IR 05000445/1978001
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DETAILS 1.
Persons Contacted Princioal Licensee Ecoloyees
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R. J. Gary, TUGCO Executive Vice President and General Manager
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L. F. Fikar TUSI, Vice President, Design and Construction
- J. B. George, TUSI, Nuclear Construction Manager
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i D. N. Chapman, TUGCO, QA Manager
- R. G. Tolson, TUGCO, Site QA Supervisor J. T. Merritt, TUSI, Resident Manager
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R. V. Fleck, TUGCO/G1H, Site QA Supervisor J. V. Hawkins, TUGCO/G&H, Site QA Representative
- 0. E. Deviney, TUGCO, QA Technician
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Other Personnel
- H. O. Kirkland, B&R, Project General Manager
- U. D. Couglas, B&P., Assistant Project Manager P. L. 3cssolini, Project QA Manager
- J. P. Clarke, B&P., Senior QC Engineer
- J. J. Pr:rhead, G&H, Resident Engineer
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- S. C. Scott, B&R, QA Engineer The inspectors also interviewed other contractor employees during the course of the inspection. They included B&R field engineers, B&R QC inspect:rs and E&R construction personnel.
- denotes these present at the exit interview.
2.
Licensee Action on Previous Insoection Findings (Closed) Noncompliance (50-445/77-10; 50-446/77-10):
Failure to Remove Weld Surface Defect Prior to Final A~cceptance. The licensee's written response, dated Nover.ber 17, 1977, did not reflect the audits and/or surveillance activities being implemented to prevent recurrence of this itec.
In a letter, dated January 3,1978, the licensee provided additional information describing planned surveillance and monitoring activities to avoid further noncompliance. During this inspection, the IE inspector made cursory observations of field weld surfaces on the component cooling water systec and reviewed the surveillance program schedules with the licensee representative. The IE inspector had no further questions regarding this item.
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(Closed) Noncompliance (50-445/77-10; 50-446/77-10):
Failure to Provide Weld Procedures at the Location Where the Prescribed Activity is Performed.
The licensee's written response dated November 17, 1977, did not reflect the audits and/or surveillance activities being implemented to prevent-2-
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recurrence of this item.
In a letter, dated January 3,1978, the licensee provided additional information describing planned surveil-
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lance and conitoring activities to avoid further noncompliance.
During this inspection, the IE inspector verified that welding and inspection procedures were located in the weld data control shack.
The inspector also reviewed the surveillance program schedules with the licensee representative. The IE inspector had no further
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questions regarding this item.
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3.
plant Tour
During the period of the inspection, the inspectors walked through various areas of the plant to observe construction activities in progress. Observations were made of activities in the Unit 1 and 2 Containment Buildings, Auxiliary Building, Safeguards Building, Emergency Service Water Intake Structure, and activities relating to the on-site fabrication of the Fuel Pool Liner Assemblies.
No itecs of noncorpliance or deviations were identified.
4.
A11ecation of poor Workmanshio During this inspection, the IE inspector conducted a follow-up review of the 3&R inspection and documentation program which was initiated to gq.
assure that all temporarily installed "Rotofoam" blocks had been remoypd n,1((
from between Category I seismic structures af ter concrete placements._.
The NRC inspector reviewed B&R procedure CP-QCl-2.4-9, " Inspection of Elastic Joint Filler Material Removal," Revision 1, dated December 12, 1977 ar.d B&R inspection reports dated December 15, 1977 and January 3, 1978.
The NRC inspector had no further questions regarding this matter.
5.
potential Construction Deficiency - Vendor Sucolied Steel Enbeds
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During this inspection, the IE inspector conducted a follow-on review of the reported discovery of "B" series Cadweld sleeves welded to eight steel plate embeds in reversed t *ientation.2/ Although an engineering disposition and resolutien wa1 c.ompleted on the eight steel plate embeds, a question arose as to the pos11bility of similar conditions of reversed orientatien of the "B" series Cadweld sleeves on other embeds being if IE Inspection Report No. 50-445/77-13; 50-446/77-13, dated December 20, 1977, paragraph a 2/ IE Inspection Report No. 50-445/77-13; 50-446/77-13, paragraph 3-3-
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utili:ed in Category I seismic structures. During this inspection,
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the IE ir.spector observed that an engineering review TUGC0 draft i'
memo dated December 23, 1977, identified seventeen areas where "B"
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series Cadweld sleeves are being utilized involving steel embeds
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and/or rebar. Of the seventeen areas, six areas involving miscel-
laneous embeds and rebar applications set in concrete could not be f
examir.ed or verified by documentation as to correct orientation.
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These specific applications have been submitted to the Design Engineer
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for evaluation.
It was also observed, by the IE inspector, that samples U
of reverse oriented production run Cadweld sleeve / plate /rebar were
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tensile tested on site. The results of these tests reflect tensile strength values frem 81,380 psi to 90,000 psi.
The G&H specification Section 7.4(A) requires that each sample. tested shall 2323-55-11, equal or exceed a rebar stress of 75,000 psi; however, Section 7.4(B)
requires that the average of each group of fifteen consecutive samples
shall exceed a retar stress of 90,000 psi. The average of the in-1-
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correctly oriented sleeves do not meet this criterion.
Section 7.8E of the referenced specification requires an engineering evaluation of acceptability of reduced average tensile strength.with respect to the required strength of a particular location. The evaluation was not
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yet completed.
This ratter will be reviewed during a subsequent IE site inspection.
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t 6.
Polar Crane Asseebly and Installation Procedures The Unit 1 polar crane is currently scheduled for assembly and instal-
lation starting January 20, 1978. During this inspection, the IE inspector reviewed the G&H specification No. 2323-MS-39 in conjunction
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with the applicable sections of the CPSES PSAR. During the review, the i'
IE inspector observed that the licensee did not have procedures for the
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activities involving the asserbly, installation, and inspection of the safety related corponents of the polar crane.
In discussing this matter l
with the licensee representatives, the IE inspector was informed that
the manufacture's representative is on site and that procedures will be
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developed and issued in compliance w'ith 10 CFR 50, Appendix B, criteria prior to the start of the assembly and installation activities. The IE l
inspector identified this matter as an unresolved item pending an IE
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review during a subsequent IE site inspection.
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7.
Reactor Coolant Pumo and Steam Generator Embed Sucoorts j
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During an independent review of structural embeds conducted by the IE inspector, the inspector observed that, although the reactor coolant
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pump and steam generator vertical support embeds were fabricated and l
being installed to approved G&H installation-drawings, the detailed l
design delineated in the CPSES PSAR, Figure 3.8-17, is substantially l
different. The detail shown in Figure 3.8-17 of the PSAR indicates
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floor liner plate I
the embed anchorage assetbly extends through theThe "as-built" condition doe
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In discussing this into the containment base mat.
penetrate the liner plate as shown in the PSAR.
E inspector was observation with the licensee representatives, the I issued inforced that the CPSES Final Safety Analysis R
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ding verification and that the matter would be reviewed.
the discrepancy would remain as an unresolved item
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d reflected in
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the SAR.
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Containment - Structural Concrete _
5.
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Observation of Work ti The inspector observed activities in the Unit Nos a.
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Activities were found to be in conformance cent.
cleaning and curing.
with Gibbs and Hill -(G&H) specification 2323-SS
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Review of Ouality Records _
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The records for two containment exterior walls we
follows:
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Date of Placement Placement No.
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Dec. 30, 1977 to El. 955'6" Unit No.1 101-5805-025 Oct.18,1977 to El. 841'6'
i Unit No. 2 201-5805-006 The review included the following records:
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Pour Cards Reinforcing Steel, Electri~ cal, Mechanical and Embedded Item
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Checklists
!i; Acceptance Tests en Concrete
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t-Concrete Placetent Reports
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Batch Tickets Sieve Analyses and Moisture Tests Material Certifications
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28 Day Compressive Tests (Unit 2 only)
Curing Report Form and Checlists (Unit 2 only)
QC Concrete Curing and Inspection Reports (Unit 2 only)
Daily Surveillance Checklists - Test Lab - Concrete Mixing
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and Conveying The records reviewed were in conformance with site procedures
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QCP-2.2, 2.3, 2.4, 2.5 and 2.6 and reflected work in conformance
with G&H specification 2323-55-9.
No items of noncompliance or deviations were identified.
9.
Foundations - Review of Quality Records The records for two structural concrete foundations were reviewed as
follows:
'Date of Placement Placement No.
Fuel Building 003-2785-002 March 29, 1977 Service Water Intake 035-2755-001 February 11, 1976 The review included the following records:
Four Cards
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Reinforcing Steel, Electrical, Mechanical and Embedded Item Checklists Acceptance Tests on Concrete
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Cencrete Placement Reports
Batch Tickets Sieve Analyses and Moisture Tests 28 Day Compressive Tests Curins P.eport Form and Checklists
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QC Cc'ncrete Curing and Inspection Reports Deficiency and Disposition Reports
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The records reviewed were found to be in accordance with site procedures QCP-2.2, 2.4, 2.5 and 2.6 and reflect work in conformance with G&H specification 2323-55-9.
No items of noncompliance or deviations were identified.
10.
Project Manacement and Orcanization
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On January 5,1976, the licensee inforned the Region IV staff of a significant project r.anagerent and organization change being implemented on the CPSES project.
The changes, effective January 3,1978, as reflected in the TOGC0/TUSI QA program (deviation f:o. 38), were reviewed by the IE inspector during
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this inspection.
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No items of noncompliance or deviations were identified, 11.
Unresolved Items Unresolved itets are catters about which more information is required in order to ascertain whether they are acceptable items, items of noncompli-Unresolved items disclosed during the inspection ance, er deviations.
regarding the lack of procedures relating to installation of the polar crane and the discrepancy between the PSAR and "as-built" conditions regarding embeds are discussed in paragraphs 6 and 7, respectively.
12.
Exit Interview The inspectors cet with the licensee representatives '(denoted in paragraph 1) at the conclusion of the inspection on January 13, 1978. The inspectors summarized the scope and findings of the inspection. The licensee repre-sentatives ackncwledged the statements by the inspector with regard to the procedures required for portions of the polar crane installation (para-graph 6) and the discrepancy noted in the PSAR (paragraph 7).
The licensee representatives indicated that installation of the polar crane would not start until procedures have been developed and approved and that the catter regarding the PSAR discrepancy would be reviewed and resolved.
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If!SPECTI0f! PLAft l
IE Inspection Report tio. 50-445/78-01; 50-446/78-01
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Licensee: Texas Utilities Generating Company Location: Dallas, Texas
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Facility: Comanche Peak Steam Electric Station (CPSES), Units 1 & 2 Type of Licensee:
W, PWR, 1159, MWe Type of Inspection: Routine, Unannounced Dates of Inspection: January 3-13, 1978
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Dates of Previous Inspection: November 28 - December 2,1977 Inspectors:
RCStewart, ABRosenberg SCOPE OF INSPECTION 307033 Management meeting
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927063 Independent inspection
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927023 Follow up noncompliance items 470548 Concrete - containment walls (observation) (50%) (10%)
47056B Concrete - containment walls (records)
(40%)(20%)
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460538 Concrete foundations - observation of work (80%) (80%)
46055B Concrete foundations - records (50% (50%)
92701B Unresolved Items
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QUALITY ASSURANCE DEPARTMENT'
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NONCONFORMANCE REPORT (NCR)
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2323-SS-9.%DEXED
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'LANT SY ST E M COMPONENT T AG/ SPIN /lOE N T NO l
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SERI AL NO.
1 CODE CODE CODE A lBlCl 0IEi F l T ' Nts t i H; qun.us l J ; (Un.ui
5 10 11 16 17 55
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,e PURCH ASE ORDE R VEND NUMBER CODE S&69 70 73 X
X C-1034R1 5 071978 X,,,,,
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I t t t t t t t t ( I e I t t t t t t t e ie i COUNT l UNITS PU RCH'S
%Sv HOLO NOJCODE INPUT MRR RIR VENDOR *$
NUMBE R NUMBER HE AT/ LOT /aATCH NO, OUANTITY OR NO.
W Us DATE 74 79 8085 8695 96 106 106 111 112 121 122 127 (33 MOMCOM PORInteN G COMOS TIOM s
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UNIT:
1, 2 {l & 2]
(Circ.Le vue)
h Aux. Blde. 852'6" elev.
SEE ATTACHMENT Material System)
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h (Concrete Component)
h (N/A (Vendor)
@ LOCATION:
Rec., Storane,(
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(Circle One)
Qg.gggO 70 WNCE DWPOS nTto N I
(38 REPORTED evs iga, oayg; Dennis Mercier_
l7-19-78
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3PREPAnEDsv
'ist D AT E s (73 REvett9s Arjanov A e tsj DATE: g,y
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l Dennis Mercier 7 '19' 78
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otr CT, U. D.
De... n 7 %9 '78 DRequired QNot Required apo v.us 9 a (3 3) DeSPOSITION e
USE AS IS SCRAP R EWOR 84 REP AI R Au PRt.M
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SEE ATTAHCMENT F0Fc a~!0RMATl0t'! MLy 1-S EE c.PP A -00333 (AMMED)
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(33l AND REvlEWf APPROV Agg u
DATEa 0A ~ 2AAAd l / 'W79 NM Av /-M-79 l(138
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QA RECO.iD l p '7h - $UI arisfactory O Unsatisfactory Not Req'd.
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EU LQf ATTACHMENT TO C-1034 R l (13) Disposition:
Defective concrete area Nos. 2.3,5,6,7,8,9,10,12,13,15 rd M N'/b3 shall be chipped to sound concrete and repaired with dry pack in accordance with Construction Procedure CCP-12. Sections 4.1.2.1, 4.1.2.2, 4.1.2.3, 4.1.2.4, 4.1.2.5, and 4.1.2.8.
Defective concrete area Nos. 1, 11 and 14 shall be chipped to sound concrete, fonned and poured back with 3/8" concrete in accordance with Construction Procedure CCP-12, Sections 4.1.2.1, 4.1.2.2, 4.1.2.5, 4.1.2.6, and 4.1.2.8.
Area No. 4 shall be re-paired by a combination of 3/8" concrete and dry pack.
Rev.1-Area #16 shall be left "As-Is."
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3g ATTACHMENT TO NCR C-1034 Nonconforming Condition:
Para. 8.2.6a of specification 2323-SS-9, Rev. 4 states, "All concrete shall be consolidated by suitable means during placement...and into the corners of the fom".
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In Auxiliary Bldg. Pour No. 002-7852-007 various areas of honeycomb & de-fective concrete were found. For exact location and descriptions, see attach-ments. All areas are at the underside of the 852'6" boric acid slab (beams
& walls).
Defective concrete dimensions: length x width x depth
Area #1 Area #9 33"x11"x4" 12"x7"x1"-4" 6 bars exposed 2 bars exposed Area #2 Area #10 12'x13"xk"-1" 57"x13"x4" no bars exposed 5 bars exposed possible cold joint Area #11 Area #3
71"x8"x4" 24"x16"x3"-6" 14 bars exposed
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3 bars exposed
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Area #12 Area #4 55"x29"x5" 43"x15"x9" 6 bars exposed 17 bars exposed Area #13 Area #5 69"x8"x31 "
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33"x7"x3" 8 bars exposed 2 bars exposed Area #14 Area #6 36"x8"x5" 32"x63s"x4" % g]M'IRIN W L
7 bars exposed 7 bars expo
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Area #7 Area #15 9"x6"x8" 15"x10"x6" 2 bars exposed 2 bars exposed Area #8 Area #16
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12"x6"x7" Linear fracture with extent unknown.
3 bars exposed
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DEFECTIVE CONCRETE REPORT PROJECT: CPSES JOB NO. 351195 UNIT:
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January 23, 1979
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R. E. Heim FROM:
JOB NO:
2323 SUBJECT:
NCR-C- 10 34 R1 REF. fl0:
NCR C-1034, R1
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Defective Concrete, Auxiliary Building COMANCHE PEAK STEAM ELECTRIC STATION 1981-83 2300 MW INSTALLATION NCR-C-1034, R1 By copy of this letter we are advising Brown & Root that the combination
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STATUS DATE 72. n SC.8 5 Si> 95 96-105 105111 112 121 1Z2127 g a s n o m:=.=. ro n me M o.com on Te o re s
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ATTACHMENT TO C-1034 (13) Disposition:
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u Defective concrete area Nos. 2.3,5,6,7,8,9,10,12,13,15, and 16 shall be chipped to sound concrete and repaired with dry pack in accordance with Construction Procedure CCP-12, Sections 4.1.2.1, 4.1. 2. 2, 4.1.2.3, 4.1.2.4, 4.1. 2. 5, and 4.1.2.8.
_..
Defective concrete area Nos.1,11 and 14 shall be chipped to sound concrete, formed and poured back with 3/8" concrete in accordance with Construction Procedure CCP-12, Sections 4.1.2.1, 4.1.2.2, 4.1.2. 5; 4.1.2.6, and 4.1. 2.8.
Area No. 4 shall be re-paired by a combination of 3/8" concrete and dry pack.
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Para. 8.2.6a of specification 2323-SS-9, Rev. 4 states, "All concrete shall be consolidated by suitable means during placement...and into the corners of the form".
In Auxiliary Bldg. Pour No. 002-7852-007 various areas of honeycomb & de--.
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Defective concrete dimensions: length x width x depth
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Area #1 Area #9 33"x11"x4" 12"x7"x1"-4"
.
6 bars exposed 2 bars exposed Area #2 Area #10 12'x13"xk"-1" 57"x13"x4" no bars exposed 5 bars exposed possible cold joint Area #11 Area #3 71"x8"x4"
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24"x16"x3"-6" 14 bars exposed 3 bars exposed Area #12 Area J4 55"x29"x5" 43"x15"x9" 6 bars exposed 17 bars exposed Area #13 Area #5 69"x8"x3 "
33"x7"x3" 8 bars exposed 2 bars exposed Area #14 Area #6 36"x8"x5" 32"x6 "x4" 7 bars exposed 7 bars exposed
%hh Area #7 Area #15 9"x6"x8" 15"x10"x6" 2 bars exposed 2 bars exposed Area #8 Area #16 12"x6"x7" Linear fracture with extent unknown.
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p-of QUALITY ASSURANCE DEPARTMENT
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DEFECTIVE CONCRETE REPORT a-PROJECT: CPSES JOB N O.351195 UNIT:
PAGE OF STRUCTURE:. t S PPM,E 6N.
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A. REBAR EXPOSED OURING PREPARATION FOR SURFACE DEFECT REPAIR 8.RESAR EXPOSED UPON FORM REMOVAL
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A. SIZE: LENGTH WIDTH
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W M a 6_rvdE f Ok)L s, % hb e%) c. *'2-E,'T~
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5. O!SPOSITION:.. _ _ _.,[
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A. NON-ROUTINE REPAIR; 00CUMENT WITH N.C.R.'
j B. ROUTINE REPAIR IN ACCORDA'!CE WITH SECTIONS t
OF CCP.12 Ll
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. Gibbs 8 Hill. Inc.
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CPP-A-00203
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Dallas
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To J. T. Merritt, Jr.
Date November 13, 1978 At TUSI - Jobsite
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. From R. E. Heim
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Ac GSH
- Jobsite COMANCHE PEAK STEAM ELECTRIC STATION
,
1981-83 2300 MW INSTALLATION
-
DEFECTIVE CONCRETE
REF: NCR C-1034 FILE 03211
.
.
Review of the defective concrete described in reference NCR C-1034 has been completed.
Repair in accordance with the disposition will assure the design intent is net.
w 4, If further review is required, please advise.
.
.
.
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R. E. Heim
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Resident Engineer M
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REH:RBW:ss a
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ARMS OL B. J. Murray IL gg U
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H. R. Rock IL
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