ML20198K581
| ML20198K581 | |
| Person / Time | |
|---|---|
| Site: | Comanche Peak  |
| Issue date: | 04/20/1982 |
| From: | Miller T TEXAS UTILITIES ELECTRIC CO. (TU ELECTRIC) |
| To: | |
| Shared Package | |
| ML20197J316 | List:
|
| References | |
| FOIA-85-59 NUDOCS 8606040056 | |
| Download: ML20198K581 (51) | |
Text
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CPSES -
/ Q PREREQUISITE TEST INSTRUCTION
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C* .. / SYSTEM CLEANLINESS VERIFICATION i
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Prepared By: T. P. Miller
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REVIEVED BY APPROVED BY f
GC0 QA MANAGER E
LEAD ^
.s STARTUP ENGINEER NUCLEAR OPER TIONS SUPERVISOR
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XCP-ME-4 l a., Rsvision 5
' Page 2 of 18 SYSTEM CLEANLINESS VERIFICATION y
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' 1.0 PURPOSE The purpose of this instruction is to define system cleanliness requirements, prescribe a means for obtaining the cleanliness requirements and to provide methods of verifying system cleanliness and documenting satisfactory cleanliness results.
I Note i
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! Chemical cleaning is not addres-sed by this procedure and if re-quired will be covered by a pro-cedure for that specific cleaning activity. FOR INFO 2.0 ACCEPTANCE CRITERIA i
i The required system cleanliness level as specified in Table I may be verified by visual observation, cloth wipe or flushing. The acceptance criteria for each of these verification methods is as follows: .
2.1 Cleanliness Level I
- A high level of cleanliness applicable to reactor coolant systems, 1 components and other items, such as the reactor coolant purification j system, which have similar cleanliness requirements. Piping and components in systems which are designed as requiring Level I cleanliness shall meet the following requirements
i 2.1.1 Visual Examination f
- a. The surface should appear " metal clean" when examined without
- magnification under a lighting level (background plus
- supplementary lighting) of at least 100 foot candles.
(Equivalent to that of regular office lighting). Scattered
' areas of tightly adherent rust are permissible provided the aggregate area of rust does not exceed two square inches in any one square foot area.
- b. The surface shall be free of particulate contaninants such as sand, metal chips, weld slag, weld spatter, etc.
- c. The surface shall be free of organic films and contaninants such as oils, paint and preservatives as detrmined by a visual exanination or an organic solvent-dampened white cloth or an equivalent alternate method.
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- d. When a visual examination is not possible and the surfaces are accessible, a dry white-cloth wipe, followed by a solvent
. dampened white-cloth wipe, may be used to evaluate the
, cleanliness of the surface. If either cloth exhibits
. indications of contamination, the system shall either be
, reeleaned or the specific contaminant shall be determined and evaluated as to its potential deleterious effect-EOR INFO i
2.1.2 Flushing ONLY d j a. If flushing is the only practical ceans for determining system t cleanliness, the system shall be evaluated by examining a i 20-mesh or finer screen, " Nainsook" sample cloth or l equivalent, installed on the outlet of the cleaning circuit or at specified sample locations. The system shall be flushed at a flowrate that is equal to or greater than the design flowrate, not to exceed equipment limitations, until the
! sample cloth / screens ' hows no more than slight particle speckling and no more than slight rust staining. There shall i be no particles larger than 1/32 inch in any dimension, except fine hairline slivers of less than 1/32 inch thickness are permissible up to 1/16 inch long. There shall be no evidence of organic contamination in the effluent water or on the sample cloth / screen. -
- b. Effluent flush water shall meet the chemistry acceptance i
criteria as follows:
Chloride ion, maximum pps as Cl- 0.15 Fluoride ion, maximum ppe as F1- '
O.15 l
l Conductivity, maximum micromhos/ct: - 5.00 Silica, maximum ppo as SiO2 0.10 pH range 6.0 - 8.0 Visual Clarity No visual turbidity oil or -
j sediment 3
2.2 Cleanliness Level 2 An intermediate level of cleanliness generally applicable to closed service water systems that cool components containing reactor coolant,
, engineered safety systeas and other high integrity systens.
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t 2.2.1 Visual Examination b Surfaces shall meet the requirements for Level I cleanliness, except as follows: -
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, a. Thin uniform rust films are acceptable on carbon steel f
surfaces.
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- b. Scattered areas of tightly adherent rust are permissible provided that the area of rust does not exceed 15 square inches in any one square foot on corrosion resistant alloys.
2.2.2 Flushing Flush samples shall meet the requirement for Level I cleanliness, except as follows:
- a. Sample cloths / screens may exhibit considerable rust staining.
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- b. Effluent flush water shall meet the chemistry acceptance t criteria es follows: --
!! r ggpo' Chloride ion, maximum ppm as Cl-Fluoride ion, maximum ppa as F1- O. gd *
- Conductivity, maximum micromhos/cm .rv. v Silica, maximum ppa as SiO2 0.10 l pH range 6.0 - 8.0 Visual Clarity No visual turbidity oil or ll - water
- c. When impingement targets are used for steam blows, the target -
shall show no more than one particle per 2500 pounds of steam sampled as a result of particulate impingement. There shall be no pits due to particles larger than 1/32 by 1/16 inch
- t long. The target surface shall be examined without ll magnification under a lighting level of at least 100 foot l} candles. (Equivalent to the lighting level found in a
,} normally lighted office). This examination will be assisted ll by back lighting the target area with a hand held flashlight i to provide particle high-lighting per normal industry l practice.
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l 2.3 Cleanliness Level 3 The level of cleanliness applicable to fire protection, open service water and similar systems requiring only a nominal degree of cleanliness. The following are acceptable on items which meet Level 3
- j cleanliness.
2.3.1 Visual Examination
- a. Tightly adherent mill scale on carbon steel surfaces.
' b. Paint or preservative coatings on carbon steel surfaces that
- will not peel or flake when exposed to cold water flushing.
- c. Rust films on carbon steel and stainless steel surfaces that resist removal by scrubing with a bristle brush.'
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l XCP-ME-4 Revision 5 i
Page 5 of 18 2.3.2 Flushing
! a. Applicable for closed loop water flushes only (i.e., turbine plant cooling water) - if flushing is the only practical means of determining system cleanliness, the system shall be evaluated by examining a 14-mesh or finer screen, cloth, or I equivalent, installed on the outlet of the cleaning circuit or at the specified sample locations. The system shall be flushed at a flowrate that is equal to or greater than the h
j design flowrate, not to exceed equipment limitations, until 1
the sample cloth / screen shows no more than occasional particle
- speckling. There shall be no particles larger than 1/16 inch
- in any dimension, except hairlike slivers of less than 1/16 inch thickness are permissible up to 1/8 inch long. There shall be no evidence of organic contamination on sample
- j screens or flush cloths. Considerable rust is acceptable.
- b. If flushing is the only practical means of determining system cleanliness of open water systems, (fire protection, service water), the system shall be evaluated by examining effluent or sample water for visual clarity at a flowrate that is equal to h
or greater than the design flowrate, not to exceed ec;uipment limitations. FOR INFO ONLY
' 2.4 Cleanliness Level 4 l
Cleanliness level applicable to the Turbine Control Fluid System only.
2.4.1 Visual Examination A
- a. All accessible components shall meet the acceptance criteria i of Section 2.2.1.
2.4.2 Flushing
- a. Two 100 milliliter samples will be obtained at the supply line and analyzed for the following micron ranges. Both samples shall meet the SAE criteria and at least one sample shall meet the ACPS1 criteria.
(1) Particle Size SAE-Acceptable ACPSI-Acceptable (Micron) Number of Particles Number of Particles 5 - 10 24,000 24,000 10 - 25 5,360 5,360 25 - 50 780 780 50 - 100 110 110 100 - 250 11 0 l
(2) Drain line filter strainer must not catch any particle larger than
. 004", tank screen must be clean. .
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XCP-ME-0 l Revision 5 l I '
Page 6 of 18 I l
2.5 Cleanliness Level 5 '
A cleanliness level applicable to the Turbine Generator Lube Oil, Lube
- 011 Purification and Seal Oil Systems only.
2.5.1 Visual Examination
- a. All accessible components shall meet the acceptance criteria
, of Section 2.2.1.
2.5.2 Flushing i
- a. Two 100 milliliter samples will be obtained and analyzed for the following micron ranges. Both samples shall meet the SAE criteria and at least one sample shall meet the ACPSI criteria. .
SAE-Acceptable ACPSI-Acceptable Particle Size
- - (Micron) Number of Particles Number of Particles I
5 - 10 32,000 32,000 3 10 - 25 10,700 10,700 25 - 50 1,510 1,510 ,
50 - 100 225 225 100 - 250 21 0 i
3.0 REFERENCES
f 3.1 ANSI N45.2.1-1973 FOR INFO
{ ONLY ~~
3.2 TBX/TCX-SU-1.2.1 3.3 Westinghouse Process Specification 292722 R7 3.4 2323-MS-100, Piping Erection Specification 3.5 Gibbs & Hill Inc., i.etter GTN-33497 3.6 Fire Protection Code - 1979 3.7 ACPSI Turbine Generator Technical Manual l
-l 3.8 ACPSI Memo ACT-737 dated June 28, 1977;
Subject:
Lube Oil Flush Criteria 4.0 PREREQUISITES l 4.1 A System Cleanliness Plan (Flush Plan - FP) shall be prepared by the appropriate STE and approved by another STE (of Level III qualifications) prior to implementation. System Cleanliness plans shall be numbered using the system number followed by a sequential flush number (i.e., the first flush of system 09 would be FP-09-01). Each
! cleanliness plan shall consist of the following:
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i ., XCP-tie-4 Revision 5 i Page 7 of 18 4.1.1 Purpose - A clear statement to define the goal of the specific cleaning activity. I 4.1.2 Prerequisites - specific conditions or activities that are required to exist or be completed prior to conduct of the cleaning activity. For air flushes, the flush plan should specify the controls needed to ensure an adequate volume and pressure source.
Note
- It is not required in the pre-1 requisite section of the clean-liness plan to repeat the gen-eral prerequisite of this pro- .
cedure.
4.1.3 Precautions - special measures and limitations to be taken or
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observed before and during the conduct of the cleaning activity for personnel safety and equipment protection.
Note __
f It is not required in the pre- 1 OR lNFO caution section of the cleanli-ness plan to repeat the general [_ ONLY
- precautions of this procedure.
4.1.4 Cleaning Sequence - a detailed sequence of cleaning and cleanliness verification activities including post flush inspections of equipment (i.e., heat exchanger).
4.1.5 Restoration - specific activities necessary to return the component or system to its operating condition or place in a condition for further testing.
4.1.6 Layup - specific activities necessary to place the component or system in a layup condition following the cleaning
<, activities.
t 4.1.7 Drawing - applicable drawing marked to show flush flow paths and boundaries.
4.2 If cleaning is to be performed with solvents, verify that only approved solvents as specified in Table II are used.
I 4.3 khen flushing activities are to be conducted, verify that the following l prerequisites, as applicable, are completed: ,
i 4.3.1 The pump casing is filled and vented.
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Revisisn 5
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4.3.2 Communications are established between the control room and necessary equipment or flushing activity monitoring and control points.
4.3.3 Adequate capabilities exist for disposal of flushing fluids.
, 4.3.4 Where clearly identified that desiccants have been installed; ensure the desiccant has been removed.
. 4.3.5 Spring hangers are in the locked position when steam or gas lines are flushed with water.
4.3.6 Spring hangers are in the unlocked position when steam or gas l lines are flushed with steam or gas.
4.3.7 Spring hangers are in the unlocked position when water lines are flushed with water or gas.
4.3.8 Permanent system orifice plates are not installed.
H1 R4F0 4.3.9 Sensitive instrumentation is removed or isolated. ,
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4.3.10 Sufficient, permanent or temporary, instrumentation is available or installed for monitoring equipment operating parameters during flushing operations. Verify instrumentation used for flushing operations is calibrated.
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4.3.11 All personnel involved with the cleaning activity are properly instructed and understand their responsibilities, system
! operating parameters, limitations and actions to be taken whenever unexpected occurances happen.
4.4 Verify that the appropriate test equipment listed in Section 5.0 is available. .
4.5 Verify that the type of oil to be used in permanent plant equipment oil ti systems complies with vendor recommendations or TUCCO's approved equivalent.
Note
! Chemical analysis of the oil is
} not required prior to filling the system unless. required by the equipment vendor.
5.0 TEST EQUIPMENT l'
5.1 Filter Cloth " Nainsook" (bleached muslin)
I with approx. 76 yarns / inch
! warp & fill, or equivalent t
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'l 5.2 Screens Cleanliness Level 1 & 2 (20 mesh) )
Cleanliness Level 3 (14 mesh-closed loop systems) i 4
- 5.3 Targets used for steam flushes shall be a square bar of polished mild ~
steel. Its width shall be one tenth of the pipe diameter or a minimum I
of .5 inches. Length shall be in excess of the pip innar diameter.
i FOR INFO .
6.0 SPECIAL PRECAUTIONS ONLY 6.1 When solvents or flammable liquids are used for cleaning, ensure the following:
-l 6.1.1 Adequate ventilation is provided and protective clothing is used when necessary.
6.1.2 Notify B&R safety to determine additional precautions. .
) 6.1.3 Clean white lint-free cloth rags si.ould be utilized
. during wiping activities.
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6.2 When flushing operations are conducted, observe the following:
6.2.1 High pressure flush exits should be securely anchored to prevent whipping. -
6.2.2 Protect electrical equipment at flush exits to prevent i
damage or electrical shock.
6.2.3 Exercise care when sampling high pressure or high velocity systems.
6.2.4 Do not exceed maximum flowrate, pressure or temperature limits on heat exchangers and other equipnent as I specified by vendor and plant operating instructions. ,
6.2.5 Monitor equipment operating parameters such as vibration, ptsap discharge and suction pressure, flow, bearing temperatures and suction strainer differential pressure j to prevent equipment damage.
I 6.2.6 Measures should be taken to direct water and steam flush effluent away from plant equipment and personnel and prevent personnel entry into the flush exit path with the j use of warning signs and barriers, as necessary.
7.0 INSTRUCTIONS The system cleanliness plan specifies the activities necessary to obtain and/or verify system or component cleanliness. During the performance of these activities, it may become necessary to. modify the plan. The System t .
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Test Engineer responsible for directing these activities is authorized to modify the plan. Modifications to the plan shall be recorded on the System Cleanliness Log shown as Data Sheet 2.
7.1 Visual Examination 7.1.1 Varify that the applicable prerequisites contained in this j instruction and the system cleanliness plan are complete.
7.1.2 Visually examine the component internal surfaces in accordance
, with the System Cleanliness Plan to verify acceptance criteria of
- Section 2.0 for the required cleanliness level.
. 7.1.3 Signify satisfactory results of the visual examination on Data Sheet 3.
FOR INFO 7.2 Flushing ONLY -
7.2.1 Verify that the applicable prerequisites contained in this l
instruction and system cleanliness plan are complete.
i 7.2.2 Begin flushing operations in accordance with the System Cleanliness Plan. k Note i The plan will specify the se-I quence for performing 7.2.3 and l 7.2.4.
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- I 7.2.3 Continue flushing operations until two consecutive three minutes (minimum) samples meet the particulate acceptance criteria for the required cleanliness level at the sample locations specified in the plan. Signify satisfactory results for the sample points specified on Data Sheet 3.
Notes
- 1. A sample time for cleanliness levels 4 and 5 is not applicable.
- 2. Systems specified as cleanliness i
Level 3, notated with an (*) in Table I do not require particulate
, sampling as described in acceptance j criteria paragraph 2.3.2.b.
- 3. Flush cloths should be secured
} around the flush sample locations j to minimize bypass flow.
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- 4. Exercise care when removing a sample cloth from the sample stream. Where
, possible, close the sample valve be-fore removing the sample cloth. .
'q 5. Sample points should be sufficiently
! flushed to clear any trapped debris or contaminants prior to obtaining a sample.
- 6. Samples should be taken at full sample flow conditions when practical (sample valve full open). Sample points should be strategically located to provide re-presentative samples of the flushing mediun. FOR INFO ONLY -
, Caution Exercise care when sampling high pres-sure or high velocity systems.
7.2.4 Continue flushing operations until the chemistry analysis results meets the required acceptance criteria at the sample locations -
specified in the plan. Signify satisfactory results for the j sanple points specified by the plan on Data Sheet 3.
f l Note i Chemistry analysis is not requir-ed on systems specified in Table I as cleanliness level 3, 4 or 5.
7.3 Records ,
7.3.1 During the cleaning activity, all significant events, major evolutions and modifications to the System Cleanliness Plan shall be recorded by the STE on Data Sheet 2, Cleanliness Verification Log. (i.e., completion of a flush path).
7.3.2 Upon completion of the flushing activity, the STE shall assemble a system cleanliness package that contains the following at a
(} minimun:
Ii i a. Data Sheet 1 - System Cleanliness Plan Cover Sheet
- b. System Cleanliness Plan
,, c. Data Sheet 2 - Cleanliness Verification Log i d. Data Sheet 3 - System Cleanliness Results Sheet
- e. Chemistry Analysis Results Sheets ll -
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XCP-ME-4 Revicien 5
. . Page 12 of 18 TABLE I System Cleanliness Level Requirements FLUSHING REQUIRED SYSTEM FLUID CLEANLINESS LEVEL
- Auxiliary Feedwater B 2 Auxiliary Steam B/ Steam 2 h
'l Boron Recycle A 1 Chemical Feed 2
' FOR INFO Chemical and Volume Control A ONLY 1
- { Chilled Water B 2 Circulating Water' D 3*
i Component Cooling Water B 2 Condensate B 2 -
Condensate Polishing B 2 l
l i Condenser Vacuum & Water Box Priming Pump B 2 i Vacuum D 3*
Containment Spray A/ Gas 1 Demineralized & Reactor Make-Up Water A 1 4 Diesel Generator Fuel Oil System 011 2 Diesel Generator Starting Air Air + 2 d
Diesel Generator Intake, Exhaust & Crankcase Air Air + 2 Diesel Generator Jacket Water B 2
,j Diesel Generator Lube 011 011 2 j Extraction Steam B 2 i Fire Protection D 3*
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- Flushing Acceptance Criteria established by paragraph 2.3.2.b l +As obtained from the System's Compressor
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- - XCP-ME-4
- Revision 5 Page 13 of 18 TABLE I (Cont'd)
. 1 Caseous Waste Processing- Cas 2 Cas 2 Cenerator Cas Supply Cenerator Primary Water Supply A 1 Generator Seal Oil Supply 011 5 B 2
- Heater Drains t
Instrument Air Gas I h Liquid Waste Processing - Reactor Coolant Drain Tank A 1 FOR INFO 3 B
Liquid Waste Processing - Drain Channel A - to evaporator OM Drain Channel A - from evaporator B 2 i
i B 3
! Liquid Waste Processing - Drain Channel B - to evaporator ,
i Drain Channel B - from evaporator B 2 Liquid Waste Processing - Drain Channel C - to R.O. Unic B 3 '
Drain Channel C - from R.O. Unit B 2 t' 3 l
Liquid Waste Processing - Evaporator Bottom and Spent Resin Lines B 1 - 2 j Main Steam Hot & Cold Reheat i
Main Steam Reheat & Steam Dump B 2 Process Sampling - CVCS VCT Sample Gas 1
- Steam Generator Blowdown Sample B 2
! - Remainder A 1 Cas 2 Plant Cas - CO2 Cas 1 Plant Cas - H2
'l Cas 1 Plant Cas - N2 i
Cas 1 f Plant Cas - 02 Reactor Coolant A 1 Residual Heat Removal A 1 l
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- Flushing Acceptance Criteria established by paragraph 2.3.2.b i +As obtained from the System's Compressor .
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XCP-ME-4
- , Revision 5 Page 14 of 18 TABLE I (Cont'd)
Safety Injection A 1 Secondary Sampling B 2 l l
Service Air Air + 2 Spent Fuel Pool Cooling & Cleanup B 2 Station Service Water D E -3*
(
i FOR INFO
'I Steam Generator Blowdown Cleanup B ONLY :
4 l Steam Generator Feedwater B 2 Turbine / Generator Lube 011 011 5 Turbine Control Fluid Oil 4
- ! Turbine Gland Steam System B/ Steam 2
[
Turbine Oil Purification oil 5 Turbine Plant Cooling Water B 3 Vents & Drains
- a. Containment Safeguards Auxiliary & Fuel Building D 3*
- b. hrbine Building Floor Drains D 3*
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- c. All drains to Atmospheric Drain Tank and Main and Auxiliary Condenser B ,2 Water Treatment Systems (@ effluent to DWST) A 1 Component External Lube Oil Systems - If' cleaning is required, the cleanliness
- level shall be established by the STE 1 based on applicable guidelines in vendor technical manuals. The flushing medium
'; will be oil.
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- Flushing Acceptance Criteria established by paragraph 2.3.2.b
+As obtained from the System's Compressor t
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TABLE II XCP-ME-4 )
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FLUSHING MEDIUM CRITERIA Page 15 of 18 !
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WATER GRADE A B C D Chloride ion, maximum ppm as Cl- 0.15 1.0 30 ---
- 2.0 Fluoride maximum ppa. as F1- 0.15 0.15 ---
j 2.0 20 700 ---
, Conductivity, maximum micromhos/cm Silica, maximum ppa as SiO2 .05 0.10 --- ---
Total solids ppm maximum 0.5 - -
,i i pH range 6.0-8.0 6.0-8.0 - -
Visual clarity No turbidity, oil or sediment. (For A, l B & C water) 8 Notes
?
- 1. Demineralized water normally meets the requirements for Grade A water. Where water has been subjected to possible CO2 absorption, such as when retained ,
' in storage tanks, the pH requirement may be lowered i to 5.8 to compensate for CO2 pickup.
- 2. Power plant consensata normally meet the require l
ments for Grade B water. -- --
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' EOR INFO
- 3. Potable tap water normally meets the requirement -- ONLy for Grade C water. _____1
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- 4. Grade D is Squaw Creek reservoir water.
OIL 1
Oil flushes will use the type of oil specified by vendor's instructions or a TUGC0 approved equivalent.
AIR / GAS j When gas is specified as the flushing fluid in Table I, it shall be clean, dry, filtered air or gas, free of oil vapor and droplets. Air or gas shall be filtered through filters rated at 10 micron removal capacity before use for flushing. Plant instrument air shall be generally used for this purpose. Air systems (i.e. , service air) shall use air as supplied by the system compressor for the flushing medium.
STEAM li When steam is specified as the flushing fluid, it shall be as obtained from the plant 4 auxiliary boiler.
5 APPROVED SOLVENTS i
If Acetone - New or redistilled, Technical grade Alcohol - Isopropyl, Technical grade l
Distilled Petroleum Spirits - Stoddards solvent, Varsol .
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DATA SHEET 1 XCP-ME-4 Revision 5 Page 16 of 18 System Cleanliness Plan Cover Sheet i System / Component:
1 _
! Plan No. FP _
EORINFo t ONLY
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Cleanliness Level
.I 1
Prepared By: Approved By: Date:
System Test Engineer *
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Applicable Prerequisites of XCP-ME-4 and -
this plan are complete: Date:
. System Test Engineer
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l Cleanliness Results: SAT UNSAT Date:
System Test Engineer .
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') Results Approved By: Date:
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, < XCP-ME-4 i . DATA S!!EET 2 Revision 5 System Cleanliness Log Date/ Time STE Activity 1
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DATA SHEET 3 Revision 5
, Page 18 of 18 System Cleanliness Results Sheet Component Satisfactory Results of
, Inspected / Visual Particulate Chemistry enalysis Sample Examination Sample Witness * (Attach Results)
. Point i
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i ll *!!ame and date of person that witnessed or performed independent verification of l visual examination or particulate sampling.
Satisfactory results of cleanliness verification shall be indicated by signature and l date of the person who performed the verification for the particular sample point or' l4 l component. Chemistry analysis results shall be reviewed, determined acceptable and attached prior to signature.
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\NDEXED l"f'A'EA~*2 .f"-lAl .
-. ATTACHMENT 10 DATE:
- hCUMENTATION CHECK LIST PACKAGE MARK NO. S F - ><- Fg-f_ 7 F4j - //
NUMBER OF PAGES TYPE OF 00CUMENT
- 1. ^- 4 Manufacturing Record Sheet (MRS) t
- 3. f Weld Filler Material Log (WFML)
- 4. e- A Material Identification Log (MIL) ,
i 5.
I Non-Destructive Examination Report (NDER)
' 6. Inspection Report (IR)
- 7. Nonconformance Report (NCR)
F
- 8. Vendor Documentation Jf I RMATIOly _~
- 9. Repair Process Sheet (RPS) 'le 5
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l 10. Operation Traveler (OT)
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- 11. Drawing (IncludingCMC)
- 12. I/ Material Requisition (MR) - PPR/
- 13. f Miscellaneous (Describe Below)
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The contents of this package as listed above have been reviewed per the !
requirements of CP-QAP-18.2 and are acceptable.
QC Superintendent ^/
'* / I Date
' ORG Representative M 8 _- _
Date I//Zf/R2
' 3 Total Number of ages in Package ANI //A FO A-85-59 K-3s3 x .- _ ._._ _ _. ._ _
- i. ,
,,- Hm0P.1 & ROOT, INC.
WDC S: rial No. i'/ h8 '
! ~ . CESE5'J08 # 35-1195 e
WELD DATA CARD Orawing No. ff r-/*& 27 .T Weld No. /'WM
- WPS # REV#/ICN# FABRICATION CODE &
Pr- O CLASS /ACC. STD.
f4 u u-x-1I-4'//r- 1 &,,ei 4
Asuc 111 y . %ti /
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FOSTWELD HEAT TREATM kh>E.MATERI 3 c.5" ,,y,,,,,,
4- Hrs. , TEMP. f F
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TIME L RCiYW nrwAva PCia7.,-n:wn -% p---w-n 0 -
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. Ts0-82495 TEXAS UTILITIES GENERATING COMPANY OFFICE MEMORANDUM Distribution June 23, 1982
., To Gen Rose. Texas g Interim Change to XCP-ME-4 t '
System Cleanliness Verification FOR INFO ONLy' This interim change supersedes the changes issued under TNO-82319. m l
The acceptance criteria for cleanliness level 1 and 2 effluent flush water requires i the pH to be between 6.0 and 8.0. The flushing medium pH as described in Table II, note 1, can be relaxed to between 5.8 and 8.0.
i Upon review of Westinghouse specification.292722 revision 9, dated April 27, 1979 I and letter TBX-M-756; the pH requirements for cleanliness level 1 and 2 acceptance I criteria and flushing medium criteria (Table II) for water grades A and B can be re-laxed to 5.5 to 8.0 due to CO2 absorption, subject to the following condition:
- 1. The water in the storage tank from which the flush water is drawn must .
have a maximum conductivity of 1.0 micromhos/cm.
A note to this.effect will be added to the acceptance criteria of the procedure for cleanliness levels 1 and 2 at the next procedure revision. A copy of the revised Table II of XCP-ME-4 is attached.
( , M r
J. C. K kendall Z
JCK/ GDS /TPM/jb Distribution:
I J. C. Kuykendall, IL, 1A M. G. Eidson, IL, lA C. M. ?uffer, IL, 1A R. E. Camp, IL, IA S. M. Franks, IL. 1A A. D. Quam, IL, lA
' R. L. Moller, IL, IA E. L. Gastinel, IL, lA G. F. Riggio, IL, lA R. G. Tolson, IL, IA M. S. Harris, IL, IA D. F. Rohrer, IL, IA R. Franks, IL, 1A K. E. Hemmila, IL, 1A R. B. Russom, IL, lA D. E. Deviney, IL, 1A J. G. Hennessy, IL, IA J. C. Sanders, IL, 1A W. E. Stone, IL, IA T. E. Hodge, IL, 1A G. C. Sandlin, IL, IA R. G. Taylor, IL, 1A C. R. Horne, IL, 1A S. L. Siebenaler, IL, 1A C. E. Scott, IL, IA T. L..Hutson,,1L, 1A G. D. Smith, IL, 1A M. J. Riggs, IL, lA A. S. Jamar, IL, 1A M. G. Smith, IL, 1A T. P. Miller, IL, 1A R. G. Johansen, IL, 1A F. R. Stough, IL, IA G. L. Kunkle, IL, IA B. W. Kaulfus, IL, IA I. M. Thomson, IL, 1A M. J. Michalka, IL, IA J. G. Kilpatrick, IL, IA J. A. VanGulik, IL, 1A
- Shif t Supervisor's Office, H. A. Lancaster, IL, IA .W. J. Weis, IL, 1A (Control Room), IL, IA A. C. Lilly, IL, IA J. E. Wooten, IL, 1A D. B. Allen, IL, 1A D. A. London, IL, 2A J. C. Zimmerman, IL, 1A C. D. Beach, IL, 1A D. L. McKibbin, IL, 1A ARMS S. J. Berra, IL, IA D. L. Marston, IL, IA P. N. Boozer, IL, IA J. L. Martin, IL, IA D. R. Bowles, IL, 1A D. E. Mayer, IL, 1A J. K. Newton, IL, IA
( D.
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. TNO-82682 / TEXAS UTILITIES GENERATING COMPANY OFFICE MEMORANDUM
!I C ,
l TO Distribution Glen Rose, Texas August 17, 1982 i
l i Interim Change to XCP-ME-4 SUMECT
! Revision 5 7 _
i Change paragraph 4.1.7 to read as follows: EOR INFO ,
.ONLY
.l 4.1.7 Drawing - applicable drawing marked to show flush flow' paths ano
.j boundaries.
1 Note "For Information Only" drawings
-I may be used.
1 4.1.7.1 Verify that all DCA's outstanding against the drawings are
(
listed on the drawings. DCA's shall be used during testing
,j as follows:
'! A. The DCA's that affect the component system to be tested may be drawn-in on the af fected drawing using RED for addi-(
tions and GREEN for deletions and highlighted during -
testing, or Note The design change number (DCA, CMC, etc.) shall be indicated j beside changes that are drawn in on drawing.
B. The DCA's may be highlighted during testing and attached to the drawing.
Change made to address concern identified in DSR-82-004. ,
t
// V J C. uykendall JCK/CDS/HAL/jb Distribution: (See attached page) l og_RO
.. .. ... . .- - w . _ .
FI . . ,
r _. _m-;g. w. .- s.
[ - - - - - - --
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TNo-82682 Page 2 f EOR INFO ONLY f Distribution:
J. C. Kuykendall, IL,1 A S. M. Franks, IL, IA G. F. Riggio, IL, 1A
- R. E. Camp, IL, IA E. L. Castinel, IL, IA D. F. Rohrer, IL, IA I R. L. Moller, IL, 1A M. S. Harris, IL, IA R. B. Russom, IL, IA
'l R. G. Tolson, IL, IA K. E. Hemmila, IL, 1A J. C. Sanders, IL, 1A R. Franks, IL, 1A J. G. Hennessy, IL, 1A G. C. Sandlin, IL, IA D. E. Deviney, IL, 1A T. E. Hodge, IL, IA S. L. Siebenaler, IL, 1A W. E. Stone, IL, IA C. R. Horne, IL, 1A G. D. Smith, IL, 1A R. G. Taylor, IL,1A T. L. Hutson, IL, 1A M. G. Smith, IL, 1A f C. E. Scott, IL, IA A. S. Jamar, IL, 1A F. R. Stough, IL, IA jl M. J. Riggs, IL,1A R. G. Johansen, IL, IA 1. M. Thomson, IL, 1A T. P. Miller, IL, IA B. W. Kaulfus, IL, 1A J. A. Van Gulik, IL, 1A j C. H. Welch, IL, IA J. G. Kilpatrick, IL, IA D. J. Weis, IL, IA
'j-M. J. Michalka, IL, 1A H. A. Lancaster, IL, 1A J. E. Wooten, IL, 1A *
. stf t Supervisor's Of fice, A. C. Lilly, IL, IA J. C. Zimmerman, IL, 1A (Control Room), IL, I A D. A. London, IL, 2A ARMS D. B. Allen,11, IA D. L. McKibbin, IL, 1A C. D. Beach,' IL, IA D. L. Marston, IL, 1A S. J. Barra, IL, IA D. E. Mayer. IL, 1A P. N. Boozer, IL, IA J. K. Newton, IL, IA D. E. Bradley, IL, IA P. E. Olson, IL, IA *
(
J. Cardoza, IL, 1A M. D. Phalen, IL, 1A l %. J. Cheatheam, IL, 1A L. A. Porter, IL, 1A M. S. Clark, IL, IA J. C. Prevo, IL, 1A J. H. Collins, IL, 1A C. M. Puffer, IL, 1A M. G. Eidson, IL, 1A A. D. Quam, IL, 1A I have received and inserted the above material in Manual No.
i Name/Date i
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- DATA SilEET 1 Revision 5 i *'[
- Z7611 Page 16 of 18 l
1
(
Systen Cleanliness Plan Cover Sheet l -
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' System / Component:
Sprarf' vin L R'cL. t' col /g d Ct.GWU9 W57FA4 i
1 Plan No. FP M7 _ .- o5 l ,
Cleanliness 1, eve 1 69.AD6' S 4 4 Vd"2 %
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',* DATA SilEET 3 Ravision 5
. Page 18 of 13
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O Satisfactory results of cleanliness verification shall be indicated by signature and date of the person who perforned the verification for the particular sample point or j component. Chemistry analysis results shall be reviewed, determined acceptable and attached prior to signature.
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NONCONFORMANCE ' REPORT (NCR)
. M-83-00154S Rev. 1 UNIT STRUCTURE / SYSTEM ITEM / COMPONENT TAG /lO NUMBER Light Pole P P1, P2, P3' LOCATION OR ELEVATION RIR NO.
1&X 4901 Fuel Building Assemble { {5,PSA,P2A Elev. 860' N/A NONCONFORMING CONDITION Reference document requires that the fuel pool cooling and cleanup system be a cleanliness classification W. Cleanliness classification W acceptance standard is
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o Cleanliness inspection was performed on two light pole assemblies in the transfer e canal and the following was revealed:
a.
e There are metal chips on the inside of the two light pole assemblies which were used y as a sample inspection of this type.
e o Hold tags applied (4 in Fuel Bldg.)
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REFERENCE DOCUVENT. CP-CPM-6.9H Supplerrent 1 0
- REV pan, 2.0 REPORTED BY:
DATE:
George Willis/Randall D. Smith 1/ 13 83 .
f OE REVIEW / APPROVAL: . .
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DEPARTMENT
.1 R Conrge/riccingar Fngineering
, DISPOSITION:
} REWORK REPAIR XXX USE AS IS SCRAP i
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M-83-013015 ;
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STRUCTURE / SYSTEM Meg
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pf,pf,g$a,P2a p3 pg P , Elev 860' N/A NONCONFORMING CONolTION Reference document requires that the fuel pool cooling and cleanup system be a a cleanliness classification E. Cleanliness cladsification E acceptance standard
, W is that no contaminants shall be evidenced under visual examination.
E 8 Cleanliness inspection was performed on two light' pole assemblies in the transfer canal, and the following was revealed:
4 e There are metal chips on the inside of the two light pole assemblies which were !
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No hold tags applied (see comments).
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' CP-CPM-6.9H Supplement 1 REv 0 ,,,, 2.0 REFERENCE DOCUMENT:
REPORTEo BY: oATE: .,
Randall D. Smith 5 ,10 ,83 ,-
OE REVIEW / APPROVAL; / OATE:
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REWOAK REPAIR XXX UsE AS IS SCRAP
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M-83-013015 s.
i M UNIT STRUCTURE / SYSTEM ITEM / COMPONENT T 10 LOCATION OR ELEVATION p 8g RIR NO.
P$ Pha, P2a Elev. 860' N/A T 901 bl ,
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NONCONFORMING CONDITION '
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CP-CPM-6.9H, Supplement 1
- REFERENCE DOCUMENT. pg, 0 ,,,, 2.0 REPORTED BY: DATE: ,
,j Randall D. Smith 5 fl0 83. f -
l OE REVIEW / APPROVAL:
li w o ACTION ADORESSEE WMi acoto n DATE:
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'r MAR 2 81933 In Reply Refer To:
0 :kets: 50-445/83-C' 50-446/83-01 d
Texas Utilities Generating Company ATTN:
R. J. Gary, Executive Vice President & General Manager i
2001 Bryan Tower '
Dallas, Texas 75201 r Gentlemen:
I ~
This refers to the inspection conducted under the Re of October 1982 through February 1983 of activities authorized by NRC ;
Construction Permits CPPR-126 and CPPR-127 for the Comanche Peak facility, Units I and 2, and to the discussion of our findings with you and other -
members of your staff at the conclusion of the inspection.
Areas examined during the inspection and our findings are discusse enclosed inspection report. selective examination of procedures and represen a
{ with personnel, and observations b( the inspector.
During this inspection, it was found that certain of your activities i wereCon 2.201
- I in violation of NRC requirements.
, to this violation, in writing, in accordance with the provi Your response should be based on the specifics contained in the Notice of j' Violation enclosed with this letter.
i In accordance with 10 CFR 2.790(a), a copy of this letter and the enclosures will be placed in the NRC Public Document Room unless you notify this office, I,
j by telephone,Such within 10 days of the date of this letter, application must be consistent with the date of this letter.
!' requirements of 2.790(b)(1).
m
'i D/ES H M DRRP&ER/RIV SRI ,. h RPS- RPB1 EJohnson JGagl'iWdo GMads'en Riay r m TWesterman 3/ '/83 3/ ./8S]
3/ /53 3/ /83 3//(./83
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1 2
Texas Jtilities Generattr4 MAR 2 81983 Cem:any 1
Shoule you have any ouestions concerning this inspection, we will be pleased to discuss tnem with you.
Sincerely, "Ori-inal Signed be
- c. L. MAOSEN"
.G. L. Madsen, Chief Reactor Project Branch 1 i
Enclosures:
j- 1. Appendix A - Notice of Violation .-:f Appendix B - NRC Inspection Report 50-445/83-03 1 2. 50-446/83-01 -_-
cc w/encls: .
Texas Utilities Generating Company ATTN: H. C. Schmidt, Project Manager -
2001 Bryan Tower Dallas, Texas 75201 ..
i bec to DMB (IE01)
.)
bec distrib. by RIV:
RPB2 Resident Inspector 4
Section Chief l TPB E. Johnson MIS SYSTEM
- RIV File Br. Reading File
' RIV Reading File RA C. Wisner M. Rothschild, ELD TEXAS STATE DEPT. OF HEALTH Juanita Ellis David Preister q'
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l APP.ENDIX A NOTICE OF VIOLATION 1, Docket: 50-445/83-03 Texas Utilities Generating Company 50-446/83-01 j
Comanc!e Peak Steam E1'ectric Station Permits: CPPR-126
' CPPR-127 i
i i i d of Based on the results of an NRC inspection conducted NRCduring Enforcement the per o October 1982 through February 1983, and in accordance 1982, withthe the Policy (10 CFR Part 2. Appendix C), 47 FR 9987, dated March 9, following violation was identified: i d .
Failure to Implement a Quality Assurance Procram for the Fabricat lies _
.4 o i
Installation of Electrical Underwater Floodlicant 11oht shallPole Asse
~
the ]7
- Criterion II .of Appendix 8 to 10 CFR 50 ide control t ms, and requires over tha quality assurance program and that the program shall prov 7 l
activities components.
affecting quality of the identified structures, the . sys e NRC Regulatory Guide 1.29 which in' paragraphs 2tsand whose 4 require "'
' applicant to identify those structures, systems, and componen ) but whose ified in
] continued function is not required (in a design bas
]-
other paragraphs to an unacceptable level.
i has t tion Contrary to the above, the Senior Resident Poles" Inspe q activities and review of design drawings that groupi of devices l t ry
'i collectively identified as " Electrical Underwater Floodlight ce ngwer 1 (Drawing 2323-EL-0925-02)
Guide 1.29 and were not included within the ifcensee's Quality Assur Program. Mechanical failure of the devices in a seismic t event l damage fuel during reactor core installation activities l failureor in the spen
, fuel storage pools, although the possibility of such tmechanica due to
, of the pole assembly resulting in damaging fuel is very remo e the design of upper and lower pole retention devices.
(Supplement II.D.)
This is a Severity Level V Violation.
4 ting Company h date of li Pursuant to the provisions of 10 CFR including: 2.201, (1) the Texas this Notice, a written statement or explanation in reply, d (2) corrective corrective steps which have been taken and the results achieve ;(3) the d steps which will be taken to avoid further violations; andConsideration may full compliance will be achieved.
your response' time for good cause shown.
MAR 2 g 1993 Eg' f& O ')
Dated: ty m %
Y, M:es *3 ,
v.
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APPENDIX E U. S. NUCLEAR REGULATORY COMMISSION REGION IV Report: 50-445/23-03 50-446/53-01 Category: A2 Dockets: 50-445; 50-446 i
l Texas Utilities Generating Company-(TUGCO)
Licensee:
' 2001 Bryan Tower Dallas, Texas 75201 Facility Name: Comanche Peak, Units 1 and 2 Comanche Peak Steam Electric Station (CPSES), Glen Rose, Texas .
Inspection At:
October 1982 through February 1983, Inspection Conducted: M.
In'spector: s Date *
/ R. G. Taylor, Senior" Resident Inspector-l
- Construction .
erw s' _
Date
/6h2 Approved:
'T. FY W(sterman, Chief '
., Reactor Project Section A .
Insoection Summary 50-445/83-03; Insoection Conducted October 1982 Through February 1983 (Recort
50-446/83-011
- l' Routine and special inspection, announced by the Senior Areas Insoectedi Resicent Inspector-Construction (SRIC) including f acility tours, t investiga
- of allegations, participation and assistance to the Construction Assessmen The inspection
'! Team Inspection, and other inspection related activities.
t involved 263 inspector-hours by one NRC inspector.
,l ii Within the areas inspected, one violation was identified (failure to Results:
l; implement a QA program for fabrication and installation of underwat Ij poles.)
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Details i
t 1 1. Persons Contacted Principal Licens_ee Personnel l
R. G. Tolson, Site Quality Assurance Supervisor
- 0. N. Chapman, Quality Assurance Manager j
- 8. R. Clements, Vice-President, Nuclear
! J. T. Merritt, Manager of StartupJ. B. George, Vice President an <
( 3
~
i Other Personnel 1 &R)
G. R. Purdy., Project Quality Assurance Manager, Brown & Root "{ (
D. Frankum, Construction Project Manager, B&R l during :
i The SRIC also interviewed other licensee and contractor personne the inspection period. },
2.
Licensee Action on Previous Inspection Findings _ Building Quality of Unit 1 Reactor
'l (Closed)
Dome Concrete.
Unresolved Item (50-445/79-24)This t building dome trolor was item rel f that a small amount of concrete placed on the Uniti 1 reac during adequate.
a rain storm without appropriate controls table. The by qua e additional j
.; testing program had indicated that the material wa i l assurance was judged to be required. structural it is judged acceptance l
- attention directed to the repair area.anomolies were identified
.! that the concrete is of adequate quality.
Desi gn of the AC
{ h (Closed) Unresolved Item (50-445/80-20; 50-446/80-20)
! Instrument Distribution Panels. , This itemi linvolved compliance t in a finding th
,1 segregation of safety and nonsafety wiring in the panels was no accordance with Regulatory Guide 1.75 but was 15.' in essent After discus-a l trical I with .the panel design displayed by FSAR developed. Figure 8.
l engineering group, a method of correcting the matter was d of j
I FSAR Figure 8.3-15 was revised by Amendment 2 correction.
of the four panels involved and had no further questions.
Control of Stainless l
l (Closed) Unresolved Item (50-445/81-14; 50-446/81-14)T Weld Repairs.
f repairs controlled program for the control of the nurnber and extent'o
- J n- - _-n _ -- n --.. ,
31 %
=i made to weld joints in stainless steel pipe had become less well con-ll The licensee revised Construction trolled due to personnel changes. Procedure CP-CPM-6.9D The engineering controls were to reflect prope and QC actions effective in January 1982.
promulgated 1982.
effective with the issuance of Procedure CP j.
being complied with and therefore, has no further questions, f
3.
Action on Licensee Identified Design / Construction Deficiencies if On September 10, 1982, 1 (Closed) Over-Torqueing of Safety Relief Valves.the It was reported licensee i i
- j under the purview of 10 CFR 50.55(e) had been It wasidentified
.4 torquaing to stop leaks during the main steam hydrostati -
instances and that some of the valves appeared to have the valve stems y bent out of. tolerance. By letter dated November 10, 1982, the licensee informed the NRC that after review, the matter was not considered formally .
reportable under the regulation. The SRIC has reviewed the documentation
,} The examination did not l of the examination of the valves by the licensee. .
it reveal any significant damage had occurred to any of the valves that would ,
l have prevented the Some valves from lifting under pressure which would satisfy of the valves may have leaked under operating -
the safety function. The SRIC
,: conditions which would be undesireable but not a safety hazard.
>j had no further questions on this matter.
H Allegations By Dennis K. Culton 4:
Mr. Dennis K. Culton made a limited public On September 16, 1982, His matter of TUGCO's application for an operating 5551 licens j'
lf i ,
statement during the appearance appears inBased through 5555.
the upon hearinga tran statement which appears in the record at 5556 through 5559.
review of the record, NRC Region IV determined that there were two areas of interest that should be evaluated for their validity and effect of
>I The first area dealt with the potential misuse safety of construction.
of a group of drawings referred to as BRHL while the second The SRICdealtwas with th alleged splicing of safety-related or "Q" electrical cables.
assigned to make the evaluation.
- 5. Allegation Relative to BRHL's Mr. Culton's concern in this area appears at Tr. 5552 through 5554 and i: 5557 through 5558. His concerns can be summarized as follows:
(a)
Based upon limited information, he was directed to generate isometric
! drawings giving support locations. 'He states at 5557 that he did not j
l' feel qualified to do this work in the manner directed.
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g The drawings that he and others in this group generated were released (b) to the field. unapproved and were used by the craf t labor personnel to locate and' instal) supports.
A BRHL is' an isometric drawing made from a modified piping installation isometric drawing to identify the supports on the pipe andThe to drawing provide locational information at an appropriate point in time.
series has no unique title with the BRHL appearing only before the drawing number to distinguish it from the parent pipe isometric which carries the same number except for its unique prefix, BRP.
-} Discussions with various licensee personnel who are familiar with the history of the development of the BRHL's indicate that the need to gen- -
erate the drawings became apparent when planning was initiated for The the
[ as-build verification program as required by NRC IE Bulletin 79-14. (
very early phase of the work appears to have started at about the same _
time that Mr. Culton was assigned to the drafting department and it is 3~
l understood.that he and others were hired and/or recruited from th 1 abor forces specifica11y for the effort. -
t
' As an aid to further understanding this matter, it is also necess'ary to
- understand the type of information that appears on individual support !.
drawings. These drawings, which carry a prefix BRH and an entirely f
? different number scheme, provide, in addition to the design details.of the I
The plan type information is provided Within theby a ses11 square, there squ four notations indicating building column lines.
is usually a dimensional figure in feet and inches from one or more of The support elevation information is furnished on the the column lines.
main face of the drawing where the elevation The use of of thethis pipe system andrequires the building
,' structure, as appropriate, are shown.
either a substantial degree of familiarity with the various buildings and their column line grids, or ready reference to a set of the architectural layout drawings which clearly show Ma column line grids.
It can no longer be establiNo %M exactly what information An interview was with given theto Mr. Culton for his use in gn< lg , the drawings.
one remaining person still in the Eginal group when Mr. Culton worked i '
there, indicated that the package contained a piping isometric and the individual support drawings along with any of their outstandingThe change pipe fl
'4 documentation (CMC) that changed the locational information.
j isometric was reproduced such that information relative to pipe instal-1 This would include deletion of weld joint data and i lation was deleted. The remaining information was the isometric line the bill of materials. detail, location data (again The modified in the form ofwere
, isometrics column thenlines and i
and* reference to connecting isometrics.
! annotated with a symbol that was to depict the approximate location The locationof supports and a support number was assigned to each symbol.
of a given support appears to have been estimated from the support drawing
' using the building column lines, elevations, and the piping isometric The dimensions that still remained on the drawing after modification.
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5 early BRHL drawings did not give any dimensional Subsequent- in tion and account' ability only" in the drawing approval show dimensions for support locations.
provide verified support locations, at which time the individual According to support O drawings are revised to delete the location information. L j the present supervisor of the central document control center, the BRH j drawings have never been routinely distributed to any of The the possible drawings U user organizations such as the support installations crews. ld be J were only available on an individual requisition basis which wou The BRHL
.I d stamped "For Information TheOnly" only use when of the BRHL given by other to the requ ,
j the final as-built stress analysis. ,
D than the stress analysis groups presently occurs when a support This arises has to ze be modified after the initial as-built verification effort. 2r
. by reason of the deletion of the support location infor '-
l: in order to find the support in the facility. ;
on a limited basis and is treated on a case basis by the support instal-ir 1ation group and the document control center. .
- . In regard to Mr. Culton's two major concerns in this area, the SRIC was ?
, able to locate a few of the early BRHL drawings which carry the initials
- ' "DKC" block.
in either the draftsman identification block or in t The SRIC can only conclude that men indicate no significant differences. Given the j i Mr. Culton was as competent as theMr. other Culton's people statement in the g l 1evel of competency appears to have been adequate.
l that the drawings were released unapproved for use by the First,construction the forces has been shown to be incorrect in two different ways.
j original issues were provided to the document control centerl"for filing
- with the note " issued for hanger identification and accountability on y
- 1
- ! on face of each drawing and were approved in the apprcpri the drawing face.
1 control center,-were never subject to a routine distribution and were
': not readily available to the construction force who in f for them.
installation process has indicated that the support location information on the support drawing was used to install and to inspect the supports ll and that any use of the BRHL Mr. Culton's for this allegations purpose regardwas
- s 1;
If ing BRHL drawings is thus considered to be refuted.
6.
Allegation Relative to the Splicinq of Electrical Cables f
At Tr.' 5551 through 5552.and 5556 through 5557, Mr. Culton stated that had observed that "Q" electrical cables had been spliced and that these splices were in the Unit 1 spread room.
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.. before the Atomic Safety and Licensing Board, Mr. C The interview was tape recorded by a j At Tr. 5552,
- more information on the matter. i representative of the intervenor CASE in the proceedings.
Mr. Culton stated that he observed the splicing to have occurred two t me and further that there were other instances for which he had some papers.
.; During the interview, Mr. Culton also indicated that he hadh other draw available to him that would pin-point the matter and promise to make t em j
' available to the NRC, or alternatively he would provide a sketch t would provide more detail.available to the NRC any of the documents to Based on the information in the hearing record and in a transcript of th ,
interview referred to above, the SRIC initiated an investigation Cultonthat 4
attempted to determine what cables may have been 6,000involved made his observation.
9 attempting to isolate the involved cables from the other estimated {
"Q" cables in the Unit 1 spread room: ;
The cables in question are 800 or more feet
- a. At Tr. 5552 and 5556: .
I long. .
Two cables were observed to have been spliced. .
j ;
- b. At Tr. 5556:
The cables were going to a relay panel.
j c. At Tr. 5557:
The relay panel was the third one in from
- d. Interview Record, Page 3:
the aisle.
Using the above statements, the SRIC was able to narrow d by the num
] possibilities down to two cables, presumably the same two as observe 4' The basis of the analysis was as follows:
Mr. Culton.
a.
The applicant has a computerized listing of all cables for the ent facility. By arrangement with tne computer operators, the SRIC was
,- able to obtain a selected sort of the cables based on th
] identification and those in excess of 800 feet.
U; b.
The list was reviewed by the SRIC to eliminate those cables that we
[l not routed to equipment in either the cable spread room or the p
control room. A total of 42 cables were then involved.
c.
Of the 42 cables, only 5 were shown by the routing records k to be terminated in a relay panel, more correctly called relay rac s.
d d.
Of the seven relay racks, only one is the third one from an aisle a ified also has "Q" cables terminated in it, this being a cabinet R 03.ident'Of as the " BOP Auxilary Relay Rack 1" iwith Tag i
ted in this panel.
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e.
The cable pulling records indicate thatwere which the twopulled cableson January were la orginally j identified as.E0009231 and E0009240 Based on his employment records, these j and 15, 1980, respectively.
dates coincide with Mr. Culton's employment in the construction
'l labor force as an electrician, j
f.
Engineering changes subsequent to the pulls changed The change the designatio
.l of cable E0009231 tothat signifies A0009231 a previously andidentifiedE0009240 safety to SP009240.
from "E" to "A" l function had been downgraded to nonsafety to "SP" indicates with that the cable s with safety grade cables.
, the electrical circuit involved has been deemed to be no longer .
required and the cable has become a spare.
are as follows:
- Specific findings relative to cables A0009231 and SP009240 l*
- a. The SRI.C, with the assistance of two other NRC insp i I
j cable A0009231 point at which the cable entered the room until it left the tray toThe G
_l ,
pass through a conduit into the relay rack. '
- cable not examined was the approximately 17' "..
1 identified.
- had been removed from the tray
- b. The SRIC found that cable SP009240 23, 1982, in response to NCR E-82-01210 The system on or about November which stated that certain tray sections were overfilled.
^
engineering solutionThe was to remove removal was through several the tray cables systemthat but been spa other design changes.
7 1 eft the cable in the conduit entrance to the relay rack, a
'l'+ approximately 17'.in a storage yard and visually examined the entire 4 .
anomalies identified.
General findings and considerations:
<l a.
Project Specification ES-100 " Electrical Erection" does not total
prohibit Mr. Culton.
the splicing of safety-related cables as indica f the engineer's direction and this has been done by the use oIt sh 9
i engineered junction boxes.(IEEE) do not prohibit field run splic
qualified.
f
- b. There have been a number of instances whe manufacture or during installation. d by i
p11shed under a standard repair procedure, EEI-13, whe the site engineers.One of the methods utili::es heat shrinkable plastic d of the procedure.
, tubing when the damaged area is not prohibitively far from the en 1!
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'I . 8 the cable and thus allows the tubing to slip down the cable. The other procedure which was much more generally used early in 1980 involved the.use of a fire resistant tape wrapped in half-laps over
the damaged area. The former procedure produces a very neat slim it appearance while the~1atter procedure is relatively bulkly and might well appear to be a splice. A number of both types of these repairs
,j-were identified during the examination of the specific cables discussed above and during an earlier more extensive examination of ll several tray runs in the spread room. All of these anomalies were i
judged by the NRC inspector to be jacket repairs.
- c. The SRIC believes that yet another consideration may well be relevant to this matter. The consideration involves a much earlier allegation that cables had been repaired in an unauthorized manner. The allega- .
tion was received by the SRIC sometime during February 1980 from an z?
electrician assigned to the electrical cable pulling crew that had
- pulled the cable then in question and the two cables identified with
]f Mr. Culton's allegation. All three cables were pulled during early ~
to.mid-January 1980. The SRIC's recollection of the person was that he was a journeyman electrician and assisted the foreman in the detail :
supervision of the crew of about 16 men, all of whom were classified
~
as helpers except for the foreman and the journeyman. Since the electrician was sufficiently concerned to report a cable jacket ',
repair involving the use of Scotch 33 tape rather than the approved ;
il tape, it seems to follow that he would have also reported an actual cable splice for which there is no approved repair. Given the electrician's position with the pulling crew, it also seems unlikely that he would not have been aware of an error of a magnitude that I
would have caused such splices to be made. (For more information about the 1980 allegation and the results of the subsequent investigation, see NRC Inspection Report 50-445/80-08; 5.0-446/80-08.) ,
1
- d. Since 17 feet of each of the identified cables were not inspected by i
the NRC during the course of this special inspection, it was not possible to conclude positively that the allegation is either 4 confirmed or refuted. Notwithstanding, the inability to positively
' state that the allegation made by Mr. Culton is substantiated or refuted, the SRIC believes th't a no further action is warranted based on the following cumulative information as follows:
(1) Cable jacket repairs utilizing wrapping with a rubber tape were not and are not unusu,al.
(2) There has been no identified . reason why the splices should have been necessary. The rubber-like jackets on the cable are relatively easy to cut with even a dull edge but the wire insulation material and the wire itself are relatively hard to cut.
4
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' 9 (3) A jacket repair made with tape would be very difficult for the The inexperienced person to distinguish from an actual splice.
splice generally would have a somewhat bulkier shape and would probably be somewhat lumpy rather than smooth.
4 (4) The probability that the SRIC would have learned of such an unusual event as a splice being made to safety-related cable through contacts that had been established in the electrical crew involved.
j (5) Removal of the cable would probably cause damage to the nearly l
30 cables in each of the conduits. ,
(6) Neither of the two cables now have a safety-related function and i
I there are no requirements that prohibit the splicing of f
j nonsafety cables. f(
1 .-
A11ecations by Arvil 01111naham. Jr.
7.
An article appearing on page 13A of the Fort Worth Star-Telegram dated ;
January 7,1983, stated that Arvil ~Dillingham, Jr. had made allegations -
which were subsequently investigated first by personnel of B&R and later by personnel of TUGCO. The article stated that Mr. Dillingham was then I, charging that these investigations were a " cover-up" to hide safety J hazards at the Comanche Peak nuclear power plant. The article stated that Mr. Dillingham had been employed at the construction site as a foreman and j
was laid off weeks after he made the allegations. The article also attributes three technical type allegations directly to Mr. Oillingham.
I In summary, the technical a'11egations appearing in the article were:
(a) Mr. Dillingham apparently stated when interviewed by the writer of the article that rejected aggregate was mixed with concrete that was i
subsequently poured to form the base for the nuclear reactor. The j article stated that a Larry Witt was the B&R equipment operator i who had apparent first hand knowledge of the matter. The article also stated that Mr. Witt could not be reached for comment. .
l (b) A second allegation, that th'e article stated was never previously investigated, involved the construction of underwater lamps for the pools surrounding the reactor. Mr. Dillingham charged that he was prevented from cleaning out drill shavings from the lampposts and that these shaving could be washed into the reactor during refueling and could jam the fuel cells and could even fuse to the control rods.
(c) The third allegation dealt with a contention that holes had been improperly drill through concrete walls and the interior reinforcing
- steel. The article attributes the information to another party identified as Danny Grisso.
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The SRIC assigned to the Comanche Peak station obtained both the B&R and TUGC0 files pertaining to the investigations that were stated by the l The B&R file was found to contain an l i
newpaper article'to have occurred. undated and unsigned letter address B&R.
The letter is indicated in two different places to have been l The letter is stated in a memorandum
,! prepared by Arvil Dillingham, Jr. addressed to abygroup vice president of Feehan Mr. Dillingham B&R division to haveThe been hand delivered memorandum to Mr.August 13, 1982.
was dated The lj' I
on August 6, 1982. undated letter to Mr. Feehan contained eight violations that th stated he had observed or had knowledge of ?. hat Review had occurred of the during letter his j
period of employment at the Comanche Peak station. addressed i
!~
correlated with the allegations appearing in the newspaper article, this being the item outlinedThe in (c) above pertaining to the drilling of holes 8&R memorandum of August 13, 1982, which is a
! in the concrete walls.
report of the internal 8&R investigation of the eight violations. 5-
- I indicates that seven of the allegations were found to be either without a
~
'! basis or were not substantiated.
The remaining item was considered in l effect to have been substantiated but the corrective measures were already taken. In each case, by what is assumed to be Mr. Dillingham's signature, l The Mr. Dillingham acknowledged his satisfaction with the B&R findings. i d I,
.above memorandum indicates that a number of other people were Mr. Witt interv ewe J by the S&R investigative group, one of whom was Mr. Witt.
apparently did not confirm Mr. Dillingham's allegations but made additional allegations related to his experiences during his pastOne employment at CPSES.
'{ the same as that appearing in the summarization of the n (a).
the concrete batch plant scales by leaning on the wires connecting the
, Additionally. Mr. Witt stated concerns about a scales to the sensors.
' possibly missed hcid point during the welding of the fuel In an pool liner and internal
- that some welding had been17, done 1082, by an uncertified welder.the B&R investigators su
'i B&R memorandum dated August The B&R
! Mr. Witt's concerns and their fin'. lings relative to the concer aggregate was apparently partially substantiated but of no concern in that the aggregated pile, rather than actually The being unacceptable, simply had matter was documented on not been tested prior to use as required.
Deficiency and Disposition Report C-446 dated December 9,1976, whichIn
[
i appears as attachment A to the memorandum. hold point
, documents that no hold point was missed.
allegations, the memorandum states that the allegations were investigate 4
and found to be without basis but provides no other information.
j Personnel of TUGC0 performed a separate investigation The results of Mr.ofDillingham's d
allegations (the Feehan letter) during August of 1982.that i This investigation found that two of eight items were 4 <
September 2, 1982. substantiated with one of these being the same item th l
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Both of the substantiated allegations were by the B&R investigation.found by the investigators to have been adeouat corrective measu'res had been taken or were in progress.
10, 1982, one of the TUGC0 -
. In a separate memorandum dated Decemberinvestigators One of these docum Mr. Dillingham apparently made yet additional allegations. i allegations regarded welding done by an uncertified welder on the turb d broken generator pedestal (by implication). mentioned Mr. ht Witt who off and was buried in the main dam.
personally driven a front loader that returned dry and lumpy l cement
- had been rejected to the bin, that this cement had been subsequent d The y illingham to writer of the memorandum stated that Mr. Dillingham in turn was reported as he had encourg T ll take his concerns to the NRC.saying that he had intended on_~goin ll instead.
'! f It appears that Mr. Dillingham carried out his above stated h b t of intention
- f
!* that the above referenced newspaper article has!. ap NRC Region IV determined that the allegations in the news t j the NRC.
article should be investigated but that those made This in the Feehan decision let er and in.the telephone conversation with TUGC0 should not. lier concerns lf was based on the premise that Mr. Dillingham has had his ear satisfied except for those appearing in the article.
Regarding tne above summarized allegation (a), the SRIC establis
, Mr. Witt was no longer an employee at CPSES and furtherC established i he had relocated from the Glen Rose, Texas,. area to another state. N f
i Region I'/ personnel made several A registered attempts to contact letter, receipt requested, Mr. Witt by at his new address, to no avail. i IV as soon as was then sent to Mr. Witt requesting that he contact Reg on f possible. Iteceipt of the letter was acknowledged but as of this date,It
- Mr. Witt has not contacted the region.
{ intend te assist the NRC in investigating allegations attributed to him j It should be noted that only the B&R investigativel group failed.has been a .
- to establish contact with Mr., Wi t; all others have apparent y I Regarding summarized allegation (c , the SRIC, with assistance o -
Region IV inspector, was able to establish that the underwater i lig i
standards were fabricated in such a manner as to leave drilling ch ps It was also established that the inside and had not been removed. lightingThere standards are no were fab e
QA program which included various welding operations.
(g records of inspection or of the welders involved or yeoft- the we procedures utilized.the A/E considered the lighting standards fuel to could be within th i
should be damaged.
tne standards physically fail during the seismic eve been classified as Seismic Category II (licensee's FSAR definition fo I
)
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12 components which have no safety function but must not fail in a seismic event since such failure could jeopardize the functioning of a
- j. safety-related. component) and should hase been included in the QA program.
This is considered to be a violation of Appendix B to 10 CFR 50.
[ Regarding the premise that the drilling chips inside the standards could j
be swept into the reactor during refueling and cause an accident, the SRIC found six of the standards are normally located with their bottoms just about the floor level of the refueling pool and that the chips that might have worked their way out of the bottom of the standard could have carried The size of into the reactor at the conclusion of the refueling process.
the chips that could work their way out through the 1/2" holes are not of l
a size that could be expected to plug a water channel through the reactor core and create a hot spot. Further, the idea that the chip could fuse to i
the control rods is equally remote in that far higher temperature would be required in the core to achieve such fusion than actually will exist i
there, the differential being 600* to 800*F. Thus, the safety significance 3(
of the chips is very small. The uncontrolled (no QA) problem with the ,
l
- c standards is relatively more important since workmanship on the devices 17~
has not been established. Regarding sumamrized allegation (c), the ;
allegation has been the subject of another allegation by a person who appears to have substantially more direct knowledge of the matter than '-
indicated by Mr. Dillingham. Under these circumstances, the NRC has j',
determined that it can address the issue in a more satisfactory manner by -J
- investigating and evaluating the second party's allegation rather than Mr. Dillingham's.
' 8. Postino of NRC Form 3 10 CFR 50 was revised by 47 FR 30452 to add 10 CFR 50.7 " Employee Protec-tion." The change was published July 14, 1982, and had an" effective date l of October 12, 1982. An important element of the change was that of a 5
requirement to post NRC Form 3 at locations where the form can be Itreadily has viewed by employees on their way to or from their placeThe of work.
SRIC learned of been alleged that the licensee did not post the form.
the allegation during early January 1983 and found that the form was posted throughout the main construction administration building and on a bulletin a
board where most of craft labor f.orce can The readily SRICsee hasit, particularily i when departing from the construction area.
been informed by licensee employed personnel that they received andA posted senior B&R the manager forms in the administration building about the first of 1983.
{ indicated th'at the forms were received, he believed from B&R's Houston office, sometime between Thanksgiving and Christmas and were posted on the
[~ craft labor bulletin board near the " brass alley" well before the first of the year. It is thus clear that the forms were not posted on the It is specified effective date of the change to 10 CFR 50 as alleged.
much less clear as to when the forms were actually posted nor Theis" brass it clear that most people would even have been aware of the posting. in size with alley" bulletin board is a large board, perhaps 4' by G' many postings. The majority of theThe postings are required under various posting of an additional form probably federal statutes or regulations.
would not draw much attention from the average worker. As of the time of f
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f 13 i tractor inspection by the SRIC, the licensee and his principal in compliance with thes te con were found to have,the form posted and to be regulation.
- 9. Management Interviews The SRIC held management interviews with one or more of the person inspec-
, identified in paragraph 1 on a nearly daily basis throughout i s special the tion period to discuss NRC findings developed during var ouThe discussio inspections and investigations.
I licensee's positions on the NRC findings.
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INSFECTOR'S REPORT i Office o' hsee:: ion and Enforcement I
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. INSPECTOR'S REPORT (Continuation)
I ! ' 8 8 8 i i i iI ill!Ili lI lt liIl Il !l , O l lj ! W i R @@
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Of fice of ins;;ection and Enforcernent I l l l l l .,s.a,# J.aes to 30 enaracters esca j 1
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- Failure to Imolement a Ouality Assurance Prooram for the Fabrication and Pole Assemoiies Installation of Electrical Unoerwater Floociiont h ll
'*I Criterion II of Aopendix B to 10 CFR 50 requires that the applicant s a identify the structures, systems, and componentsi to be trol covered over by the si quality assurance program and that the program shall prov dedcon activities affecting quality of the identified structures, system
,l comoonents.
NRC Regulatory Guide 1.29 which in paragraphs 2 and 4h require se the
!' app'licant to identify those structures, systems, and comoonents w o continued function is not required (in a design basis accident) but whose
- s. _
failure could reduce the functioning of any plant feature identified in ,
](
- other paragraphs to an unacceptable level. et ! -
- n tion -
,, Contrary to the above, the Senior Res'ident Inspecto 2' i-
- activities and rev'iew of design drawings that group of devices ul ' collectively identified as " Electrical Underwater Floodlighting
~
(Drawing 2323-EL-0925-02) *
- *l Guide'1.29 and were not included within the licensee's Quality Assurance -
Mechanical failure of the devices in a seismic tevent could a i. ' Program. .
f ,]l damage fuel during reactor core installation to activities
=l of the pole assembly resulting in damaging fuel is very remote due _
_ the design of upper and lower pole retention devices.
j,l (Supplement II.D.)
mi This is a Severity Level V Violation.
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