ML20215J921
| ML20215J921 | |
| Person / Time | |
|---|---|
| Site: | Comanche Peak  |
| Issue date: | 10/16/1986 |
| From: | Barnes I, Dale J, Jew D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20215J811 | List: |
| References | |
| 50-446-86-02-01, 50-446-86-2-1, NUDOCS 8610270247 | |
| Download: ML20215J921 (7) | |
See also: IR 05000446/1986002
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APPENDIX E
SPECIAL UNIT 2
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HVAC DUCT SUPPORT "AS-BUILT" PROGRAM INSPECTION
U.S. NUCLEAR REGULATORY COMMISSION
REGION IV
NRC Inspection Report: 50-446/86-02
Construction Permit: CPPR-127
Docket: 50-446
Category: A2
Applicant:
Texas Utilities Electric Company (TUEC)
Skyway Tower
400 North Olive Street
Lock Box 81
Dallas, Texas 75201
Facility Name: Comanche Peak Steam Electric Station (CPSES), Unit 2
Inspection At: Glen Rose, Texas
Inspection Conducted: February 25 through March 7, 1986
Inspectors:
/o!&!A(,
A. Dale,JIV Consultant
Date
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D.~ L. Jew, R M Conibltant
Dafe
Participating NRR Consultants:
G. Degrassi
J. J. Rivard
Approved:
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1. Barnes, Chief, Region IV CPSES Group
Date
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Inspection Sunnary
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Inspection Conducted:
February 25 through March 7, 1986 (Report 50-446/8602)
Areas Inspected: Special, unannounced inspection of the Unit 2 HVAC duct
supports as-built inspection program.
Results: Within the one area inspected, one violation (four examples of errors
in the as-built inspection program, paragraph 3) was identified.
8610270247 861017
ADOCK 05000445
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DETAILS
1.
Persons. Contacted
- B. Farrawood, Project Manager, Corporate Consulting Limited (CCL)
- T. Chambers, Project Manager, Bahnson Service Company (BSC)
- J. Canup, QA Corporate Manager, BSC
- G. Benfer, Project QA Manager, BSC
- W. Walker, QA Engineer, BSC
- C. Nelson, Vice President, BSC
- C, G. Hughes, Vice President Operations, CCL
- J. Gore, Subcontractor Supervisor, TUGCo
- J. Herritt, Director of Construction, TUGCo
, T. Brandt, Quality Engineering Supervisor, TUGCo
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- J. Kralik, Unit 2 Project Manager, TUGCo
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- V. English, Subcontracts, Brown & Root
- J. Walsh, Quality Engineer, TUGCo
- Denotes those person'. who attended the exit interview.-
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The NRC inspectors also contacted other applicant employees during this
inspection.
2.
HVAC Duct Support As-Built Inspection Program
a.
Unit 1: On January 17, 1986, NRR performed a site audit to determine
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the status of the HVAC duct supports at Comanche Peak. An overview
of the current Unit 1 status was presented by TUGCo.
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Subsequent to the site audit, additional information was developed
with respect to the as-built support analysis program which began in
January 1985. Preliminary results indicated that deviating
conditions exist which may impact the existing analysis. Due to the
identification of the deviating conditions, the status of CPSES
Seismic Qualification Report of Seismic Category I Duct Work and
Hangers was changed by TUGCo from " Approved" to "Not Approved" on
January 21, 1986.
A copy of the NRR trip report, which addresses the status, is
contained ir. this Appendix as Attachment 1.
b.
Unit 2: This inspection was performed to verify the adequacy of the
Unit 2 as-built inspection program for HVAC duct supports. The bases
used for this inspection were the following:
(1) BSC Procedure QCI-CPSES-012, Revision 4, dated September 6,
1984, " Surveillance and Inspection of Concrete Anchor Bolt
Installation Procedure."
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(2) BSC Procedure QCI-CPSES-016, Revision 1, dated September 6,
1984, " Verification of Weld Size for Skewed Weld Joints
Procedure."
(3) BSC Procedure QCI-CPSES-Oll, Revision 5, dated September 24,
1985, " Visual Inspection of Welds Procedure."
(4) BSC Procedure QCI-CPSES-014, Revision 4, dated September 13,
1985, " Seismic Duct Support Installation Inspection Procedure."
(5) BSC Procedure DFP-TUSI-003, Revision 10, dated May 6, 1985,
" Duct Support Design Fabrication and Installation Procedure."
(6) BSC Procedure DFP-TUSI-004, Revision 10, dated April 17, 1984,
" Drilled-In Expansion Bolts Installation Procedure."
(7) BSC Procedure DFP-TUSI-010, Revision 3, dated April 11, 1984,
" Permanent Attachments to Embedded Weld Plates Procedure."
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(8) BSC Procedure DFP-TUSI-016, Revision 0, dated /spril 11, 1985,
"As-Built Procedure."
(9) BSC Procedure WP-TUSI-001, Revision 1, dated July 1,1985,
" Welding Procedure."
(10)'AppropriateDuctSupportDesignChangeRequests(DSDCRs)and
Duct Design Change Requests (DDCRs) to further clarify the
procedures.
.(11) Appropriate Deficiency and Disposition Reports that describe and
provide disposition of discrepant condi.tions.
(12)BSCHVACductsupportdrawingswhichhadreceivedfinalQC
acceptance.
From a total of approximately 650 HVAC duct support drawings that had
received final QC acceptance, the NRC selected the following 32 supports
for inspection:
Safeguards Building
Reactor Building
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SG-773-2H-WP2
RB-808-VR-21C
SG-773-2H-4D
RB-808-2A-WP2
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SG-790-2H-1Q
RB-808-2E-7A
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SG-790-2H-1B
RB-808-2D-C2
3'
-SG-790-2H-1AC~
RB-808-2D-1B
SG-790-2J-1P
RB-832-2E-1G
SG-790-2H-RIE
RB-832-VR-17D
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SG-790-2J-1B
RB-860-VR-12A
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SG-790-2H-R1P
RB-860-2D-1Q
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SG-831-2J-1G
RB-860-VR-7H
SG-852-2H-WP16
RB-860-2E-4H
SG-852-2J-1AW
RB-905-2D-1H
RB-905-2D-4AH
Diesel Generator Building
RB-905-VR-8B
RB-905-RB2-PS-16
DG-844-2K-9A
DG-844-2K-1J
DG-844-2K-1AA
DG-844-2K-1AF
2K-PS5 (Drawing No. 2323-M2-0659-01)
As a result of this inspection, one violation of Criterion X of Appendix B
to 10 CFR Part 50 and two unresolved items were identified with respect to
major attributes associated with the Unit 2 HVAC duct support final QC
accepted as-built drawings, and applicable BSC QC procedures and
specifications.
3.
Summary of Violations to~ Criterion X of Appendix B to 10 CFR Part 50
(446/8602-V-17)
a.
Intermittent Fillet Welds
(1) Procedure Requirements
Section 9.1 in WP-TUSI-001, Revision 1, states, in part, with
respect to intermittent welds, " Weld increments shall begin and
terminate within 1/8 inch of the ends of the joints or
dimensioned length . . . ."
(2) Findings
The following list of supports had intermittent fillet welds
between the duct and the duct support, whic' did not begin or
terminate within 1/8" from the joint ends:
SG-790-2H-1Q
RB-832-VR-17D
SG-790-2H-1AC
RB-860-VR-7H
SG-790-2J-1P
DG-844-2K-1J
SG-831-2J-1G
b.
Qualitative Measurement
(1) Procedure Requirements
Section 6.5 in BSC Procedure QCI-CPSES-011, Revision 5, states,
"The quality representative shall make certain that the size,
length, and location of all welds conform to the requirements of
QCI-CPSES-014 and DfT-TUSI-003, and to the detailed drawing,
that no specific welds are omitted, and that no specific welds
have been added without engineering approval."
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Section6.3inBSCProcedureQCI-CPSES-014, Revision 4} states,
" Verify that all welding, (amount, placement, and type is in
accordance with drawing."
(2) Findings
HVAC duct support drawing No. 2K-PS5 (ref. drawing
No. 2323-M2-0659-01) requires a 2" long, 1/4" fillet weld
between the main support structure and the vertical
direction brace. Inspection revealed this weld to be
undersized by 50 percent; i.e., 1/8".
HVAC duct support drawing No. RB-905-RB2-PS-16 requires a
2-1/2" long,1/8" fillet weld between the raain support
structure and each of the two lateral braces.
Inspection
revealed these two fillet welds to be non-existent.
HVAC duct support drawing No. SG-790-2H-RIE requires a
1-1/2" long, 1/8" fillet weld on both sides of the 6" long
2X2X1/4 angle steel directly above the duct.
Inspection
revealed both welds to be 1-1/4" long.
c.
Weld Quality
(1) Procedure Requirements
Section 6.6 in BSC Procedure QCI-CPSES-Oll, Revision 5, states
in part, " Weld profiles shall meet the following requirements:
The faces of fillet welds may be slightly convex, flat, or
slig'ntly concave . . . Rejectable defects - welds shall be
visually examined to determine if the following defects are
evident: . . . Undercut shall not exceed 1/32" for material
thicker than 1/4"."
(2) Findings
HVAC duct support SG-852-2J-1AW, consisting of 1/2"
members, contained 2-4" long fillet welds in which 1/16"
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undercut was observed in over 50 percent of each weld
length,
HVAC duct support SG-852-2J-1AW contained a 1/4" and 3/8"
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fillet weld, in which grinding of the weld produced
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excessive convexity, resulting in an unacceptable profile.
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d.
Anchor Bolt Spacing
(1) Procedure Requirements
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Note 2 in Attachment 4 to BSC Procedure DFP-TUSI-004,
Revision 10, states, "Where the embedded steel plates are
occupied by attachments within the minimum distance shown above
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(12 inches), the minimum clearance to Hilti anchors shall be as
follows:
Hilti Anchor
Nelson Stud
Edce of Plate
Size
To Hilti Anchor
To Filti Anchor
1"
9"
7 1/2"
(2)
Findings
HVAC duct support DG-844-2K-1J had a 1" diameter Hilti 11" away
from an attachment on an embedded steel plate. However, the
Hilti was positioned 3/8" from the edge of the embedded plate
rather than the required 7-1/2" minimum.
4.
Summary of Unresolved Items
a.
Gap Between Concrete and Support Steel
While performing the inspections, it was observed on three supports
that the support steel which is bolted to a concrete wall with Hilti
Bolts was not completely flush with the concrete wall. Details of
gap conditions are listed below:
Support
Gap Description
RB-832-VR-17D
Gap existed for approximately 30 percent
of the length of the 6X6X5/8 angle steel
steel and measures up to .25".
The gap
encompassed the total area around one
Hilti.
DG-844-2K-1J
Gap existed for approximately 70 percent
of the length of the 6X6X5/8 angle steel
and varies up to .375".
The gap
encompassed the total area around one
Hilti.
SG-852-2H-WP16
Intermittent gaps existed between
concrete and C 6X8.2 channel steel on
the East side. Total gap region
encompassed 25 percent of the length and
was prevalent at one Hilti.
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From discussion with the applicant, BSC and CCL personnel, it was not
apparent that inspection of gap conditions had been considered as a
necessary element for factoring into the CCL reanalysis of HVAC duct
supports. This matter is an unresolved item pending clarification by
the applicant (446/8602-U-18).
b.
Analysis of Square Groove Welds
During the inspection, it was noted that certain BSC drawings, in
which square groove welds were specified for seismic HVAC duct
supports, did not specify applicable groove depths or the required
effective throat dimensions. The applicable supports were
RB-832-VR-17D, RB-860-VR-7H, RB-905-2D-4AH, RB-905-VR-88,
RB-905-RB2-PS16, SG-790-2H-1Q, and SG-790-2H-1B.
It was additionally
noted that these attributes could not be verified by the current
inspection program. This matter is considered an unresolved item
pending additional NRC review (446/8602-U-19).
5.
Exit Interview
An exit interview was conducted on March 6, 1986, with the applicant
representatives denoted in paragraph 1 of this appendix. During this
interview, the NRC inspectors summarized the scope and findings of the
inspection. The applicant acknowledged the findings.
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