IR 05000424/1986030

Insp Rept 50-424/86-30 on 860414-18,0505-09 & 20-23.Major Areas Inspected:Readiness Review Module 13C, Post-Tensioned Containment. Module Acceptable

ML20197B161
Person / Time
Site:	Vogtle
Issue date:	10/10/1986
From:	Conlon T, Imbro E, Novak T, Sinkule M NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II), NRC OFFICE OF INSPECTION & ENFORCEMENT (IE), Office of Nuclear Reactor Regulation
To:
Shared Package
ML20197B158	List: IR 05000424/1986030 ML20197B151
References
', 50-424-86-30, NUDOCS 8610280099
Download: ML20197B161 (13)

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32 Kf!q UNITED STATES Do NUCLEAR REGULATORY COMMISSION

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, ["- o REGION 11 101 MARIETTA STREET. l $ ,j

• 2 ATLANTA, GEORGI A 30323

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Report No.: 50-424/86-30

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Licensee: Georgia Power Company P. O. Box 4545 Atlanta, GA 30302 Docket No.: 50-424 License No.: CPPR-108 j

Facility Name: Vogtle 1

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Reviews conducted: May 1 - August 1, 1986

Onsite inspections conducted April 14-18, May 5-9, and May 20-23, 1986

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NRC Offices participating in inspections / reviews:

i j Office of Inspection and Enforcement, Bethesda, MD Office of Nuclear Reactor Regulation, Bethesda, MD

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Region II, Atlanta, GA Reviewers: H. B. Wang, Inspection Specialist, IE

S. P. Chan, Structural Engineer, NRR

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Inspector: J. J. Lenahan, Reactor Inspector, Region II-Approved by:Cd // .>;v '7r 7- 3' N Date Signed

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T. E. Conlon, Chief

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Plant Systems Section

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DivisioYnofReaprSafety,RegionI

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E. V. Imbro, Chief / Dat'e Sidned j Licensing Section, Division of4 Quality Assurance, Vendor and Technical Training

, Center Pro rams E w LYCL s b (C %C.

!- T. Novak, Depbty Director Date Signed

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Division of PWR Licensing A Off,1ce of uclear R actor Regul ion

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i R. V. Sinkule, Chief f Otte Signed Projects Section 20 (,e) .

Division of Reactor Projects

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TABLE OF CONTENTS TOPIC PAGE Summary 1 Scope of Review 2 Methodology 2 Evaluations 4 Findings 8 Conclusions 9 l

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V0GTLE ELECTRIC GENERATING PLANT UNIT 1 READINESS REVIEW PROGRAM MODULE N0. 13C POST-TENSIONED CONTAINMENT The Readiness Review Program is being conducted at the initiative of Georgia Power Company (GPC) management to assure that all design, construction and operational commitments have been properly identified and implemented at the Vogtle Electric Generating Plant Unit 1. Module 13C, which is the twelfth Module submitted by Georgia Power Company, presents an assessment of the program for the design, fabrication, and installation of the post-tensioning system in the Unit 1 containment building. This evaluation was conducted to determine if the results of the program review for the post-tensioned containment presented in this module are an effective and accurate assessment of design and construction requirements, that these requirements are being properly implemented, and that the resolution of findings identified in the module were correct and that the corrections were mad This evaluation was performed by NRC reviewers from the Office of Nuclear Reactor Regulation (NRR), and the Office of Inspection and Enforcement (IE) and inspectors from Region II. The evaluation was accomplished through a detailed review of all sections of the module by: Verifying that design and construction commitments listed in the module are correct and comply with FSAR commitments and regulatory requirement . Reviewing the module findings and evaluating the correctness of their resolutio r Reviewing a comprehensive and representative sample of the records reviewed by the Readiness Review Staff and an independent sample of documents selected by the inspector . Walkdown observations of construction activities, f

l During the review, it was apparent to the NRC Reviewers and inspectors that GPC l management supported the program by active participation in the development and I implementation of the program. This evaluation also indicates that the

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licensee's program review for the post-tensioned containment was comprehensive l and provides adequate assurance that the post-tensioning system has been designed l and constructed in accordance with NRC requirements and FSAR commitment During l the review of this module, two findings were identified by NRC reviewer These l items were as follows:

l Inspector Followup Item 86-42-01, Incorporation of Additional Calculations

Considering Stiffening Effect of Buttresses into Vogtle Calculation Record l

! Inspector Followup Item 86-42-02, Revise Calculation X2CJ2.9.0 to Indicate that Rebar Stresses are within allowable limits at wall-basemat interface.

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2 Scope of Review This review, which consisted of an examination of each section of the module, was performed by reviewers from NRR and IE, and inspectors from the NRC Region II Office in Atlanta. Module Sections 1.0, 2.0, 4.0, 5.0 and which contain information concerning the module introducticn, company organization, program description, results of audits, special investigations and conclusions regarding the assessment of the module did not require as detailed a review or evaluation as the remaining sections. The more significant aspects of the module appear in Sections 3.0, 6.0 and These sections discuss licensee commitments, methods of implementing

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commitments, methods of design and construction program verification and results of an Independent Design Review (IDR). Review of these sections included a detailed review of the content, examination of items identified as findings, an examination of a sample of records reviewed by the GPC Readiness Review Staff, and an examination of an independently selected sample of records. Methodology used for this review and an evaluation of each section are presented in the following paragraph . Methodology The review and evaluation by NRR was conducted in the Bethesda offic This review was initiated by a review of the commitment matrix (Section 3.4 of Module 13C). Review of Section 3.4 was performed by comparing the applicants licensing and project commitments and the corresponding source documents within Section 3.4 with the Standard Review Plan (SRP), Regulatory Guides, Industry Standards, NRC questions and answer records, the staff's SER and the FSAR.

i The review and evaluation by IE focused on Section 7.0, Independent Design Revie The review of this section was performed by inspections at the f Vogtle site and at the office of the NRC staff's civil structural consultant. During the site visit of April 14-16, 1986, the IE inspection team interviewed the GPC Readiness Review Staff associated with Section These interviews were held to deterinine the methodology and depth ui review performe Also, at the site the IE inspection team reviewed the referenced sections and related calculations. In addition to the site inspection, the IE team reviewed independently selected calculations identified during the Independent Design Review that were determined to be representative of the l subject being assessed. The purpose of this review was to determine the depth of the review performed by the Readiness Review Program Staff with respect to design aspects and supporting calculation The review and evaluation by Region II inspectors was accomplished by l reviewing the module in its entirety in the Atlanta Regional Office l beginning on April 2,1986, and by inspections at the Vogtle site on l April 14-18, May 5-9, and May 20-23, 198 . - . .__ -_ _ _ _ -- . _ - _ .

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Section 1.0, Introduction, rhich presents an introduction to the intent and content of the module and Section 2.0, Organization and Division of Responsibility, which presents a description of the organization and responsibility for design and installation of the containment building post-tensioning system, were only reviewed for general content and needed background dat Review of Section 3.0, Commitments, was accomplished by examining the Commitment and Implementation Matrices and by verifying that the applicable licensing and project commitments were being referenced and that these commitments were implemente Verification that the applicable commitments were referenced and implemented was accomplished by reviewing the FSAR, SER, design criteria, specifica-tions, procedures, regulatory guides, applicable industry standards, and responses to NRC questions and generic letter Review of Section 4.0, Program Description, was accomplished by examining the four subsections, and comparing the described program with FSAR, specification and procedure requirements. The inspector also compared the described program with the inspector's understanding of program requirements that had beerr examined during NRC inspections conducted in 1985 and 1986 during installation of the post-tensioning syste Review of Section 5.0, Audits and Special Investigations, was accomplished by examining the three subsections, referenced audit and NRC findings, and construction problems. Region II inspection reports were also reviewed to

, verify that the identified NRC findings and construction problems, had previously been reviewed and addressed by the NR Review of Section 6.0, Program Verification, was accomplished by reviewing Subsections 6.1, Design Program Verification and 6.2, Construction Program Verification. Review of Subsection 6.1, Design Program Verification included a review of the referenced design criteria, design commitments, implementation of these commitments, drawings, specifications, deviation reports and the readiness review finding involving violation of design i

control procedure Review of Subsection 6.2, Construction Program i Verification, included a review of referenced licensing requirements and commitments, the two readiness review findings and associated corrective actions, and pertinent records for installation of the post-tensioning syste Review of Section 7.0, Independent Design Review, was accomplished by reviewing the referenced FSAR requirements, design criteria, calculations, and the seven readiness review findings and their associated corrective action Design requirements and associated calculations were also discussed with the responsible licensee personne Review of Section 8.0, Program Assessment / Conclusion, was reviewed primarily for content and background information. Evaluation of this section was effectively accomplished during review of the module sections identified

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4 Evaluations The evaluation of each section reviewed is provided below. For each section, a description of the section that was reviewed, and the basis of acceptance is provide Section 1.0 - Introduction This secticn of the module presents an introduction to the intent and content of the module organization, areas of evaluation and status of the project. This section was reviewed primarily for content and background information. No additional followup or evaluation of the section was require Section 2.0 - Organization and Division of Responsibility This section presents a description of the organization and division of responsibility of Georgia Power Company, Bechtel and VSL Corporation for design, fabrication, and construction activities related to installation of the post-tensioning system. This section of the module was reviewed for content onl No additional followup or evaluation of this section was require Section 3.0 - Commitments (1) This section of the module contains a listing of commitments and implementing documents which are presented in two matrice The first matrix is the commitment matrix which contains a listing of the sources nd subject of licensee commitments. Commitments listed in this matrix were identified by the Readiness Review Staff through a review of the FSAR, responses to NRC questions, and responses to generic letters. The second matrix is the implementation matrix which contains a listing of documents and features discussed in the FSAR and implementing document The Readiness Review Staff reviewed these documents to verify compliance with the commitment requirement (2) Review and evaluation of this section was performed by comparing licensing commitments and corresponding source documents with the i

L Standard Review Plan (SRP), Regulatory Guides, the Provisions of the Industry Standards, the NRC question and answer records, the staff's SER and the FSAR documents. The review also included a review of commitment sources and implementing specifications and procedures to verify that the FSAR commitments were being correctly implemented in project document (3) Review of this section showed that the Vogtle licensing commitments and implementing documents comply with the FSAR, SRP, Regulatory Guides, and Industry Standards. No NRC findings were

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identified during the review of this section.

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d. Section 4.0 - Program Description (1) This section of the module, which is divided into four sub-sections, describe work processes utilized for design, fabrication and installation of containment post-tensioning system. Subsection 4.1, Design, discusses the design engineering scope, design criteria, design drawings, and documentation, and calculations related to the post-tensioned containment.

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Subsection 4.2, Materials, discusses controls used for procurement of material used to manufacture components for the post-tensioning syste Subsection 4.3, Training and Qualification, contains a description of the program for training and qualification of design engineers, GPC construction engineers and inspectors, and contractor staff, inspection and craf t personnel. Subsection 4.4, Post Tensioning Installation contains a flowchart illustrating the post-tensioning contractor's work activities and lists procedures and specification applicable to the post tensioning system installatio (2) Review of this section included a detailed examination of the four subsections and a comparison of the program description with FSAR requirements, and specification and procedure requirements. The described program was also compared with the inspector's understanding of program requirements that had been examined during NRC inspections conducted during tendon installation in 1985 and 198 (3) Review of this section and previous NRC inspection reports indicated that the program described in the subsections is correct and that the work processes and controls developed for the design, fabrication and installation of the containment post-tensioning system complies with FSAR commitments and regulatory requirement No NRC findings were identified during the review of this sectio e. Section 5.0 - Audits and Special Investigations l (1) This section, which is divided into three subsections, contains a i

discussion of the QA audit process, NRC inspections, and past design and construction problems. Subsection 5.1, Design, discusses GPC audits and NRC inspections pertaining to desig Subsection 5.2, Construction, discusses GPC audits and NRC inspections related to fabrication and installation of the post-tensioning system. Subsection 5.3, Past Construction and

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Design Problems, discusses problems encountered in previously l

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built post-tensioned containment and their impact on project design and construction of Plant Vogtl .- . . -

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(2) Review of this section included a review of the three subsections, the referenced audits and associated findings and corrective actions, and the referenced NRC reports and findings. Pertinent Region II inspection reports were also reviewed to verify that NRC inspection findings had been reviewed and addressed by NR Review of the referenced audits showed that seven design audits and 11 construction audits were made by GPC QA managemen Review of these audits snowed that seven findings and one observation were identified in the design area and that ten findings, one observation, and two deficiencies were identified in the construction area. In the design area, the findings were related to deficient conditions identified in the specification and vendor supplied documentation. In the construction area, the findings were related to deficiencies in materials, tendon fabrication, inspection and QA record Review of the 18 referenced audits and responses to audit findings showed that the audit process was being controlled in accordance with FSAR requirements and that proper measures were being taken to correct the deficiencies identified by the QA auditor Review of the NRC inspection reports disclosed that no violations or deviations were identified by Region II inspectors during inspection of post-tensioning system installation activitie Review of past design and construction problems encountered in previously built post-tensioned containments disclosed that these problems were evaluated by Bechtel in design -of the Vogtle post-tensioning system. Five specific problems were evaluate These were as follows:

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Farley Anchor head hydrogen embrittlement

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Turkey Point and Crystal River dome delamination

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Concrete failure around the equipment hatch l

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Calvert Cliff bearing plate collapse

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Fort St. Vrain microbiologically induced steel corrosion l

No significant unresolved problems are known to exist with

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post-tensioning system (3) Review of this section indicated that it is an accurate

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presentation of the audit process and previously identified

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construction and design problems and NRC inspection result No NRC findings were identified during the review of this sectio . __ __ __ .

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f. Section 6.0 - Program Verification (1) This section discusses methods used to verify conformance to design and construction requirements. The section is divided into Subsections 6.1 and 6.2. Subsection 6.1 covers activities related to the design program verificatio The design program was covered in two part Part I consisted of verifying proper implementation of commitments in design. Part II consisted of a programmatic review of design documents for compliance to applicable design control procedures. One findings was identified by the Readiness Review staff, pertaining to the design verification activitie Subsection 6.2 which covered activities related to tendon installation activities was also covered in two part Part I was verification of ' implementation of construction commitment Part II consisted of a review of construction procedures and a walkdown inspection of tendon installation activitie Two findings were identified by the Readiness Review staf (2) Review of Section 6.0 included a review of the design program verification activities listed in Subsection 6.1 and the resolution of the finding identified in Subsection 6.1. Review of the construction verification program in Subsection 6.2 included a review and examination of the corrective actions associated with the resolution of the two findings, a review of pertinent records for tendon installation, and a walkdown inspection to observe installation of the tendon Details of this review are sumarized in NRC Inspection Report No. 50-424/86-5 (3) Review of this section indicated that the review conducted by the Readiness Review Staff for the design and construction verifica-tion program was comprehensive and adequat Examination of the findings indicated that they were of minor significance and that the resolution of the findings was adequate. Examination of the quality records indicated they were representative evidence of quality controls for tendon installation and indicated that post-tensioning activities were being controlled in accordance with applicable requirements. No NRC findings were identified during review of this sectio g. Section 7.0 - Independent Design Review (1) This section describes the independent design review (IDR) of the containment post-tensioning system conducted by Stone and Webster Engineering Corporation (SWEC). The three key areas that the IDR focused on included containment shell and post-tensioning design, engineering specifications, and design change evaluation. The IDR yielded seven finding .

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(2) The results of the IDR were examined by the IE inspection tea The IE inspection team also reviewed independent design documents (design criteria, calculations, specifications, drawings, deviation reports, etc.) to determine the depth of the review performed by the IDR team. Details of this review are summarized in NRC Inspection Report 50-424/86-4 (3) Review of this section showed that the program developed by the Independent Design Review team to determine the technical adequacy of the containment post-tensioning team was comprehensive and adequate. The reviewers agree with the IDR team finding and their disposition, except for resolution of IDR finding numbers 1, 2, and 7. These items were identified as Inspector Followup Items and are discussed in detail in Section 4, belo . Findings The following findings were identified from the reviews by NRR and IE reviewers and Region II inspectors. The findings are identified as deficiencies. A deficiency is considered as an item having no safety significance but one that should be evaluated further to preclude safety problems. Deficiencies will be pursued as an Inspector Followup Item (IFI)

in future routine inspection Deficiency (IFI 424/86-42-01) Finding 1 of the SWEC IDR team was that the stiffening effect of the buttress was not considered in the containment analysis. The project response only addressed the membrance portions of the containment cylindrical shell. The IE reviewer agrees with the findings, but considers the project response should be extended to include the non-membrane portion where the moment and shear are affected significantly l

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by the buttress due to the discontinuity at the basement interface. Civil Engireering Study No. 91, covering the membrane portion, and all additional i calculations, should be incorporated into the Vogtle calculation record

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(0 pen Item 86-42-01 will be followed as Inspector Followup Item i

424/86-42-01).

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Deficiency (IFI 424/86-42-02) IDR Findings (2) and (7) pertain to l Calculation X2CJ2. 9.0 and deal with thermal load on the containment wall

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and containment liner, respectively. The analysis of the containment shell was performed using the computer program BSAP for the required load combina-tions, except that the thermal effects were not include In determining

! reinforcing bar stresses on each section, the computer program OPTCON was l used with the thermal effects in the membrane section introduced as a

thermal gradient through the thickness of the containment wall.

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j As the IDR report on Findings (2) and (7) pointed out, this procedure is valid for membrane zones but cannot account for the thermal effects near discontinuities. The IDR reviewer was given Civil Engineering study No. 90,

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which was performed by Bechtel for a plant similar to Vogtle. This study addressed the question of thermal effects at the discontinuity at the wall-basemat interface by comparing results from computer programs BSAP and OPTCON with the results of an analysis using the computer program FINE The FINEL results indicated the percentage changes in rebar stresses due to thermal effects in both membrance and discontinuity regions. Due to the similarity of Vogtle to the subject plant of Civil Engineering Study No. 90, the IDR reviewer was able to extrapolate the results, using the percentage differences of Civil Engineering Study No. 90, to confirm that the rebar stresses at the discontinuity of the Vogtle containment wall-basemat interface were within allowable The conclusion reached by the IDR reviewer is acceptable. Calculation X2CJ2.9.0 should be revised to clearly indicate that the rebar stresses are within allowables based on data from Civil' Engineering Study No. 90. The methodology used to. justify that rebar stresses are within allowables should be documented with all data from various sources clearly referenced (0 pen Item 86-42-02 will be followed as Inspector Followup Item 86-42-02). Conclusions Based upon the review within the scope of Module 13C, Post-Tensioned Containment, the NRC has reached the following conclusion for the Vogtle Unit 1 containment post-tensioning syste Summary of Specific Conclusions (1) Commitments - The NRC has reviewed the commitments as listed in Section 3.0 of the Module and determined that the licensing commitments and implementing documents comply with the FSAR, SRP, Regulatory Guides, and industry standard (2) Program - The NRC reviewed the description of the program as given in Section 4.0 of the module. The following areas of the program were reviewed:

Design Controls Materials Training and Qualification Fabrication, Installation, and Inspection We have determined that the program description in Section 4.0 is generally correct and is in agreement with FSAR and project requirement (3) Audit and Special Investigations - We have reviewed Section 5.0 on audits and special investigations and concluded that this is an accurate presentation of the audit process and previously identified construction problems and NRC inspection'result .

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(4) Progres Verification - The program verification conducted by GPC consisted of a design- program verification and a construction program verificatio The design program verification' consisted of verifying that the design system process for the containment post-tensioning was adequately controlled and that licensing commitments were implemented in design document The construction program verification consisted of verifying that construction incorporated licensing commitments into implementing documents such as drawings, procedures and specifications and that construction activities complied with design requirement The program verification also included a walkdown inspection of tendon installation activities to assess the implementation of requirements delineated in construction specifications and field procedures. The program verification identified one finding in the design area and two findings in the construction area. These were categorized on the bases of their individual significance and cumulative programmatic effec The review conducted by the Readiness Review Staff for the design and construction verification program was comprehensive and adequate. Findings were of minor significance and the resolution of the findings was adequate. Quality records indicated they were representative evidence of quality controls for installation of the containment post-tensioning system. Observation of construction activities observed during review of this module indicated that the tendon installation was controlled in accordance with applicable requirements and that the assessment of design and construction activities described in this module are correct. This specific conclusion can also be supported by performance of the Construction Inspection Program (IE Manual, Chapter 2512) by Region II Inspectors. This program required observation of work and work activities of the applicants'

personnel regarding the performance of their duties during construction of the facilit (5) Independent Design Review - GPC contracted an outside organization, Stone and Webster Engineering Corporation, to perform an Independent Design Review of the containment post-tensioning syste This review was performed to assess the technical adequacy of the foundation design and to verify that the design was in compliance with licensing commitments, specifications, and procedures. This is analogous on a smaller scale to an independent design verification program (IDVP) performed by other utilities and accepted by the NRC. The review resulted in seven findings being identified. The NRC concluded that the IDR program for design of 3 the post-tensiooning system was comprehensive and adequate. The

NRC agrees with the findings and their disposition, except as

noted in Section 4.0, above.

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General Conclusions This module presents an adequate assessment of the GPC process for design, fabrication, and installation of the containment post-tensioning syste During the review, it was apparent to'the NRC reviewers that GPC management supported the program by their active participation in the development of the progra Review and evaluation of Module 13C by the NRC indicates that the review performed by the GPC Readiness Review Staff was sufficiently comprehensive in scope and depth to identify problem areas, and that the dispositions of findings were proper. and satisfactory, except as noted above. The NRC findings identified as deficiencies appear to be minor and do not represent a breakdown in the quality assurance program. The procedures for design, engineering, construction, and quality control were consistent with commitments and, therefore, acceptabl Based on the review of this module, it appears that design, fabrication and installation of the post-tensioning system was performed in accordance with the appropriate procedures and records reflect the quality of that construction.

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Pending resolution of the findings identified above, the NRC finds that the Vogtle program for the design and construction of the containment and~

post-tensioning system complies with the Final Safety Analysis Report and

, that compliance is verifiable with existing documentation.

The NRC, furthermore, believes that Module 13C accurately assesses the status of design and construction activities for the containment post-

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tensioning system. This conclusion is based on information currently available to the inspectors and reviewers. Should information subsequently become available which was not considered during this review of previous inspections and which conflicts with earlier information, it will be evaluated to determine what effects it may have cn the above conclusion.

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