IR 05000483/1981023
| ML20039B614 | |
| Person / Time | |
|---|---|
| Site: | Callaway  |
| Issue date: | 11/30/1981 |
| From: | Hawkins F, Norton J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML20039B613 | List: |
| References | |
| 50-483-81-23, NUDOCS 8112230308 | |
| Download: ML20039B614 (6) | |
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U.S. NUCLEAR REGULATORY COMMISSION
REGION III
Report No. 50-483/81-23 Docket No. 50-483 License No. CPPR-139 Licensee: Union Electric Company Post Office Box 149 St. Louis, MO 63166 Facility Name:
Callaway, Unit 1 Inspection At:
Callaway Site, Callavay County, MO Inspection Conducted: November 4-6, 1981 p%Ybh Inspector: d. F. Norton
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Accompanying Personnel:
F. C. Hawkins (November 4, 1981 only)
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Approved By:
F. C. Ilawkins, Acting Chief Il M18(
Plant Systems Sectior i
Inspection Summary Inspection on November 4-6, 1981 (Report No. 50-483/81-23)
'Jeas Inspected: Observation of containment post tensioning work activities; review of post tensioning implementing procedures; review ot~ post tensioning QA records; followup on previously identified noncompliance and unresolved items. The inspection involved 26 inspector-hours onsite by one NRC inspector.
Results: No items of noncompliance or deviations were identified.
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ADOCK 05000483 PDR i
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l DETAIIS, Persons Contacted Union Electric Cempany (UE)
- W. H. Weber, Manager of Nuclear Construction M. I. Doyne, General Superintendent of Construction
- R. L. Powers, Superintendent of Site Quality Assurance
- J. V. Laux, Supervisory Engineer, Quality Assurance
- J. R. Veach, Assistant Engineer
- K. W. Kuechenreister, Supervisory Engineer, Nuclear Construction S. M. Hogan, Quality Assurance Engineer H. W. Mulliwood, Qua11cy Assurance Daniel International Corporation (DIC)
- H. J. Starr, Project Manager
- A. D. Arnold, Project Quality Manager
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- D. E. Stites, Project Quality Control Manager
- J. A. Holland, Project Piping Manager J. R. Lee, Piping P. Van Nort, Quality and Technical Services
- M. K. Smith, Audit Response Coordinator D. Dunning, Civil Quality Control Supervisor J. Pasley, Subcontract Surveillance Engineer INRYC0 Incorporated J. Herbst, Construction Supervisor
- Denotes those atterating the exit interview.
Licensee Action on Previous Inspection Findings (Closed) Noncompliance 483/80-22-01: The licensee was cited for not class-ifying heat sink rip-rap as safety related in the PSAR. Additionally, the material test results were not available for onsite review by the Region III inspector. The heat sink rip-rap has since been re-classified as safety-related and appropriate changes have been effected in contract documents and the PSAR. Also, material and test records have been reviewed by the Region III inspector for the slope protection materials.
(Closed) Noncompliance 483/80-22-02: The licensee was cited for placing approximately 800,000 tons of granular fill material without adequate density test controls. Subsequently, the licensee accomplished extensive testing oa the material. The results of this testing substantiates that the original design proctor densities werc conservative and the inplace fill was adequately densified during placement.
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(Closed) Unresolved Item (483/80-11-04): Soil density test records did not provide space to record as-placed loose lift fill thicknesses. DIC Procedure QCP-102, Eyhibit D has been revised to allow recording of per-tinent lift thicknese data.
(Closed) Unresolved Item (483/80-22-04): Records concerning licensee /
contractor audits of site soil activities could not be produced during the inspection. Records of planned and systematic audits which were conducted by the licensee and his contracter (DIC), concerning site soil activities, were reviewed.
Functional or Program Areas Inspected The inspection consisted of a review of post tensioning quality records, observation of work activities and review of installation procedures.
Details of the inspection are documented in the following sections of the report.
Containment Post Tensioning A.
Review of Quality kecords 1.
Installation. Buttonheading, Stressing, and Greasing Records of installation, buttonheading, stressing and greasing were reviewed for 10 vertical and 18 horizontal tendons. Specific records were reviewed for Tendons V29, V31, V33, V35, V37, V39, V41,
V43, V44, V46, IAC, 3AC, SAC, 7AC, 9AC, 11AC, 13AC, 17AC, 19AC, 21AC, 23AC, 25AC, 3CB, SCB, 7CB, 9CB, 11CB, and 13CB.
All records were complete and documented appropriate QA/QC inspection and review.
2.
Measuring and Test Equipment Calibration The calibration / verification records of the following equipment were reviewed:
a.
Jack Gauges: N230 and N223 (both calibrated by Forney No. 2 Master Gauge). The Forney No. 2 gauge was calibrated March 17, 1981 to Heise Digital Indicator No. 57-5233 in the INRYC0 Melrose Park plant, then reverified for accuracy October 1, 1981 at the Callaway job site.
b.
Heading Machines: 8815, 8816, 8817, 8818, and 9010.
c.
Dial Indicators:
ECC16 and ECC20.
d.
GO-NO-GO Gauges:
BH-52, BH-58, BH-84, BH-85, BH-86, and BH-87.
e.
Feeler Gauges: F17, F21, F22, and QC-24.
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Micrometer:
Q.C.24.
g.
Thermometers: T22A, T23A, T24A, T27, T28, T29, CAP-11, PK25, PK31, and PK32.
The review verified each item was properly calibrated at frequencies set forth in INRYC0 Field Installation Manual, Chapter 9, Section 4.
3.
Receiving Inspection of Tendons and Components The Receiving / Storage inspection documentation for Tendons V3, V7, V19, V25, V33, V37, V44, V62, V66, V68 and two lots of anchorages and shims was reviewei.
All records were complete and documented appropriate QA/QC inspection check points.
4.
Grease Shipments Receiving and test records were reviewed for the following lots of petroleum materials:
a.
Visconrust 1601 Amber, Batch Nos. 01191 and 81R169.
b.
Visconrust 2090P-4 Nuclear Grade Casing Filler, Lot Nos. 2492, 2733 and 2819.
The Region III inspector verified that the records properly docu-mented appropriate physical and chemical properties and that the materials were certified in accordance with Bechtel Specification 10466-C157.
5.
IKRYC0 Training Training and qualification records of post tensioning production personnel were reviewed as follows:
a.
Tendon Installation:
24 persons, trained to the requirements of Chapter 5, Sections 1 through 13 of the INRYC0 Field Installation Manual (IFIM).
b.
Buttonheading:
27 persons, trained to the requirements of the IFIM, Chapter 7, Sections 1 through 12.
c.
Greasing: 21 persons, trained to the requirements of Chapter 8, Sections 1 through 9 of the IFIM.
The records provided satisfactory evidence that the training was conducted in accordance with IFIM, Chapter 9, Section 4.
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6.
UE/DIC Audit i,
A' joint audit of INRYC0 was accomplished during June and July of 1981 by UE and DIC. The audit was performed to verify compliance to post tensioning program requirements, as set forth in the following:
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~ INRYC0 Field Installation Manual, Revision 1.
a.
b.
Bechtel Specification 10466-C-156, Revision 6 (Technical Specification for Installation, Stressing and Greasing of Reactor Building Post Tensioning System Tendons).
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INRYC0 Field Change Request (FCR)-007-A.
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d.
Modification 06 to the Post Tensioning Contract between INRYC0
and UE.
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10 CFR 50 Appendix B, Criterion V, VII, VIII, X, XII, XIII, XV, XVI and XVII.
The records indicate a comprehensive in-depth audit was accomplished.
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B.
Observation of Work Activities j
On November 4, 1981, during an inspection of the tendon gallery, the
Region III inspector observed that space heaters had been placed in the vicinity of Tendon V42. Licensee personnel stated that during the i
routine greasing of Tendon V42, difficulties had arisen which precluded
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the completion of the greasing operations. The tendon was subsequently
detensioned and heaters had been set up in the tendon gallery in an j
attempt to melt the solidified grease in the partially filled sheathing.
I Inryco is performing the repair work in accordance with the recommended disposition specified by NCR 2SN-4624-C.
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The recommended disposition provides two methods (A and B) which can be-j used to effect the necessary repairs. Method "B" involves the drilling
of a 15/8 inch hole through the dome concrete in order to puncture the i
sheathing, thereby allowing grease injection into Tendon V42.
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The Region III inspector is concerned that in the event Method "B" is
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l employed, the tendon wires may be damaged. This concern was discussed with licensee representatives and is considered open for review during
i a subsequent inspection.
(50-483/81-23-01)
Open Items Open items are matters not otherwise categorized in the report, that require
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-followup in a future inspection.
The open items disclosed during this inspec-
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Lion is discussed in Section B. of this report.
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' Exit Meeting.
The inspector met with licensee' representatives (denoted under Persons Contacted)
and conducted an exit meeting at the' conclusion of the inspection on November 6,
.1981.
The inspector summarized the purpose and findings of the inspection. The licensee acknowledged the findings reported herein.
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