ML20151N913

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Independent Measurement Insp Repts 50-445/85-13 & 50-446/85-09 on 850909-19.Violation Identified:Failure to Follow QC Instruction
ML20151N913
Person / Time
Site: Comanche Peak  Luminant icon.png
Issue date: 10/09/1985
From: Harris R, Kerch H, Wiggins J
NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV)
To:
Shared Package
ML20151N849 List:
References
50-445-85-13, 50-446-85-09, 50-446-85-9, NUDOCS 8601030219
Download: ML20151N913 (22)


See also: IR 05000445/1985013

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A_PDENDIX F

U.S. NUCLEAR REGULATORY COMMISSION

REGION I

50-445/85-13

Report No.

50-446/85-09

50-445

Docket No.

50-446

CPPR-126

License No.

CPPR-127

Priority

-

Category

C

Licensee:

Texas Utilities Electric Company

2001 Bryan Tower

Dallas, Texas 75201

Facility Name:

Comanche Peak, I and 2

Inspection At:

Glen Rose, Texas

Inspection Conducted:

September 9-19, 1985

Inspectors

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W. Kerc'h', L a~d 'eactoi Engineer

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date

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A/9/fC=~

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chard HJrris, Engineering Technician

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Approved by:

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Ja s WYgging/faterials and Processes

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ction, DRS

Inspection Summary: Areas Inspected: A special announced NRC independent

measurement inspection was conducted at the utility's construction site using_

NRC nondestructive examination (NDE) personnel.

The inspection included visual

inspection of welds on electrical raceway supports, and ultrasonic inspection

of the bolting on the steam generator upper lateral supports. Also, an inspec-

tion of concrete expansion anchor bolt installation, visual inspections of

skewed welding and configuration of large bore pipe supports were conducted.

Two Region I based inspectors were assisted by two NRC contract personnel. The

inspection involved 384 onsite hours and 72 offsite hrurs (236 hours0.00273 days <br />0.0656 hours <br />3.902116e-4 weeks <br />8.9798e-5 months <br /> for Unit

1; 220 hours0.00255 days <br />0.0611 hours <br />3.637566e-4 weeks <br />8.371e-5 months <br /> for Unit 2).

Results: One violation was identified related to failure to follow a quality

control instruction (Paragraph 5).

1030219 851224

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1.0 Persons Contacted

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Licensee

R. Hooton, Texas Utilities Generating Company

]

F. Powers, Texas Utilities Generating Company

1

T. Wright, Texas Utilities Generating Company

l

R. Muldoon, EBASCO

NRC

T. F. Westerman, NRC Region IV

I. Barnes, NRC Region IV

2.0 Purpose

The purpose of this special inspection was to provide technical' assistance

to Region IV using the NRC Mobile Nondestructive Examination Van resources.

Background

Since 1981, the NRC has issued several Safety Evaluation Reports (SER)

i

L

related to Comanche Peak Units 1 and 2.

Technical concerns and allega-

tions were a part of the regulatory issues that remained outstanding

,

toward the completion of construction of the Comanche Peak facility.

To address these outstanding concerns, the licensee has developed and

4

implemented the Comanche Peak Response Team Program Plan to identify any

design or construction deficiencies.

This inspection, using the NDE Van personnel and equipment, was designed

.

to verify, on a sampling basis, the adequacy of previous licensee efforts

under its Plan.

4

3.0 Electrical Cable Tray Supports, Unit 2

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The selected sample of cable tray supports consisted of sixty-three supports.

'

The attributes inspected included selected as-built dimensions and weld

,

characteristics. All welded joints in this selected sample were examined

after primer and epoxy coating.had been applied. Therefore, the attributes

of the fillet welds that could be evaluated were:

1.

Fillet size

.

2.

Location

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4

3.

Leg and throat size

4.

Concavity and convexity

5.

Length of weld

6.

Gross undercut and large porosity

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7.

Overall workmanship.

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The inspection was performed and an evaluation made in accordance with

the as-built drawings and considered the visual weld acceptance criteria

contained in the Nuclear Construction Issues Group acceptance standard

(NCIG-01). Cable tray supports sampled during this inspection were in the

Safeguard and Reactor buildings.

Table I lists the supports inspected.

Results of Inspection

On support 11730, torquing of support bolting appeared inadequate.

However, a review of the quality records indicated that this support had

not yet been reinspected by the licensee (licensee is committed to 100%

reinspection). Welding aad as-built dimensional configuration of Unit 2

electrical cable tray supparts met construction requirements. No viola-

tions were identified.

4.0 Electrical Cable Tray Supports, Unit 1

The licensee reinspected a sample of 451 cable tray supports in Unit 1.

The NRC independently selected a sample of 61 supports, 24 were part of

the licensee's 451 and 37 were selected out of the total remaining

population. Attributes and acceptance standards were the same as for the

sample inspection performed in Unit 2.

Cable tray supports sampled during

this inspection were selected in the Fuel and Reactor buildings.

Table II

lists the supports inspected.

Results of inspection disclosed that the welding and ~ssle'cted dimensional

configuration of the cable tray supports met construction requirements.

However, the inspector identified a generic concern with Richmond insert

bolting.

De'iciencies existed such as gaps between the head of the bolt

and the base angle of the hanger; procedure QI-QP-11-10-2 requires contact

between faying surfaces. Other gaps existed between the base angle and

concrete. Drawing CTH-1, note 18, has specific engineering angle to con-

crete bearing requirements that have not been met.

These conditions,

although in some instances were understated, were reported on the as-built

drawings for the cable tray supports.

Supports 6057, 6058, 5995 and 1973

revealed gap deficiencies between the head of the bolt and angle. Also the

supports had gaps between the angle and the concrete.

The generic bolting concern is considered unresolved pending the comple-

tion of the licensee's engineering evaluation and NRC review.

(445/8513-U-01)

5.0 Pipe Supports

A selected sample of pipe supports and hangers were inspected per site

'

Quality Instruction Procedure QI-QAP-11-1-26 and the as-built drawings. A

total of eleven were inspected in Unit I and eight in Unit 2.

Supports

were inspected for overall dimensions, location and material size.

In

addition to the dimensional inspection, weldments were visually inspected

for size, surface condition and overall wczkmanship.

Table III lists the

specific items inspected.

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Results: Drawing AF-2-SB-10, mark No. AF-2-006-412-S33A, indicated the

as-built dimensions from centerline of the pipe to the wall at line 14S

to be 11 ". This dimension when measured by NRC was shown to be 13 ".

In order to verify if this difference was recorded by the licensee, the

inspector compared NRC inspection data with the site quality dimensional

records for support AF-2-006-412-S33A, dated 4/27/85.

This review revealed

that the quality control inspector did not assign a number to the 11 "

dimension and did not record the measurement.

Procedu're QI-QAP-11.1-28

requires that each dimensional attribute be assigned a number and measure-

ments made.

Because, in this particular case, the as-built dimension had

not been recorded, as required, the inspector considered this item to be a

violation (446/8509-V-01)

Skewed Welds

A selected sample of type 2 skewed weldments, previously inrpected and

accepted by the utility, was reinspected by the NRC to verify the method

and validity of the licensee's inspection.

Skewed welds inspected included stanchion-to-stanchion, stanchion-to pipe

saddle and tube steel-to pipe or pipe saddle weldments. Nineteen pipe

supports in Unit I were inspected; approximately thirteen hundred linear

inches of weldment were inspected by NRC using fillet weld gages,

Cambridge gages and a contour gage. Areas that could not be inspected

with a fillet or Cambridge gage were inspected using the contour gage per

site Procedure QI-006, Revision 1.

Results:

No violations were identified.

No instances of undersized welds were observed when the as-built conditions

were compared to the applicable drawing requirements. Additionally, those

measurements taken by the NRC were compared to those measurements taken

and documented by site personnel.

There were no significant differences

noted.

Hilti Bolt Inspection

One hundred and twenty-four Hilti Kwik anchor bolts were inspected per

site Quality Instruction Procedures QI-QP-11-2-1, Revision 18, and

QI-QP-11.18-4, Revision 0, in conjunction with NRC Procedure NDE-18,

Revision 0.

The inspection consisted of ascertaining embedment depth,

bolt spacing and length and diameter of individual bolts as identified by

code stamp.

Table IV lists the specific items inspected.

Results: No violations were identified.

As of 9/19/85, the inspectors

had identified ore bolt on a concrete base plate which appeared to be

underlength. On 9/25/85, telephone communications from Region IV

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personnel indicated that the bolt had been verified to be the correct

length by both the licensee and NRC persennel. The inspectors had no

further questions.

6.0 Steam Generator Upper Lateral Support Bolting

Steam Generator upper lateral support bolts had been reported as

improperly shortened by the licensee. The licensee had replaced several

of the reported shortened bolts and was awaiting engineering disposition

as to the course of follow-on action. The NRC selected one hundred and

four bolts for independent ultrasonic inspection to determine their length.

Ninety-eight wert measured from the top of the bolt head to the concrete

wall (see sketch on Attachment A for dimension "A").

A calculation was

performed to determine embedment engagement.

The NRC compared its data

to the site's and there were some differences.

In order to resolve the

differences, the NRC requested bolt 1E15 be removed and a dimensional

measurement be made.

This_ revealed that the embedment plate was not flush

!

with the wall, but stuck out 5/8" (see Attachment A, dimension "C").

This

accounted for the difference between NRC data and the licensee's.

Results:

No violations were identified.

7.

Unresolved Items

An unresolved item is a matter for which more information is necessary to

determine whether the item is acceptable, a violation or deviation.

Unresolved items are contained in paragraph 4.

8.

Tables and Attachments

Table I is a tabulation of specific Electrical Cable Tray Supports

inspected in Unit 2.

Table II is a tabulation of specific Electrical Cable Tray Supports

inspected in Unit 1.

2

Table III is a tabulation of specific Hanger / Supports and skewed welds

inspected.

Table IV is a tabulation of specific Hilti Bolts that were ultrasonically

tested for length.

Attachment A is a tabulation of specific Steam Generator lateral support

bolts that were dimensionally checked for length.

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9.

Exit

A formal exit interview was not held.

However, members of the licensee's

staff and NRC Region IV personnel were informed of progress and findings

during the course of the inspection.

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ELECTRICAL CA8LE TRAY SUPPORTS

UNIT 2

TABLE I

11600

9768

9801

11603

11733

9802

11604

11825

9803

11607

11826

- -9804

11608

9850

9805

11519

9851

9806

~

11520

9852

9807

11522

9853

9808

11523

9854

9809

11524

9855

9810

11526

9836

9811

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11527

9837

9812

11528

9839

9813

10094

9840

9814

10095

9841

9815

11924

9918

9816

11933

9919

9817

10136

9920

9818

9765

9921

9819

9766

9922

9820

9767

9800

11730

Results: The above cable tray supports reinspected by the NRC for welding

and selected as-built dimensional configuration met construction

requirements.

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TABLE II

,

The NRC selected a total of 61 supports to be inspected. Asterisked supports

were selected from the 451 previously reinspected by the licensee. The remain-

der were selected from the remaining population. The Unit I supports that were

inspected are the following:

CTH-1- 236

CTH-1-1970

  • CTH-1-5918

1181

1973

5919

1184

1974

5920

1186

1975

5921

1719

1978

5922

1720

5226

5986

1722

5765

5994

1723

-

5766

5995

1724

5767

6017

1725

5769

6057

1726

5771

6058

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1727

5772

6938

1728

5773

6939

1741

5876

6940

1742

5886

6941

1743

5912

6942

1746

5914

6943

1842

5915

6944

1852

5916

6945

1862

5917

6946

6947

_

Results: The above cable tray supports reinspected by the NRC for welding

and selected as-built dimensional configuration met construction

requirements. However, a bolt torquing concern was identified

on some of these supports.

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TABLE III

LISTING 0F HANGER / SUPPORTS INSPECTED AS-BUILT AND SKEWED WELDS

Unit 1

Drawing

Building

Comments

1.

CC-1-202-001-S53A

Safeguards

Welds and Dim. Acc.

2.

BR-X-106-059-S43A

"

"

"

"

"

3.

CC-1-065-003-S33A

"

"

"

"

"

4.

CC-1-019-012-A43K

Auxiliary

"

"

"

"

5.

CC-X-079-006-A43A

"

"

"

"

"

6.

CC-1-035-018-A33A

"

"

"

"

"

7.

RH-1-001-001-C41S

Containment

"

"

"

"

8.

CC-1-110-007-A43S

Auxiliary

"

"

"

"

-9.

CC-1-235-006-C53R

Containment

"

"

"

"

10. RC-1-135-008-C41K

"

"

"

"

"

~

11.

RC-1-135-004-C51K

"-

"

"

"

"

Unit 2

Drawing

Building

Comments

1.

SI-2-071-405-S33K

Safeguards

Welds and Dim. Acc.

2.

AF-2-004-405-S33A

"

"

"

"

"

3.

CT-2-005-403-S22K

"

"

"

"

"

4.

CC-2-116-006-F43A

Fuel

"

"

"

"

5.

AF-2-101-431-S33A

Safeguards

Welds and Dim. Acc.

(CMC 87004)R3

6.

CS-2-597-403-C42A

Containment

Welds and Dim. Acc.

7.

RH-2-064-406-S22R

Safeguards

"

"

"

"

8.

AF-2-006-412-S33A

"

See Report

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TABLE IV

HILTI BOLT UT

Unit 1

Drawing

Building

Code

Total

Comments

CC-1-AB-044

Auxiliary

T

8

Acceptable

"

"

0

4

"

CC-X-AB-003A

"

R

8

"

"

"

0

4

"

CC-X-AB-002

"

0

8

"

CC-1-AB-19-11

R

4

"

"

CC-1-AB-19-12

"

R

3

"

CC-1-AB-19-13

"

R

8

"

CC-1-AB-19-12

T

1

"

"

CC-X-041-004-F43

Fuel

R

4

"

SF-X-067-002-F35R

L

8

"

"

SF-X-067-700-F35R

"

T

4

"

SF-X-066-007-F33R

"

L

4

"

SF-X-01-F51-R-3

"

R

4

"

CT-1-105-003-C62R

Containment

R

8

"

CT-1-RB-057-001

T

4

"

"

SI-1-RB-058-002

"

L

4

"

"

"

P

4

"

SI-1-RB-058-001

"

R

4

"

CC-1-242-004-C53R

"

0

4

"

SF-X-068-006-F33R

Fuel

0

4

"

CC-X-024-001-A43

Auxiliary

T

4

"

CC-X-211-010-F43

Fuel

P

4

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CC-2-116-008-F43

T

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