IR 05000458/1979004
| ML19256E628 | |
| Person / Time | |
|---|---|
| Site: | River Bend  |
| Issue date: | 09/28/1979 |
| From: | Crossman W, Randy Hall, Oberg C NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19256E625 | List: |
| References | |
| 50-458-79-04, 50-458-79-4, NUDOCS 7911080232 | |
| Download: ML19256E628 (6) | |
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k U. S. NUCLEAR REGULATORY COMMISSION l
OFFICE OF INSPECTION AND ENFORCL%NT
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REGION IV
Report No. 50-458/79-04 Docket No. 50-458 Category A2 Licensee:
Gulf States Utilities Post Office Box 2951 Beaumont, Texas 77704 Facility Name: River Bend Station, Unit No. 1 Inspection at: River Bend Site, St. Francisville, West Feliciana Parish, Louisiana Inspection conducted: September 4-7, 1979 Inspectors:
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-C. R. Oberg, Reactor Inspector, Project Date Section (paragraphs 1, 2, 3, 4, 5 and 8)
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apla, Rehetor Inspector, Engineering Date Supp rt SectMa (paragraphs 5, 6 and 7)
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Approved:
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W. A. Crossaan, Chief, Projects Section Date
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R. El Hall, Chief, Engineering Support Section D$e /
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Inspection Summary:
I Inspection on September 4-7, 1979 (Report No. 50-458/79-04)
l Areas Inspected: Routine, unannounced inspection 7f preparations for placement
of safety-related concrete; licensee action on previously identified inspection i
findings; and quality assurance program review. The inspection involved
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fifty-six inspector-hours by two NRC inspectors.
Results: Of the three areas inspected, no apparent items were identified j
in two areas; two apparent items of noncompliance were identified in one area (infraction - Failure to Control Ordering of Safety Related Concrete -
paragraph 5; infraction - Failure to Follow Manufacturer's Instructions for the Storage of Reinforcing Steel Mechanical Splice Sleeves paragraph 6)
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DETAILS 1.
Persons Contacted Principal Licensee Personnel
- J. E. Wimberley, Superintendent, Site Construction
- T. L. Crouse, Director, Quality Assurance
- G. T. Warner, QA Consultant
- M. E. Walton, Nuclear Staff Analyst
- W. Stuart, Quality Systems Representative
- J. Dunkelberg, Assistant Superintendent, Site Construction Stone and Webster
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- J. E. Loomis, General Superintendent
- W. I. Clifford, Resident Manager
- C. D. Lundin, Project QA Manager
- A. Kamdor, Resident Engineer
- R. L. Spence, Superintendent, Field Quality Control (FQC)
R. Scott, Senior Field Engineer S. Solowitz, Senior FQC Inspector The IE inspectors also interviewed other licensee and contractor employees including members of the QA/FQC and engineering staffs.
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- Denotes those present at the exit interview.
2.
Licensee Action on Previously Identified Inspection Findings (Open) Unresolved Item (50-458/79-02): Construction Deficiency -
Breakdown in Quality Assurance Program for Reinforcing Steel. The IE inspector observed the progress of marking reject rebar. Approximately 55% of the steel has been marked or shipped off the site.
Stone and Webster FQC personnel were monitoring the operation in order to prevent unmarked rebar from leaving the storage area. This item remains unresolved until all reject rebar has been marked or removed from the site area.
(0 pen) Unresolved Item (50-458/79-02): QA Program of Supplier of Material
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and Services. Certifications were submitted to the National Mobile Concrete Corporation from Missouri Portland Cement Company (dated July 20, 1979) and Dixie Sand and Gravel Company (dated July 20, 1979).
These certifications specify that the requirements of Construction Specification 210.350 and the requirements of National Mobile's QA Program Manual will be met. These certifications were submitted in place of the specific contractual QA program requirements since only
" Letters of Intent" have been issued to the suppliers identified above.
This item remains open until e contract is signed which will require a specific QA program for earn supplier.
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3.
Site Tour The IE inspectors made a general tour of the site, accompanied by licensee representatives, in order to observe general construction progress and status.
Placement of reinforcing steel for the reactor base mat is continuing. Mud mats for Control Building and emergency (safety-related) cooling towers have been placed. The IE inspectors also observed, during the tour, the painting (for identification purposes) of non-safety-related rebar.
(See paragraph 2)
4.
Review of Documents - Mixing and Delivering of Concrete The following Nonconformance and Deficiency Reports (N&Ds) were reviewed by the IE inspector:
FQS-S-9029 MillTestRepor$-28dayheatofhydration FQS-S-9034 Mill Test Report - t'.ue of ret FQS-S-9036 Concrete Aggregate No. 57 FQS-S-9040 Concrete Placement, No. 1 Reactor Mud Hat FQS-S-9044 Concrete Placement, No.1 Reactor Mud Mat -
ammended disposition No items of noncompliance or deviations were identified.
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5.
Observation of, Concrete Placement The IE inspectors observed work being done on concrete placement No. CDMM 63-3-3533, for the Control Building (Category I) soil bearing mat (mud mat) and associated sump. Batch plant tickets (No. 00345, 00346 and 00347) were reviewed by the IE inspectors in order to determine compliance with procedures. These tickets had been delivee d to the S&W FQC inspector from the concrete delivery trucks. The tickets specified a 3000 psi (at 28 days) mix, (Design Mix A).
However, the batch tickets identified above were presented as " Turbine Building Mud Mat."
The National Mobile Concrete Corporation (NMCC) Site QA Manual, Section 130, paragraph 137.1 requires that the location of placement be printed on each ticket "as requested by the Orde.."
During the discussion of this matter with constructor personnel, it was determined that a scheduled Turbine Building placement had been delayed and that the concrete trucks were sent to the Control Building area placement with the incorrect location of placement printed on the batch ticket, but with "3000 psi" hand marked on the batch ticket. The Turbine Building placement would have required 4000 psi concrete.
Subsequent batch tickets (No. 00348 through 00351) for this same place-ment, Control Building mud mat, wer: marked correctly as " Control Building Mudmat." Tickets No. 00345 through 00347 were subsequent 1/ corrected-4_
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by FQC to indicate correct placement. The actual mix proportions were verified by the IE inspector to reflect concrete mix "A"..
The cause of the wrong placement location on the Batch Ticket was determined to be the result of the use of an uncontrolled " Concrete Order." The " Concrete Orde " form is not identified in any NMCC or Stone & Webster procedure. Review of the order issued for the mud mat placement (a safety-related activity) revealed that t he concrete was ordered for the " turbine Bldg. M/M."
Uncontrolled use of this form is contrary to the requirements of Appendix B, Criterion V of 10 CFR 50, and is considered an item of noncompliance.
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Cadwelding
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Ongoing Cadwelding activities for the base mat reinforcing steel were observed. The fabrication of Cadweld No. CH2-287 in row 54 of the upper level of reinforcing steel was witnessed. The fabrication activities observed were found to be in conformance with the manufacturer's instructions and with Stone and Webster Construction Methods Procedures (CMP) No. 6.1-9.76, "Cadwelding of Reinforcing Steel Bars."
The inspection also included verifica' tion of the as-built location of six Cadweld splices in layer No. 8 of the lower base mat reinforcing steel. Drawing No. 12210-FOSK-502, "Cadweld Final Locations," was attached to S&W Quality Assurance Inspection Report No. IR-S-9000-664.
Six Cadwelds were randomly selected from the drawing and subsequently located installed in the base mat.
The Cadwelds were located as descr bed i
and the Cadweld sleeve numbers and welder identification numbers were as recorded on the drawing.
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Storage of B-series Cadwelds and associatad Containment Building floor plate sections in the reinforcing steel storage yard was also reviewed during this inspection. The followitg sister sleeves were found stored in an open box without the protective Caplugs on and without the wrapping paper inside the sleeves:
239-E56-2 248-E56-2 206-E56-2 230-E56-2 252-E56-2 201-E55-2 250-E56-2 203-E57-2 224-E56-2 238-E56-2 244-E56-2 245-E56-2 204-E57-2 207-E56-2 232-E56-2 The Erico Products, Inc., Catalog RB10M974 gives specific instructions for the protection of'B-series Cadweld slee'res af ter they are welded to steel plate sections. The catalog instruct'.ons require that the Caplugs be kept tightly in place until removed for splicing the bar to the sleeve.
Contrary to this manufacturer's requirement., the aforementiened sister
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sleeves were found to be stored without their protective Caplugs. Stone and Webster CMP No. 6.1-9.76, states in Section 2.2, "The rust inhibiting wrapper shall not be removed from the splice sleeve or plugs removed from B-series sleeves until the sleeve is to be used." This construction methods procedure further clarifies the B-series Cadweld sleeve storage requirement.
Failure to store the Cadweld sleeves properly is considered to be in non-compli.ance with 10 CFR 50, Appendix B, Criterion V.
7.
Concrete Placement Records The following concrete placement records for the Reactor Building seal slab were reviewed:
National Mobile Concrete Corporation (NMCC) Batch Tickets Stone and Webster (saw) QA Department Batch Platt Inspection Report S&W Concrete Pour Cards S&W QA Department Concrete Preplacement Inspection Report S&W QA Department Concrete Placement Inspection Report Concrete Compressive Stren;th Test Report Concrete Coarse Aggregate Test Report Concrete Fine Aggregate Test Report These records represent placements No.1-RSM-MM-1-000P and 1-RSM-MM-2-000P. The records reviewed were found to conform te the S&W Design and Construction Specification No. 210.370, " Placing Concrete and Re-inforcing Steel."
No items of noncompliance or deviations were identified.
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Exit Interview The IE inspectors met with the licensee representatives (denoted in paragraph 1) at the conclusion of the inspection on September 7, 1979.
The scope and findings of the inspection were summarized by the.IE inspectors. The items of noncompliance were discussed.
In addition, S&W training for concrete placements and the number and type of S&W construction procedures were discussed.
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