ML20141K414

Discusses Review of Current Comanche Peak Response Team Activities During 850826-31

ML20141K414
Person / Time
Site:	Comanche Peak
Issue date:	09/11/1985
From:	Keshishian P NRC - COMANCHE PEAK PROJECT (TECHNICAL REVIEW TEAM)
To:	Noonan V NRC - COMANCHE PEAK PROJECT (TECHNICAL REVIEW TEAM)
Shared Package
ML20141K401	List: ML20141K399 ML20141K414
References
NUDOCS 8601220503
Download: ML20141K414 (8)

Text

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~f UNITED STATES 8 o NUCLEAR REGULATORY COMMISSION

WASHINGTON, D. C. 20555

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%,,,,, SEP 1 I 1985 MEMORANDUM FOR: Vincent S. Noonan, Director Comanche Peak Project FROM: Paul Keshishian Comanche Peak Project '

SUBJECT:

COMANCHE PEAK RESPONSE TEAM VERIFICATION AND CORRECTIVE ACTION ACTIVITIES A review was conducted of the ongoing Comanche Peak Response Team (CPRT) activities during the period of August 26-31, 1985. The principal CPRT .

p__- activities in progress at the present time are those associated with the: .

1. - Stone & Webster (SWEC) Design Verification Effort i-

2. - Ebasco Design Verification Effort

3. - TERA Design Verification Effort

4. - 0A/QC Construction Verification Effort

5. - TRT Issue Specific Action Plans Implementation

1. Stone Webster Design Verification Effort This effort will involve a reanalysis of Unit #1 large bore Class 2 and 3 piping and supports and an evaluation of non-Westinghouse designed supports on Class 1 piping. In addition, for Unit #1, a sample reanalysis of small bore Class 2 and 3 piping will be perfonned. For Unit #2, similar work will be performed for large bore piping and supports.

- however, the reanalysis will include 100% of Class 2 and 3 r, mall bore

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piping. The reanalysis effort tvill be performed utilizing established SWEC methodologies. TERA is conducting the third-party overview of this activity.

a. Current Activities:

(1) - SWEC is continuing to mobilize manpower for this task at the site and off-site offices and present indications are that the work will be performed at a number of locations. The New York office of SWEC will manage and participate in the effort and design verification work will also be performed at their Houston, Boston, Cherry Hill and Toronto offices.

(2) - SWEC is in the process of completing two key procedures i necessary for their portion of the piping and support l verification work. Comanche Peak Project Procedure (CPPP) #7 -

" Design Criteria for Pipe Stress and Pipe Supports" is expected to be issued by September 3. CPPP #6 " Pipe Stress Analysis 8601220503 e50911 ~

PDR ADOCM 05000445 A PDR

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[ for As-built ASME Class 2 and 3 Piping Systems" is expected to be issued by September 16.

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l (3) - SWEC har completed a sample walkdown of Unit #1 79-14 program to assess the accuracy of existing as-built documentation previously verified by the project. The walkdown inspection  ;

i involved verifying piping and support attributes such as valve j location and orientation, support function and configuration,  !

j and orientation and angularity of supports. Preliminary-j indications are that problems were identified with valve  :

) orientations and strut / snubber angularities not being in i conformance with design. TUGC0 plans to reverify valve i orientations in the stress packages transmitted to SWEC and i correct the strut / snubber angularities to acceptable tolerances.

(4) - As of August 30. TUGC0 has transmitted 70 large bore stress j

packages of Unit #1 to SWEC for design verification. Each unit '

I will require 302 stress packages for verification. Of the 70 -

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- stress packages forwarded to SWEC 55 will require reverification.  ;

i that the as-built documentation is in conformance with the -

construction as to valve. orientation and strut / snubber j

j ; angularity. All future stress packages will be verified prior  ;

- to transmittal. _;

(5) - Approximately 200 supports on Unit #1 were scheduled to be i modified by TUGC0 prior to the start of the.SWEC effort. This 1 modification work is now on " hold" until a CASE notion-to the  ;

j ASLB is ruled on. The CASE position is that the planned 1 j modification would in effect destroy evidence.  !

(6) - SWEC is in the process of selecting a Unit #1 small bore l

piping and support random sample to permit stress analysis. '

i They are now in the process of determining the correct j._

representative population to permit-adequate sample size '

selection.

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. (7) - Approximately 30 SWEC engineers presently are at site and it -

! is anticipated that this group will be increased to 50. _The j- present intent _is to perform Unit #2 small bore piping analysis j and support certification and any new support work-or j

! modification required as a result of off-site analysis with the on-site SWEC engineers. All other work presently contemplated

] by SWEC will be performed off-site. .;

! 2. EBASCO Design Verification Effort-f

This effort involves a complete verification of original design and I as-built construction associated with the design and constructionLof the i Unit #1 and #2 electrical cable tray _and conduit supports.  :

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i a. Current Activities:  ;

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. 3 (1) - Ebasco has essentially completed the as-built verification of 2700 cable tray supports for Unit #2. Approximately 2300 of these supports have been design verified. TUGC0 is in the early stages of performing modifications to those supports ~ requiring changes.

(2) - In the comon area of 1200 cable tray supports for Unit #2, 750 have been as-built and 320 design verified.

(3) - In Unit #1 and those cable tray supports in the comon area serving Unit #1, of 4527 supports approximately 600 have been as-built. Of these 600, some 473 have been transmitted to Ebasco for design verification.

(4) - At the present time there are six teams of inspectors walking down Unit f1 cable tray supports to document the as-built condition. These teams consist of three men each and it is comtemplated to increase the number of teams to approximately 25

_ to expedite the as-built process. -

(5) - Corporate Consulting and Development (CCL) was on site the -

. week of August 26 for the static load testing of Unistruts for t determining their acceptability for against the wall service.

The purpose of this testing program is to demonstrate that the Unistrut supports used in the Seismic Category I conduit and junction box supports are structurally adequate to withstand the maximum loads postulated to be applied to the supports during the design earthquake conditions. TUGC0 anticipates receiving the CCL test report the latter part of September.

(6) - On Unit #1 conduit supports, Ebasco is presently determining the total population. It is planned to select a statistically based sample of conduit supports and then perform as-built.

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(7) - On Unit #1, of the total population of approximately 32,000 conduit supports there are approximately 7200 of Unistrut design.

CYGNA Energy Services has raised questions about the adequacy of these Unistrut supports. Of the 7200 supports 6000 of these are against the wall supports which TUGC0 believes they will be able to demonstrate that they are qualified. TUGC0 believes at the present time that of the remaining 1200 some 700 will need to be replaced and CCL will conduct tests to determine the adequacy of the balance.

3. TERA Design Verification Effort TERA is responsible for the Design Adequacy Plan, acts as third party over reviewer for design review, resolution of TRT issue specific action plans for the mechanical, civil and structural areas, tracking all external issues and will prepare and issue a final design adequacy report at the conclusion of their effort.

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a. Current Activities (1) - TERA is in the process of reviewing all relevant documentation in order 'to prepare a matrix and tracking system for all external issues originating from Walsh/Doyle, SRT, SIT, CAT, ASLB, SSER, applicant and intervenors. This matrix will be included in the program plan and will identify the issue, the source and where in the Program Plan it is addressed.

(2) - TERA is in the process of preparing Design Adequacy Procedures (DAP) for implementation of their review process. Of the 19 CPRT -DAP procedures required, 4 have been released for interim use and the balance are scheduled to be released for use by the end of September.

(3) - TERA's site force of a manager and 6 issue coordinators are performing their respective activities relative to the TRT Issue Specific Action Plans that they are participating in.

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(4) - TERA has received the NRC's staff programatic coments to the' CPRT Program Plan and has presented their suggested revisions to'

the CPRT Senior Review Team.

(5) - TERA is continuing with their Phase 3 effort of their Design Adequacy Plan. The Phase 3 effort involves the performance of validation checks to confirm that the design review areas selected can be utilized as representative of the total plant design. They are now in the process of preparing a schedule for completion of this activity.

(6) - They are currently reviewing detailed equipment lists to identify those vendors that are unique to determine that proper hardware has been delivered to the site in accordance with FSAR comittments and procurement specifications.

1. (7) - TERA is preparing review procedures and inspection check lists

. to implement their design verification activities for the Auxiliary Feedwater System and the Electric Power System.

(8) - TERA has received the Gibbs and Hill redesign of the control room ceiling and is in the process of reviewing them.

(9) - During the week of Sept. 9, 30 TERA personnel will receive training in the implementation of DAP procedures. One session will be held at Berkley, California and one at Bethesda, Maryland.

(10) - The TERA organization has added a DAP quality assurance auditor and a QA/QC project quality assurance engineer to see that the TERA QA/QC comitments are properly implemented.

4. QA/QC Construction Verification Effort

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This effort encompasses a statistically based sample reinspection of QC accepted construction work supplemental by a review of related quality documentation.

a. Current Activities :

(1) - The procedures that describe administrative controls for this effort are essentially complete. Of 20 required procedures 19 have been completed.

(2) - Inspection procedures and checklists are continuing to be prepared. About 50% of these procedures have been completed and issued for use.

(3) - A total of 26 hardware population descriptions have been completed which essentially completes this effort.

(4) - The internal QA program relative to the construction reinspection effort has been prepared and is presently being implemented. .

(5) - To date of the 26 hardware population inspections none have 1 been completed though a number are partially completed.

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(6) - As of the date of this inspection the review of related document packages has not as yet been initiated.

(7) - For the present scope of work, it is estimated that approximately 2500 hardware reinspection packages had been released for use and approximately 220 packages had actually been field inspected. These completed field inspection packages are now in the review process.

(8) - For the approximate 220 reinspection packages implemented 136 deviation reports were generated. Of the 44 deviation reports evaluated to date, 35 were detennined to be valid. The safety significance of the valid deviation reports is now being determined.

(9) - At the time of the inspection it is estimated that about 2-3%

of the reinspection effort has been completed. Currently this effort is 3-4 weeks behind schedule primarily because of longer than estimated times to prepare inspection procedures, checklists and establish hardware populations.

(10) - At present the manpower for this effort is 149 individuals.

It is expected to peak at approximately 175 at the end of this year. Of this total about 40 individuals will be involved in determining the safety significance of the deviation reports originating from the inspections.

(11) - As part of this effort these are approximately 2650 documentation review packages to be prepared and issued for reinspection. At the' time of this inspection 119 had been issued but none of the packages had been reviewed.

6 (12) -'RIV is closely following this reinspection effort and presently plans to witness 10% of the reinspections and independently inspect 5%. On August 29, RIV had a meeting with the Applicant at the site to indicate some of the concerns they have with the reinspection effort.

5. TRT Issue Specific Action Plans-Implementation Each of the SSER's prepared as a result of the TRT inspections resulted in specific actions required by TUEC to resolve outstanding deficiencies. ,

For each of the-issue specific items TUEC has developed action plans and is in the process of implementing them. As of each of the action plans is completed a results report will be prepared for each item. The specific details for each of the following TRT issue specific items can be found in -  ;

the respective SSERs or in the Program Plan under Appendix C.  ;

a. Current Activities:

The following is a listing of the TRT items and their status at the time

,_- of the site review: }

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ITEM STATUS

. Heat Shrinkable . Action cor.pleted. ,

Insulation Sleeves Preparing results report. '

. Inspection Reports on . Actions cumpleted..  !

Butt Splices Results report in review  !

review cycle.

. Butt Splice Qualification . Actions completed. .

Results report in review cycle. -

. . Agreement Between DWGS . Actions completed.

and Field Tenn's Revising results report.

. NCRs on Vendor Installed . Work completed.-  !

Amp. Tenninal Plugs Revising results report. ,

. Flexible Conduit To . Additional analysis in ,

Flex. Conduit Separation progress. l

. Flex. Conduit to Cable . Additional analysis in Separation progress

. Conduit to Cable Tray . Actions completed.

Separation Results report in review cycle.

. Barrier Removal . Actions completed. t Revising results report.

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7 Item STATUS

. Electrical Conduit . Analysis in progress and Supports expect to start walkdown by mid-September

. QC Inspector Qual's . Electrical Inspector l Qualifications Review t Completed. .

I Review of ASME inspector qualifications in progress.

. Guidelines for Admin. . Review completed.

Of QC Inspection Test Preparing results report.

. Reinforcing Steel In . Work Completed.

Results report in review The Reactor Cavity cycle. ,

. Cancrete Compression . Field work completed. _.

Strength Preparing results report.

. Maint. of Air Gap . Mapping of air gaps Between Concrete is complete. Evaluating bids Buildings for removal of concrete and debris.

l . Seismic Design of . Gibbs & Hill design of l Control Room Ceiling new ceiling complete. TERA j Elements reviewing design.

. Rebar in the Fuel . Evaluation Complete.

Handling Building Results report in j - review process.

. Hot Functional (HFT) . Review completed.

Data Packages Preparing results report.

. . JTG Approval of Test . Work complete. Results l Data report in review cycle.

. Technical Specification . Work complete. Results For Deferred Tests report in review cycle.

. Traceability of Test . Work complete. Results

Equipment report in review cycle.

l . Conduct of CILRT . Work Complete. Preparing l results report.

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. 8 Item Status

. Prerequisite Testing . Evaluation complete.

Preparing results report.

. Preoperational Testing . Review completed.

Preparing results report.

. Skewed Welds in NF . Sample inspected.

Supports Engineers evaluating results.

. Steam Generator . Work on " Hold". Awaiting Anchor Bolts completion of evaluation of upper lateral support t by Gibbs and Hill.

. Design Consideration . Reanalysis completed.

For Piping Systems Bet. Preparing results

. Seis CAT I & Non-Seismic report. .

] Cat I Bldgs. -

. . Plug Welds . Inspection in Progress

. Installation of Main . All field work complete.

Steam Pipes Preparing results report.

. Gap Between Reactor . Design change and critical Vessel Insulation & space review in progress.

Biological Shield Wall Preparing sample population list.

. Polar Crane Shiming . Crane test procedure being reviewed. Receiving test

equipment hardware for mid-C October crane test.

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. Valve Disassembly . Valve inspections in .

1 progress.

! . Non-Conformance and . Reviewed current procedures.

Corrective Action Systems Review of NCR populations in Progress.

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