ML20147H005
| ML20147H005 | |
| Person / Time | |
|---|---|
| Site: | Comanche Peak, 05000000 |
| Issue date: | 03/27/1984 |
| From: | NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20147G863 | List: |
| References | |
| FOIA-87-847 NUDOCS 8803080359 | |
| Download: ML20147H005 (34) | |
Text
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SUMMARY
REPORT FOR REGIONAL EVALVATION OF TEXAS UTILITIES ELECTRIC COMPANY COMANCHE PEAK S.E.S.
DOCKET 50-445 PREPARED BY U. S. NUCLEAR REGULATORY COMMISSION REGION lY 1
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MARCH 27, 1984 I
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1 A.
PROJECT HISTORY 1.
Chronological Project Milestones The application for construction permits for Comanche Peak Steam Ele c Station (CPSES), Units 1 and 2 were docketed on July 20, 1973.
LWA as granted to the licensee on October 17, 1974, and ground 3
bre ng occured on October 18, 1974.
The construction permits (Nos. CPPR-126 and CPPR-127) were issued on December 19, 1974.
There has been no change in principle contractors.
Unit 1 is presently in preoperational testing.
Precore hot functional testing d
%~ g began on February 20, 1983, and was completed on June 10. 1983.
The licensee's present projected fuel load date it7ebruary 19@Cr "Texas Utilities Electric Company (TVEC) was granted a license to receive and store fuel (SNM-1912) on April 26, 1983, and began receiving fuel on May 4, 1983.
The process will evouove vw t,he a::t sr ceaf *g f
sever:1 a n h wotil :11 Of "" 193 f;:1 c k-;nts :nd e;;;;ie4ed e-W erte er: 7:;e h ed
--S h ty : S fue! n ::-il k: for Urtt 1 bree W *M+tved-er.d are :tered i-th; ne., feel 3 tor;;; ::: -tly in ik fwl bgildtmy.
2.
Principle Contractors Gibbs & Hill, Inc. (G&H) is the architect-engineer, and Brown &
Root, Inc. is the constructor. Construction management is being performed by Texas Utilities Services, Inc., a wholly owned subsidiary of the owner, Texas Utilities.
The nuclear steam supply system vendor is Westinghouse Electric Corporation.
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B.
QUALITY ASSUPAhCE ORGANIZATION STRUCTURE Iy O af ?[*
The licensees present QA organization is shown in Exhibit 1.
The present i
structure has E2.t appreciably changed from the original description in the SAR.
The licensee has recently completed review of the QA program
)/
pursuant to 10 CFR 50.55(c). No changes in the QA program were j
identified.
j C.
SALP REVIEW Three SALP reviews have been conducted to evaluate TUEC's performance.
The SALP periods were:
1 I
August 1, 1979-July 31, 1980 (Reports 50-445/80-25 and 50-446/80-25)
July 1, 1980-June 30, 1981 (Reports 50-445/81-20 and 5 -446/81-20) a October 1, 1
-September 30,1982(Report 50-445/82 and 50-446/82 2) y j
7)
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2 During the period of August 1, 1979, through July 31, 1980, the licensee was evaluated in the following functional areas:
Functional Area increase NoV Change Decrease Quality Assurance, Management and Training X
Substructure & Foundations complete 4 Concrete X
Liner (Containment & Others)
. compl e te --t Safety-Related Structures X
Piping & Hangers (Reactor Coolant &Others)
X Safety-Related Components (Vessel, Internals & HYAC)
X Electrical Equipment X
Electrical (Tray & Wire)
X i
Instrumentation X
Fire Protection X
Preservice Inspection X
Reporting X
During the period of July 1,1980, through June 30, 1981, the licensee was evaluated in the following functional areas:
Functional Areas Category et hAb> 6t'Ler f('N Soils and Foundations NA A# e14 '
Containment and Other Safety-Related Structures Piping Systems and Supports 1
f* *w Safety-Related Components 1
Support Systems 2
Electrical Power Supply and Distribution 1
Instrumentation and Control Systems 1
Licensing Activities 2
During the period of October 1,1981, through September 30, 1982, the 1
licensee was evaluated in the following functional areas.
Perforr.ance Category l
Functional Area 1982 A.
Plant Operations - Preoperational Testing 3
B.
Construction Activities -
Soils and Foundation Not evaluated Containnent & Other Safety-Related Structures 2
(continued)
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3 Performance Category Functional Area 1982 (continued from previous page)
Piping Systems and Supports (includes welding, NDE, and preservice inspection) 2 Safety-Related Components (includes vessel, internals, pumps,etc.)
1 Supp' ort Systems (1 cludes HVAC, radwaste, fire protection)
Not evaluated Electrical Power Supply and Distribution 1
Instrument and Control Systems 1
Vendor Procurement Cycle Controls 3
Licensing Activities 1
D.
_ ESCALATED ENFORCEMENT HISTORY 1.
An Imediate Action letter An Immediate Action Letter was issued on September 7, 1979, l
confirming a licensee decision not to place concrete in the wall to done transition area of the Unit 2 containment building until such time as a prop;r engineering evaluation could be made of the omission and subsequent addition in another location of a group of reinforcing steel shear ties.
2.
Civil Penalty A civil penalty (EA-83-64) of $40,000 was proposed against the licensee for alleged violation of 10 CFR 50, Appendix B, Criterion I.
This was based on the Secretary of Labor Final i
Decision and Order in Atchison vs. Brown & Root, Inc., 82-ERA-9; June 10, 1983.
E.
INDEPENDENT DESIGN HISTORY Discussions with the licensee are in progress.
No final decision has beer, reached.
The licensee has contracted the Cygna Corporation to review the Comanche Peak design.
F.
NRC INDEPENDENT MEASUREMENTS INSPECTION The NRC perfonned an independent measurements inspection at the Comanche Peak site April 25-May 6,1983.
The report on the results of the examination are contained in NRC Inspection Report 445/83-15 and 446/83-09.
Two violations were identified during this inspection.
4 G.
GENERIC CORRESPONDENCE TUEC has established procedures providing specific instructions to thE nuclear project support group personnel who are responsible for coordination and review of IE Circulars, Bulletins, and generic letters.
In each case, a TUEC-appointed coordinater is given responsibility for assigning the cognizant responsible person to review and track all actions and provide documentation.
When required, the coordinator shall draft a response to the NRC which will be reviewed by the plant manager -
nuclear, licensing engineering supervisor - nuclear, and project support manager - nuclear. The response shall be signed by the vice president -
nuclear operations and shall include an affidavit. A permanent record of actions taken is maintained.
The licensees' response to NRC has been satisfactory.
H.
LICENSEE AND CONTRACTOR INITIATED STOP WORK ACTION There have been 46 stop work orders issued by the licensee and his contractors.
See Exhibit 2 for a sumary of the stop work orders.
1.
CONSTRUCTION DEFICIENCY REPORTS (10 CFR 50.55e)
The licensee has reported 42 significant construction deficiencies.
See
/ Exhibit 3 for a sumary of these reports.
J.
PART 21 NOTIFICATIONS 1
pf 18 Part 21 reports received by NRC, 5 are being generated as
/10 CFR 50.55e items and are being tracked by the licensee. They appear in Exhibit 3 of this report. There is a followup investigation being conducted by the Resident Reactor Inspector to determine the status of the remaining 11 Part 21 reports.
Two of the Part 21 reports were deemed s
unreportable af ter investigating the patential problems.
- @4 h K.
NRC INSPECTION ACTIVITIES 1.
Construction Inspection The routine MC 2512 inspection program is approximately 9 M complete for Unit 1 and Comon, however, an augmented program has been implemented to correspond to licensee final completion inspection.
This special program is the key to actual activities of completion and will be on-going until final construction completion.
2.
Construction Appraisal Team a.
The Construction Appraisal Team (CAT) perfortned an inspection of CPSES on January 24-February 4, 1983. Four violations were identified. Details of the inspection are contained in NRC Inspection Reports 445/83-18 and 446/83-12.
5 b.
On June 27-September 16, 1983, a followup inspection to CAT inspection was performed by the Region IV staff. No new violations or deviations were identified. Details of this inspection are contained in NRC Inspection' Report 445/83-28 and 446/83-14.
3.
Special Inspection A special inspection to evaluate the licensee's turnover / access control process was conducted of the Fuel Building on May 23-June 10, 1983. Two violations were identified. The details of the inspection are contained in NRC Inspection Report 445/83-23.
4.
Preoperational Testing and Operational Preparedness MC 2513 is directed toward inspection of activities involved in preoperational testing and operational preparedness.
These inspection activities may be sumarized as follows:
1 Complete Preoperational Test Procedure Review 95 Preoperational Test Witnessing 50 Preoperational Test Results Evaluation 25 Operation Staffing 0
Quality Assurance 80 Operating Staff Training 75 Technical Specification Review 100 (Proof & Review copy)
Operational Procedure Review 0
Radiation Protection 50 Radwaste 50 Environmental Monitoring 50 Emergency Planning 50-Security 50 5.
Startup Testing Inspection activities established in MC 2514 define the inspection program for the startup testing phase. Since this program generally starts with fuel loading, the program, except for procedure review, has not begun. The program includes:
QA/QC Technical Specification Review (complete for "Proof & Review" copy)
Startup Procedure Review Initial Fuel Load Precritical Checks Power Ascension Testing Initial Criticality / Low Power Testing Data Review
6 6.
TMI Open items Most of the TMI lessons-learned issues were specifically addressed during the FSAR review and appear in "The Safety Evaluation Report,"
NUREG-0737 and its supplements. These items are being tracked and verified during preoperational testing (MC 2513).
The individual items will be inspected and closed out in accordance with the temporary instruction.
7.
Allegations Five allegations specific to CPSES have been received during the last two years, in part due to the public licensing hearings.
Several of the investigations of these allegations are on-going at this time.
8.
NRR Confirmatory items (To be verified by Region IV program) i SER Section Description of item 5.3.1.2/5.3.1.3 Fracture-toughness properties of Unit 2 5.3.2/5.3.3 Reactor vessel materials (SSER #1 5.3.1.2, 5.3.1.3, 5. 3.2, and 5. 3.3) 7.3.2.2 Steam generator reference leg temperature compensation and low-low steam generator level setpoint per IE Bulletin 79-21 7.5.4 Confirmation of procedure review per IE Bulletin 79-27 9.1.4 Handling of heavy loads in conformance with the guidelines of NUREG-0612 (SSER)#19.1.4) 10.4.5 Protection against flooding of safety-related compartments from a failure in the circulating water expansion joint 9.4.4 Verification that auxiliary building post-l.0CA radiation levels will be low enough to pennit manual operation of exhaust damper CPX-VADP0C-83 (continued)
7 SER Section Description of item (continued from previous page) 22 TMI Action Plan 1.C.2 Shift and relief turnover procedures (SSER #1)
Procedures for feedback of operating) 1.C.5 experience to plant staff (SSER #1 1.G.1 Special low-power testing and training 11.B.1 Reactor coolant system vents 11.D.1 Performance testing of BWR and PWR relief and safety valves (SSER #1)
II.E.1.1 Recomendation GL-3:
Verification by test of the capability of the turbine-driven AFW pump to operate for 2 hours2.314815e-5 days <br />5.555556e-4 hours <br />3.306878e-6 weeks <br />7.61e-7 months <br /> without AC power ll.E.4.2 Containment isolation dependability ll.K.2.13' Thermal mechanical report - effect of high-pressure injection on vesel integrity for small-break LOCA accident with no auxiliary feedwater (SSER#1)
II.K.2.17 Potential for voiding in the reactor coolant system during transients (SSER#1)
Installation and testing (of automatic II.K.3.1 PORV isolation system SSER #1)
Report on overall safety (effect of II.K.3.2 PORV isolation system SSER #1)
II.K.3.5 Automatic trip of reactor coolant pumps during 1.0CA (continued)
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SER Section Description of item (continued from previous page) 11 K.3.11 Justification of use of certain PORVs (SSER #1)
II.K.3.30 Revised small-break LOCA methods to show compliance with 10 CFR 50, Appendix K II.K.3.31 Plant-specific calculations to show compliance with 10 CFR 50.46 SSER Section Description of Item 3.9.6 Periodic leak testing of pressure isolation valves 9.5 Documentation of applicant's commitments on fire protection L.
CONSTRUCTION STATUS The active systems have largely been completed sufficiently to conduct preoperational tests.
Pipe support design and installation remain as major pacing effort at this time. Also, there is a considerable effort in the area of attaining separation in the electrical area.
(IEEE384)
There is also a considerable effort directed to engineering design review of site changes.
In conjunction with this effort, site QA is verifying that the changes have been inspected and that proper documentation is available.
M.
PREOPERATIONAL TEST RESULTS The licensee's startup group has determined that the plant will be safe for fuel load when the following systems have been prerequisite /preoperational tested.
Not all systems are required to be preoperational tested per NRC Regulatory Guide 1.68, Revision 2.
Preoperational i
System Description
- % Complete 01 125 V DC Class IE Power Systems 50 02 6.9 KV/480v Class IE AC Distribution Systems 85 03 Startup Power Systems 100 (continued)
4 9
Preoperational System Description
- t Complete 04 Service Water System 0 (Retest) 06 Fire Protection / Detection Systems 25 07 Control Room - HVAC System 60 08 Battery Rooms HVAC System 60 11 Component Cooling Water System 0 (Retest) 12 Coninunication System 100 80 22 Sampling System 24 Primary Plant Ventilation System 75 29 Diesel Generator and Auxiliaries System 90 31 Safety Chill Water System 100 32 Auxiliary Building - HVAC 100 34 Main Steam System 90 36 Safeguards Building - HVAC System 90 37 Auxiliary Feedwater System 90 39 Diesel Generator - HVAC System 100 40 Fuel Handling and Vessel Servicing Systems 55 41 Liquid Waste Processing System 10 42 Fuel Building - HVAC System 100 44 Steam Generator Blowdown System 50 45 Containment Ventilation System 85 46 Containment Hydrogen Purge System 65 47 Fuel Pool Cooling and Cleanup System 100 48 Containment Spray System 90 49 Chemical and Volume Control System 80 55 Reactor Coolant System 65 (Retest) 56 Boron Recycle System 90 57 Safety Injection System 80 58 Residual Heat Removal System 50(Retest) 60 Solid Waste Processing System 45
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61 Gaseous Waste Processing System 0
64 Reactor Protection System 40 65 Containment Atmosphere Monitoring System 0
66 Nuclear Instrumentation System 0
67 Hydrogen Recombiner System 100 68 Rod Control System 0
70 Radiation Monitoring System 20 i
73 ProtectionandSurveillancePackage(N-16) 0 74 Movable Incore and Flux Mapping System 90 75 Structural Integrity and Leak Rate Testing 90 78 ERF Computer (SPDS) System 0
80 Seismic Monitoring System 50 81 Cranes and Hoists 50 82 Fateorological Monitoring Sys;em 0
91 Loose Parts Monitoring System 100
- 901 indicates the physical testing is complete with the remaining 10%
allowed for review and acceptance of test results.
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10 The preoperational test program is 66% complete.
There are, as of October 24, 1983, 16 preoperational tests either in draft waiting review and approval or being draf ted.
The tests are listed below with their scheduled approval dates:
ICP-PT-01-07 Class IE Emergency DC Lighting (including 10/24/83 individual battery pack lighting) 1CP-PT-04-01 Station Service Water 12/06/83 1CP-PT-06-04 Charcoal Filter Deluge 10/03/83 1CP-PT-11-01 Component Cooling Water System Operational Test 01/23/84 1CP-PT-34-01 Main Steam Isolation Valves 10/03/83 1CP-PT-44-03 HELB Mitigation for SG Blowdown Isolation Valve Test 11/14/83 1CP-PT-49-00 Boron Dilution Mitigation 02/06/83 XCP-PT-60-02 Radwaste Solidification System 02/23/83 1CP-PT-64-01 RPS Time Response Measurement 12/19/83 1CP-PT-64-03 Turbine Runback Control 10/31/83 1CP-PT-64-04 Reactor Plant System Setpoint Verification 07/29/83 1CP-PT-64-08 RPS Time Response Sumary 11/14/83 1CP-PT-64-10 Safeguards Actuation Relay Test 12/05/83 1CP-PT-66-02 Source & Intermediate Range None Test 01/09/84 1CP-PT-70-02 Report Process System 10/24/83 1CP-PT-74-04 No Title 10/31/83 N.
CONCLUSION The licensee has officially scheduled fuel load for Unit 1 in February of 1984. The assessment of the regional office, based on work to be done and the past progress rate, estimates that fuel load can take place no sooner than June of 1984.
The licensee's Quality Assurance program for design, construction, preoperational, and startup programs appears adequate to assure the necessary confidence level for these programs are attained.
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EXHIBIT 3 REPORTABLE SIGNIFICANT DEFICIENCIES Page 1 NUMBER DATE SUBJECT DISPOSITION 02/04/75 Unit 1 Reactor Building Excavation Fractured rock removed and replaced with dental concrete and grout.
07/24/75 Unit 1 Reactor Cavity Mat (Cold Joint)
Concrete removed; new joint prepared.
04/09/76 Unit 1 Containment Mase Mat Coring Concrete integrity determined acceptable through coring and core holes filled with grout or mortar.
09/20/76 SSI Dam Filter "A" Material Removed nonconforming Filter "A" material other than conforming portions of the dam.
Reconstructed dam.
77-4 05/06/77 Weld Defects in Polar Crane Brackets Rework all similar welds and perform random UT inspection on all other welds.
77-C 07/19/77 Westinghouse AR Relays All cffected contact cartridges replaced with approved relays and torque requirements place on holddown screens.
77-D 09/29/77 Westinghouse Operation of Safeguard Deficiency identified and corrected prior to Actuation Block / Reset Circuitry receipt at CPSES.
77-B 08/23/77 Design Deficiency in Fuel Building Place hold on drawings issued to contractor Crane System and redesign support structure to incorporate correct seismic loadings.
79-5 05/22/79 Pipe Wall Thickness May Not Meet Determine wall thickness by documentation ASME Code Stress Requirements review and/or UT inspection. All Class 1 piping with less than minimum wall will be repaired. All other piping greater than
.010" below minimum will be repaired.
REPORTABLE SIGNIFICANT DEFICIENCIES Page 2 NUMBER DATE SUBJECT DISPOSITION 79-6 06/19/79 Electrical Cable Tray Hangers without After review of 404 cable tray hangers l
Full Penetration Welds assigned to C8&I 210 are to be reworked per engineering direction.
79-8 11/07/79 Installation of Drilled in Expansion Revise procedures to reflect correct Anchors installation requirements, identify affected supports, rework as required.
79-9 11/15/79 Installation and Inspection of Welded Develop typical engineering drawings and Conduit Supports provide additional information on construction travelers.
Develop inspection procedures and reinspect supports to provide documentation.
79-10 11/20/79 Class V Pipe Supports Revise FSAR to delineate requirements for supports, revise specification to clarify quality requirements, develop and implement construction & inspection procedures, reinspect, and rework as necessary.
i 79-13 12/13/79 Concrete Honeycombs Unit 2 Steam Determine defective areas and repair.
Generator Compartments 80-02 02/22/80 Discs for SW Control Valves Return to vendor for repair / rework.
80-03 02/29/80 Welded Connection of Control Boards Review as-built weld configuration and rework as necessary.
80-05 07/02/80 2" Architectural Concrete in Floor NCR-M-82-01667 issued against nonconforming Slabs bolts.
80-09 09/26/80 Diesel Generator Pipe Supports Establish compliance to requirements by engineering evaluation.
Inspection and rework is required.
REPORTABLE SIGNIFICANT DEFICIENCIES Page 3 NUMBER DATE SUBJECT DISPOSITION 80-10 10/01/80 Hilti Kwik Bolt Installation Indoctrinate personnel, rework affected supports, and initiate a sampling program of UT examination for Hilti-bolt installation.
81-A 02/17/81 Westinghouse Gate Valves Modify valves as per Westinghouse Field Change Notices and perform stroking during startup testing.
81-B 03/24/81 Bahnson HVAC Anchor Bolts Revise Bahnson Procedures to require information on anchor bolts and as-built drawings; reinspect previous installations and document as as-built drawings for post installation design verification. Rework as necessary.
81-03 03/30/81 HVAC Cooling System Replace existing HVAC system with system meeting new design requirements.
81-06 06/04/81 Seismic Design Criteria for Evaluate engineering documentation and Instrumentation Supports revise, if necessary, survey-completed installations and rework as required.
81-07 11/19/81 Orifice Plates (BIF) Outside ISA Scrap existing orifice plates and procure Standard RF3.2 Tolerances new plates from a new supplier with an approved quality program.
82-A 01/22/82 Borg Warner Valves May Not Close Rework / repair.
Properly if Installed Between 221* and 1573*
82-02 02/25/82 Papco HVAC Fire Damper Dampers will be cleaned & lubricated, blade locks secure with additional fasteners, damaged closure springs replaced based on testing additional springs added, and large horizontal dampers replaced with multipanel dampers.
REPORTABLE SIGNIFICANT DEFICIENCIES Page 4
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NUMBER DATE SUBJECT DISPOSITION 82-06 07/12/82 Linear Indications Diesel Generator The existing auxiliary skids will be scrapped.
The replacement structures will be fabricated at the jobsite. Completion should be no later than September 1984.
82-07 08/12/82 Governor Drive Coupling.
Existing drive element to be replaced with Diesel Generator (Part 21 Report of new element or more suitable material 6/23/82)
(neoprene).
82-09 08/18/82 Solid State Protection System Modify test procedure.
Undetectable Failure (Westinghouse 10 CFR 21) 82-15 12/01/82 DeLaval Piston Skirt Castings (10 CFR 21 Piston skirt castings will be replaced with Report of 10/28/82) castings provided by the supplier. Replace-ments should be received no later than Phy 1984.
83-01 01/20/83 Fractured Tack Weld in Check Valve Valves redesigned to change tack weld to fillet weld. Disassemble valves supplied prior to design change.
Inspect valves supplied after design change to ensure correct weld.
83-02 01/25/83 Westinghouse Gate Valves Modify valves in accordance with manu-facturer's recommendations.
83-07 03/10/83 New Fuel Storage Racks Approved anchor design issued and racks reworked.
83-08 03/24/83 Valves Without Proper Weld Documentation Scrap existing brackets and replace.
83-09 04/20/83 05-416 Reactor Trip Switchgear Replace.
l REPORTABLE SIGNIFICANT DEFICIENCIES Page 5 NUMBER DATE SUBJECT DISPOSITION 83-10 05/06/83 Letdown Heat Exchangers The mounting configuration will be reworked in accordance with the supplier's recom-mendation. The rework will be completed no later than September 1, 1983.
83-11 05/24/83 CCW System Class V Piping (10 CFR 21 Controls added to existing level transmitters Report of 5/23/83) and nonsafety-related components upgraded.
83-15 06/14/83 Cable Tray Bolting Support Material Mild steel bolting material is acceptable for regular cable tray support clamps. Heavy duty cable tray supports clamp material and 1
torque will be verified by site QC.
83-17 07/11/83 Piping Configuration & Relief Valve System modifications will consist primarily Settings Spent Fuel Pool Cooling of pressure relief valve rework and/or i
piping reroutes to overt excessive back-pressure.
83-18 07/29/83 Reactor Containment Building Cooling The capacity of the cooling system will be System increased by reduction of the chilled water temperature and the installation of addi-tional chilled water cooling coils.
83-20 10/20/83 Broken Tack Weld in Westinghouse Brackets with defective or suspect welds will Supplied 480V Switchgear be replaced.
83-21 11/29/83 Calibration Techniques To correct the temperature deviation, a revised setpoint (1829 PSIG) will be incorporated into the CPSES I&C Equipment List i
for pressurizer pressure safety injection.
In addition, TU6C0 (Operations) I&C will change the bistable setpoints for transmitters PB-455D, P8-4560, P8-457D and PB-4580 to correspond to the revised SI actuation setpoint.
1 REPORTABLE SIGNIFICANT DEFICIENCIES Page 6 huMBER DATE SUBJECT DISPOSITION Regarding the electrical leakage path, the supplier has advised the issue does not warrant immediate corrective action.
The transmitters will be replaced or reworked per the manufacturer's recommendations.
These modifications will be completed no later than June 1, 1984.
83-22 12/20/83 FSAR Requirements for Control Room Corrective actions will consist of:
reloca-Ventilation tion of chlorine sensors and modifications to provide adequate calibration; reversing power supplies for two chlorine detectors; providing seismic supports for detector power supplies; and, realigning detectors with proper trains for respective control room inlet dampers.
Engineering will be completed no later than March 30. 1984. Construction activities should be completed no later than 30 days prior to fuel load.
84-02 01/13/83 Linear Indications in Diesel Generator The defective push rods will be removed and Welds (Push Rods) scrapped.
Replacements have been requisitioned for installation before.
operation of Unit 1.
84-04 01/16/84 Insulation Degradation on Westinghouse The transformers will be returned to the (General Electric) Transformers supplier (Westinghouse) for repair by the manufacturer. Repair will consist of:
replacing the insulation with material more resistant to abrasion; treating the insulation with hard bonding material; incorporating improved mechanical wedging for the center leg; and hi-pot production tests at 4000V (vs.
2500V) for assurance of dielectric integrity.
REPORTABLE SIGNIFICANT DEFICIENCIES Page 6 NUMBER DATE SUBJECT DISPOSITION Reinst411ation of the transformers will be completed no later than 30 days prior to fuel.
load.
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Subject:
NT0L Input
- 1. Chronological 1
i LWA issued October 17, 1974 Ground Break on October 18, 1974 i
- 2. NRC Independent Measurements Inspection The NDE van has been here but the report has not been released. Until we get the report, I don't want to talk about it, uA v;pv - z,,m g p
- 3. Licensee and Contractor Initiated Stop Work Action At4 ached-4s-e-preliminardist of-Contrattor Stop Worksr - -a more complete list wilLbe-supplied in update.. letter, h
- 4. Construction Deficiency List Attached-list-provntet p.h h
k n bel,~3 cmp. le P ~ enti be a d 4 / a s a.,, o a'e d _,, y-Q '...;
c
- 5. NRC Inspection Activities rA c 2 fl 2.
i d
The routine inspectior, program is essentially complete for Unit I and Conrnon however, an augmented program has been imp # m s-h J wI1eted to correspond to licensee final completions b
inspection.
This special program is key to actual activities of completion and will be on-going until final construction completion.
hNumerousaI ationsspecifictoComanchePeakSEShavebeenreceivedduringthelast two years, in part due to the public licensing hears everal of the investigations of these allegations is on-going at this time.
NXM IIN!M XXXyEENXE N
11 pren The active systems have largely completed sufficiently to conduct pre-operational tests. Pipe suupport design and installation remain as major pacing efforts NNMXIM at this time. Also there is s considerable effort in the area attaining separation in the electrical area (IEEE 384).
a Construction Status Cont /
There is also a considerable effort directed to engineering design review of site changes.
In conjunction with this effort, site QA is verifying that the changes have been inspecter and that proper documentation is available.
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p a *.. o - 1 STOP WORK N(yrICES STOP WORK START WORK NMICE NO.
ISSUED TO ISSUED DATE SUBJECT APPROVAL DATE DISPOSITION 1
N(yr IN FILE 2
Dodd 7/26/75 All Category 1 Concrete 8/1/75 Testing lab to irripletmen t.
their Placement quality prevar.im 'o correet defi-ciencies oral prevent re<;u r r en'ce t
3 Dodd 9/3/75 Work on containment liner 9/4/75 Perform MT examination in lieu of preclude for radiography RT on reactor cavity containment lines.
4 Dodd 4/28/76 Off-Ioading of volume control 4/29/76 Obtain acceptable purchase order-tank.
Spin #TCX-CSATUC-Ol.
P. O.
- 546-CAP-212825-BN j
5 Dodd 7/23/76 On site miscellaneous steel 8/3/76 Revise inspection procedure fabrication of Safety Related Items 6
Dodd 7/23/76 On site miscellaneous steel 7/29/76 Pevise insp.et. ton procedure installation of safety related items s
7 Dodd 8/2/76 On site miscellaneous steel 8/2/76 Revise inspection procedure fabrication of safety related items D
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STOP WORK NOTICES STOP WORK START WORK NCff!CE NO.
ISSUED TO ISSUED DATE SUBJECT APPROVAL DATE DISPOSITION 8
Catchell 8/20/76 Receiving Safety Related 9/16/76 Issue procedure f or surveillance Mechanical Equipment that of maintenance of mechanical Requires Maintenance equipnent.
9 Gatchell 8/20/76 Receiving Safety Related 9/lG/76 Issue procedure for su rvei llance.
Electrical Equipment that of mainten.ince of.lectrical Requires Maintenance equipment 10 Kinkade 11/18/76 H.
W.
Ilunt Calibration 2/15/77 Correct defsciencies and restart Activities which r'ay be work'b.med on r e:uirvey.
Affected by SSR-C-131 11 Scott 11/30/76 B&R QC Calibration activities 2/14/77 Correct response to surveillance on equipment which could.be reports and restart after resurve/.
used for qualifying and acceptance of safety related work 12 Dodd 11/30/76 H&R QC Calibration activities 2/14/77 Correct response.to surveillance on equipment which could be reports and testart after resurvey.
used for qualifying and acceptance of safety realted work 13 CPSES 1/24/77 Calibration of Optical field 1/27/77 Correct resionse to surveillance Survey Instruments reports arvi restart after resurvey..
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m 6.39 STOP WORK NOTICES STOP WORK START WORK NOTICE NO.
ISSUED TO ISSUED DATE SUBJECT APPROVAL DATE DISPX'IT10tJ _
1 14 Dodd 7/12/77 All safety related work by 8/10/77 Supplier to correct survey Dostrom Bergen in Presno deficiencies <end le r esu rveyed.
i 1
15 Dodd 7/21/77 All Safety Realted activities 7/29/77 Provide cur rent drawirvis,. stablis at miscellaneous steel fab procedure t o ca.snt. rol <trawings and y
shop audit ans! correct f i b :..
16 Dodd 7/28/77 Safety Related Construction.
8/1/77 Comply wit h procedur.tl requirement activities affected by all for DC/DDA's innd voi<l or revise DC-DDA/s issued to date.
and reissu.. DC/fif eA, as required.
Dr.R must not issue DC/DDA's 17 Douglas 1/17/78 All welding associated with 1/25/78 Plowmetet:,.ir,1 weldinq machines to-ASilf'. act ivi t ies be checke.1 1or :p;cified output an..
the checks dwamented and traceabl' to each machin.-
16 frahnson 4/18/78 All l'atir icat ion or insta11atmosi
'i/lo/78 Satisf act or f r.meilut i sin to of any Nuclear Safety Related Surveill.ino lei screp.incy facports.
e at..pu y I i t.1n e; 4.r annembl i er l
19 Douglas 9/15/78 Safety Related Welding 9/5/78 Revise Welder conformance Qualific.
tion Ix)q and up late QA records to reflect current <tuali f ication stat <
2D Douglas /
10/17/78 Origination, distribution and 10/19/78 Revise TUSI
- 1. He.R grocedures to ad.
Merritt all work performed to all quately descrile the method (s) u s. -
project CMC's for the origination, distribution, use of cme"s.
Indoctrinate projee personnel.
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i STOP WORK NOTICES STOP WORK START WORK NOTICE NO.
ISSUED TO ISSUED DATE SUBJECT APPROVAL DATE DISPOSITION 21 Douglas 10/23/78 Welding activities in main 11/15/78 Evaluate welds for acceptability.
loop piping Investigate cause of unauthorized-repairs and take appr opriate management action.
22 Douglas 10/30/78 Manual welding activities 11/30/78 Perform analysis of welding associated with the main loop' materiale..
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j 23 Douglas 2/14/79 Weldinq - ASME on WPS 88023 2/16/79 Requalify procedure 24 Douglas 2/15/79 Welding - ASME on WPS 88021 2/15/79 Evaluate throuqh wall repairs usins partial inserts.
25 Douglas 3/22/79 Welding - ASME on WPS H8023~
Closed by SWM-26 4
j-26 Douglas 4/13/79 Welding - ASME on WPS 8H023 4/16/79 Revise WPS-bHo23.imi a:isociat ed PQ u's p.
- re.pi il i t icat inn request.
27 Douglas 10/26/79 Installation of Sway Strut 2/21/80 Design drawing te. be included in Assemblics traveler package, indoctrinate personnel in ass.'mbl;, and provide inspection criteria.
28 QA/QC &
11/23/82
. Liquid Penet rant Examinations 2/9/83 Recall all penetrant materials and 1
Welding issue appr <>v. d j ene t r. int.
Engineering 4
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1 STOP WORK NOTICES Page 1 tsr START WORK ISSUED TO ISSUED DATE SUBJECT APPROVAL DATE DISPOSITION 5
4 Construction 07/2b/7S Category 1 Concrete Pours 08/01/75 Testing lab implemented their quality prograa to correct deficiencies and prevent recurrence Chicago 09/03/75 Work on containment liner 09/04/75 Performed MT examination in Bridge & Iron Co.
which precludes radiography lieu of RT on reactor cavity containiaent liner.
Construction 12/19/75 Category 1 Concrete Pours 12/22/7S Provided clarification of discrepancies noted on surveillance report Construction 12/23/75 Concrete Aggregate 12/30/75 Mixed aggregates from several locations to provide.
a composite aggregate that met requirements Construction 02/12/76 Category 1 Concrete Pours Varied with Planning implei.nented in complexi ty accordance wi th Reg. Guide 1.SS Construction 04/28/76 Off-Loading of volume control 04/29/76 Obtained purchase order tank Construction 07/23/76 On site miscellaneous steel 08/03/76 Revised inspection procedure fabrication on Safety Related items Construction 07/23/76 On site miscellaneous steel 07/29/76 Revised inspection procedure installation of safety related items
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STOP WORK NOTICES Page 2 START WORK ISSUED TO ISSUED DATE SUBJECT APPROVAL DATE DISPOSITION Construction 08/02/76 On site miscellaneous steel 08/05/76 Revised inspection procedure fabrication of safety related i tems Construction 08/20/76 Receiving Safety Related 09/16/70 Issued procedure for Mechanical Equipment that surveillance of maintenance Requires Maintenance of mechanical equipment Construc tion 08/20/76 Receiving Safety Related 09/16/70 Issued procedure for Electrical Equipment that surveillance of maintenance Requires Maintenance of electrical equipment R. W. Ib n t Co.
11/18/76 Calibration Activities 02/15/77 Established and implemented an acceptable program Construction /
11/30/76 Calibration Activities 02/14/77 Established and implemented Quality Assurance an acceptable program i
Coastruction 01/24/77 Calibration of Optical Field 01/27/77 Correcteo discrepancies Survey Instruments.
Engineering 07/01/77 Design change document None Discontinued practice of legibility telecopying design changes Bostrom 07/12/77 All safety related work by 08/10/77 Supplier corrected survey Ber. gen Co.
Bostrom Bergen in Fresno deficiencies and was resurveyea Construc tion 07/21/77 All Safety Related activities 07/29/77 Corrected document control at miscellaneous steel fab shop deficiencies
STOP WORK NOTICES Page 3 STARI WORK ISy CD TO ISSUED DATE SUBJECT APPROVAL DATE DISPOSITI0tJ Construction 07/21/77 Concreting of embedded anchor 08/01/77 Established accountability bolts in Unit 1 Contairwent of the anchor bolts Engineering 07/28/77 On site issuance of field 08/01/77 Established appropriate design changes management controls Construction 07/28/77 Safety Related Construction 08/01/77 Implemented procedural activities affected by all requirements field design changes issued to date Construction 08/19/77 Installation of safety 09/09/77 Resolved adi.iinistrative related piping concern Construction 01/17/78 All welding associated with 01/25/78 Flowneters and welding ASME activities machines were checked for specified output and the checks cocuniented and traceable to eacia machine Balwison 04/18/78 All Fabrication or Installation
.0S/10/78 Resolved surveillance Service Co.
of any Nuclear Safety Related findings Category 1 items or assemblies l
Construction 08/25/78 Welding of stainless steel Case basis Established prograia for material s closer monitoring of welders to assure procedural corupl f ance Construc tion 09/0$/78 Safety Related Welding 09/19/78 Revised Welder Confonaance Qualification Log and updated QA records to reflect welder qualification status
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STOP WORK NOTICES Page 4 4
START WORK ISSUED TO ISSUED DATE SUBJECT APPROVAL DATE DISPOSITION Construction /
10/17/78 Origination, distribution and 10/19/78 Revised procedures to Engineering all work perfonned to all adequately describe the project CMC's method (s) used for the I;
origination, distribution, I
and use of CMC's.
Indoctrinated project personnel Construction 10/23/78 Unauthorized repairs in 11/lb/78 Evaluated welds for Unit I main loop piping acceptabl ity.
Investigated cause of unauthorized repairs and took appropriate management actions.
Construction 10/30/78 Manual welding activities 11/30/78 Perfonned analysis of associated with the Unit I welding materials with main loop piping satisfactory results Construction 02/14/79 Welding - ASME on WPs a0023 -
02/16/79 Requalified procedure Question on procedure qualification Construction 02/15/79 Welding - ASME on WP5 88021 -
02/15/79-Corrected discrepancy
' Through wall repairs i
Construction 04/13/79 Welding - ASME on WP:, ac023 -
04/lti/79 Corrected docuidentation Question on procedure discrepancy qualification documentation Construction 10/19/79
+ Housekeeping in safety.
10/22/79 Accomplishea cleanup and related bulldings established ongoing progroi.:
STOP WORK NOTICES Page 6 START WORK ISSUED TO ISSUED DATE SUBJECT APPROVAL DATE DISPOSITIorJ Construction 10/26/79 Installation of Sway Strut 02/21/80 Design drawing to be included Assemblies in traveler package, indoctrinated personnel in assembly, ains provided inspection criteria Construction 10/29/79 All Class IE and associated 12/03/79 Cable pulling lubricant Class IE cable pulling activities
- tested and determined to be acceptable Construction 07/09/80 Fabrication and installation 07/25/80 Established and implemented of Class Y Pipe Supports an acceptable prograa Construction 07/2S/80 Procurement, fabrication and 01/30/81 Established and implemented installation of secondary an acceptable program restraints for essential lighting and lighting conduit Engineering 06/01/80 Design of small bore pipe 09/03/80 Established and implemented supports an acceptable progran Construction 01/20/81 Epoxy grouting of base plates
.09/30/81 Acceptable grout selected Er.gineering 01/30/81 Field design changes for 02/02/81 Established and implemented pipe supports appropriate procedural controls NATSCO 01/15/82 Lack of responsiveness to 05/04/82 Resolved deficiencies to QA Audit Deficiencies uIF 03/03/82 Nuclear QA Program not None Material scrappco and implemented by supplier repurchased from alternate sourte 6
STOP WORK NOTICES Page is ST/RT WORK ISSUEU TO ISSUED DATE SUBJECT APPROVAL DATE DISPOSITION PAPCO 07/19/82 Corrective actions froen 08/12/82 Resolved discrepancies previous audit not impleniented Chicago 08/10/82 Lack of compliance to 08/11/82 Established positive Bridge & Iron specification requireinents corrective action for pipe Wiip restraints yeality Control /
11/23/82 Liquid Penetrant Exmainations 02/09/83 Recalled all penetrant Welding Engineering materials and issued approved penetrant Bahnson 03/08/83 Structural Welding; ilVAC 04/27/83 Upgraded inspection prograu Service Co.
Supports and indoctrinated affected personnel TUCCO Operations 04/15/83 Audit deficiencies with 04/19/83 Establisneo positive Instrumentation and corrective action and Control Activities e
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EXHIBIT 3 REPORTABLE SIGNIFICANT DEFICIENCIES NUMBER DATE SUBJECT
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DISPOSITION 2/4/75 Unit 1 Reactor Building Excavation Fractured rock r.emoved and replaced with dental (Overbreak) concrete and grout.
7/24/75 Unit 1 Reactor Cavity Mat (Cold Joint)
Concrete removed; new joint prepared, f
4/9/76 Unit 1 Containment Base Hat Coring Coacrete integrity determined acceptable through coring and core holes filled with grout or mortar.
9/20/76 SSI Dam Filter "A" Material Removed nonconforming Filter "A" material and other
~
conforming portions of the dam.
Reconstructed dam.
77-4 5/6/77 Weld Defects in Polar Crane Brackets Rework ala. similar welds and perform random UT inspection on all other welds.
77-C 7/19/77 Westinghouse AR Relays All affected contact cartridges replaced with approvec relays and torque requirements placed on holddown screens 77-D 9/29/77 Westinghouse Operation of Safeguard Deficiency identified and corrected prior to receipt Actuation Block /Restet Circuitry at CPSES.
77-B 8/23/77 Design Deficiency in Fuel Building Crane Place hold on drawings issued to contractor and redest System support structure to incorporate correct seismic loadings.
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79-5 5/22/79 Pipe Wall' Thickness May Not Meet ASME Determine wall thickness by documentation review ain/<.
Code Stress liequirements UT inspection. All Class 1 piping with less than r.inimum wall will be repaired.
All other piping great than.010" below minimun will be repaired.
vage.-
REPORTABLE SIGNIFICANT DEFICIENCIES NUMBER DATE SUBJECT DISPOSITION 79-6 6/19/79 Electrical Cable tray Hangers without After review of 404 cable tray hangers assigned to CBE Full Penetration Welds 210 are to be reworked per Engineering direction.
79-8 11/7/79 Installation of Drilled in Expansion Anchors Revise procedures to reflect correct installation re-quirements, identify affected supports, rework as required.
CCvelCP tYP cal engineering drawings & provide additic-i 79-9 11/15/79 Installation and Inspection of Welded Conduit Supports information on construction travelers. Develop in-spection procedures and reinspect supports to provide documentation.
79-10 11/20/79 Class V Pipe Supports Revise FSAR to delineate requirements for supports, revise specification to clarify quality requirements, develop and implement construction & inspection proce-dures, reinspect, and rework as necessary 79-11 12/13/79 Concrete Honeycombs Unit 2 Steam Determine defective areas and repair Generator Compartments 80-02 2/22/80 Discs for SW Control Valves Return to vendor for repair / rework.
80-03 2/29/80 Welded Connection of Control Boards Review as-built weld-configuration and rework as necessary.
8C-05 7/2/80 Two Inch Architectural Concrete in Floor NCR M-81-01667 issued against non-conforming bolts.
Slabs 80-09 9/26/80 Diesel Generator Pipe Supports Establish compliance to requirements by engineering evaluation, inspection and rework if required.
Peg 3 1 REPORTABLE SIGNIFICANT DEFICIENCIES NUMBER DATE SUBJECT DISPOSITION 80-10 10/1/80 Hilti Kwik Bolt Installation Indoctrinate personnel, rework affected s,upports, and :
initiate a sampling program of UT examination for Hilti-bolt installation 81-A 2/17/81 Westinghouse Gate Valves Modify valves as per Westinghouse Field Change Notice and perform stroking during startup testing.
81-B 3/74/81 Bahnson HVAC Anchor Bolts Revise Bahnson Procedures to require information on anchor bolts, as-built drawings, reinspect previous i; stallations and document as as-built dwgs for post in stallation design verification.
Rework as necessary.
81-03 3/30/81 HVAC Cooling System Replace existing HVAC system with system meeting new design requirements.
51-06 6/4/81 Seismic Design Criteria for Instrumentation Evaluate engineering documantation and revise, if Supports necessary, survey completed installations and rework as required.
81-07 11/19/81 Orifice Plates (BIF) Outside ISA Standard Scrap existing orifice plates and procure new plates RF3.2 Tolerances from a new supplier with an approved quality program.
82-A 1/22/82 Borg Warner Valves May Not Close Properly Rework / repair 0
if Installed Between 22 0 & 1575 82-02 2/25/82 Papco HVAC Fire Damper Dampers will be cicaned & lubricated, blade locks sec!
with additional fasteners, damaged closure springs rc
.placed & based on testing additional springs added, i.;
large horizontal dampers replaced with nultipanel der 82-07 8/12/82 Governor Drive Coupling Existing drive element to be replaced with new elemer.
of more suitable material (neoprene).
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l Page 4 REPORTABLE SIGNIFICANT DEFICIENCIES NUMBER DATE SUBJECT DISPOSITION i
82-09 8/18/82 Solid State Protection System Undetectable
-Modify test procedure.
Failure (Westinghouse IOCFR21) i l
l l
83-01 1/20/83 Fractured Tack Weld in Check valve Valves redesigned to change tack weld to fillet weld.-
l Disassemble, inspect & repair valves supplied prior'to:
l j
design change. Inspect valves supplied after design l
change to insure correct weld.
l 83-02 1/25/83 Westinghouse Gate valves Modify valves in accordance with manufacturer's recommendations.
83-07 3/10/83 New Fuel Storage Racks Approved anchor design issued and racks reworked, 83-08 3/24/83 Valves without Proper Weld Documentation Scrap existing brackets and replace 8J-09 4/20/83 DS-416 Reactor Trip Switchgear Replace 83-11 5/24/83 CCJ System Class V Piping Controls added to existing level transmitters and non-safety related components upgraded.
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