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ORGANIZATION: GILBERT / COMMONWEALTHREADING, PENNSYLVANIA

indFtLi1VN IN5 PEG 110NI, ntrun 6NO.: 99900525/83-01 DATE(S) 2/28-3/4/83 ON-SITE HOURS: 64

CORRESPONDENCE ADDRESS: Gilbert / CommonwealthATTN: Mr. H. Lorenz

Executive Vice PresidentP. O. Box 1498Reading, Pennsylvania 19603

ORGANIZATIONAL CONTACT: Mr. N. R. Barker, Vice President, QATELEPHONE NUMBER: (215) 775-2600

PRINCIPAL PRODUCT: Architect engineering and consulting services.

NUCLEAR INDUSTRY ACTIVITY: The total effort committed to domestic nuclearactivities at the Reading facility is approximately 900 people. Major projectsinclude Perry, Units 1 and 2; Three Mile Island, Unit 1 restart; and continuingservices for V. C. Summer, Unit 1; Crystal River, Unit 3; Ginna Station;Virginia Electric and Power Company; and the Tennessee Valley Authority.

ASSIGNED INSPECTOR: f. k 4//3/ff8P. H. Harrell, Reactor Systems Section (RSS) 'Date

OTHER INSPECTOR (S): P. M. Sears, RSSD. Terao, Mechanical Engineering Branch, Office of

Nuclear Reactor Regulation (NRR)

APPROVED BY: [1 4 .3/T8'

C. J. Hale, Chief, RSS y Date~

INSPECTION BASES AND SCOPE:

A. BASES: 10 CFR Part 50, Appendix B and Topical Report GAI-TR-106.

B. SCOPE: Status of previous inspection findings, internal audit program,and a review of the design activities associated with clamp-induced localpipe stresses in stress analyses.

,

PLANT SITE APPLICABILITY: gg .

50-395 and 50-390/391. b

0305050226 830415PDR GA999 EECGBAS99900525 PDR

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ORGANIZATION: GILBERT / COMMONWEALTHREADING, PENNSYLVANIA

REPORT INSPECTIONN0.: 99900525/83-01 RESULTS: PAGE 2 of 5

A. VIOLATIONS:

None

B. NONCONFORMANCES:

None

C. UNRESOLVED ITEMS:

It is not apparent that Gilbert / Commonwealth (G/C) is in compliance withSection NB-3672.7 of the ASME Code which states, in part, "Whereassumptions are used in calculations or model tests, the likelihood offorces, moments, and stresses, including the effects of stressintensification shall be evaluated." For clamps and supports in the100 Kip category, G/C has not performed an evaluation of the effect of clamp-induced local pipe stresses in their stress analyses, relyingprincipally on experience and engineering judgement that excessivestresses do not exist.

D. STATUS OF PREVIOUS INSPECTION FINDINSGS:

'(0 pen) Nonconformance (82-02): Procedures / instructions in effect beforeNovember 2, 1981, did not assure that all necessary and requiredinformation was included in Engineering Change Notice (ECN) 1427-FM forthe V. C. Summer plant.

G/C has committed to do a comprehensive review of all ECNs issued prior; to November 2, 1981, to determine which ECNs are similar in nature and! application to ECN 1427-FM. Those ECNs selected will be further reviewed| to verify that all necessary and required information has been included! in the ECN. This review has yet to be completed by G/C. This item will

remain open pending the completion of committed actions by G/C.

E. OTHER FINDINGS OR COMMENTS:

1. Internal Audit Program - This area of inspection was a review of,

I the internal audit program. Based on inspection of internal auditsperformed by G/C, the following areas of concern were identified:(1) the method of design change control used for the site /home

|

office engineering interface and the design change control programused by site engineering appear questionable; (2) the handling and

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ORGANIZATION: GILBERT / COMMONWEALTHREADING, PENNSYLVANIA

REPORT INSPECTIONN0.: 99900525/83-01 RESULTS: PAGE 3 of 5

disposition of internal audit findings; (3) the disposition ofevaluations of quality assurance practices presented to management;and (4) the qualification of personnel in the internal audit group.

The areas identified above will be reviewed in-depth during a futureinspection at a site and at the home office.

2. Desi5n Inspection - This area of inspection is a followup from aprevious inspection (99900525/82-01) regarding postulated pipingfailures in fluid systems and accident analyses. The issuesdiscussed below were identified in the 82-01 report:

(a) Documentation to support the conclusion in Section 3.6.2.5.3of the V. C. Sumer Final Safety Analysis Report (FSAR), whichstates, in part, "The analytical results show that no essentialsystem or component (required for safe plant shutdown) isrendered incapable of performing its necessary functions as aresult of any pipe rupture," was not filed such that it wasreadily retrievable. Based on an inspection of the analysis ofhigh-energy lines for the V. C. Sumer and Perry projects, sup-porting documentation was found properly filed and is nowreadily retrievable.

(b) Differences were noted between the V. C. Summer FSAR comitmentsand the current NRC guidance for postulated piping ruptures influid systems outside the containment with regard to: (1) coin-cidence and size of postulated longitudinal breaks inhigh-energy piping systems; (2) definition of pipe motion asso-ciated with pipe whip; and (3) consideration of plastic hingesin piping restraint analysis. Based on a review of pipe whipand jet impingement analyses for high-energy lines, methods usedto assure that no essential system or component is-renderedincapable of performing its necessary functions as a result ofany postulated rupture appeared to be conservative and accordingto applicable sections of the NRC Standard Review Plan and otherNRC guidance.

(c) Certain analyses did not reference the supporting computeranalysis run(s) and were difficult to review due to lack ofdetail and documentation of assumptions. An audit of thecalculations concerning postulated high-energy line breaksfor the V. C. Summer and Perry projects showed all cross-referencing to be complete.

-.-_ _ -

.

ORGANIZATION: GILBERT / COMMONWEALTHREADING, PENNSYLVANIA

REPORT INSPECTIONNO.: 99900525/83-01 RESULTS: PAGE 4 of 5

3. Pipe Design Activities - This area of inspection was conducted inconjunction with an engineer from the Mechanical EngineeringBranch, NRR. The purpose of the inspection was to obtaininformation relative to a concern that pipe designers have nottaken into account the local effects of preloaded clamps in theirpipe stress analyses. The areas examined and the results arediscussed below.

Stress analysis procedures for Balance of Plant (BOP) piping werereviewed. An example system (Low Pressure Injection System, PipingSystem E-12) was chosen for the inspection. Loadings for thesnubbers and clamps on this system are 80,000 pounds and above. Toprevent gapping between the pipe and clamp during seismic and otherdynamic loadings, a new type clamp is fitted to the pipe (accountingfor slight oval shapes of the pipe due to manufacturing tolerances)and then the clamp is heavily preloaded. The preload is introducedby torquing the nuts on the U-bolts of the clamp. The preload isthen locked in with locknuts. Each clamp / snubber assembly is anindividual design with its own preload. The clamp / snubber assemblyis not designed at G/C. The assembly is designed by outsidevendors. The following items are specified to the vendor:

| (1) pipe material, e.g., SA312, type 30A;(2) pipe outside diameter and wall thickness;'

i (3) operating temperature and pressure;( (4) pipe insulation (thickness and type);

(5) spring constant of the clamp / snubber assembly;'

(6) maximum load for which the clamp / snubber assembly is to bedesigned; and

(7) physical dimensions of the support structure in relation to thepipe.

The vendor then designs a clamp / snubber assembly and determines a| preload. The vendor furnishes drawings and installationi instructions to G/C.|

G/C informed the inspection team that clamp-induced stresses; have never been factored into the pipe stress analysis. G/C also! indicated that, to their knowledge, it is not industry practice toi calculate clamp-induced stresses in piping. 10 CFR Part 50.55a

states, in part, "For construction permits issued on or afterJuly 1,1974, piping which is part of the reactor coolant pressureboundary shall meet the requirements for Class 1 components setforth in Section III of the ASME Boiler and Pressure Vessel Code."

|

1

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.

ORGANIZATION: GILBERT / COMMONWEALTHREADING, PENNSYLVANIA

REPORT INSPECTIONNO.: 99900525/83-01 RESULTS: PAGE 5 of 5

The following subsections of ASME Section III apply specifically toclamp-induced stresses: (1) NB-3111, " Loading Conditions;"(2) NB-3645, " Attachments;" and (3) NB-3672 (d), " Basic Assumptionsand Requirements."

It not apparent that G/C's present pipe stress analyses meet theintent of Section NB-3672.7 of the ASME Code. This item isconsidered unresolved (see C. above).

During the review of supporting documentation in this area of theinspection, the following items were identified that requirefurther review:

(a) Pipe supports on piping system E12 (Low Pressure Injection '

System) for the Perry project were reviewed and G/C couldnot show that sufficient lateral support had been providedto prevent buckling when the system is subjected to theupward load generated by a suppression pool flood condition.G/C agreed to provide additional analysis in this area.

(b) Pipe support on Drawing 04-4549-S-322-641 on piping system E-12contained an H-beam member which was unusual in that it wasloaded in torsion. Most such members are loaded in bending andshear only. Calculation Set 1E12G15(B) for that pipe supportwas not available for review because the calculation set was inthe process of being microfilmed.

These items will be inspected further during subsequent inspections.

1l

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Document Types: Columns:1. Drawing 5. Purchas Order 1. Sequential Item Number2. Speci fica tion 6. Internal Memo 2. Type of Document3. Procedure 7. I.e t te r 3. I'te of Document4. Q5 Manual 8. Other (Specify-if necessary) - 4. Revision (If applicable)