ML20137Z446
| ML20137Z446 | |
| Person / Time | |
|---|---|
| Site: | Braidwood  |
| Issue date: | 03/07/1986 |
| From: | Danielson D, Jeffrey Jacobson, Muffet J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML20137Z414 | List: |
| References | |
| 50-456-86-09, 50-456-86-9, 50-457-86-08, 50-457-86-8, NUDOCS 8603130039 | |
| Download: ML20137Z446 (15) | |
See also: IR 05000456/1986009
Text
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U.S. NUCLEAR REGULATORY COMMISSION
REGION III
Reports No. 50-456/86009(DRS); 50-457/86008(DRS)
Docket Nos. 50-456; 50-457
Licenses No. CPPR-132; CPPR-133
Licensee:
Commonwealth Edison Company
Post Office Box 767 -
Chicago,tIL 60690
Facility.Name:
Braidwood Station, Units 1 and 2
Inspection At:
Braidwood Site, Braidwood, IL
Inspection Conducted:
September 12, 26, October 29, November 19-21,
December 19, 1985; February 18, 24, 1986
bitmO
d
3 /7 bk
Inspectors:
J. W. Muffett
Date
([A, ttt
v
3)7)/'/
V . M. Jacobson
,
Date
,
. h Y
/L a
7-
/
3 7 }M
~
//
Approved By:
D. H. Danielson, Chief
Materials and Processes
Date
Section
Inspection Summary
Inspection on September 12, 26, October 29, November 19-21, December 19, 1985
and February 18, 24, 1986 (Report No. 50-456/86009(DRS); 50-457/86008(ORS))
Areas Inspected:
Licensee action on previous inspection related to the
retroinspection of safety related mechanical equipment installation and
procedural control of installation of safety related mechanical equipment
installation.
The inspection involved a total of 120 inspector-hours by two
NRC inspectors.
Results:
No violations or deviations were identified.
,
I
B603130039 960307
ADOCM 05000456
G
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DETAILS
1.
P_e_rs_ons Contacted
Connonwealth Edison,_(_CE_Cp)
- S. C. Hunsader, Quality Assurance Supervisor
- D. L. Shamblin, Project construction Superintendent
- P. L. Barnes, Regulatory Assurance Supervisor
- M. R. Dougherty, Project Construction Engineer
S_a,rgen_t__& Lundy Engineers
S. Putman, Structural Engineer
Phillips Getsch_ow Company
J. R. Stewart, Project Engineer
- Denotes those attending the final exit interview at the Braidwood
Station on February 24, 1986.
2.
Licensee Action on Previou_s_,Inspec_ti,on_ Fin _ ding.s
(Closed) Violation (50-456/82-05-04; 50-457/82-05-04); (Closed) 50.55E
a.
(456/82-07-EE; 457/82-07-EE) (Closed) Unresolved item (456/82-05-02;
457/82-05-02): Region III-Tracking Item No. 50-456/82-05-04;
50-457/82-05-04 was assigned to all of the deficiencies related to
the setting of safety rclated equipment identified in Sections 3.e.(1)
through (7) of Inspection Reports No. 50-456/82-05; 50-457/82-05.
The steam generator bolt (cap screws) traceability problems identified
in Sections 3.e.(2) and (4) of Inspection Report 50-456/82-05;
50-457/82-05 are resolved and closed out based upon the closure of
. Tracking Item No. 50-456/82-05-01; 50-457/82-05-01 docun'ented in
Inspection Report No. 50-456/82052; 50-457/82050.
These cap screws
are unique to the steam generator design and the design specifications
of no other equipment requires their use. The inspectors found no
instances of steam generator bolts used in other <pplicaticns. As
docunented in Inspection Reports No. 50-456/82-05; 50-457/82-05,
deficiencies were found to exist in the Quality Assurance progran for
the installation and inspection of safety-related mechanical equipment.
The licensee responded to the inspection report docunenting their
corrective actions in Cordell Reed's letter dated April 4,1983 to
James G. Keppler. The licensee developed new procedures-to cortrol
this activity and in addition the licensee performed a program to
reinspect safety-related mechanical equiptrent installed prior to the
revisicn of the procedure. Another purpose of the reinspection
program was to develop the Quality Assurance docunentation required
by Regulatory Guide 1.116 conrnitted to by the licensee in the FSAR
(Regulatory Guide 1.116 basically endorses ANSI N45.2.8 which
therefore becomes the controlling regulatory requirenent in the area
2
4
of mechanical equipment installation).
Inspection Reports
No. 50-456/85050; 50-457/85048 reviewed the Modified Procedure
QCP-B22 and found this procedure an acceptable method for controlling
compliance with ANSI N45.2.8.
In Inspection Reports No. 50-456/85050;
50-457/85048 a sample of 26 documentation packages (taken from a
total population of 216) developed by the reinspection program were
reviewed.
All of the packages reviewed conformed to the requirements
of QCP-022.
In January 1986, the licensee issued the final report on this issue,
" Report on Braidwood Safety-Related Mechanical Equipment Retrofit
Program." The purpose of this inspection report is to document the
NRC review of the final report and the activities performed during
the reinspection.
The NRC' review has revealed no disagreement with
the_results and conclusions of this final report.
The internal
cleanliness deficiencies ~ discussed in Commonwealth Edison's final
report will be reviewed and closed out as Region III tracking Item
No. 50 456/84-21-07; 50-457/84-20-07 in a future inspection report.
To clearly document the results of the NRC review individual topics
will be discussed in the following paragraphs.
(1) ANSI N45.2.8
ANSI N45.2.8-1975 is the. standard with details the Quality
Assurance requirements for installation and inspection of
mechanical equipment.
Installation inspections which are
required by the standard when appropriate are:
(a)~ Identification
(b) Location and Orientation of Components
(c) Levelling and Alignment
(d) Clearances and Tolerances
(e) Tightness of Connections and Fastenings
(f) Fluid levels and pressures
(g) Absence of leakage
(h) Physical integrity
(i) Cleanness
(j) Welding operations
(k) Adequacy of Protective Measures
(1) Adequacy of Housekeeping
The purpose of these inspections is to assure that safety-related
mechanical equipment is installed and inspected in a manner that
will provide adeouate confidence that the equioment will pei' form
its safety function Procedure QCP-822 specifically calls for the
,
inspection of the following items:
,
(a) Foundation check
(b) Bolt angularity
(c) Concrete expansion anchor documentation
(d) Torque on anchor bolts
(e) Thread engagement
3
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m
(f) Weld procedure
(g) Grout Release
(h) Grout Complete
(i) Piping Release
(j) Internal Cleanliness
(k) Driveline Cleanliness
(1) Lubrication complete
(m) Alignment complete
(n) Lubrication / Cooling piping complete
(o) Verify Equipment I.D.
These items are abbreviations of more complete activities
delineated in QCP-822 which adequately comply with the
requirements of ANSI N45.2.8.
(2) Retrofit Program Findings
The reinspection (retrofit) program discovered 156 discrepancies.
The discrepancies have either been dispositioned by a engineering
evaluation or modifications have been completed to assure
compliance with the original specifications.
Ihe final result is
that both the QA records and the equipment are in compliance
with ANSI N45.2.8.
The discrepancies are as follows:
l
!
I
4
r: -
q
",
.
,
.
-
U>
,
o
'
,
_
Distribution of Installation Inspection
Findings For All 216 Components Inspected
- \\x
'"
Documentation Package
.
Reviewed in-Inspection
"[ Component I. D.
-# Findings
~ Type of Findings
,,Rsport No. 85050
' ' DAB 01PA
3
-
.-
'OAB01PB 6 )
,-
t
0AB02DA
' 3 '-
'
c
a OAB02DB -
4
s ,
OAB02FB
-
-
.
g1
.
.s'
.IAF01PA
-
+
1
-
4
1AF01PB
2
HE, bowe'd piping
+
l
2AF01PA
'
-
+
,
2AF01PB
1
,
IBR01A
2
IC, 000.
+
.
2BR01A
2
PR, NW
i
.1BR03A
-
I'
2BR03A
-
-s
'0CC01A
2
GR, grout damage
. . .
OCC01P
2
.PR, IC
n.
1CC01A
4.
GR, NW, Grout defect, found
- '
'
pad not completely supporting
.
s
W
equipment
,g
' '
i
1CC01PA
-
1CC01PB
ts
-
2CC01A
,
-
.
2CC01PA
-
,
2CC01PB
-
,
)I
l
ICC01T
\\
6
HS, GR, Sect. XI, 00C. ,
'
I
',
.Qs
. Procedure conflict, A/E
'
',
'approv. missing
.s_
2CC01T
.
-2
Plate thick. incorrect,
_s
o
Sect. XI
'
1
'
1CS01PA
3
GR, PR, PWM
,'
ICS01PB
,3
GR, PR, PWM
.ICS01T
,-
+
'
2 2CS01PA;0
1
PWM
d 2CS01PB
1
PWM
n
).
2CS01T
-
'
.y'
l
,
"
'4
,
'
1CV01AA
-
i
1CV01AB
-
p ,2CV01AA
,
-
2CV01AB
-
. . _
ICVOIDA
-
ICV 01DB
-
ICV 01FA
-
ICV 01FB
x,s a
,-
-
'
,s
,
5
i
'
.
Distribution of Installation Inspection
,.
.
Findings For All 216 Components Inspected
Documentation Package
,
.
Reviewed in Inspection-
Component I. D.
- Findings
Type of Findings
Report No. 85050
'1CV01PA
2
GR, Mnfr. inspection
'
of install. not
performed
ICV 01PB
1
GR
2CV01PA
2
TE, EL
2CV01PB
1
i
ICV 01T
.1
PR
+
'
2CV01T
-
.
1CV02A
-
'
2CV02A
-
'
ICV 02D
1
1CV02F
-
1CV02P.
2
GR, TE
2CV02P
2
TE (2)
ICV 03AA
1
-AB
ICV 03AB
1
2CV03AA
1
Shim for contact
2CV03AB
-
,
ICV 03F
+
-
2CV03F
+
-
-
1CV04AA
3
HS, NW, HE
,
1CV04AB
1
HS
2CV04AA
-
2CV04AB
-
ICV 05A
1
2CV05A
1
+
,..
IDG01KA
2
MRR, AB
IDG01KB
1
MRR
IDG01SA
-
2DG015A
'
-
IDG01SA-C
-
+
-
1DG01SA-D
-
2DG015A-D
-
1DG01SB
-
2DG01SB
-
1DG01SB-C
-
2DG01SB-C
-
1DG01SB-D
-
2DG01SB-D
-
6
.
Distribution of Installation Inspection
Findings For All 216 Components Inspected
Documentation Package
Reviewed in Inspection
Component I. D.
.# Findings
Type of Findings
Report No. 85050
10001PA
-
10001PB
-
10001PC
-
10001P0
+
-
-
'
10002TA
-
+
20002TA
-
10002TB
-
20002TB
-
1D010T
-
20010T
-
IFC01A
1
HS
2FC01A
2
IFC01P
-
2FC01P
-
OGW01SA
1
OGWOISB
1
OGWO1TA
1
GR
+
OGWO1TB
1
GR
+
OGWO1TC
,1
GR
OGWO1TD
1
GR
OGWOITE
1
GR
OGWO1TF
3
EL, GR, TE
1PL50J
-
1PL52J
+
-
.
OPL53JA
-
+
!
l
OPL53JB
+
-
IPL53J
-
1PL54J
-
1PL55J
-
IPL56J
-
1PL57J
-
OPL60JA
-
OPL60JB
-
IPL60JD
-
IPL61JC
-
IPL61JD
-
1PL66J
-
1PL67J
-
IPL69J
-
IPL70J
-
1PL71J
-
1PL72J
-
7
.-
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Distribution of Installation Inspection
Findings For All 216 Components Inspected
Documentation Package
Reviewed in Inspection
Component I. D.
- Findings
Type of Findings
Report No. 85050
1PL74J
-
1PL75J
-
1PL76J
-
'
1PL81JA
-
2PL81JA
-
.1PL81JB
-
.
2PL81JB
-
1PL82JA
2
PR, IC
1PL82JB
-
2PL82JB
-
1PL84JA
-
2PL84JA
-
1PL84JB
-
PPL84JB
-
2PL85JB
-
IPL92J
-
1RC01BA
1
PR
2RC01BA'
1
PR
1RC01BB
3
D0C., MT, PR
2RC01BB
1
PR
1RC01BC
2
MT, PR
2RC01BC
1
PR
1RC01BD
1
PR
2RC01BD
1
PR
1RC01PA
-
2RC01PA
t
-
1RC01PB
-
2RC01PB
-
IRC01PC
-
2RC01PC
-
1RC01PD
-
2RC01PD
-
1RH01PA
2
GR, PWM
2RH01PA
1
PWM
1RH01PB
1
GR'
2RH01PB
-
1RH01SA
-
2RH01SA
-
1RH01SB
1
PR
2RH01SB
2
PR, IC
1RH02AA
4
EL, SLP, IC, PR
+
2RH02AA
-
1RH02AB
5
EL, SLP, IC(2), PR
+
2RH02AB.
2
AB, Grt, thick
8
c.
'
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Distribution of Installation Inspection
Findings For All 216 Components Inspected
Documentation Package
Reviewed in Inspection
Compon:nt 1. D.
- Findings
Type of Findings
Report No. 85050
1RY015
3
00C (2), TE
+
2RYO1S
-
ISIO1PA
3
2SIO1PA
-
ISIO1PB
2
IC(2)
2SIO1PB
1
15104TA
-
2SIO4TA
-
ISIO4TB
+
-
2SIO4TB
-
+
ISIO4TC
-
2SIO4TC
-
ISIO4TD
-
2SIO4TD
-
ISX01FA
2
GR, TR
2SX01FA
2
GR, arc strike
1SX01FB
2
GR,TR
2SX01FB
1
GR
ISX01PA
3
2SX01PA
-
ISX01PB
3
GR, TR, work w/o doc.
2SX01PB
-
IVA01SA
3
2VA01SA
2
GR, IC.
IVA01SB
2
GR, AB
2VA01SB
2
GR, IC
IVA025A
2
GR, IC
2VA02SB
-
+
IVA02SB
2
GR, AB
+
2VA02SB
1
GR
IVA03SA
1
GR
2VA03SA
1
NW
IVA0358
1
GR
2VA03SB
1
GR
IVA04SA
2
HE, IC
2VA04SA
-
IVA04SB
2
GR, IC
2VA04SB
-
+
1VA055
3
2VA055
-
IVA06SA
1
+
2VA06SA
-
9
n
.
Distribution of Installation Inspection
Findings For All 216 Components Inspected
Documentation Package
Reviewed in Inspection
Component I. D.
- Findings
Type of Findings
Report No. 85050
IVA07S
-
2VA07S
-
IVA08S
1
2VA085
-
IVP01AA
-
IVP01AB
-
IVP01AC
-
IVP01A0
-
OW001CA
-
OW001CB
-
OW001PA
-
OW001PB
-
OWX05T
-
TOTAL
216 Component 156 Findings *
- The findings presented in this table do not include fin ings reported under
programmatic NCRs that were written to address a broad class of related issues
such as storage and maintenance ((NCR 777), cleanliness (NCR 614), panel
installation (NCR 6103), and grout inspection (NCR 560)).
10
.
Symbols Used In Reporting Type of Findings
SYMBOL
Description of Findings
GR
No Grout Release or Grout Release hold point bypassed
Internal Cleanliness bypassed
PR
Piping Release bypassed or no piping release sign-off
Anchor Bolt. damage or out of tolerance or projection
Thread engagement
PWM
No preweld measurement, or not QC verified
DOC
Documentation filed improperly, or missing initial or dates or
wrong data
NW
Nut and washer concerns, loose nut, wrong nut, missing washer,
washer obstruction
EL
Equipment off location, or wrong component on location
TR.
No test release sign-off
HS
Anchor bolt hole size tolerances not met
HE
Anchor bolt hole elongation
SEC XI
Work not done under ASME Section XI where required
MRR
Work prior to MRR Approval
Nozzle end prep not HT examined
SLP
No Special lifting procedure
QC hold point. bypassed
Approximately 10,000 attributes of the 216 pieces of equipment
were inspected during the retroinspection program. Of the
approximate 10,000 attributes 156 were found discrepant during
the retroinspection (approximately 1.5% discrepant).
(3) Review of Additional Items
In addition to the random sample reviewed in Inspection Reports
No. 50-456/85050; 50-457/85048, a number of other pieces of
safety-related mechanical equipment were reviewed.
These are:
Unit 1 Steam Generators
1RC01BA; 1RC01BB; 1RC01BC; 1RC01BD
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Unit 2 Steam Generators
2RC01BA; 2RC01BB; 2RC01BC; 2RC01BD
Unit 1 RHR pumps
1RH01PA; 1RH01PB
Unit 2 RHR pumps
2RH01PA; 2RH01PB
Unit 1 Safety Injection pumps
ISIO1PA; ISIO1PB
Unit 2 Safety Injection pumps
2SIO1PA; 2SIO1PB
Unit 1 Primary Reactor Coolant pumps
1RC01PA; 1RC01PB; 1RC01PC; 1RC01PD
Unit 2 Primary Reactor Coolant pumps
2RC01PA; 2RC01PB; 2RC01PC; 2RC01PD
Unit 1 Containment Spray pumps
1CS01PA; ICS01PB
Unit 2 Containment Spr.ny pumps
2CS01PA; CCS01PB
The documentation packages associated with these pieces of
equipment have been reviewed and the following components have
been visually inspected by the NRC inspector:
ISIO1PA, 2CS01PB,
2RH01PB, IRC01PB, IRC01PA, 2RC01PD, 2RC01BD.
The documentation
complies with the requirements of ANSI N45.2.8 and is acceptable.
The visual inspection discovered no discrepancies.
Commonwealth Edison acknowledges that prior to 1982 an effective
program to control and document the installation of safety-related
mechanical equipment did not exist at the Braidwood Station.
As a
r,sult the QCP-822 procedure was developed and a retroinspection
(reinspection) program was performed.
These activities have assured
that the required inspections have been performed and their associated
documentation is properly controlled.
Based on the reviews of the
Procedure (QCP-822), the documentation associated with inspection of
installation activities, and the visual inspection of the equipment
both the documentation and the safety-related equipment installed
by Phillips Getschov Company prior the original violation are now in
compliance with ANSI N45.2.8 and are acceptable.
Also the controls
contained in QCP-B22 should minimize the possibility of reoccurrence
of these problems.
,
12
<
_ _ _ _ _ _ _ _ _ _ _ . _ - _ _ _ _ . _ _ _ _ . _ _ _ _ _ _ _ _ _ , _ . ____.____,_ , _ _ ___ _ _.._ ,_ ___ _, _ _ _ _ _ _ , . _ , _ _ . _ _ . _ _ _ . _ _ - . _ _ _ , . _ _ . _ _ _ _ _ . . . . _ _ _ _ _ . _
_ _ _ _ .
_
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(4) Steam Generator Bolting
Inspection Reports No. 50-456/85052; 50-457/85050, tracking
item 50-456/82-05-01; 50-457/82-05-01 documents review and
closure of this issue.
In addition, during this inspection
two of the damaged steam generator bolts, removed by Ceco
during the repair have been acquired by the NRC.
These bolts
were inspected by two NRC' inspectors, one a Hechanical Engineer
the other a metallurgist.
The inspectors came to the following
conclusions:
(a) Either excessive force or improperly fitting wrenches were
used on these bolts.
(b) There are marks on the head which appear to be caused by
blow by a hammer.
(c) Both bolts exhibit thread damage.
(d) One probable explanation for this type of damage is
misalignment, another is improperly manufactured threads.
In addition to the inspections documented in Inspection Reports
No.'50-456/85057; 50-457/85050, the bolts on the following steam
generators were inspected:
1RC018A
1RC01BD
2RC01BD
The bolts were found to be full tightened and appeared to be
properly seated with no deformation of the heads.
The documenta-
tion review found that all steam generator bolts to have been
removed, replaced, lubricated, and retorqued to the proper setting.
l
(5) Audits
i
Example 7 of the violation found in inspection report
i
No. 50-456/82-05; 50-457/82-05, states that "no audits were
}
performed by Ceco prior to June 30 - July 9,1980 relative to
!
mechanical equipment erection and inspection activities of
l
Phillips Getshow Company." During this inspection the NRC
!
inspectors reviewed the audit records from this period.
The
Ceco audit records shows the following:
(a) During the period of May 17-21, 1979, General Office Quality
'
i
Assurance audited the Braidwood site and identified that
i
PGCo Quality Control involvement in equipment setting was
j
not evident.
Equipment Erection Records were later produced
i
that demonstrated QC involvement for equipment grouting and
!
tightening of anchor bolts.
Based upon this the observation
j
was closed on August 31, 1979.
!
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13
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.
.-
- - - _ - . - - .
_-- . - . - .
.~.
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(b) On June 21, 1979, Site QA Audit No. 20-79-37 was performed
that addressed equipment installation. .The use of current
documents, and the use of qualified personnel, procedures,
materials, tools, and equipment were questioned.
Also the
presence of in progress inspection of the work and work
areas being done during equipment installation was checked.
[
No items of non-compliance were identified.
!
Therefore it appears that audits of this activity were
,
performed prior to June of 1980, however, subsequent NRC
-findings (Inspection Reports No. 50-456/82-05; 50-457/82-05)
'
l
appear to indicate the audits may not have been effective.
j
Based on review of audit records for audits subsequent to
inspection report 456/82-05; 457/82-05, review of installation
!
and QC inspection documentation and visual inspection of safety
i
related mechanical equipment it appears that Commonwealth
Edison is performing acceptable audits of this activity.
3
i
j
b.
(Closed) Unresolved item (50-456/82-05-03; 50-457/82-05-03):
As
documented in Inspection Reports No. 50-456/82-05; 50-457/82-05
certain discrepancies in the location of support columns for the
'
Steam Generators and Reactor Coolant pumps were discovered.
These
i
discrepancies concern the direction that the support columns lean
l
(toward the reactor or away from the reactor).
The significance of
!
the amount and direction that the columns lean is related to the
l
amount of rotational freedom at the spherical hinges in the columns,
i
The columns are designed so that they do not impede the thermal
expansion of the reactor coolant piping.
If the columns reach the
!
rotational limit the thermal expansion stresses in the reactor coolant
piping may increase,
Sargent and Lundy was asked to perform a detailed analysis of the
.
"as-built" situation regarding the columns at Braidwood.
Two columns
1
were found to have the potential to reach their rotational limit.
I
After the NRC inspector reviewed the "as-built" configuration and
!
calculations, he posed three questions for the licensee to address.
j
They are:
i
(1)
Is the change in stiffness due to modification of the base
attachment design significant?
'
(2)
If the column reaches the rotational limit and is forced to
bend will this be design significant?
(3) The cross over pipe is now extremely close to the support
column. Will there be significant thermal effects on either
the column or the piping?
14
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.
,
'
.
In addition, Westinghouse Electric Corporaticn was asked to review the
"as-built" configuration in response to the three questions and to
review the "as-built" configuration in relation to any significant
design concerns which may develop based on their experience.
The
three questions were adequately answered in a letter from
Mr. J. L. Tain of Westinghouse Electric Corporation to MR. D. L. Leone
of Sargent and Lundy on July 9, 1985.
In addition a letter from
J. L. Tain to D. L. Leone on September 12, 1985 states the following
" Westinghouse has reviewed the as-built condition of the reactor
coolant pump columns as described in your letters and finds it
acceptable." These actions adequately resolve the unresolved item
i-
j
50-456/82-05-03; 50-457/82-05-03.
J
3.
Exit Interview
The Region III inspector met with the licensee representatives (denoted
under Paragraph 1) at the conclusion of the inspection on February 24,
1986.
The inspectors summarized the purpose and finding of the
inspection.
The licensee acknowledged this information.
The inspectors
also discussed the likely informational content of the inspection report
with regard to documents or processes reviewed by the inspectors during
this inspection.
The licensee did not identify any such
documents / processes as proprietary.
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