ML20137G635

Draft Trip Rept 2178 of 851029-31 Site Visit Re Item Vii.C, Const Reinsp/Documentation Review Plan

ML20137G635
Person / Time
Site:	Comanche Peak
Issue date:	11/21/1985
From:	Flaherty J, Rivard J TELEDYNE ENGINEERING SERVICES
To:	TELEDYNE ENGINEERING SERVICES
Shared Package
ML20137G619	List: ML20137G616 ML20137G635
References
2178-DRFT, NUDOCS 8601210121
Download: ML20137G635 (8)

Text

I WTri m(NE g ENGINEERING SERVICES TRIP REPORT NO. 2178 PROJECT 6410T VISIT OF JAMES A. FLAHERTY AND JAMES J. RIVARD TO COMANCHE PEAK F0P AUDIT OF CPRT ACTION PLAN ITEM NUMBER: VII.C CONSTRUCTION REINSPECTION / DOCUMENTATION REVIEW PLAN October 29-31, 1985 The scope of this audit was the in-depth review to establish if homogeneity of the work process and attributes had been achieved for selected populations in the mechanical and structural area being performed by ERC as part of Item VII.C of the program plan. This was an extension of the previous trip of October 16 through 18, 1985, which was also held at the Comanche peak site.

TES met with other members of the NRC audit team, Tuesday, October 29, 1985 at the ERC trailer. Evangelos Marinos of the NRC was the audit leader. James J. Rivard was assigned to the structural area. James A. Flaherty was assigned to the mechanical / structural area and Robert Masterson of EAS was also assigned to the mechanical / structural area to specifically review piping and pipe-support populations.

Tuesday afternoon, I sat with R. Masterson and discussed the areas he had reviewed. Bob had reviewed rigid and non-rigid large-bore pipe-support populations. In addition, I sat in on a discussion on large-bore /small-bore piping welds.

I. PIPE WELDS / MATERIAL POPULATION ERC has revised the welding population and work processes since the audit of October 16. The revised population combines large-bore and small-bore piping weld, since the same weld-procedure specifications were used.

With'in the welding process, two welding methods were used: Gas Tungsten Arc Welding (GTAW) and Shielded Metal Arc Welding (SMAW). Both methods were utilized for carbon- and stainless-steel welding and were performed by the same work force. Therefore each welding method will have a minimum of 60 randomly selected samples. This revision of the Pipe Welds / Material Population Group (PIWM) removes my concern, which was raised during the October 16, 1985 audit. This is a more homogneous approach to the PIWM reinspection.

Bob Masterson reviewed the original Brown and Root specification. It was noted that the original specification required noting of cleanliness and listing of any base-metal defects. The attributes listed on the PIWM checklist did not include these two elements. ERC was asked to review and coment.

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'. Trip Report ENGFEERING SERVICES No. 2178 II. MECHANICAL EQUIPMENT INSTALLATION The afternoon and evening of Tuesday, Octobar 29, 1985, James A.

Flaherty reviewed the Mechanical Equipment Installation (MEIN) population.

The following documents were reviewed.

a. Work Process Definition for MEIN.

b. Population Description.

c. Population Item List.

d. QI-059, Revision 0, Draft Procedure Quality Instruction for Issue Specific Action Plan (ISAP) VII.C., " Reinspection of Mechanical Equipment Installation").

e. Original Mechanical Erection Specification 2323-MS-101, Revi-sion 4, 6/28/84, Gibbs & Hill, Inc. Specification.

f. Brown & Root Specification MCP-1, 8/1/84, Revision 4, " General Installation of Mechanical Equipment".

g. Brown & Root QI-QAP-11-1-39, Revision 4, 6/11/84, " Mechanical Equipment Installation Inspection Procedure".

h. Brown & Root, CCP-24, Revision 4, 6/26/80, " Rigging".

i. Brown & Root, " Grouting Base Plates, Bearing Plates and Equip-ment Bases, CCP-16, Revision 4, 2/8/84.

j. Brown & Root, " Installation of Hilti Drilled-In Bolts, CEI-20, Rvision 9, 12/16/83.

There are currently three work processes being reviewed. The welding work process has been deleted from the MEIN population and, as of October 28, 1985, has been put in the appropriate pipe weld work process.

ERC is also reviewing the deletion of grout from the attribute list and is establishing a new population that specifically addresses grout. This change is due primarily to the way documentation was established.

The ERC reinspection procedures and orginal construction specifica-tions and procedures were reviewed and compared for homogeneity of work processes and choice of generic attributes. The writer feels that all attributes listed are appropriate and cover the original construction sequence.

Five documentation packages from the sampled population were reviewed for completion of documentation and comparison to general specifications and attribute list.

The five documentation packages reviewed were:

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', Trip Report ENGrEERING SERVICES No. 2178 1. Service Water Pump, P.O. CP-010-001 Rotating equipment installed per Hayward Tyler manual. Manual gave specific tolerances on parallel alignment between motor half coupling and collar.

2. Pressurizer, P.O. -0001-18 All dimensions for installation are per Westinghouse drawings.

3. Safety Injection Pump, TBX-SIAPSI-01 and 02 Specified tolerances on rim-to-rim and face-to-face coupling alignment. A requirement was also given on vibration tolerance.

In a discussion with ERC, ERC stated that this attribute may be added to attribute list as a documentation check.

4. Centrifugal Charging Pump, TBX-CSAPCH-01 and CP-0001-024 for Unit 1 Installation is per manuf acturer manual. This pump is part of the Chemical and Volume Control System and was fabricated by Pacific Pumps.

5. Motor-Driven Auxiliary Feedwater Pumps, P.O. CP-007-001 Alignment is per manufacturer's specifications. Criteria given for checking anchor bolts, level and alignment and grouting.

6. Excess Letdown Heat Exchanges Criteria given for backing off of foundation bolts to allow for thermal growth. Requirement given by Westinghouse.

The above six mechanical component document packages were well doc-umented and the appropriate attributes listed on the ERC checklist. The only open item was the vibration attribution documentation check, which ERC is reviewing.

III. PIPING SYSTEM BOLTED JOINTS / MATERIAL On Wednesday, October 30, James A. Flaherty reviewed the Piping System Bolted Joints / Material Population. The following ERC procedures were reviewed:

(a) Work Process Definitions.

(b) Population Description.

l (c) Population Items List.

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i@ WE t Trip Report ENGNEERNG SERVICES No. 2178 (d) QI-021, Revision 1, " Reinspection of Piping System Bolted Joint Material.

During the October 18 audit, the NRC audit teams raised a concern on torque being an attribute and not a work process. The concern was relative to equipment specifications requiring a specific torque value on certain types of flanges and the reinspection attribute not containing sufficient samples. In the discussion with ERC, it was noted that there are approx-imately 7000 items in the piping system bolted joint population. Of the approximately 7000 items, 6700 are in line-piping connections which were installed in accordance with Brown & Root Procedure CP-CPM 6.9E. Sec-tion 3.12 of the B&R procedure did not require a specific torque value to be used. The governing requirement was that the joint "shall be tightened sufficiently to prevent leakage during pressure testing". Since ISAP VII.C is addressing QC-accepted items, only reinspection per the original spec-ification is required. The only flanges which may have required specific torque values would therefore be in the Mechanical Equipment Population.

ERC has reviewed the MEIN population and has only found approximately six flanges which required specific values. Therefore the issue raised during the October 16 audit is no longer an issue to this auditor.

It was also noted that the Population Description and Population Item Lists will be revised to delete instrument flanges. These will now be included in the electrical area.

IV. HVAC EQUIPMENT INSTALLATION This population was reviewed Wednesday af ternoon. This was a con-tinuation of the audit of October 16 on homogeneity of the population. The following ERC procedures were reviewed.

a. Work Process Definitions.

b. Population Items List.

c. QI-023, " Reinspection of HVAC Equipment".

This population has been modified based on a concern raised during the October 16 audit. The work process for Equipment Setting by Brown &

Root has been deleted and will be combined with the MEIN population since the same B&R procedures and installation specifications were used.

V. HVAC DUCTS AND PLENUMS This population contains all passive equipment in the safety-related HVAC system whereas the HVAC equipment population contains only active items.

The following ERC procedures were reviewed.

a. Work Process Definitions.

b. Population Description.

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'i Trip Report ENGNEERNG SERVICES No. 2178 c. Population Items List.

d. QI-039, " Reinspection of HVAC Ducts and Plenums".

QI-039 has been issued and is very detailed. It contains much of the original documents and sketches required during the construction phase.

The document review procedure has not been completed yet.

VI. PIPE WHIP RESTkAINTS James A. Flaherty was given an overview of the Pipe Whip Restraint Population. This population consists of moment restraints, pipe whip restraints and restraint support structures listed in Section 3.6 of FSAR.

Due to the original construction, two populations may be established, one for the restraint and one for the support structure. Nine systems have postulated line breaks. Some restraints are listed by Gibbs and Hill and other restraints are listed by Site Damage Group. At this time ERC is still reviewing the work process and is establishing which groups were responsible for installation.

VII. CONCRETE PLACEMENT POPULATION James J. Rivard reviewed the Concrete Placement Population Tuesday afternoon and Wednesday morning, October 29 and 30, 1985. During this time the following documents were reviewed to determine if homogeneity of the work processes and attributes had been achieved.

a. ERC's Work Process Definitions for Concrete Placement Popula-tion.

b. ERC's Population Description for Concrete Placement, 8/5/85.

c. ERC's Population Description for Concrete Placement, 8/5/85.

d. ERC's Population Items List for Concrete Placement, 9/5/85.

e. Procedure QI-043, Revision 0, 9/16/85, Procedure, Quality Instructions for Issue-Specific Action Plan No. VII.C,

" Reinspection of Concrete Placement".

f. Gibbs and Hill Specification 2323-SS-9, 1/16/79, " Concrete".

g. Gibbs and Hill Specification 2323-SS-30, 2/10/84, " Structural Embedments".

h. Brown & Root Construction Procedure 35-1195-CCP-11, " Concrete Placement", Rev. O.

The concrete placement population is presently subdivided into three work processes, each work process having various numbers of attributes.

Some of the attributo are to be reviewed by means of a field reinspection;

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SPTF1 STVNE I Trip Report ENGINEERING SERVICES No. 2178 others can only be reviewed by means of a document review; and some will be reviewed utilizing both field reinspection and documentation review. The field reinspection was in progress at the time of this audit and the doc-umentation review had not yet begun. No reinspection packages were reviewed.

Thc reviewer has a few concerns; however, he feels that in general the reinspection of concrete placement's work processes .ind attributes does achieve an appropriate level of homogeneity. These concerns were discussed with ERC and were lef t as open items. The following is a list of open-items which ERC should address:

1. It may be more appropriate to establish cadwelds as a work process rather than as an attribute. ERC is to review the cad-weld inspection procedure and the concrete pour card sign-off requirements to determine whether cadwelds should be a separate work process.

2. ERC to consider establishing Richmond Inserts as a separate attribute instead of including it with the embedment attribute.

3. ERC to determine if the condition exists where embedded pipe sleeves are used to anchor the piping system. If this situation does exist, the embedded sleeves should be a separate attribute.

VIII. STRUCTURAL-STEEL POPULATION On Wednesday afternoon, October 30, 1985, James J. Rivard performed a review of the structural steel population. At this time only a cursory review was done to determine if the concept of choosing work processes and attributes would achieve acceptable homogeneity. A limited review of the following documents was performed.

a. Procedure QI-045, Rev. 1, 10/23/85, and Change Notice 001, 10/23/85, Quality Instructions for Specific Action Plan VII.C, Reinspection Procedures for Structural Steel,

b. ERC's Description Memorandum for Reinspection of Structural Steel:

1. Rev. O, 9/15/85

11. Rev. 1, 10/8/85 111. Change Notice to Rev. 1, 10/23/85

c. Gibbs and Hill Specification 2323-5S 16B, " Structural Steel",

5/12/75.

d. TUGC0 Instruction QI-QP-11.0-15. " Verification of Baseplates for Grouting", Rev. 8, 3/13/85.

After performing this general overview of the structural-steel reinspection activity, it is felt that the work processes and attributes

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• ( Trip Report ENGREERNG SERVICES No. 2178 identified generally will achieve acceptable homogeneity. However, a more detailed audit of the reinspection procedures will be required to make more detailed comments.

One item of concern identified is grouting. This should be a separate population since it is now not appropriately being reinspected.

An ex't interview was held the afternoon of Wednesday to cover those areas reviewed by all members of the audit group. Comments and open-items are given above in the specific population. James A. Flaherty and James J.

Rivard left Dallas for Boston, Thursday, October 31, 1985.

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others can only be review d by means of a document review; and some will be reviewed utilizing both field reinspection and documentation review. The field reinspection was in progress at the time of this audit and the doc-umentation review had not yet begun. No reinspection packages were reviewed.

The reviewer has a few concerns; however, he feels that in general the reinspection of concrete placement's work processes and attributes does achieve i.n appropriate level of homogeneity. These concerns were discussed with ERC and were lef t as open items. The following is a list of open-items which ERC should address:

1. It may be more appropriate to establish cadwelds as a work process rather than as an attribute. ERC is to review the cad-weld inspection procedure and the concrete pour card sign-off requirements to determine whether cadwelds should be a separate work process.

2. ERC to consider establishing Richmond Inserts as a separate attribute instead of including it with the embedment attribute.

3. ERC to determine if the condition exists where embedded pipe sleeves are used to anchor the piping system. If this situation does exist, the embedded sleeves should be a separate attribute.

VIII. STRUCTURAL-STEEL POPULATION On Wednesday afternoon, October 30, 1985, James J. Rivard performed a review of the structural steel population. At this time only a cursory review was done to determine if the concept of choosing work processes and attributes would achieve acceptable homogeneity. A limited review of the following documents was performed.

a. Procedure QI-045, Rev. 1, 10/23/85, and Change Notice 001, 10/23/85, Quality Instructions for Specific Action Plan VII.C, Reinspection Procedures for Structural Steel.

b. ERC's Description Memorandum for Reinspection of Structural Steel:

1. Rev. O, 9/15/85

11. Rev. 1, 10/8/85 iii. Change Notice to Rev. 1, 10/23/85

c. Gibbs and Hill Specification 2323-SS 168, " Structural Steel",

5/12/75.

d. TUGC0 instruction QI-QP-11.0-15, " Verification of Baseplates for Grouting", P.ev. 8, 3/13/85.

After performing this general overview of the structural-steel reinspection activity, it is felt that the work processes and attributes