ML20199A503

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Rev 0 to Procedure CP-EI-4.0-50, Control of Refabrication & Installation of Diesel Generator Auxiliary Skid Base & Associated Structures - Unit 2. Supporting Documentation Encl
ML20199A503
Person / Time
Site: Comanche Peak, 05000000
Issue date: 02/06/1984
From:
TEXAS UTILITIES ELECTRIC CO. (TU ELECTRIC)
To:
Shared Package
ML17192A346 List:
References
FOIA-85-313, FOIA-85-59, FOIA-86-A-20 CP-EI-4.0-50, NUDOCS 8606120425
Download: ML20199A503 (109)
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Text

{{#Wiki_filter:_ s ( 1%e% \\j N M A A GLu 14 IW 'LG 3 TUGCO ENG ION REVISION PAGE t CP-EI-4.0-50 0 g. (.. ft/ 1 of 10 CDNI'BDL OF BE-FABRICATION & INSTALIATION OF DIESEL GENERAIOR AUXILIARY SKID PREP P (LDb b BASE AND ASSOCIATED A /$qj ' Ses--. W STBUC'IURES - UNIT 2 APPICVED BY V

1.0 REFERENCES

o f 1-A CP-EP-4.0 Design Control j 1-B AISC Manual of Steel Construction, 7th Edition 1-C AHS-D1-1-75 t 1-D tCR tb. M-62-00581,R.1 (See Attachment 2) 1-E Existing DeLaval/B&R Drawings (See Attachment 1) 1-P Material Verification Procedure QI-QP-11.14-4 1-G Brown & Root Structural Steel Erection Procedure 35-1195-CCP-22 2.0 GENERAL s 2.1 IURPOSE This instruction establishes the guidelines for replacement and reconstructicn of Diesel Generator Auxiliary skid base 'and associated structures. Se measures described herein will ensure coupliance with the general requirements of Beference 1-A and the specific requirements of anferences 1-B & 1-C and DeLaval's design. 2.2 SCDPE h Material & Fabricaticn non-conformances wre found in Unit 2 Auxiliary i skid base and associated structures as supplied by vendor (DeLaval) per P.O. CP-0034. Per Reference 1-D the dispositico to this, j problem was to replace the aforesaid structures ccmpletely. tis instruction is applicable to the activities of CPP Civil Engineering discipline associated with the specifing of section substitutions for the defective materials previously supplied and issuance of structural outline ard detail drawings. %e l classification of structures involved is as follows: A) Auxiliary Skid Base - Basic structural frame anchored to concrete foundation, supporting various equipnent arti piping. 21s is identified as "Sub-Base" on Detaval/ Brown & Poot drawings (Peference 1-E). i t 0606120425 860604 PDR FOIA )h GARDE 86-A-20 PDR

o i 'IUGCO ENGINEERDG DIVISIN INST!WCTION REVISION ISSUE PAGE DATE { CP-EI-4.0-50 0 J.(.-7/ 2 of 10 1 i l B) Associated Structures 'Ihis includes the followings i I) All the sub-assemblies supporting individual equipnent i and various pipe supports and connected to the Auxiliary ~ Skid Base. i II) Pipe supports required for the piping systems <m the i Auxiliary Skid Base. l) III) Supporting structure for the standpipe. IV) Supports for Jacket Wster Cooler & Imbe Oil Cooler, 2 anchored to concrete foundation. V) Support frame for the Heat-Shield. i l VI) Support for Air Intake Silencer. the specific scope of erk includes, couplete material replacement, fabrication and installation of all the structural steel pertaining to items A &B described above. e I 2.3 IESPG EIBILITY 2.3.1 ORIGINAL DESIW i j original design and analysis of the auxiliary skid base and associated structures is the vendor's (DeLaval) responsibility. Any wek ywh.J as per this instruction, will not adversely } affect the intent of original design. 1 2.3.2 The CPP Civil Engineer is responsible for providing technical guidanoP i and administrative direction to the Civil / Structural organisation. The CPP Civil / Structural Supervisor shall be responsible for impleman-tion of this program, in accordance with guidelines established by this instruction. i Where specific individuals are identified in this instruction, it shall i be understood that a designee may be delegated to act in that capacity. f 3.0 PICCEDURE 1 3.1 A8-eUILT SURVEY l As-built survey shall be performed on existing Auxiliary Skid Base l and associated structures, prior to their dismantling and removal. i Any danges due to as-built conditions concerning a) location (elevations & lintar dimensions) and b) structural member length shall 3 m ted in re-fabrication and installation wrk. Existing be ire a i m anchor bolts and leveling plate assemblies, orginally pro-l vided by the vendor, shall be left in place, undamaged fbe re-use. i l l ud.f A.D d uter & m,- - e t 9. 4. tM A. 4 -t h-" W 7 NWWW' w_gw ;ew"cayg. 3 rpp' y*We'* pg,, a .,,, h e g m m,. ,a

) 'IUGC0 ENGINEERING DIVISION INST 10CTION REVISION ISSUE PAGE DATE CP-EI-4.0-50 0 2 6 7T 3 of 10 3.2 STRUCIURAL CUILINE Ato DEMIL FABRICATION DRAWING Civil Engineering shall prepare structural outline and detail fabrication drawings based on Reference 1-E and as-built survey information. Original design concept of structural mmber-framing chall be maintained. If substitution of structural member sizes . - required for any reason, then substitition shall be an equivalent er better section. Material type also shall be equivalent or of a tetter grade than specified on drawings in Reference IE. Material type shall be noted on new fabrication drawings. These drawings and details shall be issued to construction for fabrication and installation in accordance with established project procedures / instructions. 3.3 DESIGN CHANGES ( Design danges issued for Unit 1 Auxiliary Skid - pipe susports by various CMC's due to changes in vendor design requirements shall be reviewed. Identical design danges in their entirety, will be irwwposated in the same pipe suwvii.5 on Unit 2 Auxiliary Skid. 3.4 (IN(ECTIONS A. Welded Connections - Welded connections shall be of the same type and size, as sho w on Reference 1-E. Where fillet weld sizes are not specified, a maxinum fillet wid based on thickness of material or ocmiplete penetration weld shall be substituted meeting the requirements of References 1-B & 1-C. B. Bolted ccmeetions - Where bolting material is not specified in Reference 1-E, the material previously used shall be verified by field inspection and equivalent material used during re-assent:1y. 4.0 MATERIAL All material shall be nuclear safety related. Material verfication shall be performed per Reference 1-F and documented on " Structural Assent:1y Verification Cards", (See Attachment 3). 5.0 FABRICATION AND INSTALIATION Fabrication and erection of the structures shall be in accordance with the requirements of anferences 1-B, 1-C and 1-G and associated drawings / details issued per this instruction. (

0 TUGCO ENGINEERING DIVISION INSTRUCTION REVISION ISSUE PAGE DATE CP-EI-4. 0-50 0 J.4-W 4 of 10 ATTAC! MENT 1 [ LISP OF EXISTING DEIAVAI/ BROWN & 100r DRAWINGS: 1. FSM-00214, Sh.1 thru 3

21. BRH-02-717-01 HP-76003 & 76004 2.

FSM-0232, Sh.1 thru 3

22. BRH-02-717-01 HQ-76003 & 76004 3.

FSM-0233, Sh.1 thru 3

23. BRH-02-717-01 HS-76003 & 76004 4.

02-717-01-JM, Sh.1 thru 3

24. BRN-02-717-01 HU-76003 & 76004 i

\\ 5. R-3943

25. BRH-02-717-01 HV-76003 & 76004 l

6. R-3944

26. BRH-02-717-01 HW-76003 & 76004 7.

R-3973

27. BRH-02-717-01 HX-76003 & 76004 8.

BRP-101347E-76003

28. BRH-02-717-01 HY-76003 & 7'6004 9.

BRP-101347E-76004

29. BRH-02-717-01 HZ-76003 & 76004 l
10. BRP-101348F
30. BRH-02-117-01 JA-76003 & 76004 i
11. BRP-101349G
31. BRH-02-717-01 JB-76003 & 76004 f
12. BRH-02-717-01 HE-76003 & 76004
32. BRH-02-717-01 JC-76003 & 76004
13. BRH-02-717-01 HF-76003 & 76004
33. BRH-02-717-01 JD-76003 & 76004 i
14. BRH-02-717-01 HG-76003 & 76004
34. BRH-02-717-01 JE-76003 & 76004
15. BRH-02-717-01 IE-76003 & 76004
35. BRH-02-717-01 JF-76003 & 76004
16. BRH-02-717-01 10-76003 & 76004
36. BRH-02-717-01 JG-76003 & 76004
17. BRH-02-717-01 HK-76003 & 76004
37. BRH-02-717-01 JH-76003 & 76004
18. BRH-02-717-01 HL-76003 & 76004
38. BRH-02-717-01 JJ-76003 & 76004 i
19. BRH-02-717-01 IN-76003 & 76004
39. BRH-02-717-01 JK-76003 & 76004 j
20. BR M-717-01 Ht+-76003 & 76004
40. BRH-02-717-01 JL-76003 & 76004 i

l

e 'IUGCO ENGINEERING DIVISION INSTRUCTION REVISION ISSUE PAGE DATE CP-EI-4.0-50 0 24-N 5 of 10 ATTACHMENT 1 (CONTINUED) LIST OF EXISTI!G DEIAVAI/BIOWN & ROCfr DRAWINGS:

41. BRH-02-717-01 JN-76003 & 76004
61. BRH-02-717-01 N-76003 & 76004
42. BRH-02-717-01 JP-76003 & 76004
62. B M-02-717-01 PX-76003 & 76004

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43. BRH-02-717-01 JQ-76003 & 76004
63. BRH-02-717-01 SK-76003 & 76004
44. BRH-02-717-01 JR-76003 & 76004
64. BRH-02-717-01 SL-76003 & 76004
45. BRH-02-717-01 JX-76003 & 76004
65. BRH-02-717-01 SM-76003 & 76004
46. BRH-02-717-01 JY-76003 & 76004
66. BRH-02-717-01 UK-76003 & 76004
47. BRH-02-717-01 IM-76003 & 76004
67. BRH-02-717-01 UP-76003 & 76004
48. BRH-02-717-01 IR-76003 & 76004
68. BRH-02-717-01 00-76003 & 76004
49. BRH-02-717-01 IP-76003 & 76004
69. BRH-02-717-01 UR-76003 & 76004
50. BRH-02-717-01 IO-76003 & 76004
70. BRH-02-717-01 0s-76003 & 76004
51. BM-02-717-01 NL-76003 & 76004 71 BRH-02-717-01 Ur-76003 & 76004 j
52. BRH-02-717-01 21-76003 & 76004
72. BRH-02-717-01 UU-76003 & 76004
53. BRH-02-717-01 W-76003 & 76004
73. BRH-02-717-01 UV-76003 & 76004
54. BRH-02-717-01 NP-76003 & 76004
74. B2-02-717-01 UW-76003 & 76004
55. BRH-02-717-01 NY-76003 & 76004
75. BRH-02-717-01 VA-76003 & 76004
56. BM-02-717-01 PK-76003 & 76004
76. BRH-02-717-01 VB-76003 & 76004 i
57. MH-02-717-01 M-76003 & 76004
77. BRH-02-717-01 W -76003 & 76004
58. BRH-02-717-01 PS-76003 & 76004
78. BRH-02-717-01 VD-76003 & 76004 I
59. BRH-02-717-01 PP-76003 & 76004
79. BRH-02-717-01 VE-76003 & 76004
60. BRH-02-717-01 PV-76003 & 76004
80. BRH-02-717-01 VF-76003 & 76004 i

j i

e 'ItJGCO ENGINEERING DIVISION INSIPDCTION REVISION ISSUE PAGE EATE J --/e-k 6 of 10 CP-EI-4. 0-50 0 ATTACHMENT.1 (CDiTINUED) LIST OF EXISTI!C DEIAVAI/BIOtt & 100T DRAWINGS:

81. BRI-02-717-01 W-76003 & 76004 101. BRH-02-717-01 WK-76003 & 76004 i
82. BRH-02-717-01 VH-76003 & 76004 102. BRH-02-717-01 WL,76003 & 76004
83. BRH-02-717-01 W-76003 & 76004 103. BRS-02-717-01 E 76003 & 76004
84. BRE-02-717-01 VK-76003 & 76004 104. BRH-02-717-01 WP-76003 & 76004
85. BBH-02-717-01 W-76003 & 76004 105. BRH-02-717-01 WQ-76003 & 76004
86. BRH-02-717-01 VN-76003 & 76004 106. BRi-02-717-01 WR-76003 & 76004
87. BM-02-717-01 VR-76003 & 76004 107. BRH-02-717-01 WS-76003 & 76004
88. BRE-02-717-01 VS-76003 & 76004 108. B M-02-717-01 WY-76003 & f6004
89. BRH-02-717-01 VP-76003 & 76004 109. BRH-02-717-01 WE-76003 & 76004
90. BRH-02-717-01 VU-76003 & 76004 110. BRH-02-717-01 XA-76003 & 76004
91. BRH-02-717-01 W-76003 & 76004 111. BRH-02-717-01 XJ-76003 & 76004
92. BRH-02-717-01 VW-76003 & 76004 112. BRH-02-717-01 XK-76003 & 76004
93. BRH-02-717-01 vz-76003 & 76004 113. BRH-02-717-01 XL-76003 & 76004
94. BRR-02-717-01 WA-76003 & 76004 114. BM-02-717-01 XM-76003 & 76004
95. BRH-02-717-01 WB-76003 & 76004 115.. BRH-02-717-01 XP-76003 & 76004
96. BRH-02-717-01 WC-76003 & 76004 116. B M-02-717-01 XR-76003 & 76004
97. Bef-02-717-01 WE-76003 & 76004 117. BRH-02-717-01 Hi-76003 & 76004 i

i

98. BRH-02-717-01 WF-76003 & 76004 118. BNi-02-717-01-xB
99. BNi-02-717-01 W76003 & 76004 119. BRH-02-717-01 XC 100.BRH-02-717-01 R7-76003 & 76004 120. BRH-02-717-01 XD i

i

1 'IUGCO ENGINEERING DIVISION INSTRUCTION REVISION ISSUE PAGE DATE CP-EI-4.0-50 0 Jg.g 7 of 10 ATSCHMENT 1 (G NfINUED) LIST OF EXISTDG DELAVAI/B10WN & 10CTf DRAWINGS: 121.BPH-02-717-01-XE ~ 122.BRH-02-717-01-XN 123.BRH-02-717-01-XQ 124.BRH-02-717-01-NR 125.BBH-02-717-01-NS 126.BRH-02-717-01-VP 127.BRH-02-717-02-BV-76003 & 76004 6 o' l 1 l 1

S TUGCO ENG3NEERING DIVISICN INSTEX2 ION REVISION ISSUE PAGE { t DATE CP-EI-4.0-50 0 j-4 -$ 8 of 10 ATDCliMENT 2 CCMANCHE PEAM STEAM ELECTRIC STATICN m was GENERATDeG CO. NCNCCNFCRMANCE REPCRT (NCR) M 2 0581 R-1 ~ ~ ~ STRUCTURE / SYSTEM ITEM /CCMPCNENT TAG /la NUMSEM LOCATICM CM ELEVAUCN RIA NO. yMcT C72-MEDGEE-01 7 ogf3 coa Aux. Skids CP2-MEDGEE-02 CG 81de. 810'6" N/A ~mmmmens 4 Supports for ASME Class 3 piping and camponents are considered ano fabricated by the j Vendor Transamerica Delaval as Mcn-NF. t These supports should be NF as specified in the applicable Gibbs & Hill specification. i 9 N -l 8 2323-MS-34 nay 1 ,ana _L 3 nerenseca occuuawf. ~ nerontso sT: oars: M. Asmussen 5 i13i 82 - - w,,m} - 1 n l =spr4., ~ 5 ~ o 1 REWCWC REPAan USE AS IS SCRAP See Attac.Neunt. l 3 l 1, i i g / M i ENG. AEVIEW/ APP 9CVA # OATE: h $ ! 9'O h, y c4TE: ca aeview Ayug) br n, ho 3 2 74 sln/n fi Hi 73,g l w i c cisposincM vEmmCATiCn a CO:sunt:

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} l 'IUGCD ENGINEERING DIVISICH INSTRUCTICN REVISION ISSUE PAGE DATE j I CP-EI-4.0-50 0 J.f-Q 9 of 10 AT mCEMENT 2 ? (CONTINUED) i l l i NCR M-82-00581 R-1 n DISPOSITION: Evaluation of the subject condition is separated into a consideration of design li and a consideration of fabrication. The Vendor, Transamerica Delaval has perfonned an analysis that shows that the worst case stresses fall within the allowables of the ASME Code. This portion of the nonconfoming condition is'therefore dispositioned "use as !s". The fabrication records have been examined and there is insufficient documentation to claim NF-equivalency. An inspection of all skid and support welds was started in order to qualify the fabrication to AWS 01-1 and the AISC Manual of Steel e Construction, seventh edition. During the inspection, various members were found to have linear indications. These findings were documented on other NCR's. In order to resolve the problem of linear indications, the base skids and component supports shall be replaced 100%. The new skid and supports shall be fabricated in i accordance with AWS D1-1-75 and the AISC Manual of Steel Construction, seventh edition. i l i

d 'IUGCO ENGINEERING DIVISICH INSTRUCTION REVISION ISSUE PAGE DATE JQ CP-EI-4.0-50 0 10 of 10 j ATDGMENT 3 s TRAVELS NO. PAGE OF _.2--_. I i I { STRUCTURAL ASSD88LY V G IFICATION CARD ti i PIECE MARK NO. AM0/0R HEAT /MIC NO. QC V E IFICATION a e.o...mm >.m a i l e i s i . -= 4 h i f i .e w j N i d e. e .e p - .. ~. s h i l~ Telephonic Interview o M i On September 6, 1983 M a former B&R carpenter and carpenter's foreman at CPSES, was telephonically interviewed by NRC Investigator H. Brooks GRIFFIN. 1 Mtated he worked at CPSES for about 2 years, but stated he did not remember c ne exact time frame. Ms' aid he worked unce6 a generai foraman, i @ said he had testified at a ASLB hearing regarding what he oelieved was " sloppy" work related to the pouring of concrete. Mstated he believed the work he performed at CPSES was done properly. M said that while he worked at CPSES, he was not intimidated by anyone nor did anybody attempt to intimidate him. Msaid he had adequate freedom to perfonn his. job and did not recall anyone threatening or harassing him. Msaid his ole concern was covered in his testimony to the ASLB regarding." bad concrete .erk." 6 technical concerns were forwarded to Region IV staff for evaluation. J r i l 'm b l

r s L e i 17 l c Telephonic Interview of M i On August 23,1983.h a Brown & Root, Inc., cable tray supports fitter at CPSES, was telephonically interviewed by NRC Investigator H. Brooks GRIFFIN. I-M stated he had been employed at CPSES for 5 years, and his supervisor was W i M was asked whether he had ever been intimidated or harassed by anyone into I violating procedure or if he had ever failed to perform his work in the proper manner. M stated he did not feel he had been intimidated, nor had anybody attempted to intimidate him. M stated he had always been instructed by his 4 j supervisors to follow procedures. @ stated that B&R supervision not only, encouraged, but required him to perfom his work in compliance with procedure. M stated that since he had been interviewed by the NRC on several occasions, s supervisors had always encouraged him to truthfully answer the NRC's questions. .i AW'jB i l i i

h Y-H / AQ Q \\ i l 24 j Telephonic Interview of OnAugust18,1# a former Brown & Root, Inc. 6 l Mat CPSES, was telephonically interviewed by NRC. Investigator H. Brooks GRIFFI6 stated he had been hired as a welder at CPSES in July 1976. l @ tated that'in October he was promoted to welding foreman and in 1978, he became a welding technician at the rod shack (welding rods).Mstated that in. April 1978, he was promoted t the Structural Iren Fabrication Shop. Maid that in ilovember 1982, he was teminated during a ROF because he to16 a supervisor of TUSI (Texas Utilities Services, l Inc..) about employee theft occurring at CPSES. 6 stated he originally wrote anonymous letters and left them wit @ M regarding thefts, but later discussed his letters with theM M 6 stated it was his understanding of the ensuing events i thatO mentioned the theft to6(title unknown). Msaid he discussed the employee theft with a superintendent nas6(not further identified).M said that as a result of his identifying the employees Md been stealing property, he believed he had been blacklisted within B&R W as evidenied by his termination during a ROF. He advised this matter had been brought to the Board's attention. M stated that while he worked at his various positions with B&R, nobody had attempted to int'imidate him nor had he been intimidated into performing his work improperly. M stated he never knowingly violated procedure. l-stated he knew a QC inspector by the name o M who had been intimidated and forced to buy-off on improper work. M stated that i M problems were documented and had been brought before the CPSES ASLB. l M said u did not know who had intimidatedM or the location and identity of the " improper work" she was forced to " buy-off." l l

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~ f -. ~..,. ] 1 5 CCNSTRUCTION CPERATICN TR AVELER 35-419 QGUANT1iY MS PA4E.1,0F"4 N/ O3 UNIT NC. N 1 ECUIPW NC. N 9 Q CP2-MEDGEE- 01 ere yne, 4, e., no TRAVE 1.IR No. 003 I Os MW84-6983-2-3 Oh o 2DC-1 [ 5YSTEM ATk T.tARY evyn LLEV. ROOM 84 ) QLOCATICNSAFFCL'ARD BLDC. CCP-22 O ATE _ 0-5 R4 _ - Q EPT.. wrr r unreu, rowm SPECJiROC/ EhME.INSTM. J s Mr J 6#AC 9I4/IY P'EPARED 8Y N 0 ATE. m ~ N/ A eA/oc-REVIEWED SY A//A O AT E _ ---.A EMG. ANI_ ANI REVIEW _ u MSB-I605-DG01. = GENERAL NOTES & REFERENCE PER DRAWING D.ma otP1". optRAT10N , TO BE INACCORDANCE NOTE #1: WJ FABRICATION OF ASSEMBLY NO. 5 DG02. ITH DRAWING (S).MSB-2605-DG09, MSB-260 - TE #2: NO W CONSTRUCTION SEQUENCE OF OPERATIONS MAY VARY TO SU VIOLATED. RIORITIES PROVIDED NO HOLD POINTS ARE IS COMPLETE, QC OTE #3: N f :.: P IF AT TIME OF INSPECTION THE OPERATIONHOWEVER, M SHALL SIGN THE FACE OF THE TRAVELER. I IBE EACH INSPECTION ON D NOTE #4: i ER WHEN THE OPERATION IS ATTACHED SAVC OR WIDC. LAST QC p j t FINALLY COMPLETE. INSPECTIONS QC TO INSPECT WELDS PER QI-QP-11.21 C A NOTE #5: TO BE DOCUMENTED ON IHE WIDC. NSTALL'.D AT A E ALL U-BOLTS WILL BE FABRICATED AND I ~ LATER DATE BY A SEPARATE TRAVELER. NOTE #6: E Y WORK. READ ENTIRE TRAVELER BEFORE STARTING ANNG(S) 1. MW REQUISITION MATERIAL AS LISTED ON DRAWI T VENTORY AND RECORD REA STRUCTURAL STEEL FAB SHOP BU J SAVC 2. MW I

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L y$ QC TO INSPECT PER QI-QP-11.14-4. WING (S) 0F NOTE #2. NO ~ MR N FABht5CATESUBASSEMBLYPERREFERENCEDDRADBL M~ SMALL ENOUGH TO ALLOW HOLES ARE TO BE TAPPED UNTIL AFTER SAN fA 3. MW FABRICATE SUBASSEMBLIES SO T D K EACH PART VITH l D' ASSEMBLY NO. AND MARK NO. PER DRAWING. g QI-QP-11.14-1/11.14-4. T AS NOTED ON DRAWINGS. .h ALL WELDING TO BE PER WPS-10046, EXCEPFOR FABRICATIO Y QC TO VERIFY PER NOTE #5 TMENT FOR SANDBLASTING 4. MW QC(V) TRANSPORT SUBASSEMBLIES TO PAINT DEPAR 34 5. MW AND PAINTING. J d IJ

( d I CONSTRUCTION CPGAT1CN TRAVELER CCNTINUATICM ACTMTY CESCRIPT1CN pact l CF - 4 TMAV" rM NC. FABRICATION OF Auxu.IARY SKID MW84-6983-2-3003 PMEPARED SYD7%7 OII CATE 9-4-84 9/k/IfY neviento # d.7'd:GP cATE kA Ulb CATE ANi MEV1CM QA/oc coerm rN o. a9: _ ore om creesiten PERFORM SANDBLASTING AND PADTING PER G&E bEC. 2323 6. PAINT DEPT. COMPLEIE FDAL FABRICATICN AND AS$ZMBLY AT PERMANENT LOCAIION. 7. MW YERITE FEE DESIGN DRAWINGS /QI-QF-L1.14-1 AS PER NOTE #4. QC(V) REQUISITION STECCTURAL BOLTING MAmm FRCM,MAmm CCNTROL. 8. MW QC(V)' g g, QC TO VERITY PER QI-QP-L1.14-4. USING REFERENCED DRAWDG(S), SEE NOTE #2,. INSTALL ASS 12fBLY NO. 9. MW TO M P'" "* EXISTING ANCHOR BOLTS.PER 8 WJ DRAWING MSB-2605-DG02. ^ *-c p STRUcavmAL BOLT INS N ATTCN PER. REFERENCED DRAWING (S). ALL A325 i .W 10. QC(V) ECLTS SHALL BE TORQUED IN ACCORDANCE WITE PROCEDURE CCP-22. QC TO VERITY PER QI-QF'-1L.14-1, DOC" MENT ON SA7C', RECORD LOCATICB NUMHR OF BOLTS,TIFE AND SIZE,,AND TIGHTINING CRITERIA. M&TZ NO. ~ CAL DUE DATE TORQUE VALUE l l t 11. QC VERITT TRAVELER COMPLEII. l 4

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'W A4 j Post CWfica Bau 1001. C en stoes. Temas 76043 CUALITY ASSURANCE DEPARTMENT VISUAL EXAMINATION CHECXLIST PnCJECT: COMANCHE PEAK JOS NO. 35 1195 ~ UNIT PAGE OF seawine systems u 9C 3C 3C OTMem p,. Enter NA adjacent to attribute when not aoplicable. Enter Sat./Unsat. or NA above results in each section 1 through 4 as applicable. WDC# ' " * ' * " ^ " * " * " ^ " " " ' * ' QI-QAP 11.1-26 Rev. CHEcx ust

1. FITUP (Prior and During) s-m.= o as G.

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P 1.1 26 Rev. U8usessut 8100st Slas Sletetene et Surman 8 .auseAumanar imenset l, 8'"""""*5"***'*'*C' Resu h aensus e vene,1_ SN N 88'efR AFB Seite Wee assester, eut % QGFR h Inspector Level Date d i 4 OC Sunarvision Jate t mee POOCSOW At e CERTIFICAT14fe JV Sb l OI-0AP 11.1-26 Rev. I 48= 846# 3* 8 88/10/74 G A-444-8 ese l l ~ Q-

\\*M i b M A hW % i U A b1 Category 1 Comanche Peak Open Issue Action Plan Task: Welding - welding accomplished with incorrect or without procedure. Ref. No.: M-34, M-35, M-38 Characterization: It is alleged that: AW-34: Temporary supports were welded without a procedure specification or a qualified welder. AW-35: A scrap piece of magnetized I-beam was welded for hanger repair. AW-38: Welding repairs were perfonned with improper filler material on a tube steel structural member on a diesel generator. Initial Assessment of Sionificance: There appears to be enough specificity in the allegations to warrant followup. Source: Mechanical & Piping Category No.1; see allegation list. Approach to Resolution: 1. Review NRC OI Report 84-006 dated March 7,1984. 2. Review procedures in question for adequacy at time work was performed. FOR-85-59 'j w/ar

e 2 3. Review applicable codes, specifications and other relevant documents to determine if the requirements were met. 4. Discuss adequacy of procedures with personnel involved with welding. Examine weldnents, as appropriate, that are associated with any inadequate procedures identified during interviews. 5. Review sample of similar-type welding procedures for adequacy. l 6. Evaluate allegations for safety significance and generic implications. i l 7. Report on results of review / evaluation of allegation. Related Open Issues: l 1. Using systen codes fran the tracking systen open iten list and i identify any open items. 2. Review activities necessary to close or partially close related l items. 4 1

. 3. While performing physical inspections, examine surrounding system, components, and structures for any apparent defect or indicator of faulty workmanship. 4. Complete portion of IE Module on welding if it relates to effort i made on allegation. ] s d 6 c l l l. L

-. - - - ~ ~... - g ~ ^ p.. I i l. .1 i I j i r ) Weldts8 P. 6 I CONTROLLED COPY j p j COMANCHE PEAK 8EICIEAR POWER PLANT l ALLEGAll0NS AN0/OR INVl5flf.Ill0N5 5t#8tARY 6 CROSS REF./0R COMPLETION ALLEGER-DATE RECEIVED l TASK SOURCE IRACKING CAIEGORY 1-7 SCHEDULE source NO. AllEGAil0N OR CONCERN ACTION /5TATUS ANON CONFIO SN/DATE SYSTEN NO. LEAD OPEN CONPLETE DDCletENT PAGE q. l AQW-30 Safety related welds were Ltr to Applicant I 1 A-3 Statement i repaired with weld toch 4/24/84 Response 01/ ART i I (W.T.) holdpoints instead due 5/25/84 of QC hold points in gp f violation of procedures. O i -1 Procedural ques on 2 4-ag-uveh,Jiits4 / i h ART A ;.,17~ involving flair evel i welds versus butt welds s AW-32 RCS piping welding not 1 84-006 3/7/84 A-7 I in accordance with pro-ART Testimony, P. 20 bl cedure p & &'U-13 N Las QC procedures Review complete ASLB Pre-filed 1 Unknown (3/82) Testi- ^' -' _ II IR-80-02 testloony (Taylor) ART many dtd 5/24/82 P. 66 & >i 7{ M A.38.d. IR-80-02 j N' Temporary hangers welded V 3 4 ^=, ;/.,64 i n i-i without procedures ART ?' .( i p 35 leproper procedures 1 84 me. Jiire4; / f ART h nt, E used on hanger welds y 9 1 Welding procedures not Initial dis-ASL8 Pre-filed 1 Testloony, dtd 5/24/82

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_g followed position IR-79-15 Testimony (Taylor) ARI P. 65 A.36.b. IR-79-15 i

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^* ckwalve weld repair Initial dis-g eT g 1 j N+ st g gay without correct position a_m ae__ st O ocedural lastructions Q j I g W6

.e ,e p j i F l e t 1 i I .o? Weldif8 P. 7 CONTROLLEO COPY b CONANCllE PEAK NUCLEAR POWER PLANT ALLEGATIONS AN0/04 INVESTIGATIONS SupetARY CROSS REF./OR COMPLETION ALLEGER-DAIE RECEIVED IASK SOURCE TRACKING CAIEGORY 1-7 SCHEDULE 50tipCE ND ALLEGATION OR CONCERN ACTION /5TATUS ANON CONFID BN/DATE SYSTEN NO. LEAD OPEN COMPLETE DOCUMENT PAGE Diesel Gener g yst 1 84- /7/84 weld repair without 4/g[ hh SheY d ARI A-4, P. 8 D authgellation/procedigp Tes y 5 11 AW-39 Vendor weld discrepancies 3 84-On6; 3/7/84 on pressurlaer tank in RIV A-45, P. 3 Unit 1 AW-40 One weld seam Isr9ely Inlllal dis-ASLB Pre-filed 1 Testloony, did 5/24/82, rust and concrete position IR-79-15 Testloony (Taylor) ART P. 65 A.36.b. IR-79-15 t AW-41 Improper welds in primary Initial dis-ASLB Pre-filed 1 Testimony, dtd 5/24/82 coolant systes posillon IR-79-22 testloony (Stewart) ART P. 65-66 A.36.c, IR-IR-80-02 79-22. IR-80-02 AW-42 Spent fuel pool liner Inlllal dis-ASLB Pre-filed 1 Testimony, dtd 5/24/82, welding conditions position testloony (Taylor) ART P. 65. A.36.b. IR-79-15 poor IR-79-15 AW-43 Improper Welding of Open RIV-84-A-0009 1 Unknown (1/84) Socket Welds ART AW-44 Improper Weld Design: Open. I. Barnes RIV-84-A-0011 1 Unknown (1/84) Welding A588 Plate to investigate ARI to Cadweld sleeves AW-45 55 Piping not purged durlag 1 A4-83-005 5/20/83 welding ART A-19 P. 2,3; Testloony P. 56, 59 ( t I AW-46 Inadequate grounding 1 84-006 3/7/84 A-7 during welding ART Testimony, P. 23 m.s

k'" 3 l 3 Q &tW % {g r f we got the new shims back from the fab shop to replace the original shims, 1 What we did was get a piece of metal that was laying 2 they wouldn't work either. I can't' remember if we on the ground and cut the shims for it out of that. 3 stamped the heat number on or air scribed it, but we marked the heat number 4 We put the number on the shims that we made so that when QC came down 5 on. and inspected, it would tiave the heat nu iber on it so QC would approve it. 6 i I was doing Jinqy Green, my foreman, is the person who told me to do this. 7 It was or.e of those rush-type deals where they had to 8 it all under nrders. have that hanger bought off that day, or someone (probably sqy foreman) would 9 He nad twen chewed out on several occasions for that. 10 have gotten chewed out. ,~ That sort of thing went on 31..t, the whole tinc I worked out there. 11 Was the hanacr yo:.'re talking about safety-related? 52 Q. A. Yes. It was, a Class ."t hanger. Does the hac.ger nu.t.er (H-CC-1-58-038-010-3) belm the drawing refer 14 Q. to the particular hanger you're talking about? 15 Another one I told the investigator about was not a Class 3 but it 16 A. Yes. 17 was in a safds-related area in the South Yard Tunnel. I believe it was a Class r e Sgr b,ut you don't construct even a class 5 hanger out of material that 18 has already been welded on to construct another hanger, the way that one was / 19 It was constructed out of pieces of I-beam that was taken out of the scrap yard, off a hanger that had been previously thrown away, taken down, discarded, 21 ~22 already painted. They' took pieces that we're cut off of it to put on that hanger that I was constructing down there.$ It was magnetized so bad that 23 every time I tried to.make a pass on it, it would spit.out arc blo'w. I had 24 to literally grind all' of the welds on it'off because they were so bad QC F0lA-85-59 m i \\

. 9 wouldn't buy them because I had such a hard time welding them. _That was 2 also a counterfeit hanger, according to Mr. Herr. the NRC investigator. 3 T_ hat's where you have all the pipes coming out of the domineralizer tank 4 going to various portions of the plant. Most.cf the places I worked were 5 safet-related, except maybe over in the Turbine Building. Usually I worked 6 on Class 3 hangers, sometimes on Class 1 in the reactor area. 7 Q. Did you ever have any problems with the Class 1 hangers? 8 A. There was one problem we had sometimes. It was with limited access 9 welds, creating a bad weld. 10 Q. What are limited access welds? 11 A. Welds which are within 6" of something else, which makes it hard a 12 to get your welding rod in there to weld. You have limited access to them. i Q. You, were talking a minate ago ebout a counterfeit hanger and you said that was a counterfeit hanger, according to Mr. Herr. What did you mean e, i 15 about that? j 16 A. The term " counterfeit hanger" was his term, not mine. He got very 17 interested when I began telling them about the incomplete hangers or hangers 18 made out of scrap material. He informed me then that what I was about to do i O f e e O emp e 4 e e e .ee e emm e. -o-m.-

) f

  • 1 could cost them millions of dollars, and that every time he went out of his i

2 house he looked over his shoulder, because counterfeit hanaart is what got i 3 them shut down at South Texas Nuclear Proinct. He stated if what I was s4ying f 4 was true, they'd be shut down. f 5 Q. What happened regarding the counterfeit hangers? { 6 A. Later the investigators came back and told me that all the hangers i 7 whose numbers had been aiven to them had all been taken down. I asked Mr. i 8 Driskill wasn't that strange. I asked him the date on the removal of those l 9 hangers. He said here just in the last day or so (from the time I had told 10 then about the hangers). I said, isn't that a strange coincidence._ He said 11 I could have told somebody about it and it might have slipped out and they esent 12 out and took care of it. He was insinuatina that I had told someone and they _ started the rumor on it and they went around and +aak "

11 hr..

The whole time I worked there. I can't recall any other specific areas. 14 15 _but there were other hangers constructed usino scrap material which had been l 16 taken down off another hanger and put in the scrap ollai-It was generally 17 because when they would go out to the laydown yard where they had new metal. 18 if they were out of the specific item you needed, you'd have to go find another 19 piece somewhere. That led to a lot of fitters getting scrap material. Once 20 ' metal has been welded on and cut on with a cutting torch, it builds up a magnetic 21 field which causes are blow (that's what I would call it) where metal spits out 22 on you and doesn't want to deposit correctly. You have to keep grinding it l l So lots of times, people will run a downhill weld instead 23 off and rewelding. 24 of doing it correctly, because then you're going in the direction of the 25 magnetic field. By reversing direction, you cut down on the arc blow effect.; e

, -; _ _._...r v l - l t i. l, 1 ~ -Q. What are 'the effects of downhill welding? ~ ? 2 A. You have slag, trapped inclusions. lack of fusion and various other 3 undesirable weld conditions. There~is a process for downhill welding, but it's i I 4 not allowed on the jobsite at'all. 5 Q. Is there a procedure that says you can't downhill weld? i 6 A. I believe CPM 6.9 does. 7 Q. Is there arything further you'd like to say regarding the counterfeit l 8 hangers? g A. The hanger which had the couae mark (which I believe was the reason 1 i 10 for my tennination) was also a counterfeit hanger. After I was fired for I i 11 turning in a gouge mark to QC, I realized that this could happen to anybodf i 12 and that it set up a situation where the rest of the workers would be more 3 job-scared. After what happened to me. I realized why they were so job-scared l 14 and I realized something had to be done, not only for the things I had seen r ( 15 happen out there, but for the simple fact that they were setting up a situation l l 16 where nothing would be turned in. it would all be covered up. And I knew that f 17 in my own craft and my own group of people that I worked with that was the f 18 situatton. I got to thinking that if the same situation was happening with the 19 other crafts (and I feel like they were because I had talked to other crafts j l 20 and they told me they had the same problems) something had to be done. 21 That's when Darlene and I decided to go to the NRC and report what we knew, even if it meant Darlene being terminated too. I don't really knot! 22 ( 23 why she hasn't been tenninated already, other than that they may be scared 24 it would incriminate them. That.'s the reason I believe they haven't terui-t l 25 nated her yet. l! i i t i 1 y a

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C e,A*n 1 Au W, At 3 uw Rt 1 35-1195-PCP-1, June 7, 1977 REVISION O PAGE 16 of 59 4.5.3 S'tainless steel covered fabrication tables, rolls, etc. which have been used for fabrication of carbon steel items shall be de-l contaminated prior to reuse on stainless steel items by removing loose dirt, steel fillings, etc. with a standard comercial dust brush, vacuum cleaner, rag, or other similar means; decontanina-tion by solvent cleaning, shot-blasting, and the like is not re-quired. 4.5.4 All instruments except for measuring devices such as framing squares, protractors, hand levels, pocket tapes, 50 feet tapes, and tri-squares, shall be calibrated in accordance with Refer-ence 19. 4.5.5. Certain tools such as files, vises, hack saw blades, chucks, car- ..e ~ bide tips, drills, hole-saws, etc. are made 'of carbon steel and will not be used interchangeably on carbon steel and stainless o steel. Those tools used for stainless steel shall be color coded flourescent orange. 4.5.6, No instruments, tools, etc. containing mercury shall be used unless specifically required by the design drawings and/or spec-ifications. 4.6 ERECTION Y 4.6.1 The normal sequence for erection of pipe spools and components should be as follows: a. Select pipe spool, valve, etc. by identification number shown i on installation drawing from the staging-area. b. Rig components into the supports either permanent or temporary; ] placing shims as required. c. Remove end cap -l t d. Prepare weld ends and flange faces as required -l e. Prepare in-line components for welding as required e.g., open gate valves half-way, disassemble diaphragm valves, etc. i 4 F0lA-85-SS m m33

---~u v iv W 35-1195-PCP-1, June 7, 1977 REVISION O PAGE 17 of 59 f. Make joint fit-up g. Purge weld joint as required h. Complete joint either weld-out or bolt torquing 1. Stress relieve joint as called for on installation drawings

j. Apply color ribbons as required to indicate radiography re-quirements shown on installation drawing or as requested by B&R QC Inspector.

k. Lay-up system as required 5 1. Paint field welds and touch'-up as required m. Pressure test system n. Insulate piping as required 4.6.2 No piping joints to equipment may be made until approved by TUSI. Once the equipment has been approved for piping hook-up by TUSI the PME will place a tag on the equipment indicating the approval, see Attachment 4. This tag must be on the equipment prior to con-e nection or a written memo by the PME releasing the equipment for connection must be received by the GPS prior to connection. 4.6.3 All welding, weld material control, weld documentation and inspec-tions shall be performed in accordance with the project welding,

j QA/QC, and associated procedures.

4.6.4 Pipe cutting shall be performed by machining, sawing or cutting with iron-free aluminum oxide abrasive discs. Torch cutting is allowed on carbon steel materials only and provided the surfaces are ground smooth after the cutting operation. When torch cut-ting, the material shall be preheated to the same temperature used in qualifying the welding procedure which will be used to weld the cut piece. Preheat requirements will be indicated on 0 the fabrication drawing when the temperature is higher than 60 F for carbon steel. Aw a

---~u u f., tt ~ 35-1195-PCP-1, June 7, 1977 REVISION O PAGE 18 of 59 4.6.5 Post weld heat treatment shall be performed in accordance with Reference 14 as called for on the fabrication drawing. 4.6.6 Arc strikes are strictly forbidden, however if they inadvertent-ly occur they shall be removed by grinding and the ground areas liquid penetrant examined. The QC Inspector.shall be notified by the Pipe Foreman prior to grinding on "Q" items while the PME or weld technician shall be notified on Non "Q" items. The PME will check the wall thickness on Non "Q" items when a possible minimum wall violation has occurred. 4.6.7 All weld spatter shall be removed from piping surfaces by buffer wheel, chipping, grinding, wire brushing and/or shot blasting ex-ti cept when prohibited by Paragraph 4.6.8. After weld spatter re-i moval on "Q" piping by the grinding method, the surface shall be liquid penetrant examined. Grinding of stainless steel surfaces shall be performed with carbide or aluminum oxide grinding wheels which have been color coded for use on stainless. Wire brushing of stainless steel surfaces shall be performed using stainless

  • steel brushes properly color coded. Shot blasting of stainless steel materials shall be performed using iron free alumina grit, iron free silica grit, or iron free silicon carbide grit. The blasting equipment shall be thoroughly cleaned of other materials used in previous operations prior to use on stainless steel.

4 4.6.8 Surfaces which require L.P. examination shall not be shot blast-ed or power wire brushed prior to the L.P. examination. If they inadvertently are shot blasted or power wire brushed then the surface to be L.P. examined shall be cleaned with an abrasive flapper wheel. 4.6.9 Machining of pipe weld ends, fittings, etc. shall be performed in accordance with Reference 7. f. 4.6.10 After drilling piping all bores shall be deburred. 4.6.11 Tape used on butt weld joints to maintain weld gas purges shall l be Nashua No. 357, grey or approved equal. i I i nu m n = LLL- ~ _. _ _ _ _ - -., _ - - _ _ _ _ ~ _ _ _ _,, _ -. _ - -. _. -, - _ _. ~.

y,y d 4 35-1195-PCP-1, June 7,1977 REVISION O PAGE 19 of 59 i 4.6.12 All weld end valves except diaphragm, control and check valves shall be opened approximately 50% prior to welding. Diaphragm valves:shall have the diaphragm removed prior to welding. All other valves and in-line components which due to their internals require special considerations during the welding process will be noted on the installation drawing. Valve disassembly shall be performed in accordance with Reference 27. 4.6.13 Screwed Joints 4.6.13.1 The joint compound used on screwed joints shall be Rectorseal i No. 5 as manufactured by Rectorseal Corporation Houston, Texas. Joint compound shall not be used on joints which are to be sub-t sequently seal welded. A batch analysis is. required when pur-i "; chasing the Rectorseal No. 5 stating that it has less than 15 ] PPM and 10 PPM leachable chlorides and fluorides respectively. 4.6.13.2 Where screwed joints are to; be seal welded, the exposed thread l shall be completely covered with weld metal. l 4.6.13.3 Tapered threads in pipe sha'11 be of proper length and depth to l ensure the drawing up of a pressure-tight joint without exces-sive length of male thread showing outside of the fitting, see for proper length. All cut and threaded ends shall

y be reamed and free from burrs and obstructions.

l 4.6.14 Flange Joints 4.6.14.1 Flange faces shall be thoroughly cleaned as required to remove , y' rust, scale, dirt, old paint, etc. Flange faces on lined equip-ment and piping systems such as the Circulating Water System, Service Water System and Chlorine System will have the internal lining on the flange face; this lining or coating shall not be i ~ removed from the flange face. 4.6.14.2 Gasket materials shall be in accordance with that shown on the installation drawings. No gaskets or gasket material shall be l reused unless approved in writing by TUSI. l 4.6.14.3 Stud and nut materials shall be in accordance with that shown on i the installation drawings. The stud length shall be such that i at least one full thread appears on the stud past the nut face for the tightened bolted joint. f _ -.. -. - - -, ~ - -. - - -.. - - - - - -.,, - - - -

.. ~. _, _ yfy ? ( 35-1195-PCP-1, June 7, 1977 REVISION O PAGE 20 of 59 4.6.14.4~ For underground flanges, the nut seat flange surfaces shall be .2 cleaned of all protective coating and film before assembly of the studs and nuts. 4.6.15 Expansion Joints 4.6.15.1 The piping and/or equipment connected to the expansion joint shall be aligned to within the tolerances given by the expan-sion joint manufacturer. Where excessive misalignments do occur, the GPS should consult with the PME who will advise in writing, after approval by TUSI, the acceptable misalignment. 4.6.15.2 Expansion joints received with factory-set sizing bars shall M" be erected and bolted or welded in position prior to removing the sizing bars. 4.6.15.3 After expansion joint installation the piping permanent sup-ports, anchors and guides shall be completed to the extent tha distortion of the expansion joint during completion of the re p maining work on the system does not occur. If the permanent supports, anchors and guides are not available then temporary ones shall be installed to safely handle loads affecting the f expansion joints. The PME will design the temporary hangers. anchors and guides and issue the design to tha GPS after TUSI ,' 6 has approved the design. 4.6.15.4 Expansion joints not furnished with insulation covers shall be protected with temporary sheet metal covers until all welding and burning in the area is completed. The cover shall p.* ovide g a minimum of,1 inch clearance beyond the outside of the bellows. 4.6.15.5 The temporary sizing bars should be removed prior to hydrostat-L' ic testing, unless otherwise instructed by the manufacturer. The PME will advise in writing the GPS of cases where the tem-porary sizing bars are to remain during the hydrostatic test. 1 1 + ) mw

-. - -. - ~ - usu } l CP l 6 35-1195-PCP-1, June 7,1977 4 REVISION 0 PAGE 21 of 59 l 4.6.16 Penetration Through Walls and Slabs 4.6.16.1 Sleeves shall be placed around the pipe where it penetrates floors and walls as called for on the G&H composite and/or structrual drawings. Sleeves through blockouts shall be concentrically po-4 sitioned around the pipe by wooden chocks unless shown otherwise i on the drawings. When sleeves are installed in blockouts, their i centerlines shall be within 1/4 inch of the piping centerlines. 1 I Piping and sleeves shall be parallel within 1/16 inch per foot. I 4.6.16.2 When it becomes necessary to cut rebar extending through a block- 'p out, unless otherwise called for on the drawings, the PME shall request TUSI permission to cut the rebar by use of a Request for

b Information or Clarification or a Field Design Change Request.

l i The rebar shall be cut so as to provide approximately 1/2 inch l; clearance from the pipe or pipe sleeve. There shall be no weld-ing other than cadwelding to the rebar. i 4.6.16.3 Filler material shall be placed between pipes and sleeves, or ' between the pipe insulation and the sleeves as required on G&H j drawings. The filler material shall be approved by TUSI prior to use. The PME will advise the GPS in writing of the filler i material to be used. !O 4.6.16.4 Seal boots shall be installed per the manufacturer's instruc-tions where called for on the G&H drawings. i 4.6.17 Valves I ik 4.6.17.1 Valve operator orientation will normally be shown on the instal-lation isometric. However, in some cases this may be impractical, l therefore, prior to welding or bolting any valve in the system its operator orientation shall be checked against the G8H compo-site piping drawing by the GPS. i ( 4.6.17.2 Unless otherwise noted on the installation drawing or valve body, globe valves shall be installed such that the flow goes under the r l valve seat. 4.6.17.3 When it becomes necessary as determined by the GPS to install pipe spools adjacent to valves which are not available for installation, i temporary spools may be installed in place of the missing valves, i see Attachment 6 for typical valve spool configurations. Once the valve is received and released for installation, the temporary { spool should be removed and the valve installed. Welding operations on temporary valve spool installations on "Q" lines will be in-4 spected by the B&R QA/QC Department. 3 --,y,.,.-, -m_, .._,-.--.r c,.. -. - -. .__m--,-.._.y.~ .---e-% m-.

vn M 35-1195-PCP-1, June 7,1977 REVISION 0 i PAGE 22 of 59 4.6.18 Temporary Strainers 4.6.18.1 Temporary strainers shall be installed as called for on the in-stallation drawings. 4.6.18.2 The strainers will remain in-place until flushing is complete. The strainers shall not be removed after system turnover with-out a written directive from TUGCO. 4.7 ALIGNMENT 4.7.1 The piping shall be located to the dimensions shown on the G&H composite drawings and/or the B&R installation drawings. In

4; cases of discrepancies between B&R installation drawings and G&H composite drawings, G&H composite drawings shall govern.

For piping 2 inch diameter and smaller G&H approved Grinnell piping isometrics shall govern. 4.7.2 Final connections to equipment and valve flanges or nozzles e shall be accomplished by adjustment of the piping and supports to provide accurate alignment at these joints without stress-ing of the pipe, equipment or valves. Springing, bending, or localized heating to obtain alignment is not to be done with-out approval of TUSI. This approval may be obtained by use of g Attachnent 7. 4.7.3 Temporary attachment lugs, straps, etc. used for weld fit-up and alignment shall be as called for in references 21 and 22. a 4.7.4 Weld joint alignment shall be in accordance with References 21 and 22. 4.7.5 Once the piping has been brought into position, the piping lo-cation shall be checked against the installation drawing for conformity by the craftsman. Piping out of design location greater than that allowed in Paragraph 4.7.9 shall be adjusted until it is within the allowed tolerance. When this tolerance cannot be met without bending of the piping, cold springing, or localized heating, the GPS shculd advise the PME. A technique for line-up will be prepared and submitted to TUSI for approval. This will be done by the PME normally by completing Attachment 7 and submitting it to TUSI. 6 M

x .w. _. a (Jer _ uv**** Q-e 6 35-1195-PCP-1, June 7,1977 REVISION O PAGE 23 of 59 4.7.6 Reasurements for piping locations shall be taken using control base lines and bench marks set up by the B8R Field Engineering Department. The use of as-built column lines, floor lines and other structures as references is not permitted. 4.7.7 Carbon steel piping with a wall thickness greater than 3/4 inches must be heat treated after cold bending per Reference 14. 4.7.8 Flange face alignment shall be within 3/64 inches normal and with respect to flange, outside diameter. The craftsman shall I measure the flanges at fit-up to assure this recuirement is met. 4.7.9 Design location tolerances are as follows: a. Gradient - 1/16 inch per foot maximum b. All Process. Piping + 2 inch maximum c. Constraints - A minimum 2 inch clearance shall be main-tained, inciding pipe insulation, with respect to other piping. Minimum slopes as designed on drawings shall be a maintained for proper venting and drainage. 4.7.10 Mitering of pipe joints except as shown on the design drawing is not permitted unless approved by TUSI. When larger mitering is considered advantageous by the GPS he should notify the PME who q will obtain TUSI approval, see Attachment 7. 4.8 MATERIAL DEFECTS 4.8.1 The minimum wall thickness for pipe called out to a " schedule" ,d on the fabrication drawings shall not be less than shown on At-fi tachment 12; while the minimum wall thickness for pipe called out as " minimum wall" shall not be less than the thickness called for on the fabrication drawing. 4.8.2 Defects in the base materials of pressure boundry items which either encroach on the minimum wall thickness of the components or are suspect of violating minimum wall shall be brought to the attention of the PME for resolution. The minimum well thickness for pipe and butt weld fittings shall be determined per Paragraph 4.8.1; while the minimum wall thickness for all other items shall be determined by the PME on a case by case basis. When it is un-determinable by the PME whether a defect does encroach on minimum wall TUSI will be advised by a Request for Clarification form. i l V 4

C. A 5-t.9% % M W2 i Ntw \\ \\ COM A..CHE FEAK STEAM E. ECTRICi, b. A'llCN 3 3 4 sc-r INSPECTION REPORTi No1*A-/11H S-/3 & ,,e ITEM DE!;a:7f cs Nf.5 SEISMIC CAT.II r NT,7 cA.cn so tv sysrEw sTaver at cE s c8Ar:cs cc 2 8/~/- 6 73 -(d/- d 87~ 18 f43 M.weZ. I .a. SUPPORTS FOR CLASS V PIPING cesi. no lRu cc acc. s new s cnANce No pp.fo usasat ;a resi Ea se srEc..so. new. g.m . g,, 01-0P-11.11-1, Rev. g g y Nsp ICN 4F C 0 INsP C 1 NhECTioN Ns E TloN p: iMSP. REsuLTS jgj[ /gj, kiNsPECTICN compt.ETED, AL;,. Apot.: CABLE ITEMS roRv ^'E' i O iNspEcrioN couettrEo, uNsArisrAcToar irEvgg@ew IN hOATE SIGNATURE 5 3 it m E. t2 a A. IF/BRICATION g/ l I M l 1. l Check hanger materials for compliance with bill of I ! raterials (Paragraph 2.2) lM i \\ 2. Support dimensions comoly with dwg/ instruction td.IN d '' k. i(Paragraph 2.2) { g\\)@" 3. Held area clear of scale, grease, etc. (Para. 3.2\\1)"i JW, .,? l l 4. jFit-up* oer dwg/WPS (Para. 3.1.2) \\ { ' hpg, l' i 5. Weld free of slag, undercut, porosity (Dara. 3.2.2)\\V l77 (.s. ; ! 6. Weld as per drawing (Para. 3.1.2) I h/Y @.r ' 7. Supoort level and plumb (Para. 3.7) Tg 8. Location (Para. 3.7)

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B. EEISMIC LIMITERS / SWAY STRUTS / SPRING CANS ** ig1g. I 1. Ispherical bearing alignment / condition gapo 3l.yg3 y@. g 8 2. Correct location and orientation (Para. 3.7.2) ll/W 't 1 3. Threads upset (Para. 3.8.2) MIM*n 4 i ' I 4. Cold setting as per drawing (Para. 3.9.5) l#'#5 4 7 5. l Cycle inspection (Para. 3.9.1) I)/MM I-D 6. hardware correctly installed (Para. 3.8; 3.9) IM/5 YI I C. l RECORD THE FOLLOWING-Y! lN. MS I 1. Support Drawing Nqgfj,opf.g.ym Rev. / t/l i :-t $ d 2. CMC No..g4 76,l7 Rev. O M $ N,N 3h%Ieider5v%c1 E 7N 8 H/./

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- _ - - _ - _ - - - - _ _ - - - - - - - - - - - - - - = - - - - - - - - - - - _ _ -. = - - - (L sq \\ u h b DCP2 - SSER AP-4 d g. b i) Draft 3 - 12/13/84 A SSER \\ 1. Allegation Group: Mechanical and Piping Category No.11, Pipe Installation 2. Allegation Number: AP-4, AP-9 and AP-13 3. Characterization: It is alleged that: (1) piping systems were cold sprung; two cr three one-hundred ton jacks were used to cold spring 28. inch lines in the reactor coolant system (AP-4); (2) a stainless steel line in the Containment Spray System was heated to " move it" during installation; the line was probably non Q" (i.e., not related to safety (AP-9); and (3) a 32 inch main steam line was forced into position with the polar crane and 3-ton come-alongs; the pipe was moved 6 inches vertically and 4 inches horizontally; the force exerted by the polar crane may have been 85 tons (AP-13). 4. Assessment of Safety Significance: With respect to Allegation AP-4, the TRT wculd note the following. The term " cold springing" in the A5ME B&PVC, the ANSI B31.1 standard and paragraph 4.13 of the Gibbs & Hill (G&H) Piping Erection Specification 2323-MS-100 refers to a controlled prccess te reduce the adverse effects of stresses due to thermal expansion. This is achieved by introducing stresses in the piping system at ambient temperatures which are opposite to those F01A-85-59 MM -a

i, which will be induced by thermal expansion at temperature. The term " springing" in Paragraph 4.7.6 of the G8H Specification 2323-MS-100 refers to the practice of mechanically deflecting the piping to correct misalignment. The terms " springing" and " cold springing" as used in Paragraph 3.12 of Brown & Root (B&R) Pipe Fabrication and Erection Procedure CP-CPM 6.9E, various paragraphs of the B&R ASME Pipe Fabrication and Installation Inspections and Requirements Prior to System / Subsystem N-5 Certification Instruction / Procedure QI-QAP-11.1-26 and by the alleger are used interchangeably but, in fact, refer to the process identified above as " springing". s Uncontrolled springing could introduce stresses in piping systems which would not be relieved by thermal expansion at elevated temperatures and hence be detrimental to the piping and nozzles or flanges of attached equipment. Since the TRT learned that no cold springing operations had been performed at CPSES, its assessments were limited only to springing in piping system. With cold springing and springing as defined above, the TRT review of applicable documents concluded that although G&H Specification 2323-MS-100 provided procedures for cold springing which were adequate to satisfy the requirements of the applicable codes and standards, the B&R procedures for springing were inconsistent. Adequate requirements for springing were included in B&R Procedure CP-CPM 6.9E only since May 1980 and B&R Instruction / Procedure QI-QAP 11.1-26 prohibited springing to varied degrees only since March 1982. l I --,a a w-- - w -- ~ e w

e 4 i This inconsistency in the B&R documents in a violation of Paragraph l 3.4 of Rev 6, June 26, 1984, through Rev. , of B&R Preparation of QA Procedures and Instructions CP-QAP-6.1, which requires QA Procedures and Instructions shall be revised for technical content, code requirements and conflict with other documents. In view of the above, the TRT interviewed personnel in TUEC's Mechanical Engineering and QA/QC departments and B&R Construction and i QA/QC departments to determine the actual practice at CPSES. Although 4 i the Construction and QA/QC personnel said that springing was ] prohibited, a TUEC Mechanical Engineering supervisor said that authorization for springing was permitted in all piping systems on a case-by-case basis. Criteria for authorization were based on the Appendix 0 requirements to an incomplete copy of an unidentified Bechtel Corporation Specification 10466-M-204. A review of the ] Bechtel specification indicated that the springing guidelines provided were intended to limit springing stresses to 1000 psi in nuclear and non-nuclear carbon steel and stainless steel piping in the range of Sch. 105 to Sch. 160. Although the guidelines may be acceptable, the TRT found that use of the Bechtel specification for installation of piping systems at CPSES was unauthorized and undocumented. This was contrary to the requirements of paragraph 3.3 of Rev. 3, June 11, 1982, through Rev. _, , of TUSI Design Control Procedure CP-EP-4.0 which required that design inputs on which final design were based shall be identified, documented and approved on a l

l l I timely basis. The inputs were.also required to be detailed enough to provide a consistent basis for making design decisions, accomplishing design verification and evaluating design changes. Relative to the specific aspect of the allegation regarding cold springing (sic) of the reactor coolant system piping (RCS), the TRT reviewed the requirements for and records associated with the installation of the piping system to assess the possible use of cold springing during its installation. The review concluded that the installation procedures for the RCS piping were such as to preclude springing of the piping. The TRT believed that the alleger mistakenly identified jacking operations for maintaining vertical positioning of the steam generators during installation of the RCS hot leg piping as springing. Jacking was necessary due to anticipated axial movements in the RCS hot legs caused by weld shrinkage during the fabrication of field welds in the hot legs. During its review of the piping installation travellers for the RCS piping, the TRT identified deficiencies in their documentation. These deficiencies related to inappropriate or incomple'te documentation, contrary to the requirements of paragraph 3.12 of B&R Procedure QI-QAP-11.1-26, Rev. __, , through Rev.16, June __, 1984, which required per Attachment 2 to the procedure that QCE/QE review documentation for completeness, traceability and compliance with procedural requirements. j

c, l , l l The TRT interpreted AP-9 to relate to localized heating of a stainless steel line to achieve proper alignment of the line. The line was not a j identified but was characterized as probably located in the l l Containment Spray System and probably nonsafety related. Due to the lack of identification of the line and the large extent of the Containment Spray System, the TRT review could not substantiate or refute the specific incident in the allegation. (Further, relative to the incident described in the allegation, the TRT noted that the Containment Spray System does not contain any nonsafety related stainless steel piping.) The TRT noted, however, that the construction practice at CPSES included provisions for localized l heating of some carbon steel piping. The TRT review of specification and procedures, including Gibbs & Hill (G&H) Piping Erection Specification 2323-MS-100, B&R Pipe Fabrication and Installation Procedure CP-CM-6.9E and B&R Welding and Related ProcessesProefdureCP-CM-6.9D,concludedthatsince1980the specifications and procedures contained sufficient provisions for controlling localized heating of carbon steel piping not requiring i' Charpy impact values. The exclusion of these provisions in B&R ASME Pipe Fabrication and Installation Inspections and Requirements Prior to System / Subsystem N-5 Certification Instruction / Procedure QI-QAP I 11.1-26 was identified as a weakness in the applicant's procedures. Additionally, a TRT review conducted to assess the implementation of j the procedures concluded that the localized heating procedures had 3 j been implemented properly. Misapplication of these proceduces to I i

m._. _ . stainless steel piping which will be inactive for long periods of time, such as the Containment Spray System piping, could be detrimental. The piping would be sensitized thereby increasing it's susceptability to stress corrosion cracking. The TRT addressed'the following claims during its investigation of AP-13 regarding the forcing into proper alignment of a Unit 1 main steam line: (1) the installation of the main steam line was not complete during the incident; the portion of the line which had been installed was anchored at one end to the containment penetration for the line and attached at the other end to a temporary flushing line which in turn was attached to a nozzle at the lower end of a steam generator; (2) prior to the incident it had been discovered that the installed portion of the main steam line had been mislocated by 6 inches vertically and 4 inches horizontally; (3) the line had been forced into proper alignment by means of the polar crane and 3-ton to 5-ton come-alongs; (4) the force exerted by the polar crane was applied at the " expansion chamber" (sic) in the line, i.e. the j expansion loop nearest the steam generator; (5) the force exerted by l the polar crane was variously described as several tons, 85 tons, 40 tons, or unknown; (6) the force exerted was monitored on "a big round gauge" (sic) (in fact, a Dynamometer); (7) permanent pipe supports which had been installed prior to movement of the line were removed during movement of the line and redesigned to maintain the line in its forced position, the claim was that " tension" (sic) (actually, stresses) induced in the line during its movement were still present;

! l (8) the incident was not supervised by engineering personnel; and i f (9) when the temporary flushing line was disconnected from the steam generators, the flushing line vibrated about 14 inches with a loud j noise audible throughout containment. I The TRT reviewed the statements of 27 persons interviewed by OI between May 1983 and January 1984 during its investigation of the allegation. Additionally, the TRT interviewed the allegor on September 19, 1984, and B&R and TUEC construction and engineering personnel during its investigation. 6 d Based on its investigation the TRT found that the incident related to p j the Unit 1, loop 1 main steam line and relative to the above enumerated ij claims by the allegor, that: (1) the configuration of the piping involved was as described by the allegor except that the flushing line j was not attached to the steam generator but was attached to the steam generator feedwater line; (2) contrary to the claim, the line had been installed correctly but had been displaced during flushing operations due to sagging and settlement [of temporary supports the movement of the line observed by the allegor was intended to restore the line to { its init,ial correct installation position, however, the amount of settlement is not known exact the claim was substanti s A47tfeclaimwassubstantiated,J(5)themagnitudeoftheforces ed~are unknown; 6)theclai s substantiated; (7) the claim that supports were redesigned was substantiated, however, the TRT found that the redesign was necessary only to support the line in its

correct insta11ation position and not to maintain the line in a forced, stressed position; (8) contrary to the claim, the incident was pcrformed under the cognizance of engineering personnel; and (9) the claim could not be substantiated. The TRT reviewed a TUEC analysis performed in February 1983, one year af ter the incident, to assess stresses induced in affected piping during the inccident. The review concluded that the analysis was inadequate since enly operations durWg restoration of the line to its initial position were addressed. The conditions during flushing 1 including the piping affected, the weight of added water and sati.lement of temporary supports were not addressed. The TRT also reviewed the results of Region IV inspections documented in Region IV IE Report 50-445, September 29, 1983, and does not agree with the findings of the Region IV inspections. Specifically, the TRT disagreed with the Region IV findings that: (1) the flushing line was attached to the steam generator feedwater nozzle; (2) the temporary Supports had sagged due to the weight of the flushing line only; l (3) the TUEC analysis was acceptable; and (4) Westinghouse was t involved in the incident. l Goring its investigation the TRT also found that the Unit 1, loop 4 l steam line was also involved in a similw incident. i I r

. i l l 5. Conclusion and Staff Positions: Based 6n its investigation of AP-4, the TRT determined that uncontrolled and undocumented springing of piping systems had occurred at CPSES contrary to procedures but that I the effects may have been minimal. The specific aspect of the allegation regarding springing is: RCS pipes could not be substantiated. The TRT judged that the alleger had mistakenly identified jacking activities during installation of the hot-legs between the reactor vessel and the steam generator as steam generator springing activities, Jacking was used to mainta.in vertical tolerance of the steam generator during axial motions of the hot-leg piping due to weld shrinkage. The TRT review of traveller packages during its inspections identified deficiencies in the Applicants' documentation procedures. The deficiencies relate to incomplete, incorrect and ) inconsistent documentation. The TRf investigation of AP-9 concluded that the allegation could not be substantiated or refuted. Although the TRT found that procedures i for localized heating in carbon steels not requiring impact vetlues i were properly implemented and documented, possible misapplication of 1 the procedures to stainless steel piping would enhance the suscept-i ability of the piping to stress corrosion cracking. ~ The TRT investigation of AP-13 concluded that the allegation was substantiated in part. The TRT judged that the alleger had mistakenly identified operations for realignment of a Unit 1, loop 1 main l i

. steamline as the correction of construction deficiencies by forcing ~ the line into position. The TRT determined that the partially installed lir.e had been used in flushing operations and misaligned due to settlement of temporary supports during flushing. Applicants' analysis performed to assess stresses in the main steam line due to j the realignment operations were inadequate. Stresses due to the misalignment were not evaluated. The TRT also determined that similar realigncant operations had been performed on the Unit 1, loop 4 steam line. No assessment of this second incident has been performed by the Applicants. i j 6. Actions Required: Based on its investigation of AP-4, the TRT will l require the following TUEC actions: (1) Justify the current undocumented springing practice employed at CPSES. (2) Modify their procedures to incorporate the current spring practice employed at CPSES. e (3) Clarify their procedures to differentiate between cold springing I and springing in piping systems. (4) Review correct and complete the documentation in the piping j installation traveller packages and related drawings for the RCL piping systems. I s 6

, Relative to AP-13, the Applicants will be required to: (1) Mqdify Gibbs & Hill Specification 2323-MS-100 reouirement, and institute procedures for support of the main steam line during flushing and temporary supports for pioina and equipment 1,n general to assure that the quality of affac+a5? piping and equipment is not affected, t (2) Perform an assessment of stresses in the portions of the Unit 1, loop 1 main steam and feedwater lines th:t were affected in the sequence of events involved during their initial installation, flushing and final installation. Conditions of concern are: l a. flushing condition when the lines were full of water and temporary supports had sagged or settled. i b. Disconnecting condition when vibrations of the temporary line could have occurred. I c. Lifting condition when forces were applied by the polar crane and comealongs. These assessments shall be based on appropriate piping configurations involved. 1

\\. i. (3) Perform a nondestructive examination of locations in the Unit 1, f loop l main steam and feedwater piping involved where stresses greater than relevant stress allowables were exceeded during the i conditions of concern in a. through c. above. I i (4) Review the existing baseline UT examinations for those portions f of the Unit 1, loop 1 main steam and feedwater piping involved in all the conditions of concern in a. through c. above for unacceptable indications. 1 i (5) Review records of hydrostatic testing of the Unit 1, loop 1 main ' steam and feedwater piping to verify the quality of piping involved in the incident. I (6) Provide similar assessments for circumstances involved in lifting incident identified during the TRT inspections of the Unit 1, 4 l loop 4 main steam line. (7) Provide assessments of effects on quality of safety related N l piping and equipment which were involved in similar incidents of sagging, settlements and failures, if any, of temporary supports. (8) The results of analysis, examinations and reviews shall be documented and submitted in a report for TRT review. V

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C Akoq l A W 'by \\bl i 7/11/77 ,13 - j (;9 r 35-1195 Brown & Root,Inc. east artice Box 1001, cien nose Texas 7e043 ,,2aM July 11, 1977 e BRF-6565 Mr. J.T. Merritt, Jr. Texas Utilities Services, Inc. P.O. Box 1002 Glen Rose, Texas 76043 \\ ! _',..,r" Texas Utilities Services, Inc. Comanche Peak Steam Electric Station 1980-82 2300 MW Installation Re f.- 9.0.~ kw...<. o U" i

Dear Mr. Merritt:

Subject procedure is transmitted herewith for your approval, per specifi-cation requirements. ARMS INDEXE0 CCW C. 2// /n/ p - Olc 5 /r 6 Mic: TAN f/R//t?5-00 h-l // 66 01: 7?3W/ 10:7/6 l J 7/' FROM:dl// s i G 7a" f3i88very truly yours, i DNO BROWN & ROOT, INC. DCN: CL 7 L * /7.7 z. -A3 5 5 5 MSC:TPPc P/ 65--Il45-PC.P.1// 6 L 01:"/ o'e-10: 8[ l /K'd FROM: 7F6/ D/ H.C. Dodd, Jr. g Sr/ - 4e f g Pmject Manager 1 HCD/WHH/sn j Attachment TUF-3588 cc: APPROVED: L.A. Ashley (ll,lA) P.L. Bussolini (lL) /. M.M. Fitch/L.O. Pyeatt (IL) .l / - ~ / / ', V[. A ~ J.T. Merritt (0,l A) d* L[.c*' H.C. Schmidt (3L,3A) J.T; Merritt, Jr. Date R.G. Tolson (ll,lA) Resident Manager 7," H.L. Jenkins (ll) TUSI W.E. Childress, Jr. (lL) ,.;'\\ V ', \\ k F0lA-85-59 @

~ - - -~ uw 0N'- 35-1195-PCP-1, June 7,1977 REVISION O PAGE 16 of 59 4.5.3 Stainless steel covered fabrication tables, rolls, etc. which have been used for fabrication of carbon steel items shall be de-contaminated prior to reuse on stainless steel items by renoving ? loose dirt, steel fillings, etc. with a standard consnercial dust brush, vacuum cleaner, rag, or other similar means; decontamina-tion by solvent cleaning, shot-blasting, and the like is not re-quired. 4.5.4 All instruments except for measuring devices such as framing squares, protractors, hand levels, pocket tapes, 50 feet tapes, i and tri-squares, shall be calibrated in accordance with Refer-ence 19. i 4.5.5. Certain, tools such as files, vises, hack saw blades, c. hucks, car-bide t1ps, drills, hole-saws, etc. are made 'of carbon steel and. will not be used interchangeably on carbon steel and stainless i steel. Those tools used for stainless steel shall be color coped j flourescent orange. 4.5.6l No instruments, tools, etc. containing mercury shall be used unless specifically required by the design drawings and/or spec-ifications. l 4.6 ERECTION ( 4.6.1 The normal sequence for erection of pipe spools and components i should be as follows: a. Select pipe spool, valve, etc. by identification number shown on installation drawing from the staging-area. b. Ric components into the supports either permanent or temporary; i placing shims as requirec. i l c. Remove end cap l 'd. Prepare weld ends and flange faces as required I e. Prepare in-line components for welding as required e.g., open gate valves half-way, disassemble diaphragm valves, etc. I w.,s a ._. -. ere- - mem-- --e r c.--,-

-~v v gy 35-1195-PCP-1, June 7, 1977 REVISION O PAGE 17 of 59 f. Make joint fit-up g. Purge weld joint as required h. Complete joint either weld-out or bolt torquing 1. Stress relieve joint as called for on installation drawings

j. Apply color ribbons as required to indicate radiography re-quirements shown on installation drawing or as requested by B&R QC Inspector.

k. Lay-up system as required 1. Paint field welds and touch-up as required m. Pressure test system n. Insulate piping as required I No piping joints to equipment by be made until approved by TUSI. 4.6.2 j Once the equipment has been approved for piping hook-up by TUSI the PME will place a tag on the equipment indicating the approval, see Attachment 4. This tag must be on the equipment prior to con-l. nection or a written memo by the PME releasing the equipment for connection must be received by the GPS prior to connection. t l i 4.6.3 All welding, weld material control, weld documentation and inspec-l tions shall be performed in accordance with the project welding, I QA/QC, and associated procedures. l 4.6.4 Pipe cutting shall be performed by machining, sawing or cutting with iron-free aluminum oxide abrasive discs. Torch cutting is allowed on carbon steel materials only and provided the surfaces are ground smooth after the cutting operation. When torch cut-ting, the material shall be preheated to the same temperature I used in qualifying the welding procedure which will be used to l weld the cut piece. Preheat requirements will be indicated on the fabrication drawing when the temperature is higher than 600 F for carbon steel. l l l l M t

-~~~u un i 35-1195-PCP-1,~ June 7,1977 REVISION O PAGE 18 of 59 4.6.5 Post weld heat treatment shall be performed in accordance with Reference 14 as called for on the fabrication drawing. 4.6.6 Arc strikes are strictly forbidden, howen if they inadvertent-ly occur they shall be removed by grinding ud the ground areas liquid penetrant examined. The QC Inspector shall, be notified by the Pipe Foreman prior to grinding on "Q" items while the PME or weld technician shall be notified on Non "Q" items. The PME will check the wall thickness on Non "Q" items when a possible minimum wall violation has occurred. 4.6.7 All weld spatter shall be removed from piping surfaces by buffer wheel, chipping, grinding, wire brushing and/or shot blasting ex-cept when prohibited by Paragraph 4.6.8. After weld spatter re-moval on "Q" piping by the grinding method, the surface shall be liquid penetrant examined. Urinding of stainless steel surfaces shall be performed with carbide or aluminum oxide grinding wheels which have been color coded for use on stainless. Wire brushing of stainless steel surfaces shall be performed using stainless steel brushes properly color coded. Shot blesting of stainless steel materials shall be performed using iron free alumina grit, iron free silica grit, or iron free silicon carbide grit. The blasting equipment shall be thoroughly cleaned of other materials used in previous operations prior to use on stainless steel. 4.6.8 Surfaces which require L.P. examination shall not be shot blast-i sd or power wire brushed prior to the L.P. examination'. If they l inadvertently are shot blasted or power wire brushed then the surface to be L.P. examined shall be cleaned with an abrasive flapper wheel. I 4.6.9 Machining of pipe weld ends, fittings, etc. shall be performed in accordance with Reference 7. 4.6.10' After drilling piping all bores shall be deburred. 4.6.11 Tape used on butt weld joints to maintain weld gas purges shall l be Nashua No. 357, grey or approved equal. i

~~~-- y py e l 35-1195-PCP-1, June 7, 1977 REVISION O PAGE 19 of 59 4.6.12 All weld end valves except diaphragm, control and check valves shall be opened approximately 50% prior to welding. Diaphragm valves:shall have the diaphragm removed prior to welding. All other valves and in-line components which due to their internals require special considerations during the welding process will be noted on the installation drawing. Valve disassembly shall be performed in accordance with Reference 27. 4.6.13 Screwed Joints 4.6.13.1 The joint compound used on screwed joints shall be Rectorseal No. 5 as manufactured by Rectorseal Corporation Houston, Texas. Joint compound shall not be used on joints which are to be sub-sequently seal welded. A batch analysis is. required when pur-chasing the Rectorseal No. 5 stating that it has less than 15 PPM and 10 PPM leachable chlorides and fluorides respectively. 4.6.13.2 Where screwed joints are to be seal welded, the exposed thread, shall be completely covered.with weld metal. 4.6.13.3 Tapered threads in pipe sha'115 of proper length and depth to j ensure the drawing up of a pressure-tight joint without exces-sive length of male thread showing outside of the fitting, see i ~ for proper length. All cut and threaded ends shall be reamed and free from burrs and obstructions. 4.6.14 Flange Joints 4.6.14.1 Flange faces shall be thoroughly cleaned as required to remove rust, scale, dirt, old paint, etc. Flange faces on lined equip-ment and piping systems such as the circulating Water System, Service Water System and Chlorine System will have the internal lining on the flange face; this lining or coating shall not be l removed from the flange face. 4.6.14.2 Gasket materials shall be in accordance with that shown on the i installation drawings. No gaskets or gasket material shall be i reused unless approved in writing by TUSI. i 4.6.14.3 Stud and nut materials shall be in accordance with that shown on i the installation drawings. The stud length shall be such that at least one full thread appears on the stud past the nut face for the tightened bolted joint. 1 .""'X;R ~ MW

-~~-- ugy y 35-1195-PCP-1, June 7,19,77,*E+ '. a REVISION 0 i PAGE 20 of 59 4.6.14.4 for underground flanges, the nut seat flange surfaces shall be cleaned of all protective coating and film before assembly of the studs and nuts. 4.6.15 Expansion Joints 4.6.15.1 The piping and/or equipment connected to the expansion joint shall be. aligned to within the tolerances given by the expan-aj sion joint manufacturer. Where excessive misalignments do occur, the GPS should consult with the PME who will advise in i, writing, after approval by TUSI, the acceptable misalignment. '4.6.15.2 Expansion joints received with factory-set sizing bars shall a 4 be erected and bolted or welded in position. prior to removing j */ the sfting bars. ? l 4.6.15.3 After expansion joint installation the piping permanent sup-j ports, anchors and guides shall be completed to the extent that distortion of the expansion joint during completion of the re-maining work on the system does not occur. If the permanent supports, anchors and guides are not available then temporary ones shall be installed to safely handle loads affecting the expansion joints. The PME will design the temporary hangers, q anchors and guides and issue the design to the GPS after TUSI j3 has approved the design. 4 i 4.6.15.4 Expansion joints hot furnished with insulation. covers 'shall be ] protected with temporary sheet metal covers until all welding and burning in the area is completed. The cover shall provide i j a minimum of.1 inch clearance beyond the outside.of the bellows. 4.6.15.5 The temporary sizing bars should be removed prior to hydrostat-ic testing, unless otherwise instructed by the manufacturer. The PME will advise in writing the GPS of cases where the tem- . porary sizing L.rs are to remain during the hydrostatic test. 1 j l' l e e .- ~ - -,.. a-- - - o,; 1. _ _ _ _,

(JU V 35-1195-PCP-1, June 7,1977 REVISION O PAGE 21 of 59 4.6.16 Penetration Through Walls and Slabs 4.6.16.1 Sleeves shall be placed around the pipe where it penetrates floors and walls as called for on the G&H composite and/or structrual drawings. Sleeves through blockouts shall be concentrically po-sitioned around the pipe by wooden chocks unless shown otherwise on the drawings. When sleeves are installed in blockouts, their centerlines shall be within 1/4 inch of the piping centerlines. Piping and sleeves shall be parallel within 1/16 inch per foot. 4.6.16.2 When it becomes necessary to cut rebar extending through a block-out, unless otherwise called for on, the drawings, the PME shall request TUSI permission to cut the rebar by use of a Request for Information or Clarification or a Field Design Change Request. i ' The rebar shall be cut so as to provide approximately 1/2 inch clearance from the pipe or pipe sleeve. There shall be no weld-ing other than cadwelding to the rebar. 4.6.16.3 Filler material shall be placed between pipes and sleeves, or between the pipe insulation ariif the sleeves as required on G&H drawings. The filler material shall be approved by TUSI prior to use. The PME will advise the GPS in writing of the filler material to be used. l; 4.6.16.4 Seal boots shall be installed per the manufacturer's instruc-tions where called for on the G&H drawings. 4.6.17 Valves 4.6.17.1 Valve operator orientation will normally be:shown on the instal-t l' lation isometric. However, in ~some cases this may be impractical, therefore, prior to welding or bolting any valve in the system l its operator orientation shall be checked against the G&H compo-j site piping drawing by the GPS. 4.6.17.2 Unless otherwise noted on the installation drawing or valve body, j globe valves shall be installed such that the flow goes under the valve seat. j h 4.6.17.3 When it becomes necessary as determined by the GPS to install pipe spools adjacent to valves which are not available for installation, temporary spools may be installed in place of the missing valves. i l see Attachment 6 for typical valve spool configurations. Once the valve is received and released for installation, the temporary spool should be removed and the valve installed. Welding operations on temporary valve spool installations on "Q" lines will be in- ,spected by the B&R QA/QC Department., O L -- m

~ ver w 35-1195-PCP-1, June 7,1977 REVISION O PAGE 22 of 59 4.6.18 Temporary Strainers 4.6.18.1 Temporary strainers shall be installed as called for on the in-l stallation drawings. 4.6.18.2 The strainers will remain in-place un!til flushing is complete. The strainers shall not be removed after system turnover with-out a wrttten direc.tive from TUGCO. '. 4.7 ALIGNMENT 4.7.1 The piping shall be located to the dimensions shown on the G&H composite drawings and/or the B&R installation drawings. In cases gf discrepancies between B&R installation drawings and G&H composite drawings, G&H composite drawings shall govern. For piping 2 inch diameter and smaller G&H approved Grinnell i piping isometrics shall govern. 4.7.2 Final connections to equipment and valve flanges or nozzlis shall be accomplished by adjustinent of the piping and supports to provide accurate alignment at these joints without stress-ing of the pipe, equipment or valves. Springing, bending, or localized heating to obtain alignment is not to be done with-I out approval of TUSI. This approval may be obtained by use of } Attachrr.ent 7. } c 4.7.3 Temporary attachme'nt lugs, straps, etc. used for weld' fit-up ] and alignment shall be as called for in references 21 and 22. 4.7.4 Weld joint alignment shall be in accordance with References 21 and 22. i 4.7.5 Once the piping has been brought into position, the piping lo-J cation shall be checked against the installation drawing for j conformity by the craftsman. Piping out of design location j greater than that allowed in Paragraph 4.7.9 shall be adjusted until it is within the allowed tolerance. When this tolerance cannot be met without bending of the piping, cold springing, or localized heating, the GPS should advise the PME. A technique I for line-up will be prepared and submitted to TUSI for approval. This will be done by the PME normally by completing Attachment 7 and submitting it to TUSI. 9 f5' Ne o'S. h ...e m. .,--~~..~-w"vm,s.u. . -MW. e-- -- - -ow~. wmv r* *@h. L

~ o,.,,... v, 'e. 35-1195-PCP-1, June 7, 1977 REVISION O PAGE 23 of 59 4.7.6 Measurements for piping locations shall be taken using control base lines and bench marks set up by the B&R Field Engineering Department. The use of as-built column lines, floor lines and other structures as references is not permitted. 4.7.7 ' Carbon steel piping with a wall thickness greater than 3/4 inches i l must be heat treated after cold bending per Reference 14. 4.7.8 Flange face alignment shall be within 3/64 inches normal and with respect to flange, outside diameter. The craftsman shall measure the flanges at fit-up to assure this requirement is met. 4.7.9 Design location tolerances are as follows: I a. Gradient - i/16 inch per foot maximum b. All Process. Piping + 2 inch maximum c. Constraints - A minimum 2 inch clearance shall be main-tained, inciding pipe insulation, with respect to other piping. Minimum slopes as designed on drawings shall be, maintained for proper venting and drainage. 4.7.10 Mitering of pipe. joints except as shown on the design drawing is not permitted unless approved by TUSI. When larger mitering is considered advantageous by the GPS he should notify the PME who ,p will obtain TUSI approval, see Attachment 7. i 4.8 MATERIAL DEFECTS 4.8.1 The minimum wall thickness for pipe called out to a " schedule" on the fabrication drawings shall not be less than shown on At-i tachment 12; while the minimum wall thickness for pipe called out as " minimum wall" shall not be less than the thickness called for on the fabrication drawing. 4.8.2 Defects in the base materials of pressure boundry items which i either encroach on the minimum wall thickness of the components or are suspect of violating minimum wall shall be brought to the attention of the PME for resolution. The minimum wall thickness for pipe and butt weld fittings shall be determined per Paragraph 4.8.1; while the minimum wall thickness for all other items shall be determined by the PME on a case by case basis. When it is un-determinable by the PME whether a defect does encroach on minimum wall. TUSI will be advised by a Request for Clarification form. DISD

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Specification 2323-MS-100 Revision 5 4 February 26, 1979 Page 7-8 \\ i thread engagement and proper erection of thread locking devices or upsetting of hanger rod threads. Hanger travel stops shall not be removed unless the owner directs specific hanger travel stop pin removal.

7. 4,. 3 Hanger Adjustrent fcr Pipe System Cperation 7.4.3.1 The owner's procedure on removal of hanger travel stops, hanger adjustments for the design ccid load, and other steps to place completed systems into operation shall be followed by the Ccntractor as
  • directed by the owner.

The Ecrk requirement of this specification covers up to the accepted pipe hydrostatic tests. The subsequent application of insulation and finish painting or coating shall be performed by the Contractor according to separate specifications. 7.4.3.2 t s All temporary attachments and devices used in installing the Work j, shall be removed from the work areas prior to pipe system turnover to the owner. M 3 5 IRS To rinimize risk of personnel or equipment injury or damage, all Q iping shall be erected in _its permanent hangers. Where not (h u possible,,,-sppioVKI' ~Esist~ be obtained from the Cuner for use of ~p < temp 6rary h'ahg~ers Pipe ~ shall not be supported from other I g {} piping, valves,~ anges or equipment. ~ 3,,* 7.6 SUPPORT GUICIIINES PCR PLUMEING l# ' 7.6.1 .\\ Plumbing hanger Work by the Contractor shall be as shown on drawings and as described in this Section. Seismic supports will be supplied by others and erected by the Contractor in accordance with supplier's instruction. ? .!<.c Q w }, f ~ ;l r . ;<, nr- - i p, n t. ,m>s~:ay ,, ~ m ....... - s ~. 7 9 l p ; g g _ g 9 ms/ I

..n. ( Gibbs & Hill, Inc. Specification 2323-MS-100 Revision 6 s March 15, 1982 Page 7-11 7.4.3 Hanger Adjustment for Pipe System Operation l 7.4.3.1 [ The owner's procedure on removal of hanger travel stops, hanger adjustments for the design cold load, and other steps to place completed systems into operation shall *be followed by the i Contractor as directed by the Owner. The Work requirement of t.hi s specification covers up to the accepted pipe hydrostatic tests. The subsequent application of insulation and finish painting or coating shall be performed by the Contractor according to separate specifications. 7.4.3.2 All temporar y attachments and devices used in installing the Work shall be rerived from the work areas prior to pipe system turnover to the owner. l 7.5 TEMPORARY HANGER To minimize risk of personnel injury or equipment damage, all 4 If permanent {$1pingshallbeerectedinitspermanenthangers. s 3 hangers are not installed, temporary hangers may be used. Piping f ,e' may be temporarily supported from other piping provided that the Id, 1-contractor takes adequate precautions to assure that the h V i \\ supporting piping is not damaged. Piping shall not be supported 5) ,I from valves or equipment. 7.6 SUPPORT GUIDELINES FOR PLUMBING ,r. ( l 7.6.1 L 4 hanger Work by the Contractor shall be as shown on \\pr Plumbingdrawings and as described in this Section. Seismic supports will [, I be supplied by others and erected by the Contractor in accordance l () \\Y with supplier s instruction. ,~ i .T > ' 7.6.2 g) For I# pernanent hanger installation, the Contractor shall use available, existing embedded inserts or plates or, if not q-available, core drilled anchor bolts, plates, or similar devices for hanger attachments as shown on drawings. Unless shown otherwise on drawings, attachments to concrete surfaces shall be

l 00tMETED 850002 UNITED STATES OF AMERICA ifJCLEAR REGULATORY CCP. MISSION g g p{jg- ~.BEFORE THE ATOMIC SACETY AND LICENSING BOARD N the Matter of l 1-TEXAS UTILITIES GENERATING l 00cket' Nos. 50'-445-/f COMPANY, et al. and 50-446-T O/.- (Ccmanche Peak Steam Electric Sta-icn l Staticn, Units 1 and 2) { CASE'S PROPOSED FINDINGS OF FACT ON k'E1. DING ISSUES ' 1' s Pursuant to the Eoard's Order, CASE (Citizens Associatica for Sound Energy), is filing these Proposed Fir. dings of Fact on Velding Issues, for overnight delivery to Judge McCollon, Applicant's, and NRC Staff on Monday, l 9/10/84. (See discussion contained in General Discussion herein.) Respectfully subnitted. 4 ss d 2 g.rs.)JuanitaEllis, President CASE (Citizens Association for Sound Energy) 1426 S. ,1k

Dallas, xas 75224 214/9-6-9446 g.uu Auk du b

( gg., ww.h A.A W ps, A-s mp M AA 'ggg, er ~wM h k~,p*,l 4 gw c w% w, g ow.. 1% ov PDR ow be h. F01A-85-59 ewb A Dsa ?

. ~,... II I foreman) would have gotten chewed.out. He had been chewed out on several j occasions for that. That sort of thing vent on a lot, the whole time I vorked out there." (Tr. 4244.) :He stated that later the NRC investigators came back and told him that all the hangers whose numbers had been given to 4 them had all been taken down. (Tr. 4246.) Ee stated that the whole time he i i vorked at Conanche Peak, although he couldn't recall any other specific areas, there were other hangers constructed using scrap saterial which had S been taken down off another hanger and put in the scrap pile. JEe stated } that once metal has been velded on and cut on with a cutting torch, it builds up a cagnetic field which causes what he called "are blow" where iE-metal spits out on you'"and doesn't want to deposic correctly, which necessitatedhavingtokeepgrindingitoffandrevelding.jfHestated: "So lots of ' times, people vill run a downhill veld instead of doint it correctiv, because then you're going in the direction of the magnetic field. By reversing direction, you cut down on the are blev effect." (Emphasis t added.) He also stated that the hanger which had the gouge mark which he believes was the reason for his ternination was also a counterfeit hanger. (Tr. 4247.) y.r. Seiner testified that the ef fects of downhill velding are that you have slag, trapped inclusions, lack of fusion and various other undesirable He stated that there is a process for downhill velding, weld conditions. but it's not allowed on the jobsits at all. (Tr. 4247.) He stated that he 6.9.11032,11065, and 10046 stated that you believed that procedures CPM can't downhill veld. (Tr. 4247.) l 4 t t i 1 l a* __}}

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