts with visible thread engagement less than required by Specification 13-CM-308, documented in -
the tabulated NCRs,' were plug welded in accordance with Section 7.4 of Specification No.13-CM-308 (except in the elevator shaf t of the Auxiliary Building-NCR CA-4460, where anchor bolts with recess greater than v
.3/16" were plug welded).
- 3. One embed plate on the Turbine Pedestal without any v-anchor bolts was removed and deleted from the Unit 3 Engineering design drawing (documented in NCR CT-4286),
since it was not being utilized.
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DER!8h53
<-PagelSeven-
.4. Embed plates wit.h (a) bolts covered by attchments and
.:(b) missing bolts (1 or 2 = bolts missing) were evaluated
. based on the assumptions -that the bolts covered by the
- = -
Eattachments are existing but. with 1/4" recess f rom the face of:the plates;- AM. embed plates were found to be
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structurally acceptable as the "as-built" embed plate design capabilities are higher than the applied loads.
(Approximately 97%.of evaluated plates are loaded to
- 25%,
- or less, of their calculated capacities.) However, LDCNs have been issued for the few plates with heavier-loading conditions: to prevent additional attachments and
. loads without : prior Engineering evaluation and approval.
Bolts covered by attachments have been randomly selected by Engineering f or field inspection to verify the existence'of the bolts'and the conditions of thread' eagagements. The number of the selected plates; represents 32% of the embed plates with' heavier ~1oading conditions. Results. of this inspection verified '
assumptions made. relative to bolt existence and thread engagement.
(2;
- 15. Subsequent to completion of the inspection of accessible wall embed plates,~it was determined that embed plates installed on the bottom'of beams.and slabs, i.e.,
soffit embed' plates, may have been installed in the same manner as wall embed plates. Based on this, a 100% inspection
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of accessible ~. soffit embed plates will be performed prior to fuel load sin' Unit 3.
All nonconformances will be reported in.accordance with project procedures and will be cross-referenced to this DER.
B. Units 1 and 2
- 1. One defective Type J embed plate in the Unit 2 Auxiliary Bu!1 ding documented in the NCR CA-4423, was corrected ' by adding Maxi-bolts'to anchor the existing plate to the concrete in accordance with Specification No.13-CM-307.
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' ! DER 83-53 lPage Bight,
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- 2. Embed plates with (a) bolts with visible thread engagement less than required by Specification 13-CM-308
-(b) bolts covered by attachments and (c) missing bolts w
-(1 or 2 missing bolts per plate) were evaluated based on l
1' the assumptions that the bolts. covered by the attachment are existing' ~ but with the same amount: of thread engagement recess as those visible on the plate. Field inspections were made to verify Engineering assumptions relative to bolt existence and' thread engagement. Thc -
evaluation revealed that approximately 94% of plates were loaded'to 25%, or less,.of their calculated
- capacities.- Plates which have thread engagement less -
than required by Specification 13- 01-308 but which have been shown by Calculation 13-CC-ZS-015 to have nc reduction in rated capacity'will be accepted "as-is" with no plug welding required. Plates which require a reduction in capacity-due to excessive bolt recess
'and/or missing bolts, bot which have been shown by
- Calculation 13-CC-ZS-015 to be able to adequately 7
support existing attachments, will be accepted "as-is" with no rework but will be identified on drawings to require prior Engineering approval for any future attachments. These plates will also be identified in the field by a permanent (engraved) marking to warn L
against making any further attachments without prior
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Engineering approval. ' Plates which cannot adequately support ~axisting attachments due to excessive bolt recess and/or missing bolts will.be reworked by plug welding and/or providing alternative anchorage.
- 3. Base-1 on' results of the partial (10%) inspection, a 100%
inspection of accessible wall and soffit embed plates will be performed. Special CIP No. 553.0 was ' issued by Construction to provide procedures and documentation for this inspection. All work in Unit 1 was completed by September 1, 1984 and will be completed prior to fuel load in Unit 2.
C. Project Work Plan Procedure 54.0 has been revised to I
require inspection for anchor bolt thread engagement using a depth gauge.
D. Other work plan procedures have been reviewed and revised as applicable to provide adequate criteria and inspection requirements. This is documented in the project's :asponse to the NRC CAT audit (ANPP-28749-EEVB/WEI, dated January 31, 1984).
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