IR 05000424/1986123

Insp Repts 50-424/86-123 & 50-425/86-58 on 861117-21.No Violations or Deviations Noted.Major Areas Inspected: Structural Concrete & Backfill,Post Tensioning,Previously Identified Unresolved Items & Inspector Followup Items

ML20207J091
Person / Time
Site:	Vogtle
Issue date:	12/16/1986
From:	Conlon T, Harris J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II)
To:
Shared Package
ML20207J046	List: IR 05000424/1986123 ML20207J041
References
50-424-86-123, 50-425-86-58, NUDOCS 8701080298
Download: ML20207J091 (7)

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UNITED STATES

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$ j 101 MARIETTA STREET, * e ATLANTA, GEORGI A 30323

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. Report Nos.: 50-424/86-123 and 50-425/86-58

- Licensee: Georgia Power Company P. O. Box 4545 Atlanta, GA 30302 Docket Nos.: 50-424 and 50-425 License Nos.: CPPR-108 and CPPR-109 Facility Name: Vogtle 1 and 2 Inspection Conducted: yovember 17-21, 1986 Inspector: O 32:~f/; ' 7/ W @ / 2 -/G-b J. R. fiarrYs

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0, Date Signed Approved b -[Ng N#7 / % - / /,. - %

T. Eonlon, ChTef ' ,

Date Signed

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Plant Systems Section Engineering Branch Division of Reactor-Safety

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SUMMARY Scope: This routine, . unannounced inspection was : conducted in the areas of structural concrete and backfill, post tensioning,. and previously identified -

Unresolved Items and Inspector Followup Items.

i Results: No violations or deviations were identifie PDR ADOCK 05000424 O PDR

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REPORT DETAILS Persons Contacted Licensee Employees

• E. Conway, Senior Vice President

• D. Rice, Vice President, Engineering

• H. Pinson, Vice President, Construction

• W. Hayes, Quality Assurance (QA) Manager

• D. Groover, Site QA Manager

• G. A. McCarley, Project Compliance Coordinator

• B. C. Harbin, Manager, Quality Control (QC)

• N. Lankford, QC Supervisor Other licensee employees contacted included construction craftsmen, engineers and technician Other Organizations J. Bond, VSL Foreman, Post Tensioning Operations D. Summers, VSL QC Inspector, Post Tensioning NRC Resident Inspectors

• Rogge

• H. Livermore

• Attended exit interview Exit Interview ( The inspection scope and findings were summarized on November 21, 1986, with

! those persons indicated in paragraph 1 above. The inspector described the areas inspected and discussed in detail the inspection finding No

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dissenting comments were received from the licensee. The licensee did not l identify as proprietary any of t.ie materials provided to or reviewed by the l inspector during this inspectio . Licensee Action on Previous Enforcement Matters (Closed) Unresolved Item 85-19-03, Maximum Allowable Water on Batch Tickets.

L Review of batch tickets for eight concrete pours placed between January 29 l and February 27, 1981 showed that these tickets had a maximum allowable water content of 380 gallons for each 10 cubic yards of concrete batched.

l This quantity of water if used would exceed the maximum allowable amount of j water allowed by the design mix.

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Investigation of this matter by the licensee showed that the batch plant operator had keyed an artificial amount into the computer greater than allowed by mix design to allow him to work to the allowable one percent tolerance. A review of records for concrete pours made from September 13, 1980 to May 6, 1981 was performed to verify the maximum water was not exceeded. Review of these records showed no evidence that the maximum allowable water was exceeded. Review of concrete pour records during this inspection and during previous inspections by NRC inspectors showed no evidence that the maximum allowable water was exceeded. Review of these records showed that the batch plant operator did not approve the batch ticket These were reviewed and approved by a QC inspector. This item is close (Closed) Unresolved Item 85-19-01, Review of Results of Testing Performed on Concrete Materials by the Independent Testing Laborator Review of these records _ by NRC inspectors showed several discrepancies in the test dat In followup on this item, the licensee reviewed all Law Engineering Testing Comp:ny test reports. The review was performed to verify the accuracy of results accepted. As a result of this review, 26 reports were found to contain sonie type of discrepancy. Deviation reports were written to address these discrepancie Review of these deviations reports by the inspector showed that the identified discrepancies were of minor significance and that these discrepancies were properly resolved. This item is close (Closed) Unresolved Item 85-19-02, Review of Civil Open Item Reports. The NRC inspectors could not determine from review of the Civil Open Item Reports whether or not the corrective actions had been completed, and whether of not the reports had been reviewed and accepted by engineerin In followup on this item, the licensee reviewed all Civil Open Item Reports in the vault. A total of 43 Civil Open Item Reports were found. Of these 43 reports, closing reports could not be found for 26 of them. Closing reports were generated for two of these reports based on a review of other documentation in the vault which documented the corrective action take Deviation Reports were generated to address the remaining open report Review of these Deviation Reports by the NRC inspector showed that proper corrective actions were taken to resolve the open items and that these items were reviewed by engineering. This item is closa (Closed) Unresolved Item 85-19-04, Certification of QC Inspectors on Concrete Pour A-118-00 Review of certification records of concrete QC inspectors showed that a Level I fresh concrete tester, who had his card revoked, conducted inprocess testing of fresh concrete and that a Level I inspector was evaluating and verifying acceptability of concrete batch tickets.

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Investigation of this item showed that the Level I QC inspectors, whose card had been revoked, did initial batch plant tickets and sign the bottom of the pour log. However, these records were also signed or initialed by a certified inspector. Review of records of the Level I inspector, who was evaluating batch tickets, showed that his duties were to check the concrete batch print out ticket against a predetermined mix design. In case of a problem, a Level II batch plant inspector was available for advice or guidance. A review of batch tickets inspected by the Level I QC inspector showed that the batched mixes met design requirement Review of ANSI N45.2.9-1978, showed that on the job participation should be included in the training program for QC inspectors and that when inspections require implementation by a team or group, personnel not meeting the requirement of this standard may be used in data taking assignments provided they are supervised or overseen by a qualified individual participating in the inspectio This item is closed.

4. Unresolved Items Unresolved items were not identified during the inspectio . Independent Inspection Effort (92706)

Construction Progress The inspector conducted a general inspection of controls for the soils and concrete testing laboratory and observed ongoing backfill operation . Containment (Post-Tensioning) - Review of Quality Records (47065) - Unit 1 The inspector examined quality records relating to post-tensioning activities for the Unit 1 containmen Records examined included tendon grease reports, receipt inspection records, and installation records for the following vertical and horizontal tendons:

Vertical Tendons Tendon 3-109 Tendon 3-107 Tendon 4-108 Tendon 6-106 Horizontal Tendons Tendon 55 Tendon 59 Tendon 56 Tendon 60 Tendon 57 Tendon 61 Tendon 58 Tendon 62 Examination of records for the above tendons showed that the tendons were installed in accordance with applicable specifications and drawings and that the installations were witnessed and documented by QC inspector ,

Within the areas inspected, no violations or deviations were identifie . -

7. Containment (Post Tensioning) Observation of Work (47063) - Unit 2 l The inspector observed stressing of vertical tendons in the Unit 2 tendon galler Tendons installed and witnessed by the inspector were Tendons 7-105,1-110,54-132, 56-130 and 62-12 During the installation of these tendons, the inspector was witness to installation problems on three of the tendon These were Tendon Numbers 7-105,54-132 and 62-124. During the installation of Tendon Number 7-105, numerous wires broke behind the anchor head at the number seven end. These wires broke while pressurizing to remove the shim stack. Deviation Report Number VF-0117 was written to address the problem. The licensee intends to remove this tendon and replace it with another tendon which is currently on order. During the stressing of Tendon Numbers54-132 and 62-124, three strands (seven wires per strand)

failed on Tendon 54-132 and two strands failed on Tendon 62-12 Specification X2A F04, Rev. 3, Containment Post-Tensioning System 'llows only one strand failure per Tendo Deviation Reports were writtan to address these failures and tendon operations were stopped until the cause of these problems could be resolve Within the areas examined, no violations were identifie . Inspector Followup Items (IFI)

(Closed) IFI 83-11-03, Use of Deleted Steel. Deleted Steel is surplus steel resulting from modifications and design change Since the steel was originally received and inspected under the QA program, its reuse is permitted in safety-related areas. Requisition of this steel for use is coordinated by the miscellaneous steel coordinato Modifications and inspections prior to use are made in the miscellaneous steel fabrication sho Investigations by the inspectors disclosed two instances where deleted steel beams were taken from storage areas and modified for use without coordinating their use with the yard coordinator, and without being inspected at the miscellaneous steel fabrication sho These were identified by the licensee on Deviation Report CD-3288 and Corrective Action Request (CAR) Number C-107. In one instance, the modification was stopped before installation and, in the other instance, a modified beam was installe The beam was removed and replaced by a beam modified and inspected in the fabrication shop. To prevent further occurrences of misuse of deleted steel, the licensee held a meeting with responsible engineers and modified procedure CD-708, Field Fabrication Miscellaneous Steel. A further investigation of this item regarding the use of deleted steel by the licensee included:

• Review of FCRs/DCNs written against all "F" (structural and miscellaneous) steel drawing: for Level A and Level I in the Auxiliary Building and Level II and Level III in the Control Buildin * Selected FCRs/DCNs that would have been good vehicles for field fabricated " deleted beams".

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• Determined if miscellaneous steel fabrication forms had been generated for selected FCRs/DCN * Compared Civil QC inspection packages with selected FCRs/DCN *

Verified field conditions of beam Results of this investigation showed that controls for deleted steel were done in accordance with procedure CD-T-08. This item is close (Closed) IFI 84-09-02, Effect of Moisture Variation Between Placed Fill and Laboratory Optimum. Review of records showed that the average optimum moisture method being used to control the backfill moisture sometimes allows the placed. backfill moisture to vary from minus nine percent to plus five percent of the laboratory optimum moisture.

In evaluating this item, the licensee collected samples of the various backfill materials from the borrow area and had density tests made on the materials in their site test laboratory and an independent laboratory operated by Law Engineering Test Company. Results of these test showed that the density of the materials were not very sensitive to moisture change. In addition to these tests, the licensee performed inplace density tests on the backfill to verify that the density of the backfill met design requirement Results of these tests showed that the backfill meets design requirement This item is close (Closed) IFI 85-28-01, Purchase of Superplasticizer as Non Q Materia Module 1, Reinforced Concrete Structures, indicates that superplasticizing agents (water reducing admixture used in concrete) are considered non- Review of this item showed that the superplasticizer Melement used in the concrete was purchased as Non Q material. However, examination of receipt documents did show that the material does meet specification requirements for concrete as specified by ASTM C-494. A change order was made to Specification X2AP01 to require the material to be purchased as a Q ite This item is close (Closed) IFI 85-28-03, Timeliness of Writing and Addressing a Deficiency Report on Cadweld Failures. Review of Deficiency Report Number DR CD-2276 showed that this deficiency was written in July 1982 to address four Cadweld tensile test failures that had taken place in June and September of 198 Review of records did show that a stop work order was issued in September 1981 to address two of the failures and that additional testing was don However, DR CD-2276 did not address the lack of timeliness in issuing a DR for these four tensile test failure Review of this item by the licensee indicated the failure to report the failing Cadwelds was a procedural violation. As a result, Deviation Report CD-07849 was written to address this deficienc As a result of this deficiency, the licensee reviewed all tensile test evaluation reports from the beginning of the cadweld testing program from November 1, 1977 to

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February 25, 1985. This review revealed a failure rate of less than one half of one percent. This extremely low rate of occurrence of cadweld test failures provides assurance that the cadweld splices made on the in place reinforcing bars in the structures will achieve the load carrying capability of the bars. Thus, even though there was a minor procedure violation, no evidence of any impact on hardware was identified. This item is close (Closed) IFI 85-28-02, Retrievability of Record Review of records identified several examples of problems with missing and misfiled records due to the filing system and lack of retrievabilit Examples of this

. problem included the finding of the LA abrasion tests for aggregates and cadweld inspection records by NRC inspectors that were reported missing by licensee reviewers. These are further examples of a problem concerning the filing and retrievability of records which were identified by the licensee in section 6.2 of Module 1, Reinforced Concrete Structure *

In followup on this item, the licensee established a task force to review the documentation filing system to establish an efficient filing system for specific types of records and to decide what records are required so that adequacy of records can be verified prior to turnover. Review of results of

- this task force identified several deficiencies which were listed on a matrix with action items for resolution. Review of resolution of these deficiencies by the inspector indicated that proper actions were taken to improve the filing and retrievability system for records. This item is closed.

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