IR 05000320/1975005
| ML19220B293 | |
| Person / Time | |
|---|---|
| Site: | Crane  |
| Issue date: | 05/08/1975 |
| From: | Haynes R, Varela A NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | |
| Shared Package | |
| ML19220B289 | List: |
| References | |
| 50-320-75-05, 50-320-75-5, NUDOCS 7904250599 | |
| Download: ML19220B293 (10) | |
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U. S. ';UCLE AR ECUI.ATO!:Y CC:'.'!I C 5I C'.
JFFICE Or I::SP: CTIL;:: /.':D E';TO:'C E:'~.:;T TICIC: I IE Inspecticn reper: rr 50-200/~5-05 Docket I:c :
e n _ v r-License ?:o:
crrn_c; r mar.
Licensee:
':e t re n ol i t a n Ediscn e
Priority.
vnrm u, Reading, Pennsvivania 19603 Category:
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Location: Middletown, Dauphin County, Pa. (Three Mile Safeguards
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Island Unit #2)
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FWF E71 M'ie G&m Type of Licensec:
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Type of Inspection:
Routine, Unannounced Dates of Inspection:
April 17, 18, 21. 22 and 23, 1975
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Dates of Previous Inspection: April 9, 1975
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Reporting Inspector:
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A. A. Varela, Reactor Inspector Acco=panying Inspectors:
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Date Date Date
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Date other Accenpanying Personnel:
?one Date
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Reviewed By:
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R. C. Haynes, SeN Rehetor Inspector Date
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SU""ARY OF FI" DINGS Enforcement Actice A.
Itecs of Soncennlicnce None L.
Deviations _
None Licen:ee Action en Preriousiv Identified Enforcement Itecs
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Not inspec t ed Desien Changes None identified
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Unusual Occurrences None reported Other Significant Findings A.
Current Findings
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Acceptable Areas a.
'_I=olecentation of_ Licensee's OA Program for Containment Prestressing An audit of the onsite organizatien with QA responsibilities related to the reactor contain=ent prestressing syste= was conducted.
(Details, Paragraph 3).
b.
Containnent Prestressinc OC Syste:
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A review of the QC system of the prestressing contractor with quality control responsibilities related to reactor containment prestressing was conducted.
(Details, Paragraph 4).
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c.
Chservation cf Prestressing Installatien and tensioning of two hocp tendons and grouting of one was observed.
Except as identified in Unresolved Items below, the work perforced was found acceptable.
(Details, Paragraph 5).
d.
Prestressina record Eeviet A review was conducted of prestressing records.
Except as identified in Unresolved Itces belot, the records were fcund acceptable.
(Details, Paragraph 6).
2.
Unresolved Itc=s Prestress Field Insta11aticn Procedure for Placine Wedces a.
Incorrect placement of one of eighteen wedges at one end of a
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hoop tendon, resulted in slippage of one strand af ter stressing.
The contractor issued two non-confor ance reports for this and the construction manager issued a deviation report.
This is an Unresolved Item which requires engineering disposition.
(Details, Paragraph 9).
B.
Status of Previous 1v Identified Unresolved Itecs (Reference Inspectica Report 50-320/75-03)
1.
Review of OC System for Conatin=ent Prestressing a.
Containment Prestressing Tendons - Interval 3etween Shircing and Grouting The contractor's containment tenden prestressing procedure
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" Installation and Field Quality Assurance Procedure" revision of March 24, 1975 contains provisions for up to 15 calendar days interval between re= oval of tendon from storage and the grouting of the tendon.
The A-E's specification will be revised to permit over 7 day exposure but cnly with the Engineer's approval and based on an examination of the tenJ'n for corrosion. This ite= is considered closed.
(Details,
Paragraph 7).
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b.
( or r or.i nn Protec.+<n of Prent r e'
in-F t r.md in c h i n _e m.
The int.pc eter revicued specif i ca ti o n r-anu cert if icate ci c u. -
pliance on an approved vapor phase rust inhibitor used to the coils of prestressing strand wire shipped frcn protect the Florida Uire and Cable to tendon f abrication centractor 's shop in Wilkes-Earre, Pa.
QC records of inspecticn of the wire received at Kilkes-Earre previous to tenden fabricatien vcre also rcviewed. This iten as considered closed.
(Details, scraprcp!- S',
Manacenent I * e rr i e-At the conclusion of the inspection a neeting was he:d by the inspcc:cr the site with the f ollcuing personnel to discuss the at inspection finc_ngs.
Personnel Present General Public Utilities Service Corocration
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Mr. W. T. Gunn, Proj ect Site Manager Mr. S. Levin, Proj ect Engineer Mr. P. A.
Levine, QA Site Auditor Mr. D. A. Perry, QA Engineer Mr. M. J. Strcnberg, Site Auditor Mr. J. H. Wright, Resident Civil Engineer United Enrineers and Constructors Mr. J. Carrabba, QC Engineer Mr. V. E. Cichocki, Construction QC Coordinating Superintendent Mr. D. C. Lanbert, Field QC Supervisor Mr. F F. Lang, QC Engineer Mr. R. H. Mason, Superintendent Ad=inistrative Assistant Burns & Roe
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Mr. G. T. Harper, Jr., Site Proj ect Engineer Stressteel Corporation Mr. M. G. Suarez, Project Manager Mr. R. Bonomo, Field Engineer
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The f oll m..n,.
tenc ere d;scutted and the noted by the licensee.
inspector's fincings vert-A.
Purcose of the Inspection The inspectcr stated the purpose of this inspectica vac te re c.
centainment
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- .e deternine whe ther the C.i Prcgran asprestressing systc= cf the vender and contrac te i=plemented co.formec applicaticn, to review the contractor's to t :..
QC Syster and to observe secrh performance in installatica, stressing and grouting of the first hecp tcnd ns.
The
- c inspecter stated his review also cevered twc previousy identified unresolved itens in prestressing.
B.
Accettable Areas The items discussed are as delineated in paragraph A.1 of the Other Significant Findings section of this report.
C.
Resolution of Previousiv Identified Unresolved lters The items discussed are as designated in paragraph B.1 of the Significant Findir.gr sections of this report.
Other D.
Prestressine Field Installation Procedure for Placine Wedres Findings section of this report.The iten discussed is as shown in para
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cant E.
Hoop Tendon Duct Found to Contain Water Durint Tendon Installatio The ites discussed is as shcun in Details, Paragraph 5 b
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_ Specifications Recuire Datq_to Preclude Tendon Strand Bendin?
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Stress The item discussed is as shavn in Details, Paragraph 5 c
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Persens Contacted Genera? Public Utd itiet Service Certcrctier
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L. Caribien. Structural Engineer (Parsippar; Office)'
Mr. U. T.
Genn, Proj ect Site !bnager
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S. Levin, Project Engineer Mr. P. A.
Levine, QA Site Auditor 15. D. A. Perry, QA Engineer Mr. M. J.
Stenberg, Site Auditor Mr. J. H. Wright, Resident Civil Engineer United Encineers and Constructors
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Mr. J. Carrabba, QC Engineer Mr. V. E. Cichocki, Construction QC Coordinating Superintendent
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D. C. Lanbert, Field QC Supervisor 15. F. F. Lang, QC Engineer Mr. R. J. 1b s on, Superintendent Administrative Assistant
Mr. 1;. Reitzi, QC Inspector Mr. W. Tinlin, Construction Civil Supervisor Eurn & Roe Mr. J. Archer, Chief Engineer, Civil Mr. G. T. Harper, Jr., Site Proj ect Engineer Mr. O. Mallon, Supervising Civil Engineer
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Stress Steel Corcoration Mr. R. Barr, QC Inspector Mr. R. Bonome, Field Engineer Mr. M. Johnson, Construction Supervisor Mr. H. Papworth, QC Supervisor Mr. M. G. Suarez, Proj ect Manager '
2.
Construction Status Post tensioning of the containnent building tendons is in progress and
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two circu=ferential hoop tendons have been installed and tensioned.
One of these tendons was grouted and the other tendon will be grouted after disposition of deviation report as discussed in paragraph 9 of these Details.
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Friction f actor testin;; has beta corn et td f or circumf er rat ial hee:
tenden*
Installatien, tensioning and grouting of all vertical tendann will be undertaken bef ore any other hoop tendons are in-stalled as required by specifications.
3.
Irelencntation of Licencee 's OA Pr, rce for Containment Prestressine The inspector verified that the Of. propran, cs irplettntti, cen-forms to the application in the following areas:
(1) Independence cf QA/QC percennel.
(2) Definition of respcnsibilities cf QA/QC persennel.
(3) Audit f requency and scope is established.
(4) Audit activities are documented.
(5) Audit report.s are submitted to appropriate canagement.
4.
Containment Prestressinc CC Svstem The inspector reviewed the QC program of the Stressteel Corporation,
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with the first level QC responsibilities, for confor=ance to the application in the following areas:
(1) Procedures ide:.:ify items where witnessing or inspection is required.
(2) Provisions authorizing inspection personnel to stop work.
(3) Provisions for qualifying inspection personnel.
(4) Provisions to assure equip =ent calibration.
(5) Require =ents on tendon handling, installation, protection, tensioning and data recording.
The inspector found the above areas ere acceptable.
5.
Observation of Prestressing a.
Tendon k'ork The inspector observed work performed on two hoop tendons.
Except as identified in paragraph 9 of these Details, the following work confor=ed with construction specifications and QC requirements.
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(1) Tendon handling and installation and related QC inspection.
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(2) Tendon tensiening, including sequence and related QC inspections.
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("I b i t tenden w,:s grout ( d n thin neven calendar day-aiu :
renovel irer o." ! L _ t u ntor:.te at UllLeu-Larre.)
b.
Hoen Duct Feund to Centcin c:a t e r Durint Tendon insta22atier During instaliation of hoop tenden 2401 on 4/21/75 (buttress ?4 to buttress #2) a quantity of clear water was observed to spill cut cf t r.e L2 trumpet.
The OIE inspector requested that a sc=ple ce t a :. :
for cnalysis.
This was perforrad and the nnclysis shcued 3.G pp:
chlorices and c ph cf 10.7 The inspector was inferred and verif.t_
that all require:ents of speci.icaricns, codes and QC procecures had beer cet in prcviding assurance th:
this duct was inspectt.
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before, during and after concreting and thct protectier of
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Therefore, it was concluded that the drain had not been opened to drain any water it cay have contained before installation of tendon 2401.
How the water got into the tenden duct could not be deter =ined.
Ecuever, it appeared the water was of recent origin and the sana as would be used
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for the grout.
The inspector was infor:cd at the management teeting that the presence of water in duct 2401 would not cause delay in greating the tendon since the water was alkali, contained insignificant chlcrides and the grout would displace any water that remained.
Soecifications Reautres Data to Preclude Tendon Strand Bendinn Stress c.
E&R specification requires the prestress centractor to control the paths of individual strands within the duct to preclude conditions causing bending stress in strands and to ensure equal distribution of Icad.
The inspector inquired as to how the above was satisfied.
The answer was provided by the Stressteel Ccapany who referred to their fabrication shop =anual which was approved by the A-E.
Section 8.5.3 of the " Strand Tenden Fabrication Procedure" states: "Since the in-dividual strands are being pulled from the center of stationary packs,
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each strand must turn one revolution for each coil that ccmes out of the pack.
When the 54 strands are brought together by the censtric-ting ring, the turns will occur in unison and will result in a parallel-s'erand tenden that is twisted approximately every 12 feet.
This procedure will fulfill the requirement of Spec. Section 2A, Paragraph 6.1.5."
At the management meeting the contractor stated that their tenden fabrication procedure had been discussed with the AE and, it was accepted that twisting every 12 feet would cause helical wrap in the tendon and provide unif orm stresses in the strands. The
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licensee stated this had been accepted in previous discussion with the B&R.
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6.
Pre.,tre inn ik e rri s" Jc.
The inspector revieued r. :ords on two hoop tendons f or cenf ormance te as identified in paragraph 9 of these details QC requirements. Encept the follcwin; records conformed to ecnstruction specifications and QC recuirements.
(1) Flcrida Uire and Cable Ccrpany'r catcrial records anc certif icate:
cn strand fc: fabrication into tendcas.
(2) Stressteel Ccepany receipt inspecticn en strands.
(3) GPU surveillance inspections of strand caterial received and tendca febrication at Wilkes-Earre.
(4) Tendon installation, tensicning and grouting.
(5) Grout cix ingredients: certificates and analysis on cecent,
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water and proprietary admixture.
Prestrersine Tendens - Interval Eetreen Shipning and Grouting 7.
Containrent Stressteel Corporation's installaticn and field quality control procedure,
" Tendon Exposure Control," established an exposure limitation of seven calendar days between removal from enclosed jobsit. or offsite stcrage and grouting, as required by the job specification s.
The procedure however, per=its this exposure limitation to be exceeded to fif teen da,a with the Engineer's approval and an examination, in presence of the A-E's site proj ect engineer, of a control strand f or signs of corrosion. The inspector was informed by the licensee that engineer's specifications would be revised to allow suspension of the specified exposure limitation under these conditions. This item is resolved.
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8.
Corrosion Protection of Prestressine Strand in Shirrent Corrosion protection of the prestressing strand during shipment fres Florida to Wilkes-3arre is required by specifications to be accompliched by treatment of the caterial with an approved vapor phase inhibitor in to be effective. The a procedure de=onstrated by experience or test specific records reviewed by the inspector on the vapor phase inhibitor used are as follows:
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'M 3 it ary speci f i ca tion, :IL-P-34 20C, 5/7/69, "Pactaninn ::aterini:
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Wlatile Cerro:., ion Inhibiter *I r e a t e d, Upaque."
b.
Acceptance test report and certificate of cc=pliance to ':IL-P-3420; for #60 crepe VP1 pap.r used in urapping the weldless LO-Lac strand.
c.
Federa} Test ':cthod Standard No. 1015.
T:>e inspcctor censiders the above adequate.
This itc is resolvec.
9.
Frestress Field Install,tien Drocecure for Plactne 3:edces During installatic cf hocp tenden #2401 (the first 150 circunfertn-C tial hocp beticen buttress #2 and 64) ene of the eighteen split-cone wedges, gripping three of the 54 strand tendons at P2 buttress, was installed incorrectly at the anchor plate.
Stressteel's fielc in-stallation procedure requires: " Check and take sure that the three wedge pieces occupy their proper relative position.
The catch-mark
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notches in the two side pieces cust be adjacent to each other and facing the key piece diametrically opposite." The procedure check-cff sheet also requires craft supervisor and QC inspector sign off for this ites.
Tendon 2401 (and tenden 4201) was fricticn tested and tensioned frc=
both ends.
This required additional vedges on the pulling head for each jacking ran at both buttresses. After cc=pletion of the tensicning of tendon 2401 at buttress #2 slippage of one strand occurred when the jack was retracted.
It was deter =ined after removal of the jacking equiptent that one strand had slipped about 4".
Stressteel followed their procedure requirement and issued two nonconfor=ance reports as a consequence of this. Report No. 1 dated 4/22/75 describes the ncnconf or=ance as f ollows:
" Anchorage at buttress No. 2.
At the end of tensioning procedure (friction test) cne S/303-5EE anchor vedge was found to be placed incorrectly.
One of the three strands anchored by that vedge slipped approxi=ately 4" and then held.
Other rands anchored at proper load."
The recc== ended disposition reads:
" Accept Tenden as is.
Loss of stress is insignificant and at one end only (see attached calculation sheet). Recurrence will be prevented by taking greater care in placing wedges and in inspecting anchorages before placing jacking equipment f or tensioning." Nonconforcance Report No. 2, dated 4/23/73 states that the installation procedure requirement for QC checks was not followed prior to proceeding to the tensicning operation.
The recc= mended disposition required all Stressteel field construction and QC personnel be re-instructed on the necessity to
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follow requirerets of the field =anual.
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