ML20203H405

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Package of Documents Re Insp Repts 50-445/85-13 & 50-446/85-09
ML20203H405
Person / Time
Site: Comanche Peak  Luminant icon.png
Issue date: 04/04/1986
From:
NRC
To:
Shared Package
ML20203H364 List:
References
FOIA-86-36 NUDOCS 8604290489
Download: ML20203H405 (227)


See also: IR 05000445/1985013

Text

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                                              CPRT OBJECTIVITY QUESTIONNAIRE
                   1.        Kane
                                                .
                  2.         Position on CPRT
                  3.         Name of current employer
                  4.         Data this questionnaire is completed

. 5. Do you hold any stock or other securities of Texas Utilities

                             Company?                                                       .
                  6.         Have you ever been a director, officer, or employee of Texas
                             Utilities Company or any,of its subsidiaries *?
                  7.         Have you ever entered. into a contract, 'whether oral or written,
                             with Texas Utilities Company or any of its subsidiaries or with
                             another person; fira, or corporation who has acted as a contractor
                             for the Comanche Peak project other than a centract relating to
                             your involvement in the current CPkT program?

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                  8.         Would the answer to any of the above questions be "yes" if answered
by any member of your immediata fanily (father, mother, spouse,
                             son, or daughter)?
                  9.         Have you been promised any additional compensation or reward or
anything of value by anyone, contingent upon the position you take
                             on any issue being considered by you in the CPRT program?
                   10. Do you know of any reason, whether inquired about in this
                             questionnaire or not, which would affect your ability to be
                             completely objective in performing any of the tasks assigned to you
                             under the Comanche Peak CPRT program?_

! ! 11. Would the answer to any of the above questions be "yes" if answered

                             by your current employer?_
                   12. If the answer to any one or more of the above questions was "yes"
                             then please fully explain each such "yes" answer, by number, on the
                             reverse side of this questionnaire. Attach additional sheets to

[ provide further information, if necessary. l I-

   -
                                                                    Signature

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                  *          Subsidiaries of Texas Utilities Company are Texas Utilities

! ' .

                             Electric Company, which has four divisions: Texas Power & Light

!

                             Company Texas Electric Service Company, Dallas Power & Light
                             Company, and Texas Utilities Cenerating Company; Texas Utilities
                             Mining Company; Texas Utilities Fuel Company; Basic Resources Inc.;
                             and Chaco Energy Company.

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                                 B604290489 860409
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            1.     Allegation Categoryi ' Mechanical and Piping 11, Pipe Installation.
            2.     Allegation Number:    AP-4,'AP-9 and AP-13
            3.     Characterization:    It is alleged that:
                   AP-4
                   Two or three 100-ton jacks were used to " cold spring" the reactor coolant
                   syspemlines.
                                            .
                                                                         .
                   AP-9
                   A stainless steel piping spool was heated during installation to achieve
                   proper fitup. The alleger indicated that the spool piece was probably
                   nonsafety-related and probably located in the Containment Spray System.
                  ;AP-D
                   A 32-inch Main Steam line was forced into position by the polar crane and
                   3-ton come-alongs.
           4.      Assessment of Safety Significance:
                   AP-4
                   In assessing allegation AP-4, the NRC Technical Review Team (TRT) reviewed
                   the configuration of and the installation requirements for the Reactor
                   Coolant System (RCS) piping to assess whether " cold springing"* was likely
                   to be used during installation of the RCS piping. The TRT concluded that
                   the configuration and installation procedures for the RCS piping were such
                   as to preclude the need for springing of the piping.     Brown & Root (B&R)
                   Drawing BRP-RC-1-520-001, " Reactor Coolant Loops, Layout and Details,"
                   Rev.10, July 1984, showed that each loop of the RCS piping consists
                   essentially of two straight pieces of pipe, the hot and cold legs, which
                   connect the steam generator and reactor coolant pump, respectively, to the
                   reactor pressure vessel and a U-shaped crossover leg which connects the
                   steam generator to the reactor coolant pump. Additionally Westinghouse
                   Specification PSPAS-01, " Assembly, Fitting and Welding Sequence for Primary
                   Loop Piping," Rev. O, May 26, 1977, indicated that both the hot and cold
                   legs were supplied as single lengths of pipe while the crossover leg was
                   supplied in two sections and that c ch leg was installed by fabricating
                                                                                                    ,
           "The term cold springing, as used in Se' tionc   4.13 of G&H Specification 2323-MS-100,
              Rev. O, March 1, 1976 through Rev. 8, July 5, 1984, refers to a controlled process
              to reduce the effects of stresses due to thermal expansion in piping systems
              and is consistent with the use of the term in subparagraph NB-3672.8 of the
              ASME B&PVC and paragraph 119.9 of the ANSI B31.1 Power Piping standard.       The
              term springing as used in Section 4.7.6 of G&H Specification 2323-MS-100,
               Rev. O through Rev. 8 refers to the uncontrolled practice of mechanically
              deflecting piping at closure joints in piping systems to correct construction
              misalignments.
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           Comanche Peak SSER 10                      N-99
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                   all welds in the leg simultaneously. Consequently, there was no oppor-
                   tunity for misalignment and no need for springing of the piping.               f
                                                                                                   .
                   Additionally, figures 5.4-13 and 5.4-14 of the CPSES Final Safety Analysis
                   Report (FSAR) showed that the steam generator and pump in each loop were
                   supported vertically by pin-ended columns but that lateral support of the
                   steam generator and pump were provided by the attached RCS piping and
                   and auxiliary structures. Due to their method of support and the antici-
                   pated shortening of the attached piping due to weld shrinkage, measures
                  were taken to monitor and maintain the vertical positioning of the steam         &
                l generator and pump casing during hot and cold leg installation, respec-          ,
                   tively (the pump internals and motor were not installed during RCS piping             i
                   installation). TRT reviews of data packages for the welds in the Unit 1        ', ' ~
                  RCS piping indicated that vertical positioning of the steam generator was       -l
                  maintained by the use of jacks. Jacks were not employed to maintain ver-              ;
                  tical positioning of the less massive and more compact pump casing.              {
                  Based on the results of the above described reviews, the TRT believed that          '
                  the alleger mistakenly identified jacking operations for maintaining ver-           1
                  tical positioning of the steam generators during installation of the RCS
                  hot leg piping as springing.
                  The TRT also reviewed applicable specifications and construction proce-
                  dures and inspection instructions to evaluate the requirements for and the
                                                                                                               .
                 construction practices related to springing and cold springing. The re-              .
                 view determined that the requirements of all revisions of G&H Specifica-             '
                  tion 2323-MS-100 " Piping Erection Specifications," were adequate to assure
                  that springing and cold springing were controlled such that the related
                 design requirements of the ASME B&PV Code and ANSI B31.1 Standard would be          ,
                 satisfied.
                 The TRT review of B&R Procedure CP-CPM-6.9E, " Pipe Fabrication and Instal-
                  lation," determined that:     (1) cold springing was not addressed in all is-
                 sues of the procedure and (2) springing requirements were addressed
                 adequately only in Rev. 1, May 23, 1980 through Rev. 7, May 14, 1984. A
                 similar TRT review of B&R Instruction QI-QAP-11.1-26, "ASME Pipe Fabrica-
                 tion and Installation Inspections and Requirements Prior to System / Subsystem
                 N-S Certification," determined that:      (1) cold springing was not addressed
                 in all issues of the instruction and (2) springing requirements were ad-
                 dressed adequately only in Rev. 10, February 2, 1983 through Rev. 15,
                April 18, 1984.      The TRT reviews also determined that: (1) both B&R Proce-             3
                 dure CP-CPM-6.90 and B&R Instruction QI-QAP-11.1.26 used the term " cold
                 springing" to describe springing-related activities, and hence, (2) that                  i
                                                                                                               ,
                 the use of the term " cold springing" in both B&R documents was inconsis-              /      ,
                 tent with the use of the term in the G&H Specification 2323-MS-100, the             ~j
                                                                                                      .
                ASME Code, Section III and the ANSI B31.1 standard.
                                                                                                         a
                With respect to the failure of both B&R Procedure CP-CPM-6.90 and B&R In-                  i
                                                                                                             '
                 struction QI-QAP-11.1-26 to address cold springing requirements the TRT                 T
                was informed by TUEC and/or B&R Engineering, construction. and QA/QC per-
                sonnel that no piping systems had been cold sprung. Subsequent TRT dis-                  }g
                cussions with G&H piping design engineering personnel confirmed that there
                was no G&H requirement for cold springing of ,niping systems.
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            Comanche Peak SSER 10                    N-100                                      .h
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                    However, the TRT found that the failure of B&R Procedure CP-CPM-6.90 and
                    B&R Instruction QI-QAP-11.1-26 to adequately address springing require-
                    ments of G&H Specification 2323-MS-200 prior to May 1980 and February 1983,
                    respectively, and the use of the term " cold springing" in a manner which
                   was inconsistent with the use of the term in G&H Specification 2323-MS-100
                   were in noncompliance with the requirements of B&R Procedure CP-CPM-6.1,
                   " Preparation & Control of Construction Procedures & Instructions," and B&R
                    Instruction CP-QAP-6.1, "Preparetion of QA Procedures and Instructions,"
                   respectively.            B&R Procedure CP-CPM-6.1 required that the construction
                  procedures be reviewed for adequacy. Paragraph 3.4 of B&R Instruction
                  CP-QAP-6:1 required that QA Procedures and Instructions shall be reviewed
                  for technical content, Code and Regulatory requirements, grammatical cor-
                  rectness, clarity and for any conflict or redundancy with other documents.
                 In view of inadequate treatment of springing by B&R Procedure CP-CPM-6.90
                 and B&R Instruction QI-QAP-11.1-26, the TRT interviewed TUEC mechanical
                 engineering and QA/QC and B&R construction and QA/QC personnel to deter-
                mine the actual practice for springing at CPSES. Although the B&R con-
                struction and QA/QC personnel said that springing was prohibited, a TUEC
                mechanical engineering (ME) supervisor said that authorization for spring-
                 ing was permitted in all piping systems on a case-by case basis. Criteria
                for authorization were based on guidelines in an Appendix D to an uniden-
                tified Bechtel Corporation Specification 10466-M-204. (The TUEC ME super-
                visor had a copy of the Appendix only.) The TRT observed that Appendix 0
                to the Bechtel specification stated that the springing guidelines provided
               were intended to limit springing strdsses at nozzles to 1000 psi in nuclear
               and non-nuclear carbon steel and stainless steel piping in the range of
               Sch. 105 to Sch. 160. Although the use of guidelines may be acceptable
               for the installation of Comanche Peak Steam Electric Station (CPSES) piping
               systems, the TRT found that use of the Bechtel specification for installa-
               tion of piping systems at CPSES was unauthorized and undocumented. This
               was contrary to the requirements of Paragraph 33 of TUEC procedure CP-EP-4.0,
               " Design Control," Rev. 3, July 11, 1982, which required that design inputs
               on which final design were based were to be identified, documented and

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               approved on a timely basis. The inputs were also required to be detailed
              enough to provide a consistent basis for making design decisions, accom-                    .

i plishing design verification and evaluating design changes.

              During subsequent interviews with the B&R QA personnel the TRT was in-
              formed that springing in piping systems at closure joints was limited to
              cases where gaps at the joint could be closed by hand. (The TRT notes
              the discrepancy in the B&R QA/QC personnel's response.) During similar
              subsequent interviews with B&R construction personnel, a general superin-
             tendent claimed to have no knowledge of uncontrolled springing in piping
             systems.
                                      The TRT found that it was unreasonable to expect piping systems
             to be installed without some springing.
             AP-9
             During its assessment of allegation AP-9, the TRT attempted to cuntact the
             alleger on August 1, 1984, to obtain clarification and specific informa-
             tion regarding the allegation, The alleger declined to meet with the TRT.

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        Comanche Peak SSER 10                               N-101
                                                                                                            i
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       The TRT also found that the allegation had been investigated by the NRC
       Office of Investigations (01).    The results of the NRC 01 investigation,
       which included an interview with the alleger, were documented in 01 Report
       50-445/84-006, March 7, 1984.
       The TRT review of the 01 interview with the alleger found that the alleger
       had implied that: (1) the alleged heating process was permitted to achieve
       proper fitup in " normal" piping but was not permitted in stainless steel
       piping and (2) during the alleged heating process heat was applied locally
       by a " rosebud" (gas torch) at welds in the piping.                                .
           .
                                                                                          b
       The TRT found that the' Containment Spray System was a safety-related, stain-      3
       less steel piping system.    Table 6.2.2.1 and Table 6.2.2.4 of the CPSES           i
       Final Safety Analysis Report (FSAR) indicated that the Containment Spray
       System is a nuclear-safety related system and that Containment Spray Sys-
       tem piping material was to be ASME B&PVC SA-312 or SA-358 stainless steel          4
       piping. Consequently, due to the lack of identification of the stainless           i
       steel piping spool involved in the alleged incident, the complexity of the       I
       safety-related, stainless steel Containment Spray System Piping, and the          U
       large number and complexity of other safety-related and nonsafety-related
       stainless steel piping systems, TRT investigations could not substantiate
       the allegation.                                                                   I..
                                                                                        y
                                                                                         h
       Other TRT investigations found that localized heating in some carbon steel       s
       piping was permitted but not permitted in stainless steel piping. Para-           A.'
       graph 3.12 of B&R Procedure CP-CPM 6.9E, " Pipe Fabrication and Installation,"    '
       Rev. 1, July 23, 1980 through Rev. 7, May 14, 1984 required engineering            -
       approval for localized heating to obtain proper alignment during piping
       installation.    Paragraph 3.21.10 of B&R Procedure CP-CPM-6.9D, " Welding
       and Related Processes" Rev. 1, September 23, 1980 through Rev. 6,
       January 12, 1984 specified that localized heating for minor adjustments in
       alignment were permitted on a case-by-case basis as approved by the Owner
       but prohibited the use of such heating in stainless steel material or
       carbon steel piping requiring Charpy impact values.
       AP-13
       During its investigation of allegation AP-13, the TRT found that the al-
       leged incident was discussed in affidavits by the alleger submitted by
       intervenor CASE to the CPSES Atomic Safety and Licensing Board (ASLB) or.
       February 3, 1983 and November 28, 1983. The extent to which the alleger's
       allegations were open in the CPSES operating license (0L) proceeding was
       clarified by the ASLB Memorandum and Order (Clarification of Open Issues),
       March 15, 1983.                                                                   ;
                                                                                          $
       The TRT also found that the allegation had been investigated by NRC Office        i
       of Investigations (OI) and RIV. The OI investigation was documented in
       OI Report A4-83-005, May 20, 1983; OI Memorandum, " Assistance to In-              3
       spection Report No. A4-83-005," June 2, 1983; 01 Supplemental Report              e
       Q4-84-007, February 9, 1984. The 01 investigation included an interview
       with the alleger on April 14, 1983 and interviews with 27 other persons
       relating to the allegations.     The NRC RIV investigation was documented in      .
        IR 50-445/83-27, September 29, 1983 and had concluded that:
                                                                                        j.
                                                                                       }
                                                                                      1
   Comanche Peak SSER 10                  N-102
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    ,      .
                      Although B&R personnel named by [the alleger] contradicted his          '
                      allegation, the NRC inspector conducted an independent review
                      of the onsite documented records regarding this matter.                      !
                      It was observed by the NRC inspector that the specific 32-inch
                      stcam   line mentioned by [the alleger) is, Loop 1, Line number
                     MS-1-R8-001-1302-2,
                                             and the reactor building polar crane was
                      utilized   in a vertical
                     this permanent piping.
                                                lift to assist repositioning a section of
                     engineering
                        e
                                     record of theThe   licensee
                                                     specific linehas maintained a documented
                                                                   movement.     The NRC in-
                     sp' ctor noted that the movement of the line was necessary in
                     order that a large section of temporary piping (attached to the
                     steam generator feedwater nozzle and previously used for water
                     flushing) be removed and to relocate the permanent section'of
                    the main steam line that had " sagged" due to the weight of the
                    temporarily installed flushing pipe.
                                                                   The record folder contains
                    meeting notes (memorandum) which reflect discussions with Westing-
                    house (NSS Supplier) and the cognizant A/E representatives prior
                    to   the work activity, in addition to establishing engineering
                    limitations and acceptability. The line was moved on January 16,
                    1982 under the supervision of the field mechanical engineering
                   group, and was witnessed by an engineering representative who
                   observed the installation and use of the dynamometer (to regis-                 .
                   ter crane lifting loads) throughout the operation.            The lift
                                                                                                   !
                   connections
                   file.
                                    and applied forces were recorded and retained in the
                             The Itfting points were consistent with the hanger loca-
                   tions to simulate the permanent support system. The as-built
                  configuration
                  the line confirmed.was analyzed for stress and the acceptability of
                                            In addition, the recent completion of the
                  " Reactor Hot Functional Test" did not reveal any undue stress
                  conditions. This allegation cannot be substantiated.
                  No     violations or deviations were identified in this area of the
                  inspection.
          The TRT investigation of the allegation was based on the numerous claims
         by the alleger made during the OI interview on April 14, 1983, additional               '
          information obtained by the TRT during its September 19, 1984 interview
         with the alleger, and other information contained in the alleger's
         February 3,1983 and November 28, 1983 affidavits.
                                                                          Based on its reviews
         of these interviews and affidavits, the TRT found that the alleger made
         the
         line:following claims regarding the forced movement of the main steam (MS)
        1.
                The incident occurred in 1982, prior to the summer.
        2.
                The piping involved in the incident consisted of a portion of the M5

( line and an attached temporary flushing line (installation of the MS i

               line was incomplete). During the incident, the installed portion of

, l the MS line was attached at one end at the containment penetration l

for the line and attached at the other end to the temporary flushing ]

l line, which in turn was disconnected from a nozzle at the lower end of

               the steam generator.

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                                                                                                   i
   Cominche Peak SSER 10                           N-103        ,
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       3.     During disconnection of the temporary flushing line from the steam
              generator, the line vibrated about 14 inches with a loud echoing'          3
              noise audible throughout containment.
                                                                                         t
       4.     After disconnection of the temporary flushing line from the steam
              generator, it was discovered that the installed portion of the MS
              line had been placed incorrectly 6 inches vertically and 4 inches
              horizontally from its design location.
       5.     During the incident, the MS line was forced into its proper design
              location by the polar crane and 3- to 5-ton come-alongs.                    <
       6.     The force exerted by the polar crane was applied at "the expaasion
              chamber." The force was monitored by "a big round genge [that]
              look[ed] like [a] big clock."
                                                                                           '
       7.     The magnitude of the applied force was estimated to be between 40
              tons and 85 tons (The alleger stated:    "I cannot remember the exact        '
              tonage").
                                                                                            -
       8.     Four to six permanent pipe supports which had been installed prior to
              the alleged incident were redesigned to maintain the MS line in its
              forced position.
       9.     The incident was not supervised by engineering personnel.
                                                                                            1
       The alleger was concerned that " tension" induced in the MS line as a re-
       sult of movement during the alleged incident was still present in the                 .
        line.
                                                                                               :
       Based on TRT reviews of statements of the five persons interviewed by 01
       between May 1982 and January 1984 who claimed to have knowledge of the
        alleged incident, TRT interviews with B&R construction and QA/QC and TUEC              i
                                                                                               -
        engineering and QA/QC personnel, and TRT reviews of the construction records
        for the MS and Feedwater piping system, the TRT found the following
       with respect to the alleger's claims:
        1.     The alleged incident was related to the Unit 1, Loop 1 MS line, Line
               MS-1-RB-001-1303-2, and occurred in January 1982.    The date of entry          ,
               for the Unit 1, Loop 1 reading of 31,250 (1bs) on M&TE Issue Record             1
               for MTE Serial No. MTE-357 was January 16, 1982. The January 1982               {
               date was also confirmed by two persons interviewed by 01. Additionally,         f
               component modification card (CMC) 61306 Rev. 4, March 23, 1982, which           {
               documented modifications to pipe support MS-1-001-007-C72K for the Unit        4
               1, Loop 1 MS line contained the note: " Pipe was moved." RIV also              i
                                                                                              i
                                                                                                 t
                found that the alleged incident had occurred in January 1982 and was             f
               related to the Unit 1, Loop 1 MS line.                                         p
                                                                                            NI
               The configuration of the piping involved was as described by the al-            t
         2.
                leger, except that the temporary flushing line had not been discon-
               ected from a steam generator nozzle but was disconnected from a field
               weld (FW) in a feedwater line to which it had been attached.
   Comanche Peak SSER 10                     N-104
                                                   .
                                                                -    _
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       ,     .
                                                                                                 =
                                                                                                 E
                                                                                                _
                   TRT reviews determined that the Loop I temporary flushing line as      '
                   shown on B&R Drawing FSM-00165, Rev.1 (undated) was intended to be           -
                   attached at field weld (FW) locations FW-5 and FW-4 in Loop 1 MS Line        -
                   32"-MS-1-01-1303-2 and Loop 1 Feedwater Line 18"-FW-1-19-1302-2,
                   respectively. Additional TRT reviews of documentation packages for the       E
                   field welds verified that the temporary flushing line was installed as
                   intended by temporary field welds FW-T5 and FW-T4 to the Loop 1 MS and     6 -
                   Feedwater lines, respectively, on February 5,1980 and June 19, 1980,         g
                   respectively.
                  The TRT was informed by a TUEC mechanical field engineer that, prior
                  to the incident, the temporary flushing line was cut at approximately
                  30 ft, below the 899-ft, 91-inch
                                               s       elevation and that the piping involved ;
                  in the alleged incident consisted of the portion of the MS line between     j
                  the containment penetration and FW-5 and the attached portion of the        '
                  temporary flushing line above the cut.                                      !
                  Because of the expanded scope of its assessment, the TRT finds it
                  unlikely that the temporary flushing line was attached to the steam
                  generator, since the line was intended to be a steam generator bypass
                  line. If the temporary flushing line were attached to the steam
                 generator, it could not function as a bypass line.
t
          3.     The alleger's claim that the temporary flushing line vibrated about
                 14 inches when the line was disconnected coulc not be substantiated.
                 Two persons interviewed by 01 and/or the TRT refuted the claim.
          4.     Prior to the incident, B&R discovered that the installed portion of
                 the MS line had deviated from its initial installation position prob-
                 ably due to settlements at temporary supports (for the installed pip-
                 ing) during construction and/or flushing. B&R could not provide
                 surveying documentation to substantiate the deviation in location;
                however, four persons interviewed by OI and/or the TRT supported this
                TRT determination.     Furthermore, since B&R and TUEC personnel had
                informed the TRT that temporary support of the installed piping had
                been provided by wooden cribbing and " lashing" (retal cables) the TRT
                cid not consicer settlements at the support, unreasonable. This TRT
                finding was in agreement with the related RIV finding but was contrary               I
                to the alleger's claim that the MS line had been incorrectly installed
                and that operations during the alleged incident were necessary to force

I

                the MS line into its correct location.

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                The TRT could not determine exactly how much settlement had occurred
               at the temporary supports.
                                                 Vertical movements of the MS line (at             >
               unspecified locations) during the alleged incident were reported by
               persons interviewed by 01 and/or the TRT to be between 1-1/2 inches
               to 6 inches and between 4 inches and 5 inches for horizontal
               mvvement s ,

l i l 5. The alleger's claim that the polar crane and 3- to 5-ton come-along l

               were used to move the MS line was confirmed in whole or in part by all                j
               but one of the persons interviewed by 01 and/or the TRT who claimed
               to have knowledge of the incident.                                                    !

( i ' i Comanche Peak SSER 10 N-105 l

                                                                                                   ;i
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                                                                                              ..
                                                                                            b
                A TUEC mechanical field engineer, who claimed to have been involved in
                the incident, stated that initial attempts to use the main polar crane
               were unsuccessful and the 20-ton auxiliary crane was used during the         ,
                incident "because it could be controlled more accurately" (TUEC Of-               l
                fice Memorandum, " Comanche Peak Steam Electric Station," February 4,             8
                1983).   However during an interview with a rigger who was involved
                in the alleged incident, the TRT was informed that initial attempts to
                use the "small" (auxiliary) crane were unsuccessful due to uncontrolled         .
                slippage and that subsequently the "large" (main polar) crane was             }
                used to move the MS line.                                                     $
                                                                                               3
               All but one person' interviewed by 01 and/or the TRT confirmed the               3
               alleged use of both the polar crane and come-alongs during the alleged         Y
                incident. The one person discussed the use of the polar crane only.           5.
                                                                                               ?
          6.   The alleger's claim that the force exerted by the polar crane was             Y
               applied at "the expansion chamber" was partially confirmed by two              ~t
               persons (including a TUEC field mechanical engineer) interviewed by           i
               01 and/or the TRT who stated that the force was exerted at a thermal         4
               expansion loop in the MS line). The alleger's claim that the force            [;
               was monitored by " clock"-like instrument (actually a dynamometer) was         .
               substantiated. M&TE Issue Record for MTE Serial No. MTE-357 docu-
               mented a dynamometer reading related to the alleged incident. RIV            -
                inspections also substantiated the claim regarding the use of a dyna-
               mometer during the alleged incident.
               During an interview with a TUEC field mechanical engineer, the TRT
               was informed that during the alleged incident a chain was installed
               between the legs of the expansion loop to which the polar crane
               force was applied. The chain was intended to distribute the polar
               crane force in the section of the installed MS line consistent with
               the manner in which the section of line was to be supported in its
               design configuration. The use of the chain during the alleged inci-
               dent was refuted by the alleger and a rigger involved in the
               incident.
         7.    The magnitude of the force exerted by the polar crane could not be
               determined exactly.    As noted previously, M&TE Issue Record Ior MTE
               Serial  No. MTE-357 recorded a value of 31,250 (lbs.).    However, a
               rigger  involved in the incident stated that the force applied was
               47,500  lbs.  Additionally, the magnitude and points of application
               of the  forces applied by the alleged 3-to-5-ton come-alongs could
               not be determined.
         8.    The alleger's claim regarding the redesign of previously installed
               pipe supports was substantiated. A TRT waldown inspection of the MS
               line and review of pipe support designs dete,rmined that modification
                                       _
               of- permanent pipe supports'had-been made to accommodatema-movemenbof
                                                                 ~
               the MS line in an eastern direction.     Visual inspections of spring
               hanger supports MS-1-001-002-C725 and MS-1-001-001-C725 and vertical
               seismic (snubber) support MS-1-001-007-C72K indicated that support
               details had been modified to accommodate a lateral movement of the M5
               line in the eastern direction.      CMC 61306 Rev. 4, March 23, 1982 (which
               stated that the reason for the change was " Pipe was Moved") indicated
                                                                                           9
     Comanche Peak SSER 10                   N-106
                                                                                           2
                                                                                           L,
                .
  '
                    .                                                                                            I
                                                                                                                 }
                                                                                                                 :
                                                                                                                 !
                                                                                                                  l
                                        that modifications were made to support MS-1-001-007-C72K to accommo-    '
                                        date lateral movements of the MS line in the eastern and northern
                                        directions.
                                       ments of the MS Modifications to acocmmodate eastern and northern move-
                                                          line were also noted at seismic supports MS-1-001-
                                        005-C72K and MS-1-001-006-C72K.                                          !
                                  9.

i.

                  '
                                       The alleged incident was performed under the cognizance of the TUEC
                                       field mechanical engineering group. Seven persons interviewed by 01
    '
                ;
                                       and/or the TRT disagreed with the alleger's claim that the alleged
                '
                          .'
                                       incident was not supervised by engineering personnel. A TUEC field
                                       mechanical engineer stated that he was present during movement of the
     '                                 MS line "to insure that the activity was within proper engineering
                                       limitations for the equipment" involved. This TRI finding was in
                                       agreement with the related RIV finding.
     -        -                  The TRT reviewed a TUEC analysis performed in February 1983, 1 year after
         <                       the incident, to assess strasses induced in the MS line during the inci-
                                 dent.
                                         The TRT review concluded that the analysis was inadequate since
         <
                                 only operations during restoration of the MS line to its initial position
                                were addressed.
                                                    The conditions during flushing, including the piping
                                af fected, the weight of added water, and settlement of temporary supports,
                                were not addressed.
                                During its investigation of allegation AP-13 the TRT also found that the
                                Unit 1, Loop 4 Main Steam Line 32"-MS-1-004-1303-2 was involved in a
                                similar indident which has not been evaluated by TUEC. M&TE Issue Record
                                for MTE Serial No. MTE-357 also documented a dynamometer reading of
                               17,750 lbs. on January 16, 1982 related to the Loop 4 MS line.
          g                                                                                          The TRT
                               noted that the dates recorded on the M&TE Issue Form for both the Loop 1
         3'                    and Loop 4 dynamometer readings were identical (the recorded dates were
                              January 16, 1982).
                                                        The TRT noted, however, that it was unreasonable that
                              both the Loop 1 and Loop 4 lines could have been moved on the same day.
                              Furthermore, during an interview with a rigger who claimed to have been
            ;
                               involved with both incidents, the TRT was informed that the incidents had
           .i
                              not occurred on the same day.
           t-
                              further TRT reviews determined that the use of temporary supports during
                              the alleged incident was in noncompliance with the requirements of Sec-
                              tion 7.4, " Adjustments of Hangers," and 7.5, " Temporary Hangers," of G&H
                              Specification 2323-MS-100, Piping Erection Specification," Rev. 5,
          4                   Februa y
           F                              26, 1979 (Rev. 5 was in effect during the alleged incident).
                             Section 7.5 stated that all piping was to be erected in its permanent
                             hangers, but where not possible, the Owner's approval was to be obtained
                             for the use of temporary hangers. Section 7.4.2, " Adjustment Prior to
                             Testing and Flushing," only addressed requirements prior to hydrostatic
                             testing of erected piping systems. During an interview with the TRT a TUEC
                             chief engineer for piping informed the TRT that Owner (/ Engineer) approval
       '                     for the use of temporary supports during piping erection was granted to
      '                      B&R by TUEC approval of B&R Procedure PCP-1, " Process Pipe Installation,"
                             Rev. O, June 7, 1977 (TUEC approval in note TUF-3388, July 28, 1977 on B&R
         '                   BRF-6565, July 11,1977). Paragraph 4.6.1 of Procedure PCP-1 stated that
                             pipe spools were to be rigged into permanent or temporary supports during
                             erection.      The TRT questioned whether Note TUF-3388 satisfies the intent
            .
                      Comanche Peak SSER 10                        N-107
                                                                                                               U
   .

. .

 ,   . .
              of the approval requirement in Section 7.5 of G&H Specification
                                                                                   -
              2323-MS-100.
              In view of the above identified noncompliance with the rcquirements of G&H
              Specification 2323-MS-100 and the TRT observation that the requirements of
              Sections 7.5 and 7.4.2 of this G&H Specification were unchanged in Rev. O,
              March 1,1976 through Rev. 5, February 26, 1979, the TRT interviewed TUEC
              engineering and B&R construction personnel to determine the practice re-
              garding temporary supports. The TRT determined that there was no formal
              procedure to evaluate the adequacy and temporary supports during piping
              installation. A B&R general superintendent stated that the previous undoc-
              umented practice of the unrestricted use of lashing was discontinued due      ,
              to problems with uncontrolled movements of the piping. The TRT was in-       .
              formed by the general superintendent that the previous practice was modi-
              fied to require that the piping was to be fixed against movement at every    }j
              fourth support during erection.     The TRT found that the above practice      e
              was not in compliance with the requirements of G&H Specification 2323-MS-100 l[
              for temporary supports, Rev. O, March 1, 1976 through 5, February 26, 1979
              that all piping be erected in its permanent supports and that Owner ap-       j%
              proval be obtained for the use of temporary hangers.                           p
                                                                                              i
              The TRT also noted that Sections 7.4.2 and 7.4 of G&H Specification              l
              2323-MS-100, Rev. 6 and 7, March 15, 1982 and December 2, 1983, permitted
              the use of temporary hangers without Owner's approval but required that
              during flushing and hydrotesting of steam lines with demineralized water
              the deadweight supports were required to be in place with all spring hang-
              ers in the locked position.
         5.   Conclusion and Staff Positions:
              AP-4
              Based on its investigation the TRT determined that the allegation regard-
              ing springing in RCS piping could not be substantiated. The TRT believes
              that the alleger had mistakenly identified jacking activities during in-
              stallation of the hot-leg piping between the reactor vessel and the steam
              generator as cold springing activities. Jacking was used to maintain verti-
              cal positioning of the steam generator during axial motions of the hot leg
              piping due to weld shrinkage during welding.
              Other TRT investigations of cold springing and springing determined that
              no piping systems were intended to be or had been cold sprung but that,
              contrary to the requirements of TUEC Procedure CP-EP-4.0, unauthorized and
              undocumented springing of piping systems had occurred. The TRT, however,
              assessed that the safety significance of the unauthorized and undocumented
              springing practice may be negligible; guidelines for the unauthorized and
              undocumented springing stresses to only 1000 psi at nozzles.
              The TRT found that the failure of all issues of B&R Procedure CP-CPM-6.9E
              and B&R Instruction Ql-QAP-11.1.26 to adequately reflect the springing and
              cold springing requirements of all issues of G&H Specification 2323-MS-100
              were in noncompliance with the requirements of B&R Procedure CP-CPM-6.1 ana
              B&R Instruction CP-QAP-6.1, respectively.
          Comanche Peak SSER 10                  N-108
                                                                                               .
                                                                                                 J
 -
       -
                                                                                                      1
                                                                                                     '
    .    .-
                                                                                                     l
                                                                                                     i
                 Additionally tso matters relating to an inconsistency in responses of B&R
                 QA were
                 nel personnel
                          noted.and possible misleading statements by B&R construction person-
                 The TRT cont. acted the alleger on August 20, 1984 and October 29, 1984 to
  8             arrange
                tigations.
                          a meeting to discuss his allegation and the results of its inves-
                             The alleger declined to have a meeting with the TRT.
                AP-9
                The TRT investigation of alleged localized heating of a stainless steel
                line to obtain proper alignment of the line could not substantiate the
                allegation.
               Because the alleger declined to meet with the TRT, the TRT could not con-
               duct a followup interview to discuss its findings with the alleger.
               AP-13
 9'            The TRT investigation of allegation AP-13 concluded that the allegation
 g            was substantiated in part. The TRT found that the alleger had mistakenly             ,
                                                                                                   '
 4
               identified the repositioning of a Unit 1, Loop 1 Main Steam line due to
              during initialofinstallation.
              settlements       temporary supports as the correction of alignment errors
                                                The TRT determined that the partially in-         .
              stalled main steam line had been used in flushing operations and sagged             ;
              due
              tion.to settlement   of temporary supports during flushing and/or construc-
                       TUEC's analysis to assess stres'ses in the main steam line due to
             the repositioning operations was inadequate because stresses due to the             ,
             full sequence of events involved in the incident were not evaluated.                .
             The TRT also determined that similar repositioning operations had been
             performed on the Unit 1, Loop 4 main steam line. No assessment of this
             second incident has been performed by TUEC. An apparent anomaly in the
             recorded dates of the Loop 1 and Loop 4 MS line was noted.
            TRT reviews also found that the B&R construction practice of using tem-
            porary supports during piping erection was not in compliance with the G&H

l Specification 2323-MS-100 requirements.

            Based on the deficiencies identified in its assessment of allegation AP-13,
            the TRT concluded that it has safety significance and generic implications.
            Additional information required to resolve concerns related to the alle-
            gation was requested in an NRC letter to TUEC dated November 29, 1984.
            During a telephone call with the alleger on October 31, 1984, the TRT pre-
            sented the results of the assessment of allegation AP-13 and the TRT con-
           clusions to date. The TRT accompanied the alleger on a walkdown inspection

t,

           on November 7, 1984. During the walkdown the alleger identified the loca-
           tion on the expansion loop where the force exerted by the polar crane was
           applied.
                         Subsequently, the alleger declined to have any further contact
          with the TRT.
      6.  Actions Required:
                                  Based on its evaluation of AP-13, the TRT will require
          the following TUEC actions:                                                          .

. 4

                                                                                               1
     Ccmanche Peak SSER 10                      N-109
                                                                                               
     .
 '
   .    .l
             (1) Modify Gibbs & Hill. Specification 2323-MS-100, and institute proce-
                   dures to support the main steam line during flushing and provid'e                 I
                   temporary supports for piping and equipment in general to assure that
                   the quality of affected piping and equipment is not affected.
             (2) Assess stresses in the portions of the Unit 1, Loop 1 main steam and
                   feedwater lines that were affected in the sequence of events involved
                   during their initial installation, flushing and final installation.
                   Conditions of concern are:
                   a.    the condition when the lines were full of water and temporary   .
                         supports had sagged or settled.
                  b.     the condition when vibrations of the temporary line could have
                        occurred.
                  c.     the condition when forces were applied by the polar crane and
                        come-alongs.
                                                                                           &
                  These assessments shall be based on appropriate piping configurations
                   involved.
             (3) Perform a nondestructive examination of locations in the Unit 1, Loop 1
                  main steam and feedwater piping involved where stresses greater than
                  relevant stress allowables were exceeded during the conditions of
                  concern in a. through c. above.
            (4) Review the existing baseline UT examinations for those portions of
                  the Unit 1, loop 1 main steam and feedwater piping involved in all
                  the conditions of concern in a. through c. above for unacceptable
                  indications.
            (5) Review records of hydrostatic testing of the Unit 1, Loop 1 main steam
                  and feedwater piping to verify the quality of piping involved in the
                  incident.
            (6) Provide similar assessments for circumstances involved in the lifting
                  incident identified during the TRT inspections of the Unit 1, loop 4
                  main steam line.                                                             -
            (7) Provide assessments of effects on quality of safety-related piping
                  and equipment which were involved in similar incidents of sagging,
                  settlements and failures, if any, of temporary supports.
            (8) Document the results of analysis, examinations and reviews and submit
                  them in a report for TRT review.
                                                                                             '
            Reference Documents:
                                                                                                   .
           AP-4
            1.    NRC 01 Report 50-445/84-006.                                                 1
           2.     G&H Specification 2323-MS-100 Rev. O through Rev. 8.                         R
                                                                                               l'

, I,

                                                                                                 ;
       Comanche Peak SSER 10                   N-110
                                                                                              ,
                                                                                             J   w
         .
 '
       ,   ...-
                3.       Westinghouse Process Specification PSPAS-01, Rev. O.
                4.       Traveler HE-78-014-5505.                                         *
                5.       Traveler HE-78-026-5505.                                                             ,
                6.        Traveler HE-79-035-5505.                            .
                                                                                                              l
                7.       Traveler ME-79-036-5505.                                                             '
                8.       Traveler ME-79-037-5505.
                9.       B&R BRF-9181.                                                                         i
                10. B&R BRF-9211.                                                                             !
                11. Southwest Fabricating & Welding Drawing Q-6214-T8X.
                12. B&R BRF-9348.
                13. NC.R M-2305.
               14. B&R QI-QAP-11.1-31,.Rev. 3.
                15. TUSI CP-EP-4.0, Rev. 3.                  ,
               16. B&R QI-QAP-11.1-26, Rev. O through Rev. 15
                                                                                                               l
               17. ASME B&PVC Section III.
               18. ANSI B31.1
               19. B&R CP-CPM-6.1, Rev. 6.
               20. B&R CP-QAP-6.1, Rev. 4
               21. Data Package WE-78-006-5505.
               22. Data Package WE-78-028-5505.                                                               '
               23. Data Package WE-78-025-5505.
               24. Data Package WE-78-016-5505.
               25. Data Package WE-78-024-5505.
               26. Data Package WE-78-029-5505.
               27. Data Package WE-78-030-5505.
               28. Data Package WE-78-019-5505.
               29. Data Package ME-78-009-5505.
               30. Data Package ME-78-019-5505.
               31. Data Package ME-78-010-5505.
               32. Data Package ME-78-013-5505.
               33. Data Package ME-78-021-5505.
               34. Data Package ME-78-008-5505.
              35. Data Package ME-78-020-5505.
              36. Data Package ME-78-007-5505.
              37. Data Package ME-78-015-5505.
              38. Data Package ME-78-022-5505.
              39. B&R Drawing BRP-RC-1-520-001.
              40. Bechtel Specification 10466-M-204, Appendix D.
              41. FSAR Figure. 5.4-12.
              42. FSAR Figure. 5.4-12A.
              43. FSAR Figure. 5.4-128.

4

              44. FSAR Figure. 5.4-13.

4 45. FSAR Figure. 5.4-14.

              46. FSAR Figure. 5.4-15.
              47. FSAR Figure. 5.4-16.
              48. FSAR Figure. 5.4-17.                                                                      '
              49. FSAR Figure. 5.4-18.
              50. FSAR Figure. 5.4-19.
              51. ASME B&PVC Section III.
              52. ANSI B31.1
        Comanche Peak SSER 10                          N-111
                                                               *                                          '
                                                     .
   ._.             ._ _ ___.____. __ _ _..___. _ __.                  _ _ . _ _ _.___...-- .-.._. --__ _ k
   F

-

 ,   . ; ,-
       .-
               AP-9                                                               -
               1.    NRC Reg. Guide 1.44.
               2.    G&H Specification 2323-MS-100, Rev. O, 8.
              3.     NRC IE Report 50-445/79-06; 50-446/79-06.                                  3
              4.     B&R CP-CPM-6.9E, Rev. I through Rev. 7.                                    1
              5.    B&R CP-CPM 6.90, Rev. 1 through Rev. 6.                                      ;
                                                                                                *
              6.    FSAR Fig. 6.2.2-1.
              7.    B&R Heating Alignment Record Folder.                                     }
              8.    FSAR Table 6.2.2-4.
              9. J NRC OI Report 50-445/84-006.
                                                                                              t
              10. Deposition of alleger A-21, July 12,1984, pp.1-35.
              11.
              12.
                    Deposition of alleger A-21, July 12,1984, pp. 49500-49514.               l
                    Conversation Record, alleger A-21, 9/1/84                                  .
              AP-13
                                                                                             i.
              1.    G&H Specification 2323-MS-100, Rev. O through Rev. 8.
             2.                                                                                 ;
                    B&R letter BRF-6565.                                                         *
             3.     B&R PCP-1, Rev. O.
             4      NRC IE Report-50-445/83-27.
             5.     CASE letter 2/3/83 with alleger's affidavit.
             6.     CASE Letter 11/28/83 with allegers affidavit.
             7.     NRC TRT Technical interview with alleger 9/19/85.
             8.
             9.
                   CPSES ASLB Memorandum and Order (Clarification of Open Issues).
                   NRC OI Report A4-83-005.
             10.                                                                                   :
                   NRC OI Memorandum " Assistance to Inspection Report No. 14-83-005.               ~
             11.   NRC 01 Supplemental Report Q4-84-007.
             12. B&R M&TE Issue Record for MTE Serial MTE-357.
             13.                                                                                     <
                   B&R CMC 61306 Rev. 4.
             14.   B&R Drawing FSM u0165, Rev. 1.
             15.                                                                                   p
            16.
                   TUEC Memorandum " Comanche Peak Steam Electric Station," Feb. 4, 1983.           .;
                   B&R Mk. No. MS-s1-01-007-C12K Data Package.
            17. B&R Mk. No. MS-1-01-001-C725 Data Package.
            18. B&R Mk. No. MS-1-01-002-C725 Data Package.
            19. B&R Mk. No. MS-1-01-005-C72K Data Package.                                             .
                                                                                                       I
            20. B&R M. No. MS-1-01-006-C72K Data Package.
            21. B&R Drawing BRP-MS-1-RB-002, Rev. 13.                                                   ,
            22. B&R Drawing BRP-FW-1-R8-002, Rev. 18,
            23. B&R MS-1-R8-001 FW-TS Data Package.
            24.   B&R FW-1-RB-001 FW-T4 Data Package.                                             ..
            25. ADLPIPE Output, 2/24/83.
            26. AOLPIPE Output, DAMS 2, 8/24/84.
            27. ADLPIPE Output, DAMS 5 8/24/84.                                                   3
                                                                                                 ,
                                                                                                '.
                                                                                                   .
                                                                                                1
                                                                                                 Y
                                                                                                  I
                                                                                                 J
                                                                                              t
                                                                                              .
                                                                                                          ,
       Comanche Peak SSER 10                  N-112
                                                     :                                    '
                                                                                           .
         . *i
       ..      .
       !
                                                                                       .
                                                                                                        :
                4.   Actions Required of TUEC
                TUEC shall submit additional information to the NRC, in writing, including a
                program and schedule for completing a detailed and thorough assessment of the
                issues identified in the following sections. This program plan and its imple-
              -mentati.on will be evaluated by the staff before NRC considers the issuance of
                an operating license for Comanche Peak, Unit 1. The program plan should address
                the root cause of each problem identified and its generic implications on
     .          safety-related systems, programs, or areas. The collective significance of
     .
                these deficiencies should also be addressed. The program plan should also
                include the proposed TUEC action to ensure that such problems will be precluded
                from occurring.in the future. The specific actions required of TUEC are
     *
               described in the following sections.
   '
               4.1 Civil and Structural (C&S) Area
               4.1.1 Rebar Improperly Installed or Omitted (See Attachment 2, C&S Category 6)
 .
  4
                -
                      Provide an analysis of the as-built condition of the Unit I reactor cavity
     l                that verifies the adequacy of the reinforcing steel between the 812-foot
 #
 '
                      and 819-foot, -inch elevations. The analysis shall consider all required
                      load combinations.
               4.1.2 Falsification of Concrete Compression Strength Test Results (See Attach-
                        ment 2, C&S Category 8)

.

               -
                      Determine areas where safety-related concrete was placed between January
                      1976 and February 1977, and provide a program to assure acceptable con-

} crete strength. The program shall include tests such as the use of random -

                      Schmidt hammer tests on the concrete in areas where safety is critical.
                     The program shall include a comparison of the results with the'results
                     of tests performed on concrete of the same design strength in areas where

J the strength of the concrete is not questioned to determine if any signifi-

                     cant variance in strength occurs. TUEC shall submit the program for these        i
                     tests to the NRC for review and approval prior to performing the tests.         j
                                                                                                      :
              4.1.3 Maintenance of Air Gap Between Concrete Structures (See Attachment 2,
                        C&S Category 11)
                                                                                                    f ,
                                                                                                    ?
               -     Perform an inspection of the as-built condition to confirm that adequate       r
                     separation for all seismic. Category I structures has been provided.           !
               -     Provide the results of analyses which demonstrate that the presence of         i
                     rotofoam and other debris between all concrete structures (as determined       )
                     by inspections of the as-built conditions) does not result in any signi-      ,
                     ficant increase in seismic response or alter the dynamic response charac-
                     teristics of the Category I structures, components, and piping when cota-
                                                                                                   {
                                                                                                   1
                     pared with the results of the original analyses.                              y
                                                                                                   )
                                                                                                   4
                                                                                                   3
                              .
                                                                                      h(h&-%    ,j
              Comanche Peak SSER 8                       K-16                                     N. ,

6 )

,

                                                                                                     -
                                                                                                          -
                  *~
    $$           .   .
    l!  '
    s
    :
   :                   e.   (1) The reinforcing steel that was placed between the 812-foot and
   b
                                   819-foot, \-inch elevations in the reactor cavity wall of the
   L
   !
          .
                                   Unit 1 Reactor Building was completed and inspected to draw-
                                   ing 2323-51-0572, Rev. 2. After the concrete was placed, Brown
                                  & Root received Rev. 3 to the drawing showing a substantial in-
     [                             crease in reinforcing steel over that which was installed.
      l                                                                                         G&H
                                   engineering was informed of the omission by Brown & Root non-
                                  conformance report C-669, which is referenced in the Brown &
                                  Root internal deficiency report CP-77-6. G&H engineering replied
            i
                                   that the omission of this additional reinforcing steel did not
                                   in any way impair the structural integrity of the structure.
  i                               G&H stated that the additional rebar was added as a precaution
                                  against cracking which might occur in the vicinity of the neutron
                                  detector slots should a loss of coolant accident (LOCA) occur.
                                  A portion of the omitted reinforcing steel was placed in the
                                  next concrete lift above the 819-foot, 1/2-inch elevation. G&H
                                  stated that this was done to partially compensate for the rein-
   [
   4
                                  forcing steel omitted below and to minimize the overall area
       ,
                                  subject to possible cracking.
                                  The TRT requested documentation to indicate that an analysis was
                                 performed supporting this conclusion. The TRT was subsequently
  U
                                  informed that an analysis hac* at been performed.
   ,                       (2)    In response to Brown & Root construction's Request for Informa-
  p                              tion or Clarification (RFIC) RBCR-37, Design Change / Design Devia-
 @                               tion Authorization (DC/DDA) No. 832 was issued stating that the
 !-                              configuration of the 2x9-No. 9 reinforcing bars (two rows by
 [                               nine layers), as shown on drawing 2323-S1-0572, Rev. 4, could be
                                 changed to a continuous circumferential arrangement. The TRT
 ,j                              reviewed this drawing and determined that these bars were among
  g                              those omitted in the concrete placement between the 812-foot and
  1                             819-foot, 1/2-inch elevations and subsequently placed above the
 d                              819-foot, 1/2-inch elevation (See e(1) above.) Revision 4 shows
 U                              each of the four sets of No. 9 bars used to form the configura-
 :'
 x                               tion required were to be bent in two places to form an approxi-
                                mate circular configuration when placed. The DC/DDA stated the
                                bars could be bent to a specified radius to form a true circular
   ,'                           arrangement. The change, therefore, only affected the way in             .
                                which the bars were bent and did not reduce the load-carrying            )
      ;                         capacity of the structure.                                               1
                                                                                                         1
                          (3) During the placement of reinforcing steel within the triangular
                                columns surrounding the reactor cavity at the 826-foot, 11-inch
          .,                    elevation, interferences were encountered. The horizontal tails
               i
               ,
                                of the No.11 vertical reinforcing bars were interfering with
                                14-inch-diameter sleeves already in place.     The TRT reviewed
               l                DC/DDA No. 6918 and the attached sketches which showed that             I
             '                  six bars were cut and replaced with bars tailed up to achieve
                                total anchorage and three bars were bent down to clear the
                                sleeves.
                                Also, due to congestion problems, the design of the No. 4               e
                                stirrups surrounding the ten No.18 circular bars was modified          j
                                                          K-52                                         i
                                                                                                       J

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          L.       ~t 9e          Rch                   O    hsL +h
              .L wm3Juek               lbm    .
                                                  A A E /et il - U -ol          (open         -
                                                                                               ,
                                                                           AMS              '-
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                                                 CPSES/FSAR
   -e            10.3     MAIN STEAM SUPPLY SYSTEM                                       ,

,

     \
                 10.3.1     DESIGN BASES                                                             "
                 The main steam supply system is considered part of the Main Steam,
                 Reheat, and Steam Dump System.    It conveys steam from the outlet of the
                 steam generators to the various system components throughout the
                 Turbine Building. The . steam is primarily used for driving the main
                 turbine and for heating service in the MSRs. In addition, it is used
                 for various auxiliary services such as the following:
                 1.     Steam generator feed pump turbine
                 2.    Auxiliary feed pump turbine
                                 .
                3.      Steam dump' system
   ,
                4.     Turbine shaft seal system
  t.
                5.     Plant process steam system
                Steam from the outlet of the four steam generators (a total of
                15,140,016 lb/hr, at 1000 psia and 0.25 percent moisture) is routed in
                the main steam piping to the turbine. The piping is sized for a
                pressure drop of less than 25 psi. The design pressure-temperature
                rating of the main steam piping is 1200 psig at 6500F. The full-load
                steam flow from the reheaters to the feedwater pump turbines is
                approximately 242,472 lb/hr at 152.1 psia. The steam supply from the
                main steam lines to the auxiliary feedwater pump turbine is in the
                range of 9,575 to 51,524 lb/hr at 1200 to 125 psia, respectively.
                The main steam supply system is used for plant cooldown. This is
                achieved by progressively lowering the pressure of the steam
                generators; the decay heat and the sensible heat are removed by the
 n
                                                  10.3-1
                                                                                         : eta-26-3h
                                                                                                   '

- .

                                                                                        Als        ii

IT

        *
          .
           -
  . .~.
                                              CPSES/FSAR
               generation of steam. When steam generator pressure has been reduced to
                125 psia, the Residual Heat Removal (RHR) System is placed in              I
               operation.
               The main steam supply system is designed to meet all applicable
               requirements of 10 CFR Part 50. This system is designed in accordance
               with NRC Regulatory Guides 1.26 and 1.29.
               The main steam safety valves are rated to pass 105 percent of the       ,
               engineered safeguard design (ESD) steam flow at a pressure not
               exceeding 110 percent of the main steam system design pressure (ESD -
               flow equals 104.5 percent of the guaranteed 3425 MWt). These safety
               valves prevent overpressurization of the system as specified in the
               ASME 8&PV Code.
               The steam generator power-operated relief valves pass 10 percent of the
               steam flow used for the plant design at no-load stean pressure
               (1107 psia).
                                                                                         (
              The main steam isolation valves (MSIVs) are designed to stop flow from
              either direction within 10 sec (five sec af ter receipt of signal to
              close) to prevent uncontrolled steam release from more than one steam          !
                                                                                             i
              generator.                                                                     <
                                                                                             ,
              The steam dump system design bases are given in Section 10.4.4.                .
              The main steam lines from the steam generator, out through the
             Containment, and up to the first moinent restraint beyond the MSIV, are
                                                                                               )
             designed in accordance with the ASME B&PV Code, Section III, Code
             Class 2. Beyond this moment restraint, the main steam lines to the
             main turbine and the lines to tne feedwater pump turbines, the
             condensers (steam dump), and the reheaters are non-nuclear-safety-                !
             related and are designed in accordance with ANSI B31.1, Power Piping.
                                                10.3-2                                   k
                                                       *
             .
 ,
        *
          .
   s t~    *
                                                                                     '
                                               CPSES/FSAR
                                                                                  .
                The lines to the auxiliary feedwater pump turbine are designed in
                accordance with the ASME B&PV Code, Section III, Code Class 3.            !
                The MSIVs, integral bypass valves, and bypass piping are of Code Class
                1 design. (The applicant has optionally upgraded this equipment to
               Code Class 1.) The MSIV actuators, safety valves, and power-operated
               relief valves are of Code Class 2 design.
               The piping is insulated, and where exposed to the outdoor environment,
               it is suitably protected from the weather.
               The total plant releases associated with a LOCA, including steam side
               leakage, are within the 10 CFR Part 100 limits. The steam generator
               shell and lines which emanate from the steam generator shell side are
              barriers against release of containment atmosphere.
              Steam is conveyed from the steam generators to the main turbine by four
              steam lines. Upstream from the MSIVs, each line is provided with five
              spring-loaded safety valves and one power-operated relief valve. It is
              essential that the heat load be evenly shared between the four loops of
              the Nuclear Steam Supply System (NSSS). To achieve this, the four main
              steam lines are interconnected by a pressure equalizing header

'

              downstream of the steam generator isolation valves.

l '

              The sizes and routing of the main steam piping are such that under
             design flow, a pressure drop of approximately 22 psi is obtained          13
             between the steam generator nozzle and the turbine stop valve inlet        *
             with a steam velocity of approximately 115 ft/sec. Each steam line
             uses a drain system to remove accumulated condensate from the line.

l

             To ensure steam supply to the auxiliary feedwater pump turbine (even in

! the steam generator isolation), two separate steam supply lines are

             provided from two main steam lines.

l(

                                                     -
                                                                     AMENDMENT 13
                                                i0.3-3               DECEMBER 15, 1980    a
  _
                                                                                                  -
         V.
    .x;<-
       .
                                                    CPSES/FSAR
                                                                                               (
             ~
                    A direct connection is provided downstream of the isolation valves *for
                     the startup of the steam' generator feedwater pump turbines.
                    Table 10.3-1 shows the design bases of the main steam piping.
                    The environmental design bases are given in Section 3.11.
             55lTheinserviceinspectionrequirementsaregiveninSection6.6.
                    The inservice inspection program for the turbine generator is described
                    in-Section 10.2.3.6.
                    10.3.2     DESCRIPTION
                   The main steam supply system and interconnected piping are shown
                   schematically on Figure 10.3-1.     The nuclear safety class is applied to
                   the main steam lines from the steam generator, up to and including the
                   first moment restraint beyond the MSIVs located outside the                (
                   Containment. The nuclear safety class is also applied'to the blowdown
                   and process sampling lines from the steam generator, up to and
                   including the pneumatically operated isolation valves. (See Figure
                  .10.3-1, sheet'l of 2.) The non-nuclear-safety class portion includes
                   the remaining portion downstream of the moment restraint.      (See Figure
                   10.3-1, sheet 2 of 2.)
                  Each main steam line has a number of branch-off lines located
          12      downstream of the main steam isolation valve. All these branch-off

'

      Q040.136   -lines are provided with steam shut-off valves as listed in Table
                  10.3-11.

i a ! ! '

~
                                                                                              (

'

                                                        10.3-4

,

                AMDEMENT 55
               -JULY 19, 1985~                             .                                        .
                                                           '
.._
               - - _ - _ _ _ _ _ _ _ _ _ _ _ _ _                 _
                                                                                                                                                                                                          ,
   -
         ;* ..                                                                                                                                             [1A McMp p>W
                                                                                                                                                                 CPSES/FSAR
                                                                                                                                                                                         .
       (.3                                                 The graphs of the steam generator compartment pressures
                                                           resulting in the maximum differential pressure on the steam
                                                           generator are presented as Figure 6.2.1-29. These result
                                                           from the 763-in.2 hot-leg split.
                                                           The graphs of the pressurizer compartment pressures
                                                           resulting in the maximum differential pressure on the
                                                           pressurizer are presented as Figure 6.2.1-30.
                                                           For all differential pressures on structures or components,
                                                           the structure or component across which the differential
 _                                                         pressure is to be calculated must be located on the

l schematic drawings mentioned in Section 6.2.1.2.2,

                                                           Paragraph A.                                                                 When the relevant volume nodes have been

! located, the differential pressure history can be found

                                                           from the differential in the pressure-time histories given                                                                                10

e ' for the volumes in Section 6.2.1.2.3, Paragraph D. QO22.3

     (
                                                 E. Structural Peak Pressures
                                                    I.    Peak pressures, used in compartment structural design, are
                                                          given in Table 6.2.1-23. Note that in the case of the
                                                          reactor cavity, the nozzle cavity pressure represents the
                                                          peak pressure which could be experienced by Volumes 1-8
                                                           (the design pressure for the hot-leg inspection compartment
                                                          being set equal to that of the cold-leg compartment, even
                                                          though evaluation shows a higher pressure would exist in a
                                                          cold-leg inspection compartment). The pressure between El .
                                                          823.125 ft and El. 834 ft.-0.5 in. is given by nodes 9 to
                                                          16, between 809.844 ft and 823.175 ft is given by nodes 17
                                                          to 24, between 798.667 ft and 809.844 ft is given by nodes
                                                          25 to 28, between 783 ft 7 in. and 798.6672 ft is given by
                                                          node 29. Volume 32, the free containment volume, is
                                                          evaluated for maximum pressure by procedures described in
     <
                                                                                                                                                                     6.2-14k
                                                                                                                                                                             fotA-W%AMENDMENT 10
                                                                                                                                                                                    MARCH 31, 1980
                                                                   - _ _ _ _ . _ _ . _ _ _ - - _ _ _ . _ _ _ _ _ _ . _ _ - _ _ _ _ - . _ - _ _ _ . _ _ _ . _ . _ _ _                  -.                 ..J

~

        .
 ~
   :.1  '$
      (                                                                         ~
                                                CPSES/FSAR
                                              TABLE 6.2.1-23
                                      SUBCOMPARTMENT PRESSURE SUEBARY
                                                                      Design Pressure
           Location                                                         (psia)
           Mozzle cavity (el. 823 ft to
                                                                                   *
           el. 829 ft 4 in.)                                              - 475
           Reactor cavity (el. 829 f t 1/2 in. to
           el. 834 f t 1/2 in.)                                              67
           Reactor cavity (el. 822 f t to
           el. 829 f t 1/2 in.)                                              75
           Reactor cavity (el. 810 ft to
           el. 822 f t)                                                      44
           Reactor cavity (el. 798 f t 10-1/2 in,
           to el. 810 ft)                                                     7
                                                                                         10
    (      Reactor cavity (el. 783 f t 7 in. to
           el. 798 f t 10-1/2 in.)                                            7
           Steam generator compartment                -
            (below el. 858 f t 6 in.)                                        46
           Steam generator compartment
           (el. 858 ft 6 in. to 895 ft 9 in.)                                17
           Steam generator compartment
           (above el. 895 f t 9 in.)                                         12
           Pressurizer compartment
           (above el. 853 ft 6 in.)      .
                                                                             21.0
           Pressurizer compartment
           (below el. 853 f t 6 in.)                                         28.0
                                                                           AMENDMENT 10
                                                                           MARCH 31,1980
                                       .
                                                   *
                                                   .               .
           _. -     __         _     . . _ __   . _ . __ . . - - . - _ . . ._ .-___ -_ _ __            _ _ _ _ _ _ _ _ _ _
                                                                                                                 -
      .
 .      .
         .
         '
                                                                                            NUREG-0797
                                                                                            Supplement No. 7                     .
                                                                                                    .
                                                                                                                           _
                Safety Evaluation Report
                related to the operation of
                Comanche Peak Steam Electric Station,
                Units 1 and 2
                Docket Nos. 50445 and 50-446
                Texas Utilities Generating Company, et al.
                                                                                                     _
                U.S. Nuclear Regulatory

l Commission

                Office of Nuclear Reactor Regulation
                January 1985
                  .r ~%.,
                  ,       /
    ,
    !
    '
                                                                                                   lf *
   '
                                                     .                                                                       A l

I -

    .     .
      -
           '.
                                                                    r-
  1
      .                                                                            *
                                          ACRONYMS AND ABBREVIATIONS
                 AA    -
                            independent assessment program allegation
                AB     -
                           American Bridge
                AB   ,-    bolt allegation
                AC   ;-
                           concrete /rebar allegation
                ACI    -
                           American Concrete Institute
                AD     -
                           design of pipe / pipe support allegation
                ADS    -
                           audit discrepancy report
                AE     -
                           electrical allegation
                AE00 -     Office for Analysis and Evaluation of Operational Data (NRC)
                AFW   -
                           auxiliary feedwater system
                AH    -
                           hanger allegation
-
                AI    -
                            intimidation allegation
                AISC -     American Institute of Steel Construction
                AM    -
                           miscellaneous allegation
                ANI   -
                           authorized nuclear inspector
                /J;S  -
                           American Nuclear Society
                ANSI -     American National Standards Institute
                A0    -
                           protective coating allegation
                AP    -
                           pipe and pipe support allegation
                APC   -
                           AMP Product Corporation
                AQ
                      -
                           quality assurance / quality control allegation
                AQB
                      -
                           QA/QC bolt allegation
                AQC
                      -
                           QA/QC concrete /rebar allegation
                AQE
                      -
                           QA/QC electrical allegation
                AQH
                     -
                           QA/QC hanger allegation
                AQO
                     -
                           QA/QC coating allegation                     -
                AQP
                     -
                           QA/QC pipe and pipe support allegation
                AQW -      QA/QC welding allegation
                ARMS -     Automated Records Management System
                ASLB -     Atomic Safety and Licensing Board
                ASME -     American Society of Mechanical Engineers
                ASTM -     American Society for Testing and Materials
                AT   -
                           acceptance test
               AT    -
                           test program allegation
               AV    -
                           vendor / generic allegation
               AW    -
                           welding allegation
              - B&PVC -    Boiler & Pressure Vessel Code
               B&R   -
                           Brown & Root, Inc.
               BRIR -      Brown & Root Inspection Report
               BRHL -      Brown & Root Hanger Locations
               BRP   -
                           Brown & Root piping isometric drawing
               CAR   -
                           Corrective Action Request
               CASE -      Citizens Association for Sound Energy
               Comanche Peak SSER 7                    . vii
                                                                                    _
  .         .
    i        :
       ~C&L:,-       Corner and Lada (computer program)                           *
        C&S -        civil and structural
        CAT        . Construction Appraisal' Team (NRC)
        C8&I.-       Chicago Bridge & Iron Company
        CCS      -
                     Component Cooling System
        CEL -        Coating Exempt Log
                     Code of Federal Regulations
                                                                       '
                 -
        CFR
       ~CHN -        construction hold notice
        CILRT_-      containment integrated leak rate test
        CMC      -
                     component modification cards
        COT -        construction operation traveler
        CP       -
                     Comanche Peak
        CP       -
                     construction permit
        CPPE -       Comanche Peak Project Engineering
        CPSES -      Comanche Peak Steam Electric Station
        CPSIG -      Comanche Peak Seismic Interaction Group
        CSTS -       Construction and Startup/ Turnover Surveillance Group (TUEC)
        CVCS -       chemical and volume control system
        CZ-11 -      Carboline Carbo zinc 11
                                                                                         ,
        DBA -        design basis accident

i DCA -

                     design change authorization
        DCC     -
                     Document Control Center (TUEC)
        DCTG :       Design Change Tracking Group
      .DCVGi-        design change verification group                                    '
        DE      -
                     Division of Engineering (NRC)

j DFT -

                     dry film thickness
DL -
                     Division of Licensing (NRC)
        D-6     -
                     Ameron Dimetcote 6

, EDO -

                     Executive Director for Operations (NRC)

l E&I -

                     Electrical and Instrumentation

l ETG -

                     Electrical Test Group (TUEC)

i

       FDSG -        Field Damage Study Group (TUEC)
       FJO     -
                     field job orders
       FP      -
                     fire protection
       FSAR -        Final Safety Analysis Report
       FW      -
                     field weld

l. GAP - Government Accountability Project l GDC' - general design criteria

       GE      -     General Electric Corporation
      :GED
               -     General Equivalency Diploma
       G&H     --
                     Gibbs & Hill
       GHH -         Gibbs & Hill hanger (isometric drawing)
       Comanche Peak SSER 7                     viii    .
                                                                                      __
   .
 l  .'
       HFT  -
                   hot functional test
       HIR -       hanger inspection report                          .
       HP   -
                   hanger package
       HVAC -      heating, ventilation and air conditioning system
       HX   -
                   heat exchangers
       IAP  -
                   Independent Assessment Program
       IE   -
                   Office of Inspection and Enforcement (NRC)
       IEEE -      Institute of Electrical and Electronics Engineers
       IM   -
                   interoffice memorandum (TUEC)
       INP0 -      Institute for Nuclear Power Operations
       IR   -
                   inspection report (NRC)
       IRN  -
                   item removal notice
       ITT-G -     ITT Grinnell
       JTG  -
                   Joint Test Group (TUEC)
       JUMA -      Joint Utility Management Assessment Group
       LOCA -      loss of coolant . accident
       LP   -
                   liquid penetrant
       MAR  -
                   maintenance action request
       M&P  -
                   mechanical and piping
       MCC  -
                   motor control center (GE)
       MDB -       master data base
       MIFI -      mechanical fabrication inspector
       MIL  -
                   material identification list (or log)
       MIME -      Mechanical Equipment Inspector
       MQE
            -
                   Mechanical Quality Engineering
       MRS  -
                   manufacturer's record sheet
       MWDC -      multiple weld data card
       N/A -       not applicable
       NCR -       nonconformance report (TUEC)
       NDE -       nondestructive examination
       HDT -       nondestructive testing
       NI   -
                   never inccrporated

l NONSAT - nonsatisfactory l NOV - Notice of Violation (NRC) l

       NPSI -      Nuclear Power Service Incorporated
       NRC  -
                   U.S. Nuclear Regulatory Commission
       NRR  -
                   Office of Nuclear Reactor Regulation (NRC)
       NSSS -      nuclear steam supply system

l O&M -

                   Operations and Maintenance (TUEC)

! OBE -

                   operating basis earthquake

l

       OI   -
                   Office of Investigations
       OJT  -
                   on-the-job training

l l

       Comanche Peak SSER 7                   ix
                                           _
                .
   .                                  _ _      -- .                        . - - - _ -  .    . . . .   _
 .          .                                                                                              -
     .   . .
     .
                                                                                                         .
             ~ OL          -
                                              operating license                                      -
               ORNL -                         Oak Ridge National Laboratory'
               PC          -
                                             protective coating
               PET         -
                                             permanent equipment transfer                 
              PFG          -
                                             paper flow group
            -PFS          -
                                             pipe fabrication shop
              PS4R -                         Preliminary Safety Analysis Report
              PSE         -
                                    ,        Pipe Suoport Engineering (TUEC)--

<

              PT          -        -
                                             preoperational test-
              PWR         -
                                             pipe whip restraints                                              ,
              P-305
                                 ~
                                             Carboline Phenoline 305
              QE         -
                                             quality engineer

,

              QA         -
                                             quality assurance
              QAI;
                                                                        _
                                                                                                               j
                               .
                                             quality assurance investigation (TUEC)
             QC
                        -
                                             quality control                  ,
                                                                                                               l
             RCB             '
                                            Reactor Containment Building
             RES -                          Office of Nuclear Regulatory Research (NRC)
             RFIC -                         request for information or clarification (B&R)
             RG        -
                                            Regulatory Guide (NRC)
            RI         -
                                            NRC Region I Office
       .    RIR        -
                                            receipt inspection report (TUEC)
            RIV        -
                                            NRC Region IV Office
            RHRS -                          residual heat removal system
            RPI -                           rod position indication
            RPS -                           report process sheet (TUGCO)
            RPV -                          reactor pressure vessel
            RPVI -                         reactor pressure vessel reflective insulation
            RRI -                          Resident Reactor Inspector (NRC)
            RV        -
                                           reactor vessel
            RWN       -
                                           room work notifications
           SAP       -
                                           startup administration procedure
           SALP -                         -Systematic Assessment of Licensee Performance (NRC)
           SAT      -
                                           satisfactory
           SAVC -                          structural assembly verification card
           SER      -
                                           Safety Evaluation Report-(NRC)
           SIS      -
                                           Special Inspection Services
           SMAW -                          shielded metal arc welding
           SNM      -
                                           special nuclear material
           50RC -                          Station Operations Review Committee
           SRIC -                          Senior Resident Inspector for Construction (NRC)
           SRT' -                          Special Review Team (NRC)
           SSE     -
                                          safe shutdown earthquake
           SSER -                         Safety Evaluation Report Supplement
          SSPC -                          Steel Structures Painting Council
          SSWP -                          station service water pumps
          SSI      -
                                          safe shutdown impoundsent
                                                                                                             i
          Comanche Peak SSER 7                                       x     .
 .
   .
  .
     STE~ -      system test engineer
     SWA  -
                 s.tartup work authorization                          *
     TDCR -      test deficiency change request
     TDR  -
                 test deficiency report
     10 CFR 50 - Title 10 rode of Federal Regulations Part 50
     TIDC ---    Division of Technical Information and Document Control (NRC)
     THE  -
                TUEC Nuclear Engineering
     TP   -
                 test program
     TPD  -
                 test procedure deviation
     Tr   -
                 transcript
     TRT -      Technical Review Team (NRC)
     TSI  -
                 thermolag
     TSMO -      Technical Services Mechanical Drafting
     TSP  -
                 tri-sodium phosphate
     TUEC -      Texas Utilities Electric Company
     TUGC0 -    Texas Utilities Generating Company
     TUSI -      Texas Utilities Service, Inc.
                                                                 '
     UCC   -
                 University Computing Company

1 UT -

                 ultrasonic test
     VCD -       vendor-certified drawing
     VT    -
                 visual weld (inspector)
     WDC -       weld data card
     WFML -      weld filler metal log
     WPS -       welding procedure specification
     Comanche Peak SSER 7                 ,
                                            xi
                                  .                                                                                                  .             - .
     .            ..
         , .         .
            .        .
                                                                                                                                                                      l
                                                                                                                                                                 }-   l
                -
                         Ecluate the adequacy of craft personnel training in the use of instaJla-                                                                y
                         tion manuals to establish root causes and appropriate corrective actions.                                                               f
                                                                                                                                                                      ,
                         This action shall be. integrated with other actions concerning craft                                                                    i    {
?=
                         personnel training addressed under QA/QC Category 8, "As Built."                                                                        0
                                                                                                                                                                      !
;-
               4.1.3 Electrical Equipment Separation (See Attachment 2, E&I Category 3)                                                                          h
                -
                         Reinspect all panels at CPSES, in addition to those in the main control                                                                 e
                         room for Units 1 and 2, that contain redundant safety-related cables within                                                             /
                         conduits or safety and nonsafety-related cables within conduits, and                                                                    :    ,

', either correct each violation of the separation criteria, or demonstrate t

                         by analysis the acceptability of the conduits as a barrier for each case
                         where the minimum separation is not met.

4

               -
                         Reinspect all panels at CPSES, in addition to those in the main control                                                           !

, . room identified in Table 1 of SSER for E&I Category 3, and either correct i

                         each violation of the separation criteria concerning separate cables and                                                         ;r
                         cables within flexible conduits, or demonstrate by analysis the adequacy                                                      - i.
                         of the flexible conduit as a barrier.                                                                                            -
               -
                        Correct two instances of violation of the separation criteria inside
                   - panels CPI-EC-PRCB-09 and CPI-EC-PRCB-03 concerning a barrier that had
                       .been removed and redundant field wiring not meeting minimum separation.
               .
                       . Submit the analysis that substantiates the acceptability of the criteria
                        stated in the electrical erection specifications governing the separation                                                                ,
                        between independent conduits and cable trays.                                                                                    ;
                                                                                                                                                         ;
              +
                        Evaluate the adequacy of the QC inspection program as related to the                                                             u
                        deficiencies identified above to establish root causes and appropriate                                                           i .'.
                        corrective actions. These actions shall be integrated with other actions
                                                                                                                                                         l'           ,
                        addressed under E&I Category 6, " Electrical QC Inspector Training and                                                           -
                        Qualifications," and QA/QC Category 8, "As Built."
              4.1.4        Control Room Ceiling Fixture Supports (See Attachment 2, E&I Category 4)                                                     i.
i             -
                        Substantiate (1) the adequacy of the overall seismic support system                                                             i <.

4 installation for all the items located above the ceiling in the control y

                        room, including nonsafety-related conduit, suspended ceiling and lighting                                                      !
                        and (2) the adequacy of the seismic support system installation for                                                            -
                                                                                                                                                               +
                        nonsafety-related conduit in Seismic Category I areas of the plant other                                                       :
                                                                                                                                                                 .'
                                                                                                                                                                   .

< than the control room. This action shall be integrated as appropriate

                       with other actions addressed under Civil / Structural Category 14, " Seismic                                                             "
                        Design of Control Room Ceiling Elements."                                                                                      i
                                                                                                                                                                 y
              4.1.5 Electrical QC Inspector Training / Qualifications (See Attachment 2,                                                                       N
                           E&I Category 6)
                                                                                                                                                               .
                                                                                                                                                                {

! -

                        Evaluate the testing program for QC electrical inspector qualifications                                                         . di.
                       and develop a testing program which optimizes administrative guidelines,                                                                F
                       procedural requirements and test flexibility to assure that suitable
                       proficiency is achieved and maintained.
                                                                                                                                                                    t

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                                                                                                                                                             .
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                 1.      Allegation Category: Electrical and Instrumentation 4, Control , Room
                         Ceiling Fixture Supports
                2.       Allegation Number: AE-17
                3.
                         Characterization: It is alleged that the field run conduit, drywall,
                         and lighting installed in the area above the equipment panels in the
                         control room were classified as nonseismic, and as such were only
                         supported by wires.
                4.      Assessment of Significance:                The implied safety significance is that the
                         seismic qualification of certain equipment located above the ceiling in
                        the control room could be indeterminate and consequently its behavior
                        during a seismic event could not be predicted.
                        The central concern of this allegation is whether Texas Utilities Electric
                        Company (TUEC) considered the positions of Regulatory Guide (RG) 1.29,
 "
                        " Seismic Design Classification," as augmented by Final Safety Analysis
                        Report (FSAR) Section 3.2.1.2, " Seismic Category II," during the design of
                        the support systems in the control room for the nonsafety related field
                        run conduit, for the suspended drywall ceiling, and for the lighting
                        fixtures.
       ,
                       Regulatory Guide 1.29 states that nonsafety-related structures, systems,
                       or components whose failures could reduce the functioning of any plant
   ;
    l l  ,
                       feature to an unacceptable safety level or could result in incapacitating
 j
       ;
                       injury to occupants of the control room should be designed and constructed
                      so that the safe shutdown earthquake (SSE) would not cause such failure.
    1
                      FSAR Section 3.2.1.2 provides TUEC's commitments to these positions, and
   d                  designates as seismic Category II the nonsafety related equipment that
    ,
                      will be encompassed by the positions of RG 1.29.
     t
                     Field Run Conduit.                   The NRC Technical Review Team (TRT) examined conduit
                      seismic installation notes and detail drawings, design change author-

) iji

                      izations (DCAs), work packages, physical configuration drawings and other
                     documents pertinent to this issue. The TRT also inspected conduit

lh i

   l                 installation in the area above the control room ceiling and determined
                     that the safety-related' conduit was fastened by seismic Category I
                                                                                                                  ,
   .;
                     supports typical of those used in other areas of the facility.                  The

L nonsafety-related conduit was secured by supports which were of a dif-

                     ferent design than those for safety-related conduit. None of the non-

li safety-related conduits examined by the TRT were greater than 2 inches in

 ;                  diameter. In addition, they were not supported by seismic C:ategory I

J

                    supports and did not have seismic Category II cable restraints. The TRT

i dete~rmined that engineering drawing 2323-5-0910, " Conduit and Junction

 !
                    Box Supports," did not require seismic Category II cable restraints for
 j
                    nonsafety-related conduits less than or equal to 2 inches in diameter,
                    but required them for conduits greater than 2 inches in diameter.
 <
                    The TRT also examined similar nonsafety-related conduit installations
 t
                    in other seismic Category I areas of Unit I and found that seismic
                    Category II stainless steel cable restraints were used as bcckup to the

,

                    nonseismic dead weight supports for the conduits greater than 2 inches

'

                                                                    J-45
                                          . . - . . . - -                F
             , -
         :
     _ _
               -
         .     .
                    in diameter.     Tl.e TRT staff also found that the installation of nonsafety-
                    related conduit less than or equal to 2 inches in diameter in the' control
                    room was consistent with that used throughout the plant.
   ,
                    Suspended Drywall Ceiling.     The TRT found that the suspended ceiling
                    above the central part of the control room was made of drywall sheets
                    arranged to form a sloping wall around that area. These drywall sheets         i
                    were fastened to a metal framework (metal batten) supported by thin-           :
                                                                                                   '
                    walled channels (1-1/2-inch by 1/2-inch) attached to the primary building
                    concrete. The metal framework was also attached to the concrete by a           i
                    system of 1/8-inch stainless steel cables such that if the thin-walled
                    channel supports failed during a seismic event, the weight of the framing
                    and drywall would be assumed by the cabling.
                     Lighting Fixtures.     The TRT reviewed the installation of the lighting
                     fixtures over the control panels and central part of the control rcom
           '
                    and found that they were supported from an intermediate substructure
                     of "unistrut" by light-weight conduit. The substructure was likewise
                     supported by light-weight conduit from the primary building ceiling.
   ,
                     The conduit used is typical of that supporting the light fixtures in
                     suspended ceiling applications. Parallel with each lighting support
                     conduit are two 1/8-inch stainless steel cables which would assume the
                     load if the support conduit or its attachment were to fail. Other
                     individual light and reflector assembly fixtures, separate from those
                     supported by the intermediate "unistrut" substructure, were secured by
                     a similar type of conduit and backup cable design arrangement with the
                     cable attached to the edge of the light reflector assembly.
                     Based on the review of engineering drawings and direct inspection of
                     the installation, the TRT determined that the positions of RG 1.29, as
                     augmented by FSAR Section 3.2.1.2, were not met by the installation of
                     the fixtures located in the area above the panels and central part of the
                     control room.
                     As discussed above, the nonsafety-related conduit in the area above the
                     control room suspended ceiling was not fastened by seismic Category I
                      supports and/or seismic Category Il cable restraints. With regard to the
                      suspended drywall ceiling, it appeared that the installation met TUEC
                      commitments to the positions of RG 1.29. However, the final resolu-
                      tion of this technical issue, including the nonsafety-related conduit
                      support system, will depend on the review and approval by the TRT of an

t

                      analysis to be provided by TUEC concerning the adequacy of the seismic
                      support system installation in the control room.

e

                      The TRT inspected selected seismic Category I areas of the plant, reviewed

( associated engineering drawings, and determined that only nonsafety-related

                      conduits of less than or equal to 2 inches in diameter were not fastened
 s
                      by seismic Category II cable restraints.
 h
 i'              5.   Conclusions and Staff Positions: The TRT concludes that the installation
 b                    of the nonsafety-related conduit in the control room appears to be
 4                     inconsistent with the positions of RG 1.29. Accordingly, this part of
                       the allegation is of concern. With regard to the suspended ceiling and
                                                         J-46
 k
 c
                                                                                                                                1
                             . .
                           -
                  -              .                                                                                              1
                ,                ~
               ;         l                                                                                                      !
               <         t                     lighting supports, the acceptability of the installation will depend on          ,
                                               the approval by the TRT of the analysis to be provided by TUEC concerning        i
               j
                                               the adequacy of the seismic Category II restraints in the control room.          I
           "                                  This technical issue, including the nonsafety related conduit support
               !
                                               system, will be resolved after the review of TUEC's seismic analysis
                1                             substantiating the adequacy of the overall seismic support system installa-
                                              tion in the control room. The results of the TRT review of TUEC's
              J
                       .
                                              analysis will be reported in a supplement to this SSER.
              f       i
                s
                                              Based on the review of other seismic Category I areas of the plant,
               i
                    -
                                              the TRT concludes that the acceptability of the installation will
                                              depend on TRT approval of TUEC's analysis of the adequacy of the
                                              seismic support installation for nonsafety-related conduits in areas
              4
                                              of the plant other than the control room.
              c
              il                             The TRT further concludes that the lack of analysis to substantiate the
                                             adequacy of the seismic design installations inspected may be an indica-
              ,
                                             tion of weakness in the QA/QC program concerning design control. This
                                             area is addressed under the QA/QC Category 1, " Design Process."*
                                       5.    Action Required:    TUEC shall perform the following actions prior to fuel
              *
                                             load:
            .I
                                             (a) Provide the TRT with analyses that substantiate (1) the adequacy of
                                                    the overall seismic support system installation for all the items
                                                    located above the ceiling in the control room, including nonsafety-
            Q
            t
                                                    related conduit, suspended ceiling, and lighting fixtures and (2) the
                                                    adequacy of the seismic support system installation for nonsafety-
           l                                        related conduit in seismic Category I areas of the plant other than
                                                   the control room. This action shall be integrated as appropriate
                                                   with other actions addressed under Civil and Structural Category 14,
                                                   " Seismic Design of Control Room Ceiling Elements."
                                                                                                                              i
           j
           !
                                            (b) Evaluate the adequacy of the QA/QC program related to the deficiencies        I
          !
                                                   identified above to establish root causes and appropriate actions.         l
                                                  These actions should be integrated with other actions addressed under
          .
                                                   the QA/QC Category 1, " Design Process."
        t
        !
      ,     .
                                   .
          i
                                                                                                                            !
    '

i

   i

, 1 !

        :
                                     *The TRT evaluation of QA/QC allegations is in progress and will be published
   j                                  in a subsequent supplement to this SSER.                                            i
                                                                                                                          '
   1
                                                                              J-47                                        )

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         __                                                                                                             ..
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                                                                                                                           .
                                                                                                                           ,
             .       .
                                                                                                                           I
                                                                                                               .
                                                                                                                 *
                                                                                                            .
     C                                                    COMANCHE PEAK RESPONSE TEAM
                                                                                                             .
                                                                       ACTION PLAN
                                                               Item Number:       II.a
                                 .
                                              Title:
                                                        Reinforcing Steel in the Reactor Cavity
                          Revision No.                0                       1
                                                                                                   2
                          Description          Original Issue
                                                                  Revised to Reflect          incorporates
                                                                  NRC Comments                     SSER
                                                  fed 4L        /
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                        ' Prepared and
                         Recommended by:
                        Review Team Leader
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       -    *
    ,,     ..
              .
                                                                                        Revision:   2
                                                                                        Page   1 of 7
                                                                                           .
                                                         ITEM NUMBER II.a
                                            Reinforcing Steel in the Reactor Cavity
         .
                       1.0 DESCRIPTION OF ISSUE IDENTIFIED BY NRC
                .
                  -
                              The TRT investigated a documented occurrence in which reinforcing
                              steel was omitted from a Unit I reactor cavity concrete placement
                              between the 812-foot and 819-foot 1/2 inch elevations. This
                              reinforcement was installed and inspected according to drawing
                            .2323-S1-0572, Revision 2. However, after the concrete was placed.
                              Revision 3 to the drawing was issued showing a substantial increase
                              in reinforcing steel over that which was installed. Gibbs & Hill
                             Engineering was informed of the omission by Brown & Root Non-
                             conformance Report CP-77-6. Gibbs & Hill Engineering replied that
                             the omission in no way impaired the structural integrity of the
                             structure.    Nevertheless, the additional reinforcing steel was
                             added as a precaution against cracking which might occur in the
                             vicinity of the neutron detector slots should a loss of coolant
                             accident (LOCA) occur. A portion of the omitted reinforcing steel
                            was also placed in the next
                             level. This was done to' par
                                                                  te lift above the 819-foot -inch
                                                                   compensate for the reauforcing
                             steel omitted in the previous         .te lift and to minimize the
                            overall area potentially subject . cracking.
                     '      The TRT requested documentation indicating that an analysis was
                            performed supporting the Gibbs & Hill conclusion. The TRT was
                            subsequently informed that an analysis had not been performed.
                            Therefore, the TRT cannot determine the safety significance of this
                            issue until an analysis is performed verifying the adequacy of the
                            reinforcing steel as installed.
                    2.0 ACTION IDENTIFIED BY NRC
                           Accordingly, TUEC shall provide an analysis of the as-built
                           condition of the Unit I reactor cavity that verifies the adequacy
                           of the reinforcing steel between the 812-foot and 819-foot 1/2-inch
                           elevations. The analysis shall consider all required load
                           combinations.
                  3.0 BACKGROUND
                           3.1     Information Supplementing NRC Description of Issue
                                  The concrete placement of the reactor cavity wall between
                                  elevations 812'-0" and 819'O " was made according to
                                  Revision "2" of Gibbs & Hill drawing 2323-S1-0572. Subsequent
                                  Revision "3" of the same drawing added reinforcing steel in
  (-
  f                               part of the wall that was already constructed in accordance
                                  with the prior revision of the drawing. Upon receipt of this
                                  drawing in the field, SDAR CP-77-6 and NCR-C-669 vere issued
                                  to document that the concrete placement had been performed to
                                                            .
 s'-                                                                              4
        -
          .- ,
   ,,
                                                                                     Revision:    2
                                                                                     Page   2 of 7
                                                   ITEM NUMBER II.a
                                                          (Cont'd)
                  3.0 BACKGROUND (Cont'd)
                               Revision "2" of the drawing and the reinforcing steel added
               A
                               per Revision "3" was not installed. Gibbs & Hill reviewed the
                               design with respect to this as-built condition and determined
                               the as-installed reinforcement to be acceptabic. The Gibbs &
                              Hill Structural Job Engineer had these rebars added on
                              " Revision "3" based on engineering' judgement to minimise the
                              possibility of cracking, although calculations for the cavity
                              had not required these bars. The Gibbs & Hill reply forwarded
                              by GTN-19823 confirmed the as-built condition did not impair
                              the structural integrity of the reactor cavity wall. Specific
                              calculations justifying the adequacy of the reactor cavity
                              were  not generated by Gibbs & Hill, because the initial design
                              per Revision "2"
                                                 of the drawing along with its design
                              calculations did not require the reinforcement.
                       3.2 Preliminary Determination of Root Cause and Generic
                              Implications
                             The preliminary reviews conducted to date have not identified
      .
                             a root cause for this item. Implementation of the action plan
                             is necessary before a root cause determination can be made.
                             The consideration of generic implications will include a
                             review of all reinforcement omissions as documented on project
                             NCRs.   Generic implications will be evaluated based on the
                             results of the implementation of the action plan and the
                             results of the root cause determination.
                4.0   CPRT ACTION PLAN
                      4.1    Scope and Methodology
                            This action plan Ie designed to assess the design adequacy of
                            the existing as-built condition of reactor cavity wall and
                            other areas within Units 1 & 2 where rebar were omitted
                            including an evaluation of the engineering / field design change
                            interface. An analysis of the as-built reactor cavity wall
                           vill be performed to demonstrate adequacy of installed
                            reinforcing steel considering all applicable loading
                           combinations. Engineering calculations with applicable
                           assumptions stated therein will be performed to evaluate the
                           subject wall with "as installed" reinforcing steel between
                           elevations 812'-0" and 819'-01".    s   A third-party reviewer will
                           verify the adequacy of the calculations.
                           The circumstances and engineering evaluation that led to the
 .

'

                           provision for, and subsequent deletion of, the subject
                           reinforcement in reactor cavity wall vill be analyzed in light
                          of design intent and structural integrity of the wall.
                                                        .
 .                                                     .

I *

                                                                                                    ,,
                                                                         ._    _
          - -
              .
   ,,
                                                                                     Revision:    2
       -_                                                                            Pag,e  3 of 7
                                                                                         .
                                                     ITEM NUMBER II.a
                                                            (Cont'd)
                     4.0 CPRT ACTION Pl.AN (Cont'd)
        .

,

                ,
                                In order to consider possible generic implications, all
                   -            instances of reinforcement omissions for Units 1 & 2 as
                 '
                                documented in project NCRs will be researched. This effort
                                will cover all the safety related Class I building structures.
                                A review of every case will be made to ascertain proper
                                engineering evaluation and documentation exists in support of
                                the disposition of each item. Additional documentation will
                               be developed as required to insure appropriate disposition.
                               As a further test, a random sample of 60 concrete pour cards
                               will be selected and reviewed to verify that the current
                               design documents pertaining to reinforcement were'used in
                               construction. This activity will also provide an increased    ~
                               level of assurance that all instances of reinforcement
                               omissions were identified. For this purpose, the revision
                               numbers of the reinforcement drawings referenced on the pour
                               cards will be comparsd to the current design documents and all
                               reinforcement differences noted and evaluated.

,

        ,
                              An overall review of procedures governing design changes will
                              be performed to verify the adequacy of methods for controlling
-
                              Laplemention of design changes into construction. Emphasis
                              will be placed on a review of project procedures used to
                              convey impending design changes immediately affecting ongoing

+ construction activity. The effectiveness of procedures

                              controlling such construction activities will be verified by
                              reviewing implementation of all rebar omission cases and major
                              embedments. The engineering field interface review of major

l l embedments will serve as another " test" of the adequacy of

                              controls implemented by the civil discipline. The flow of
                              activities initicted by engineering to convey impending design
                              changes to the field as well as action leading towards
                             appropriate construction hold will be identified and
                             evaluated.                                                                 ;
                                                                                                        t
                                                                                                        1

i L Upon conclusion of the procedural implementation review of ! rebar omissions and embedments, a determination will be made

                                                                                                          i
                             of the potential applicability of any findings to other areas
                            within the civil discipline. The engineering field design                    '
                             change interface review will be broadened to include further
                             evaluation outside the civil discipline if findings suggest              f'
                             that other disciplines could have similar problems.                      !
                            The overall process for closure of this issue will be reviewed
                            by the third-party reviewer.                                             I

i(/ !

    _,
                            The attached logic diagram identifies major tasks and the

l interrelationships of taska necessary for meeting the E L

                            preceding objectives.
+ ,
                                                          7
                                                       .._ - _ - - - - - - - - - - - -
                                                        .

_

        
 .,        .
                                                                                   Revision:    2
                                                                                   Page  '.4 of 7
       -
                                                                                      .
       l                                         ITEM NUMBER II.a
                                                      (Cont'd)
                4.0 CPRT ACTION PLAN (Cont'd)
                     4.2 Responsibilities
             I.
             ~            The organizations and personnel that will participate in this
                          effort are described below with their respective scopes of
                          work.
                          4.2.1     Comanche Peak Project Civil Engineering
                                    4.2.1.1  Scope
                                                  -
                                                     Reviewing project NCR's for rebar
                                                     omission cases
                                                  - Developing additional documentation if
                                                     required to insure appropriate
                                                     disposition of rebar omission NCR's.
                                         '
     .
                                                 -
                                                     Reviewing pour card for rebars
                                                -
                                                     Reviewing pour card for embedments
                                                -
                                                     Aaatstance in procedural review
                                                     governing design changes and control of
                                                     construction activities
                                                -
                                                     Assistance in overall engineering
                                                     evaluation and development of Action
                                                     Plan Results Report
                                   4.2.1.2  Personnel
                                            Mr. C. R. Hooton         Project Civil Engineer
                                            Mr. D. C. Patankar Civil / Structural Lead
                                                                     Engineer
                        4.2.2    Gibbs & Hill, Inc., New York, N.Y.
                                 4.2.2.1    Scope
                                              -
                                                    Cibbs & Hill, Inc., Structural
                                                    Department - will perform the analysis /
                                                    design calculations as required under
                                                    this action plan including the required
                                                    design review of these calculations.
  s_ .
                                                                                                  I
                                 -
                                                                                                  :
                                                                                                  !-
         ~

,,.* ... ,

                                                                                       Revision:     2
                                                                                       Pag,e   5 of 7
                                                                                           .
                                                  ITEM' NUMBER II.a
  ,
                                                        (Cont'd)
               4.0 CPRT ACTION PLAN (Cont'd)
                                   4.2.2.2     Personnel
            I-
                                               Mr. E. L. Beskor          Structural Job Engineer
                                               Mr. A. M. Kenkre         Structural Squad Leader
                                               Mr. S. Sengupta          Senior Engineer
                                               Mr. C. Zion
                                 -
                                                                       Senior Engineer
                                               Mr. M. N. Shah          Senior Engineer
                         4.2.3     Third-Party Activities
                                   4.2.3.1     Scope                                         '

.

                                                  -
                                                     perform design review of calculations
                                                     prepared by Gibbs & Hill, Inc.
          -
                                                 -
                                                     review of engineering / field design
                                                     change interface.
                                                 -
                                                     overview of NCR and pour. card reviews
                                                 -
                                                     evaluation of overall conclusions
                                                -
                                                     preparation of Results Report
                                 4.2.3.2    Personnel
                                            Mr. H. A. Levin         TERA - CPRT Civil /
                                                                    Structural Review Team
                                                                    Leader
                                            Dr. C. Mortgat          TERA - Senior Structural
                                                                    Engineer
                                            Dr. J. Arros            TERA - Structural
                                                                                                       '
                                                                    Engineer
                   4.3 Personnel Qualification Requirements
                        Participants in the implementation of this action plan meet                    1
                        the personnel qualification requirements of the Program Plan
                        or the CPSES Quality Assurance Program as applicable.
                                                                                     .
                                                      .
    '
                          _    ,    .        .       _f              _ . . _ _  _    -.
 .,,...*'.
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                                                                                   Revision:   2
                                                                                   Page   6 of 7
  . -
                                                                                      ,
     ,
                                                  ITEM NUMBER II.a
                                                        (Cont'd)
                                s
                  4.0. CPRT ACTION Pl.AN (Cont'd)
                        4.4 Procedures
                               Calculations and evaluations performed by CPPE Civil
               -
              *
                               Engineering and Gibbs & Hill will be performed in accordance
                               with the procedures normally applicable to those activities
                               for CPSES. Third-party activities will be conducted in
                               accordance with applicable CPRT guidelines.
                        4.5 Standards / Acceptance Criteria
                              Building Code Requirements for Reinforced Concrete -
                              ACI-318-71 and stipulations of section 3.8 of FSAR form the
                              basic standard / acceptance criteria of calculations performed
                              under this action plan.
                       4.6    Decision Criteria
                        '                                                                        -
                              If the documentation supporting "use as-is" rebar omission
                             approvals is found insufficient, the documentation will be
                             supplemented as required to provide complete justification for
       _
                             prior engineering judgements.
                            The results and conclusions of analysis / calculations performed
                            and the evaluation of procedures governing the engineering /
                             field d' sign change interface and the evaluation of
                            implementation of these procedures in two areas of the civil
                            discipline will provide the basis for determination of the
                            potential applicability to other areas and the need to broaden
                            the review further.
                5.0 SCHEDULE
                      Cavity Wall Analysis:                      Complete
                      Documentation Review:                      04/26/85
           ..
                      Procedure Review:                          05/10/85
                      Procedure Implementation Review:           05/10/85
                     Conclusions:                                06/01/85

,

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                                              COMANCHE PEAK RESPONSE TEAM
                                                      ACTION PLAN
                      ,
                                                 Item Number:      II.e
                     ,-              Title: Rebar in the Fuel Handling Building
               Revision No.                0                     1             2
                                                    Revised to Reflect     Incorpora tes
               Description.       Original Issue    NRC Comments               SSER
                                  WQC5
      -
                                     tels Itt
  (.                                                                                .
              Prepared and                                                 ,
                                                                               ,
              Recommended by:                                              ./
              Review Team Leader
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              Approved by:            /] 7;/*'
                                             7 [                                                 !
              Senior Review Tess   
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                                                                                   Revision:    2
                                                                                   Pagg   1 of 7
                                                                                       .
                                                     ITEM NUMBER II.e
.
                                           Rebar in the Fuel Handling Building
                  1.0 DESCRIPTION OF ISSUE IDENTIFIED BY NRC
              *
               .
                           The TRT investigated an alleged instance of unauthorized cutting of
               .
                           reber associated with the installation of the trolley process aisle
                           rails in the Fuel Handling Building. The claim is that during
                           installation of 22 metal plates in January 1983, a core drill was
                           used to drill about 10 holes approximately 9 inches deep. The TRT
                           reviewed the reinforcement drawings for the Fuel Handling Building
                          and determined that there were three layers of reinforcing steel in
                          the top reinforcement layer of the slab. This reinforcement layer
                          consisted of a No.18 bar running in the east-west direction in the
                          first and third layers, and a No. 11 bar running in the north-south
                         direction on the second layer. The review also revealed that the
                          layout of the reinforcement and the trolley rails was such that the
                         east-west reinforcement would interfere with the drilling of holes
                         along only one rail location. However, if 9-inch holes were
                         drilled, both the first and third layers of No. 18 reinforcement
                         would be cut.     Design Change Authorization No. 7041 was written for
                         authorization to cut the uppermost No. 18 bar at only one rail
                         location, but did not reference authorization to cut the lower No.
                         18 bar. DCA-7041 also stated that the expansion bolts and base
                        plates may be moved in the east-west direction to avoid
                        interference with reinforcement running in the north-south
                        direction. The information, described in DCA-7041, was
                        substantiated by Gibbs & Hill calculations. If the ten holes were
                        actually drilled 9 inches deep, then the allegation that the
                        reinforcement was cut without authorization would he valid.
               2.0 ACTION IDENTIFIED BY NRC
                                                                                                     [
                      Accordingly TUEC shall provide:                                                i
                      -
                                Information to demonstrate that only the No. 18 reinforcing
                                steel in the first layer was cut, or
                     -
                               Design calculations to demonstrate that structural integrity
                               is maintained if the No. 18 reinforcing steel on both the
                               first and third layers was cut.
              3.0 BACKGROUND
      -
                     3.1       Information Supplementing NRC Description of Issue
                              It is alleged that during the drilling of holes for

{* --

                              installation of the Hilti Kwik bolts for process aisle trolley
                              rails at El. 810'-6", 10 holes were drilled approximately 9
                              inches deep. This depth would cut through top and bottom
                                                                                                    J
                                                         *
                                                         .
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                                                                                          Revisien:    2
         .
                                                                                          Page,  2 of 7
                                                        ITEM NUMBER II.e
                                                             (Cont'd)
                       3.0 BACKCROUND (Cont'd)
                                     (1st and 3rd layers) of the east-west No. 18 reinforcing steel
                    .
                                    located in the top reinforcement of the concrete mat. No. 18
                   :
                                    reinforcing steel also runa longitudinally along the aisle
                                    rails in the east-west direction but without a potential for
                                    interference since the Hiltis and rail do not line up. The
                                   governing design document (DCA #7041) authorized cutting of
                                   only top (1st layer) No. 18 bar at only one rail location.        It
                                    is evident from a review of drawings that reinforcement would
                                   be encountered at only one rail location in east-west
                                   direction due to the spacing of rebars running east-west
                                   compared to the spacing of rails and Hilti bolts. The design
                                   required the rail base plates to be so located in east-west
                                   direction to avoid cutting of 2nd layer of No. 11 rebar which
                                   runs in the north-south direction. A field inspection has
                                  verified that at one location in the east-west direction, the             *
                                                                                                             .
                                   1st and 3rd layers of rebar could have been cut, based upon
    -
                                   the size of Hilti bolt installed.
                                                                                            .
                            3.2 Preliminary Determination of Root Cause and Generic
                                  Implications
     -
                                 The preliminary reviews conducted to date have not 1!entified
                                 a root cause for this ites. Implementation of the action plan
                                 is necessary before a root cause determination can be made.
                                 Generic implications will be evaluated based on the results of
                                 the implementation of the action plan and the results of the
                                 root cause determination.
                   4.0     CPRT ACTION PLAN
                           4.1  Scope and Methodology
                                This action plan is designed to assess the as-built condition
                                of the concrete mat at elevation 810'-6" of the fuel handling
                                building, to assess the work of the construction crew that
                                could have cut an additional rebar without proper                                t
                                                                                                                  ,.
                                authorization, as well as a review of controls governing rebar
                                cutting.                                                                         [
                                                                                                                 {
                                Design calculations will be generated to demonstrate that the                    l-
                                                                                                                 -
                                structural design requirements of the concrete mat at

i

                                elevation 810'-6" will be met assuning a No. 18 bar in the 3rd                   f
                                layer is cut.
                                                                                                                (

-

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                                                                                     Revision:    2
                                                                                     Pag,e  ,3 of 7
                                                                                            _
      (.
                                                  ITEM NUM3ER II.e
                                                                                         .
                                                          (Cont'd)
                    4.0 CPRT ACTION PLAN (Cont'd)
                              The adequacy of procedural controls govmdag rebar cutting
                 -l           either at Hilti or core bore installt*. lens will be reviewed.
                 -            These activities will include control ci~ cebar cutting
                              machines, craft procedures, inspections and proper engineering
                              authorization.
                              All the cases from Unit 1 & 2 where rebar cutting was
            -
                              requested for installation of Hilti bolts will be studied.        A
                              determination of the possibility of additional (i.e.
                              unauthorized) rebar cut will be made based on reinforcement
                             pattern in slab or wall vis-a-vis embedment depth of the Hilti
                             bolt installed. Field inspection will be conducted in such
                             cases to verify actual installed embedded length of Hilti
                             bolts.
                             The Hilti bolt installation work performed by the construction
                             crew that installed the subject 'Hilti' bolts, will be
                             reviewed over a period of eight months (i.e. timeframe crew
                             worked together) surrounding the subject installation. This
       .
                             review will include installations where rebar cut
                             authorization was requested by this crew and a potential
                            violation of such authorization by this crew while installing
                            Hilti bolts.
                            The attached logic diagram identifies tasks and the inter-
                            relationship of taska for resolution of this action plan.
4.2 Participants Roles and Responsibilities

! , i The organizations and personnel that will participate in this

                            effort
                            work.
                                     are described below with their respective scopes of
                            4.2.1    Comanche Peak Project Civil Engineering

i

                                     4.2.1.1   Scope
                                                                                                         .

l

                                                    -
                                                            will perform design calculations

l documenting the adequacy of the I

                                                            elevation 810'-6" mat

l

                                                   -
                                                           will review controls for cutting
                                                            rebar                                      i'

i l

                                                   -
                                                           will evaluate work of subject                I
                                                                                                         !
 (                                                         construction crew and selected
   _
                                                           review of other rebar cut situations
                                                                                                       e

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                                                      -
                                                                                                       3
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                                                                                                                                                                       ITD( NUMBER II.~e
                                                                                                                                                                                  (Cont'd)
                                                                                               4.0 CPRT ACTION Pl.AN (Cont'd)                                                 .,
                                                                                                                                                                                                                 .
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                                                                                                                                                                                           will; assist' tai overall? engineering 
 d                                        v                                                                                                                                             ' evaluations'and' development-of 3-
                                                                           3. -                                                                                                            Action Plan Results Raporti
                                                                                                                                           4.2.1.2                 Personnel
                                                                                                                                                                  Mr. C. R. Hooton                         Project Civil Engineer
                                                                                                                                                                  Mr. D. G. Patankar Civil / Structural Lead
                                                                                                                                                                                                          Engineer
                                                                       .
  .             -
                           ,
                                                                                                                                                                  Mr. S. A. Raz                           Structural Engineer
                                                                                                                         4.2.2 Cibbs & Hill - Site Design Review Team
                                                                                                                                                                                                                                                               .
                                                                                                                                         4.2.2.1                  Scope
                                                                                                                                                                            -
                                                                                                                                                                                          site design Review Team will design
                                                                                                                                                                                          review calculations performed by
                    4-
                                                                                                                                                                                          CPPE Civil Engineering
 i
                                                                                                                     .
                                          '
                                                                                                                       6                 4.2.2.2                                                                     f
                 }                                                                                                                                                Personnel                                                           .-
                                                                                                                                                                                                                                               v
                                                                                                                                                                 Mr. B. Wilcoxson                        Design Review Group
                                                                                                                                                                                                         Supervisor
                                                                                                                                                                 Mr. B. K. Bhujang                       Structural Group Lead
                                                                                                                                                                Mr. k. P. Shah                           Principal Engineer
                                                                                                                       4.2.3            Third-Party Activities                                                                                                               ',
                                                                                                                                       4.2.3.1                  Scope                                                              ,
                                                                                                                                                                                                                                                                             t
                                                                                                                                                                                                                                               . .
                                                                                                                                                                          -
                                                                                                                                                                                        overview inspection to determine.                                                    j
                                                                                                                                                                                        actual lengths of Hilti boltsfused.                                                  I
                                                                                                                                                                                        where rebar cutting was required for                                                {
                                                                                                                                                                                        Hilti bolt installation                              * 
                                                                                                                                                                                                                                                     '
                                                                                                                                                                                                                                                                            !
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                                                                                                                                                                                                                                                                            k
                                                                                                                                                                          -
                                                                                                                                                                                        review of analysis / calculations to
                                                                                                                                                                                       verify adequacy of elevation 810'-6"
                                                                                                                                                                                       mat
                                                                                                                                                                        -
                                                                                                                                                                                       review of procedural controls for
                                                                                                                                                                                       rebar cutting
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                                                                                                                                                                                    ITEM NUMBER II.e
                                                                                                                                                                                                                                           '
                                                                                                                                                                                                                                   "
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                                                                                                                                                                       (Cont'd)

, , , ?n 4.0 CPRT ACTION PLAN (Cont'd) *

                                                                                                                                                                                                       '
                                                                                                                                                               - .                                                              ~

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                                                                                                                                                                                                                     ,
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                                                                                                                                                                            verification 'of,isplementation of"

1,

                                                  (;                                                                                                                        installation by. subject crew and

p

                                                                                                                                                                 '
                                                                                                                                                                            other reber cut ofcuations-
                                                                                                                                                                     -

l overall evaluation of resolution of

                                                                                                                                                                           action plan
                                                                                                                                                                     -
                                                                                                                                                                          preparation of Results Report.
                                              '

/ .

                                                                                                                                          4.2.3.2          Personnel

l .

                                                                                                                                                          Mr. H. A. Levin                           TERA, CPRT Civil /
  .                                                                                                                                                                                                 Structural Review Team ,,
                                                                                                                                                                                                    Leader
                                                                                                                                                          Dr. C. Mortgat                            TERA, Senior Structural
      ,
                                                                                                                                                                                                    Engineer
                                                                                                                                                          Dr. J. Arros                              TERA.' Structural Engineer
 y.         ,
                                 '
                                                                                                                                                       'Mr. G. Lagleder^                                               ^
                                                                                                                                                                                                    Soutdures""t Researc' h i
                                                                                                                                                                                                    Institute
                                                                                  4.3 Personnel Qualification Requirements
                                                                                                                             Where inspections require the use of certified inspectors,
                                                                                                                             qualification will be to the requirements of ANSI N45.2.6 at
                                                                                                                              the appropriate level. CPSES personnel will be qualified in
                                                                                                                             accordance with applicable project requirements. Third-party
                                                                                                                             inspectors will be certified to the requirements of the third-
                                                                                                                             party employer's quality assurance program and specifically
                                                                                                                             trained to the requirements of the CPSES quality procedures.
                                                                                                                                                                                                                              . ,
                                                                                                                             Other participants will be qualified to the requirements'of
                                                                                                                                                                                                                                     ,
  '
                                                                                                                             the CPSES Quality Assurance Program or to the specific
                                                                                                                             requirements of the Program Plan.                                                              '
                                                                                                                                                                                                                            4;
                                                                             4.4 Procedures                                                                                                                                     '
                                                                                                                            Calculations and evaluations performed by CPPE Civil
                                                                                                                            Engineering and Gibbs & Hill will be performed in accordance
                                                                                                                            with the procedures normally applicable to those activities
                                                                                                                            for CPSES. Third-party verification activities will be
       ,                                                                                                                    conducted in accordance with applicable CPRT guidelines.                                                            A
      (. , t                   ,m      ,     #
                                                                                                                            procedure will be developed:for inspection lof Hilti bolt ..
                                                                                                                            installations where* embedded len
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                                                                                                                  ITEM NUMBER II.e
                                                                                                                           (Cont'd)
                                                4.0 CPRT ACTION PLANI (Cont'd),
 ;                                       -
                                                                         .-M....,                                                                                                                                              .

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                                            p[~.c 4'.5 " Standards
                                                                                                              ,
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                                         *                            ACI-318-71 Building Code Requirements For Reinforced. Concrete
                                                                      and stipulations of FSAR Section 3.8 formed the basic
                                                                      standards and acceptance criteria for original design of
                                                                      concrete sat at El. 810'-6" in Puel Handling Building which
                                                                      are documented in Calculation Book No. SFB 102C Section 1.
                                                                      The design calculations generated with this action plan will
                                                                      be consistent with the original design criteria.
                                                                                            '
                                                           4.6 Decision Criteria
                  -
                                                                      The results and conclusions of analysis / calculations performed
                                                                      as well as conclusions drawn from:
                                                                         -
                                                                                         review of procedural controls on rebar cutting
                                                                                        activity,

t

                                                                        -
                                                                                        review of situations where rebar cutting waa' necessary
                                                                                        for Hilti bo2t installation, and
                                                                                          ,,y
                                                                        -
                                                                                                       ..
                                                                                                                    ..
                                                                                                                             . r?: m            < */ u ,
 .
                                                                                        review of work performed by subject construction crew
                                                                                                            .
                                                                                                                               .
                                                                   will determine the acceptability of the as-built condition of
                                                                   the subject
                                                                   other       areas. case as well as the potential applicability to
                                                                                                       Any other unauthorized rebar cuts will be
                                                                   evaluated.
                                                                                                 Procedural controls will be revised to strengthen
                                                                   rebar cutting operations if determined appropriate.
                                            5.0 SCHEDULE
                                                         Mat Analysis:                                                                                                                                                                                    i
                                                                                                                                              Complete                                                                                                    i
                                                                                                                                                                                                                                                          j
                                                                                                                                                                                                                                                          (
                                                         Procedure Review                                                                     Complete
                                                                                                                                                                                                                                                          l
                                                         Procedure Revision:                                                                                                                                                          *
                                                                                                                                                                                                                                                          !
                                                                                                                                             05/06/85                                                                                                     i
                                                        Documentation Review:
                                                                                                                                                                                                                             .
                                                                                                                                                                                                                                 .
                                                                                                                                             04/26/85
                                                         Inspections:
                                                                                                                                             05/06/85
                                                        Engineering Evaluation (as required):                                                05/06/85
                                                        Results Report:                                                                                                                                                                                     I
                                                                                                                                             06/01/85                                                                     ,
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                                                                                                                  .
                                                                      COMANCHE PEAK RESPONSE TEAM
                                                                                  ACTION PLAN
                                                                          Iten Number:      II.d
                    ,
                     .
                                                 Title: Seismic Design of Control Room Ceiling Elements
                                                                                                        .
               Revision No.                                      0                        1               2
               Description-
                                                                             Revised to Refleci.     Incorporates
                                                       Original Issue        NRC Consnents                SSER
                                                       WlW/
    .
       '
                                                             nJsh'
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                                                                                                                                 .
              Prepared and
              Recommended by:                                                            7
               Review Team Leader
                                                                  i                   j
                                                             CCTb1                    --                  j, M
              Date                                       /cfC                      ; l lg5'         g     ylg(
                               .
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                                                                       .-
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                                                                                           Revision:   2
                                                                                           Page i of 18
        (                                                                                     .
                                                         ITEM NUMBER II.d
                                        Seismic Design of Control Room Ceiling Elements
                      1.0 DESCRIPTION OF ISSUE IDENTIFIED BY NRC
                               The TRT investigated the seismic design of the ceiling elements
                  l            installed in the control roca. The following matrix designates
                               those ceiling elements present in the control room and their
                               seismic designation:
                                1.  Heating, Ventilating and Air           '-
                                    Conditioning                              - Seismic Category 1
                               2.   Safety-Ralated Conduits              !    - Seismic Category I
                               3.   Nonsafety-Related Conduits                - Seismic Category II
                               4.   Lighting Fixtures                  '
                                                                              - Seismic Category II
                               5.   Sloping Suspended Drywall Ceiling         - Non-Seismic
                               6.   Acoustical Suspended Ceiling              - Non-Seismic
                               7.   Louvered Suspended Ceiling                - Non-Seismic
                               According to Regulatory Guide 1.29 and FSAR Section 3.7B.2.8, the
                               seismic Category II and non-seise.ic items should be designed in
                               such a way that their failure would not adversely affect the
                              functions for safety-related components or cause injury to
                              operators.                                                        *
       *
                              For the non-seismic items (other than the sloping suspended drywall
                              ceiling), and for nonsafety-related conduits whose diameter is 2
                              inches or less, the TRT could find no evidence that the possible
                              effects of a failure of these items had been considered. In
                              addition, the TRT determined that calculations for seismic Category

I

                              II components (e.g., lighting fixtures) and the calculations for
                              the sloping suspended drywall ceiling did not adequately reflect
                             the rotational interaction with the non-seismic items, nor were the
                             fundamental frequencies of the supported masses determined to
                             assess the influence of the seismic response spectrum at the
                             control room ceiling elevation would have on the seismic response
                             of the ceiling elements.

l 2.0 ACTION IDENTIFIED BY NRC i I Accordingly. TUEC shall provide

                           O       The results of seismic analysis which demonstrates that the
          (,     ]        l
                            -
                yw                 non-seismic items in the control room (other than the sloping
                                   suspended drywall ceiling) satisfy the provisions of
                                   Regulatory Guide 1.29 and FSAR Section 3.75.2.8.
    (-
      s
                                                            *
                                                                                                     +

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                                                                .

-

   ,-      :.
                                                                                     Revision:    2
                                                                                     Page 2 of 18
                                                                                        .
                                                       ITEM NUMBER II.d
                                                             (Cont'd)                           *
                       2.0 ACTION IDEhTIFIED BY NRC (Cont'd)
                              -
              d                    An evaluation of seismic design adequacy of support systems
                                   for the lighting fixtures (seismic Category II) and the
      \,   CO"{.  *
                    ,
                                   suspended drywall ceiling (non-seismic item with modification)
      _
                .
                                  which accounts for pertinent floor response characteristics of
                                   the systems.
                             -
                                  Verification that those items in the control room ceiling not
                                  installed in accordance with the requirements of Regulatory
                                  Guide 1.29 satisfy applicable design requirements.
                            -
                                  The results of an analysis that justify the adequacy of the
                                  non-safety related conduit support system in the control room
                                  for conduit whose diameter is 2 inches or less.
                #       '                                                                           .
                            -
                                  The results of an anaJysis which demonstrate that the
                                  foregoing' problems are not applicable to other Category II and
           ~                      non-seismic structures, systems and components elsewhere in
                                                                         '
                                                                                                      -
                                  the plant.
                                                                                          .
                      w-                                       .
   k
                      3.0 BACKCROUND
     _
                            3.1 Discussion of Specific Technical Issue
                                 Regulatory Guide 1.29 states: "Ihose portions of structures,
                                 systems, or components whose continued function is not
                                 required but whose failure could reduce the functioning of any
                                 plant feature included in Items 1.a through 1.q above to an
                                 unacceptable safety level should be designed and constructed
                                 so that the SSE would not cause such failure." Specifically
                                 Item 1.n states: "The control room, including its associated
                                 vital equipment, cooling systems for vital equipment, and life
                                 support systems, and any structures or equipment inside or
                                 outside of the control room whose failure could result in
                                 incapacitating injury to the occupants of the control room."
                                 The specific issue involves the ability of the control room            -
                                 ceiling and other non-safety related ceiling elements, i.e.
                                conduite and lighting fixtures to remain in place during a
                                seismic event thus avoiding the potential of disabling
                                operators due to its failure. Portions of the ceiling are
                                non-seismic, non-safety related and do not have provisions of
                                seismic Category II installations which are seismically
                                supported or restrained as described below.
                                In reviewing the design of the control room ceiling the TRT               i
    ,
                                has requested that anslyses be provided which demonstrate that
                          ,     the provisions of Regulatory Guide 1.29 and FSAR section
                                3.7B.2.8 have been satisfied for all non-safety related items.            ;
                                                                                                          i
                                                           .
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                                                                    ._.             .                                                                        _ _ -
              '
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                                                                                                                                                                                      Revision:            2
                                                                                                                                                                                      Page 3 of 18
                                                                                                                           ITEM NUMBER II.d

. , (Cont'd)

                                            3.0 BACKGROUND (Cont'd)
                                                                    This request encompasses the architectural ceiling system and
                                                                    non-safety related conduit whoce diameter is two (2) inches or
                                          ,                         less.
                                         .
                                                                    The TRT has requested that seismic calculations for the
                                                                    support systems of the lighting fixtures and the suspended
                                                                   gypsum ceiling in the control room reflect all loading
                                                                   conditions that would be experienced due to a seismic event.
                                                                   In addition, an analysis has been requested by the TRT to show

' that the present design of the attachment of gypsum to its

                                                                   frame will ensure separation will not occur during a seismic
                                                                   event.
                                                      3.2 Description of Existing Ceiling and Other Ceiling Elements

1

                                                                   The control room ceiling at the location of the control board
                                                                   area proper is comprised of three (3) ceiling systems. Refer

i to isometric sketch II.d-1. '

   (                                                               The ceiling system directly adjacent to the control boards at
          ,
                                                                   elevation 839'-6" has suspended louvered panels with exposed
                                                                  grid utilizing interlocking main and cross tees for panel

.

                                                                  support. The louvered ceiling is directly below the lighting
                                                                  fixtures above the control boards and is supported by 12
                                                                  gauge, minimum, cold drawn wire attached to the seismically
                                                                  restrained unistrut lighting support grid l'-0" above. The
                                                                  2'-0" x 4'-0" louvered ceiling panels are supported by the
                                                                  main and cross tee grid and by closure strips at edge
                                                                  intersections. Above the louvered ceiling, at the location of
                                                                  the lights is mineral acoustical tile which rest on the light
                                                                  fixture flanges with tee sections installed perpendicular to
                                                                  the light fixtures for end of tile support.
                                                                 The second ceiling system, a sloping gypsua vall, is near the
                                                                 center of the control board area and extends from elevation
                                                                 839'-6" to the underside of the above floor. This sloping
                                                                 gypsum wall was originally constructed as non-seismic and
                                                                 non-safety related. The construction used 1 " supporting
                                                                 channels attached to the underside of elevation 854'-4" floor
                                                                 slab with a 16 gauge C channel secured with 2-3/8" 6 Hilti
                                                                 Kwik Bolts. The vertical 1 " channel supports for attaching
                                                                 the horizontal furring channels is attached to the supporting
                                                                 channels at the bottom of the wall. The upper attachment for
                                                                 the 1 " vertical channel is by a bolted connection to a 16
                                                                 gauge C channel secured to the underside of elevation 854'-4"
 r
                                                                 floor slab with 2-3/8" 6 Hilti Kwik Bolts. The bolted                                                                                                     -
 (,                                                              connections used k" 9 bolts. The 1 " channels are by U. S.
                                                                 Cypsum, constructed of cold rolled 16 gauge steel with 19/32"
                                                                                                                              .
                                                                             e
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                                                                                    . _ _ . _ _ _ _ . __              _ _ _ . _ _
            _.           :.
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                                                                                                                                    I
                                                                                                         Revision:  2
                                                                                                         Page 4 of 18
                                                                ITEN NUMBER II.d'
                                                                     (Cont'd)
                                  3.0 BACKGROUND (Cont'd)
                                            flange and 1 " depth. Horizontal " hat shaped" furring
                                            channels are placed on l'-0" C.to C for attaching the 3/8"
.
                               '
                                -
                                            gypsum panels. The horizontal furring channels are secured to

{ the support channels with galvanized furring channel clips.

                                                                                                                                   i
                                            A review of the mass involved in the sloping gypsum well                               l
                                            determined that seismic restraint was necessary to assure                               !
                                            integrity of the ceiling system during a seismic event. To
                                            provide assurance that the sloping gypsum well framework would
                                            remain in place during an SSE, restraints were added by
                                            attaching stainless steel cable through alternating horisontal
                                            furring channels next to each vertical 1 " channel. The six
                                            1/8" stainless steel cables are suspended from two (three
                                            each) angles which are anchored to the underside of elevation
                                            854'-4" floor slab.    In addition the furring channel
,
                                           attachment to the vertical channels was reinforced by adding
 i
                                            2-k" self tapping sheet metal screws at each intersection.
            ,
                                           The 3/8" gypsum board is attached to the sloping wall furring                          i
 ;
            \
                                           channels with 1" type S bugle head screws on 12" vertical and
                       ,
                                           7" horizontal spacing. Screw attachments, of this type, in                   -
                                           gypsum panels meeting ASTM C-36 requirements typically exhibit
                                           60 pound pull out each.
                                           The sloping gypsum wall was evaluated for acceptability and
                                           compliance with Regulatory Guide 1.29. Based on the original
                                           design and addition of seismic restraint cables, and
                                           considering the quantity and pull out strength of she screw

<

                                                                                                                                  '
                                           attachments securing the gypsum panels, the sloping gypsum

> ! wall was considered acceptable as restrained.

                                           The third ceiling system is at elevation 847'-2" in the center
                                           of the control board area. This ceiling is again the louvered
                                           ceiling configuration which is supported by suspending the
                                          main tees from the seismically restrained unistrue lighting
                                           support grid above. Suspension of the main tees is by 12

i gauge, minimum, cold drawn wire. The 2'-0"x4'-0" louvered i_ '

                                          ceiling panels are supported by the main and cross tees grid
                                          and closure strips at sloping wall intersection.                                        ,
                                          All lighting fixtures in the control room complex are                                   l
                                          seismically restrained in accordance with the restraint

i i

                                          details shown on Gibbs & Hill drawing 2323-El-1704-01. The
                                          lighting fixtures located in the control board ares proper are
                                          also attached to seismically restrained unistrut grid
                                          framework. The seismic restraint of these fixtures and
          ;
             O-
                                          members was deemed necassary to ensure compliance with the
                                          requirements of Regulatory: Guide 1.29.
                                                                                                                                  '
                                                                     :            .
                             .
   - . , . - - _ _ - . -
            -           .                     .                                  ..              .- .-    .      -   -            . _ .
   ,
       ..
 _
                                                                                                              Revision:               2
                                                                                                              Page 5 of 18
                                                                                                                   .
     (                                                                      ITEM NUMBER II.d
                                                                                 (Cont'd)

-

                    3.0 BACKGROUND (Cont'd)
                           3.3 Approach Selected
              *
                .
                                      TUEC has reviewed the issue raised by the TRT, and a decision
                                     has been made to modify the control room ceiling in the
                                      interest of an expeditious resolution. A recent assessment of                                       '
                                      the ceiling design indicates that the structural integrity of
                                      the three systems could be demonstrated, but the process would
                                     be time consuming. Details of such evaluations involve
                                     modeling assumptions or test configurations for which it is

'

                                     anticipated that technical consensus would be required. Since

' such details are not likely to be discussed in published '

                                     literature or regulatory consunications the resolution could
                                    delay closure of the issue. The approach taken to the ceiling
                                    design modification is to establish a design which can readily
                                    be qualified seismically and to subject the design to a third-
                                    party review.
                                   Action Plan Ites Number I.c addresses the other specific
                                   technical issue, 2 inch and smaller non-seismic conduit.
     N
                                   In addition to the specific technical issues there were
                                   questions raised by the NRC regarding the general methods
                                  utilized for addressing potential damage to safety-related
                                  items caused by non-Category I items. This aspect was
                                  discussed during the October 23,'1984, public meeting
                                  regarding the plan for responding to TRT issues. Based on
                                  that meeting CPRT has elected to conduct a third-party design
                                 verification of the damage study program to address generic
                                 implications of the two specific technical issues previously
                                 identified. The verification effort will include an
                                assessment of the control room lighting fixtures and all other

4

                                plant architectural features, for example non-seismic
                                partitions, other architectural ceilings, doors, etc.
                  4.0 CPRT ACTION PLAN
                          4.1  Scope and Methodology
                               The resolution of the control room ceiling seismic design
                               issue will be addressed as three related but distinct tasks:
                                        -
                                            Seismic interaction design of control room ceiling
                                            elements
                                        -
                                            Verification of seismic damage assumptions for 2 inch
   h,a                                      and smaller conduit
                                                                               .
          -
                              - , . - -         , - - - , - , - - . - - . ,             ,- .. , ,-     n.   - ,,        , , - . -       .
  .                       .                  .             - _ ___                        _                 _     _                         _            _ ._                        ._   __ _  -
                                                                                                                                                                                                    _    __   _-     _
                         .
            .            ..
      .

,

                                                                                                                                                                                               Revision:    2
                                                                                                                                                                                               Page 6 of 18

<

                                                                                                               ITEM NUMBER II.d
                                                                                                                               (Cont'd)
                                               4.0 CPRT' ACTION PLAN (Cont'd)                                                                                                                                          t

i '

                                                                                           -
                                                                                                Verification of seismic damage study methods and
                                                                                                implementation, including non-seismic architectural
                                        ,
                                         .
                                                                                                features review

l ,

                                                                                  The first task is restricted to a technical resolution of the
                                                                                  specific issue regarding seismic interaction from control room
                                                                                  ceiling as identified by the TRT. The second task is
                                                                                  incorporated in its entirety within Action Plan Item I.c. The
                                                                                  third task is being undertaken to evaluate generic

' implications of the issues raised in the first two tasks, and  :

                                                                                  to independently verify the adequacy of the resolutions.                                                                             '

' Design changes, based on necessity or expediency, might result , ,

                                                                                 to address results of the verificatior effort.                                                                                        !
                                                                                 4.1.1 Ceiling Element Design

1 -

                                                                                               The present design of the ceiling systems was based on                                                                  1
                                                                                               the premise that failure of architectural features with                                                                 .
                                                                                              small masses would not be adverse to the occupants of

4

        #

l

      \                                                                                       the control room. Although a preliminary design
'
               -
                                                                                              assessment supports the position that the design
                                                                                              complies with Regulatory Guide 1.29, that assessment

i

                                                                                              relies on that same judgement. In lieu of efforts
                                                                                              directed at developing confirmatory analysis to further
                                                                                              support the position and to finalize the structural
                                                                                              evaluation, TUEC has elected to revise the design of-
                                                                                                                                                                                        ~
                                                                                              the ceiling systems to preclude unacceptable seismic
                                                                                              interaction. Figure II.d-1 is a flow diagram-for
                                                                                              activities associated with the design effort. The-

,

                                                                                              major steps are discussed in the following-
                                                                                              subparagraphs.
                                                                                              4.1.1.1      Any unacceptable interactions will either be
                                                                                                           eliminated (e.g. by moving the safety related

, item) or prevented by restraining the motion ,

                                                                                                           of the ceiling structures through the use of
                                                                                                           horizontal seismic restraints on the ceiling
                                                                                                           support system. These horizontal restraints
                                                                                                          will act together with the e'xisting vertical
                                                                                                           cable seismic restraints. The design
                                                                                                           criteria will incorporate displacement

i

                                                                                                           limitations based on an interaction
                                                                                                          assessment of the ceiling and safety related
                                                                                                           items.

' f The existing ceiling structures, consisting

    (                                                                                                     of an interlocking grid cf unistruts, dead
  .
          '
                                                                                                          weight supporta and vertical seismic
                                                                                                                            .                                                                                  ,
                           9
      --~~--r--,,--,e,,%     , - - , , , , -     ,.,.,,-,---,r...-y-,,,,-,vr-w,,,,_,,w,---w,,                   .---,--wy.v.,,.-y.,.,m..v-.,,,--,.-.v.,,,.,.---w-,,m--w,,,,.,,,.-,,,v..                          ,--
                      - - _ _ .                                                                                                              . .
                                                                                                                                                   ,
         -
       .
 ,
                                                                                                                                 Revision:       2
                                                                                                                                 Page 7 of 18
                                                                                              ITEN NUMBER II.d
                                                                                                    (Cont d)
     .
              4.0 CPRT ACTION PLAN (Cont'd)
                                                                                           restraints, together with the new horizontal
                                                                                           seismic restraints will be evaluated and
           *
            .
                                                                                           augmented where necessary to confirm their
                                                                                           adequacy to carry loads from any contributing
                                                                                           structural and architectural elements.
                                                   4.1.1.2                                 TUEC has elected to remove the gypsum panel
                                                                                           and replace it with lightweight metal panels
                                                                                           included in the evaluation below.
                                                  4.1.1.3                                  An evaluation of the acoustical and louvered
                                                                                           ceiling panels will be performed to
                                                                                           demonstrate that the physical arrangement of
                                                                                           these modular lightweight architectural
                                                                                           features meet the requirements of Regulatory
                                                                                          Guide 1.29 and FSAR Section 3.78.2.8.         This
                                                                                          evaluation will either confirm that
                                                                                          individual components will not fail due to
                                                                                          seismic interactions or the design will be
                                                                                          modified to incorporate seismic restraints
                                                                                          which prevent the component from falling.

,

                                               4.1.1.4                                    Items which are designed and constructed to
                                                                                          seismic Category I and seismic Category II
                                                                                          criteria receive Quality Control inspection
                                                                                          in accordance with applic.able criteria
                                                                                          established per 10CFR50 Appendix B.        Items
                                                                                          which had been non-seismic did not require
                                                                                          inspection by the Quality Control
                                                                                          Organization. To comply with the TRT request
                                                                                          for verification that control room elements
                                                                                          comply with the design additional QC will be
                                                                                          performed as follows:
                                                                                              -
                                                                                                        Existing Category II QC records will
                                                                                                       be reviewed to verify required
                                                                                                       inspections were performed
                                                                                             -
                                                                                                       All design modifications to
                                                                                                       Category II ceiling elements will
                                                                                                       receive a QC inspection with
                                                                                                       Engineering inspection and overview
                                                                                                       for other items (e.g., if- restraints
                                                                                                       of lowered panels are required.)
 (,,
                                                                                             -
                                                                                                       The third-party will review
   ,
                                                                                                       inspection documentation.
                                                                                        a         e
                                _ _ _ _ . _ _ _ _ _ . _ _ _ . _ _ . _ _ _ _ _ _ _ _ _ _
               *
     ,,.     ..
   ;
                                                                                                                    Revision:  2
                                                                                                                    Page 8 of 18
                                                                                                                       .
      (                                                     -
                                                                           ITEM NUMBER II.d
                                                                                   (Cont'd)
                          4.0 CPRT ACTION plt.N (Cont'd)
                                                               4.1.1.5    All design and analysis activities associated
                                                                          with the evaluation of seismic interaction of
                     -
                      .
                                                                          architectural features above the control room
                                                                         and with the ceiling design modifications
                                                                         will be subjected to a third-party review.
                                                                         This will include an independent verification
                                                                         of the methods used to evaluate displacement
                                                                         interactions, failure of architectural
                                                                         features, interaction consequences, and a
                                                                         design verification of all ceiling
                                                                         modifications to confirm the seismic
                                                                         capability,
                                          i.1.2                Conduit of Diameter Less than or Equal to 2 Inches
                                                               See 1.c Action Plan.
                                         4.1.3 Damage Study Verification
                                                              The third task of the II d Action Plan to resolve the
           -                                                  TRT issues is directed at a determination of the extent
                                                              to which winilar aspects of the Unit I damage study
                                                              program could require technical resolution.
                                                             Additionally if technical issues develop, the. plan
                                                              includes a course of action to determine the
                                                             applicability to Unit 2 and resolve them for both
                                                             units.
 ,

( The seismic /non-seismic interaction study, which was l

                                                             performed, in 1983, involved the walkdown of 287 rooms.
                                                            All potential interactions were evaluated to the
                                                            acceptance criteria developed for the study. Methods
                                                            for resolution of potential interactions of a falling
                                                            source impacting a nuclear safety class target
                                                            consisted of analysis, evaluation, use of barriers.

l ,

                                                            administrative controls, addition of seismic supports
                                                            or restraints. Each of these activities includes

l pertinent requirements of the CPSES QA Program. !

                                                            The design of the ceilings in the control room was
                                                            predicated on the position that failure of

i

                                                            architectural features with small masses would not
                                                            adversely affect the occupants of the control room and,

j consequently, the safety of the plant. On this basis,

                                                            Engineering advised the Damage Study Group that the

, !. control room architectural features in question should !

     ,-                                                    not be evaluated as part of the Damage Study Program.

!

                                                            Therefore, these features were not evaluated by the
      ,

i

                                                                                 *
         ,,.     - .  . -       . - - . . . - - - . - . - .                  . -     .   .  - _ _ - . - - .- -.- ..
        .
      -
 ..
                                                                                  Revision:  2
                                                                                  Page 9 of 18
                                                ITEM NUMBER II.d
                                                      (Cont'd)
              4.0 CPRT ACTION PLAN (Cont'd)
                              Damage Study Group. Exclusion of other areas of
                             evaluation due to similar inputs and assumptions is a
          ,
            .
                              focal point for the Damage Study verification.
                             The activities in this phase include a project review
                             of all plant architectural features, and design
                             modification, if required, to resolve resulting              *
                             concerna. The preliminary TUEC assessment of the
                             entire damage study area indicates that if omissions
                             exist they would most likely be in that aspect of the
                             program. Also included in the action plan is an
                             extensive third-party evaluation of all aspects of the
                             Unit 1 Damage Study Program. The major steps are
                             discussed in the following subparsgraphs. Refer to
                             Figure II.d-2 which is a flow chart of activities.
                             4.1.3.1         Architectural features e.g., doors, ceramic
                                             tile, gypsum board, etc., were not viewed as
                                             structural in nature therefore considerations
 (',                                         such as seismic qualifications may
                                            inadvertently have.been omitted.
                                            A TUEC evaluation will be performed on
                                            architectural specifications and drawings tc
                                            identify non-seismic sources to be evaluated
                                            in accordance with Regulatory Guide 1.29 and
                                            FSAR Section 3.7B.2.8. Any architectural
                                            features in Units 1 and 2 which are
                                           determined to have a potential for seismic
                                           interaction will be either modified or
                                           subjected to a damage study assessment.
                            4.1.3.2        A third-party review of the architectural
                                           featu.res evaluation will be performed
                                           including verification of:
                .
                                                  -
                                                        The entire structural assessment
                                                        which is performed by CPPE-TUCCO to
                                                        determine which architectural
                                                        features have a potential for
                                                        seismic interaction.
                                                 -
                                                        The damage study of all
                                                        architectural features which

,

                                                        potentially cause seismic
                                                        interactions.
 '
   ..
                                                    .
                                                                 ^
                                    .-r-,_
                       .                                                                                               -       . .                  - - . . .        .            -
                           '
                              '
       .
            ,
                                                                                                                                                                             Revision:                           2
                                                                                                                                                                             Page 10 of 18
                                                                                                        ITEM NUMBER II.d
                                                                                                               (Cont'd)
                                                   4.0 CPRT ACTION Pl.AN (Cont'd)

4 -

                                                                                                                          A design review of all resolutions
                                                                                                                          to unacceptable interactions
                                                 ,                                                                        including review of all drawing
                                                -
                                                                                                                          revisions which result.
                                                                               4.1.3.3                Procedures and methods for conducting the
                                                                                                      seismic damage study will be evaluated by a
                                                                                                      third-party including a ~ review of interfaces
                                                                                                      between the damage study group and other
                                                                                                      disciplines which either provide input for

, ~

                                                                                                      the evaluation or act upon the damage study
                                                                                                      group's recommendations. This evaluation
                                                                                                    will examine whether there are other generic
                                                                                                     areas in addition to the architectural
                                                                                                      features which may have been omitted.

- '

                                                                              4.1.3.4                To identify the set of all non-Category I
                                                                                                . systems, structures and components which are

,

          '
                                                                                                    considered for seismic interaction with
~'
                                                                                                     safety-related items, selection criteria have
         'a
                                                                                                    been established. The exclusion of Category
                                                                           -
                                                                                                    II items, is one of the selection criteria
   .                                                                                                because they are supported or restrained to
                                                                                                    preclude seismic interaction. Design
,
                                                                                                    criteria for Category II items and all other
                                                                                                    selection criteria will be subjected to
                                                                                                    third-party review. The detailed Category II
                                                                                                    criteria will be compared with Category I
                                                                                                   criteria and methodology as well as the more
                                                                                                   general Category II FSAR coc:mitments. Where
the Category II criteria is not the same as
                                                                                                   Category I or is less detailed the
                                                                                                   acceptability will be assessed based on
                                                                                                   application of engineering principals

j applicable to the specific methodology.

                                                                            4.1.3.5                The basis for determining specific physical

i

                                                                                                   interactions for displacements of items
                                                                                                   identified in Section 4.1.3.1 will be
                                                                                                  subjected to third-party review.
                                                                            4.1.3.6               Criteria for evaluation of the consequences
                                                                                                  of interactions will be subjected to third-
                                                                                                  party review.
                                                                                                                                                                                                                    i
        o
          6
                                                                                                              .
                                           4                                                                  4
     w        v. + --.. .-- , - - , +.. e-. . .     % ,m.,--., , . , , , .   -.,---.m,e. #w.-.,-,s,w-        ,,n,wy,-.-.y          .. , , .m,y-r,,-           ---x-,   -,-,- .- , - - - . . , - - . - , - . . - - -
        -
    ..
                                                                                                    Revision:   2
                                                                                                    Page 11 of 18
                                                                   ITEM NUMBER II.d
                                                                        (Cont'd)
             4.0 CPRT ACTION PLAN (Cont'd)
                                          4.1.3.7               . Implementation of-the methods for performing
                                                                 the damage study will be design reviewed in a
          -
           ,
                                                                 third-party engineering audit of the
                                                                 documentation, including as necessary            .
                                                                 physical verificatica. The engineering audit,    !
                                                                 will assess adequacy of documentation and
                                                                 validity of engineering conclusions.
                                                                 Included within this task is a review of the
                                                                 way in which classified and declassified
                                                                 rooms were distinguished and addressed.
                                                                 The basis for selection of implementing
                                                                documents reviewed will be those which are
                                                                most substantially supported by engineering
                                                                judgements as distinct from simple
                                                                calculation or direct application of rules.
                                                                The selection process will be thoroughly
                                                                documented. Based on a complete review of
                                                                the various methods for categorizing
                                                                interactions as acceptable, cases will be

t

    (                                                           selected to check the implementation of each
     -
                                                               method. This checking of implementation
                                                               will be weighted towards interaction
                                                                resolutions which are, of necessity, less

L

                                                               subject to procedural definition and more
                                                               dependent on individual judgements.

li 4.1.3.8 A third-party comparative damage assessment

                                                               will be performed in the selected rooms to
                                                               assess the consistency with which
                                                               interactions were identified. The rooms will
                                                               be chosen based on a selection criteria which
                                        .
                                                               consider the following aspects:
                                                                    -
                                                                          Functional and physical aspects of
                                                                          the systems and components within
                                                                          the space

l -

                                                                          Importance of components and systems
                                                                          to safety
                                                                   -
                                                                          Representativeness of the room from
                                                                          the standpoint of physical proximity
                                                                          of potentially interactive items
                                                                   -
                                                                          Balance of types of non-seismic
                                                                          items, i.e. architectural, conduit

! - 'y - piping, equipment

                _ -. , . . _ . - . . -    - . . - . - - . .- -
                                                                               ._...-,-..-.---..--.-,._-_.O
           _-_                - - _ _ _ _ _ _ - _ _ - - _ _ _ _ _ _ _ _ _ _ _ _ - _ _ _ _                                        _ _ _ _   . _ _ _ _ . --          -_        _     _--_   .
         '
     .-
                                                                                                                                                                      Revision:    2
                                                                                                                                                                      Page 1.2 of 18
                                                                                                                    ITEM NUMBER II.d
                                                                                                                             (Cont'd)
                  4.0 CPRT ACTION PLAN (Cont'd)
                         4.2 Procedures To Be Used
               -
                ,
                              In addition to the applicable analysis, design, construction
                              and QC procedures which will be used to implement the control
                              room ceiling modifications, precedures directly applicable to
                              the damage study will be used. 71ey are CP-EI-4.0-53,
                              " Maintenance of Damage Study Analysis" and CP-EI-4.0-63,
                              " Review of Architectural Specifications and Drawings to
                              Identify Non-Seismic Sources".
                         4.3 Participants Roles and Responsibilities
                                                                                                                                                                                        .
                              The following organizations and personnel will participate in
                              this effort:
                              4.3.1                                                       Comanche Peak Project Engineering and Gibbs & Hill
                                                                                          4.3.1.1            Scope
                                                                                                                           -
                                                                                                                                perform architectural features
     (L'                                                                                                                        evaluation (4.1.3.1)

l

                                                                                                                           -
                                                                                                                                recommend and implement design
                                                                                                                                modifications resulting from
                                                                                                                                architectural review or third-party
                                                                                                                                verification of damage study program
                                                                                                                          -
                                                                                                                                design (as required) structural
                                                                                                                                horizontal restraint system for
                                                                                                                                ceiling elements (4.1.1.1)
                                                                                                                          -
                                                                                                                                redesign sloped ceiling panel system
                                                                                                                                (4.1.1.2)
                                                                                                                          -
                                                                                                                                evaluate and modify, as required,
                                                                                                                                acoustical and louvered ceiling
                                                                                                                                panel restraints (4.1.1.3)
                                                                                                                          -
                                                                                                                                assist in preparation of Results
                                                                                                                                Report
                                                                                        4.3.1.2              Personnel
                                                                                                             Mr. C. R. Hooton                          Project Civil Engineer
                                                                                                             Mr. M. Wells
 . -
                                                                                                                                                       Engineering Specialist
     .
                                                                                                             Mr. D. A. West                            Damage Study Engineer
                                                                                                                             .
                       .                                                                   _.________m______
                                                                                                  .           _ - - - - _
    ,. ..
    .
.
                                                                                                      Revision:   2
                                                                                                      Page 13 of 18
                                                                                                          =              l
     s                                          ITEM NUMBER II.d                                                         l
                                                          (Cont'd)                                                       i
               4.0 CPRT ACTION PLAN (Cont'd)
                                              Mr. J. Eichler                     Gibbs & Hill, Manager of
                                                                                 Civil / Structural
          ,-                                                                     Departnent
                                              Mr. E. Berkor                      Gibbs & Hill, Structural
                                                                                 Job Engineer
                                              Mr. M. Pope                        Gibbs & Hill, Structural
                                                                                 Engineer
                         4.3.2 Brown & Root. Inc.
                               4.3.2.1        Scope
                                                    -
                                                                  install ceiling system supports and
                                                                  restraints
                                                   -
                                                                  provide as-built data on
                                                                  architectural features
  d
                        4.3.3 TUCCO Quality Assurance
  (

- 4.3.3.1 Scope

                                                   -
                                                                  inspect control room ceiling
                                                                  modifications
                                                   -
                                                                  inspect other modifications
                                                                  resulting from damage study
                                                                  interaction resolution
                               4.3.3.2        Personnel
                                              Mr. P. Halstead                   Quality Engineering
                                                                                Supervisor (Acting)
                        4.3.4  Third-Party Activities
                               4.3.4.1        Scope
                                                   -              review of control room ceiling
                                                                  analysis and design (4.1.1.5)
                                                   -
                                                                  review of architectural features
                                                                  evaluation (4.1.3.2)
  (
                                                          ,
             ,      ,             -~    _ , ,     , , - - - - - -    - , - -   ,,,.,r--,   -e , , - -  -
                                                                                                                ,   . r,
                 ___           _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ - _ _ _ _
             '
      a:    -
                                                                                                                                                                               Revision:   2
                                                                                                                                                                               Page 14 of 18
                                                                                                                                             ITDi NUMBER II.d
                                                                                                                                                   (Cont'd)
                             4.0 CPRT ACTION PLAN (Cont'd)
                                                                                                                                                .
                                                                                                                                                 -
                                                                                                                                                      review seismic damage study
                                                                                                                                                      procedures and criteria (4.1.3.3,
                          .
                           ,
                                                                                                                                                      4.1.3.4. 4.1.3.5 and 4.1.3.6)
                                                                                                                                                -
                                                                                                                                                      Design review implementation of
                                                                                                                                                      damage study procedures (4.1.3.7)
                                                                                                                                                -
                                                                                                                                                      perform independent damage study
                                                                                                                                                   ,  walkdown (4.1.3.8)
                                                                                                                                                -
                                                                                                                                                      prepare Results Report
                                                                                                   4.3.4.2                                 Personnel
                                                                                                                                           Mr. H. A. Levin        TERA CPRT Civil /
                                                                                                                                                                  Structural Review Team
                                                                                                                                                                  Leader
                                                                                                                                           Mr. D. Witt            TERA Senior Mechanical
                                                                                                                                                                  Engineer
               .
                                                                                                                                           Mr. P. Streeter        TERA Senior Mechanical

>

                                                                                                                                                                  Engineer
                                                       4.4 Standards / Acceptance Criteria
 .
                       (
                        [                                                                  The FSAR will be used as the base document for establishing
          -                                                                                acceptance criteria. Where the criteria in the FSAR requires
                     i                                                                     increased detail to define specific requirements not covered
                       (                                                                   by the standards and regulatory guidance referenced in the
                                                                                           FSAR, the basis will be established engineering principles
     --
                                                                                           applicable to the same or similar situations.
          '
                                                     4.5 Decision Criteria
                                                                                           The control room ceiling design will be modified if it is
                                                                                           determined that its behavior during a seismic event may lead
                                                                                           to unacceptable interactions with safety related items or have

l-

                                                                                           a potential of interfering with operators in the control room.
                                                                                           The Damage Study / Architectural Features evaluation will
                     -

l l

                                                                                           establish whether or not the plant design conforms with
                                                                                           requirements of Regulatory Guide 1.29 and FSAR section
                                                                                           3.7B.2.8. Any identified deficiencies will be evaluated and
                                                                                           corrected as necessary to meet these commitments.
   (
        .
                                                                                    .
                                                                                                         _ - - - - _ _ - . _ _ - - - _ _ -
                                                                                                                                                           l
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                                                                                                           Revision:                             2
                                                                                                           Page 15 of 18
                                                                                                                       .
                                                         ITEM NUMBER II.d
                                                              (Cont'd)
                 5.0 SCHEDULE
                       Ceiling Analysis and Redesign:                                                   06/08/85
               .      Verification of Design:                                                           06/08/85
                      Architectural Features Review:                                                    06/01/85                                         -
                      Third-Party Review of Architectural Features:                                     07/01/85
                                                                                                                                                            '
                      Damage Study Criteria and Procedures Verification: 05/15/85
                      Design Review of Damage Study Implementation:                                     05/30/85
                      Independent Damage Study Walkdown                                                 05/30/85
                      Resolve Damage Study Findings:                                                    06/26/85
                      Review Resolution of Findings:                                                    07/12/85
                      Results Report:                                                                   08/12/85
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     _                                         COMANCHE PEAK RESPONSE TE.'M
                                                         ACTION PLAN

>- Item Number: VII.b.2

                         ,
                          .
                                                Title: Valve Disassembly

.

                Revision No.              0                            ..
         ,
                Description         Original Issue
       -

5 Prepared and

                Recommended by:
                                       g
                Review Team Leader
                Date                   6'hf'EC .
                                   -
              -                              -
                                             -
                                                                   ...
                                                                                                 ,
              Approved by:
               Senior Review Team  h 4). 1
               Date                    (o f1,1 fy(
                                                                                                 ;
                                                              :           FotA-W 36      A\\\
                                     .           ..                         . .      .        ..
   ~
                         .
                            ...
          ,               ,
                              ,
       .
     ,
                                                                                                  Revision: O
                                                                                                  Page 1 of 9
                                                                                                         ,
 '
         r~sg
                                                                                                      ,
         k'                                                      ITDI NUMBER VII.b.2
          .
                                                                  Valve Disassembly.

>

                                   1.0 DESCRIPTION OF ISSUE IDENTIFIED BY NRC
                                         "The TRT found that installation of certain butt-welded valves in
                                 .       three systems required removal of the valve bonnets and internals
                                -
                                         prior to welding to protect temperature-sensitive parts. The three
                                         systems involved were the spent fuel cooling and cleaning system,

-

                                         the boron recycle system, and the chemical and volume control.
                                         system. This installation process was poorly controlled _in that
                                         disassembled parts were piled in uncuntrolled areas, resulting in
                                         lost, damaged, or interchanged parts. This practice created the
                                         potential for interchanging valve bonnets.and internal parts having :
                                         different pressure and temperature ratings."
                       _
                                   2.0 ACT' ION IDENTIFIED BY NRC
                                         Evaluate the TRT findings and consider the implications of these
                                         findings on construction quality. "... examination of the potential
                                         safety implications should include, but not be limited to the areas

3

                                         or activities selected by the TRT."

' '

                                         " Address the root cause of each finding and its generic
                                         implications..."
                                         " Address the collective significsnee of these deficiencies..."
                                         " Propose an Action Plan...that will ensure that such problems do.
                                     ,
                                         not occur in the future."

'

                                   3.0 BACKGROUND
                                         3.1   Information Supplementing NRC Description of Issue
                                               Other possible reasons for valve disassembly include
                                               hydrotest, flushing, purging and repair, and therefore many
                                               different valve types are potentially affected.
                                              . Additional background information such as valve manufacturers,
                                               types,' sizes, ratings, installation dates, etc. will be

4

                                               obtained as a part of the implementation of this Issue-
                                               Specific Action Plan.
                                         3.2 Preliminary Determination of Root Cause and Generic
                                               Implications
       /                                       The preliminary reviews conducted to date have not identified

, ! '

       (                                       a root cause for this item. Implementation of the action plan
                                               is necessary before a root cause determination can be made.
                                               Generic implications will be evaluated based on the results of
                                               the root cause determination.
                                                                       -

c

                                           4                           4
            , . - . - - -..
              .
                  .
    ..            ,
                                                                                                                             Revision: O
                                                                                                                             Page 2 ,of 9
                                                                                                                                 .
                                                                                                         ITEN NUMBER VII.b.2
                                                                                                                 (Cont'd)
                                        4.0 CPRT ACTION PLAN
                                              4.1 Scope and Nbthodology
                                      .
                                                    The scope of this action plan is to evaluate if valves that
                                                    required disassembly were properly reassembled; and, if not,
                                                    whether an improperly reassembled valve could result in a code
                                                    violation or have a safety consequence. Valves installed in
                                                    Units 1, 2 and Common will be considered in this plan. Any
                                                    valve which has been disassembled will be included in this
                                                    plan, regardless of reason for disassembly or plant system.
                                                    The plan consists of two phases. Phase I consists of
                                                    reviewing construction and QC procedures and verification of
                                                    QC documentation for adequacy of material traceability and
                                                    control; and performing analysis to determina the safety
                                                    consequences and/or code violations of any valves that were
                                                    potentially reassembled incorrectly. Further evaluations will.

1

                                                    be made in Phase II to determine root causes of the problem,.
                                                    and whether the problem is generic or specific in nature.
          '*
                                                    The specific methodology is described below (see Flow Chart,
            j                                      Attachment 1):
                                                   4.1.1                 Identify the valves that required disassembly. The
                                                                         generic valve types will be determined by reviewing the
                                                                         valve specifications, purchase orders, operation and
                                                                         installation instruction manuals, construction, test

l and other piping procedures and by vendor contact, as

                                                                         required. The specific valves in question can then be

j identified from the valve list.

                                                                         In addition to generic valve types that require
disassembly, other specific valves disassembled for

!

                                                                         test and/or repair will be identified by reviewing

! operations travelers. l

                                                                        A reference data base will be established for the
                                                                         specific valves identified. The disassembly / reassembly
                                                                        history will be reviewed. Applicable manufacturer
                                                                        drawings will also be obtained.

,'

                                                   4.1.2                Review applicable procedures, for both construction and
                                                                        QC, to determine if they provided adequate controls of
                                                                        materials during valve disassembly and reassembly. In
                                                                        addition to proper matching of components, the
     ,_                                                                 procedures will be reviewed for their adequacy to
                                                                         identify and replace parts damaged during the
          ,/                                                            disassembly, storage and reassembly process.
 3
  .
                                                                                                                  *
                                                                                                                  .       .
        .
                . _ . - _ _ . . . _ . . _ .        _ . _ . _ _ _ . _ _ _ . _ . _ _ _ . . _ . . . _ _ _ . . _ _ .
                      - __      _ _ _ _ _ _ _ _ _ _ _ _ - - _ _ _ - _ _ _ - - - - - - _ - - -
    . _ . .
                 .
                    .
                   .

!

                                                                                                                                                                                                                                                                                    Revision: O
                                                                                                                                                                                                                                                                                    Page 3,of 9
                ,
                                                                                                                                                                                                                                                                                        .

I ITEM NUMBER VII.b.2

     ..
                                                                                                                           (Cont'd)
                              4.0 CPRT ACTION PLAN (Cont'd)
                                                                                                  If procedures have changed during the course of
                                                                                                  construction the historical file of procedures will be
                           '
                            -
                                                                                                  reviewed to determine if taproper reassembly were more
                                                                                                  likely to occur during a particular time frame. If the
                                                                                                  procedures for Units 1, 2 and Common are different,
                                                                                                  they will each be evaluated.
                                                                                            4.1.3 In parallel with the procedure review, an analysis will
                                                                                                  be made to determine the safety consequences of
                                                                                                  improperly assembled valves. The analysis will include
 ,
 '                                                                                                potential failure modes resulting from improper
                                                                                                  reassembly of the valves in question. For example,
                                                                                                  reassembly using a valve bonnet with a lower service
                                                                                                  rating than called for in the design drawings could
                                                                                                  result in external leakage. The generic effect on the
                                                                                                  system, e.g. loss of system pressure would then be
                                                                                                  identified. A sample format for this analysis is shown                                                                                                                                        I
                                                                                                  in Attachment 2.                                                                                                                                                                              I
              '
                                                                                                  In addition, an evaluation will be made to define
                                                                                                  potential code violations which could result from
                                                                                                  improperly assembled valves.
   s
                                                                                            4.1.4 The conclusion reached based on the procedure and QC
                                                                                                  documentation review performed to date is that improper
                                                                                                  reassembly was possible due to insufficiently rigorous
                                                                                                  procedures or inconsistencies in documentation. A
                                                                                                  random sample will be selected, which will be
                                                                                                  statistically based at the 95/95 confidence level. The
                                                                                                  random sample size will be based on the population size
                                                                                                  to be determined in Phase I.
                                                                                                  A second set of valves will be selected to provide
                                                                                                  greater assurance that the valves were correctly
                                                                                                  reassembled.     The sample would be randomly selected
                                                                                                  from a population of those valves originally identified
                                                                                                  in the specific TRT issue and will be statistically
                                                                                                  based on the 95/95 confidence level.
                                                                                           4.1.5 Manufacturers drawings and disassembly procedures will
                                                                                                  be reviewed and documentation packages will be
                                                                                                  assembled for those valves selected in the random
                                                                                                  sample. Inspection procedure will be predicated on the
                                                                                                  results of this review. If review of the documentation
            -
                                                                                                  for a specific valve indicates probable improper
                                                                                                  reassembly, reinspection will include a verification of
                                                                                                  internal parts.
                                                                                                                                     .
                                                                                                                                     4
                                                                                                                  _ _ _ . _ _ . , _ _ - _ _ _ _ _ . _ . _ - _ - _ . _ _ _ _ _ - - _ - _ - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
                _-                              _-                                       _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ - _ _ _ _ _ _ - _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ - _ _ _ _ _
     .
       .
   .
       .
 ,
                                                                                                                                                                                                                           Revision: O
                                                                                                                                                                                                                           Page 4,of 9
                                                                                                                                                                                                                               .
                                                                                                          ITEM NUMBER VII.b.2
                                                                                                                                                 (Cont'd)
              4.0 CPRT ACTION PLAN (Cont'd)
                        4.1.6 Deviations that are found will be evaluated and if
                                                                   safety significant.or a code violation, will require
           '
            -
                                                                    the sample size to be expanded. All safety significant
                                                                   discrepancies will be evaluated for root causes. In
                                                                   addition, all valid discrepancies will be reviewed, as
                                                                   a group, to identify any adverse trends and their root
                                                                   causes.
                                                                  TUGCO will be advised of specific hardware
                                                                  discrepancies, if any, to be entered into the CPSES NCR

L Program for resolution and disposition.

                                                                  Programmatic implications, if any, will be reported to

i

                                                              .the Manager QA/QC Programmatic Issues, and those with
                                                                  potential impact on other action plans will be
                                                                    identified and addressed by the affected Issue

l Coordinators.

                   4.2 Procedures

L

                        Operations, construction and/or QC procedures now in effect
                        will be reviewed and if found satisfactory, will be used for

>

                        disassembly, inspection, reassembly and test as required.
                   4.3 Responsibilities

f

                        The organizations and personnel that will participate in this
                        effort are described below with their respective scopes of
                        work.
                        4.3.1                                     TUGC0 Comanche Peak Project Engineering CPPE
                                                                  4.3.1.1                                 Scope
                                                                                                         -
                                                                                                                                                                             Assist the QA/QC Review Team in the
                                                                                                                                                                               identification and provision of all
                                                                                                                                                                              necessary specifications, drawings,
                                                                                                                                                                              procedures and other documentation
                                                                                                                                                                              necessary for the execution of this
                                                                                                                                                                              action plan.
                                                                                                         -
                                                                                                                                                                              Assist in determining the physical
                                                                                                                                                                               location of the valves selected for
                                                                                                                                                                               inspection.
                                                                                                         -
                                                                                                                                                                              Process NCRs that may be generated
                                                                                                                                                                              due to this action plan.
                                                                                                                                                         *
         .                                                                                                                                               .
                            _ _ _ _ _ _ _ _ _ _ _ _ . _ _ _ _ _ _ _ _ . - _ . _ _ . - --
            -
                                                                                                                                                              t
 .,,
                                                                                                                                           Revision: O
                                                                                                                                           Page 5,of 9
                                                                                                                                               .
          f
                                                                             ITDI NUMBER VII.b.2
                                                                                               (Cont'd)
                                                                                                                                                              .
                                                                                                                                                              '
                              4.0 CPRT ACTION PLAN (Cont'd)
                                                              4.3.1.2       Personnel
                        y                                                   Mr. C. Moehlman                     TUGC0 Coordinator
                                               4.3.2 CPRT-Civil / Structural Review Team
                                                              4.3.2.1       Participate in the evaluation for safety
                                                                            significance.
                                                           ' 4.3.2.2        Personnel
                                                                            Mr. H. A. Levin                     Review Team Leader
                                              4.3.3          Brown & Root Millwright Shop
                                                             4.3.3.1        Scope
                                                                            Disassemble and reassemble valves, as
                                                                            required, for inspection.
                                                             4.3.3.2
        '
                                                                            Personnel
                                                                            Mr. C. Moehlman                     TUCCO Coordinator
                                                                                                                                                              l
                                              4.3.4          CPRT-QA/QC Review Team
                                                             4.3.4.1        Personnel
                                                                            All activities not identified in 4 3 1. . , 4.3.2
                                                                            and 4.3.3 above will be the responsibility of
                                                                            the QA/QC Review Team.
                                                             4.3.4.2        Personnel
                                                                           Mr. M. Obert                         Issue Coordinator
                                                                          Mr. J. L. Hansel                      QA/QC Review Team Leader
                                       4.4 Personnel Qualification Requirements                                                                               *
                                              Personnel qualification and training will be in accordance
                                              with the CPRT Program Plan.                                                                                     '
                                       4.5 Sampling Plan                                                                                                      !
  -
                                              The samples will be selected to provide a 95/95 confidence

'

                                              level.                                                                                                          '
                                                                                               *
                                                                      .                        .
    g -
              , e - --.   _m,     .w_.  m , ~   .m.., .. ,  ,.,_e.-_.   . . _,.,,,,_y..,__,.._.,,-,-.,.~__-.,,s        ~ , . _ . , , , - .     ,.~._m, ,ys ,_
          .
            .
 .,         .
                                                                                    Revision: O
                                                                                    Page 6,of 9
         ,
                                                                                                          .
       -                                        ITEM NUMBER VII,b.2
                                                     (Cont'd)
                 4.0 CPRT ACTION PLAN (Cont'd)
                          -For large populations this means that a minimum random sample
                           size of 60 is required, with*zero safety significant
              '
               -
                           discrepancies in order to accept a population. If one or more
                           safety significant discrepancies are discovered, the sample
                           size will be increased as required. If no additional
                           significant discrepancies are discovered the population will
                           be accepted.
                           If more than one safety significant discrepancy is found in
                           the initial sample, the sample size will be increased up to
                           100 percent for reinspection.
                           NOTE - In all cases, reinspections performed for expanded
                                    samples vill look at only the attribute associated with
                                    the safety significant discrepancy.
                      4.6 Acceptance Critoria
                           Acceptance criteria will be based upon a review of the
                           following:
    ..
                           4.6.1   Site Q.C. inspection acceptance criteria for valve

$ installations.

                           4.6.2 A detailed review of specifications, drawings,
                                   referenced codes and standards in order to identify and
                                   verify safety significant attributes and minimum
                                   acceptance criteria necessary to meet design
                                   requirements.     Inspection checklists and instructions
                                   will be developed bared on the results of this review.
                      4.7 Decision Criteria
                           4.7.1   The action plan will be closed if all the design
                                   requirements are met, otherwise necessary corrective
                                   action will be recommended to meet the design
                                   requirements.
                           4.7.2 Programmatic and generic implications, if any, will be
                                   identified and additional activities recommended as
                                   required.
                                                      .
                                                                ,,g..,..e, --m.--s - . . - - - - - - - - -  ----~----,-'rsv 'T'
 -
         -
   -
           -l
                                                                              Revision: O
                                                                              Page 7,of 9
                                                                                  .
                                              ITEM NUMBER VII.b.2
                                                    (Cont'd)
                                                                                           l
                  5.0 SCHEDULE                                                             ,
                                                                                           i
              ,
                       The schedule for implementing the Plan is as follows:
                l
                        5.1 Phase I                                                        i
                             Start: April 8. 1985
                            Completion: July 5, 1985
                            Assumptions
                             (1)    SRT approval of the plan by July 1,1985.
                       5.2 Phase II
                            Start: July 5, 1985
                            Completion: October 15, 1985
                            Assumptions
       j                     (1)   Phase I results indicate that a random sampling program
                                   is required.
                            (2)    Valve disassembly is required for inspection.
                            (3)    Satisfactory results are obtained from the first
                                   sample, and therefore an expansion of the sampling
                                   program is not required.

!

    r"
                                                    :
     .      .
                                                           .

.

           4
                                                                                                                                                           Revision: O
                                                                                                                                                           Page 8 of 9
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                                                                                                                                                                                                        Revision! O
                                                                                                                                                                                                        Page 9 of 9
                                                                                                                                                                                                              .
                                                                                                                                            ITDt NUMBER VII,b.2
                                                                                                                                                  ATTACHMENT 2
                                                                                                                                                                    .
                                                                                                                                                                                                                                .
                                                 .
                                               .
                                                                                                                                          GEntRtc 5ArtTY Cons (OutmCES ANALYSIS
  .         . .: DESCRIPflon                                            SAFETY !PR($5uRE                                      POTinTIAL         .
                                                                                                                                                                      I
                                                                                                                                                                            POTENTIAt.
                                                                        class                                    RATIrt.      RfA55teLY Ena0R                               FAILURE & (FrtCT5
                     !TT.Grinnell                                                                      {*
                     Diaphro p Valve                                           3                                  300pst      1.  Bonnet asseely from C.S.                  1.
                   . nanu al                                                                                                                                                    No fatters. A11 tonnets are 5t. St. =tth internals
                                                                                                                                  valve                                         of same meterials.
                     3/4 inch
                     stainless Steel                                                                                          2.  Dennet assemely from 150 pst              2.  No failure. The bonnet and disparagn thicknesses are the
                                                                                                                                  va've                                         same for 150 pst and 300 pst valves.
           '
                                                                                                        !                     3.  Ioanet assently from non-A5mt             3.  a.   Potental fatture during a setssic event. Loss of
             j
                                                                                                        g                         valve                                              function. Isakage.
                                                                                                        i                                                                       b.   Code violation.
                     ITT.Grinnell
                     Diasheep valve                                           2                                   150 pst     1. Sonnet assently from non.A9E               1.  a.  Potenital fallare during a seism * * event. Less of
                     manusi                                                                                                       velse                                              function. leekage.
                     3/4 inca
                     Carmen Steel                                                                                             2.  Bennet assemely from A5ft III.                b.  Come violation.
                                                                   '
                                                                                                        ,
                                                                                                                                  Class 3 valve
                                                                                                                                                                          , 2.  Code violetton.
                       TT.Grinnell                                                                                                                                      *
                     Otapeep Valve                                 ! 2                                                        1.  Sonaet assesely from C.S.
                     nanual
                                                                                                                 150
                                                                                                                                  valve
                                                                                                                                                                        !1.
                                                                                                                                                                        ;
                                                                                                                                                                                No failure. All bonnets are 5t. St. =tth internals of
                                                                                                                                                                                same materials.
                     . incn
                     stainless 5 teel                                                                                         2.  Sonnet assemely from non-A5PE                 a.  Potential failure during a setsetc event. Loss of
                                                                    '                                                             valve                                 ' 2.
                                                                                                                                                                                     function, leatage.
                                                                                                                              3.  Bonnet assesely Asnt Ill. Class 3 3.          Code violetton.
                                                                                                                                  valve
                                                                                                                                                                                                                 .
             t
            /
                                                                                                                                                        .
                                                                                                                                                                .

.. . ._

<

         ~
             "
   *
..
             .
              '
                                 VA LVE RE INSPECTION CHECKLIST
                                             ISSUE 3Z[I.b.2
        T/.G 110.
                         '
                                       ITEIA IJO.                 GErf. SAMPLE 7
                j. 76 7;2C           .         4/4                SUB. sat-IPl.E D
                                                                  RIR NO.
                                                                        /34-5
             VALVE MARKillGS:
                                                          YES NO
                                DODY C BONNET ACCESS. @ _-
                                DODY NO.          6 349 -3/ ~6
                                BONNETT NO.       E34B-26-5
               TRA JE AEILITY *
     '
                            ACCEPT]        REJECT]         DATE:  #I/IPS'
                                                                   /
             REtAAf NS:     5/W 79 /So??-8- 30 M[oD6 MM W-
       ,
                                                                       4
                                                                          <,,    ./;
          INS           BY-                                      y Fo/A-E-36        A se
      ajPELT * e c                            ,~Se Se -               'S e< Eo     .
                                                                                      ,
 .   ',
             '
               '.
                                   VA LVE RE INSFECTION CHECKLIST
                                             ISSUE EI.b.2                      .
                                                                                   -
         TAG NO.                        ITEM NO.                   GE'4. SAMPLE 7
                 MON"Od//                        32I               SUE. CAMPLE D
                                                                   RIR NO.
                                                                             6 834
                                                                                             ,
               VALVE MARKINGS:
                                                                                        .
                                                         YES NO
                                GODY C BONNET ACCE 55. [] {
                                BODY NO.
                                EONNET' NO.
              T; A fi./ lL!TY '
      i                    ACCEF ,
                                    u
                                      i    REJECT        [ ATE:
      g                                           -
      .
      '
           REMAGN5:
                              0edf Of th74108 /E'Sub47d0s  MEW Y'
                              Vey mow
   i
                                                                     '
                                                                           (ppd

L

                                                                               e/[$f~

'

      IN PECTE,C BY:
      l ,, , ~ -- , . .
                                 '
                           f#;dm$ ,/ _ , , _INSR SUPd
                                         .
                                                     ./_
                                                            -
                                                                'V . ' , ,l*
   ;                                                             -
                                                                     ISSUE COORD. .       .,

,

        -                                                                            ,,
 ,
                 '
        .
   , . , -       .
                                      VA LVE  RE INSFECTION CHECKLIST
                                                ISSUE E.b.2                    .
              TAG NO.                      ITEM NO.                GEN. SAMPLE 7
                     2o3-&#40                       27+            SUE. LAMPLE [
                                                                    RIR NO.
                                                                             visb
                  VALVE MARKINGS *
                                                                                   .
                                                            YES NO
                                     BODY 8 BONNET ACCE55.      ]]
                                     BODY NO.      Y og/ -/3 9/
                                     EONtJET- NO. E M 4P/ C - 9
                  TL A li.t ?iL!TY :
                                 ACCE F-{:    REJEOT]       [ ATE: 8I5/85
.
                                                                         "?      '
          I
          ;     REMAr.kS :       OfN ?S~SS5?/Y 0# c
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                                                                                     7
                                                                                   -
                                           AP     /
                                                     5:

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          (&Eg/6,BY*x f/Erds-                        ,,
                                              Inte Supy
                                                           /h/'
                                                                     '&n/sifs'
                                                                      lSSUE COQRD.

I

       .
          .
 ,

.

 .        .
                                VA LVE RE INSFECTION CHECKLIST
                                            ISSUE BI.b.2                   -
       TAG NO.                         ITEM NO.               GE'4. SAMPLE O
             /-70/4D                .           542           sus. EAMPLE [
                                                                  .
                                                              RIR NO.
                                                                         / 3 %~
          VALVE MARKINGS:                                                          -
                                                                                 .
                                  -
                                                       YES NO
                              BODY $ BONNET ACCESS. 5I 7
                                                       a   _J                        .
                              BODY NO.        E 34Q -7-4
                              EONNETT NO. f34 7 o -/
                                                                                         1
                                                                                       -
          T; A .'i A EILITY :
    !
                         AC CE '-{i      REJECT]       [4TE:     5 8f  .
   !
         REMAGNS: hops On m RYA M MK -VM 73~~M27 -2-72 'S
                        #iss, .
   !
                                                                              /h
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                                                                             j,
                                          -
                                      APP        S
     INSPECTEC BY"
         O,d/dm. E4/4Y
                                             g,     [[g'
                                                              QMgr
                                          INSR StJPk            ISSUE CO'ORD.
      -
       -
  .

- , .

                              VA LVE RE ItsSFECTION CHECKLIST
                                         ISSUE H.6.2                          -
    TAG NO.                        ITEM NO.                   GE'J. SAMPLE D
       2PCV-6//T                                tr7           SUE. EAMPLE V
                                                              RIR NO.
                                                                         2 VV3
       VALVE MARKINGS:                                                                 .
                                                                                     e
                                                      YE S NO
                            BODY 8 BONNET /,CCE 55. [ ]
                            BODY NO.          S 3 22 - 2D
                            EONNci   no.      rics,- 9 7
       T; A fi. A clL! Y .*
                       ACCE4-@       REJET,T]         [4TE.   8b!#J
 l    neuAnus:          ys ps-/sp7-5 -/ co cove oors -sq
 .
                                                                                   _
                              '
                                  AP              -
               '
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     A                                                   TION RESEARCH CORPORATION
                                                   EVYUdNTROLLE        D COPY
                                                    CONTROL No           ?L Q-
                                                    COMANCHE PEAK RESPONSE TEAM

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                                  QUALITY INSTRUCTION FOR ISS11E SPECIFIC ACTION PLAN VII.b.2
                                                          CHANGE NOTICE 001
                                                    INSTRUCTION NO: QI-018
                                                            REVISION: 0
                                                         ISSUE DATE:    09/19/85
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                                       REINSPECTION OF PREVIOUSLY DISASSEMBLED VALVES
                                         The QI identified above is hereby changed as
                                          shown on the attached pages of this notice.
                                           .. -
                          Prepared by: -/[/[CJ                               Date:  '7 / P     *
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                         Approved by:
                                                                             Date: 9 f       [
                                      Issue Coordinator                            '
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                         Approved by:            .
                                                                             Date:    7-/9- 6
                                      On-Site QA 1epresentative
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                                      Qy..vI..,..... der
                                                                            Date:
                                                                                    f.      f. 8 7
                                                                _
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                                ---________ ______ ________-_______ _______-__ _______________________________ ________-________ ___________________
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                                                                                                                                                                                                          4
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                              of the hearings. However, any proposed set.edule should be keyed to the
                              tining and adequacy of responses to discovery requests; only in this way
                                                                                                                                                                                                 n*
                             will it be possible for the Board to fulfill its promise to CASE that
                                                                             all parties (as memorialized in the Board's 6/29/84 Memorandum and
                                                                             Order (Written-Filing Decisions, #1: Some AWS/ASME Issues)).
               -
                                                 1.                         The Board should invite the Applicants to respond to CASE's                                                                 .
                                                                              A - rs to Applicants' seventeen various Motions for Summary
                                                                             Disposition by a date certain, which CASE suggests should be
                                                                             September 4, 1985 g /.
                                                 3.                         The Board should also itivite the NRC Staff to respond to CASE's
           }                                                                 responses to Applicants' Motions for Summsary Disposi, tion. Since
             ,                                                               the Staff has not yet responded (with one exception, to our
           ~-

, recollection) to any of Applicants' Motions oe-CASE's responsesf ~

                                                                             it might be appropriate for the Board to allow the Stinff/
                                                                             additional time, which CASE suggests should be by September 16,
                                                                             1985.
                            /2f2 CASE considers this amount of time to be very generous, in;1ight of the
                                                many months which have already passed without Applicants responding.
                                                Further, additional time should not be necessary since Applicants
                                                apparently have already been working on this; they have sta,ted that
                                                they are " currently committed to provide the Board with corrections to
                                                all affidavits." See Applicants' 7/5/85 First Partial Response to Ripe
                                                Discovery Raquests, page 5, Footnote 2.
                                                                                                                                                                                             2
                                     *
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                                                                                                                                                                                               *
                          . ..                                .
                                                                               -___                                                                  _ - _ _ - _ - _ _ _ _ - _ _ _ - - _ _ -                a

- _ _

                  . .
      .
              *
                      ,
                                                                            h . _.                          - _ . _
     .          .
            -
                                                                                                   .
                              4    Since Applicants are now apparently attempting to phase out
                                   Cygna's independent protocol-controlled effort with the CPRT Plan
                                                                                             ?I
                                   which is governed by no such restrictions (and therefore qualifies
                                   only as yet another Applicant-dependent effort), CASE suggests
                                    that the Board request that Cygna Energy Services also respond to
                                   the Applicants' Motions for Summary Disposition and CASE's
                                   responses to them.    CASE suggests that the same time be allowed
                                   Cygna as is allowed the NRC Staff, until September 16, 1985.
                              5.   The Board should invite Applicants to respond to CASE's First,
                                   Third, and Fourth Motions for Summary Disposition (filed 10/6/84,
          .
                                   11/2/84, and 1/14/85, respectively) /3,/.       We suggest that the date
                                   for the filing of such response should be September 4, 1985.
                             6.    The Board should invite the NRC Staf f to respond to CASE's First,
                                   Third, and Fourth Motions for Summary Disposition. We suggest
      ,
                                   that the date for the filing of such response should be September ~
        ~
                                   16, 1985.
                             7.    The Fos?d should invite Cygna Energy Services to respond to CASE's
      -
                                   First , Third, and Fourth Motions for Summary Disposition f4,/. We
                                   suggest that the date for the filing of such response should be
                                   Septembe r 16, 1985.
                        /3/ CASE's 10/22/84 Second Motion for Summary Disposition was covered by
                             the Board's 10/26/84 Memorandum (Intent to Retain Academic Expert).
                             See also the Board's 11/9/84 Memorandum (Testiomony from Dr. Arthur P.
                             Boresi).
                                                                                            -
                        /4/ We note that Cygna " responded" to CASE's Third Motion for Summary
                             Disposition by basically stating that they didn't want to answer it,
                             they wanted to have hearings instead. This is clearly contrary to the
                             intent of NRC regulations governing Motions for Summary Disposition and
                             their responses, since one of the primary reasons for them is to narrow
                             the issues for trial so that hearing time is not unnecessarily wasted
                             by the Board and parties.              .
                                                  .
                                                                  .
                                                           3
            . .
 .
       '.      .
 .
          .
                                                                                                            .
                        8.       The Board should order Applicants to file by a date certain
                                 exactly what their intentions are regarding Cygna's , role in the
                                                                                                        *
                                 design review.of Comanche Peak.                This is necessary s%nce it
                                 appears that Applicants are now apparently attempti'g               n to phase out
                                 Cygna's independent protocol-controlled effort with the CPRT Plan
                                                                                                                                .
                                 ...ich is governed by no such restrictions. CA'E suggests that the
                                 date for filing be September 4,1985.
                       9.        If any of the parties does not respond at all or does not respond
                                 by the date designated by the Board (with any extensions being
                                 granted only upon a showing of extraordinary necessity), the Board
                                 should rule upon what is in the record regarding each Hotion for
                                 Summary Disposition and responses.
                       Applicants' previous and latest litigation strategies have already
                 severely damaged CASE's due process rights in these proceedings. The Board

, should require Applicants, NRC Staff, and Cygna (should it want to

                                                                                                                  - .
 ,
                 participate) to comply with NRC regulations regarding Motions for Summary
   '
                 Disposition, as modified with the approval of the Board and all parties.
     .
  __                   CASE urger, that the hoard adopt these preliminary steps which will
                 allow the Board and parties to better determine the status of the record
                 regarding design / design QA issues. After that time, it will be appropriate
                 to consider the next step to resolve these issues or to deny the operating

,

                 license.

,

                                                                      Respectfully submitted,
                                                                             22     53             N
                                                                          s.) Juanita Ellis, President
                                                                     p'E
                                                                      CAS (Citizens Association for Sound
                                                                                       Energy)

, 1426 S. Folk

                                                                      Dallas, Texas     75224
                                                                         214/946-9446
                                                                           .
                                                           4
                       - . - - .         . . --.      - - . _ _ - _ .                    - . . - .    -   -    -.     . _ - ---

, _ __ _ _ _ _ _ _ -- ..

                                                                                                                                          ,
 .                .
              y    .
         -
                                                                                                                              .
                                                                                                                            .
In reviewing some of the welding information in our files, additional -
                     support of CASE's position regarding the willful and deliberst -
                     misrepresentations by Applicants' counsel was found.                                              '5
                           We call the Board's attention to the Board's Order at page 1 (which
                     CASE asked the Board to reconsider in our 1/7/85 Motion for Reconsideration
                     at pages 20 and 21). The Board stated:
                           ". . . we find that Henry Stiner had a long-standing absentee problem
                           at work and that he was discharged from the plant because of his
                           absenteeism, not because he gave information to a OC inspector about a
     ~                     gouge ina pipe preceding
                                               "
                                                       the three day a*asence that precipitated his
                           termination.    . .
            .
                           And in Applicants' 1/22/85 Reply to CASE's Motion for Reconsideration
       '        "
                     of Licensing Board's Memorandum (Concerning Welding Issues), Applicants
                     counsel argued against CASE's Motion, stating:
                           " CASE alleges that the Licensing Board erred in finding that Mr. Stiner
                           was discharged because of a longstanding absentee problem and not
                           because he gave information to a QC inspector regarding a gouge in a
                           pipe. Accordingly, CASE moves that this finding be stricken and the
                           Board exclude its findings regarding Mr. Stiner's credibility from                                   . .
   -
                           consideration concerning the issue of his termination. CASE's Motion
    .                      at 20-21.
       -
                           " Applicants maintain that the unrefuted evidence currently in the                    _
          .                record and briefed by Applicants and CASE provides substantial evidence
                           to support the Licensing Board's finding regarding Mr. Stiner's
                           termination.     See, e.g., Applicants' Proposed Findings at 3 and CASE's
                           Proposed Findings on Welding Issues at 6-7 (September 9,1984). For
                           this reason the motion for reconsideration should be denied."
                           (Emphases added.)
                           CASE calls the Board's attention to Applicants' 8/30/82 Answer to
                     CASE's Motion for Protective order at page 5, second paragraph (copy of
                     applicable portions are attached for the Board's convenience)~, khere
                     Applicants' counsel made the represent'ation to the Board:
                                                                                                                          .
                                                         5
                                                                                                                                        '
                                                                         -
                                                                 _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
                                     ._              _    _ _ _ _ _ - - _ _ - _ - _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ - _ _ _ _ _ _ _ _ _ _ - _ _ - _ _ _ _ _ _ _ _ _ - _ _ _ _ _ _ _ - - _
                      .
 . .         .
                 .
                    .
           .
   .              .
     .
                                                                                                                                                                                                                                                                  .                         -
                                                                                                                                                                                                                                                                                       8/15/85
                                                                                            UNITED STATES OF AMERICA
                                                                  NUCLEAR REGULATORY C0lWISS10N
                                                    BEFORE T14E ATOMIC SAFETY AND LICENSING BOARD                                                                                                                                                                                3'
                                                                                                                                                                                                                                                                                 s-
                      In the Matter of                                                                                                                                                                                                                          '   Docket Nos. 5.0-445
                                                                                                                                                                                                                                                                            and 50-446
                      TEXAS UTILITIES ELECTRIC
                         COMPANY,       '~ -
                                             et al.
                                                     -
                                                                                                                                                                                                            l
                                                                                                                                                                                                                                                                    (Application for an
                      (Comanche Peak Steam Electric                                                                                                                                                    l                                                             Operating License)
                         Station, Units 1 and 2)                                                                                                                                                       l
                                                 CASE'S PROPOSAL REGARDING DESIGN / DESIGN OA ISSUES
                                        IN RESPONSE TO APPLICANTS' 6/28/85 CURRENT MANAGEME M VIEWS
                                                   AND MANAGEMEM PLAN FOR RESOLUTION OF ALL ISSUES
                                  on 7/29/85, CASE filed its Initial Response to Applicants' 6/28/85
         '     '
                           Current Management Views and Management Plan for Resolution of All 1s, sues,
                           4.1.J.   e hwiporate herein by reference. As stated at that time, CASE is
                          very conscious of the Board's previous admonitions that parties have a

$ responsioility to present an orderly case to the Board Lif. CASE is still

                          in the process of preparing a coherent, comprehensive proposal of how we , .
      .
       ,
                          believe the rest of the case should be handled. We are still unable (as we
         .
                          were then), primarily because of the uncertainties associated with receipt
      ~
                          oi discovery responses, to siet forth a proposed scheduled for the remainder
                        ~ /1/ It should be noted that Applicants have not followed the Board's orders

,

                               .in this regard. They have instead presented a Plan to the> Board in
                                bits and pieces, which is still incomplete and lecks sufficient
                                 specificity to enable a reviewer to thoroughly critique it. This is
                                not helpful to the Board. Further, it is grossly unfair te CASE and
                                puts CASE at a tremendous disadvantage and severely damages our due
                                process rights in these proceedirige. In addition, new information
                                which CASE received just yesterday and is still reviewing clearly
                                indicates that Applicants have been planning this for many months, far
                                in advance of what has been indicated before. We will be addressing

-

                                this in more detail in a later pleading.

?

                                                                                                                                                                                                                                                                                   0
                                                                                                                                                                     1                                  .
           .                                                                                                                                                                                            .                                                             ;
                                                                                                                                                  _                                                 _ _ _ _ _ _ _ _ _ _ _ _ _ - . _ _ _ _ . _ - - _ _ - - - - -                      -
                                                                                                        %
                                                                                                          l
          - .

.

      2-    .
         ..
                                                                                               "
                                                                                          .
                                                                                   *
                                                                                     .
                                                                                     .
                                           UNITED STATES OF AMERICA                  **
                                         NUCLEAR REGULATORY COMMISSION           2.  .
                                                                                           '
                      .
                                BEFORI THE ATOMIC SAFETY AND LICENSING BOARD
               In the Matter of                        }(
                                                       )(
              TEKAS UTILITIES ELECTRIC                 )(      Docket Nos. 50-445-1
                 COMPANY, et,jal.                      }{               and 50-446-1
               (Comanche Peak Steam Electric           )(
                 Station, Units 1 and 2)               }(
                                            CERTIFICATE OF SERVICE
              By my signature below, I hereby certify that true and correct copies of
    .
               CASE's Proposal Regarding Design / Design QA Issues in Response to Applicants'
               6/26/05 Current Management Views and Management Plan for Resolution of All
               Issues
              have been sent to the names listed below this 15th day of August               ,19 BJ_,
              byr EX,EEEXEXXXII where indicated by * and First Class Mail elsewhere.

.

                     Federal Ex,=ress                                                              -
 -
              * Administrative Judge Feter E. Elech.      * Nicholas S. Reynolds, Esc.
   '
                 U. S. Nuclear Regulatory Coe=ission         Eishop, Liberman, Cook, Purcell
                 4350 East / West Eignvay, 4th Floor           & Reynolds
                 .ethesda, Maryland      20E14               1200 - 17th St., N. V.
                                                            Washington, D.C.     20C36
              * Judge Elizabeth E. Johnson
                 Oak Ridge National Laboratory            * Ceary S. Mizuno, Esq.
                 P. O. Box X, Building 3500                 Office of Executive Legal
                 Oak Ridge, Tennessee      37830               Director
                                                            U. S. Nuclear Regulatory
              * Dr. Kenneth A. McCollom                        Commission
                 c/o Neal McCollem    .                     Maryland National Sank Bldg.
                 4851 Winesanker Way                           - Room 10105
                 Fort Worth, Texas      7E123               7735 Old Georgetown Road
                                                            Bethesda, Maryland, ,20814
              * Dr. Walter H. Jordan                    .   Chairman, /. comic Safety and Licensing
                 881 W. Outer Drive                            Board Panel
                 Oak Ridge, Tennessee      37830            U. S. Nuclear Regulatbry Commission
                                                            Washington, D. C.       20555
              * Administrative Judge Herbert Grossman
                 U. 5. Nuclear Regulatory Commission
                 4350 East / West Highway, 4th Floor
                 Bethesda, Maryland      20814                                                        .
                                                        .
   '
         .
           .    .
   .        . .
                                                                                                    9
                                                                                           .
                   Chairman   _
                                                               Renea Hicks, Esq.
                   Atomic Safety and Licensing Appeal          Assistant Attorney General
                     Board Panel                               Environmental Protect $on' Division
                   U. S. Nuclear Regulatory Commission         Supreme Court Building -
                   Washington, D. C.      20555                Austin, Texas 78711,.
                  Mr. Robert Ma**.in                         * Anthony Z. Roissan Esq.      '
                   Regional Adminictrator, Region IV           Trial Lawyers for.Public Justice
                  U. S. Nuclear Regulatory Commission          2000 P Street, N. W., Suite 611
                   611 Ryan Plaza Dr., Suite 1000              Washington, D. C.     20036
                  Arlington, Texas 76011
                                                               Mr. Owen S. Merrill
                  Lanny A. Sinkin                              Staff Engineer
                  3022 Porter St., M. W...e304                 Advisory Committee for Reactor
                  Washington, D. C.       20008                     Safeguards (MS H-1016)
                                                               U. S. Nuclear Regulatory Commission
                  Dr. David H. Boltz                          Washington, D. C.      20555
                   2012 S. Polk
                  Dallas. Texas      75224                     Robert A. Wooldridge, Esq.
                                                               Worsham, Forsythe, Sampels
       .          William Counsil, Vice President                   & Wooldridge
                  Texas Utilities Generating Company           2001 Bryan Tower, Suite 2500-.
                  Skyway Tower                                 Dallas, Texas    75201
                  400 North Olive St., L.B. 81
                  Dallas, Texas     75201                      Thomas G. Dignan, Jr., Esc.
                                                               Ropes & Gray
                  Docketing and Service Section                225 Franklin Street
                     (3 copies)                                Boston, Massachusetts     02110

, Office of the Secretary

                  U. S. Nuclear Regulatory Commission         Ms. Nancy H. Williams             ..
  -
                  Washington, D. C.      20555                Project ManaFer
    -                                                         Cygna Energy Services
                  Ms. Billie P. Carde                          101 California Street, suite 1000
      -
                  Governcent Accountability Project           San Francisco, California
  --.             1901 One St ree t . N. W.                         94111-5894
                  Vashington, D. C.       20009
                                                              Mark D. Nozette, Counselor at Law
                                                              Heron, Burchette, Rockert & P,othwell
                                                               1025 Thomas Jefferson Street, N. W.,
                                                                    Suite 700
                                                              Washington, D. C.      20007
                                                 02D                      D ', ,   *   ;
                                                g ,i's.),Juanita Ellis, President
                                                VCASE (Citizens Association for Sound Energy)
                                                  1426 S. Polk                        -
                                                  Dallas, Texas      75224
                                                         214/946-9446
                                                     2
                                                           .
 4
                -    -
 .
            '
              .     .
         .        .
 ..
                                                                                                         .
                          Chairman                                         Ranen Hicks, Esq.
                          Atomic Safety and Licensing Appeal              Assistant Attorney General
                            Board Panel                                   Environmental Protection. Division
                          U. S. Nuclear Regulatory Commission             Supreme Court Building
                          Washington, D. C.       20555                   Austin, Texas 78711 {~
                                                                                                 . ;.
                       5
                          Mr. Robert Martin                             * Anthony Z. Roissan. Esq.
                          Regional Administrator, Region IV               Trial Lawyers for Public Justice
                          U. S. Nuclear Regulatory Commission             2000 P Street, N. W., Suite 611
                          611 Ryan Plaza Dr., Suite 1000                  Washington, D. C.     20036
                          Arlington, Texas 76011
                                                                          Mr. Owen S. Herrill
                          Lanny A. Sinkin                                 Staff Engineer
                          3022 Porter St., N. W., f304                    Advisory Committee for Reactor
                         Washington, D. C.       20008                          Safeguards (MS E-1016)
                                                                          U. S. Nuclear Regulatory Commission
                          Dr. David H. Boltz                             Washington, D. C.      20555
                          2012 S. Polk
           '
                         Dallas, Texas      75224                         Robert A. Wooldridge, Esq.
                                                                          Worsham, Torsythe, Sampels
                         Villiam Counsil, \* ice President                      & Wooldridge
        -
                         Texas Utilities Generating Company               2001 Bryan Tower, Suite 2500
                         Skyway Tower                                     Dallas, Texas    75201
                         A nn a - * b Olive St., L.B. 61
                         Dallas, Texas      75201                        Thomas G. Dignan, Jr. , Esq.
                                                                         Ropes & Cray
      .                  Docketing and Service Section                   225 Franklin Street
                            (3 ccpies)                                   Boston, Massachusetts         02110
                         Office of the Secretary
                         U. S. Nuclear Regulatory Commission             Ms. Nancy H. Williams
   ,
                         Washington, D. C.     20555                     Project Manager                          - -
    *
                                                                         Cygna Energy Services
                         Ms. Eillie P. Carde                              101 California Street, Suite 1000
      ,                  Ccvern=ent Accountability Project               San Frarcisco, California
                         1901 Oue Street, N. U.                                94111-559'
   ~~
                         Washington, D. C.       20009
                                                                         Mark D. Nozette, Counselor at Law
                                                                         Heron, Burchette, Ruckert & T.othwell
                                                                         1025 Thomas Jefferson Street, N. W.,
                                                                               Suite 700
                                                                         Washington, D. C.     20007
                                                                   DA            .  fA/6
                                                                 s.) Juanita Ellis7 President
                                                                                                     -
                                                               SE (Citizens Association for bound Energy)
                                                             1426 S. Polk                            -
                                                             Dallas, Texas      75224
                                                                   214/946-9446

l

                                                                                                *
                                                               2
                                                                      .
                                                           *
                                             e     e
                                                                                       _7    r ,- ,-        - - , w
                           - _ - - __. _ _ _ -
 .           . .
          .-     .
                                                                                              '
                                                                        '
                      .                                                                                             .
                                                                                                               .
   i                                                                                            '
                                                                                                             ~
                                                              UNITED STATES OF AMERICA
                                                           NUCLEAR REGULATORY COMMISSION                 8~

! *:

                                                                                                       '

! BEFORE THE ATOMIC SAFETY AND LICENSING BOARD . 1

                     In the Matter of                                       )(
                                                                            }{
                   . TEXAS UTILITIES ELECTRIC                               }{       Docket Nos. 50-445-1
                        COMPANY, et al.                                     }(                and 50-446-1
                    -(Comanche Peak Steam Electric                          }{
                        station, Units 1 and 2)                             }{
                                                               CERTIFICATE OF SERVICE
      .
                     By my signature below, I hereby certify that true and correct copies of
        -
                      CASE's 8/15/85 Supplement to CASE's 1/7/85 Motion for Reconsideration of' Board's
                      uno'oa %c-=nd.sn (Concerning Weldina Issues) (LBP-84-54)
                     :. . . Li. . . 4 c r. : to the names listed below this 15th day of August                     ,198 5 ,
                     by: EKp%ENEXXXII where indicated by * and First Class Mail elsewhere.
                                  Federal Ex, tress
                                                                                                                                      ..
   -
                     * Adcinistrative Judge Peter E. Bloch                     *   Nicholas S. Keynolds, Esq.
     ~
                        l'. S. Nuclear Regulaccry Com=ission                       Eishop, Liber =an, Cook, Perce11
        .               4353 Eas:/ West F.ighway, l.th Floor                         & Feynolds
   ~
                        lethesda, Maryla :d                20 S i t.               1200 - 17th St., N. W.
                                                                                   Washington, D.C.     20036
                     * Judge Elizabeth E. Johnson
                        Oak Ridge National Laboratory                          *
                                                                                   Ceary S. Mizurso Esq.
                        P. C. Box X, Building 3500                                 office of Ixecutive Legal
                        cas. raoge, 'lennessee                37830                  Director
                                                                                   U. S. Nuclear Regulatory
                     * Dr. Fenneth A. McCollan                                       Com:sission
                        c/o Neal McCollers              .                          Maryland National Bank Bldg.
                        4851 Winesanker Way                                          - Room 10105
                        Fore Worth, Texas                 "16123                   7735 Old Georgetown Road -
                                                                                   Bethesda, Maryland      20814
                                                                                                       - :
                     * Dr. Walter H. Jordan                                        Chairman, f.tomic Safety and Licensing
                      . 881 W. Outer Drive                                   -
                                                                                     Board Panel
                        Oak Ridge. Tennessee                  37830                U. S. Nuclear Regulatory Cosmaission
                                                                                   Washington, D. C.     70555
                                                                                                          '
                     * Administrative Judge Herbert Crossaan
                        U. S. Nuclear Regulatory Commission
                        4350 East / West Highway, 4th Floor
                        Bethesia, Maryland                 20814
                                               ...                           ,
                                                                                                             .
                         W
                                                                             Q
                                                                     k..*,.      .
                                                                                                                      . _ _ _ _ _ _ _ _ _ _ _ _ . _ _ _ _ . .
                                               _ _ _ _ _ _ _ _ - - _ - _ _ _
 .
               ..
               '              '
                                                                                                                                                                                                        '
                                                                                                       10
                                          '
     :            -
                             .
                                                                                          :      .
                                                                                                                                                         .
                                                                                                                                                                                                            ..
                                                                                                                                                                                                            .
                                                                                                                                                                                                                   W.: ..
          .*
                                    '       _'                                                       -$_                                                                                                           *
                                                                                                                                                                                                                     .
   !               .                                                                                                                                                                          .
                                                                                                                                                                                                   .-            ,
                                                                                                                 .
                                                                                                                                                                             -
                                                                                                                                                                                                   u             -
    l-                                                                                                                                                                                                *
          .                                           Clearly, an employee's remedy for alleged discriminatory
                                                                                                                                                                                -
                           .                                                                                                                                .                                                              .
                                                                                       .                                                                         .
                                   ,ptats.us= by an NRC licensee lies with the Department of Labor,
                          *                                                                                                                                              ~
         .,-                                                                                                                                                                                                                -
                                                                                                                                                                    t'
                                jyursuant to 42 U.S.C. 55851, and not with the NRC. .This Board,
             '
                                                                                                                                                                    '
      .
                                ;                                                                                                                           -
                                 ;being vested with only such authority,.as the Commission may                                                                                                   .
                                 .
                                                                                                                                                                                                                       .
                          '
                                   delerate, accordingly, is not empowered to pr'oVTWe CASE with-
                                      -
                                                                                                                                                                                                                   .
                                    the relief it seeks.                                    Thus, the Board should deny CASE's motion
                                                                                                                                                                                                                     .
                                    as being not within.the Board's autho rity.
                                                                             B.  In Any Event, The Motion Is Without Merit
           '
          .                                        Assuming arguendo that the Board had jurisdiction over a
                -
                                    claim under Section 210 of the Energy Reorganization Act.
             -
                                    42 U.S.C. 85851, nevertheless the Board should deny CASE's
                 *
                                   motion as being without merit or substance.                                                                           As to Mr. Stiner,
                                   even CASE concedes that Mr. Stiner's efforts to reverse his
                 .
                                    terminations in 1980 and 1981 started "long before CASE had                                                                                                                          ,
                                   any Id. a Mr. and Mrs. S r I nse r would h t- t c re r I f yi n g In these                                                                                                                   ,
        }                          proceedings" (CASE Hotion,, ut 1).                                       Mr. .Stiner's situation is                         ,
            ,
                                   purely a personnel matter between him and Brown & Root.                                                                                                   His
        -
                                   efforts to obtain his personnel records pre-date these hearings
                ,.
                                   and therefore have no rational connection to them.                                                                               Further,
                                        .                                                                                                                                                                      .
                                   as a_ forcer Brown & Root employee who was fired for unsatisfactory
     .
      r
        ,
                                   job performance (and not matters r'                                     e lated to these hearings),                                                                                ,,
                                                                                                                                                                                                                              ,
                     ,
                                   Mr..Stiner's election to testify in these hearings does not                                                                                                                             ,
                                                                                                                                                                                                                              *
              .                    bring him within the sqope of Section 210 of the Energy   ,
                                                                                                                                                                                                                         ,
                                                                                                                                                                - *
                                   Reorganization Act.                                                                                                                           .
                                                                                                                                                                                                          '               *

' *

                                                   As to Hra. Stiner, the allegations raised by CAS,E are
                                   false.                                    Applisants have taken ne astion "in retaliation for her
                                    testifying in the operating license hearings for Comanche Peak"
                       -
                                                                                     .                                                                                 .
                                                                                                                                                                  ,
                                                                                                         *
                                                                                                                                                                                                   l'              o-
                                                                                                   .                                                                                                                        .
                                                                                                                                                                                                                         .
                                                 . . - -                                                           - - - _ - - - - - - - - - - - . _ - -                   - - - _ - - - - -
                                                                                                                                                                                                   .
                                                                                                                                                                                                         .__              .-
                                                                                                                  ._                                                 .
       .                  * -                                                                                                                                                                    1
                   .                                                                                                                                                                             l
                     .        .
                                    *
 Af,                   .*                                                                                                .
                                                                                                                             *:s34;l                      ' .Y.:{?.l( \
        o
           s           .          .                                   ll                                                      ,;
                                                                                                                                     *-
                                                                                                                                                                  :^. , , = l-
     -
                                   ,. .
                                                                   ~1-                                .                       -               .,                  . ,.: ^. , , i.
                                                                                                                                                                                             -
                 -                                                                                                                                                                            -
                                                                                                        .       .      .         .          h:          . q*                .
                                                                                                                                                                                    .
                                                                                                                     .                         .- .                              ,
                                                                                                                                                                                         .
        -                                                                                                                                    '
                                                                                                                                                                    . .b '.'../.
                                 of Mrs. Stiner.    Accordingly, CASE's motion should be denied.",
                                                      .
                                                                                                                                                             ', f,j$;          4&
                                                                                                                                . . ,1            .                 s.              .
                                                    *                                                  *                                                 -
                                                                                                           .                           'M ,                                ',**            .
                                                                                                            *
                                                                                                                                                                            . .
       .                                                                                                           .       .           ..                         ' ; ,.5.. .
                                                                                                                                                                       -
     e.                                                  III.   ' CONCLUSION                                                                                -
 .                                                                                                       . ., .                                .
      -
                                                            .                                                                                                              r.             .

'

                                        For the foregoing reasons. Applicants urge the Board
                                                                                 .
                                                                                                                             to
                                                                                                                                s.
                                                                                                                                                                ' ' '

,

                                                                                                                                                                                         ..

'

                                                                                                                                                       '
                                deny CASE's motion for lack of jurisdiction over the subject                                                                    ,,-            ,
                                                                                                                                                                     ;.
                                                                                                                                                                   ...          .
   .
                                matter or, in the alternative, for lack of merit.                                                                             ~
                                                                                                                                                              ..          ;         .
                                                                                                                                                                       .s'
                                                                                                                                 .'                                         *.                 .

.

                                                              .
                                                                                           .                                                                                  .-{..         _
                                                                                                                                                                                              -
                                                                                                                                                                                  .
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                                                                                                            .
                                                                                   '
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                                                                                Respect u      y Subnitted,
               .
                                                         -
           .
                                                                   .
                                                                               Nicholl             Reynolds
                              ,
                                                                                           h
                                                                                                -
                                                                                                              +
                                                                               William A. Horin                                     - -
      .
          ~
                                                                    Debevoise & Liberman
                                                                    1200 17th Street,        N. W.
     --
                                                                    Washington., D. C.             20036
                                                                     (202) 857-9817                                                                                                      .
             *
                                                                    Counsel for Applicants
      *                                                                                                                             '

l August 30,.1982 - l . .

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      .                                         ,                    UNITED STATES OF AMERICA                           *
                                                                                                                                         ^
          ,
               '                         '
                                                                  NUCLEAR REGULATORY COMMISSION
         l                                                                                                                  *
      U                                                 BEFORE TEE ATOMIC SAFETT AND LICENSINC' BOARD
                                                                   *
                                                                                                             ~.       .
                                              In the Matter of                     )                            .                     -
                                                                                                                                                 '
                                                                                                                                                      .
                                                                                                                :.-
                                                                                                     '
                                         .
                                              .
                                                                                   >
                            ,        or.EEEAS UTILITIES CENERATING '               )       Docket Nos. 50%A)5 and
                                        ,
                                            ; COMPANY, et,al.                      )                     50-446                        ,
                                                                                   )
                                                                                                                                    -
                                         ""         .
                                                                                                                    .
                                             1(Comanche Peak Steam Electric )              (Application for                     '
                                             ' 0 ::':.:, Units 1 and 2)            )        Operating Licenses)                                ,
                                                                                                                                                           ;
                                                                  APPLICANTS' ANSWER TO CASE'S
    -                                                              MOTION FOR PROTECTIVE ORDER           ,
                                                                                                                                .
                                                                                       *                                                               ,.
                                                                                                                                             ,
                                                                          %
                                                     Pursuant to 10 C.F.R. 82.730(c). Texas Utilities Cenerating
                                                                                                                                                         -
            -
                   '
                                             Company, et,al.      (" Applicants")..hereby submit their answer to
              "            '
                                             CASE's Motion for Protective 0,r d e r , served August 12, 1982, as
si;;1: :.::d by letter from CASE dated August 19, 1982. For
                        .
                                             the reasons set forth below, Applicants urge the Atomic Safety
                                             and Lluensing Board       (" Board") to deny CASE's motion as beyond
                                             the jurisdiction of the Board or, in the alternative, as being                        -
                                                                                                                                               ,.
         .
           *
                                             without merit or substance.                                                                             ,
      .
              .
                                                                                               .
         ~"

t

                                                                           I.  BACKCROUND

\ '

                         .
                                                    During the evidentiary hearings conducted July 26-30, 1982,                                         .

I

                                             CASE identified and' sought a subpoena for the attendence of                          -              .
         .
                                             Mrs. Darlene Stiner, a QC inspector at the,Comanch's Peak site.
                                                                                                       ,
                                                              .
                                                                                                              .

t

'
                                             CA8E stated that Mrs. Stiner possesses information relevant to                                         ..
                                             matters at issue in Contention 5.             The board granted the requested                         .
                                                                                                                                           "        *
                                           ' subpoena, Tr. 2964.        Mrs. S t in e,r is scheduled to testify upon
                 -
                             s
                                             the resumption of the evidentiary hearings on September 13, 1982.
  .                                                 On August 11, 1982 Applicants' Counsel became awar( that
                                                                                         *
                                    .        ,1                                                    .
                                                                                                                  .
                                  , d;,Mr s . Stiner had been engaged in efforts during working hours to
                                                                ,
     *'
                                  fi.:13                                                                   .
        ,a .                          l/                                             :
     ti                   u       lLd                                                                                             -
         . .
 .
     .
       .   .-
                                                                      ,
   .                                                 / '2
                                                                                       .
                   "His [Mr. Stiner's] efforts to obtain his personnel records pre-date
                   these hearings and therefore have no rational connection to them.
                   Further, as a former Brown & Root employee who was fired fbr
                   unsatisfactory job performance (and not matters related to'these
                   hearings), Mr. Stiner's election to testify in these heatings does not
                   bring him within the scope of Section 210 of the Energy Reorganization
                   Act."   (First emphasis in the original; second emphases added.)
                   CASE does not accept the representations by either Applicants'
              witnesses or of Applicants' counsel regarding the reasons alleged by
              Applicants for Mr. Stiner's firing. Whether or not the Board ultimately
              accepts Applicants' reasons, however, the above representation by
              Applicants' counsel is inconsistent with the later sworn testimony of
              Applicants' own witnesses.     It is a gross misrepresentation to the Licensing
   *
              Board, and the Board should so rule.
                   0/.   asks that the Board consider this in connection with CASE's 1/7/85
              Motion for Reconsideration.     Further, we ask that the Board take this and
              other misrepresentations of Applicants' counsel into consideration in the
              overall context of these proceedings and in any future Board decisions as, to
              whether or not to accept representations of Applicants' counsel.
                                                     Respectfully submitted,

_

                                                          J t .e~ b6~        fi>
                                                        s.) Juanita Ellis, President
                                                      ASE (Citizens Association for Sound
                                                                     Energy)
                                                     1426 S. Polk
                                                     Dallas, Texas    75224
                                                        214/946-9446
                                                                                - ;
                                                        .
                                                                                  O
                                                  6       -

.

  ,             .   .
          *
            ,       .

j

    '
        .         *                                                                         /M
                                                                                                                                                                    :
                                                                                                                                                                .
                               CASE submits that this new and significant information, especially when                                                      ,
                         combined with the information contained in our 1/7/85 Motion fq'r.
                         Reconsideration and its 3/16/85 and 3/19/85 Supplements, fully kindicates
                         and supports Mr. Stiner and his testimony in this regard.
                               turther, since the "one overriding factor regarding the Board's
                        decision involves Mr. Stiner's incredible statement" regarding the manner in
                        which, and the time in which, he completed a " plug weld" (Board. Memorandum
                        at page 59, second paragraph), this clarification and substantiation of Mr.
      '
                        Stiner's testimony should add credibility to any other testimony of his
                         .tich the Board questioned and go far towards establishing his overall
        .     .
                        credibility -- and correspondingly call into question the testimony of
                        appiteaut.      witnesses.
                               However, CASE does not ask that the Board close the record and rule
                        based on what is currently before it regarding the welding issues. There is
                        much additional information already in the TRT's SSER's and expected to he ,
                        in future SSER supplements which the Board should consider prior to closing
                        the record on welding. We therefore again ask that the Board continue to                                                                                                j
                        hold the record open awaiting receipt of this additional information                                                                                '
                                                                                                                                                                                                j

.

                        (although we must admit that we, and undoubtedly Mr. Stiner, would not be
                        adverse to a ruling by the Board at this point reversing its previous ruling
                        on this particular point).
                        Representations by Applicants' Counsel
                                                                                                                                                          -   ;
                              In our 1/7/85 Motion for Reconsid'eration (pages 7 through 19), CASE
                        submitted information regarding what we consider to be deliberate violations
                        by Applicants' counsel of the Board's specific orders.
                                                                          -4                         .
                                                                                                       *
t
      .               -               -    . _ _ . . . _ . , . _ . . _ . . . . . , , _ . _ . _ _ _ ,     . . , _ _ . , . . . _ . , _ . . . . _ . , ,.. ,,         . _ _ , . _ _ _ _ , . . . . -

.

       * .
                                                                                             ;
    '.   .
                                                                                             )
  .
                                                 /3       .
                                                                                             i
                                                                                    *
             .
                 It is important 'to remember the time frame during which the various
                                                                                 _
            events discussed herein occurred. CASEfileditsProposedFindfngsofFact
                                                                              ^
            on Welding Issues on 9/9/84. TheBoard'sMemorandum(ConcernindWelding
            Issues) was issued December 18, 1984.
                 CASE now calls the Board's attention to SSER No. 10 /4/, page N-57,
            regarding the TRT's investigation of " plug welding," as alleged by Henry
            Stiner.  In the next-to-last paragraph, last three sentences, it is stated:
                 "In a telephone interview with the alleger on September 10, 1984, the
                 alleger clarified this allegation.     The alleger stated that the number
                 of electrodes used was only an estimate, and that such holes were
                 ' capped' with a weld on either face and had slag and an air pocket in
                 the ciddle. A ' plug weld' made in this manner woulld obviously require
  .              fewer electrodes."
                 Thus, on September 10, 1984 (the day after CASE filed its Proposed
            Findings), months before the Board's 12/18/84 Memorandum was issued and
            before Henry Stiner or CASE realized that the Board had misinterpretted the
            testimony in the record regarding this matter, Mr. Stiner explained to the
                                                                                         - _

-

            TRT his method of " plug welding." His explanation at that time was
.
            consistent with the interpretation giv,en de; CASE in our 1/7/85 Motten f er

_ Reconsideration. The TRT's SSER No. 10 car.e out in April 19F5.

                 CASE has not completed reviewing the several SSER's issued by the TRT
            in recent months; in addition, we have been involved with various other
            pleadings and matters relating to these proceedings.     It was not until Mr.
            Stiner recently called the statements by the TRT to CASE's attention that we
            realized their full significance.
                                                                             - .
           /4/ NUREG-0797, Supplement No. 10, Safety Evaluation Report related to the
                 operation of Comanche Peak Steam Electric Station, Units 1 and 2,
                 Docket Nos. 50-445 and 50-446, April 1985
                                                      *
                                              3
                                                                                                           . _ - _ _ _   - _ - _ - _
    .
             .  .
          ~. ., .
        -                                                    /
                                                                                                           .
                                                                                                       .

.

                         The Board stated, on page 10, last sentence of second paragraph:
                                                                                            ~.
                         "Mr.Stinersubsequentlytestifiedthathehadperformed20lor30 plug
                        welds in a single day (Tr. 10699-70)."
                                                                                           **
                        The Board stated, on pages 59 and 60:
                         "The one overriding factor regarding the Board's decision involves Mr.
                         Stiner's incredible statement that a 1 1/4 inch hole in two inch thick
                        material (on which he allegedly welded many times (Tr. 10683-84)) could
                         be easily welded in about two minutes (excluding the blending of the
                        weld with surface material (Tr. 10698-9)), and it would only require
                         two veld rods to complete (Tr. 11158)." (First emphasis added; second
                        emphasis in the original.)
                        "Mr. Stiner's sworn testimony on this point is not accurate and
                         reliable. The board believes that any welder who had ever veld-
                         repaired a misdrilled hole of this large size or smaller would have
        ,                been able to at least provide a response that was in the ballpark. In
                         that Mr. Stiner was not able to do so, the Board questions whether Mr.
                        Stiner has ever performed a weld repair on a misdrilled hole. . ."
                         (copnasis added.)
                        In CASE's 1/7/85 Notion for Reconsideration, CASE explained (pages 31
                   through 39) the correct interpretation of Mr. Stiner's testimony as CASE
                                                                                                                       ~
      -
                   understood it and as it was explained by Mr. Stiner. As discussed therein,
                   it appears to CASE that          the Board has misinterpretted the testhmony in the
      _            record regarding this matter.
                        However, CASE can understand that the Board might be reluctant to
                   accept some counsel's representations of the correct interpretation /3,/.
                   Fortunately, it is not necessary for the Board to do so, because there is
                   now new and significant information which fully supports and corroborates
                   CASE's interpretation of the record, and which vindicates Henry Stiner's
                   testimony.and credibility.                                             - *
                   /3/ The Board has good cause to doubt representations made by Applicants'
                        ettorneys, as discussed later in this pleading; however, CASE does not
                        believe that it has given the Board reason to doubt its
                        representations.
                                                           2        -
 _.              -
                    .-       .      .     . . . - -              __       - . -   - - . -      , . - . - -                           -.
                                                                                                                       . _ .   ._. --
.           ..
      N . . ...

.

    .                                                                 y
                     ,                                                                                               .
                   m
                                                                                                            8/15/85
                   '
                                                         UNITED STATES OF AMERICA
                                                       NUCLEAR REGULATORY COMMISSION
                                                                                                     ~
                                        BEFORE THE ATOMIC SAFETY ff;D LICENSING BOARD                  -
                                                                                                       8 .*
                 In the Matter of                                       }            '
                                                                                       Docket Nos. 50r445
               -
                                                                        l                      and 21446
                 TEXAS UTILITIES ELECTRIC                               i
                    COMPANY, et al.                                     l
                                         -
                                                                        Q              (Application for an
                 (Comanche Peak Steam Electric                          i               Operating License)
                    Station, Units 1 and 2)                             i
                           CASE'S 8/15/85 SUPPLEMENT TO CASE'S 1/7/85 MOTION FOR RECONSIDERATION
                           OF BOARD'S 12/18/84 MEMORANDUM (CONCERNING WELDING ISSUES) (LBP-84-54)
      -
                             In CASE's 3/19/85 Supplement to CASE's 1/7/85 Motion for
    .
                       Reconsideration of Board's 12/18/84 Memorandum (Concerning Welding Issues)                            ,
                       (LBP-84-54). we stated that we would be filing additional information (some
                                                                                                                                            l
                       of which we believed would be new and signficant). There is still                                                    l
                                                                                                                                            l
                       sdeftfonal information which we expect to file following further contact                                             j
                       with the NRC Technical Review Team (TRT) to clarify a few matters, but there                                         l
                       mie 6-v opeciaAc mattets wnacu we pea 2 eve are especially important to get
  .
                       into the hands of the Board right away.
                      Board's Order at Page 10, last sentence of second paragraph; and page 59 and                                           l
                       first full paragraph of page 60; re: Welding of Misdrilled Holest
                                                                                                                                             l
                                                                                                                                             .
                             In CASE's 1/7/85 Motion for Reconsideration /1/ (pages 31-39) and                                              '
                                                                                                                                             l
                     briefly in our 3/16/85 Supplement /2/ (bottom of page 32 and page 33),
                     CASE discussed statements of the Board regarding its strong doubts both of
                      the credibility of CASE Witness Henry Stiner and of his testimon,y.
                    /1/ CASE's 1/7/85 Motion for Reconsideration of Board's 12/18/84 Memorandum
                             (Concerning Welding Issues) (LBP-84-54)                                   -
                     /2/ CASE's 3/16/85 Supplement to CASE's 1/7/85 Motion for Reconsideration
                   """
                             of Board's 12/18/84 Memorandum (Concerning Welding Issues) (LBP-84-54)
                                                                    1    -
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               Othe< obse<va.uons :O
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     ,
                                          to em bad. Plaio. Two ans.kov bott. hotas. Mot
    ,
                                          d.viLLed_. Thit cond.itiou aMea,cd to be into
                                              '
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     '                                     sistent wit.k utews .shotun om .s k e e f d. o f % d v a a .<
                                       @ Leuses baseolate. weldad. on 4.of to tubeol.
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            "                              Plate.. One. sntitor ball hole ts not drilled. (ondlbion
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                                                                                  9-M-85
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               Fol. Lod--UP SH6ET ComPLGTet i                                    4-M-BC

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                      ; C c_ '1 - o'2_8 - 414                       ,f 3 3 R.
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                   L3eecha of skewe.ot t.actds.
            Othe, ee m acta: chaga shown 6ctow a,c not on drawi,,3, E.1
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                    VERS F. PKG. (o F A PPL1 CA GL E            CT-? - DO4 - 407- $ 32_ A
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    )           _o 6 sFRVATierd        DFFici FN cT / comment
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            Td a.;n s pec.tio n of Pi Ae. AuP&ovt for Plug wetd.i . Mo PLog wetdt found. .
              Othav obse.,va tion A. :
    -
                                            l' b2ScPlate., 5h .Slud standout boew Concrete..
   '                                          4 141Lh.i boLit used., doubte_ muned.. Dolit av.c.
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                       'Ra msoe< tion of cabte.tva.< han3 cv fov Pl.ug welts klo PLog weld.s found..
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  ' '          # Met.ed. t.wo dxiLtcd., onve.ealyed. holes i.w .supeovt F.SE.- OoISS,Jheaf /0403.
                          MisduiLLs.d. holn a,c. 4' seated. 2.1 weziuved_ conter to center Nm
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                 INPUT             log s HEt- t       NoT'E O          .

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                                No. (o r APPL s cAet E)
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    <                    UNIT No. 1                                                '
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   ,                 b.; n s.oe c.t.ia n o{ calla. tva.4 .tuPoovt 40v
                                                                      Plug taa.Lds. No Plug totids found,
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                     Otha< esewtons:
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                               stGt4ATURE            [                          DAT E
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                                                                                0-M-86
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         <          Found that certain daarturei fvom h ha_ sic hawau d<aiutoo a,e pe,
                    M'ttnf aL 113ted Ln 40tt.1 d. And.1.e4 f.ke dv3Luink.
       ;            C1kLt tray hanau was Fahr:c hi by CB tex.                            ~
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                   Mo f urthu act:on vtouived.
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      '            _Alote 3. of the. dyawing .tlates, that "attachmewis arc shown l
     )                      ,ef e,tnte Daly. The datovm.*nsLion of attachutnt detail
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                            to be. used_ to;tt be made in h /idd"
    ,                                                                                                                                        \
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                                      the drawing'
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                                                              states:#<Ynaximum LengfA
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                          .IS A P Alo.                       U . d.
                           N/ER F. Pc6, (e s= n eeci ca et c.)                                                FSE - 00159 - 2&so
                          MLEth 140. (I f A PPLICAGc 6)

l<' uraiT No. d. -

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                                   -
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], _o G sFRVAT/ord / defic s FN CT ! CommFNY

                     1fIniPect.ed. fov Plug wet.d.s . de plug us4Ld2 found.

lt o t.hev obsc<vations : t'

, E 2.sz. elate. Il sec.twe.d. -f.o n e c.c'Liag tuith on e_
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                                                                Richmond. i.wse t ana. ono. 64itti kwi*-h olt .

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                                   .
                                                                                                                                     9 -/ 7 -8.5-
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       . - _ _ _ -           -    - - . - - - - - _ _ . . .                 . - - . . - - _ . . _ _ . _ . . . . - -         .     -.
                                                                                                                                    DATE    . . - . _ . . . _ .
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                                FSE. - Oo isa - us o Rev. 3 .ref ers to FS E. - 001'43 for
                                i.w3EaLL24: ion details. FSE.- Ool73 permits latert.haage of
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                                Richmond. in.tevis and llitti. bolts., and al. lotus to l' u se. HILii
 <                              bolts, t.uhtn RI ckmond. [.nied.t arc. wel avaltable'.'(Ref. F.5E -00173,
 l                              Skeel 2. , re. vision I2.).
 )                              Ths. installed lickwsoud. incevf. taas insoccit4 on .IR - OISS
 <(g                             ow 1- 13-8 3 3 UT ihickness tenort Mo. T- o(oS3, Per Procedure.
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        ouAport      F.i E - oo 1s3 - 2.'6 30, u nit. d i,usith ERI_ inseacto,
                                                                            .
        MaA rapant. h:41ee et:en uas in acco,aamc                                                with DI- co7,
        hug walds. .
        Observation:        Bua.eLat.c is secured. to the cet =9 u:(k oaa
        hithrnond. Inic.et Snd. one Nitt' Kwick.. bott.                                                                                                          N
                                     Qachmo K
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                                                                          A. 'A ne/e to FDE - Oo / ?9.
      FsE-ool%           Pn :h h.h,-clup'~p y h't/~ , ~4 kh                                                                        c .d
     H.x han , c~d nJL~ to " ou N.st: bat, tJu R, etna
   &k sk<. mo4 w AaAAn. { ALl- FSE - 0of 99, 3haf 2. , stsnh.% /2
               TdA d_ Lwt spects .Ta _o( 99 (z/is/ss)
               U T ti,icA # eu.pt d. r-06,93
               RI - &P - u . i 4 - 8 h. o .
                   .

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                                  .                ._           -          _   _.     ._      ..  ._   .

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                         N/Eg:F. PKG. (,e neeci caete) FSE - 60159 -- 4o2.3/ _.4039
          ;             'CTEin No. (s f APPL e cAec 2)
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                      FSE. - 00(59 - 40n . Reinspection of cabu. t.<av haage< (ov etug werdt .

'{ No plug weld.s (cond.. t'

      #
                      FSE. - Oo 153 - 4o3 9 . Located. adiacent to FIE -00159 - 402.3
      '
 ,,                                                   b.ucPlatw of f.Mi SUPoovt .Ikwi i.Md.icalidHS
                                                      of potential tepaiv by plugtuelding af. One. Location.
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                                                                   -
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       . - - - - _                                                                   _
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                        -
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                                S IGMATURE                        OgTE
                     .IMPNY LoS : SHEET NoYED          :                 :< ^       .
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                                                - .,
                                                      - - , -      - , - - - - - -      - - - - - - - - - - - - - , - - - - -
    '.  .
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 .
                                                                                       9-6-85'
                                                                                                                 .
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        Iwet.Pand.ent i.ns eecuon ,_ On:t # 1. C2Al, spren,4 voom.
        cahte. tvas sueeovts

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                  ,                           .                                      .
                                                                                                                              ...
                 ,
        FS t _ o o i sa '- 402.1                              @ no plug wetEs fou,id

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        Fit - ooisoa - 4039                                   _Incucauen ow bas.eptate
                                                              Of fotawkialitPalt bN Plug                                                  ;
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                                                            Wrbi.ing of a. M 1dylLLed. hola.                                              )
                                                         (Oht Localich).
                                                     em-um moro
                             @          d@
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    )           .rTEtn No. (o r Aepts cneL2) b'8 SIOb l TDb6 Laeldi fM13f'l$   ,
                    Uta iT No. .d.
    <             Lo cxr noa hietaL Generaton bulld;ae. kooms 99 b lc. Sev. 884'.
   <
   )           o GsFPWATioM /OFrici e's cT / commFNT
   ,
   ;           Fictd obso v2 tron : mies,t s,ca,<2to 1 Fuel Oil bay tanks,
   ,
                                         S m a LL- bove. PiFih3 Syilde.
   -
  d
                                        A s- butts vertricat. ion hold tag.s arPLied .several
                                         ih dHO11 ago.
  )                                      Chukfor problem s .
                                        Roo m s, SS b/c vequire_ ha<d. key entry
  ,
  *
 - -
                                        Potential conura vePorted b1 MRt_ Ichn Gib. son [Eu
                                                                                         ci -i3 85
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             Fottow- or Saeer CometertE :                 .
                                                                                                   -
                                                                               ATE _
                                           .           -               .      .--    --
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                             5 IGN6TURE                                           DATE
                .I N PUT     log st4EET NoTED            .                                            '
                                         _     _____       - - - -       -------- 3E          - - - - ~ ~

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                                                                                                             I
 -    1
                                                                             M .R.), tson nan c e. rg
                                                                                     .0 -13 -8 5
        F PRT - I s.c uc. s pe_cific action PLa ns,
                                                                                       .
   EN                                         ,7o com0Left anticipatect ant *cipated      final tecort
                                               veinspecflon   com pletion c.omotetim by veview(fovec24t.)
                                               ortevictso( b's Gird.
                                               doturwentat;s. P26c.5
                                                                          r4R.C flag E
                                                                          a3roup.
Xa          Skawed.wehL$_                           S3          9ll8l85      10l2lBs         s zl.2il8s

H.d hg wetd.s 99 9//6/Bs S/23/ss /2/21/gs

   .e      %ain Sicam ?ioing(NDE)                 1.00        comolttrM.      9/20/85        12/2.i/B.S
   .b      iolly Crane. . Shims                     W           /O/23/BS     ///fo/B5        12/2//B5
                                                             qcc<ateaa)
               S,E.irt. d Ate 1 :
        .  ra'iL m oticw itudy,wk c[ 9/10
        . Jhim inspettions .          - Sln
        * p ent<JL in sfes.t*cus . .. n 10[ 4
                                                                                         Yolh- BV%
                                                         ~
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        T.      ,                                                                                 . LOG ~           IMPUT~
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      .<

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       <                UN IT No,           i                                                                           -
                     L o cATiet4
     }
     -
                                           32 '.:.c.: 2. d._ b d'Er. ;                            AuxiLiarv 6utist a.
      ;            _o6.sFRVATrord /oFricireacT / comment
                                                                                                                        -
      <

l'

      ,
              hiwceerte d. fo< Plug ws.Lat . tdo otug wetd4 found .
  '4
              Othtv obse< vat;on:                        1"4.htc.k. has,c.0 Late t ake.s

f- t er, 4 Hitti botts,

    o
     ,
                                                                  r L ir) Leagui.
                                                        ~Ihr e.g.
  is                                                               botti ave. (4;Lti ktvik. b cLli , on 4 t ne6.                                       *

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                                                         'Tha. un c.onvasitoma t. Stud .tlands out S M8' from
                                                          the fac.c. of' use baie etate..
   ,          ;

., ( Emb4d.mewt d.eeth, hott inst,ti.n o< Lougl i- w2u

   s
          \
                                                      head <d tod. fasten:n3 m,thod m, ed.c to b. 42eaw2h,/.
   4
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                                                                                                                                    Alst
                           udoks LO.Suk                                                                                9 -ic. g s-
!           N                       beeruse                       V
                                                                                                                      we
                               .
              Y*LLoUS.Uf.SneET Comet. erg :                                                                           9-/4-85
             :
                                                                               ,
                                                                               -
                                                                                                             _
                                                                                                                "
                                                                                                                     DATE
                                                                                                                                                         ?'i
                     -                           _ _ . -            . -. -           . - , _ - . - _- ._ -                     - _ _ _ - -                ...
                                                                                                                         - _ _ _ _ _     _ _
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,,g' ; ',' .

  $                              OBsERNATsoH S                         LoS -
  ~<                                                                                    FoLLov/~ O P
   <

,g( lNPOT .s OGNTlFICATloN Checked waak pakaae dero >a an ia t to., .

   <
   <                      9.svision L af d,2wina spec:nes 3 14itti bolts and 1 -Lhread ,od 1"e
                          x 0 ' .9 " t o.,3
  <
 r
 1                                                                     '

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  t.                 Action! / REsoLUTiohl
  c                                                                                      .-
                                                                                                                      .
  (
 '                  A' threaded nod. soec:Cied as 4"Lon9
                   base.0L2ts thikutts is
 '.                                                               1". Stud sla-dout from the basentale face is. S 'l8
 i
                   It as ocars that em bedmeaf o/ tlie Gread ed_ tod il 2.'/B '.
 *
                            .'. 1" _a PLste_
                                        a     3        thitkneic i .itud itandout of S'/8' s fo'/8 stando
                                                 - n *lo"
                                   tickmond intert used wit.k '$" t,kended Rod., A-3(o munterial .
               Inita,LLatic a
         ;      I n stvucbio n                of baseolate was acomoGJhed. in accovdance. with T
                                             LO.~.t- O.P- ll. l(o - 1, Rev. 2.1, and infoected. to tili procedure .
           >
      ,          \-CLA:s
     (                           hotu asd R.'thmond. intest faitenu.L Can los. infeschanged'.
                i.nto A Euse of &if(. TOC =CO 2nstruch
                                                 .supoorts lov Cla.s1       l.aspecticu ef NNS .teismic cate)go
                                                                                    \/ Piping are. prov'dal in EsowasasRoot

-

                                                 Procedurc O.1-0.AP- ll.1- 2.8, Fabrication a.d. issf au.a
                     ndaH lb.RTnweet:ca                                             Class Cosus nnent dupAcits.
                                                   n ~/s.cof Jafelst
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                                      sisarruRE.                                                           OATE
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             .IN90T log : SHEET NoT-EO                                                          --
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                                                 1" Sk. 'Eaie plate +_2kes- 4. ' 14Mi bot +.s.. / _.I."8# J.__ leo /Ag si ,
                                                                                              -

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                                                                                     9-10-85
     %                              OBS6RMATION S           LOG - IMPU 1
      T<  T                                                                       .
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                                        .d
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                 \/ERI F. PKG, (IF A ppli co 6L E) s5 F- X - O SE - Oo3 - F4s R
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                          No. (If APPcscAeLE)
     <
    <             .Ut4 T No. lommon.                                         '
     <           l.ocatiora      EueL huD).*no   -
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  <
  .
  <         Plug wet.d1 obse<ued. hs ~fom. Loesta<mm aad Ett DM* c,
  ,
  '         and. cketkaoC hv R. hanubevg.
 '          on 'INPt .su Apod SF -x - Os 5 -col- F45 R , -{_too Plug uald.
   .
            'Tcuits wert Pevformed
            and. Do IMO,4 Plug t.oeld NEeuir'on                    h Jouth west hampv (b
                                                      W tc c fo DM d
 d                                                                    .t
                                                                          fitA A Od k - Wt.ib
            k it k h ? l h t e. O f b k e .C a m e. f uMoylb   PPm       i . 7khLku
                                                                     -421k        t. PL'2te.
             E,Xhibit.i One unv4Pa'. red hIld,*lled ble.
-
            ms<. et2tes Le ana' krcke< oestes (2.i take. fout
                            '
                                                                           14:tu kwik betts
             e.2 ck ,   'It .er x s '/t L3 (T).
                                                                   '

, . . -

                                                                                                l
                                                                                                \
                                                                                                !
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                                                                                               o

,

           WO rk Pac.kaa e d.ocu mentaion ~evle.wed at at bct_- BOP vautt.
                                                                                 f oth %-36    [
                                                                                    k
                   .ItdoM N nO WL.s~.A%                                   0- 20 - 85~
     5,                  Isist4ATuRE         7                             OAT E
          Fou. v .uF SHEET CometerE : :                                   4-2o-85             .[
        .=.                       ._            .         .       .  .              .
     s,      ,
    t          -                                                                         9..u.a. fl o w a. a c g

4

   c                                                                                              4-2.0-85       .

.K OBsERQATsad S 4 log . l 't T 'FoLLov/-UP .'

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    <
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                    INPUT .t O6NTIFicAT1oN

,T Checked Wavk AAckage docu,w, datta .

   T               _ofMisdeiLLc4           helsi we<c me eat.<cd in a c.coM aac 4. win <4.oul
                       Procedurer and ~caui<tmanff Liited b,kw.                                 '
    c                                               '
                                                                                                                      ,
  T                                                                                                                   <
 3                                                       -                               *
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   p              ACTioW / R65cLUTiord                                 .                                              i
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  ,                                                                                                                   i
  '
                 Ba c.l<_opouncl:                                                                                     '
                    *  C_ M C.
 l                                   klo. 4 l 30, vestilow 1, w a.1 issued on '2./s/7.9                                I
 '
                       L rev;st Locat iou of ancho< bou holn .a sd to renal,-
                       four mitd.eitted helet h, fintd. welding [ pt.g , pe, Wp_q No,
                       ll o'5 2. .
     (             *
                      Raon; r wtLLs wa<e. m nd..e 64 totLd4<s h\lO and ATN.                                *
                   *
                       Weld acd h/B'&) was withd4 awn o n w ald ovlo ter ra t <<_ -
                       Otuis.itiow * A-S4030, S rodi, for uie on IF-k. - oss-co3,-F4se.,
                     dior use. tuith WP.S S ll032.                               '
                    . W M9_ sourced % weld. f;ttemate< tat.-lo Meaf O 4 (2.E.7 0 H.
                    . Q.C. i osec.c. tion of field wotdt, wato:st,                 weld.e< e. Procedure _
                       %3t M ; c at ; c., wa1 A cc u e t a te c)         ~
                                                                           JM ' ca in10t d:co at poit Mc -
                      2 R - Ma s - 8588.
                   .
                      This Suppo<t (Cl. ass 5) tuas, originalty f abricated and in -
                      Stalled linsretted -la ua vo.qu:<e.ments of AMS.t 'B S I. I;
                       O.I- LQ.P
                                         t t.l(o - i , hv. B ; WP.S - 11o17_)and. CP- cPH [. 9.                     ;
                  * %'t supo<t was dedast;fted to non /la(etv/non-Sei.r nie. Later                 '
                                                                                                                    ,'
                      by 'b c A N.o. sou , hu.~4.
          '      n dolt4
                               lu.knale<c                                               c).zo.gs-
                             sicourvae              //                                  oste.
                                                                             F0(h -8b~% hl6f
             .I M 90T , log SHEET NoT-EO                        -
                                                                                      9-2o-85                      q
           ~ '
 -
       *
               -
                   Dake.:-                7//4/PC                    Pa" a e . I of . l                  Re in s.oeeCon .
                   ... .
                   _15 A PNo
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                                                                                                                 PE+EE7A
                                    ,
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                                                                                 ~ i ..] 9e.  a..
                                                                                            dis.  ....
                                                                                                 Pka.  -
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                                                                                          .                     a : ,        ,s vi
      (           _Io o . ' /s mes :
                                                        
                                                             A0"'. NadAv 6
                          .
                            '
                                   .                       .
                                                             .
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                                                                                                               $.".
                                                                                                                 ec ,. TOC 1 T
                                                                                                                 :.                            -
                         '1 *;n-         Alo- l 0;   [belm$4b
                                                           & o3.
                                                                            C.>duY.*z &8 GC:/9 -/-HV- +',7,9 - oj                                '
                                                                                                                                               .
                                                                                                      '
                                      *
                   Lnen 6i oa :. ,tdit M..t- Ae4z 84fe .- stw:. _ e3 2d" . _ .                                                             .
        E em                                          zdM l-iw--wi7a - 78 ic -p 7/ N
        yEl=                                             -
                  .Docu mea t s 4) Pka A Rev. Ab
                                                                                                                                            .
                                                                                                                                 .'
        ;;$$
        "
                   siu. Data. Base iZZrspection Repord                                                                 l         ll##l%
        n::        'eu. CP87~ (ERC ) Chee klis t/ W).af e t ;<
        ???       _ ?'r Acces albi*/?                             wolk o'owa Ch ec k /is t
         ;         upo- Pro c c o%rs                           ..         GI-o!O                 Rev.           O
       L           ?u         Dewin
                            Cr.:'?-         E/ g s Coug. ,uo. 2 Re v. )
                                                A S~o d - o 2         l',.? / g
                            (% & n > % o /h d Jwt. / W z!)

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   [\              yle Otlter Docames ds                                    (AlcR's, DCA * s, Dch C%e l>y (ocn-cQ eb..)                            .
                  Til/t : DC A - CI> Jhun EJ- Os~o o - o 2                               fu- 23                    i              ?//o/RC'
                            AM,c/w,,rd&. /2 % rpI-oto .une. /- g
                           be,ch-ws/,%pr<G
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                       -
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                     ct. ;1p x l g cor q & o n. EcSA-/-//V-f//7.2 ' bsce.

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                      b. ea  ifA'ico
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                       c , ac.au lhere a<wd'~b'N 9 "'^ A'^*                              Y"'      d I o -'
                                  Aptq' fed j rz.                 e d iM /.s .                                           '% N-        -
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                       e. o.%                                                      .koA.<-= Aa. A.u.,.,, , ,,, , ,i                     . .
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                 y - e tc a y op.y u 4 4.                                                                                  '
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- , --

                   Date :- }'//e/?5             Pa a e / of        /       Re ;ne cec-/-io n
                                                     '~ '
                   N5 A P bo? ^*.         111L c.           ~ ,'ye,,;S.)Qo,' X-T-25% )-sb?f
       (         _ Io s o . 6,re s :        um NAx~~                            '
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    f                              SSGR                2ce.
          1.         Allegation Category:                 Civil and Structural 15, Rebar Improperly Drilled
                                        '
          2.        All ation Number: AC-13,~AC-14, AC-15, AC-18 and AC-40
          3.        Characterization:                It is alleged that undocumented and unauthorized
                    holes were drilled through reinforcing steel (rebar). The issue includes
                   allegations relating to:
                   a.
                                 ~ the loan of rebar drills without proper documentation (AC-13),
             '
                  b. l the unauthorized Jcutt:ing of rebar in non-specific locations
                                  (AC-14,AC-18,AC-40),and
                                                                                                                                  !
             '
                  c.              the unauthorized cutting of rebar used in the in tallation of the
                                  trolley process aisle rails'in the Fuel Handling Building (AC-15).
         4.      Assessment of Safety Significance:
                                                                            The NRC Technical Review Team (TRT)
                 contacted
                 his concerns.            the individual   who    made     allegations AC-13 and AC-14 to clarify
                                               The TRT did not initially attempt to contact the individuals
                who made allegations AC-18, AC-40, and AC-15.

t

                a.
                                 AC-13 concerns the loan of rebar drills allegedly used for the
                                 unauthorized cutting of rebar. During the NRC investigation of this
                                 matter, the NRC Office of Investigation (OI) interviewed nine
                                 individuals alleged to have knowledge of unauthorized cutting of
                                 rebar. These individuals provided sworn statements denying any
                                 knowledge of this activity. These statements are a part of OI Report
                                A4-83-005 (May 20, 1983), which concludes that "there was no
                                testimony received indicating that holes were drilled or rebar was
                                cut without proper documentation, and no evidence was found to
                                contradict the testimony of these individuals." One instance of                                i
                                possible unauthorized cutting of rebar is discussed in a supplement
                                to the OI report (September 7, 1983).                                                          i
                                below in relation to allegation AC-15. This instance is discussed                              ,
                                                                                                                              j
                                Because the alleger did not specifically identify who made
                                                                                                                              i
                                unauthorized cuts of rebar, or where this cutting took place, the TRT                         <
                                                                                                                                  '
                               attempted to quantify the amount of rebar that allegedly was cut
                               without authorization. In discussions with the TRT, the alleger                                ;
                               estimated that approximately five percent of the diamond core drill                            r
                               bits ordered by him were used in an unauthorized manner. He further                             !
                                                                                                                                  ;
                               estimated that one drill could be used to cut up to five rebars,                                   !
                               depending upon the extent of cutting required. Although he could not
                               be specific as to how many drills he ordered, the alleger thought
                              that the number would be in the thousands. The NRC Region IV
                               Investigation.of this issue indicated that 415 diamond core drill
 {.
                              bits were purchased during the period in question (IE Report 03-27).
                              Using the actual number of drill bits purchased, together with.the
                              information provided by the alleger, the TRT estimated that there
                              could be approximately 100 alleged unauthorized rebar cuts.
                              Considerint the large amount of reinforcing steel used in the plant,
                              and the fact that the structures consist primarily of heavily
                              reinforced concrete walls and slabs, the TRT determined that, if such
                                                                                                                                 "
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                                                                                                                                               ~
            unauthorized rebar cutting occurred, the amount involved would have
            an inconsequential effect on the safety of the structures.
      b.    Allegations AC-14 AC-18 and AC-40 also raise questions regarding the
            unauthorized cutting of rebar, but do not identify specific
            locations.   During the course of the NRC Region IV investigation of
            this matter, the alleger provided a log book which, it was reported,
           would identify the unauthorized and undocumented rebar cutting.                                                                       I
           However, the Region IV inspector could not identify one rebar cut                                                                      '
            listed in the log that was not authorized. The TRT also reviewed                                                                      '
           the log and came to the same conclusion.                                                                                               ,
                                                                                                                                                   ~
            In discussing this matter with the TRT, the alleger confirmed that
           there was documentation supporting "ninety nine and three quarter
           percent" of the rebar cuts identified in the log. As part of Report
           83-27, the NRC Region IV investigator traced 32 authorizations,
           approximately half of the documents noted in the log for the rebar
           cutting. He found that in all cases rebar cuts were properly
           identified on a design change authorization (DCA) or on a component                                                                    '
           modification card (CMC).    In addition, the rebar cuts were traced to
           and identified on specific building structural drawings, with the
           corresponding authorizing document number. The TRT reviewed 10 CMCs
           and confirmed the findings of the Region IV investigation.
           In reviewing authorizations in the log, the TRT noted that certain
          CMCs involved a number of rebar cuts in one area, and selected these                                                                      '
           for review. In one case, 7 different CMCs (3307, 3664, 3665, 3666,                                                                        '
                                                                                                                                                     .
          3667, 3668 and 3669) seemed to pertain te one area and accounted for
          68 rebar cuts. Upon reviewing the documentation, the TRT found that                                                                      g
          these cuts were made in a tunnel area in the Fuel Building. (The                                                                         g
                                                                                                                                                   g
          alleger identified this as a location where a large number of ecbar                                                                       4
          was cut.) However, the 68 cuts were ' arranged such that only 9 bars
          actually had been cut. In another case, the log indicated 25 rebar                                                                         f
          cuts pertaining to CMC 00979. In this case, the TRT determined                                                                             a
                                                                                                                                                    t
          that all the cuts were made on one reinforcing bar in a support beam,                                                                      t
          Finally, the log indicated eight rebar cuts pertaining to CMC 3022.                                                                      6        '
         Once again, these eight cuts were to one bar in a support beam. All                                                                      .L
         cuts were made in accordance with the rebar cutting criteria provided
         by Gibbs & Hill.      These examples also illustrate the point that a                                                                         r.
          large number of rebar cuts recorded are not necessarily synonymous
.
                                                                                                                                                       "

i with an identical number of rebar actually being cut. In all cases,

                                                                                                                                                            i

l  ! i one bar was cut a numt.ar of times, but adjacent bars were not. Thus, [  !

         the cuts were arranged 'o minimize the overall effect on the strength
         of the structure.                                                                                                                       !p
         The TRT estimates that approximately 335 rebar cuts are indicated in
         the alleger's log. Discussions with the alleger revealed that he                                                                        i
                                                                                                                                                 ',          l
         believes he cut approximately five percent more rebar than was                                                                           'e
         authorized, a number that corresponds to approximately 17                                                                                          !
         unauthorized rebar cuts. As noted earlier, such a number would have                                                                     5[
                                                                                                                                                 i,
         little effect on the safety of the structures.
                                                                                                                                                        ,    ,
                                                                                                                                                             I
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                   c.    Allegation AC-15 identifies a specific instance of the possible
                         unauthorized cutting of rebar. In this case, a former Brown & Root
        '
         ,
                         employee stated he possibly drilled holes through rebar in a concrete
                         floor without a component modification card (CMC) or a design change
        4
                         authorization (DCA).    He explained that in January 1983 he drilled
         i              approximately 10 holes about 9 inches deep while installing 22 metal
        ;
         ?              plates with a core drill.    He said the metal plates were used to
                         secure the trolley process aisle rails located on the 810-foot,
                        6-inch floor level in Room 252 of the Fuel Handling Building.
              .
         '
                        The TRT inspected the trolley process aisle rails and its anchoring
        (               system and observed no violations of pro. ject drawings or
        ".              specifications.     The TRT reviewed the reinforcement drawings
        :
                        (2323-S-0800 and 2323-5-0820) for the Fuel Handling Building to
        i   t
                        determine the location of rebar. The drawing showed three layers of
        j
        : i
             i          reinforcement in the upper part of the mat, which consisted of a No.
                        18 bar running in the east-west direction, in the first and third
         f              layers, and a No. 11 bar running in the north-south direction, in the
           j            second layer.
          :
        2
          *            The review of the reinforcement drawings (2323-5-0800 and 2323-5-0820)                                                                       i
                       revealed that the layout of the east-west reinforcement and the                                                                              I
          &
                       trolley process aisle rails was such that only one bar of the east-
                       west reinforcement could be cut by drilling holes for rail anchors.
                                                                                                                                                                      .
                                                                                                                                                                    1
       j
         (             However, if 9-inch holes were drilled, both layers of the No. 18
                       reinforcing bar would be cut. De' sign Change Authorization (DCA) No.
        j              7401 was written for authorization to cut the uppermost No.18 bar at
                       only one rail, but it did not reference the authorization to cut the
                       lowermost No. 18 bar.
                                                                                                                                                                    .
                                                The DCA (No. 7041) also stated that the expan-                                                                      l
                       sion bolts and baseplates could be moved in the east west direction
                       to avoid interference with the No. 11 reinforcement running in the                                                                            l
                       north south direction. The information described in DCA No. 7041 was                                                                          I
                       substantiated by Gibbs & Hill calculations. The DCA approval was
                       based on the understanding that only the uppermost No. 18 reinforce-
                      ment would be cut. If the 10 holes were actually drilled 9 inches
                      deep, then the allegation that reinforcement was cut without proper
                      authorization may be valid.
                      The DCA indicated that the holes were drilled to accommodate 1/2-inch
                      Hilti bolts, which require a minimum embedment of 5-1/2 inches (as
                      noted in Fig. 39, Sh. 5 of 5, attached to DCA-7041). Since there was
    p
      ,
                      no need to drill the holes deeper than 5-1/2 inches, the alleger may
                      not be correct in stating that the holes were drilled 9 inches deep.
                                                                                                                                                                    3
     6                                                                                                                                                               l
    i
                      Although the allegations discussed above, with the exception of AC-15
    I{                which requires further action, cannot be substantiated, the fact that
                      such allegations were made indicated that there was no effective
                      quality assurance program to oversee the issuance and use of diamond                                                                          ,
    .
                      core drill bits.                                                                                                                              l
  .%                                                                                                                                                                {
    $
  j
                      The TRT interviewed the individual concerned about the loan of rebar
     j
                      drills without proper documentation and the unauthorized cutting of                                                                           i
  l,                  rebar at nonspecific locations to inform him of the TRT's finding.                                                                             l
  l
      i
                      This individual did not agree with certain TRT findings. In                                                                                    l
                                                                                                                                                                     l
                                                                                                                                                                     .
                                                    K 'B9

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                                                                                                                                                                  ,
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                                    particular, the alleger felt that the TRT's estimate of approximately

- 120 unauthorized rebar cuts was much too low. He believes that the

                                    number of drill bits ordered by him was in the thousands and that as
                                    much as 20 percent of the drill bits may have been used in an
unauthorized manner. It was also his opinion that the unauthorized
                                   cutting of rebar was not limited to his period of employment,' but
                                   occurred for the duration of the project.
       -                           As a result of these additional discussions with the alleger, the TRT
                                   searched TUEC's files relating to the purchase of diamond drill bits
                                   and found that 1170 drill bits were purchased between January 13,
                                   1978 and January 14, 1980. This number is more in agreement with the
     a
     4
                                   alleger's assessment and is higher than the previously reported
                                   number of 415 (IE Report 83-27). The TRT also found that there were
     }                                                                                                                 -
   >                               a total of 3368 drill bits ordered from one manufacturer between                    '
                                   January 13, 1978 and March 18, 1983.            After this period, other
 S                                manufacturers supplied the drill bits.             Based on the usage through
                                  March 10, 1983, the TRT estimates that approximately 5000 diamond
                                  drill bits have been used to date on the project. Assuming that 20
                                  percent of these drill bits were used in an unauthorized manner and
                                  that each drill bit could be used to cut _up to five rebars, the TRT                 ,
                                  estimates that there could be approximately 5000 alleged unauthorized

, rebar cuts.

                                                                                                                       L
                                  The TRT estimated that, depending upon the average ~1ength of rebar
                                 assumed, there are approximately 800,000 to 1,200,000 bars installed
                                  in all of the concrete structures. Thus, if 5000 bars were cut
                                 without authorization, they would represent approximately 0.6% of the
                                 total rebar in the plant. Even if all 5000 drill bits were used in
                                 an unauthorized manner it still would only represent 3% of the total
                                 rebar in the plant. Thus the percentage of rebar that could have                    ,1
                                                                                                                       '
                                been cut without proper authorization is low. Since no information
                                was supplied to the contrary,.the TRT assumed that these unauthorized
                                cuts, if they did occur, were scattered throughout the plant and not
   '                            concentrated in one localized area. In addition, as noted earlier, a
                                 large number of rebar cuts are not necessarily synonymous with an
                                 identical number of rebar actually being cut. It is also noted that
                                                                                                                    i
                                nuclear structures are very conservatively designed. In addition to
                                the conservative loads, load combinations, and safety factors                      fj
                                                                                                                   f'

> utilized in the design, it is the common practice of the design { I engineer

                                required by  to specify   5 to 10 percent more rebar than is actually
                                                  his calculations.                                                d
                                                                                                                       .

E This occurs because it is difficult to' i

                               obtain the exact area of reinforcement required using standard bar
                               sizes and standard bar spacing. The area of reinforcement is
 I
                               selected from charts which show the area provided for each bar size                 (t
                                                                                                                    <
 {                             at a given spacing. Rather than underdesigning, the designer selects
 I
                               an area of reinforcement from the charts which is higher than that                  $
 I
                               which is actually required. In addition, because critical structures                T
                                                                                                                   *
                               contain a large number of bars, they are not generally vulnerable to                    j
                               the random cutting of a small number of bars.                                            i
                                                                                                                  4l
                   5.    Conclusion and Staff Positions: The TRT concludes that allegations AC-13,                      i
                                                                                                                        '
   .
                         AC-14, AC-18 and AC-40 have no structural safety significance.
                                                                                                                       ,
                             -
                                                                  K-90 -
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[. -

                                                                  - _ _ _ _ .   - ___________       ___ . - ________ _ _
                        /*
          .'           .-
    ,
3
.
                                                                                              . . .
                                a.     The allegations were not specific as to who made unauthoriged cuts of
                                       rebar er where the cuts took place.

,

                                b.    The cumber of unauthorized rebar cuts alleged, if true, would have an

I

                                      inconsequential effect on the safety of the structures.
                                However, the results of these evaluations will be further assessed as a
                                part of the programmatic review concerning procedures addressed under
                                QA/QC Category 6, "QC Inspection." Therefore, the final acceptability of
                                these evaluations will be predicated on the satisfactory results of the
                                programmatic review of this subject. Any adjustments to the existing
                               conclusion of this evaluation resulting from the programmatic review will
                               be reported in a supplement to this SSER.
                               Allegation AC-15 will remain open until the information requested of Texas
                               Utilities Electric Company (TVEC) in " Actions Required" is provided.
                               The TRT attempted to contact the individuals who made allegations AC-18
   ,
                               and AC-15 to inform them of the TRT's findings. The individual who made
                               allegation AC-18 will be informed of the TRT's findings by letter. One of
                               the two individuals involved in allegation AC-15 cannot be located; the
                              TRT is still attempting to contact the other. The TRT also contacted the
                               individual who made allegations AC-13, AC-14, and AC-40 to discuss the
                              TRT's findings pertaining to the concerns he raised in the first closure
                              interview. An interview was arranged; however, later the alleger indicated
                              he did not want to meet with the TRT. A letter will be sent to him
                              informing him of the TRT's findings.
                           6. Actions Required:     TUEC shall provide:
      A
                              1.
      3                              Information to demonstrate that only the No.18 reinforcing steel in
      j
      s
                                     the first layer was cut, or
                              2.
                                     Design calculations to demonstrate that structural integrity is
                                     maintained if the No. 18 reinforcing steel on both the first and
   y
      ,                              third layers was cut.
     4.
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            1.  Allegation Catecory:    Miscellaneous 11, Polar Crane Shimming             .
            2.  Allegation Number: AM-15, AM-16
            3.  Characterization: It is alleged that the shimming of the Unit'l polar
                crane rail system supports was improper and that the polar crane system is
-                improperly installed.
            4.  Assessment of Safety Sionificance:        The NRC Technical Review Team (TRT)
               .tried to contact the alleger during its inspection to learn more details
                about the allegation. On August 14, 1984, two TRT members visually
                inspected the shims from the polar crane. During the first 180* rotation
                of the crane, the TRT members stood on the platform above the operator's
                booth to view the radial restraint brackets and the seismic restraint
                brackets. Several brackets at different locations appeared to have gaps
                in excess of 1/16 inch. However, this only confirmed what had been                                            ,
                previously observed by an NRC Region IV Resident Inspector and was docu-                                      l
                mented in NRC Inspection _ Report (IR) No. 50-445/84-08. which required
                corrective action which was not yet completed.
                The TRT then moved below the operator's booth to view the polar crane rail
                system from another vantage point. The TRT observed the shims used for
                shimming 28 crane girder to girder-support brackets. During this 180*
                rotation, the TRT observed large gaps, particularly on the inside edge
                (looking from the inside of the Containment Building to the outside),
 g
 E              The TRT met with the Texas Utilities Electric Company (TUEC) project civil
 C              engineer, the Brown & Root (B&R) project control manager, the B&R subcon-                                     l
                tracts supervisor, and a representative from Chicago Bridge and Iron                                           '
                (CB&I) to determine the gap-tolerance specification between be'aring plate
               "A" .(Dwg. 2323-SI-0515, Revision 4) and the girder to girder-support
   4           bracket. Neither Gibbs & Hill (G&H) specification SS-14 ncr the Crane
 4             Manufacturers Association of America Manual (CHAA-70) addressed this issue.
 j             The meeting failed to produce a specific answer; however, copies of two
   M            letters related to the issues were provided. The first, a B&R letter
  ,
                (No. BRF-7404), dated November 8, 1977, contained the as-built measure-
               ments of gaps at all shim locations and a request for G&H to evaluate this
                information and provide direction.       At 28 locations, the as-built drawings
               showed gaps that ranged up to 0.581 inch.              In the second letter, G&H
               (GHF-2207, dated November 28, 1977) responded as follows:
 .                   Girder Seat Connections
[                    These scated connections will not require shimming since the area in
                     bearing is at least the width of the bottom flange of the crane girder.
                     The gap dimensions indicated in the Brown & Root survey exist only at
                      the extreme edges of plate A, Section 3-3, Dwg. 2323-S1-0515, Revi-
                      sion 4.
 ..
Q              The TRT noted that the bottom flange of the girder referenced in the
j              G&H letter (the bearing surface) is 20 inches wide.

l? !J On August 30, 1984, an NRC inspector, accompanied by a TUEC quality con- 'p trol (QC) inspector, inspected the 28 crane girder to girder-support hMr i

    '
                                                K-121
                                                                  .
                                                                    '

Jl

                                                                      __ - - ____ .  _ _ _ _ _ _ _ _ _ _ - _ _ _ _ _ _ _ _ _ _ _ _ _ . - _ _ _ _ _ _
              .
                     .
        -                                                                                                                                                   .
      .
                .
  L
 k                              bracket shims. Nine girders, identified as A7-6 right-end (RE), A7-8 (RE) A
 k
                                A7-12 (RE), A7-14~(RE), A7-18 left-end (LE), A7-19 (RE), A7-20 (RE). A7-24 '
                                (RE), and A7-25 (RE) .had gaps in excess of 1/16-inch extending under the
                                bottom flange. This observation invalidated the G&H assumption of 20 in-                                             ,
                                ches of bearing surface.                                                                                               1
                                                                                                                                                        9
                                The TRT closely observed girder A7-20 (RE) as the crane wheels passed
                               directly
                               of        over the support bracket and saw no visible compression (closure)
                                  the gap.                                                                                                              ..
                                               In addition, a visual inspection of the complete rail system                                             ?
                               revealed that the rail has-moved or is moving circumferential1y,-as-indi-                                               '
                               cated by the fact that some of the 1-inch-diameter stabilizing rods are
                              * bent from the force of this movement. The 3/8-inch designed gap between                                                (y
                               the ends of the rail section also varied from 0.000-inch to 0.875-inch, h                                                 4
                               when measured at the inside edge of the rail. In addition, three of the                                                   ;
                               rail-to-rail ground wires and two Cadwelds were broken, and at least two                                                  l
                               rail shim plates had partially worked out from under the rail,                                                            r
                                                                                                                                                          :
                              The TRT interviewed the polar crane operator and asked if he knew of any
                              existing problems with the crane or its operation. He replied that the
                                                                                                                                                          .
                              crane operates satisfactorily and has experienced no apparent problems.
                              He also stated there are no " dead spots" (i.e., no loss of electrical
                              energy at spots) in the bus bars.
                              The TRT found additional shimming problems and additional types of problems,
                             described above, that had not previously been identified. These deficien-                                                             ,
                             cies appear to be safety significant and generic.                                                                                >
                        5.
                             Conclusion and Staff Positions:       Based on the above inspections, the TRT
                             concludes
                                                                                                                                                              j
                             significant.that this allegation is substantiated and is potentially safety                                                      !
                                               The problem with shimming and inspection of safety related
                            work was first identified in 1982. Because problems still existed in 1984,
                             this matter appears to be generic.                                                                                                    !
                                                                                                                                                              >
                                                                                                                                                                   j
                            On    November     8, 1984, the TRT interviewed the alleger to provide the above                                                  il
                            findings    and conclusions.     The alleger stated that his concerns were                                                        ;    !
   y      I , s , N L,      resolved.                                                                                                                         1
   ..
                       6.   Actions Required:
                                                    TUEC shall inspect the polar crane rail girder seat
    %1 -               27   connections for the presence of gaps which reduce the twring surf ace to
                            less than the width of the bottom flange.
                            TUEC shall perform an analysis which will determine whether existing gaps
                           are acceptable or if. corrective actions are required. TUEC shall determine
                     20
                                                                                                                                                               '
   Ok -                    if additional rail mova=-at-is accurrino and, if so, provide an evaluation'
                                                           -
                                                                                                                                                                   l
                           of safety significance and the need for corrective action.
                           TUEC shall perform a general inspection of the polar crane rail and the
      30 "        fo       rail support system, correct identified deficiencies of safety signifi-
                                                                                                                                                               <
                           cance, and provide an assessment of the adequacy of existing maintenance                                                            9
                                                                                                                                                                   !
                           and/or surveillance programs.                                                                                                        j.
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                                                               K-122                                                                                           1l
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                                                                         al3hdDisitcifrestrafatty:                            y
                                                                                                                                                 ectMCR}{{t,s_p._eL,If
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                                                         41                                    .W H446 M 18[and
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                                                                                                                                                   $violationswere
                                                                                                                                           ve een evaluated and
             f                                                                      .
                                   a response'sade to the referenced violations, TUEC shall consider this
                                   matter as a part of the inspection of the polar crane system.
              > . ..
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