ML20137Z446

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Insp Repts 50-456/86-09 & 50-457/86-08 on 850912-860224.No Violations or Deviations Noted.Major Areas Inspected: Licensee Action on Previous Insp Findings Re Retroinsp of safety-related Mechanical Equipment Installation
ML20137Z446
Person / Time
Site: Braidwood  Constellation icon.png
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)
v • d • e


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

Inspectors: J. W. Muffett bitmO d 3 /7 bk

Date

([A, ttt v

V . M. Jacobson 3)7)/'/ ,

,

Date

Approved By:

.D.hH.YDanielson,

/L a 7-

Chief

~

/7 }M

3//

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.

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B603130039 960307

PDR ADOCM 05000456

G PDR

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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

a. (Closed) Violation (50-456/82-05-04; 50-457/82-05-04); (Closed) 50.55E

(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

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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

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(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:

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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 t 6 ) ,-

0AB02DA ' 3 '- . AB(2),- QC

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c

a OAB02DB - 4 AB(2),IC,QC s ,

-

OAB02FB -

.s' .

g1 .

-

.IAF01PA -

1 4 +

1AF01PB 2 HE, bowe'd piping +

l

2AF01PA '

,

-

+

2AF01PB 1 AB

,

IBR01A 2 IC, 000. + .

2BR01A 2 PR, NW i

.1BR03A -

I' 2BR03A -

-s

'0CC01A 2 ... GR, grout damage l

OCC01P 2 .PR, IC

n. 1CC01A 4. GR, NW, Grout defect, found

  • ' '

. pad not completely supporting

s

W

,g equipment

' '

1CC01PA

-

i

1CC01PB - ts

,

. 2CC01A -

,

2CC01PA -

2CC01PB ,

-

l

)IICC01T '

\ 6 HS, GR, Sect. XI, 00C. ,

I ', .Qs . Procedure conflict, A/E '

',

.s_ 'approv. missing

2CC01T _s

.

-2 Plate thick. incorrect,

o Sect. XI

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1CS01PA 3 GR, PR, PWM ,

'

ICS01PB ,3 GR, PR, PWM

.ICS01T

'

,- +

2 2CS01PA;0 1 PWM

d 2CS01PB 1 PWM

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'4

2CS01T -

.y'

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1CV01AA -

i 1CV01AB -

p ,2CV01AA

,

-

2CV01AB -

.._

ICVOIDA -

-

ICV 01DB

ICV 01FA -

ICV 01FB x,s a ,- -

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,s , *

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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

'

'1CV01PA 2 GR, Mnfr. inspection

of install. not

performed

ICV 01PB 1 GR

2CV01PA 2 TE, EL

2CV01PB 1 TE

i' ICV 01T .1 PR +

2CV01T -

.

'

1CV02A -

2CV02A -

'

ICV 02D 1 IC

1CV02F -

1CV02P. 2 GR, TE

2CV02P 2 TE (2)

ICV 03AA 1 -AB

ICV 03AB 1 AB

2CV03AA 1 Shim for contact

, 2CV03AB -

ICV 03F -

+

- 2CV03F -

+

,

1CV04AA 3 HS, NW, HE

1CV04AB 1 HS

2CV04AA -

2CV04AB -

ICV 05A 1 IC

2CV05A 1 IC +

,.. IDG01KA 2 MRR, AB

IDG01KB 1 MRR

IDG01SA -

'

2DG015A -

IDG01SA-C -

+

20G01SA-C -

1DG01SA-D -

2DG015A-D -

1DG01SB -

2DG01SB -

1DG01SB-C -

2DG01SB-C -

1DG01SB-D -

2DG01SB-D -

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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

10001PA -

10001PB -

10001PC -

-

10001P0 -

+

'

10002TA -

+

20002TA -

10002TB -

20002TB -

1D010T -

20010T -

IFC01A 1 HS

2FC01A 2 IC, AB

IFC01P -

2FC01P -

OGW01SA 1 IC

OGWOISB 1 IC

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 -

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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 -

t

2RC01PA -

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

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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 IC, IC, TE

2SIO1PA -

ISIO1PB 2 IC(2)

2SIO1PB 1 TE

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 GR, TR, AB

2SX01PA -

ISX01PB 3 GR, TR, work w/o doc.

2SX01PB -

IVA01SA 3 TE, GR, IC

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 TE, IC, NW

2VA055 -

IVA06SA 1 IC +

2VA06SA -

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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

IVA07S -

2VA07S -

IVA08S 1 IC

2VA085 -

IVP01AA -

IVP01AB -

IVP01AC -

IVP01A0 -

OW001CA -

OW001CB -

OW001PA -

OW001PB -

OWX05T -

AB

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)).

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Symbols Used In Reporting Type of Findings

SYMBOL Description of Findings

GR No Grout Release or Grout Release hold point bypassed

IC Internal Cleanliness bypassed

PR Piping Release bypassed or no piping release sign-off

AB Anchor Bolt. damage or out of tolerance or projection

TE 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

MT Nozzle end prep not HT examined

SLP No Special lifting procedure

QC 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.

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_ _ _ _ . _ _ _ _ _ _ _ _ _ _ _ . _ - _ _ _ _ . _ _ _ _ . _ _ _ _ _ _ _ _ _ , _ . ____.____,_ , _ _ ___ _ _.._ ,_ ___ _, _ _ _ _ _ _ , . _ , _ _ . _ _ . _ _ _ . _ _ - . _ _ _ , . _ _ . _ _ _ _ _ . . . . _ _ _ _ _ . _

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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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(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.

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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)

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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

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Edison is performing acceptable audits of this activity.

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:

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(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?

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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

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acceptable." These actions adequately resolve the unresolved item

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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