ML20199D543
| ML20199D543 | |
| Person / Time | |
|---|---|
| Site: | Crystal River  |
| Issue date: | 10/28/1996 |
| From: | Wais E External (Affiliation Not Assigned) |
| To: | |
| Shared Package | |
| ML20199D486 | List: |
| References | |
| 96-04-002, 96-4-2, NUDOCS 9711200358 | |
| Download: ML20199D543 (20) | |
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Report Number 96 04 002 ;
Evaluation i of ;
Piping and Support Documentation for Crystal River 3 l t
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Date:- October 28,1996
_p By: , r 3
-Edward A. Wals NYo [ .m i
3845 Holcomb Bridge Road, Suite 300 Norcross, Georgia 30092 (770) 242 9525. FAX (770) 409 0530
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Report Number 96 04003 .
Evaluation of Piping and Support Documentationfor Crystal River 3
, EXECUTIVE
SUMMARY
! Wais and Associates, In:. has conducted a review of the documentation for large bore piping and associated supports for the Crystal River 3 nuclear power plant. The purpose of this review was to determine the adequacy of existing documentation to satisfy licensing commitments and ensure reliable plant operation. This report provides the fmdings and recommendations resulting from this review. Items considered in the revbw were criteria, documentation, and reconciliation with the as built condition.
The review was based on a preliminary set ofissues on piping and suppens which i had been considered at other nuclear plants. The initial onsite survey of the criteria and documents narrowed the issues to those common to plants of the same vintage as Crystal IUver 3. The one week onsite inspection consisted of review of the analysis
- documentation. interviews with key personnel, and a walkdown of specific areas in the plant.
The review found discrepancies in the documentation, particularly in the areas of consistent application of methodologies and reconciliation with the as built conditions.
The individual conditions represented little safety significance; however, many involved potentially important procedural, or quality (Q A) problems. Over time the cumulative effects of these design issues and lack of documentation could raise safety questions.
! There are current criteria documents for the design and analysis of piping and
! supports which were considered by the reviewers to be well written, comprehensive
, documents. These documents should be maintained, updated and could be used for
} original analysis.
i This report provides the specific items reviewed and the results of these reviews.
( It also contains an attachment of examples of pipe supports discussed in the report. ,
Recommendations on improving the documentation, addressing generic issues, and implementing a pilot program are also included.
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I Repor1 Number %04 002 . ;
Evaluation ofPiping and Support Documentationfor Crystal River 3
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I I. INTRODUCTION !
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This repon documents the results of a review of the status of the design .
documentation for the large bore piping and associated supports for the Crystal River 3 -
, nuclear power planti The overall scope of the review was as follows: .
, a s ,
. Identification ofIssues " !
. Preliminary Assessment ofIssues e Appraisal of Documentation ;
l . Development of a Plan of Action !
- The review consisted of an initial two day site visit by the Lead Engineer, Dr. Ed ;
Wais for a " kick of!" meeting and to become familiar with the documentation. This was l followed by a one week effort on site by the project team, consisting of Dr. Wais and Ms.
1 Jane Hatcher.
l These items are discussed in the following sections.
- 2. IDENTIFICATION OF ISSUES l The first step in the review, prior to the first visit, was the identification of potentialissues observed at other nuclear plants. The potentialissues were classified in three categories: Cdteria, Documentation, and Reconciliation with the As Built Condition.
These items are discussed below.
l' Criteria. This category includes those items related to the technical aspects of the l l analysis and design of the piping and supports. A list ofissues that have been raised at ,
l- other plants was compiled. It must be pointed out that this list (see Table 1) includes -
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issues that are 021 applicable or significant for Crystal River, The determination of _ j applicability must be based on consideration of the vintage of the plant, FS AR . i requirements, o..ier commitments, etc. This list served as a basis for the review.
l i Documentation. The issues identified were the completeness of calculations, consistency of methodologies employed, and revision control. The records and lists of calculations drawings and related documents were also items for review. :
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ReportNumber 96 04007, Evaluation ofPiping amlSupport Documentationfor Crpral River 3 Reconciliation with the As. Built Condition. The reconciliation of the design packages (calculations) to the as built condition is very important. The identified issues were consistency of information between the various calculations and drawings which represent the piping and suppen systems.
- 3. APPROACH The overall approach for this efTon was to review the Criteria documents, perform survey of piping / pipe support calculations and drawings, conduct interviews with key personnel, and perform a walkdown inspection.
Criteria Documents. The review included the Code of Record, FSAR commitments, NRC submittals (Response to Bulletin 7914 and a repen on bent main steam rod hangers), and the Design Guides for piping and pipe suppons. It should be
, noted that the Design Guides are fairly recent documents and, therefore are not applicable to the earlier design calculations.
Piping and Pipe Suppoit Calciilations and Drawings. The review included a scan for specine attributes of over 150 pipe stress analysis calculations. Attributes were selected from the items described in Section 2 abo a as being most pertinent to the Crystal River 3 plant. Ten pipe stress analysis calculations were reviewed in detailincluding a review of all applicable "ributes and a comparison of the calculation to associated drawings and suppon sketches The pipe support calculations reviewed were recently generated as a result of plant modi 6 cations.
Interviews. Plant personnel were interviewed to gain insight into the commitments and responses to the NRC on piping and pipe support issues. The primary focus was on the response to Bulletin 7914. The onsite project engineer aad the licensing I group provided information which was helpful in the overall review.
Walkdow n. The review task included a walkdown in the auxiliary building .
focusing on the decay heat : - " ' W~ d-were compared with the calculations and drawings fe: ir.e wiem. eau pipmg and sqpva., v cre casened
- for nn overall view cf the typicd con 6;urations in the plant.
- 4. ODSERVATIONS Table 2 lists the items from Table I that were deemed to be applicable to Crystal River 3 piping and suppen design in addition, other items were noted and are also listed in Table 2. The evaluation of these issues has led to the following observations of specinc issues.
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l Report Number 96-04 002 Evaluation of Piping and Support Documentationfor Crystal River 3 e
1 Uplift on Rod Hnngers. Rod hangers are supports designed to carry the weight of the pipe and its contents. Therefore, the load on the support is vertically down. Rod hangers have been cc.nsidered active in the scismic pipe stress analysis. There can, however, be instances where the combined thermal and seismic in the upward direction is greater than the weip) t loid causing uplift. Then the suppon becomes ineffective. This was not ahvays censidered in the stress calculations, and in some instances where it was considered, it was treated in an unconservative manner.
Evaluntion of Wtided Attachments. There were very few evaluations available on the local effects of welded attachments, such as lugs or trunnions. Because the attachment is welded to the pipe, it affects the pressure boundary. An evaluation of the increased stress on the pipe is necessary to assure stresses remain below allowable Code prescribed limits.
Excessive Snubbers. Snubbers are mecht.nical restraint devices that allow a certain amount of thermal movement, b'". *re set to become rigid (snubber lockup) during shock loads such as a seismic event. c : w L.'hn packages reviewed showed that there were multiple snubbers on relatively lu &v ture lines Snubbers require an ongoing inspection and mamtenance program to assute tnat these supports perform as analy:cd.
The reviews of the pipe stress analysis calculations showed that many of the devices could possibly be climinated.
Axial Trunnion Supports on Elbows. A number of tmnnion supports on cibows were observed. Most of these were installed with slide plates" at the base to I
allow for movement in the axial direction. Over time the sliding medium (generally graphite) wul have dissipated and the support would restrict axial motion causing 1 increased local stress on the pipe. Even when there is little or no restriction to axial
', motion, there is a certain amount oflocal stress on the elbow wall. No qualification analysis of the local stress for these supports was observed during the review. Attachment j 1 to this report is an example of an axial trunnion support on an elbow.
Tempernture Cut Off. The temperature below which a thermal analysis was not' 3 required was defined as 150" F. This cut off was not observed in all cases. Several j sysann uhich had temperatures in excess of 150' F. were not apparently analyzed for i thermal nressu Anchor Design, Different types of non standard anchor designs were observed in the review of support sketches and during the walkdown. No support design analysis was l found to document the ability of the anchors to perform their design function. Some, such as trunnions on elbows without slide plates (rigidly attached to a building structure), can produce very high local stresses on the pipe that may not have been considered. Others, u 5 t ,
Report Number 96-04002 .
Evaluation of Piping and Support Documentationfor Crystal River 3 such as a small diameter trunnion on a large diameter tee connection may not act as anchors at all. Attachment 2 to this repon is an example of a non standard anchor design.
Uncinched U bolts Acting as Two Way Restraints. Piping is often supponed by a structural member through a U bolt which encircles the pipe and is bolted to the structural member. There is usually a small gap between the pipe wall and the U bolt to
, allow for radial thermal expansion, thus, the U bolt is termed "uncinched". The U bolt is
', designed to take primarily venical loads; however, :t v.ill in many cases experience horizontalloads. Therefore, U bolts are considered vertical and horizontal (two way) restraints in the pipe stress design analyses. Acceptable loads for U bolts in the Wrizontal j direction are much less than those for the venical direction, and should be evaluated to assure that the U bolt will fanction as a two way restra'nt. Crystal River 3 has many U-(' bolts analyzed as two way restraints; however, no evaluation of the horizontal functional capability of these restraints was observed during this review. Attachment 3 to this report is an example of an uncinched U bolt acting as a two-way restraint.
i Strut / Snubber Angularity. Restraints containing struts or snubbers are used
, primarily to restrain excess movement of the pipe during a seismic event. The design pipe j stress analyses for Crystal River 3 considered restraints of this type to act perpendicular or l parallel to the axis of the pipe. The review of the pipe support drawings and the walkdown showed that some of this type of supports were installed at varying degrees of angularity to the axis of the pipe. The restraining action is therefore not perpendicular or
, paratiel to the axis of the pipe as was analyzed. Attachmen'. 4 to this report is an example of strut / snubber angularity.
Dual Snubbers, The review of the support sketches and the walkdown j observations showed that some restraints were designed with two snubbers acting together in the same restraint. Ideally these snubbers would " lock up" at the same time to l limit the deflection of the pipe. However, because of the difTerent " lock up" rates, it is
- unlikely that the two snubbers would react identically to a shock load. During the review, _
i there was no evidence that this had been considered. Attachment 5 to this repon is an example of a dual snubber support.
Use of Nonstandard (Unstable) Supports. Unstable supports are supports that
- may move axially and/cr rotate around the pipe moving the suppon to a position not consistent with the assumed position in the pipe stress analysis. The review showed sorm
! potentially unstable suppon configurations. Attachment 6 to this report is an example of j an unstable support.
5.0 APPRAISAL OF DOCUMENTATION The evaluation of piping and suppon documentation depended heavily on review of calculations, drawings, sketches, and other documents such as correspondence with the 6
Report Number 96-04 002 Evaluation of Piping and Support Documentati6nfor Crystal River 3 s
NRC. The documents were not always easily retrievable and in some cases the information was inconsistent. Four specific observations warrant additional discussion.
Support Calculations. There are no original support design calculations available at Crystal PJver 3. There are some calculations associated with modi 6 cation or repair to suppons, but the earliest of these calculations were generated in the late 19S0s.
Therefore, it is dimcult to verify the support capability to function as assumed in the pipe stress analysis. Funher, for supports with attachments welded to the pipe, there is no documentation of the local stress on the pipe.
Unrd Copics of the Pipe Stress Calculations The hard copies of the pipe stress calculations do not always represent the latest revision of the calculation. Use of these documents in review of the piping and support design could lead to incorrect conclusions.
j Uncontrolled Documents. Documents related to the piping and suppon design t
are not kept in a controlled environment. SpeciGcally, the hard copies of the stress calculations and micronlm reels are not located in the vault. For the more recent calculations, some of these hard copies are the originals. While calculation packages are microfilmed, traceability to the original calculation may be compromised if the hard copy is lost.
, Accessibility to Pertinent Documents. Documents related to piping and support issues are not maintained in fles and there is no record of the exact location of these l' documents. For example, the documents related to the work done in support of the response to Bulletin 7914 were not accessible during this appraisal. There was no i
documentation of the exact number of pipe stress calculations or supports. Retrieval of
- associated drawings or sketches was diMeult because lists of applicable documents have not been generated. Apparently there is no document correlating system P& ids (or ,
equivalent), piping isometrics, piping analysis and support designs. , .
Consistency Between Design Packages. The design packages reviewed did not show a consistency in the analysis methodology or presentation. For example, the review showed that at least seven different pipe stress analysis computer programs were used and there is no documented veriDeation of these programs.
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1 Rep:rtNumber 96 04002 .
Evaluation ofPiping and Support Documentationfor Crystal River 3 !
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6.0 PLAN OF ACTION i 1
i Based on the review and appraisal of the piping and suppen documentation at Crystal PJver 3, a proposed plan of action has been developed. This proposed plan includes the l attributes necessary to ensure a proram which is adequate to address all concerns and '
satisfy licensin3 requirements without being overwhelming. The plan consists of the l following general tasks:
i Master List Development. Prior to other activities a review of the status of the documentation should be performed. The Srst step in this effort is to develop a l computerized master list which identifies and correlates the P&lDs (or equivalent), the piping isometrics,; stress analysis packages,Lsupport design caiculations, and any other calculation packages (i.e. nozzles qualitication calculations) for seismic category 1 piping.
The P&lDS should serve as the basis of this master list and should be marked up to ensure that all piping has been covered. In addition, non seismic category 1 piping which requires analysis because of 2/1 issues should be included. This effort is required to ensure that all the required piping is identined and addressed.
! Through this mechanism, the overall status of the documentation will be established. Missing calculations will be identified.
Document Retrieval A concened effort should be made to obtain any support calculations through Gilbert. The lack of documentation on support design analysis is a real concern in the ability to efficiently address the issues concerning supports. In addition to this efTort,it is recommended that a program with controls be developed to facilitate the retrieval of hard copies of the latest revision of documents. This is particularly important for calculation packages.
Commitment Evaluation and Design Guide Update. Aho prior to other activities, it is recommended that a review and evaluation of the Nuclear Operations Commitment System (NOCS) commitments related to piping and supports be performed '
to identify all requirements pensining to piping and rupports. These commitments should '
be reviewed to determine if they afTect the design guides or any aspect of the efTort.
I In addition, the design guides should be reviewed to determine if they should be
- updated to present industry practice. Also the design guides should be extended to cover tolerances. These tolerances should not only cover construction tolerances, but analysis tolerances. Since it is likely that any reanalysis would involve different computer programs, an analytical tolerance should be established.
The design guides should be modified as required.
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Report Number 96M002 .
Evaluation ofPiping and Support Documentatio'nfor Crystal River 3 Generic Issues As a priority activity, suppons which may not perform the analyzed function should be identi6ed and evaluated. These include rod hangers with uplift, unstable suppons, uncinched U bohs acting as two way restraints, strut / snubber angularity, and dual snubbers. These issues have been resolved to some degree by analysis methods at other plants, minimizing hardware changes.
The review showed a number of supports which included attachments such as lugs or trunnions welded to the pipe. These attachments need to be identified and reviewed to assure that the local stresses induced by these welded attachments, when combined with the analyzed stresses, do not exceed the allowable stress limits.
It was observed that various types of standard and nonstandard support con 5gurations were incbded in the pipe stress calculations as anchors. The anchors are
- often located at the intersection of two and sometimes three pipe stress calculations.
These anchors need to be identified and the ability of the support con 0guration to function as an anchor needs to be determined.
This preliminary reviaw indicates that these issues occur often enough that a generic approach is warranted.
Limited Pilot Program. The objective of this pilot program is to verify that there are no related signifcant safety issues. This will be accomplished by reviewing a segment of the piping and supports.
This segment should be representative of the various safety related or high energy systems and be from various locations in the plant. A limited pilot program should be initiated where from five to ten pipe strcss calculation packages are selected for a
- complete review. The packages should include all related drawings and calculations. The exact number of packages should be such that they are representative of the overall plant .
design. .
The review should cover all aspects of the design process. It should verify correlation between the installation, the drawings and the calculations. A walkdown of the
! piping and suppons should be made to compare with the documentation, e g. support
] drawings and piping isometrics. This documentation should then be correlated with the analysis or calculations. Where required, the documentation, drawings or calculations should be updated. Verification should be documented in the calculation.
This review should include the commitments for the piping and supports associated j , with the package. Specine items to be included in the review are the issues listed in Table 2 of this report. The results of pipe stress analyses and pipe suppon calculations of the '
c selected packages will provide a basis for generating generic calculations for the majority l of the remainder of the plant piping and supports as required.
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Report Nunsber %0h002 .
Evaluation ofPiping andSupport Documentationfor Crystal River 3 s
Any additionalissues which appear to be common should be identified and <
resolved on a generic basis rather than on a case by case basis. ,
It is recommended that this program be linked with a program to eliminate the excess snubbers in the plant by showing in the analyses that they are not required and may l be replaced by rigid restraints or eliminated completely.
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t TABLE 1 EXAMPLE ISSUES RELATED TO PIPING AND SUPPORT DESIGN l
1 The following list contaltts issues which have been raised at various plants regarding i documentation /quallucation of piping and support systems. It is not intended to imply ,
that all these issues are applicable to Crystal River. The applicability is dependent on the l plant vintage, licensing commitments. etc.
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- Modeling of valves (offset mass and thermal expansion)
- ZPA consideration -
Evaluation of welded attachments
- Decoupling (run branch separation of criteria)
- Clearances
. SAMs Consideration of friction forces
- Code of Record
. Damping
- Spectra definition Differential thermal modes Missing mass effects (high frequency mass participation)
. Uplift on rod hangers
. Support mass effects
. Nonstandard designs Wall to wall and floor to-ceilings supports Uncinched U bolts acting as two way restraints Bolt hole gaps Support mass in piping analysis Local stress in pipe support members
- Strut / snubber angularity l
- Computer program verification .
- Unanalyzed vents and drains I Nozzle qualification methodologies .
Use of " rigid" versus " actual" support stiffness
- Over'ap criteria e SIF selection Use of ncn:;tandard supports Spectra broadening methods e
j Qualification of Tie back supports
- - Axial trunnion supports on elbows
- Anchor design ,
Temperature cut off for requiring analysis l
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TABLE 2 -
ISSUES OBSERVED RELATED TO PIPING AND SUPPORT DESIGN The following list contains issues that were observed during the review of Crystal River 3 ;
piping and supports.
From the Table 111st of example issues, examples of the following issues were observed. !
. Modeling ofvalves :
.- ZeroPened Acceleration (ZPA) consideration Evaluation of welded attachments Clearances Seismic Anchor Motions (SAMs)
Consideration of friction forces Code ofRecord
. Damping Selsr& r:sponse spectra definition Differential thermal modes Uplift on rod hangers
. _ Support mass effects Uncinched U bolts acting as two way restraints Strut / snubber angularity Computer program verification Use of" rigid" versus " actual" support stiffness -
. Overlap enteria ,
Stress Intensificatioa Fattor (SIF) selection Use of monstandard (unstable) supports Axial trunnion supports on elbows Anchor design Temperature cut offfor requiting analysis Additionally, the foilowing items were observed during the review:
The hard copy of the pipe stress analysis calculations nin the files does 'ot ainys represent the latest revision of the calculation.
The reconciliation of the calculations with the Bulletin 79-14 results is not always complete.
. -Rod Hangers have been preloaded by tightening the turnbuckle on the rod to offset upward loads.
There is an excess of snubbers.
Some supports consist of dual snubbers Some stress calculations have a number (in excess of five) ofidentified discrepanci Spring hangers are considered active in the seismic pipe stress analysis.
A total of sever, different computer programs have been used for pipe stress anal 4
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ATTACHMENT C Letter to FPC from J.D. Stevenson Consulting Engineer Dated October 31,1997
" Overview of Safety Related Large Bore Piping and Piping Support Design and Construction Currently Existing at Crystal River-3 Nuclear Power Plant, Kevision 0" l
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m a j g ,1-iftg l Ji.D. Stevenson Consulting Engineer a structural mechanical consulting engineer 9217 Midwest Avenue
- Cleveland, Ohio 41125
- Tel: (216) 587 3808
- Fax: (216) 587 2205 97cl74g jorigbor.itt 31 October 1997 Mr. Daniel 1.. Jopling Supervisor, Nuclear Operations Engineering Mail Code NT6D Florida Power Coiporation 15760 W. Powerline Street Crystal River, FL 34428 6708
Dear Dan:
Enclosed herewith please find 3 copics of Rev. O of a report entitled " Overview of Safety Related Large llore Piping and Piping Support Design and Construction Currently Existing at Crystal River 3 Nuclear Power Plant," which was prepared as a response to the Wais report and other issues raised regarding design of safety related large bore piping installed at CR 3. This Rev. O includes the text of an expanded section on Safety Significance of Current Design and Installation of Large llore Safety Related Pipinh at CR 3. Please advise if you desire any clarifications of the attached material. Sincerely,
- b. JW
~
Gbhn D. Stevenson Consulting Engineer JDS:ms cc: Don Rutherford Programmatic Solutions, Inc. 24 Woodbine Ave., Suite 12 Northport, NY l1768 w/ Enclosure i
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