ML20199G775
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1, 1-l Revision 1 10/25/84
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l AQ-41 CP6 SSER 1.
Allegation Group: QA/QC Category No. SE 2.
Allegation Number: AQ-41 3.
Characterization: It is alleged that safety-related butk pipe 'jaants-d k' f'W.
were sandblasted on the outsidef which removed all of the heat markings used for traceability.
4.
ssessment of Safety Significance:
d signif a e of this f
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allega o is tha f ilure to tain cea ity of 4 pipe, joints cold [es t in pipes f._in eterminate q/ ity be(ng /nstal ed in safety-!
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relatfdsystems.
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w In assessing this allegation, the Technical Review Team (TRT) reviewed Brown & Root (B&R) prccedure CP-CPM 6.9, Revision 0, dated October 6, 1978.
Paragraph 3.5.4.4 of procedure CP-CPM-6.9 requires positive identification.
i 8606300389 860611 PDR FOIA I
GARDE 85-59 PDR t
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i of heat / code markings prior to cutting pipe for fabrication. This para-graph states in part, "Under no circumstances may piping materials without heat number and code traceability be used for ASME fabrication."
The TRT reviewed 22 pipe spool assembly documentation packages and 12 receiving inspection pipe documentation packages to ascertain if any $of 3k pH m p.la A = 4 s E W W Q thepipesweresandblasted.5TheTRTdidnotfindanyipdicationof M
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sandblasting of the outside surface of the pipingA The TRT also physically inspected 32 pieces of piping at the Comanche Peak site for legibility, identification, and method of identification.
Identi.
fication was visible on the outside of the pipe and had been applied by paint stick or steel stamping. There was no evidence of sandblasting l
of the outside surface on any of the bulk piping stock inspected.
l TheTRTtouredthepipefabricgtfonshop(PFS),interviewedseveral hA Q 4t Pp- ~
t shop personnel, and verifiedAthat there are tbree main categories of.
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-JJL 6 eL-A a-W il piping material that are routinely sandblasted. A These c&'ies are ategor p.
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as follows:
s 1.
Completed carbon steel spool pieces, which are sandblasted on the outside prior to painting. These pieces are normally identified by an attached stainless steel band on which the identity is encoded J
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l by steel stamping. (Ref. paragraph 3.4 of QI-QAP 11.1-5, Revision 0.)
Should the tag be mutilated or lost, the identity of the piece can be reestablished since each spool is unique and is fully described l
by its isometric drawing.
2.
Carbon steel pieces cut to length, but otherwise in an unfabricated ccndition. These pieces are sent to sand-blasting to have the inside cleaned prior to further fabrication. The outside surface of the pipe, which is not sandblasted, carries the heat markings.
3.
Bulk carbon steel pipe materials used for making equipment stands A
and supports sandblasted and painted prior to fabrication. This material is used in nonsafety related systems.
If bulk pipe is sandblasted on the outside surface in error, thereby removing q
the identification, and the identification cannot be reestablished by heat i
number or physical dimensions, it is turned over to the quality control cP-c PM -L.9 inspector, who processes the piece per appraed procedurepp At the time of the allegation, an adequate c oss-check system was in effect in the quality B
j assurance program to preclude untraceable pipe spools from being installed l
in safety-related systems.
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. During the TRT investigation, all pipe to be used for safety-related systems examined in the PFS was observed to be sufficiently I
identified. Thesematerialswerg"alsosubjectedtoasystemof n p.u. p - '"
Gr-o M. 1. I-s' quality control verification,jduring fabrication to preclude improperly or unidentified material being used or installed i
in a safety-related system.
Conclusion and Staff Positionssted nn.tbe 6t-iled Nae +5 Hon 5.
and.dce
- 2. 2 tic..,;27the ~" concluerth:t f t'cr? the p* diem The TRT reviewed alized-=.r-Se ',,- 4 d, it ::al J norouacm ed.
the procedures in effect at the time of the allegation and those currently in force and confirmed that there are sufficient quality checks and verifications to prevent the use of any unidentified bulk pipe material from being installed in safety systems. The procedures in effect are apprcpriate for the control of material and', if effectivelycouJl d A l-implemented, should prevent a loss of trace flity. This allegation b 6,. d o k
gno apparent safety significance or generic implications.
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Actions Recuired: None.
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Attachments: None.
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Reference Documents:
i 1.
B&R Procedure CP-CPM 6.9, Revision 0, dated October 6, 1978.
2.
B&R Procedure QI-QAP 11.1.5, Revision 2, dated August 28, 1980.
3.
Report of TRT, visit to bulk storage yard and review of i
documentation packages (IR-79-11).
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- 10. This statement prepared by:
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9/84 n
L. Jackson, TRT Date j
1 Technical Reviewer Reviewed by:
, M L u % q t_.
/-22-b H. Livermore Date Group Leader Approved by:
V. Noonan Date Project Director i
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QS p, M, SSER WRITEUP DOCUMENT CONTROL / ROUTE SHEET 0
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legation Numbers N
Subject of Allegation rd Acr
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1 Author:
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0 This sheet will be initialed by each reviewer.
It stays with all revisions to the
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SSER writeup and serves as a routing and review record.
It will be filed in the l
work package when the writeup is published.
Draft Number s
Draft 1
2 3
4 5
d Author o
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Group Leader
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Tech. Editor
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U-/IV/ft-Wes; man /Vietti
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Ku 4 de F 0
J. Gagliardo
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0#6 f lill T. Ippolito
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Revision Number i
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Final 4
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Tech. Editor
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1 Group Leader GM/F /MA" j
J. Gagliardo M d B %.i/rs/
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Writeup integrated into SSER k
Potential Violations to Region IV l*
Workpackage File Complete f
Workpackage Returned to Group Leader e
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AQ-53 Req' estor's ID:
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Chet Poslusny I
Document Comments:
l 1/15/85 Redraft 15 space i
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Rev.1(10/9/84
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AQ-53/CP 4 1-SSER 1.
Allegation Category: QA/QC,
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2.
Allegation Number: AQ-53 3.
Characterization:
It is alleged that Texas Utilities Electric Company (TUEC) failed to maintain traceability on a large motor-operated valve (MOV).
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Assessment of SafAty Wnificance: The implied M ance of this al gation at mate -
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i intained compone3ts 1
of rminate quality may be installed in safety-related systems.
The alle r state hat because he code was missing, Brown & Root (B& ) was e ser alve an attemp s
biIity.
trac The information furnished by the alleger was not adequate to enable the NRC Technical Review Team (TRT) to identify the specific valve in question.
Therefore, the TRT reviewed drawings associated with the' containment purge systems, the boron injection system, and the containment isolation sump outlet, as the valves in these areas most closely fit the description pro-vided by the alleger. The TRT also reviewed the B&R nonconformance log to identify valves with missing ASME-code nameplates; however, the TRT was unable to identify the specific valve described in the allegation.
Q 960 Subsequent to making the original allegation, the a leger st teI March 7, 1984%thatthetraceabilityofthevalvewas,infact,maintainedan.dtha l
new nameplate was attached and the paperwork taken care of."
Although the TRT could not identify the specific MOV described in the allegation; nonconformance report (NCR) M-1163, which pertained to a similar incident involving a missing code nameplate on a 16-inch Borg-Warner MOV, was found. 'According to the disposition of NCR M-1163, 1
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site records enabled traceability of the valve; a replacement code name-plate was furnished by Borg-Warner; and the replacement code nameplate was attached to the MOV in the presence of an ANI witness. The TRT verified by inspection that a code nameplate had been attached to the valve (1-HV-4758, in room 76). The TRT also made a spot check of several simi-l lar type MOVs to verify the attachment of code nameplates on the valves.
I All of the MOVs checked had code nameplates attached to the valves.
The ASME code permits removal of nameplates (Code Case N-232) from certain valves if the following requirements are met:
(1) The Certificate Holder's Quality Assurance Program includes I
provisions of positive identification and traceability of the
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valve to a specific location and Code Data Report.
(2) The Certificate Holder responsible for completion of the N-5 Data Report shall verify and document that the required name-plate was attached to the valve at the time of installation.
k (3) Implementation of the provisions in (1) and (2) above shall be acceptable to the Inspector.
(4) Use of this Code Case shall be shown on the N-5 Data Report.
The ASME Code (1983) also describes acceptable means of verification of items with nameplates removed (in paragraph NCA-8240) as follows:
Alternately, if nameplates secured as noted in NCA-8220 are removed from items i,hich have been installed in a nuclear power plant system, j
the Certificate Holder responsible for completion of the N-5 Data Report shall verify and document that the required nameplate has been
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attached to the item.
Provisions of positive identification and traceability of the items to a specific location and the applicable Data Report shall be included in the Quality Assurance Program or e
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procedure of the Certificate Holder responsible for installation.
This alternative shall be reviewed with and found acceptable to the Authorized Inspection Agency (NCA-5121) before being used by the Certificate Holder.
B&R QA procedure " Identification, Traceability, and Retention of ASME Code Nameplate" (CP-QAP-12.4) also permitted the removal of valve nameplates if a methed of material traceability was maintained for such components. M CL M 3-
)4 The TRT verified / chat B&R was implementing CP-QAP-12.4 and that the program was in compliance with the ASME Code.
5.
Conclusion and Staff Positions: Based on a review of applicable drawings, documentation, and verification of implementation of an acceptable program, the TRT concludes that the allegation that TUEC failed to ma ain trace-a at /.
'2t rv ability on large MOVs cannot be substantiated. Mcp a-var - tna all
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st:t:d tha. m.uve. c e u.. T. w.. ;.- ;f t M valva wac fa # et,... f ita i n ed.
Accor* 9'y, th; TET ;;.ic'.d;a
... t.h i : 2agation has neither Aa.fety d'T % "D b ' g7infane2 k r raf /usGF2 significance nor generic implications. od hQAusceds Amu wu eemcrEbA Aab 4. -r/f g 1(
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Actions Recuired: None.
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Attachments:
None.
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Reference Documents:
i 1.
B&R Procedure CP-QAP-12.4, REl.
I, M/3*/!3 2.
B&R Drawing BRP-VA-RS-005.
3.
NCR M-2967 Rev. 1.
4.
NCR M-1163.
5.
Final Safety Analysis Report, Figure 6.2.2.3.
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Testimony AQ-53: 84-006, March 7, 1984; A-7, pp. 16-17.
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- 10. This statement prepared by:
L. Jackson, TRT Date Technical Reviewer Reviewed by:
H. Livermore, Date l
Group Leader i
Approved by:
V. Noonan, Date i
a Project Director 1
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b QA/QC No. 6 i
t COMANCHE PEAK OPEN ISSUE ACTION PLAN I
Task: QA/QC Category 6, Travelers t;
l Ref. No.: AQ-70
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Characterization:
It is alleged that craft Personnel made unauthorized design document changes in the field. They did this by writing a
" Traveler'! which allowed them to use an incomplete design document in the field.
y Initial Assessment of Significance: Unknown, the applied significance of 4
this allegation is that the quality of safety-related items or systems may 2
have been compromised if constructed in accordance with unauthorized design document changes.
i Source: As statement 3/19/84, A-2 interview 4/5/84, p. 40-54 i
4 Approach to Resolutions:
1.
Review / evaluate' source documents.
2.
Review NRC requirements, FSAR requirements.
3.
Review contractor document control and traveler procedures for
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adequacy of implementing NRC requirements. Examine procedures for t
identification of traveler initiation, approval and control authority.
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- QA/QC No. 6
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Review traveler records for accuracy, completeness and compliance
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with contractor procedures.
5.
Interview personnel involved with initiation / approval of traveler.
6.
Refer any examples of wrongdoing or significant deficiencies to TRT leader.
7.
Evaluate allegaticas for safety / generic implications.
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8.
Report on results of reviewed / evaluation of delegations.
Related Open Issue Identification:
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'4 Status:
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Review Lead:
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CLOSURE:
Reviewed by:
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work package when the writeup is published.
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SSER 1.
Allegation Category: QA/QC, Category 8 2.
Allegation Number:
AQ-135 3.
Characterization:
It is alleged that the post-censtruction verification program (PCVP) was conducted in such a inanner that it failed to adequately process the results of quality contrcJ, (QC) inspections as required by 10 CFR 50, Appendix B.
It is alleged that the scope af.d depth of the program were inadequate, that reviews of identified deficiencies were inadequate, and that management of program results was inadequate.
The PCVP was alleged to be:
(1) a " blitz inspection" consisting of an
" instant review and an instant fix," (2) of narrow scope, encompassing only a few cable trays, (3) an inspection program with no requirement to identify problems which were fixed on-the-spot, and (4) a program that was stopped prematurely in February 1984.
The alleger maintained that the PCVP was a " violation of law" that lacked "
data on engineering review of identified problems and a method of tracking and trending deficiencies.
The alleger asserted that the PCVP was "out of control" and that the facility constructor, Brown and Root, Inc. (B&R), was " turning over a mess" to the owner, Texas Utilities Electric Company (TUEC).
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4.
Assessment of Safety Significance: The implied safety significance of f
thisallegationisthataninadequatelymanagedandsupervisedinspectioni f
program may:
(1) fail to identify and correct actual quality-related
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problens;(2) fail to ensure timely and effective correction of f
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identified problems; and (3) fail to analyze quality-related problems f
for fundamental, underlying causes and for adverse trends with generic
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implications.
If this allegation were substantiated, the quality conditions of portions of the facility would be indeteminate.
The echnical Review Team (TRT) found that in FSAR Section 8.1.4.3 TUCC committed to implementing Institute cf Electrical and Electronics Engineers, Inc. (IEEE) standard 336-1971, " Installation, Inspection, and Testing Requirements for Instrumentation and Electric Equipment During the Construction of Nuclear Power Generating Stations. Section 6 of this standard requires that post-construction verification consisting of tne inspection of installed equipment and systems be conducted. This requirement states that installed equipment and systems shall be inspected to verify the following:
(1) that equipment and materials have not sustained damage during installation (2) that good and proper workmanship has prevailed (3) that the installaticn has been made in accordance with specified re,quirements, (4) that all nonconforming items have been satisfactorily resolved, (5) that appropriate protective measures are applied for lay-up after installation, and (6) that all temporary conditions such as jumpers, bypass lines, and temporary set points have been clearly identified so that subsequent restoration can be ascertained prior to placing the items in service.
The TRT found thrcugh intarviews with the managers, supervisors, and inspection personnel associated with the PCVP that TUEC chose to im,ilement IEEE-336 with a series of post-construction inspections of instrumentation, electrical equipment, and raceway. These post-construction inspactions followed in-process and final inspections and were made prior 1.0 & plant area being turned over to the startup testing organization. Therefore, the post,-construction inspections reexamined previously inspecte.1 equipment and raceway.
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TUEC's written description of the PCVP was contained exclusivel i
administrative and implementing proceduresh The TRT found no g
higher-tiered post-construction inspection plan to describe the scope, I
J control, and management of the PCVP. The TRT reviewed these procedures i
as a part of its examination of this allegation.
4 PcVP==e' wM N
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A TUEC managers and supervisors involved in the PCVP indicated to the _TRT p
that other post-construction inspection activities were conducted in a similar manner, i.e., they occurred after final inspection. These other activities included:
(1) the American Society of Mechanical Engineer's (ASME)N-5certificatio.nprogramconductedbyB&R,(2) post-construction i
inspections of Hilti anchor bolt separation, and (3) post-construction verification of baseplates, grouting, and Richmond inserts.
N TUEC managers also indicated that startup testing personnel made additional room and system walkdowns prior to testing, as did plant operations personnel prior to TUEC's formal acceptance of these rooms and
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systems. These walkdowns were not considered to be inspections, and were not necessarily conducted by personnel certified as inspectors in accordance with American National Standards Institute (ANSI)/ASME N45.2.6-1978; however, these. walkdowns served to identify and control the ccrrection of any remaining identifiable deficiencies.
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e TRT concentrated its review on those post-construction inspections implementing IEEE-336 and on the final walkdown and acceptance by TUEC plant operations.
Based on its review of TUEC's written description of the PCVP, the TRT found two principal prograrrrnatic weaknesses. These were:
(1)lackofa program pltn for t.'1e PCVP, and (2) lack of written guidance on the type i
or level of deficiency which required issuance of a r.onc+nfancc report e __.
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i reauirements, s TUEC complied with IEEE-336 by implementing I
procedures QI-QP-11.3-40, " Class IE Electrical Post-Construction i
Verification," and P-11.8-14 " Instrumentation System Turnover."
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Nonetheless, g we ness indicated,the lack of a management program to define the scope of the post-construction verification program. The lack
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of a program plan could have to the perception of inadequate scope, as maintained by the alleger.
The second weakness in the PCVP did nct--constitut ; regulata [
violation, 58was considered to be significant by the TRT and to have broad generic implications and involved a lack of defined thresholds for -
triggering corrective actions.
In ascending order, the corrective action systems available to TUEC personnel as a part of the PCVP and other inspection activities at CPSES were:
(1) line items on punchlists, deficiency reports (DRs), and deficiency lists (DLs), which were attached to inspection reports (irs); (2) unsatisfactory irs, (3) NCRs; (4) corrective action reports and corrective action requests (CARS); and (5) reports submitted to the NRC in accordance with 10 CFR 21 and 10 CFR 50.55(e).
During the review of TUEC's PCVP, the TRT found no guidance other than
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general definitions of how to initiate a higher-tiered corrective action system for an identified problem.
In particular, the TRT found no s
guidance concerning the types' or levels of unsatisfactory IR attributes that required generation of an NCR.
During int'erviews with PCVP personnel, the TRT found a nearly universal wm 4he. PcvP understanding that an NCR was required for those deficiencies for which an engineering evaluation was necessary.
In addition, most personnel interviewed stated that an NCR was initiated for those deficiencies that c
b could not be corrected using normal craft procedures. These concepts and only miminal guidance for NCR initiation were contained in TUEC uQ '[ -pgn a
procedures, CP-QP-16.0 and CP-QP-18.0.
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A further indication of the lack cf effectiveness of some of TUEC's procedures on nonconformances appeared in an error in Revision 20 to j
Section 3.2 of this procedure described the processing of irs. The third paragraph of Revision 20 to this procedure, issued August 9,1984, stated:
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When all unsatisfactory conditions have been corrected and reinspected and accepted, or when an NCR or superseding IR has been prepared for the unsatisfactory condition (s) per approved i
procedures / instruction, the.QC Inspector shall Block 16). The closed IR shall then be forwarded to the PPRV by the IR clerk.
Evidently, some portion of the first sentence was missing from line 4.
The TRT noted this error on October 2, 1984, and discussed it with TUEC management, who confimed the error. They also noted that the same error l
had been present in Revision 19. Such an error in a procedure was not l
surprising; however, its uncorrected existence through two revisions issued two months apart caused doubts regarding the usefulness of this l
procedure among the personne.1 who generated and processed irs.
The TRT reviewed TUEC's program for trending nonconformances which were generated as a result of the PCVP. Thetrendingprfgramwasdescribedin-CP-QP-15.7 and CP-QP-17.0, and the results were documented in quarterly trending reports issued by TUEC's site QA organization..The TRT found that the description of analytical considerations of the trending program was weak in that the propedures Jistqd above failed to include:
(1)a NN' discussion e $
to account for the effects of varying 4 A y
I construction or inspection activities, (2) g11 dance on the characterization of nonconformances, (3) methods for determining I
fundamental underlying causes of nonconformances, and (4) guidance for r
using the trend analysis results to initiate CARS.
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- The allegation that the PCVP was not trended was incorrect; however, the quality and uses of this trending were weak. The TRT found that the quarterly trend reports contained little more than gross statistical categorizations o_f dif_ferent' types of deficiencies in the form of tables l
and bar graphs. TheTRTdidnotfindanalyticaldescriptionsofthedata
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or discussions of any determination of the root causes of significant nonconforming conditions; however, the quarterly trend reports did contain a tabulation of deficiencies identified by the PCVP.
A typical categorization contain6d in the fourth quarter 1 trend report identified a total of 1168 deficiencies (through the PCVP) with the following breakdown:
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Work Incomplete /Not per Requirements 778.
Procedure Violation (Upgraded to NCR) 0 Poor Workmanship / Improper Hardware 8
Bend Radius Violations O
Color Code /ID Violations 288 Continuity Check /Megger Failure 0
Damaged Equipment / Cables 94 i
Raceway Unacceptable for Pull 0
Hilti Bolt Violation /No Sealant 0
5 The TRT examined TUEC's prog, ram for final acceptance of systems and areas by plant operations. This program was described in STA-802 and was designed to take place after all final QC inspections and' all post-l construction verification were completed, and following testing by the startup organization.
- The program included a review of master data base l
items, a review of test results and outstanding deficiencies, a l
verification of the accuracy and adequacy of drawings needed to support operations, and system and area walkdowns.
Walkdowns were conducted by operators, instrument and control l
technicians, electrical and mechanical maintenance personnel, radiation l
protection personnel, and plant engineers from the plant operations l
organization. TUEC personnel stated that walkdowns were not intended to l
serve as a final construction QC inspection, but were intended to take l
advantage of the perspective of plant operations personnel to identify i
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the facility.
Items identified during the STA-802 walkdowns included those items requiring resolution as a part of TUEC's final acceptance of hardware condition problems, problems with equipment access for
' operability and maintainability, and potential problems from a radiation protection standpoint.
Items identified as a result of the STA-802
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program were documented, tracked, corrected, and reviewed by managers and supervisors. The TRT found that the STA-802 program went beyond regulatory requirements and was an effective mechanism for ensuring the operability of the facility prior to fuel load.
j To evaluate the effectiveness of the PCVP and to detennine the merits of the allegation, the TRT reviewed:
(1) 22 irs associated with the PCVP; (2) attachments to the irs, including punchlists, post-construction deficiency reports and lists, electrical equipment punchlists, and deficiency reports; (3) selected NCRs; (4) quarterly trending reports for 1983and1984;and(5)CARswrittenduring1983and1984.
l As a reruit of its review of the PCVP documentation, the TRT observed that irs were sometimes generated later than the attached DRs, punchlists and other attachments. Two examples of irs with this characteristic were j
numbered PCV-1-0028616 and PCV-1-0016954. TUEC personnel stated that during the early stages of the PCVP, irs were not always initiated at the start of a post-[ construction inspection for a particular room.
In some cases irs were generated after completion of a room inspection; in others, irs had not been generated for a particular room.
In the latter instances, the post-construction inspection was repeated for'those rooms.
TUEC's practice at the time of the TRT review was to initiate an IR at the start of the inspection.
In all cases examined by the TRT, irs were closed after all unsatisfactory attributes had been corrected and satisfactorily reinspected by QC.
Because the unsatisfactory IR was the administrative vehicle for tracking i
correction, reinspection, and closecut of identified deficiencies, the lack'oftimelygenerationofhlendscredencetotheallegationthat
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the PCVP discrepancies were not always tracked. However, the TRT review indicated that TUEC strengthened the program to include timely initiation e
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responsibilities for unsatisfactqry irs to the Pa er Flow Grou (PFG).
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A TRT review of the PFG administrative control system showed that the PFG l
was not only tracking unsatisfactory irs, but was also tracking the j
correction, reinspection, and closecut of individual deficiencies using a:t 4 % pu ed master data base (MDB). The TRT detemined that the MDB i
the com o
Tra r m Awas ar R _cthe management tool that was updated continually.
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i The TRT observed that there was no documented QC supervisory review of irs and attachments. The TRT found that the IR fom did not contain blanks for a QC lead inspector or supervisor to document his or her i
l review with a signature and date.
In some cases, individual supervisors documented a review by signing in an open space at the bottom of the IR form. TUEC's IR procedure, CP-QP-18.0, did not describe supervisory review of irs.
The TRT found that during the 19 revisions to QI-QP-11.3-40, 8 different DR and punchlist forms were promulgated to list the individual deficiencies and to serve as attachments to an IR. None of the foms attached to the various versions of the procedure contained blanks for signatures or dates to denote a QC supervisory review. However, some of 1,, o the printed DR foms used by TUEC did contain blanks for QC supervisory
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review. The TRT detemined through a review of records.that ther.e 3
gC signature blanks were not 'always used' Procedure CP-QP-18.0 did not J
address QC supervisory review of irs; however, TUEC QC supervisors stated that they reviewed the irs and attachments as part of their nomal practice.
, /,,
The TRT considered TUEC's lack of a fomal mechanism to document QC supervisory review to be a weakness that became more significant when coupled with the lack. of guidance on the level of a daficiency that would require initiating an NCR. % d u I_.
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The TRT observed the lack of a consistent administrative control system to ensure that all required attachments were part of a given IR. During a review of TUEC's written program, the TRT found no description of a method which ensured that all required punchlists and DRs remained attached to an IR. Some individual inspection groups sequentially numbered each attachment:and denoted the total number of attachments on the IR, but other irs reviewed by the TRT contained several attachments, eachlab)ed"page1of1,"withnoindicationofthetotalnumberofDR or punchlist pages. TUEC supervisors stated that the responsibility for completeness of an IR package rested with the inspector generating the IR. TUEC's later practice of entering individual deficiencies into the MDB tende,d to mitigate the adverse consequences of this weakness.
The TRT observed an inconsistency between the post-construction deficiency report (PCDR) and electric equipment deficiency report (EEDR).
Revision 19 to QI-QP-11.3-40 included both an attached PCDR fom with a blank for a QC reinspection signature and date and an attached EEDR fom without such a blank. The PCDR was used to document raceway deficiencies, and the EEDR was used to document electrical equipment deficiencies. The TRT was unable to detemine any reason for this inconsistency.-
The TRT found that NCRs generated during a post-construction inspection were not always listed on the IR. Such NCRs were listed with the c
particular deficiency on the DR or punchlist, but these were not cross-referenced to the appropriate block (block 15) on the IR. This cross-reference was a specific procedural requirement of QI-QP-11.3-40, Revision 18; however, not one of the 22 irs reviewed by the TRT included this cross-reference.
l The TRT also found that some DR foms were used that were not described in an approved procedure. Three of the irs examined by the TRT had foms attached entitled " Post-Construction Verification Deficiency Report" (emphasis added)'that were not included with any of the 19 revisions to i
QI-QP-11.3-40.
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. In addition, the TRT found that inappropriate attributes were listed on an IR and an incorrect DR was used.
IR E-1-0015374 listed attributes applicable to cables and raceway which were marked as unsatisfactory.
The attached DRs were intended for raceway, but described deficiencies associated with a single piece of electrical equipment (an emergency light fixture) rather than those associated with raceway.
The TRT noted that there were unexplained line-outs on a DR. Twenty-six deficiencies on IR PCV-1-0034919 were lined-out and no indication of the reason for the line-out was provided. The TRT could not determine whether the items had been incorrectly recorded, if entries had been l
duplicated, or if there was some other plausible reason.
I Individually, these weaknesses found by the TRT have little safety significince; however collectively, they point to a program that, althoughsubjecttohn ew and evaluation, suffered from a lack of administrative precision. The TRT considered the following weaknesses to be far more significant, particularly when coupled with the progransnatic weakness regarding the lack of guidance for initiation of i
NCRs.
d l
The TRT reviewed deficiencies listed on irs and found a numberpsimilar l
deficiencies for which an NCR was initiated in some cases, but not in j
others.
Examples of these deficiencies are as follows:
cables not properly trained into a motor control center lack of torquing of limit switch cover fasteners 1ack of color coding on conduit and junction boxes missing identification broken flexible conduit
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- 11 The TRT also found some deficiencies listed which appeared to require an engineering evaluation or repair or rework using other than nonnal
' construction procedures. However, these were not listed with an NCR number.
Examples of such deficiencies are as follows:
rusted tenninal points twisted lugs broken terminal blocks a bent transfonner top corrosion in a cable tray 5.
Conclusion and Staff Positions: The TRT found much of this " allegation to.
be without basis. THE PCVP was not a " blitz inspection" consisting of an
" instant review and an instant fix" that was stopped prematurely in 1984.
Rather, the PCVP was an ongoing program beginning in 1982 and continuing for Unit 1 in October 1984.
(The PCVP for Unit 2 had not yet begun.)
The TRT could find no evidence that the PCVP failed to document problems which were identified by QC but were corrected by the craft personnel on-the-spot. The PCVP was, ot limited in scope to "only a few cable trays"; howeverh[ehleger's perception of a limited progr L'nd=" + 3 a d 2 M i; to the la.ck of a program plan for the PCVP and due to the limited regulatory basis contained in IEEE-336.
Contrarytotheallegation,TUEC'sPCVPwasnot"aviolationoflaw{v._g.
wemely the ALw ;c D ergy Act of 10M, :: readedj In fact, the PCVP met
~
TUEC's regulatory commitments to IEEE-336. The PCVP included tracking and trending of all identified deficiencies including line items on DRs and punchlists, unsatisfactory irs, NCRs, and CARS. However, the TRT did (k
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- find TUEC'; trending program to be weak.
The alleger's assertion that the PCVP lacked an engineering review of identified problems was essentially correct, since o'nly NCRs and separation violations received engineering review. The vast majority of deficiencies identified during the PCVP were miner and inappropriate for engineering review, for example, chipped paint and loose cabinet fasteners.
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The alleger's description of the PCVP being "out of control" and E&R
" turning over a mess" to TUEC was exaggerated.
However, the TRT did find that the PCVP suffered from a number of administrative weaknesses that collectively detracted from a smooth running program.
Based on its k'
review of the PCVP and related programs not find that B&R T
_ as " turning over a mess" to TUEC. On :.nc ccr.trarg UEC's final d
w acceptance by plant operations appears to have been thorough, well-managed, and effectively implemented. The fi.nal acceptance program, which followed the PCVP and testing, was specifically designed to prevent TUEC's acceptance of "a mess."
In surr.ary, the TRT concludes that the PCVP meets the requirements of IEEE-336. Most aspects of the allegation were not substantiated, had no safety significance, nor any generic implications. However, the allegation of inadequate review of identified deficiencies led the TRT to detemine a zip"inngrogramatic weakness involving the lack of M
f guidance on the level of deficiency needed to initiate an NCR. This Jd finding has generic implications for TUEC's erem_tinspection and set-ll y 0
corrective action programs for the design and construction of CPSES.
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, k4 Review of this allegation also led the TRT to conclude that TUEC's 4
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program for trer. ding nonconf.omances was weak, 6i' ' "
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i 6.
Actions Recuired: TUEC shall review its corrective action systems and e
develop written guidance describing the thresholds of deficiencies and i
nonconfomances that trigcer increasingly higher tiers of corrective action.
TUEC shall refine and further develop its trending program to include SM descriptions of N To k i b, trend analysis, root cause deter-A minatio6, corrective acticn, tracking, and close out.
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Attachments: None.
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Reference Documents:
9 1.
Comanche Peak Steam and Electric Station (CPSES) FSAR, Section 8.0,
" Electric Power."
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2.
Texas Utilities Generating Company (TUGC0-TUEC's operating division and wholly owned subsidiary) Quality Assu'rance Procedure CP-QP-15.0, I
Revision 4. " Tagging System."
t 3.
CP-QP-15.7, Revision 2, " Tracking of Audit Reports / Corrective Action Reports."
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4.
CP-QP-16.0, Revisions 12 and 14 "Nonconformances."
5.
CP-QP-17,.0, Revision 4, " Corrective Action."
6.
CP-QP-18.0, Revision 20, " Inspection Report."
1 7.
QI-QP-3-29, Revision 16 " Electrical Separation."
8.
QI-QP-3-29.1; Revision.16 " Verify Electrical Separation."
[
9.
TUGC0 Quality Assurance Instruction QI-QP-11.3-40, Revisions 0 through 19,," Class IE Electrical Post-Construction Verification."
- 10. QI-QP-11.8-14, Revision 3 " Instrumentation System Turnover."
l
- 11. TUGC0 Startup Administrative Procedure CP-SAP-3, Revision 12,
" Custody. Transfer of Station Components."
12.
CP-SAP-16, Revision 8, " Test Deficiency and Nonconformance Reporting."
13.
CP-SAP-20, Revision 2, " Guidelines for System Walkdown Inspections."
.,.~,-,,..----3..
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l 14 -
- 14. CPSES Station Administrative Procedure STA-802, Revisiori 2, " Final Acceptance of Station Systems, Structures and Equipment."
- 10. This statement prepared by:
C. Haughney, Date TRT Technical Reviewer Reviewed by:
H. Livermore, Date Group Leader e
l Approved by:
V. Noonan, Date Project Director I
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SEER WRITEUP DOCUMENT CONTROL / ROUTE SHEET A1' legation Numbers AQ-%
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Subject of Allegation As-Iu.u LT NsR;r=rcyncN TRT Group CA/CC C ATEr r
- 8 Author:
M. EE L I / R. HN2PReN / R.. B e ns s m F=tt?c_
This sheet will be initialed by each reviewer.
It stays ith all revisions to the SSER writeup and serves as a routing and review record.
It will be filed in the work package when the writeup is published.
Draft Number Draft 1
2 3
4 5
M. EE L lw M. 2:i.-I i%
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't Group Leader Tech. Editor
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Wessman/Vietti
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Revision Number Final 1
2 3
4 5
l Author Tech. Editor Grouc Leader J. Gaoliardo T. Iooolito Administrative b
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f Writeup integrated into SSER Potential Violations to Region IV h3 Workpackage File Complete l
Workpackage Returned to Group Leader Qf~??~
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t-j Document Name:
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Requestor's ID:
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Author's Name:
f Chet Poslusny Document Comments:
2/7/85 REDRAFT 1-I/2 space KEEP THIS SHEET WITH DOCUMENT e
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Rev. 1, February 7, 1985 SSER AQ-50 SSER L
1.
Allegation Category - QA/QC 8, As-Built 2.
Allegation Number: AQ-50 3.
Characterization:
It is alleged that the "As-Built" inspection program used by TUEC to address Inspection and Enforcement Bulletin (IEB) 79-14 for pipe supports was too narrow in scope and ignored dimensional'discre-pancies that might exist between the field condition and final "as-built" drawings.
4.
Assessment of Safety Significance: The implied safety significance of the allegation is that incorrect information relative to the configuration and location of pipe supports could have been used in the pipe stress analysis, thereby invalidating the calculations which potentially could result in overstress on and possible failure of critical piping systems.
A.
IEB 79-14 Program In assessing this allegation, the NRC Technical Review Team (TRT) thoroughly reviewed the as-built reverification records (ABRR) for the disposition of I
37outofthe97pjpesupportsidentifiedbytheallegerashavingdocu-mented unsatisfactory findings. The TRT also completely field-examined 5 of these 37 pipe supports.
One purpose of IEB 79-14 was to assure that the as-built pipe and support configuration was used in the final stress analysis of critical piping systems.
IEB 79-14 also identifies the critical systems to be considered in the stress analysis.
9 02/07/85 1
AQ-50 II O
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TUEC engineering procedure CP-EI-4.5-1 defined the program for developing f
and using the information needed to comply with IEB 79-14. This program was to be implemented in addition to the normal QA/AC process, although
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the primary responsibility for assuring overall hardware compliance with established procedures and drawings remained with the QA/QC process.
TUEC procedure CP-EI-4.5-1 listed pertinent do'cuments that,would describe the as-built configuration of the piping and support systems, such as Brown
-& Root (B&R) piping isometrics (BRP), B&R hanger drawings (BRH), and B&R i
hanger location drawings (BRHL).
It defined field checks which must be made to verify pipe support location, direction, support type, and clear-ances.
It also provided instructions for integrating this as-built infor-mation into the final stress analysis of the piping systems..This' program was initiated in April 1981.
The allegation implied that the as-built inspection program was restricted to a limited number of systems and types of attributes only, and that it therefore did not provide adequate coverage.
It was further alleged that dimensional variations existed between installed conditions and final as-built drawings.
The TRT interviewed the alleger by telephone on August 21, 1984 and August 23, 1984, and in person on August 25.
The alleger who had been a QC inspector on one of the Unit I as-built
, teams, had the following concerns:
(1) Installation location for hangers was accomplished by craft personnel and field engineers without QC involvement.
(2) Hanger dimensions were not checked during the as-built verification inspection.
(3) The writing of non-conformance reports (NCRs) was discouraged. Defic-tencies such as loose bolts or bad welds went. unreported.
02/07/85 2
AQ-50 II 6
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i (4) Nuderous sway sthIts were installed out of angular alignment tolerance.
(5) None of the personnel involved in the as-built program had hanger inspection experience.
(6) There was no engineering review of the inspection data.
e (7) Boundaries of the inspection were not defined.
The as-built teams consisted of a party chief, an instrumert man, a rod
]
man, and a QC inspector. The alleger maintained a logbook during this i
period (January to May 1983), which listed the identification numbers'of the ABRRs. ABRRs were used to reverify the as-built condttion of modified I
pipe hangers. The alleger identified 97 ABRRs as unsatisfactory. Of these, 93 described hangers with excessive sway strut angularity. The logbook identified " stress problems" for 37 of the 97 unsatisfactory ABRRs. This information allowed the TRT to identify the corresponding hanger numbers easily.
The TRT selected 5 ABRRs from the group of 37 described above and performed a complete field re-inspection of the corresponding individual pipe sup-l ports. These five supports were ASME III, NF,' Class 2 & 3.
Each of these ABRRs had documented snubber or sway strut angularity that deviated more than 2* from the angularity specified.
In no case did the deviation exceed 1 5' offset, which was the allowable limit for snubber or strut misalign-ment in a system's cold or hot setting. B&R procedure QI-QAP-11.1-28A, Revision 4, Paragraph 5.7a., " Inspection Criteria for snubbers," states that "to prevent binding within the clamp and/or bracket, snubber shall not be installed with an offset of more than 5 (five) degrees." The TRT measured this angularity and in each case was able to confirm the angularity documented on the ABRR. All other hardware attributes s.ere inspected and recorded on the documentation reviewed for these 5 supports.
These attributes were those mentioned on the QC checklist in B&R procedure QI-QAP 11.1-28, as well as in applicable codes or standards not covered by l
02/07/85 3
AQ-50 II
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s the procedure.# One support was found to have two hardware deficiencies,
~
while another had one. The results of this inspection are incorporated in Section 8 of this report.
f The TRT reviewed applicable QC inspection procedures in effect at the time of the ABRR field work and learned that strut and snubber angularity which did not deviate more than 5* was acceptable. (Reference B&R procedure l
QI-QAP-11.1-28 Sec. 6.3.1.1.d, Revisions 16 thru 23, issued between j
12-15-82 and 10-24-83.) The five inspected supports did not violate this a
QC inspection criterion for angularity.
4 l
'The next step by the TRT was to interview responsible persons associated with the IEB 79-14 program. The 37 ABRRs previously noted were the sub-3 ject of a meeting between the TRT, the technical services as-built coordi-
"}
nator (TSABC), and the technical services design review engineer (TSDRE).
The purpose of the meeting was to determine how these ABRRs were addressed, whether the documentation supported the disposition, and whether the dis-position complied with the requirements of IEB 79-14.
i j
The ABRRs were studied one by one.
In every case, the TSABC had documen-
]
tation showing that the ABRRs had been referred to a design review com-f mittee or displacement review committee, and the results of the review
]
were also documented.
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The TSABC and TSDRE stated that one of the purposes of the as-built program lj was to identify those sway struts or snubbers whose as-built angularity j
deviated from specified angularity by more than 12* in order to review
)
total displacement of the support during hot loads. Angular deviations greater than 2* were identified on ABRRs for reverifications. The design j
review or displacement review consisted primarily of adding the angular 3
displacement due to thermal growth of the pipe to the as-built angularity.
3
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This was necessary to determine whether the movement exceeded 5 during hot or cold system conditions. This review could provide confidence that 1
a misaligned snubber or sway strut would not bind under hot or cold conditions.
I 3
02/07/85 4
AQ-50 II l
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AccordingtotbeTSABCandTSDRE,iftotalangulardisplacementunder Q
either hot or cold conditions exceeded 5*, the hanger was turned over to i
l construction for field adjustment to correct the excessive angularity.
]
If correction could not be made by field adjustment, a modification j
package would be issued to the drawing and the support would be reworked 1
where necessary. According to the TSDRE, appropriate modifications to i
4 stress analysis models were made to reflect as-built configurations.
Stress calculations were then repeated as required. The TRT generally i
agrees with this approach.
According to the TSABC and TSDRE, deficiencies discovered during as-built verification or re-verification that were outside the scope of IEB 79-14 were transmitted to QA for their disposition. The TRT reviewed transmittal documentation supporting this assertion.
B.
Additional Pipe Support Inspection Since the subject matter of IEB 79-14 was narrow in scope, and because of the overall concern by the TRT due to investigation of this and other alle-gations, an expanded field review of QC-accepted, as-built hardware in Unit I was conducted. This TRT inspection sample was used as a measure of the effectiveness of the applicant's QA/QC program for work performed prior to the initiation of the TRT effort.
The TRT selected 42 pipe supports (ASME III, NF, Classes 1, 2, and 3) for complete field inspection in 10 plant systems throughout 4 safety-related 3
buildings (safeguards, fuel handling, auxiliary, and containment) in Unit 1; 37 were selected randomly,' and 5 were from those considered in the IEB l:
79-14 assessment discussed above.
1 L
Five electrical supports (Class'1E) for conduits and raceways were thor-o B
oughly field-reviewed in areas of the cable-spreading room, auxiliary 1
4 d
02/07/85 5
AQ-50 II e
=. - - -. -. -
e building, and containment building. Three instrumentation tubing supports (nuclear safety related, Class 1) were inspected in the containment building.
Also, a sample of 92 sway struts and snubbers was checked in Room 77N of the safeguards building by the TRT for spherical bearing clearance and for missing locking devices on load pins. The TRT also inspected 40 sway struts and snubbers in the same room in the safeguards building for pipe clamp halves that were not parallel.
In addition, 19 snubbers were examined in the above-mentioned room for adapter plate bolts on snubber body transition kits that exhibited less than full thread engagement.
In the cable-spreading room, 24 "Hilti Kwik" bolts (concrete expansion anchor bolts) on base plates were checked for minimum embedment and for full thread engagement.
Excessive radial weld shrinkage was investigated on eight stainless steel piping welds in the Unit 1 pipe tunnel, Room 850, adjacent to the safe-guards building.
Use of painted threads in lieu of other approved locking devices for ASME III, NF supports was investigated by TRT.
A material traceability documentation audit was performed for 33 of the pipe supports inspected by the TRT, as well as a check for the appropriate heat numbers on the material in the field.
l All TRT inspected supports were from safety-related piping systems such l
as: safety injection (SI), component cooling (CC), containment spray (CT),
residual heat removal (RH), auxiliary feedwater (AF), main steam (MS),
chemical volume and control (CS), and reactor coolant (RC). Over three quarters of the supports in the sampling group received 100% visual inspection of welds with the paint removed. The balance of the 42 supports were inspected with the paint left on the welds.
O
- 02/07/85 6
AQ-50 II
m.
s-During' its inspection of the 42 component supports, the TRT found a number of discrepancies (see Tables 1, 2, and Figure 1) indicating questionable.
QC effectiveness.
5 The TRT findings of weld discontinuities were submitted to TUGC0 opera-tions and the QA managers._ Three rejectable welds identified by the TRT were repaired, and one component support was completely removed and has since been rebuilt. Weld-related deficiencies found by the TRT included undersize welds, weld undercuts, excessive grinding resulting in reduction of the base material, and poor weld appearance. One support had some
^
welds performed with no QC inspector signature or initials on the corre-spending blocks of the weld data card for that support inspection package.
In two cases, the TRT found that the manufacturer's model numbers on shock arrestor components were not the same as the model numbers shown on the as-built drawings for the same assemblies.
4 l
0 8
02/07/85 7
AQ-50 II l
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Table 1 Pipe Supports in Unit 1 Supports Inspected by TRT As-Built group
- 42 Class I supports inspected 4
Class 2 supports inspected 14 Class 3 supports inspected 24 Hangers with problems 26 Total problems identified 46 Procedure adequacy problems 5
Hardware-related problems 16 As-built drawing related problems 8
Component identification problems 2
Weld-related problems 10 QC record problems 1
Material identification problems 4
Welds inspected without paint by TRT 305 Welds inspected with paint by TRT 89 Total welds inspected by TRT 394 Welds needing weld repair 10
% of welds inspected 2.5%
Supports involving weld repair 6
% of supports inspected 14%
No. of Supports Bldg System Inspected Containment Safety Injection (SI) 1 Containment Reactor Coolant (RC) 6 Containment Residual Heat Removal (RHR) 2 Fuel Handling Component Cooling (CC) 11 l
Safeguards Residual Heat Removal (RHR) 1 Safeguards Containment Spray (CT) 8 Safeguards Demineralized Water (DD) 1 Safeguards Auxiliary Feedwater (AF) 8 Auxiliary Chemical Volume & Control (CS) 1 Safeguards Main Steam (MS) 2 Safeguards Chilled Water (CH) 1
- All 42 pipe supports inspected by the TRT had been previously accepted by site QC.
l l
f 5
i 02/07/85 8
AQ-50 II 1
7 Table 2 Pip 3 Suppsrts in Unit 1*
b No. of Problem Category Hanger No.
Problems Type h
1.
No locking device for threaded fasteners RC-1-901-702-C82S 2
Hardware problem (see Figure 1)
CS-1.085-003-A42K I
i i
2.
Min. edge distance (on base plate) violated CC-X-039-006-F43R 1
Hardware problem 3.
Base plate hole-location dimensions out of tolerance CC-X-039-007-F43R 4
As-built problem f
CC-1-126-010-F33R CC-1-126-011-F33R CC-1-126-012-F33R 4.
Spherical bearing / washer gap excessive (see Figure 1) CC-1-126-015-F43R 4
Hardware prob.
RC-1-052-016-C41K I
RC-1-052-020-C41K MS-1-416-001-S33R 5.
Spherical bearing contamination (see Figure 1)
SI-1-090-006-C41K 2
Hardware prob.
j MS-1-416-002-533R i
6.
Snubber adapter plate-insufficient thread engagement MS-1-416-002-S33R 3
Proced. prob.
f (See Figure 1)
SI-1-090-006-C41K CT-1-013-012-S32K 6
7.
Insufficient threaded eng'mt, threaded rod RC-1-901-702-C82S 1
Hardware prob.
(sight holes, see Figure 1)
.t 8.
Snubber / Strut load pin locking device broken or AF-1-001-014-533R 1
Hardware prob.
missing (see Figure 1) 9.
Load side of pipe clamp halves not parallel AF-1-001-001-S33R 2
Proced. prob.
(see Figure 1) i 10.
Pipe clearances w/ support out of tolerance CC-1-126-013-F33R 2
Hardware prob.
AF-1-001-702-S33R 11.
Pipe clamp locknut loose (see Figure 1)
AF-1-035-011-533R 1
Hardware prob.
l l
12.
Snubber / Sway strut misalignment CC-1-126-014-F43R 2
Hardware problem i
RC-1-052-020-C41R J
- All 42 pipe supports inspected by TRT had been previously accepted by site QC.
l' Table-2 (Centinu:d) Pip 2 Supp:rts in Unit 1*
i No. of Problem Category Hanger No.
Problems Type 13.
Snubber cold set dimension does not match drawing CS-1-085-003-A42K 1
As-Built prob.
14.-
Snubber orientation does not match drawing CT-1-005-004-S22K 2
As-Built prob.
CT-1-013-010-S22K 15.
Component type /model no. installed does not match SI-1-090-006-C41K 2
Compon. ID prob drawing RC-1-052-020-C41R 16.
No identification for support materials, parts, and CT-1-013-014-532R 4
Natl. identific.
components CC-1-126-012-F33R prob.
t CC-X-039-005-F43R AF-1-035-011-533R 17.
BRP column line dimension does not match BRHL Support not affected 1
As-Built prob.
Dimension 18.
Weld porosity excessive AF-1-001-001-533R 1
Weld-related prob.
19.
Weld undercut excessive AF-1-001-702-S33R 1
Weld-related prob.
- 20. Weld length undersized AF-1-001-001-S33R 1
Weld-related prob.
21.
Weld leg or effective throat undersized AF-1-001-001-533R 3
Weld-related prob.
RH-1-006-012-C42R CC-X-039-007-F43R
,l
- 22. Weld called out on drawing does not exist in field CC-1-126-013-F33R 1
Weld-related prob.
23.
Welds added in field are not reflected on drawing AF-1-001-702-533R 1
Weld-related prob.
numerous welds l~
24.
Excessive grinding resulting in min. thickness AF-1-037-002-533R 2
Weld-related prob.
violations (weld clean-up)
CT-1-013-014-532R 25.
No QC Buy-off on weld data card CC-1-126-013-F33R
_1 QC record problem 46 Total problems identified by TRT
- All 42 pipe supports inspected by TRT had been previously accepted by site QC.
I.
t
- 5 Figure 1.
Marc' ware Examples f.
/(d I
c Lood Bolt.
One Nut Only,
<g g
- c. Lock Nut N
[
L~
22#
Sprina 3
with Cette-Lecd P.r.
~
- c. '--
Con g
Pin Locking
- ,::="~
Ttreep Device
~
Sight
-)
[=
N w
Sway Strut 8
M C
M,,
p.
O Snubber n
Three-oM Adcpter P:cte T.-p d
Topped Hole Pipe Cicmp k
b i
Extension Kit
\\ jmt\\\\ t
[
t 5 Plate
,Not Tcpped' P,ipe I l iCic m p One Nut Only, No Lock Nut R.
LP i
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. Sphe-icet "Bec-ing
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(@
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$ *mt. tu u \\ u s u m
+
d c.
.5 I
Snubber l
Extension Kit i
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P A
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Figure 1 Hardware Examples b
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C.
Potentially Generic Pipe Support Deficiencies The TRT found potentially generic deficiencies beyond its sample in the course of its work throughout the plant that included insufficient bolt thread engagement, absence of proper locking devices for threaded fas-teners and load pins, and excessive free gap at the spherical bearing interface in snubbers and sway struts. As previously noted, the 42 pipe supports encompassed ASME Section III NF Class 1, 2 and 3 code jurisdic-tions and were located within the Containment, Fuel, Auxiliary, and. Safe -
guards Buildings of Unit 1.
The TRT identified six potentially deficient areas that required further evaluation for generic implications:
(1) Strut and snubber load pin spherical bearing clearance with washers was excessive.
(Reference procedure QI-QAP-11.1-28, Sec. 3.7.3.1, Rev. 25: The bearing gap was defined as the space between the outside surface of the race and the inside surface of the clevis bracket and may not be more than one thickness of the vendor-supplied spacer washer to prevent bearings from dislodging from their seats. Bearing dislodgement could cause snubber or strut misalignment and change its moment range, or angle of loading, degrading the enubber's or strut's loading capacity accordingly.)
(2) Strut and snubber load pin locking devices (cotter pins or snap lock rings) were missing. QI-QAP-11.1-28 does not address load pin locking devices. This appears to be an inadequate procedure.
l (3) Pipe clamp halves on the load side were not parallel.
(Ref QI-QAP-11.1-28, Sec. 3.7.3.1, Rev. 25.)
(
(4) Thread engagement of bolts into tapped holes of snubber adapter plate I
was less than full.
(Ref. ASME Sec. III, NF 4711.)
02/07/85 12 AQ-50 II l
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(5) "Hilti Kwik" bolts (concrete expansion anchors) as installed did not meet minimum effective embedment criteria. (Ref. QI-QP-11.2.1, Sec. 3.5.1, Rev. 16.)
(6) Locking devices for threaded fasteners were missing or of a nonapproved type. (Ref. ASME Sec. III, NF4725.)
In order to further evaluate the generic relation of these types of defi-cierties, the TRT undertook additional inspections (see Table 3). A large number of supports within a designated area were inspected for these specific deficiencies. These areas were di.fferent from those previously selected for TRT inspection of pipe supports. All accessible pipe sup-ports in Room 77N, elevation 810'-6" of the Unit I safeguards building, were inspected for deficiencies identified as items (1), (2), (3), and (4) above. Safety injection and chilled water piping supports were included within this room sample.
To assess the frequency of occurrence of the item 5, the TRT inspected electrical support "Hilti" baseplates located in the cable spread room 133, elevation 807'-0" of the Unit 1 Auxiliary Building. These electrical baseplate "Hilti Kwik" bolts (concrete expansion anchors) were chosen because of their accessibility and because there were numerous installa-tions in the area. The procedures for installation of the "Hilti Kwik" l,
bolts were the same governing installations for expansion anchors on pipe supports.
Ii The inspection criteria for items (1), (2), and (3) were based on B&R procedure QI-QAP-11.1-28. The inspection criteria for item (4) regarding thread engagement of snubber adapter bolts was based on full thread engage-ment. Those bolts lacking full engagement through the adapter plate were cited, even though procedure QI-QAP-11.1-28, Attachment 29, allowed less than full engagement.
For example, Attachment 29 showed a minimum thread engagement of 3/16 inch for snubber sizes 1/4-1/2 inches; for snubber sizes 1 inch through 3 inches, the minimum thread engagement is 5/16 inch, etc.
In all cases, the thickness of flanges and lengths of tapped threads in respective adapter kit flanges were ignored in Attachment 29. B&R proce-dure QI-QAP-11.1-28A, " Installation Inspections of ASME Class 1, 2, and 3 02/07/85 g
'AQ-50 II L
]S
Table 3 Summary of Frequently Occurring Hardware Deficiencies Area: Room 77N, El 810'-6" Unit 1, Safeguards Bldg No. of Supports No. of Supports Deficiency Inspected Deficient
% Deficient Item 1.
Excessive 92 5
5.4%
Spherical Bearing Clearance Item 2.
Load Pin Locking 92 14 15.2%
Device Missing Item 3.
Pipe Clamp Halves 40 9
22.5%
Not Parallel Item 4.
Snubber Adapter 19
- 13 to be Plate Bults With determined Less Than Full Thread Engagement Item 5.
Hilti Kwik Bolt 24 (Bolts 3 (Bolts 12.5%
Does Not Meet inspected) deficient)
Minimum Embedment**
Item 6.
Locking Devices For (See Text)
Threaded Fasteners
- Bolts had less than full thread engagement.
- Area: Cable Spread Room 133, El 807'-0", Unit 1, Auxiliary Bldg.
Note: Taking into account the " allowed" slippage of the bolt for a distance of one nut thickness due to torquing (Ref. " Installation of 'Hilti' Drilled-In Bolts" 35-1195-CEI-20, Rev. 3, Para. 3.1.4.1) and the minimum specified embedment, the above Hilti bolts violated the
" effective" embedment requirements.
i I
02/07/85 y
AQ-50 II IY
6 7
Snubbers," Attachment 10, also showed the same minimum bolting engagement allowances. The TRT concern is that this may violate ASME Se: tion III,
~
Subsection NF 4711, and additionally may not be certified as etceptable by the manufacturer.
The inspection criteria for item (5)~regarding "Hilti" installation was based on B&R construction procedur'e CEI-20, " Installation of Hilti Drilled-In-Bolts," and TUEC quality procedure QI-QP-11.2-1, " Concrete Anchor Bolt Installations." "Hilti Kwik" bolts were checked for minimum embedment.
The TRT noted that the floor of the cable spread room had a 2-inch topping, which cannot be considered as structural embedment.
Item (6), absence of proper and sufficient locking devices for threaded fasteners, is an apparent iol tion of ASME Sect. III, Subsection NF, NF-4725. See Section F 15- ' = --
" ( :.. O. -;., = ^ r e--
- p- ^'-
' """"' for discussion. on locking devices; and also see Category 1 of Table 2 for two examples of support [without proper locking devices on threaded fasteners.
D.
Class IE Electrical Cable Tray and C'onduit Supports The TRT expanded the sampling inspection of component supports and hangers to include a number of electrical cable tray and conduit supports.
Five hangers and supports in this category received 100% inspection by the TRT.
Two other supports were inspected for weld size and bolt torque verifica-tion only.
The TRT inspected electrical' conduit supports and cable tray hangers to the requirements of procedures QI-QP-11.10-1, " Inspection of Seismic Electrical Support and Restraint Systems"; QI-Qp-11.21-1, " Requirements of Visual Weld Inspection"; and other applicable instructions for conduit support and cable tray hanger inspections. All electrical supports included in TRT inspections had been previously inspected and accepted by QC. Table 4 summarizes the results of these QA/QC group inspections.
e 02/07/85 15 AQ-50 II
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Table 4 Summary of Electrical Conduit and Raceway Support Inspection - Unit 1 I
Support welds inspected 59 Suppports inspected 5*
Supports with problems 3 (60%)
Types of problems Hardware related, other than welding 6
Unauthorized configuration change 1
Weld related types of problems (categories)
?
Welds requiring rework 41 Welds made in field but not recorded on drawing 80**
Beam stiffeners added but not recorded on drawing 40 Building / Area Supports Cable Spread Room CTH 12646 C 130-21-250-3 C 120-21-194-3 Auxiliary Building CTH 6742 Containment Building CTH 5824 "All electrical supports inspected by the TRT had been previously inspected l
and accepted by QC.
- Full visual inspection was not performed by the TRT on these extra welds.
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l Five of the seven hangers and supports inspected by the TRT exhibited a variety of discrepancies. Although no unsatisfactory oppn items remained in the inspection records of B&R, a high percentage of inspectable characteristics failed on TRT inspection. The principal types of unaccept-able conditions were on welding. Most of the inspected hanger and support welds were undersize.
Some welds were made in the wrong direction on a support, while another hanger had a substantial number of welds which were not shown on the installation hanger drawing nor incorporated on the as-built drawing.
Other defects were found in the installation, such as anchor bolts exces-i sively skewed; minimum bolt hole edge distance violations; unmarked "Hilti" bolts; undersized nuts; missing washers; and frame clip (stiffener plate) sizes different frc's the dimensions given on the drawing. The TRT inspec-tiens of electrical cable tray and conduit supports were performed in the presence of B&R QC inspectors, who recorded all of these TRT inspection findings.
E.
Inspection of Instrument Tubing supports The TRT elected to perform a random sample inspection of Class I nuclear safety-related instrument tubing supports as part of the overall TRT QA/QC is-built inspection effort. Three Class I supports were selected which j
were located in the Unit 1 Containment Building. These supports were on
)
instrument tubing emanating from ASME Class 1 reactor coolant lines.
1
)
[
Hardware attributes such as location, support type, configuration, dimen-sions, and welding were checked for compliance with applicable standards, drawings, procedures, and other pertinent documents.
In addition, the TRT
[
reviewed record documentation for the supports which consisted of drawings l
and their' applicable change addenda, construction operation travelers,
}
weld filler metal logs, and inspection reports.
b The results of the TRT hardware inspection of instrument tubing supports revealed no reportable discrepancies. One tubing support exhibited a f
small dent that was not considered significa6t. The documentation review l
02/07/85 17 AQ-50 II e
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i indicated that the record software completely and accurately representated the hardware found in the field, and the in process and final inspections were comprehensive and provided sufficient evidence of acceptance.
F.
Other Conditions Observed The following conditions were observed during the foregoing reviews.
Material Traceability s
The TRT examined 33 component support packages to det' ermine whether mate-rial traceability existed from marked and identified material through the various records to the Certified Material Test Report (CMTR) or a Certifi-cate of Conformance (C of C).
The TRT found that through various logs and records an audit trail could be established satisfactorily to the material source and certification, as long as the material was properly identified, i.e., the material heat lot or control number was stamped or etched on the part. The TRT found four supports not traceable because the identification number was either not stamped or etched on the installed material or was not entered in the material identification log.
Locking Devices The TRT also. investigated the omission of locking features for NF support threaded fasteners. ASME Section III, Subsection NF, Subarticle NF-4725 states in part that "all threaded fasteners shall be provided with locking devices to prevent loosening during service."
Noncompliance with this requirement was recognized by TUEC and B&R quality inspection, and followed in April 1984, by a " Request for Informa-tion and Clarification" (RFIC) to TUGC0 engineering, rcquesting direction for resolution of this issue.
The failure to comply with ASME Code requirement was not reported as a non-conforming condition with a non-conformance report (NCR) at that time, nor during the following months.
Howev,er, on'May 24, 1984, TUGC0 engineering advised by memorandum (CPPA 38997) that tne paint which was applied to Unit 1 component supports, t
02/07/85 18 AQ-50 II
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including fasteners, was' of such substance that, when set or hardened, the paint coating would act on bolt and nut threads to prevent the nut from loosening.
TUGC0 engineering had performed a series of torque tests to substantiate their position.
Samples, coated with a multi process epoxy formula, were chosen by TUGC0 on the basis of sizes and included in the test.
Regarding the utility and reliability of coating used as a locking device D
for threaded fasteners, the TRT has several concerns.
(1) No notification of deviation to code and specification requirements was submitted to the NRC.
(2) Paint-coated threads were tested in the weld shop under normal envi-ronment and ambient temperature. Useful life or holding capability
- under anticipated service conditions, including design basis tempera-tures and radiation aging, was not considered.
(3) The type of coating which was torque tested was not identified in TUGCO's documentation of the " Multi process Epoxy Formula Torque Test," attachment to TUGC0 CPPA 39209, office memorandum. The E -
unanswered question is whether the coating tested was CZ 11/P 305
[
(Carbo-zine 11, prime, and phenoline 305, top-coat) or C193/P305
[
(carboline 193, epoxy primer, and phenoline 305, top coat); and i
whether torque test conclusions for one coating would be the same for the other coating formula. Both coatings ware used on threaded j
fasteners in Unit 1.
(4) There was no evidence that an effective plan had been initiated to provide for routine maintenance activicies in order to ensure that
{
all painted fastener threads on NF supports maintain sufficient
{
thread-lock reliability for the length of the life of the plant, or L
until the paint lock method is replaced by a different procedure.
t O 02/07/85.
19 AQ-50 II
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(5) It appears that TUGC0 attempted to correct code violations in late i
May 1984, after most of the pipe hangers and c'omponent supports had been installed, by assuming the position that paint on a thread was indeed an acceptable locking device and complies with the require-l ments of ASME,Section III, NF-4725. The TRT could not locate any NCRs, or ASME/ANI notification, or documented reporting to NRC, describing absence of approved locking devices, when the component supports were installed and inspected in 1983 and earlier.
f Excessive Radial Weld Shrinkage During inspection of pipe supports under the TRT hardware inspection pro-gram, radial weld shrinkage was noted on nearby stainless steel piping l
welds. One weld in particular exhibited considerable weld shrinkage. The exhibited radial weld shrinkage was excessive and potentially re:ulted from too much heat input being applied during weldout.
The examined weld was in a 12" diameter SI line located in a Unit 1 pipe tunnel designated as Room 850. The line number was 12"-SI-1-031-151R-2 9
and the weld number was FW 98 as detailed on piping isometric BRP SI-1-YD-03-1.
This line was an ASME code Class.II line and was NA stamped j
at the time of our inspection. The TRT measured shrinkage at this weld
[
joint in excess of 3/16". According to B&R quality inspection procedure for pipe installation (QI-QAP-11.1-26, Rev. 16, issued June 11,1984),
3 this is a violation of inspection criteria delineated in Section 3.6.8.4.
f This requiremer.t was taken verbatim from Gibbs and Hill piping installa-(
tion specification 2323-MS-100 Section 4.27.8.
A review of.the weld documentation indicates that weld FW 9B was visual
[-
test (VT) accepted on June 28, 1979, as noted on Weld Data Card (WDC)
(
13265. The TRT was able to establish that in 1979 the piping inspection j
procedure, QI-QAP-11.1-26, did not contain inspection criteria for l-measuring weld shrinkage nor did the Gibbs & Hill specification
}
2323-MS-100. At that time, the Gibbs & Hill specification simply stated that " welding parameters shall be controlled to avoid excessive heat input 02/07/85 20 AQ-50 II
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resulting in necking down of butt welds" (Ref. Sec. 4.27.8). The inspec-
)
tion criteria for measuring radial weld shrinkage first appeared in Rev. 7 of MS-100 Sec. 4.27.8, issued December 2, 1983.
i l
A comprehensive documentation review of the weld package checked out okay.
It was determined that original weld FW 9A at this same location was cut out due to rejection of radiographic test number #5478 and was rewelded as FW 98.
5.
Conclusion and Staff Position: The alleger had seven areas of concern with the IEB 79-14 program and, together with the TRT comments, are as follows:
(1) " Hanger location was accomplished by craft people and field engineers,
- without QC involvement." This is normal construction practice, using engineering drawings. QC inspects the location during installation inspection; then location is rechecked in the IEB 79-14 program.
(2) "No hanger dimensional checks were made during the verification inspection." This is clearly a requirement for installation inspec-tion and was not in the scope of the IEB 79-14 program.
If, as alleged, many discrepancies were noted early in the as-built program, the installation QC inspection group should have been notified and then should nave taken appropriate corrective and preventive action.
l (3) " Writing of NCR's was suppressed." This allegation was assess'ed in AQ-37 and AQ-80, Category 5D.
c
" Deficiencies such as loose bolts or bad welds were not reported."
These should have been reported to the installation QC inspectors when detected, who would process NCRs; however, the identification of these type deficiencies was not the principal purpose of the IEB
]
79-14 program.
)
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02/07/85 21 AQ-50 II 1
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(4) " Numerous sway struts were installed out of angular tolerance." This allegation probably originates in the fact that there were various angularity tolerances applied to sway struts and snubbers prior to April 18, 1984. Most important was the overall installation and inspection tolerance on angularity of plus or minus 5 degrees, with the exception that dead weight supports must be within plus or minus 2 degrees. However the IEB 79-14 program required all angles over 12" to be measured and reported. The TRT found no instance of sway strut or snubber angularity exceeding the allowable installation tolerance.
(5) "None of the personnel involved in the as-built program had hanger inspection experience." With the exception of the alleger, the as-built crew consisted of degreed civil engineers. The primary task in the IEB 79-14 program was checking for support type as well as measurement of location, direction, clearances, and angularity.
Assuming proper training, these men had sufficient qualifications.
The IEB 79-14 inspection work did not resemble QC installation inspection and was not a part of that program.
(6) "There was no engineering review of the inspection data." TRT investigators found that engineering review by the TSABC and TSDRE was prompt, competent, and well-documented.
(7) " Boundaries of the inspection were not defined." TUGC0 engineering procedure CP-EI-4.5-1, " General Pr'ogram for As-built Piping Verifica-tion," provided sufficient definition of the inspection package and j
instruction for what attributes were to be checked within the IEB 79-14 program.
'On Thursday, February 7,1985, the TRT contacted the alleger in a tele-i phone interview and provided results and conclusions of the TRT assess-l ment. The alleger did not identify any further concerns or allegatio's7 i
The TRT notes that items (1),.(2), (3), and (5) of the potentially generic j
issues (Table 3) are deficiencies that do not meet established inspection criteria. The TRT considers that the inspected level of occurrence of s
02/07/85
-22 AQ-50 II
.. ~.....
i l
i items (1), (2), (3), (5), and (6) is excessive and indicates QA/QC break-l down with regard to these inspections. The TRT notes that the frequency of less than full thread engagement of snubber adapter plate bolts is tolerated by B&R procedures QI-QAP-11.1-28, Attachment 29, and QI-QAP-11.1-28A, Attachment 10. This does not appear consistent with the intent of ASME Section III, NF 4711. The TRT was not able to find records 3
j of correspondence by QA/QC or engineering which may have been raised by l
the question of possible code violation, which may have requested vendor concurrence with less than full" thread engagement, or which may have raised questions of how minimally threaded fasteners were properly accounted for in the final as-built stress analyses.
]
The safety-related significance of each noted deficiency varies.
Item (1) j (excessive spherical bearing clearance) may allow dislodgement of the i
bearing from its race and detrimentally affect function of the support.
I j
The TRT noted that in each case the excessive clearance was not enough j
to allow total dislodgement of the bearing.
This deficiency is not considered safety significant.
Item (2) (load pin locking device missing) could permit dislodgement of the load pin.
In effect, the support would lose its functional operabil--
4
}
ity. This deficiency is considered potentially safety significant.
i h
Regarding ii.em (3) (pipe clamp halves not parallel), it is not apparent i
to the TRT that there is a necessity forjrequiring the load-side clamp halves to be parallel without any tolera'nce. The TRT recognizes that at
(
some point a non parallel condition would be unacceptable, and maintains 1j that an installation tolerance should have been instituted in project l.
procedures. The non parallel conditions found did not appear excessive; i
and the TRT does not regard this item as safety significant.
I h.
Item (4) (snubber adapter plate bol ts not fully engaged) may have signifi-I cant safety impact.
It is not apparent to the TRT that the snubber design j
l allows for less than full thread engagement. Therefore the load capacity i
of the snubber may be redt..?d by this condition.
l f.
l 02/07/85 23 AQ-50 II MG" N
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Item (5) ("Hilti Kwik" Bolts installed with less than minimum embedment) is safety significant in that the amount of embedment directly affects load capacity.
I Item (6) (absence of proper and sufficient locking devices for threaded f
fasteners) is a violation of ASME Code requirements and may have safety implications.
In conclusion, the TRT staff position is that items (1), (2), (3), and (5) of the potentially generic issues occur at levels within sampling by the TRT that are excessive.
Items (2) and (5) are considered safety signifi-cant, while items (1) and (3) are not. The TRT believes the item (3) occurrence level is related to an inspection criteria that may be too stringent (i.e., with no construction or inspection tolerance).
Items (4) and,(6) may be safety significant.
Based on the inspection of 42 NF component supports, the TRT concluded that the ASME code requirements and quality acceptance standards, as well as site QC procedures were compromised in some of the systems and compo-nents inspected.
i The TRT observed that the characteristics of identified discrepancies were both specific to individual supports and potentially generic.
Frequency and repeatability of deficiencies were most ryotable in categories of:
excessive free gap at the spherical bearings of snubbers and sway struts; strut and snubber fasteners not properly secured; and insufficient thread engagement of bolts in shock arrester adapter plates.
Unsatisfactory QA/QC performance was most visible in the inadequacy of inspections in the field, a problem compounded by occasional poor work-manship; neglect of some requirements of the ASME code, other standards, and station procedures; and in one instance, disregard of the reporting l
requirements of the Code of Federal Regulations (CFR), Title 10, Part 50.55(e).
1 02/07/85 24 AQ-50 II
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i Material traceability could not alway be properly established from the parts or records inspected by the TRT. Deficiencies were found in unmarked I{
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material and omission of the material's heat number from the material identification log.
The TRT's findings with regard to TUGCO's omission of locking devices for NF suppurt threaded fasteners are that QA/QC failed to report the viola-tion of the requirements of ASME III, NF, subarticle 4725, via a formal non-conformance report.
Further, TUEC failed to report this incident of ASME code violation to the NRC and therefore was in noncompliance with the requirements of 10 CFR 50.55(e).
The QC inspection criteria for the weld joint involving radial weld shrink-age was not violated at the time of the visual test inspection. The TRT acknowledges that the ASME code does net specifically address acceptance criteria for weld shrinkage, but the TRT believes that an acceptance standard with regard to shrinkage is necessary. The TRT requested that TUEC address the situation that weld joints do exist in NA-stamped systems that exhibit excessive weld shrinkage when measured against their current procedure and that the safety significance af this situation be assessed.
Based on inspection findings in Class IE electrical supports and the'high rate of rejectable characteristics, perhaps unique te electrical supports, the TRT concluded that B&R inspection of these electrical supports was unsatisfactory and that objective evidence of ccmpliance with specified.
engineering and construction criteria wsa not provided.
t The TRT found nothing deficient within the Class I instrument tubing sup-port inspection sample.
During the TRT's assessment of allegations in the areas of design and document control (Categories 1 and 2), a number of conditions may have
)
been in existence during the early stages of construction that could have resulted in problems significant to safety. Whether actual problems did occur could only be determined from this as-built assessment. While the 02/07/85 25 AQ-50 II b ~
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as-built assessment did not specifically associate the identified problems with design or document control deficiencies, many of the problems identi-fied could have been the result of incorrect or obsolete documents being used for construction and/or inspection.
The as-built verification effort conducted by the TRT provides evidence of faulty construction by craft personnel, installed hardware that does not match as-built drawings, and ineffective QA/QC inspections.
Cespite thesmallsizeoftheTRT'ssample,there$36k*'=bealargenumbercf deficiencies mer not represented correctly in the final stress analysis.
6.
Actions Recuired:
Se'e Item No. 4 of the enclosure to the D. Eisenhut letter to M. D. Spence dated January 8, 1955.
TUEC should undertake actions in response to the conclusions contained in this report necessary to improve overall confidence in the as-buiit con-dition cf hardware associated with plant safety-related systems.
Corrective action should also be taken by TUEC regarding the se.;>
ng t u_ _g,r._._
3 4 -, m. e m m es-ris,sa-ee: e c'tusr-that weld joints do
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exist in NA-stamped systems that exhibit excessive radial weld shrinkage when measured against current procedures, c;;;;; th: ::#ety -:ignicance of this-s4 tuati e n, and sub 't a p'2" mf $c'#nn
+n rasni"e defici:n:'c4.
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. m A.. ' 4. [.] j c..m....... l 8. A;tachments: None 1 9. Reference Decuments: 1. Comanche Peak Steam Electric Station, Final Safety Analysis Report. '2 Ccce of Federal Regulations, Title 13, Part 50 (10 CFR 50), Appendix 2 " Quality Assurance Criteria for Nuclear Power Plants and Fuel Reprec-essing Plants." 3. 10 CFR Part 50.55(e), "Concitions of Construction Permits: Reporting Criteria f or Significant Ceficiencies." 4. American $cciny of Mecnarical Engineers ( ASME), Boiler ?nd Pressure Vessel Code, Section III, Civision 1, 1974 Ec: tion. 5. U.S. Nuclear Regulatory Ccmrission, Inspection and Enforcement Eulletin No. (IEB) 79-14. 43 AQ-50 II 0?/07/35
~ 6. IEB 79-02', " Pipe Support and Baseplate Design, Using Concrete Expansion Anchor Bolts." 7. American Welding Society, Structural Welding Code (Steel), AWS 61.1-79. 8. HILTI " Architects and Engineers Anchor and Fastener Design Manual." 9. Gibbs and Hill specification: 2323-MS-100. ~
- 10. Gibbs and Hill specification: 2323-MS-46 " Nuclear-Safety Class Hanger & Supports"
- 11. TUGC0 engineering procedure:
CP-EI-4.5-1 " General Program for As-Built Piping Verification."
- 12. B&R quality procedure: QI-QAP-11.1-28 " Fabrication, Installation and Inspection of Safety Class Component Supports," Rev. 25, 7/11/84, and previous revisions.
- 33. B&R quality procedure: QI-QAP-11.1-26, Rev. 16, 6/11/84, and previous revisions.
- 14. B&R quality procedure: QI-QAP-11.1-37 " Instruction for QA/QC Review, Approval and Utilization of Construction Operation Travelers."
- 15. B&R quality procedure: CP-QAP-12.1, Rev. 11, 6/11/64, and previous revisions.
- 16. B&R quality procedure: CP-QAP-16.1 " Control of Nonconforming Items."
- 17. E&R construction procedure: 35-1195-CEI-20 " Installation of 'HILTI' Drilled-In Bolts," Rev. 10, 9/14/84, and previous revisions.
02/07/85 44 AQ-50 II
C
- 18. TUGC0 quality procedur2: CP-QP-11.2 " Surveillance and Inspection j
of Concrete Ancho" Bq1t Installations," Rev. 8, 7/13/84, and previous revisions.
- 19. TUGC0 quality procedure: QI-QP-11.2-1 " Installation of 'HILTI' Drilled-In Bolts," Rev. 16, 7/20/84, and previous revisions.
2'0. TUGC0 quality procedure: QI-QP-11.2-2 " Abandoned Cor. crete Anchor Holes," ano historical revisions.
- 21. TUGC0 quality procedure: QI-QP-11.2-3, " Torquing of Concrete Anchor Bolts," and historical revisions.
- 22. TUGC0 quality procedure: QI-QP-11.2-4 " Inspection of 'HILTI' Super
- Kwik Bolts," and historical *evisions.
- 23. B&R procedure Q1-QAP-17.1-28A, " Installation Inspections of ASME Class 1, 2 and 3 Snubbers."
- 24. B&R Quality Assurance Manual.
I
- 25. TUGC0 instruction CP-QP-11.10-11, " Inspection of Seismic Electrical Suppcrt and Restrain: Systems."
[
- 26. TUGC0 instruction CP-QP-11.10, " Inspection of Electrical Raceway Support Systems."
h l [
- 27. TUGC0 instruction QI-QP-11.21-1, " Requirements of Visual Weld f
Inspection." [
- 28. TUGC0 instruction QI-QP-11.10-2, " Cable Tray Hanger Inspections."
I
- 29. B&R co~nstruction procedure CP-QP-18.0, " Inspections Reports.'
f e 02/07/85 45 AQ-50 II L
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- 30. Gibbs & Hill drawing 2323-S-910, " Seismic Support of Class I-E Conduit."
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- 31. Gibbs & Hill drawing 2323-5-902, " Electrical Supports Standard 1
}- Details." i ~
- 32. Gibbs & Hill Specification ECP-10 for electrical conduit supports.
- 33. Region 4 Inspection Report 83-24, p.12 (Tracking System
- RIV-83-A-0026), 8/24/83 (source of AQ-50 allegatien).
- 34. Region 4 Report of Inquiry, Q4-83-009, 4/8/83 (source of AQ-50 allegation).
- 35. - Telephone interviews by TRT with Alleger, A6, on 8/21/84 and 8/23/84.
36. Interview by TRT in person with Alleger, A6, on 8/24/84, 8/25/84, and 8/26/84.
- 37. Telephone interview by TRT with Alleger, A6, on 2/7/85.
t [
- 10..This statement prepared by:
M. Eli, fRT Date Technic.a.i Reviewer i Reviewed by: H. Livermore, Date Group Leader I Approved by: ) V. Noonan, Date j Project Director i ? 4 02/07/85 46 AQ-50 II a
Figure 1. Harcl ware Examples Lect Bolt, . e- ~ ' -~' One M.rt Only, No Lock Nut q Q ~ Lood Pin ~ ,$$,2#' Spring { With Cotter "*,;r con Pin Locking Threod { Device sight h-N.1 g Sway Strut -f f snubber Three-Bolt Adopter Plate N ) P~pe Cicmp Topped Hole 4 3 Extension Kit 1 Plate MM_ Not Topped-Pipe E h Clamp One Nut Only, No Lock Nut _sphericci Be&ing
- )
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i j Figure 1. Hardware Examples \\ -t i Lood Bolt, One Nut only. %y o Lock Nut ( :': $ N Lood Pin .....::',. Spring i with cetter i Con Pin Locking Throod j Device .c.., sight m ~ M He4N'1'g ~ Sway Strut Ef a 0 m Three-Bott Adopter Plate ( : : ] Fpe Clamp Topped Hole 4 ] Extension Kit [ Plote %t Toppect f pipe ' M._, h IClamp One Nut Only, No Lock Nut t 4 ) P Spherical secring 3, h gjy unuuuun .:s I Snubber Extension Kit i
~ Figure 1. Hardware Examples 1 6 2 Lood Bolt, One PM Only. p ~2[ Spring with cotter Con Pin Locking Throod Device
- 1. #
Sight i Nb HokN'1.'g ~ Sway Strut E>f lif;r I Snubber Three-Bolt Adopter Plate ( : : ] Fpe Qurp Topped Hole 4 3 Extension Kit Mi[ Nt ed Pipe ' Clamp o One Nut Only. No Lock Nut I: 9 sphericol secring 3, qjjj M \\\\\\\\\\\\\\\\\\\\\\\\ l .::) l, Snubber Extension Kit I ]'
g,) / SSER WRITEUP 000UMEtiT C0tiTROL/ ROUTE SHEET s' Allegation fiumbrs A h-N M- /N2; OA /C C (14 TF6 OM 3 3 o Subject of Al1egat)Ge on A S-B u.t 7-I M 06,g,t n,
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/s_....xc {. TRT Group G /1 / _/ / Author: />. </, # f./ d :- e r This sheet will be initialed by each reviewer. It stays with all revisions tc the SSER writeup and serves as a rcuting and review record. It will be filed in the work package when the writeup is published. Draft tiumber Draft 1 2 3 4 S Author R. IkEh, kh Group Leader /
- fV,
.#p# 4 2 -f Tech. Editor / //fhtg Wessman/Vietti / ~ f// / J. Gaoliardo / '/( /o/ / i _T. Iocalito / l Revision flumber Final 1 l 2 3 .A 5 ll{Y;.,,'* **EY I fe9' Futhor /G o Tech. Editor 4lt/~TQ'f?_ _Grcuo leader "" M $leWO%c i J. Gaoliardo T/' n/ 3s T. locolito
- 8 Administrative
. :r. f., A. Writeup integrated into SSER l Potential Violations to Region IV f f,/ h'[sf/ Workpackage File Complete / / Workpackage Returned to Group Leader '\\j' I 2 wM no-vi, Awe e,m-n, g g jo g, e ,v r,.i.. :.v. is - ),ll. toi s,lQ l' l' obYI A G 'l '/ l C /. i g -:,1. 'I I +
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b Document Name: i / AQ-44, AQ-128 Requestor's ID: DEEQB01 Author's Name: Chet Poslusny Document Comments: Rev. A h 2f s/ss-i e + + 9 6 l. I l
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l. AQ-44,AQ-128 Revision 4 - 2/28/85 SSER 1 1. Alleoation Group: QA/QC Category No. 8 2. Allegation Number: AQ-44 and AQ-128 - 3. Characterization: It is alleged that there were instances when craft personnel would "make things fit" and have an engineer write "as-built" on the document instead of following the appropriate design docu' ment. It is also alleged that an as-built verification program was initiated as a result of the above practice (AQ-44). It is further alleged that nonconformance reports (NCRs) were voided (improperly dispositioned) by an engineer writing "as-built" and "use-as-is" on them (AQ-44, AQ-128). t. Assessment of Safety Significance: The NRC Technical Review Team (TRT) ' evaluated the Texas Utilities Electric Company (TVEC) procedures for implementing 10 CFR Part 50, Appendix B, Criterion V, " Instructions, Procedures and Drawings"; Criterion X, " Inspection"; and, NRC Office of Inspection and Enforcement (IE) Bulletin No. 79-14 " Seismic Analyses for As-Built Safety-Related Piping Systems." O P
. I IE Bulletin No. 79-14 requires a seismic analysis of all safety-related systems, as-built verification of safety-related systems, evaluation of nonconformances found during as-built verification or correction of the nonconformance, and revision of documents to reflect as-built conditions in the plant. TUEC's implementing procedures for 10 CFR Part 50, Appendix B and IE Bulletin 79-14 requirements included the following: TUGC0 QI-QP-15.2-1, "Startup/ Turnover Record Requirements"; B&R SFI-1, "Startup/ Turnover Record Requirements"; TUGC0 CP-EI-4.5-1, " General Program for As-Built Piping Verification"; TUGC0 CP-EP-4.5, " Design Verification"; TUGC0 CP-EI-4.5-4, " Technical Service Engineering Instruction for Pipe Hanger Design Review and Verification"; TUGC0 CP-QP-16.0, "Nonconformances"; TUGC0 CP-QP-11.13, "As-Built Verification"; TUGC0 QI-QP-11.13-1, "As-Built Piping Verification Instructions." d a 4 a4.,wg e- + i,. = e
1 The TRT verified that 'these procedures satisfy both 10 CFR Part 50 Appendix B (Criteria V and X) and IE Bulletin 79-14. Texas Utilities Generating Company (TUGCO) procedure CP-EI-4.5-1 includes verification of piping isometric drawing dimensions, elevations, valves, angles, sleeves, and interconnecting equipment. This procedure also' includes verification of the pipe hanger location, configuration, and clearances. The procedure requires analyses of the as-built condition, resolution of unacceptable analysis results, and certification of each anlaysis (furnished by the responsible analysis organization). Title 10 CFR Part 50, Appendix B, Criterion III, states that: " Design changes, including field changes, shall be subject to design control measures commensurate with those applied to the original design..." The TRT determined that TUEC prepared engineering procedures (CP-EP-4.6, " Field Design Change Control," and CP-EP-4.7, " Control of Engineering / Design Review of Field Design Changes") and implemented them to satisfy this requirement. These procedures required design verification by authorized personnel either prior to or following implementation. Revision of any design document invalidates the design verification of that document; therefore, it requires verification by the organization responsible for the original design. Both principal support vendors (ITT Grinnell and NPSI) had personnel onsite who verified changes to vendor drawings and recertified these drawings when required. e-- e+ -9'- --4w -w e --w9a vryi
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TUGC0 procedure CP-QP-16.0, Section 3.2.4.1.d. states that, "Use-as-is dispositions shall include sufficient engineerino technical justification to establish that the nonconforming characteristic will result in no adverse conditions and that the affected item will centinue to meet all ~ engineering functional requirements, including performance, maintain-ability, fit, and safety." The TRT reviewed 72 nonconformance reports (NCRs) that were dispositioned "use-as-is.d In all cases the technical justification, component modification card (CMC) or design change authorization (DCA) supported the "use-as-is" NCR disposition. In no case did the TRT find an NCR that was improperly dispositioned "as-built" or " accept-as-built." In addition to the 72 NCRs examined in connection with this allegation, the TRT performed an in-depth evaluation of NCR activity, including voided NCRs. The TRT reviewed 206 NCRs and found none that were voided by an engineer writing " void as-built" on them. (Refer to QA/QC Category No.5.D,allegationsAQ-31andAQ-120.) 5. Conclusion and Staff Positions: Based on a review of design, inspection, and as-built procedures, the 'TRT concludes that the allegation that an as-built verification program was implemented to compensate for failure to follow the appropriate design documents is substantiated. Supports were changed after the drawings had been vendor-certified, and drawings were revised to reflect the as-built condition. The TRT also concludes' that those design modifications that were made were recertified by the gc-
principal support vendors' cnsite staff in accordance with NRC requirements. (For additional information, refer to QA/QC Category No.1, allegations AQ-21 and AQ-22.). Based on interviews with B & R Engineering and TUEC QA personnel a review of inspection and nonconformance procedures and the 72 "use-as-is" dispositioned NCRs, the TRT staff concludes that the allegation relating to improper voiding of NCRs cannot be substantiated. Accordingly, these allegaticns have neither safety significance relative to ti,2 programmatic and technical implen.entatier of NRC requirements and commitments, nor do they have generic implication's. The TRT plans to send a letter to the alleger regarding the TRT's assessment and conclusion of these allegations, once the QA/QC SER is published. t 6. Actions Reouired: N ne. ~ -- s,s.1.aqawqs.yn 8. Attachments: None. 9. Referenca Documents: i 1. USNRC 50-445/IE Bulletin No. 79-14, "Seisnic Analysis for As-built Safety-Related Piping Systems." l
~ - - - ,' 2. TUGC0 CP-QP-4.6, " Field Design Change Control." 3. TUGC0 CF-QP-16.0, "Nonconformant.e." 4. hRC TRT QA/0C Category 8, Allegation No. AQ-50, AQ-55 and AQ-135, l "As-Built Program." 19,1984(AQ-44). 5. GAP 2.206 Petition No. 13, dated March 6. AQ-44 and AQ-128: A-1 Statement dated March 19, 1984, and A-1 Interview pp. 57-63, dated April 6, 1984. 7. A-1 Interview pp. 136-137, dated August 1, 1984. 8. TUEC Letter TXX 4180 dated Mcy 25, 1984, Nonconformance Reports (N.CRs) as follows: 4 i 83-03110 84-00686 84-00607 l 03114 00398 00609 03093 00469 00596 03089 00470 00578 03090 00456 00570 03063 00463 00554 l 03066 00444 00557 03048 00434 00560 i 03053 00443 00551 i 03035 00424 00537 03039 00397 00519 03040 00375 00495 l 03042 00709 00500 03035 00713 00483 03027 00673 00339 03010 00645 00340 03015 00627 00341 02988 00633 00343 i 02992 00605 00344 l 02981 00473 00346 03017 00458 00337 03C04 00455 00361 l 02475 00608 00371 4 00579 f 00485 00362 h f. {.
10. Deposition of C. Thcmas Brandt, Tr. 45,273-45,276 (submitted as prefiledwrittentestimony). 11. 01 Report 4-84 008 (July 9, 1984). 12. OI Report 4-84-006 at 26 (March 7, 1984). 13. Deposition of 14. Deposition of C. Thomas Brandt, Tr. 45,287 (submitted as prefiled written t'estimary).
- 15. March 19-20, 1984 Hearing Session Transcripts Tr. 10,383.-11,018.
- 16. April 24, 1984 Hearing Session Transcripts Tr. 12,138-12,285.
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- 18. Deposition of C. Thomas Brandt, Tr. 45,280-45,287 (submitted as profiled written testimeny).
i
- 10. This statement prepared by:
R. Hedderick, TRT Date Technical Reviewer ~ H. Livermore, Date Group Leader } V. Noonan, Date Project Director i s 4 f. 1 1 ) 4 l d 4 i e i 1 1
ft ' .i v, Document Name: AQ-50 III Requestor's ID: LINDA Author's Name: Chet Poslusny Document Comments: 3/7/85 REDRAFT 1-1/2 space KEEP THIS SHEET kTTH DOCUMENT c
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,W 1 ^ l' t 4 s. Rev. 1, March 1, 1985 'SSER AQ-50 SSEP 1. Allecation Cateaory - QA/QC 8, As-Built ~ 2. Allegation Number: AQ-50 3. Characterization: It is allrrai that the "As-Built" inspection program used by TUEC to address Inspection and Enforcement Bulletin (IEB) 79-14 for pipe supports was too narrow in scope and ignored dimensional discrep-ancies that might exist between the field condition and final "as-built" drawings. 4. Assessment of Safety Significance: A. IEB 79-14 Program One purpose of IEB 79-14 was to assure that the as-built pipe and support configuration was used in the final stress analysis of critical piping systems. IEB 79-14 also identifies the critical systems to be considered in the stress analysis. TUEC engineering procedure CP-EI-4.5-1 def.ined the program for developing and using the information needed to comply with IEB 79-14. This program was to be implemented in addition to the normal QA/AC process, although the primary responsibility for assuring overall hardware compliance with established procedures and drawings remained with the QA/QC process. TUEC procedure CP-EI-4.5-1 listed pertinent documents that would describe the as-built configuration of the piping and support systems, such as Brown & Root (B&R) piping isouetrics (BRP), B&R hanger drawings (BRH), and B&R hanger location drawings (BRHL). It defined field checks which must be made to verify pipe support location, direction, support type, and 03/07/85 1 AQ 50 III
. _m clearances. It also provided instructions for integrating this as-built information into the final stress analysis of the piping systems. This program was initiated in April 1981. 3 The allegation implied that the as-built inspection program was restricted to a limited number of systems and types of attributes only, and that it therefore did not provide adequate coverage. It was further alleged that i dimensional variations existed between installed conditions and final as-built drawings. The TRT interviewed the alleger by telephone on August 21, 1984 and August 23, 1984, and in person on August 25. The alleger who had been a QC inspector on one of the Unit 1 as-built teams had seven areas of concern with the IEB 79-14 program and, together with the TRT comments, are as follows: 1 (1) " Hanger location was accomplished by craft people and field engi-neers, without QC involvement." This is normal construction prac-tice, using engineering drawings. QC inspects the location during l installation inspection; than location is rechecked in tne IEB 79-14 program. ] (2) "No hanger dimensional checks were made during the verification in-l spection." This is clearly a requirement for installation inspection and was not in the scope of the IEB 79-14 program. If, as alleged, many discrepancies were noted early in the as-built program, the in-sta11ation.QC inspection group should have been notified and then should have taken appropriate corrective and. preventive action. (3) "The writing of nonconformance reports (NCRs) was discouraged." This allegation was ast.essed in AQ-37 and AQ-80, Category 5D. " Deficiencies such as loose bolts or bad welds were not reported." i These should have iieen reported to the installation QC inspectors 03/07/85 2 AQ-55III \\ E
e when detected, who would process NCRs; however, the identification of these type deficiencies was not the principal purpose of the IEB, 79-14 program. (4) " Numerous sway struts were installed out of angular tolerance." This allegation probably originates in the fact that there we're various angularity tolerances applied to sway struts and snubbers prior to April 18, 1984. Most important was the overall installation and in-spection tolerance on angularity of plus or minus 5 degrees, with the exception that dead weight supports must be within plus or minus 2 ~ degrees. However the IEB 79-14 program required all angles over t2' to be measured and reported. Of the five supports chosen by TRT for review of IEB 79-14 program, the TRT found no instance of sway strut or snubber angularity exceeding the allowable installation tolerance. 4 (5) "None of the personnel involved in the as-built program had hanger inspection experience." With the exception of the alleger, the as-built crew consisted of degreed civil engineers. The primary task in ^ the IEB 79-14 program was checking for support type as well as mea-surement of location, direction, clearances, and angularity. Assum-ing proper training, these men had sufficient qualifications. The IEB 79-14 inspection work did not resemble QC installation inspection and was not a part of that program. i (6) "There was no engineering review of the inspection data." TRT investi-gators found that, of the documents looked at by TRT, engineering review for IEB 79-14 program was prompt, competent, and well-documented. I l (7) " Boundaries of the inspection were not defined." TUGC0 engineering procedure CP-EI-4.5-1, " General Prograv for As-built Piping Verifica-tfon," provided sufficient definition of the inspection package and instruction for what attributes were to be checked within the IEB 79-14 program. i h 1} 03/07/85 3 AQ-50 III
.p l e } In assessing this allegation, the NRC Technical Review Team (TRT) thor-oughly reviewed the as-built reverification records (ABRR) for the dispo-sition of 37 out of the 97 pipe supports identified by the alleger as } having documented unsatisfactory findings. The TRT also comoletely field-examined 5 of these 37 pipe supports. The as-built te.ans consisted cf a party chief, an instrument man, a rod man, and a QC inspector. The alleger maintained a logbook during this period (January to May 1983), which listed the identification numbers of the A8RRs. ABRRs were used to reverify the as-built condition of modified pipe hangers. The alleger identified 97 A8RRs as unsatisfactory. Of these, 93 described hangers with excessive sway strut angularity. The logbook identified " stress problems numbers" for 37 of the 97 unsatisfactory ABRRs. This information allowed the TRT to identify the corresponding hanger num-bers easily. The TRT selected 5 ABRRs from the group of 37 described above and per-formed a co,tplete field re-inspection of the corresponding individuti pipe supports. These five supports were ASME III, NF, Class 2 & 3. Each of these ABRRs had documented snubber or sway strut angularity that deviated more than 2* from the angularity specified by CP-EI-4.5.1. In none of these cases did the deviation exceed i 5' offsat', which was the allowable limit for snubber or strut misalignment in a system's cold or hot setting. B&R procedure QI-QAP-11.1-28A, Revision 4, Paragraph 5.7a., " Inspection Criteria for snubbers," states that "to prevent binding within the clamp and/or bracket, snubber shall not be installed with an offset of more than 5 (five) degrees." The TRT measured this angularity and in each case was able to confirm the angularity documented on the ABRR. The TRT reviewed applicable QC inspection procedures in effect at the time of the ABRR field work and learned that strut and snubber angularity which did not deviate more than i 5' was acceptable. (Reference B&R procedure QI-QAP-11.1-28 Sec. 6.3.1.1.d, Revisions 16 thru 23, issued between 12-15-82and10-24-83.) The five inspected supports did not violate this QC inspection criterion for angularity. All other hardware attributes 4 were inspected and recorded on the documentation reviewed for these 5 4 03/07/85 4 AQ-50III
o supports. These attributes were those mentioned on the QC checklist in t B&R procedure QI-QAP 11.1-28, as well as in applicable codes or standards I not covered by the. procedure One support was found to have two hardware deficiencies, while another had one. The results of this inspection are incorporated in Section B of this report. One of the purposes of the as-built program was to identify those sway struts or snubbers whose as-built angularity deviated from specified angu-larity by more than 22' in order for Engineering to review total displace-ment of the support during hot loads. Angular deviations greater than 2* were identified on ABRRs for reverifications. Review by engineering con-sisted primarily of adding the angular displacement due to thennal growth of the pipe to the as-built angularity. This was necessary to determine whether the movement exceeded 15' during hot or cold system conditions. The main reason for this review was to provide confidence that a mis-aligned snubber or sway strut would not bind under hot or cold conditions. B. Additional Pipe Support Inspection Since the subject matter of IEB 79-14 was narrow in scope, an expanded field review of QC-accepted, as-built hardware in Unit I was conducted. This TRT inspection sample was used as a measure of the effectiveness of the applicant's QA/QC program for work performed prior to the initiation of the TRT effort. The TRT selected 42 pipe supports (ASME III, NF, Classes 1, 2, and 3) for . complete field inspection in 10 plant systems throughout 4 safety-related buildings (safeguards, fuel handling, auxiliary, and containment) in Unit 1; 4 37 were selected and 5 additional supports were from those considered in the IEB 79-14 assessment discussed above. All TRT inspected pipe supports were from safety-related piping systems such as: safety injection (SI), component cooling (CC), containment spray (CT), residual heat removal (RH), auxiliary feedwater (AF), main steam (MS), chemical volume and control (CS), and reactor coolant (RC). 9 03/07/85 5 AQ-50 III
~ During its inspection of the 42 component supports, the TRT found a number j of discrepancies (see Tables 1, 2, and Figure 1) which warrant further consideration of QC effectiveness: I l Over three quarters of the supports in'the sampling group received 100% visual inspection by TRT of welds by TRT with the paint removed. The balance of the 42 supports were inspected with the paint left on the welds. The TkT findings of weld discontinuities were submitted to TUGC0 opera-tions and the QA managers. Three rejectable welds identified by the TRT were repaired, and one component support was completely removed and has since been rebuilt. Weld-related deficiencies found by the TRT included undersize welds, weld undercuts, excessive grinding resulting in reduction of the base material, and poor weld appearance. One support had some welds performed with no QC inspector signature or initials on the corresponding blocks of the weld data card for that support inspection package. In two cases, the TRT found that the manufacturer's model numbers on shock ar-restor components were not the same as the model nu.nbers shown on the as-l built drawings for the same assemblies. C. Potentially Generic Pipe Support Deficiencies In the course of inspecting the previously-mentioned 42 pipe supports, the TRT found potentially generic deficiencies that included insufficient bolt f thread engagement, absence of proper locking devices for threaded fasteners and load pins, and excessive free gap at the spherical bearing interface in snubbers and sway struts. As previously noted, the 42 pipe supports i encompassed ASME Section III NF Class 1, 2 and 3 code jurisdictions and j were located within the Containment, Fuel, Auxiliary, and Safeguards Build-t ings of Unit 1. I l The six potentially deficient areas that required further evaluation for generic implications were: ) + l { 03/07/85 6 AQ-50 III ,-w- --g,> v+ w m-w--h-e--
Table 1 Pipe Supports in Unit 1 Supports Inspected by TRT As-Built group
- 42 Class 1 supports inspected 4
Class 2 supports inspected 14 Class 3 supports inspected 24 Hangers with problems .26 Total problems identified 46 Procedure adequacy problems 5 Hardware related problems 16 As-built drawing relatad problems 8 Component identification problems 2 Weld-related problems 10 QC record problems 1 Material identification problems 4 Welds inspected without paint by TRT 305 Welds inspected with paint by TRT 89 Total welds inspected by TRT 394 Welds needing weld repair 10 % of welds inspected 2.5% Supports involving weld repair 6 % of supports inspected 14% No. of Supports B1dg System Inspected 1 Containment Safety Injection (SI) 1 Containment Reactor Coolant (RC) 6 Containment Residual Heat Removal (RHR) 2 Fuel Handling Component Cooling (CC) 11 Safeguards Residual Heat Removal (RHR) 1 Safeguards Containment Spray (CT) 8 Safeguards Domineralized Water (DD) 1 Safeguards Auxiliary Feedwater (AF) 8 Auxiliary Chemical Volume & Control (CS) 1 Safeguards Main Steam (MS) 2 Safeguards Chilled Water (CH) 1 p "All 42 pipe supports inspected by the TRT had been previously accepted by site QC, I u ] 03/07/85 7 AQ-50 III l
l Tabla 2 Pipe Supports in Unit la No. of l Problem Category Hanger No. Problems M 1. No locking device for threaded fasteners RC-1-901-702-C825 2 Hardware problem j j (see Figure 1) CS-1-085-003-A42K 2. Min. edge distance (on base plate) violated CC-X-039-006-F43R 1 Hardware problem 3. Base plate hole-location dimensions out of tolerance CC-X-039-007-F43R 4 As-built problem CC-1-126-010-F33R i CC-1-126-011-F33R i CC-1-126-012-F33R i l 4. Spherical bearing / washer gap excessive CC-1-126-015-F43R 4 Hardwaie prob. i RC-1-052-016-C41K i RC-1-052-020-C41K l MS-1-416-001-S33R l S. Spherical bearing contamination (see Figure 1) SI-1-090-006-C41K 2 Hardware prob. .1 MS-1-416-002-533R l 6. Snubber adapter plate-insufficient thread engagement MS-1-416-002-533R 3 Proced. prob. 4 (See Figure 1) SI-1-090-006-C41K CT-1-013-012-532K j 7. Insufficient threaded eng'et, threaded rod RC-1-901-702-C82S 1 Hardware prob. 4 (sight holes, see Figure 1) ) i 8. Snubber / Strut load pin locking device broken or AF-1-001-014-533R 1 Hardware prob. missing (see Figure 1) 9. Load side of pipe clan halves not parallel AF-1-001-001-S33R 2 Proced. prob. (see Figure 1) i l
- 10. Pipe clearances w/ support out of tolerance CC-1-126-013-F33R 2
' Hardware prob. AF-1-001-702-533R
- 11. Pipe clamp locknut loose (see Figure 1)
AF-1-035-011-533R 1 Hardware prob. l l
- 12. Snubber / Sway strut misalignment CC-1-126-014-F43R 2
Hardware problem ) RC-1-052-020-C41R ) f
- All 42 pipe supports inspected by TRT had been previously accepted by site QC.
{ l-l
-~ Tabla 2 (Continued) No. of Problem Category Hanger No. Problems Tye l
- 13. Snubber cold set dimension does not match drawing CS-1-085-003-A42K 1
As-Built prob. 1 1
- 14. Snubber orientation does not match drawing CT-1-005-004-S22K 2
As-Built prob. CT-1-013-010-522K
- 15. Compoi. m type /model no. installed does not match SI-1-090-006-C41K 2
Compon. 10 prob. drawing RC-1-052-020-C41R 1 16 No identification for support materials, parts, and CT-1-013-014-S32R 4 Matl. identific. j costponents CC-1-126-012-F33R prob. CC-X-039-005-F43R AF-1-035-011-533R l
- 11. BRP column line dimension does not match BRHL Support not affected 1
As-Built prob. { Dimension
- 18. Weld porosity excessive AF-1-001-001-533R 1
Weld-related prob.
- 10. Weld undercut. excessive AF-1-001-702-533R 1
Weld-related prob. l
- 20. Weld length undersized AF-1-001-001-S33R 1*
Weld-related prob.
- 21. Weld leg or effective throat undersized AF-1-001-001-S33R 3
Weld-related prob. 1 RH-1-006-012-C42R I~ CC-X-039-007-F43R
- 22. Weld called out on drawing does not exist in field CC-1-126-013-F33R 1
Weld-related prob. ~
- 23. Welds added in field are nit reflected on drawing AF-1-001-702-S33R 1
Weld-related prob. numerous welds 24. Excessive grinding resulting in ein. thickness AF-1-037-002-S33R 2 ' Weld-related prob. j violations (weld clean-up) CT-1-013-014-532R i
- 25. No QC Buy-off on weld data card CC-1-126-013-F33R 1
QC record problem i T6 Total problems identified by TRT i
i i l i 4 i ? 3 1 1 i. i ? 1 t i 1 1i i ? Figure 1 Hardware Examples t 9 t j 03/07/85 10 AQ-50 III
u [ (1) Strut and snubber load pin spherical bearing clearance with washers Wa5 excessive. (Reference procedure QI-QAP-11.1-28, Sec. 3.7.3.1, f Rev. 25: The bearing gap was defined as the space between the out-l side surface of the race and the inside surface of the clevis bracket j and may not be more than one thickness of the vendor-supplied spacer j washer to prevent bearings from dislodging from their seats. Bearing i dislodgement could cause snubber or strut misalignment and change its moment range, or angle of loading, degrading the snubber's or strut's loading capacity accordingly.) (2) Strut and snubber load pin locking devices (cotter pins or snap lock rings) were missing. QI-QAP-11.1-28 does not address load pin lock-ing devices. This appears to be an inadequate procedure. ~ (3) Pipe clamp halves on the load side were not parallel. (Ref QI-QAP-11.1-28, Sec. 3.7.3.1, Rev. 25.) (4) Thread engagement of bolts into tapped holes of snubber adapter plate was less than full. (Ref. ASME Sec. III, NF 4711.) (5) "Hilti Kwik" bolts (concrete expansion anchors) as installed did not meet minimum effective embedment criteria. (Ref. QI-QP-11.2.1, Sec. 3.5.1, Rev. 16.) 1 (6) Locking devices for threaded fasteners were missing or of a non-approved type. (Ref. ASME Sec. III, NF4725.) In order to further evaluate the generic relation of these types of defi-ciencies, the TRT undertook additional inspections (see Table 3). A large number of supports within a designated area were inspected for these spe-l cific deficiencies. These areas were different from those previously se-1ected for TRT inspection of pipe supports. ,.11 accessible pipe supports in Room 77N, elevation 810'-6" of the Unit 1 safeguards building, were inspected for deficiencies identified as items (1), (2), (3), and (4) above. Room 77N was chosen because it was a typical room containing an ample amount of pipe supports. 03/07/85 11 AQ-50 III I i i i s
._._m._ a Table 3 Summary of Frequently Occurring Hardware Deficiencies ] Area: Room 77N, El 810'-6" Unit 1, Safeguards Bldg 'i No. of Supports No. of Supports q, Deficiency Inspected Deficient % Deficient Item 1. Excessive 92 5 5.4% { Spherical Bearing Clearance l Item 2. Load Pin Locking 92 14 15.2% Device Missing Item 3. Pipe Clamp Halves 40 9 22.5% Not Parallel ~ Item 4. Snubber Adapter 19
- 13 to be Plate Bolts With determined Less Than Full Thread Engagement Item 5.
Hilti Kwik Bolt 24 (Bolts 3 (Bolts 12.5% Does Not Meet inspected) deficient) Minimum Embedment** Item 6. Locking Devices For (See Text) Threaded Fasteners
- Bolts had less than full thread engagement.
- Area:
Cable Spread Roam 133, El 807'-0", Unit 1, Auxiliary Bldg. Note: The above "Hilti Kwik" bolts violated the " effective" embedment requirements when the following is taken into account: (1) the minimum required embedment is reduced by an amount of one nut thickness due to slippage of the bolt caused by torquing (Ref. " Installation of 'Hilti" Drilled-In Bolts" 35-1195-CEI-20, Rev. 3, Para. 3.1.4.1) and l l I' (2) the 2" thickness of the topping slab on the cable-spreading room 1 floor cannot be included as structural embedment length. e A sample of 92 sway struts and snubbers was checked in Room 77N by the TRT for spherical bearing clearance and for missing locking devices ors' load ^ pins. The TR1 also inspected 40 sway s+. ruts and snubbers in the' same room j in the safeguards building for pipe clamp halves that were not parallel. 1 In addition, 19 snubbers were examined in the above-mentioned room for adapter plate bot ts on snubber body transition kits that exhibited less 1j than full thread engagement. 4 03/07/85 '12 AQ-50 III J e
l w l To assess the frequency of occurrence of item 5, the TRT inspected elec-trical support "Hilti" baseplates located in the cable spread room 133, i ) elevation 807'-0" of the Unit 1 Auxiliary Building. These 24 "Hilti l Kwik" bolts (concrete expansion anchors) were chosen because of the large amount of exposed threads that were visible and because there were numer-ous installations in the area. The procedures for installation of the "Hilti Kwik" bolts were the same governing installations for expansion anchors on pipe' supports. The inspection criteria for items (1), (2), and (3) were based on B&R pro-cedure QI-QAP-11.1-28. The inspection criteria used by TRT for item (4) regarding thread engagement of snubber adapter bolts was based on full thread engagement. Those bolts lacking full engagement through the adapt-er plate were cited, even though procedure QI-QAP-11.1-28, Attachment 29, allowed less than full engagement. For example, Attachment 29 showed a minimum thread engagement of 3/16 inch for snubber sizes 1/4-1/2 inches; for snubber sizes 1 inch through 3 inches, the minimum thread engagement is 5/16 inch, etc. In all cases, the thickness of flanges and lengths of tapped threads in respective adapter kit flanges were ignored in Attach-ment 29. B&R procedure QI-QAP-11.1-28A, " Installation Inspections of ASME Class 1, 2, and 3 Snubbers," Attachment 10, also showed the same minimum l bolting engagement allowances. The TRT concern is that the procedure was inconsistent with ASME Section III, Subsection NF 4711, and the condition L for thread engagement should have been certified as acceptable by the man-ufacturer. It appears that the QC Engineer implemented an inadequate procedure. L The requirement of NF-4711 that "the threads of all bolts or studs shall h be engaged for the full length of thread in the nut" also implies that there be a full length of a threaded hole in plates, shapes, or bars where the required threaded hole length is the same as the bolt diameter. Fur-J ther, there is no evidence that partial thread engagement at the snubber adapter plate connection has been given consideration in the design proce-dures for linea'r-type supports, nor does it appear that sufficient design j margins have been introduced to allow for less than full-threaded connec-l tion. The TRT did riot check "as-built" analyses to determine whether any l j 03/07/85 13 AQ-50 III
a.--.---- i l such variations from the design norm had been considered in the "as-built" stress calculations. What is in question is whether any calculations had been made to address this particular thread engagement condition for each size snubber being used in the plant. ~ The inspection criteria for item (5) regarding "Hilti" installations was ' based on B&R construction procedure CEI-20, " Installation of Hilti Drilled-In-Bolts," and TUEC quality procedure QI-QP-11.2-1, " Concrete Anchor Bolt Installations." "hilti Kwik" bolts were checked for minimum embedment. Two factors were considered in figuring the " effective" embedment for each concrete expansion anchor: (1) B&R procedure CEI-20 for "Hilti Kwik" bolt installation (Ref. Rev. 3, ^ Para. 3.1.4.1) allowed minimum embedment as shown on the design draw-ing er as specified by the "Hilti" catalog, minus one nut thickness l to account for slippage due to torquing. 1 (2) The 2" topping slab on the floor of the cable-spreading rcom cannot be included as structural embedment for the concrete expansion anchor ("Hilti Kwik" bolt). Item (6), absence of proper and sufficient locking devices for threaded fasteners is discussed in Section F of this report. Also see Category 1 of Table 2 for two examples of supports without proper locking devices on r threaded fasteners. l D. Class 1E Electrical Cable Tray and Conduit Supports l l The TRT expanded the sampling inspection of component supports and hangers to include a number of Class 1E electrical cable tray and conduit sup-ports. Five hangers and supports in this categ)ry received 100% inspec-tion by the TRT. Two other supports were inspected for weld size and ' bolt torque verification only.. These electrical supports for Unit I were in l the areas of the cable-spreading room, auxiliary building, and containment t building. 03/07/85 14 A,Q-50 III i .N
The TRT inspected electrical conduit supports and cable tray hangers to i the requirements of procedures QI-QP-11.10-1, " Inspection of Seismic Elec-trical Support and Restraint Systems"; QI-QP-11.21-1, " Requirements of Visual Weld Inspection"; and other applicable instructions for conduit support and cable tray hanger inspections. All electrical supports in-cluded in TRT inspections had been previously inspected and a'ccepted by QC. Table 4 summarizes the results of these QA/QC group inspections. Five of the seven hangers and supports inspected by the TRT exhibited a g variety of discrepancies. Although no unsatisfactory open items remained in the inspection records of B&R, a high percentage of inspectable charac-teristics failed on TRT inspection. The principal types of unacceptable conditions were on welding. Most of the inspected hanger and support welds were undersize. Some welds were made in the wrong location on a support, while another hanger had a substantial number of welds which were not shown on the installation hanger drawing nor incorporated on the as-built drawing. Other defects were found in the installation, such as anchor bolts exces-sively skewed; minimum bolt hole edge distance violations; unmarked "Hilti" j bolts; undersized nuts; missing washers; and frame clip (stiffener plate) sizes different from the dimensions given on the drawing. The TRT inspec-tions of electrical cable tray and conduit supports were performed in the presence of B&R QC inspectors, who witnessed and concurred with these TRT inspection findings. E. Inspection of Instrument Tubing Supports l The TRT performed an inspect. ion of Class I nuclear safety-related instru-ment tubing supports as part of the overall TRT QA/QC as-built inspection j effort. Three Class I supports were selected which were located in the j Unit 1 Containmert Building. These supports were on instrument tubing emanating from ASME Class 1 reactor coolant lines. J 03/07/85 15 AQ-50 III l a
Table 4 Summary of Electrical Conduit and Raceway Support Inspection - Unit 1 Support welds inspected 59 Suppports inspected 5* Supports with problems 3 (60%) Types of prob'lems Hardware related, other than welding 6 Unauthorized configuration change 1 Weld related types of problems (categories) 2 Welds requiring rework 41 Welds made in field but not recorded on drawing 80** Beam stiffeners added but not recorded on drawing 40 Building / Area Supports Cable Spread Room CTH 12646 C 130-21-250-3 C 120-21-194-3 A niliary Building CTH 6742 Containment Building CTH 5824
- All electrical supports inspected by the TRT had been previously inspected and accepted by QC.
- Full visual inspection was not performed by the TRT on these extra welds.
Hardware attributes such as location, support type, configuration, dimen-l sions, and welding were checked for compliance with applicable standards, drawings, procedures, and other pertinent uocuments. In addition, the TRT reviewed record documentation for the supports which consisted of drawings and their applicable change addenda, construction operation travelers, l weld filler metal logs, and inspection reports. l I The results of the TRT hardware inspection of instrument tubing supports l revealed no discrepancies. One tubing support exhibited a small dent that was not considered significant. The documentation review indicated that the record software completely and accurately representated the hardware found in the field, and the in process and final inspections were compre-hensive and provided sufficient evidence of acceptance. 1 03/07/85 16 AQ-50 III y
.~ i!' F. Other Conditions Observed The following conditions were observed during the foregoing reviews. I Material Traceability The TRT examined 33 component support packages to determine whether mate-rial traceability existed from marked and identified material through the various records to the Certified Material Test Report (CMTR) or a Certifi-cate of Conformance (C of C). The TRT found that through various logs and records an audit trail could be established satisfactorily to the material source and certification, as long as the mate' rial was properly identified, i.e., the material heat lot or control number was stamped or etched on the part. The TRT found four supports not identifiable because the identifi-cajon number was either not stamped or etched on the installed material or was not entered in the material identification log (Ref. 10 CFR 50 App. B, Criterion VIII and B&R procedure QI-QAP-11.1-28, Rev. 19, Sect. 3.1.2). Locking Devices The TRT also investigated the omission of locking features for NF support threaded fasteners. ASME Section III, Subsection NF, Subarticle NF-4725 states in part that "all threaded fasteners shall be provided with locking devices to prevent loosening during service." Noncompliance with this requirement was recognized by TUEC and B&R QC who , issued a " Request for Information and Clarification" (RFIC) to TUGC0 engi-neering in April 1984, requesting direction for resolution of this issue. On May 24, 1984, TUGC0 engineering advised by memorandum (CPPA 38997) that the paint which was applied to Unit 1 component supports, including fas-teners, when set or hardened, would act on bolt and nut threads to prevent the nut from loosening. TUGC0 engineering had performed a series of torque tests to substantiate their position. Samples, coated with a multi-process epoxy formula, were chosen by TUGC0 on the basis of sizes and in- ' cluded in the test. 03/07/85 17 AQ-50 III
_=.:. - _ _x 3 s Regarding the utility and reliability of coating used as a locking device for threaded fasteners, the TRT has several concerns: (1) The TRT could not locate any NCRs, or ASME/ANI notification, or docu-mented reporting to NRC, describing absence of approved locking de-vices, when the component supports were installed and in'spected.in 1983 and earlier. (2) If an NCR w'ould have been written, the applicable procedure (Ref. TUGC0 CP-QP-16.0, "Nonconformances") required that the NCR receive an engineering disposition. The TRT has the following concerns about TUGCO's engineering justification for use of paint in lieu of ap-proved locking devices: l (a) Paint-coated threads were tested in the weld shop under normal environment and ambient temperature. Useful life or holding capability under anticipated service conditions, including de-sign basis temperatures and radiation aging, was not addressed. (b) The type of coating which was torque tested was not identified inTUGCO'sdocumenta5ionofthe"MultiprocessEpoxyFormula Torque Test," attachmant to TUGC0 CPPA 39209, effice memorandum. The unanswered question is whether the coating tested was CZ 11/P 305 (Carbo-zinc 11, prime, and phenoline 305, top-coat) or C193/P305 (carboline 193, epoxy primer, and phenoline 305, top coat); and whether torque test conclusions for one coating would be the same for the other coating formula. Both coatings were used on threaded fasteners in Unit 1. (3) There was no evidence that an effective plan had been initiated to provide for routine maintenance activities in order to ensure that all painted fastener threads on NF supports maintain sufficient thread-lock reliability for the length of the life of the plant, or until the paint lock method is replaced by a different procedure. 03/07/85 18 AQ-50 III
^ Excessive Radial Weld Shrinkage j f j During inspection of pipe supports under the TRT hardware inspection pro-gram, radial weld shrinkage was noted on nearby stainless steel piping welds. One weld in particular exhibited considerable weld shrinkage. The exhibited radial weld shrinkage was excessive and potentially'resulted from improper fit-up of the weld joint along with too much heat input be-ing applied duttng completion of the weld. The examined weld was in a 12" diameter SI line located in a Unit 1 pipe tunnel designated as Room 850. The line number was 12"-SI-1-031-151R-2 and the weld number was FW 9B as detailed on piping isometric BRP SI-1-YD-03-1. This line was an ASME code Class II line and was NA stamped at the time of the TRT inspection. The TRT measured shrinkage at this weld joint in excess of 3/16", which is a violation of inspection criteria delineated in Section 3.6.8.4 of B&R quality inspection procedure for pipe installation QI-QAP-11.1-26, Rev. 16, issued June 11 1984. 5 A review of the weld documentation indicated that weld FW 98 was visual test (VT) accepted on June 28, 1979, as noted on Weld Data Card (WDC) 13265. The TRT was able to establish that in 1979 the piping inspection procedure, QI-QAP-11.1-26, did not contain inspection criteria for measur-ing weld shri.akage nor did the Gibbs & Hill specification 2323-MS-100. At that time, t!,o Gibbs & Hill specification simply stated that " welding pa-rameters shall be controlled to avoid excessive heat input resulting in necking down of butt welds" (Ref. Sec. 4.27.8). The inspection criteria for measuring radial weld shrinkage first appeared in Rev. 7 of MS-100 l Sec. 4.27.8, issued December 2, 1983. i A comprehensive documentation review by TRT showed that the weld package was acceptable. It was determined that original weld FW 9A at this same location was cut out due to rejection of radiographic test number #5478 and was rewelded as FW 98. This may have also contributed to the radial weld shrinkage. 2 03/07/85 19 AQ-50 III i
.a.___ w... - : ~ j 5. Conclusion and Staff Position: On Thursday, February 7, 1985, the TRT contacted the alleger in a telephone interview and provided results and l conclusions of the TRT assessment. The alleger did not identify any fur-ther concerns or allegations. The TRT notes that items (1), (2), (3), and (5) of the potentlally generic issues (Table 3) are deficiencies that do not meet established inspection criteria. The TRT considers that the inspected level of occurrence of items (1), (2), (3), (5), and (6) is excessive and indicates QA/QC break-down with regard to these inspections. The TRT notes that the frequency of less than full thread engagement of snubber adapter plate bolts is al-lowed by B&R procedures QI-QAP-11.1-28, Attachment 29, and QI-QAP-11.1-28A, 0. This does not appear consistent with the intent of ASME Section III, NF 4711. The TRT was not able to find records of correspon-dence by QA/QC or engineering which may have been raised by the question of possible code violation, which may have requested vendor concurrence with less than full thread engagement, or which may have raised questions of how minimally threaded fasteners were properly accounted for in the final as-built stress analyses. The safety-related significance of each noted deficiency varies. Item (1) l (excessive spherical bearing clearance) may allow dislodgement of the bear-l ing from its race and detrimentally affect function of the support. The TRT noted that in each case the excessive clearance was not enough to al-low total dislodgement of the bearing. This deficiency is not considered safety significant. Item (2) (load pin locking device missing) could permit dislodgement of the load pin. In effect, the support would lose its functional operability. This deficiency is considered potentially safety significant. Regarding item (3) (pipe clamp halves not parallel), it is not apparent to the TRT that there is a necessity for requiring the load-side clamp halves to be parallel without any tolerance. The TRT recognizes that at some point a non parallel condition would be unacceptable, and maintains that 03/07/85 20 AQ-50 III I
. _ ~ -~ an installation tolerance should have been instituted in project proce-i dures. The non parallel conditions found did not appear excessive; and the TRT does not regard this item as safety significant. Item (4) (snubber adapter plate bolts not fully engaged) may have signifi-cant safety impact. It is not apparent to the TRT that the shubber design allows for less than full thread engagement. Therefore the load capacity of the snubber may be reduced by this condition. Item (5) ("Hilti Kwik" Bolts installed with less than minimum embedment) is safety significant in that the amount of embedment directly affects load capacity. Item (6) (absence of proper and sufficient locking devices for threaded fasteners) is a violation of ASME Code requirements and may have safety implications. In conclusion, the TRT staff position is that items (1), (2), (3), and (5) of the potentially generic issues occur at levels within sampling by the TRT that are excessive. Items (2) and (5) are considered safety signifi-cant, while items (1) and (3) are not. The TRT believes the item (3) oc-l currence level is related to an inspection criteria that may be too f stringent (i.e., with no construction or inspection tolerance). Items (4) and (6) may be safety significant. Based on the inspection of 42 NF component supports, the TRT concluded that the ASME code requirements and quality acceptance standards, as well as site QC procedures were compromised in some of the systems and components inspected. The TRT observed that the characteristics of identified discrepancies were both specific to individual supports and potentially generic. Frequency I and repeatability of deficiencies were most notable in categories of: l excessive free gap at the spherical bearings of snubbers and sway struts; r j strut and snubber fasteners not properly secured; and insufficient thread engagement of bolts in shock arrester adapter plates. 03/07/85 21 AQ-50 III t l
i Unsatisfactory QA/QC performance was most visible in the inadequacy of inspections in the field, a problem compounded by occasional poor workman-ship; neglect of some requirements of the ASME code, other standards, and station procedures; and in one instance, disregard of the reporting re-quirements of the Code of Federal Regulations (CFR), Title 10, Part 50.55(e). Material identification could not always be properly established from the parts or records inspected by the TRT. Deficiencies found were unmarked i material and omission of the material's heat number from the material identification log. The TRT's findings with regard to TUGCO's omission of locking devices for NF support threaded fasteners were that QA/QC failed to report the viola-tion of the requirements of ASME III, NF, subarticle 4725, via a formal non-conformance report. Further, TUEC failed to report this incident of ASME code violation to the NRC and therefore was in noncompliance with the i requirements of 10 CFR 50.55(e). The QC inspection criteria for the weld joint involving radial weld shrink-age was not violated at the time of the visual test inspection. The TRT-acknowledges that the ASME code does not specifically address acceptance i l criteria for weld shrinkage. The TRT requested that TUEC address the sit-uation that weld joints do exist in NA-stamped systems that exhibit exces-sive weld shrinkage when measured against their current procedure and that thesafetysignificanceofthisfsituationbeassessed. i. Based on inspection findings in Class 1E electrical supports and the high rate of rejectable characteristics, p~erhaps unique to electrical supports, the TRT concluded that B&R inspection of these electrical cable tray and conduit supports was unsatisfactory and that objective evidence of compli-t ance with specified engineering and construction criteria was not provided. ( The TRT found nothing deficient within the Class I instrument tubing sup-port inspection sample. f 03/07/85 22 AQ-50 III I L L -
1 ..L l i During the TRT's assessment of allegations in the areas of design and doc-ument control (Categories 1 and 2), a number of conditions may have been in existence during the early stages of constrJCtion that Could have re-sulted in problems significant to safety. Whether actual problems did occur could only be determined from this as-built assessment. While the as-built assessment does not specifically associate the identified prob-l lems with design cr document control deficiencies, many of the problems identified could have been the result of incorrect or obsolete documentIs being'used for construction and/or inspection. The as-built verification effort conducted by the TRT provides evidence of l faulty construction by craft personnel, installed hardware that does not match as-built drawings, and ineffective QA/QC inspections. Despite the small size of the TRT's sample, there could be a large number of deficien-i cies not represented correctly in the final stress analysis. l l 6. Actions Recuired: See Item No. 4 of the enclosure to the D. Eisenhut let-ter to M. D. Spence dated January 8, 1985. l TUEC should undertake actions in response to the conclusions contained in this report necessary to improve overall confidence in the as-built condi-tion of hardware associated with plant safety-related systems. Corrective action should also be take.n by TUEC regarding the condition that weld joints do exist in NA-stamped systems that exhibit excessive radial weld shrinkage when measured against current procedures. s e t S' 03/07/S5 23 AQ-50 III
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A,ttachments: None 9.
Reference Documents:
}
1.
Comanche Peak Steam Electric Station, Final Safety Analysis Report.
I 2.
Code of Federal Regulation:, Title 10, Part 50 (10 CFR 50), Appendix B " Quality Assurance Criteria for Nuclear Power Plants and Fuel Reprocessing Plants."
~
3.
10 CFR Part 50.55(e), ' Conditions of Construction Permits:
Reporting Criteria for Significant Deficiencies."
4.
American Society of Mechanical Engineers (ASME), Boiler and Pressure Vessel Code, Section III, Division 1, 1974 Edition.
5.
U.S. Nuclear Regulatory Commission, Inspection and Enforcement Bulle-tin No. (IEB) 79-14.
6.
IEB 79-02, " Pipe Support and Baseplate Designs Using Concrete Expan-sion Anchor Bolts."
7.
American Welding Society, Structural. Welding Code (Steel), AWS
[
01.1-79.
l 8.
HILTI " Architects and Engineers Anchor and Fastener Design Manual."
9.
Gibbs and Hill specification:
2323-MS-100.
L
?
10.
Gibbs and Hill specification:
2323-MS-46 " Nuclear-Safety Class Hang-er & Supports" e
i p
- 11. TUGC0 engineering procedure: CP-EI-4.5-1 " General Program for As-i Built Piping Verification."
i 1
03/07/85 40 AQ-50 III
_._..._...i.._...
~E s
- 12. B&R quality procedure: QI-QAP-11.1-28 " Fabrication, Installation and
- 1 Inspection of Safety Class Component Supports," Rev. 25, 7/11/84, and I
j previous revisions.
'\\
- 13. B&R quality procedure: QI-QAP-11.1-26, Rev. 16, 6/11/84., and previ-j ous revisions.
1
- 14. B&R quality procedure: QI-QAP-11.1-37 " Instruction for QA/QC Review, Anproval and Utilization of Construction Operation Travelers."
- 15. B&R quality procedure:
CP-QAP-12.1, Rev. 11, 6/11/84, and previous revisions.
- 16. B&R quality procedure:
CP-QAP-16.1 " Control of Nonconforming Items."
- 17. B&R construction procedure:
35-1195-CEI-20 " Installation of 'HILTI' Drilled-In Bolts," Rev. 10, 9/14/84, and previous revisions.
- 18. TUGC0 quality procedure:
CP-QP-11.2 " Surveillance and Inspection of Concrete Anchor Bolt Installations," Rev. 8,7/13/84, and previous revisions.
o
- 19. TUGC0 quality procedure: QI-QP-11.2-1 " Installation of 'HILTI' Drilled-In Bolts," Rev. 16, 7/20/84, and previous revisions.
l
- 20. TUGC0 quality procedure: QI-QP-11.2-2 " Abandoned Concrete Anchor Holes," and historical revisions.
i
- 21. TUGC0 quality procedure:
QI-QP-11.2-3, " Torquing of Concrete Anchor Bolts," and historical revisiens.
- l.
- 22. TUGC0 quality procedure: QI-QP-11.2-4 " Inspection of 'HILTI' Super.
Kwik Bolts," and historical revisions.
- 23. B&R procedure QI-QAP-11.1-28A, " Installation Inspections of ASME
~
Class 1, 2 and 3 Snubbers."
3 03/07/85 41 AQ-50 III 3
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i fa 24.
B&R Quality Assurance Manual.
t l
- 25. TUGC0 instruction CP-QP-11.10-11, " Inspection of Seismic Electrical l
Support and Restraint Systems."
- 26. TUGC0 instruction CP-QP-11.10, "Ir.spection of Electrical' Raceway Sup-port Systems."
27.
TUGC0 instruction QI-QP-11.21-1, " Requirements of Visual Weld Inspection."
- 28. TUGC0 instruction QI-QP-11.10-2, " Cable Tray Hanger Inspections."
29.
TUGC0 quality procedure CP-QP-18.0, " Inspections Reports."
30.
Gibbs & Hill drawing 2323-5-910, " Seismic Support of Class I-E t
Conduit."
- 31. Gibbs & Hill drawing 2323-5-902, " Electrical Supports Standard Details."
I l
- 32. Gibbs & Hill Specification ECP-10 for electrical conduit supports.
33.
Region 4 Inspection Report 83-24, p. 12 (Tracking System #RIV-83-A-0026),
8/24/83 (source of AQ-50 allegation).
34.
Region 4 Report of Inquiry, Q4-83-009, 4/8/83 (source of AQ-50 allegation).
- 35. Telephor.e interviews by TRT with A11eger, A6, on 8/21/84 and 8/23/84.
i 36.
Interview by TRT in person with A11eger, A6, on 8/24/84, 8/25/84, and c
8/26/84.
}
03/07/85 42 AQ-50 III s
I V.-
- 37. Telephone interview by TRT with A11eger, A6, on 2/7/85.
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l 10.
This statement prepared by:
M. Eli, TRT Date Technical Reviewer Reviewed by:
H. Livermore, Date Group Leader Approved by:
V. Noonan, Date ProjectDirector l
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AQ-135 CATEGORY 8 Requestor's ID:
LAVERNE Author's Name:
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g. AQ-135 CPE i Rev. J'- JLCn44-- 7/H[55 C I SSER 1. Allegation Catecory: QA/QC Category 8 4 2. Allegation Number: AQ-135 l 3. Characterization: It is, alleged that the Post Construction Verification Program (PCVP) was conducted in such ' manner that it failed to adequately 1 a reocess the results of quality control (QC) inspections as required by 10 CFR 50, Appendix B. It is alleged that the scope and depth of the program were inadequate, that reviews of identified deficiencies were inadequate, and that management of program results was inadequate. The PCVP was alleged to be: (1) a " blitz inspection" consisting of an i- - " instant review and an instant fix," (2) of narrow scope, encompassing only a few cable trays, (3) an inspection program with no requirement to identify problems which were fixed on-the-spot,'and (4) a program that was stopped prematurely in February 1984. Tne alleger maintained that the PCVP was a " violation of law" that lacked 7 data on engineering review of identified problems and a method of tracking and trending deficiencies. j The alleger' asserted that the PCVP was "out of control" and that the faci:'ty constructor, Brown and Root, In:. (B&R), was " turning over a mess" to tha owner, Texas Utilities Electric Comoany (TULC). t 4 i-4. Assessment of Safety Significance: The Technical Review Team (TRT) found that in FSAR Section 8.1.4.3, TUEC committed to implementing Institute of b 02/26/S5 1 AQ-135 CATEGORY S l I p--- ^- 1- - r e' y y-,re, ww e ywie-y-.-y + w vi. wr, e-er .9m.t--w-mme e-e ,w a. - %-ww w -e y, ,,p-*, pm,p-=,wc.,m.,-.e 9 -w,-pe,,-,,e 9myise-a wp. g--
l. Electrical and Electronics Engineers, Inc. (IEEE) standard 336-1971, " Installation, Inspection, and Testing Requirements for Instrumentati.on and Electric Equipment During the Construction of Nuclear Power Generating Stations." Section 6 of this standard requires that post-construction verification consisting of the inspection of installed equipment and sys-tems shall be inspected to verify the following: (1) that equipment and materials have not sustained damage during installation, (2) that good and proper workmanship has prevailed, (3) that the installation has been made in accordance with specified requirements, (4) that all nonconform-ing items have been satisfactorily resolved, (5) that appropriate pro-tective measures are applied for lay-up after installation, and (6) that da all temporary conditions such as p'umpers, bypass lines, and tempor:ry set ,A( points ',1 ave been clearly identified so that subsequent restoration can be ascertained prior to placing the items in service. The TRT found through interviews with the managers, supervisors, and inspe:- tion personnel associated with the PCVP that TUEC c)'ose to implement IEEE-336 )( with a series of post-construction inspections of instrumentation, electri-cal equipment, and raceway. These post-construction ir.spections followed in process and final inspections and were made prior to a plant area bein; turned over to the startup testing organization. Therefore, the post-construction inspections reexamined previously inspected squipment and raceway. TUEC's written description of the PCVP was contained exclusively in admi-nistrative and implementing procedures (
References:
9.7-9.10). The TRT found no higher-tiered post-construction inspection plan to describe the scope, control, and management of the PCVP. The TRT reviewed these pro-cedures as a part of its examination of this allegation. n The PCVP was exclusi.vely as electrical inspection activity to satisfy )( IEEE-336. TUEC managers ar.d supervisors ir.volved in the PCVP indicated to the TRT that other post-construction inspection activi ties wer e con-ducted in a similar manner, i.e., they occurred after final inspection. These other activities included: (1) the American Society of Mechanical 02/26/85 2 A0-135 CATEGORY S er =---. - -- n--
I j Engineer's (ASME) " ; srti'ic:ti:-' program conducted by B&R, (2) post-construction inspections of Hilti anchor bolt separation, and (3) pc st-construction verification of baseplates, grouting, and Richmond inserts. TUEC managers also indicated that startup testing personnel made additional room and system walkdowns prior to testing, as did plant operations per-sonnel prior to TUEC's formal acceptance of these rooms and systems. These walkdowns were not considered to be inspections, and were not neces-sarily conducted by personnel certified as inspectors in accordance with American National Standards Institute (ANSI)/ASME N45.2.6-1978; however, these walkdowns served to identify and control the correction of any re-maining identifiable deficiencies. Since the PCVP was related to electrical inspections and since the alleger's W concerns werehrelated to electrical inspections, the TRT concentrated its X review on those post-construc tion inspections implementing IEEE-336 and i on the final walkdown and acceptance by TUEC plant operations. Based on its review of TUEC's written description of the PCVP, the TRT found two principal programmatic weaknesses. These were: (1) lack of a program plan for the PCVP, and (2) lack of written guidance on the type of level of deficiency which required issuance of a particular corrective action report. TUEC complied with IEEE-336 by implementing procedures QI-QP-11.3-40, i a c. X< l AClass IE Electrical Post-Construction Verification," and QI-RP-11.8-14,_ [ " Instrumentation System Turnover." Nonetheless, the first weakness indi-cated the lack of a management program to define the scope of the post-construction verification program. The lack of a program plan could have led to the perception of inadequate scope, as maintainec by the alleger. ihe second weakiess in the PCVP was considego gignificantbythe l - TRT and to have broad generic implications W " da lack of definec ( thresholds for triggering corrective actions. In ascending order, the I corrective action systems available to TUEC personnel as a part of the PCVP and other inspection activities at CPSES were: (1) line ite.u on I f' 02/26/S5 3 AQ-135 CATEGORY S 5-J.-. .. m ~ .__,-..__,_,,,,_.m. m_.._._,
I.
- punchlists, deficiency reports'(DRs), and neficiency lists (DLs), which were attached to inspection reports (irs); (2) unsatisfactory irs, (3) NCRs; (4) corrective action reports and corrective z.ction requests (CARS); and (5) reports submitted to the HRC in accordance with 10 CFR 21 and 10 CFR 50.55(e).
OJring theLreview of TUEC's PCVP, the TRT found no guidance other than general definitions of how to initiate a higher-tiered corrective action I' particular, the TRT found no system for an ider,tified problem. n L guidance concerning the types of levels of unsatisfactory IR attributes that regt. ired generation of an NCR. During interviews with PCVP personnel, the TRT found a arly universal { understanding within the PCVP that an NCR was required w those deficien-cies for which an engineering evaluation was necessary. In addition, most personnel interviewed stated that an NCR was initiated for those deficien-A .c es that could not be corrected using normal craft procedures. The;e ;.. a...w'd%nly minimal guidance for NCR inittation were contained in TUEC
- u-c.-
a procedures, CP-QP-16.0 and CP-QP-18.0. Evidently, this minimal guidance X wasinsufficient;forinspectorslistedidenticaldeficienciesokNCRsin z some cases, but only on DLs in others. 6t M "d dE [ fc2 s, Auw2. SD, A further indication of the lack of effectiveness of some of TUEC's pro-cedures of nonconformances appeared in an error in Revision 20 to CP-QP-18.0. Section 3.2 of this procedure described the processing of irs.
- The third paragraph of Revision 20 to this procedure, issued August 9, 1984, stated
i When all unsatisfactory conditions have been corrected and i [ reinspected and accepted, or when an NCR or superseding IR has been prepared for the unsatisfactory condition (s) per approved procedures / instruction, the QC Inspector shall Block _16). The closed IR shall then be forwarded to the PPRV by the IR clerk, i!' E 9 6 y 02/26/S5 4 AQ-135 :ATEGORY 8 b - ~
P l.- L Evidently, some portion of the first sentence was missing from line 4 3 The TRT noted this error on October 2, 1984, and discussed it with TUEC i l man % ement, who confirmed the_ error. They also noted that the same error had been present in Revision 19. Such an error in a procedure.was not t' sgprising;however,itsuncorrectedexistencethroughtworevisions X issued two months apart caused doubts regarding the usefulness of this I procedure among the personnel who generated and processed irs. { The TRT reviewed TUEC's program for trending nonconformances which were generated as a result of the PCVP. The trending program was described in CP-QP-15.7 and CP-QP-17.0, and the results were documented in quarterly trending reports issued by TUEC's site QA organization. The TRT found that the description 'of analytical considerations of the trending program was weak in that the precedures listed above failed to include: (1) a discussion of data normalization to account for the effects of varying construction or inspection activities, (2) guidance on the characteriza-tion of no'nconformances, (3) methods for determining fundamental underly-I. ing causes of nonconformances, and (4) guidance for using the trend ana-lysis results to initiate CARS. The allegation that the PCVP was not trended was incorrect; however, the quality and uses of this trending were weak. The TRT found that the quarterly trend reports contained little more than gross statistical i categorizations of different types of deficiencies in the form of tables and bar graphs. l A typical categorization contained in the fourth quarter 1983 trend report identified a total of 1168 deficiencies (through the PCVP) with [ the following breakdown: s Work Incomplete /Not per Requirements 778 Procedure Violation (Upgraded to NCR) 0 i. Poor Workmanship / Improper Hardware 8 l-Bend Radius Violations 0 ? Color Code /ID Violations 288 f Damaged Equipment / Cables 94 Raceway Unacceptable for Pull 0 i Hilti Bolt Violation /No Sealant 0 2 02/26/85 5 AQ-135 CATEGORY 8 - rse w 6 i >-em a.e m.m-
- = - * =
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e d c._ i The TRT did not find andjtica decr!ptf d of the data or discussions y of any determination of the root causes of significant nonconforming con-ditions; however, the quarterly trend reports did contain a tabulation d4 M of deficiencies identified by the PCVP. The TRT examined TUEC's program for final acceptance of systems and areas f by plant operations. This program was described in STA-802 and was designed to take place after all final QC inspections and all post-construction verification were completed, and following testing by the startup organization. The program included a review of master data base items, a review of test results and outstanding deficiencies, a verifica-tion of the accuracy and adequacy of drawings needed to support operations, and system and area walkdowns. Walkdowns were conducted by operators, instrument and control technicians, electrical and mechanical maintenance personnel, radiation protection pe.r-sonnel, and plant engineers from the plant operations organization. TUEC personnel stated that walkdowns were not intended to serve as a final con-struction QC inspection, but were intended to take advantage of the per-spective of plant operations personnel to identify those items requiring resolution as a part of TUEC's final acceptance of the facility. Items identified during the STA-802 walkdowns included hardware condition pro-blems, problems with equipment access for operability and maintainability, and potential problems from a radiation protection standpoint. Itemsk identified as a result of the STA-802 program were documented, trac 1;ed, x corrected, and reviewed by managers and supervisors. The TRT found that the STA-802 program went beyond regulatory requirements and was an effect-ive mechanism for ensuring the operability of the facility prior to fuel load. To evaluate the effectiveness of the PCVP and to determine the merits of the al'egatier, the TRT reviewed: (L) 22 irs associated with the pCVP; (2) attachments to the irs, including punchlists, post-construction deficiency reports and lists, ei ptrical equipment punchlists, and deficiency reports; (3) selected NCRs; (4) quarterly trending reports for 1983 and 1984; and (5) CARS written during 1983 and 1984. 02/26/85 6 A0-135 CATEGOEY 8
As a result of its review of the PCVP documentation, the TRT observed that irs were sometimes generated later than the attached DRs, punchlists and other attachments. Two examples of irs with this characteristic were numbered PCV-1-0028616 and PCV-1-0016954. TUEC personnel stated that. during the early stages of the PCVP, irs were not always initiated at the In some start of a post-construction inspectior. for a particular room. cases' irs were generated after compl.etion of a room inspection..In the latter instances, the post-construction inspection was repeated for those TUEC's practice at the time of the TRT review was to initiate an rooms. IR at the start of the inspection. In all cases examined by the TRT, irs were closed after all unsatisfactory attributes had been corrected and satisfactorily reinspected by QC. Because the unsatisfactory IR was the administrative vehicle for tracking correction, reinspection, and closeout of identified deficiencies, the lack of timely generation of some irs lends credent. to the allegation that the PCVP discrepancies were not.always tracked. However, the TRT review indicated that TUEC strengthened the program to include timely initiation of irs. Furthermore, in November 1983, TUEC shifted tracking responsibilities for unsatisfactory irs to the Paper Flow Group (PFG). The TRT's review indicated that the tracking of IRsg# atisfactory. Y A TRT review of the PFG administrative control system showed that the PF:- was not only tracking unsatisfactory irs, but was also tracking the cor-rection, reinspection, and closecut of individual deficiencies using the computerized master data base (MOS). The TRT determined that the MDB at the time of the TRT review was used as a management tool that was update: i' continually. l The TRT observed that there was no documented QC supervisory review of Its j The TRT found that the IR form did not contain blanks and attachments. L 7 l for a QC lead inspector or supervisor to document his or her review #a TUE:'s a review by signing in an open space at the bottom of the IR form. j l 1R procedure, CP-QP-18.0, did not describe supervisory review of irs. Y Y, W di sb L 02/26/85 7 AQ-135 CATEGORY S k e v,.-
The TRT found that during the 19 revisions to QI-QP-11.3-40, 8 different DR and punchlist forms were promulgated to list the individual deficiencies and to serve as attachments to an IR. None of the forms attached to the various' versions of the procedure contained blanks for signatures or dates to denote a QC supervisory review. However, some of the printed OR forms used by TUEC did contain blanks.for QC supervisory review. The TRT deter-mined through a review of records that these signature blanks were not always used. Procedure CP-QP-18.0 did not address QC supervisory review of irs; however, TUEC QC supervisors stated that they reviewed the irs anc attachments as part of their normal practice. The TRT considered TUEC's lack of a formal mechanism to document QC super-visory review to be a weakness that became more significant when coupled with the lack of guidance of the level of a deficiency that would equire ^ initiating an NCR. The lack of a strict requirement to conduct 4 document N QC supervisory review of irs may have contributed to the inconsistent re-porting of identical deficiencies on NCRs in some cases but only as purch-list deficiencies in others. y e. The TRT observed the lack of a consistent administratasa control system to .X ensure that all required attachments were part of a given IR. During a review of TUEC's written program, the TRT found no description of a method e which ensured that all required punchlists and DRs remained attached togIR. g Scme individual inspection groups sequentially numbered each attachment and denoted the total number of attachments on the IR, but other irs reviewed by the TRT contained several attachments, each labeled "page 1 of 1," witn no indication of the total number of DR or punchlist pages. TUEC supervi-sors stated that the responsibility for completeness of an IR package rested with the inspector generating the IR. TUEC's later practice of entering individual deficiencies into the M03 tended to mitigate the adverse conse-i quences of this weakness. The TRT obser.ved an inconsistency between the post-construction deficiency report (PCOR) and electric equipment deficiency report (EEDR), Revision 3 to QI-QP-11.3-40 included both an attached PCOR form with a blank for a C 02/26/85 S AQ-135 CATEGORY S 6 .___,.m .__ _ _.e.- .y
reinspection signature and date and an attached EEDR form without such a l blank. The PCDR was used to document raceway deficieacies, and the EEDR was used te document electrical equipment deficiencies. The TRT was unabic to detern'ine any reason for this inconsistency. T The TRT found that i generated during a post-construction inspection' were not always listed on the IR. Suchthswerelistedwiththeparti-X cular deficiency or, the DR or punchlist, but these were not cross-referenced to the appropriate block (block 15) on the IR. This cross-reference was a specific procedural requirement of QI-QP-11.3-40, Revision 18; however, not E of the 22 irs reviewed by the TRT included X this cross-reference. The TRT also found that some DR forms were used that were not described in an approved procedure. Three of the irs examined by the TRT had forms attached entitled " Post-Construction Verification De.ficiency Report" (emphasis added) that were not included with any of the 19 revisions t,o QI-QP-11.3-40. a.a In addition, the 'iRT found that inappropriate attributes were listed on A IR and an incorruct DR was used. IR E-1-0015374 listed attributes applicable to cables and raceways which were marked as unsatisfactory. The attached DRs yere intended for raceway, but described deficiencies associated with a single piece of electrical equipment (an emergency light fixture) rather than those associated with raceway.' The TRT noted that there were unexplained line-outs on a DR. Twenty-six deficiencies on IR PCV-1-0034919 were lined-out and no indication of the reasonforthelihoutwasprovided. The TRT could not determine whether the items had been incorrectly recorded, if entries had been duplicated, or if there was some other plausible reason. Individually, these weaknesses found by the TRT have little safecy signi-ficance; however, collectively, they point to a program that, although subject to site supervisory review and evaluation, suffered from a lack The TRT considered the following weaknesh 'g of administrative precision. 02/26/85 9 A0-135 CATEGORY 8
i to be far more significant, particularly when coupled with the programmatic l weakness regarding the lack of guidance for initiation of h. [ The TRT reviewed deficiencies listed on irs and found a number of similar deficiencies for which an NCR was initiated in some cases, but not in others. Examples of these de'ficiencies are as follows: i cables not properly trained into a motor control center o o lack of torquing of limit switch cover fasteners lack of color coding on conduit and junction boxes a missing identification o o broken flexible conduit The TRT also found some deficiencies listed which appeared to require an engineering evaluation or repair or rework using other than normal con- 'struction procedures. However, these were not listed with an NCR number. Examples of such deficiencies are as follows: rusted terminal points o twisted lugs o o broken terminal blocks rp o a bent transformer top a corrosion in a cable tray G I' 5. Conclusion and Staff Positions: The TRT found much of this allegation t: be without basis. The PCVP was not a " blitz inspection" consisting of an " instant review and an instant fix" that was stopped prematurely in 1984 rather, the PCVP was an ongoing program beginning in 1982 and continuing E cl for Unit 1 in October 1934 (The PCVP for Unit 2 hag not yet begun.) Tne X TRT could find no evidence that the PCVP failed to document problems whic.- were identified by QC but were corrected by the craft personnel on-the-sp:t. The PCVP was not limited in scope to "only a few cable trays"; however, t e TRT attributed the alleger's perception of a limited program to the lack :# a program plan for the PCVP and due to the limited regulatory basis con-tained in IEEE-336. 02/26/85 10 AQ-135 CATEGCRY 3
i Contrary to the allegation, TUEC's PCVP was not "a violation of law." No particular violation of law was identified by the alleger. In fact, the l PCVP met TUEC's regulatory commitments to IEEE-336. The PCVP included I i tracking and trending of all identified deficiencies including line items on ors and punchlists, unsatisfactory irs, NCRs, and CARS. However, the I j TRT did find tUEC's trending program to be weak. y 3 The elleger's Essertion that the PCVP lacked an engineering review of identified problems wu essentially correct, since only NCRs and separc-tion violations received engineering revi u. The vast majority of defi-ciencies identified during the PCVP were minor and inappropriate for engineering review, for example, chipped paint and loose cabinet fasteners. The alleger's description of the PCVP being "out of control" and B&R " turning over a mess" to TUEC was exaggerated. However, the TRT did find I Y that the PCVP and related programs, the TRT did not find that B&R was gurningoveramess"toTUEC. AlthoughthePCVPcontainedweaknessht XX was implemented and met the requirements of IEEE-336. In addition, TUEC's 4 final acceptance by plant operations appears to have been thorough, well-managed, and effectively implemented. The final acceptance program, which followed the PCVP and testing, was specifically designed to prevent TUEC's acceptance of "a mess." t In summary, the TRT concludes that the PCVP meets the requirements of IEEE-336. Most aspects of the allegation were not substantiated, had no l safety significance, nor any generic implications. However, the allega-tion of inadequate review of identified deficiencies led d the TRT to f determine a programmatic weakness involving the lack of guidance on the level of deficiency needed to initiate an NCR. This finding has generic implications for TUEC's other inspection and corrective action programs I for the design and~ construction of CPSES. Review of this allegation also led the TRT to conclude that TUEC' 0: ^.: S.: d 'c3W :" ' ' r M " y s TUEC's program for trending ncnconformancaAwas weak. x TRT w c ~.a= w. / a A J'W A~ s d -~Q g w w w/& w 02/26/85 11 AQ-135 CATEGORY 8 w , ee n ..e.w ne w--m = - m-- ma- -e+
- = - i On November 8, 1984, the tdt had an interview with the alleger. The TRT's assessment of the allegation was discussed with the alleger. At that time, l the alleger did not identify any further concerns or allegations, f-6. Actions Recuired: TUEC shall' review its corrective action systems and develop written guidance describing the thresholds of ' deficiencies and i s nonconformance that trigg.er increasingly higher tiers of corrective x/ g
- action, i
TUEC shall refine;r further develop its trending program to include je i-descriptions of data normalization, trend analysis, root cause determina-tion, corrective action', tracking, and close-out. .) ' r r None. 8. Attachments: 9. Reference Documents: 1. Comanche Peak Steam and Electric Station (CPSES) FSAR, Section 8.0, " Electric Power." 2. Texas Utilities Generating Company (TUGCO-TUEC's operating division and wholly owned subsidiary) Quality Assurance Procedure CP-CP-15.0, Revision 4, " Tagging System." 3. CP-CP-15.7, Revision 2, " Tracking of Audit Reports / Corrective Action Reports." 4. CP-CF-16.0, Revisions 12 and 14 "Nonconformances." 5. CP-07-17.0, Revision 4. "Cerrective Action." 6. CP-CF-13.0, Revision 20, " inspection Report." t i 02/26/S5 12 AQ-135 CATEGCRi S 1 s s
i 7. QI-QP-3-29, Revision 16, " Verify Electrical Separation."
- 8. - QI-QP-3-29.'1, Revision 16, " Verify Electrical Separation."
i ~ 9. TUGC0 Quality Assurance Instruction QI-QP-11.3-40, Revisions 0 '% rough 19, " Class 1E Electrical Post-Construction Verification." I
- 10. QI-QP-11.8-14, Revision 3, " Instrumentation System Turnover."
l
- 11. TUGC0 Startup Administrative Procedure CP-SAP-3, Revision 12, Custody, Transfer of Station Components."
- 12. CP, SAP-16, Revision 8, " Test Deficiency and Nonconformance Reporting."
i j
- 13. CP-SAP-20, Revision 2, " Guidelines for System Walkdown Inspections."
- 14. CPSES Station Administrative Procedure STA-802, Revision 2, " Final Acceptance of Station Systems, Structures and Equipment."
- 10. This statement prepared by:
C. Haughney, Date TRT Technical Reviewer Reviewed by: 4 H. Livermore, Date l Group Leader Approved by: V. Noonan, Date Project Director i i i 1 4 i i i i 02/26/85 13 AQ-135 CATEGOR'Y 8 i l
(' Name: a ,(Occur .Q-128 i Requestor's ID: JEAH I Author's Name: Chet Poslusny Occument Comments: 5/6/85 rev. 4, keep cover sheet with document = . ew r.'. l !>.,a {'",1 >w,>-,u. y * >,,.'n ( t,, 4 h J ! L \\ \\ \\ _ \\
t Ep, p. ~ 3 r 1. -Allegation Category: QA/QC 8, As-Built l 2. Allegation Number: AQ-44 and AQ-128 f 3. Characterization: It is alleged that there were instances when craft personnel would "make things fit" and have an engineer write "as-built" on i the document instead of following the appropriate design document. It.is i also alleged that an as-built verification program was initiated as a result of the above practice (AQ-44). It is further alleged that nonconformance reports (NCRs) were voided (improperly dispositioned) by an i engineer writing "as-built" and "use-as-is" on them (AQ-44, AQ-128). i i 4. Assessment of Safety Significance: The NRC Technical Review Team (TRT) evaluated the Texas Utilities Electric Company (TVEC) procedures for 4 implementing 10 CFR Part 50, Appendix B, Criterion V, " Instructions, Procedures, and Drawings"; Criterion X, " Inspection"; and NRC Office of l Inspection and Enforcement (IE) Bulletin 79-14, " Seismic Analyses for j As-Built Safety-Related Piping Systems." IE Bulletin 79-14 requires a seismic analysis of all safety-related systems, as-built verification of safety-related systems, evaluation of nonconformances found during as-built verification or correction of the nonconformance, and revision of documents to reflect as-built conditions in the plant. TUEC's implementing procedures for 10 CFR Part 50, Appendix B and IE Bulletin 79-14 requirements included the following: j Texas Utilities Generating Company (TUGCO) QI-QP-15.2-1, "Startup/ Turnover Record Requirements" Brown & Root (B&R) SFI-1, "Startup/ Turnover Record Requirements" TUGC0 CP-EI-4.5-1, " General Program for As-Built Piping l Verification" TUGC0 CP-EP-4.5, " Design Verification" TUGC0 CP-EI-4.5-4, " Technical Service Engineering Instruction for Pipe Hanger Design Review and Verification" TUGC0 CP-QP-16.0, "Nonconformances" TUGC0 CP-QP-11.13, "As-Built Verification" TUGC0 QI-QP-11.13-1, "As-Built Piping Verification Instructions" The TRT verified that these procedures satisfy both 10 CFR Part 50, Appendix B (Criteria V and X) and IE Bulletin 79-14. TUGC0 procedure CP-EI-4.5-1 includes verification of piping isometric drawing dimensions, elevations, valves, angles, sleeves, and interconnecting equipment. This procedare also includes verification of the pipe hanger location, configu-ration, and clearances, and requires analyses of the as-built condition, resolution of unacceptable analysis results, and certification of each analysts (furnished by the responsible analysis organization). Title 10 CFR Part 50, Appendix B, Criterion III, states that; " Design changes, including field changes, shall be subject to design control measures commensurate with those applied to the original design...." e The TRT determined that TUEC prepared engineering procedures (CP-EP-4.6, 1 i e S e+
i. 3 Fw s. . ~ 'r T ~ " Field Design Change Control," and CP-EP-4.7, " Control of Engineering /Desion Review of Field Des'ign Changes") and implemented them to satisfy this re:uire-ment. These procedures required design verification by authorized personnel either prior to or following implementation. Since revision of any desien document invalidates its design verification, the organization responsibie for the original design must verify these changes. Both principal supper: vendors (ITT Grinnell and Nuclear Power Service, Inc.) had personnel onsite who verified changes to vendor drawings and recertified these drawings,when required. TUGC0 procedure CP-QP-16.0, Section 3.2.4.1.d, states that, "Use-as-is dispositions shall include sufficient engineering technical justification to establish that the nonconforming characteristic will result in no ad-verse conditions and that the affected item will continue to meet all engineering functional requirements, including performance, maintain-ability, fit, and safety." The TRT reviewed 72 nonconformance reports (NCRs) that were dispositioned "use-as-is." In all cases, the technical justification, component modification card, or design change authorizatien supported the "use-as-is" NCR disposition. In no case did the TRT find an NCR that was improperly dispositioned "as-built" or " accept-as-built." In addition to the 72 NCRs examined in connection with this allegation, the TRT performed an in-depth evaluation of NCR activity, including voide: NCRs. The TRT reviewed 206 NCRs and found none that was voided by an engineer writing " void as-built" on it. (Refer to QA/QC Category 50, alle-gations AQ-31 and AQ-120.) 5. Conclusion and Staff Positions: Based en a review of design, inspection, aiia as-built procecures, tne TRT concludes that supports were changed after the drawings had been vendor-certified, and drawings were revised :: reflect the as-built condition. Hcwever, these design modifications were recertified by the principal support vendor's onsite staff in accordance with NRC requirements. (For additional information, refer to QA/CC Cate-gory 1, allegations AQ-21 and AQ-22.) The TRT could not substant. fate tha: changes were made to the' drawings for the reasons alleged. Based on interviews with both Bl.R engineering personnel and TUEC QA pers:n-nel and on a review of inspection and nonconformance procedures and the 72 NCRs dispositioned "use-as-is," the TRT staff concludes that the allegati:n relating to improper voiding of NCRs cannot be substantiated. The TRT plans to send a letter to the alleger regarding the TRT's assessment and conclusions. 6. Actions Reautrod: ( T.* , ? h b k N,&:h h; h. p) >c -w , u-e.
y 4 I E.
- k[.'m.
t a i; 8. Attachments: None. R'eference Documents: l 1. IE Bulletin 79-14, " Seismic Analysis for As-built l Safety-Related Piping Systems." 2. TUGC0 CP-QP-4.6, " Field Design Change Control." l 3. .TUGC0 CP-QP-16.0, "Nonconformance." l 4. GAP 2.206 Petition item No. 13, dated March 19, 1984 (AQ-44). L 5. AQ-44 and AQ-128: A-1 Statement dated March 19, 1984, and A 1 Interview pp. 57-63, dated April 6, 1984. 6. A-1 Interview pp. 136-137, dated August 1, 1984. l 7. TUEC Letter TXX 4180 dated May 25, 1984. 8. Nonconformance reports as follows: 83-03110 84-00686 84-00607 03114 00398 , 00609 03093 00469 00596 1.3089 00470 00578 'J3090 00456 00570 03063 00463 00554 03066 00444 00557 03048 00434 00560 03053 00443 00551 03035 00424 00537 03039 00397 00519 03040 00375 00495 03042 00709 00500 03025 00713 00483 l 03027 00673 00339 l 03010 00645 00340 l 03015 00627 00341 02988 00633 00343 02992 00605 00344 02981 00473 00346 03017 00458 00337 03004 00459 00361 02476 00608 00371 00579 00485 00362 9. Deposition of A-50 (July 13, 1984), Tr. 52,055 Line 21; 52, 079-52,084; 50,182-52.190; Case Exhibit 667, pp. 54-55.
- 10. Deposition of C. Thomas Brandt, Tr. 45,273-45,276 (submitted as l
profiled written testimony). l
- 11. 01 Report 4-84-008, dated July 9, 1984.
l i e 3 1 l I
r-1 Aa ... g ).I t
- 12. OI Report, 4-84-006 at 26, March 7, 1984.
- 13. Deposition of A-50 (July 13, 1984), Tr. 52,085-52,105.
I
- 14. Deposition of C. Thomas Brandt, Tr. 45,287 (submitted as prefiled
( written testimony).
- 15. ' March 19-20, 1984, Hearing Session Transcripts, Tr. 10,383-11,018.
- 16. April 24, 1984, Hearing Session Transcripts, Tr. 12,138-12,285.
- 17. Deposition of A-50 (July 13, 1984), Tr. 52,108-52,111; 52,199-52,202.
I
- 18. Deposition of C. Thomas Brandt, Tr. 45,280-45,287 (submitted as profiled written testimony).
9. This statement prepared by: M. Eli, TRT Date Technical Reviewer H. Livermore, Date Group Leader V. Noonan, Date Project Director i 4 I
~. - gggogggn n w. a AQ-44, AQ-128 R;qu:stor's 10; JEAN t Author's Nama: Chet Posiusny / Document Comments: 5/6/85' rev. 4, keep cover sheet with document / / / / /n / / / l 3 e auP* r~ L [.t,,.. y" i..., .i s <; p, # 's,. I pu, f, [ 3 'IfrC ,/ l' I i i e 0
L e 1. Allegation Category: QA/QC 8, As-Built l -2. Allegation Number: AQ-44 and AQ-128 I 3. Characterization: It is alleged that there were instances when craft personnel would "make things fit" and have an engineer write "as-built" on the document instead of following the appropriate design document. It is also alleged that an as-built verification program was initiated as a result of the above practice (AQ-44). It is further alleged that nonconformance reports (NCRs) were voided (improperly cispositioned) by an engineer writing "as-built" and "use-as-is" on them (AQ-44, AQ-128). 4. Assessment of Safety Significance: The NRC Technical Review Team (TRT) evaluated the Texas Utilities Electric Company (TVEC) procedures for implementing 10 CFR Part 50, Appendix B, Criterion V, " Instructions, Procedures, and Drawings"; Criterion X, " Inspection"; and NRC Office of Inspection and Enforcement (IE) Bulletin 79-14, " Seismic Analyses for As-Built Safety-Related Piping Systems." IE Bulletin 79-14 requires a seismic analysis of all safety-related systems, as-built verification of safety-related systems, evaluation of nonconformances found during as-built verification or correction of the nonconformance, and revision of documents to reflect as-built conditions in the plant. TUEC's implementing procedures for 10 CFR Part 50, Appendix B and IE Bulletin 79-14 requirements included the following: Texas Utilities Generating Company (TUGCO) QI-QP-15.2-1, "Startup/ Turnover Record Requirements" Brown & Root (B&R) SFI-1, "Startup/ Turnover Record Requirements" TUGC0 CP-EI-4.5-1, " General Program for As-Built Piping Verification" TUGC0 CP-EP-4.5, " Design Verification" TUGC0 CP-EI-4.5-4, " Technical Service Engineering Instruction for Pipe Hanger Design Review and Verification" TUGC0 CP-QP-16.0, "Nonconformances" TUGC0 CP-QP-11.13. "As-Built Verification" TUGC0 QI-QP-11.13-1, "As-Built Piping Verification Instructions" The TRT verified that these procedures satisfy both 10 CFR Part 50, Appendix B (Criteria V and X) and IE Bulletin 79-14. TUGC0 procedure CP-EI-4.5-1 includes verification of piping isometric, drawing dimensions, elevations, valves, angles, sleeves, and interconnecting equipment. This procedure niso includes verification of the pipe hanger location, configu-ration, and clearances, end requires analyses of the as-built condition, resolution of unacceptable analysis results, and certificatter of each analysis (furnished by the responsiole analysis organization). Title 10 CFR Part 50, Appendix B, Criterion III, states that; " Design changes, including field changes, shall be subject to design control ^ measures commensurate with those acclied to the original design...." The TRT determined that TUEC prepared engineering procedures (CP-EP-4.6, 1
l " Field Design Change Control," and CP-EP-4.7, " Control of Engineering /Ce:ign Review of Field Design Changes") and implemented them to satisfy this re:; ire-These procedures required design verificaticn by authorizec perscc el ment. either prior to or following implementation. Since revision of any desi;- document invalidates its design verif.ication, the crganization res;cnsible for the original design must verify these changes. Eoth principal sucperc vendors (ITT Grinnell and Nuclear Power Service, Inc.) had personnel cnsi.e who verified changes to vendor df awings and rece'rtified these drwings Me. required. TUGC0 procedure CP-QP-16.0, Section 3.2.4.1.d. states that, "Use-as-is dispositions shall include sufficient engineering technical justifica ic-to establish that the nonconforming characteristic will result in ne ad-verse conditions and that the affected item will continue to meet all engineering functional requirements, including performance, maintain-ability, fit, and safety." The TRT reviewed 72 ncnconformance re:crts (NCRs) that were disposittened "use-as-is." In all cases, the tecnnical justification, component modification card, or design change authcrizati:- supported the "use-as-is" NCR disposition. In no case did the TRT fine a-NCR that was improperly dispositiened "as-bailt" or " accept-as-built." In addition to the 72 NCRs examined in connection with this allegation, the TRT performed an in-depth evaluation of NCR activity, including voics: NCRs. The TRT reviewed 206 NCRs and found none that was vcidec by an engineer writing " void as-built" en it. (Refer to CA/QC Category 50, alle-gations AQ-31 and AQ-120.) Conclusien and Staff Positiens: Eased on a review of design, inspecticn, 5. and as-cuilt procecures, tne TRT concludes that supports were changed after the drawings had been vendor-certified, and drawings were revised :: reflect the as-built condition. However, these design modificaticns were recertified by the principal sucport vendcr's onsite staff in acc:rdance (Fer additional information, refer to CA/CC Ca:e-with NRC requirements. gory 1, allegations AQ-21 and AQ-22.) The TRT could not substantia.e that changes were made to the drawings for the reasons alleged. Based on interviews with both E&R engineering personnel and TUEC CA pers:-- nel and on a review of inscection and nonconfor anca procedures anc the Z NCRs dispositioned "use-as-is," the TRT staff concludes that the allega: fen relating to improper voiding of NCRs cannot be substantiated. L.:.d.) N., pint:<. M ;6 g u.!.q k M :1.. wL x a.. ~,w. ; :- n WM:.;1&n.a.+ 3 g."1.h5,7,;,,,;g,g:p.. wy. - ~ - - ~ f e. ' Actions Required: C* . 5 ( c p,., e .s L r} \\ 1,, t ~% /
4 8. Attachments: None. Reference Documents: 1. IE Bulletin 79-14, " Seismic Analysic for As-built Safety-Related Piping Systems." 2. TUGC0 CP-QP-4.6, " Field Design Change Control." 3. TUGC0 CP-QP-16.0, "Honconformance." 4. GAP 2.206 Petition item No.13, dated March 19, 1984 (AQ-44). 5. AQ-44 and AQ-128: A-1 Statement dated March 19, 1984, and A-1 Interview pp. 57-63, dated April 6, 1984. 6. A-1 Interview pp. 136-137, dated August 1, 1984. 7. TUEC Letter TXX 4180 dated May 25, 1934. 8. Nonconformance reports as follows: 83-03110 84-00686 84-00607 03114 00398 , 00609 03093 00469 00596 03089 00470 00578 03090 00456 00570 03063 00463 00554 03066 00444 00557 03048 00434 00560 03053 00443 00551 03035 00424 00537 03039 00397 00519 03040 00375 00495 03042 00709 00500 03025 00713 00483 03027 00673 00339 03010 00645 00340 03015 00627 00341 02988 00633 00343 02992 00605 00344 02981 00473 003?6 03017 '00458 00337 030C4 00459 00361 02475 00608 00371 00579 00485 00362 9. Deposition of A-50 (July 13,1954), Tr. 52,055 Line 21; 52, 079-52,084; 52,182-52,190; Case Exhibit 667, pp. 54 55.
- 10. Deposition of C. Thomas Brandt, Tr. 45,273-45,276 (submitted as prefiled written testimony).
- 11. 01 Report 4-84-008, dated July 9, 1984.
3
,./' r
- 12. OI Report, 4-84-006 at 26, March 7, 1984.
- 13. Deposition of A-50 (July 13, 1984), Tr. 52,085-52,105.
- 14. Deposition of C. Thomas Brandt, Tr. 45,287 (submitted as prefiled written testimony).
- 15. March 19-20, 1984, Hearing Session Transcripts, Trt 10,383-11,018.
- 16. April 24, 1984, Hearing Session Transcripts, Tr. 12,138-12,285.
- 17. Deposition of A-50 (July 13, 1984), Tr. 52,108-52,111; 52,199-52,202.
- 18. Deposition of C. Thomas Brandt, Tr. 45,280-45,287 (submitted as prefiled written testimony).
9. This statement prepared by: M. Eli, TRT Date Technical Reviewer H. Livermore, Date Group Leader V. Noonan, Date Project Director i t k i l 4 l}}