IR 05000508/1979003
| ML19261D855 | |
| Person / Time | |
|---|---|
| Site: | Satsop |
| Issue date: | 04/18/1979 |
| From: | Albert W, Haynes R, Hutson T NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V) |
| To: | |
| Shared Package | |
| ML19261D850 | List: |
| References | |
| 50-508-79-03, 50-508-79-3, 50-509-79-02, 50-509-79-2, NUDOCS 7906260525 | |
| Download: ML19261D855 (11) | |
Text
.
U.S. tlUCLEAR REGULATORY COMMISSION
-
OFFICE OF INSPECTION AND EllFORCEMEllT 50-508/79-03 Report !!o.
50-509/79-02 50-508 CPPR-154
-
Docket No.
50-509 Licensee flo.
CPPR-155 Safeguards Group Licensee:
Washington Public Power Supply System P. O. Box 468 Richland, Washington 99352 Facility llame:
WNP-3 and WNP-5
-
Inspection at:
WNP-3 and WNP-5 Site (Satsop)
Inspection Conducted:
flarch 12-15, 1979 Inspectors:
heut M
Y//f[7[
W. G. Albert, (eactor Inspedtor Date Signed Wnh g//r/7'l T. W. Autson, tieactor Inspector Date Signed 3%n 9// W 7 7 P. P. Narbut, Reactor Inspector Date Signed Approved by:
fu,cm
f///
R. C. Nay' e'sgChief, Project Section, Reactor Date Signed n
Construction and Engineering Support Branch Sunnry:
Inspection during period of March 12-15,1979 (Report Nos. 50-508/78-03 and 50-509/79-02)
Areas Inspected: Unannounced routine inspection by regional based inspectors of construction activities including licensee corrective actions and followup of PTL -
deficient conditions; changes in site QA/QC' organizations; and structural concrete quality assurance procedure review, work observation, and record review. The inspection involved 73 inspector-hours onsite by three NRC inspectors.
Resul ts:
No items of noncompliance or deviations were identified.
2313 l96 7906260525 RV Form.219 (2)
.:...*,*-
-
-
.
.
DETAILS 1.
Persons Contacted Washington Public Power Supply System (WPPSS)_
- W. J. Talbott, Project Division Manager
- J. C. Lockhart, Project Quality Assurance Manager
- J. M. Walker, Senior Project Quality Assurance Engineer
- C. A. Cal, Senior Project Quality Assurance Engineer
- L. E. Nilsen, Quality Assurance Engineer
- E. L. Stephens, ~ Quality Assurance Engineer
- M. L. Joner., Project Engineering Ebasco Services Ins. (Ebasco)
- A. M. Cutrona, Senior Project Quality Assurance Engineer
- J. R. Sowars, Senior Project Quality Assurance Engineer
- J. P. Sluka, Engineering T. F. Tully, Quality Assurance Engineer J. R. McCutchen, Assistant Contracts Manager R. Potter, Contract Engineer M. Shannon, Contract Engineer N. Goodwin, Quality Assurance Engineer R. Jurbala, Quality Assurance Engineer L. Adams, Lead Principal Quality Assurance Engineer G. Zerbst, Principal Quality Assurance Engineer Morrison-Knudsen Company (M&K)
F. C. Edler, Project Quality Engineer D. D. Reader, Lead Quality Control Inspector R. B. Balthazor, Lead Auditor J. A. Williams, Senior Documentation Control Clerk Pittsburg Testing Laboratory (PTL)
M. R. Tallent, Jr., Site Manager M. A. Hudson, Assistant Manager Two Inspectors Guy F. Atkinson (GFA)
D. Summers, Quality Control Supervisor H. Hansen, Assistant Quality Control Supervisor 2313 197 F. Craig, Quality Control Inspector W. Graves, Quality Control Inspector P. McCarty, Msident Engineer
,...
.
-2-Boecon Fegles (B-F)
R. Davis, Assistant Quality Control Supervisor State of Washington
- G.Hansen, Engineer (EFSEC)
- Denotes those attending exit interview.
2.
Licensee Action on Items of floncompliance The licensee response to the following items of ncncompliance was examined:
,
a.
(0 pen) floncompliance (50-508/78-08-01):
Falsification of personnel qualification records by PTL.
This item will remain open pending receipt of an addendum to the licensee's written response on this item documenting the personnel corrective actions taken by the licensee.
b.
(Closed) Noncompliance (50-508/78-08-03):
Five initial set concrete tests and one concrete sampling procedure were performed by uncertified technicians.
The licensee response was summarized in WPPSS letter flo. G03-79-346 of February 26, 1979.
The recertification and reexamination of person-nel by PTL and the evaluation of the significance of the test results by engineering were examined and found satisfactory.
This item is closed.
3.
Licensee Action on Previously Identified Followup Items a.
(Closed) Revision and Issue of Concrete Management and Engineering Nonconformance Report Procedures 78-09-02)
The Concrete Management Procedure was revised and issued for construction on January 28, 1979.
The procedure for Site Engineering Disposition and Evaluation of Nonconformance Repcrts was issued on January 28, 1979.
The inspector had no further questions on this iten, b.
(Closed) Modification of Ebasco Frogram to Require More Comprehensive QA Audits 78-09-06 A revised procedure QAI-18-1, QA Audits, has been issued by the onsite QA organization. This procedure requires comprehensive audits dealing with implementation of the 18 criteria of 10 CFR 50, Appendix B, and takes a 2313 198
.
-3-systematic / programmatic approach to the area being audited. Audits 216-16 and 219-2 were reviewed to ascertain compliance with the scope, purpose and requirements of QAI-18-1. The inspector found that these audits met procedural requirements.
This item is closed.
c.
(Closed) Resolution of Audit Findings Regarding Guy F. Atkinson Co.
Concreting Activities 78-09-07 Responses from GFA to all 38 audit findings were evaluated by the licensee and either accepted and verified or accepted as of liarch 14, 1979.
All responses to audit findings impacting on the GFA concrete placements had been evaluated as acceptable and closed prior to any concrete placement in Unit 5.
This item is closed, d.
(Closed) PSAR Change Control Approval Form Revision (79-01-01)
Engineering Department Procedure 8.5, Attachment 5.1, has been revised to include review by the Project Engineering Manager.
All previously approved PSAR Deviations were reviewed by the licensee to assure that the required approvals were documented. This item is closed.
e.
(Closed) f4CR Requiring Further Concrete Tests was Improperly Closed 79-01-02 The inspector reviewed fiCR 242 and noted that the f1CR had been re-opened and entered on the computer listing of open fiCRs.
The two additional initial set tests on mix 4000.75N had been performed as required by the tiCR and accepted. The NCR was then closed. The inspector had no further questions on this item, f.
(Closed) Calibration of Unit Weight Buckets SE 120 and SE 121 (78-09-08)
The calibration of unit weight buckets SE 120 and 121 was reexamined.
Errors in the previous calculations had been corrected.
The buckets were now designated Uti-3 and UM-4 under a revised PTL calibration con-trol system. The inspector had no further questions and the item is closed.
g.
(0 pen) Corrective Actions on PTL Deficient Conditions (78-09-01)
The flRC inspectors reviewed an internal WPPSS memo of 12/01/78 which listed nine separate corrective actions concerning this matter. The corrective actions listed were:
2313 199
.
-4-(1) Requalify PTL site technicians under the surveillance of the Owner / Engineer.
(Closed - Ref:
IE Inspection Report flo.
50-508/78-09)
(2)
Recalibrate test equipment used at site.
(Closed - Ref:
IE Inspection Report tio. 50-508/78-09)
(3) Review soils test records.
(4) Completion of test records.
(5) Review / revision of PTL certification and training programs.
(6)
Development of a preventative maintenance / equipment repair program.
(7)
Evaluation of consequences of test performance by improperl,y trained personnel.
(8) Submittal of all test records to the project within one week of the test.
(Closed - Ref:
IE Inspection Report tio. 50-508/79-01)
(9) PTL Corporate QA increase frequency of audits.
In this listing, items (5) and (6) remaio open.
Examination of the open items during this inspection is described below:
(1) Since all PTL soils testing has been performed on backfill which is not safety related backfill (excavation ramps)
which will utilize soil cement and, therefore, will not be subject to the conventional soils density neasurements. This item is closed.
(2) The completion of test records was examined by the inspector.
-
flail basket records direct from the field were sampled and examined. Also, surveillance records of project QA person-nel were exanined. The inspector found that the records were complete. This item is closed.
(3) The review of revision of PTL certification and training programs was examined against the current PTL procedures (PQ-2). The PTL position was that the training certification program was never deficient in itself, but that problems arose because the program was not properly implemented. The licensee agrees with this posi-tion. The records of training / certification were examined 2313 200
.
-5-against a matrix showing the status of individual qualifica-tions.
It was apparent that the full review of training certi-fic.ation records was not completed.
The PTL manager stated that the review and cleanup of record deficiencies would be comp 1eted before April 1,1979. The item remains open.
(4)
PTL's conmitment to develop a preventive maintenance / equipment repair program was examined.
The PTL program was described in a letter of 12/07/78 from D. H. Perry of PTL. This communica-tion indicated that PTL preventive maintenance controls would normally be part of the individual procedures which were imple-mente_d at the time equipment is recalled for calibration; how-ever, the Forney testing machine would be subject to a separate preventive naintenance program. The inspector's examination of this showed that not all the individual equipment recalibration procedures had preventive maintenance requirements defined, nor did the inspector find a specific program which controlled per-iodic maintenance / inspection of the Forney testing machine. The item remains open.
(5) The evaluation of consequences af test performance by improperly trained personnel was address 6d in a report prepared by Ebasco and forwarded to WPPSS by a letter cated February 20, 1979. This report addresses potential variations in concrete temperature, air content, slump, compressive strength, unit weight, grout testing, and concrete materials.
The report was examined by the flRC inspector with particular attention to the compressive strength test results. The data from these tests had been reduced to provide coefficients of variation for the data and within test variation for double cylinder samples.
Comparison with ACI 214-78 shows that quality concrete has been produced consistently with satisfactory strength during the period when the qualifications of PTL inspectors were in question. Variables such as a problem with the Forney testing machine would distort results in a conser-vative direction. The inspector discussed the statistical treatment of the data with Ebasco engineers. All questions were satisfac-torily resolved. This item is closed.
(6) Closed previously - Ref:
IE Inspection Report flo. 50-508/79-01.
However, the inspector did examine a completed audit report by PTL Corporate QA. Also, a WPPSS-Ebasco audit report was examined.
Findings and corrective actions appeared satisfactory and the inspector had no further questions.
2313 201
.
-6-4.
Site QA/0C Oraanizational Changes a.
WPPSS-Ebasco Project Ouality Assurance Organization The Project Quality Assurance organization on the site was changed by adding the receiving inspection function.
Also, a "0A Engineering" organization was formed from appropriate functions and personnel in other branches of the QA organization. The inspector found that these organizations and personnel had sufficient organizational freedom and authority, to perform their quality assurance functions.
The inspector had no further questions, b.
PTL In order to strengthen concrete receiving inspection function, PTL has obtained five inspectors who are referred to as " concrete receiv-ing inspectors." These individuals are responsible for the accept-reject function at the point of concrete placement. They report to PTL administratively, but receive their operational direction from within the Project QA organization.
The PTL site laboratory manager now reports directly to the Pittsburg Corporate office rather than the Seattle district office.
5.
Structural Concrete a.
Morrison-Knudsen (1)
Review of Ouality Assurance Implementing Procedures The inspector reviewed the 18 procedures in the Corporate QA Manual corresponding to the 18 criteria of 10 CFR 50, Appendix B, 11 administrative instructions and four construction procedures to ascertain whether the quality program established by this contractor met PSAR commitments.
The Administrative Instructions (AI) are written by the site project organization to supplement the requirements of the Corporate QA Manual.
The administrative instructions reviewed included:
(a) AI-01: Material Control (b) AI-02:
Inspection Stamp Control (c) AI-03:
Procedure for Indoctrination of Supervising Personnel 2313 202
.
.
-7-
.
(d) AI-04:
Document Control Procedure (e) Al-06:
Nonconformance Reports (f) AI-07: Welding Material Control Procedure (g) Al-08: Tag Control Procedure (h) AI-09: QA Records Control Procedure (i) AI-10:
QA Indoctrination and Training Program (j) AI-ll : QA/QC Qualifications, Certifications and Training
, Program The construction procedures reviewed included:
(a) CP-01: Concrete Placement (b) CP-ll: Reinforcing Steel Installation and Inspection (c) CP-12:
Installation and Inspection of Embedded Items (d) CP-15:
Field Fabrication of Reinforcing Steel The site OA/QC organization and manning level were discussed with the Project Quality Engineer and it appears that sufficient qual-ified QC personnel are available to handle the present workload.
No items of noncompliance or deviations were identified.
(2)
Observation of Work and Work Activities The reinforcing steel laydown yard and receiving inspection area were toured by the inspector.
The accepted rebar was properly tagged and stored on dunnage as required by the applicable proce-dures. The laydown area was orderly and each release of rebar was roped off to further identify the bundles associated with the release and prevent the inadvertent use or movement of a wrong bundle.
The inspector observed that reinforcing steel for the Reactor Auxiliary Building outer walls was being laid out and preassembled for each placement on jigs.
By using the jigs, alignment and spacing of the rebar is accurate and within the tolerances esta-blished by CP-il, Reinforcing Steel Installation and Inspection.
No items of noncompliance or deviations were identified.
23i3 203
.
-8-(3) Review of Quality Records The inspector reviewed the following quality records for compliance with the M&K QA Manual, Administrative Instructions (AIs) and Construction Procedures (cps).
(a)
Biweekly Inspection Reports of Storage Areas from December 19, 1979 to March 2,1979.
(b)
Entry of changes and the latest revisions, including FCRs, in three controlled copies of Specification 3240-263 and three
' copies of the Als and cps.
(c), Sixteen Nonconformance Reports (total to date)
(d) QC Tag Issue Log (e)
Personnel Qualifications for two Level III and four Level II Inspectors (f) Qualifications of the Lead Auditor (g)
Personnel Indoctrination and Training Records for seven personnel (h) Calibrated tool list and calibration records for anrneter number 4200, vibrator number 12-14-78C, thermometers 27 and 28, and contact pyrometer 4674.
(i) Receiving Inspection Reports Nos:
R-10, Rebar; R-il, Anchor Bolts; R-17, Held Filler Metal; R-18, Rebar; R-20, Rebar; R-27, Nelson Studs; R-49, Rebar; R-64, Embeds; R-65, Embeds; and R-69, Embeds.
(j) Selected audit checklists and the audit schedule.
(k) Audits AI-04, No. 1 and QCM GEN-18/ ANSI N45.2.6, No. 1.
The inspector found that the Receiving Inspection Reports were not being completely filled out in that the applicable drawings used for receipt inspection and dimensional checks were not always listed. The reports on the rebar contain neasurement lengths and discussions with personnel confirned that dimensional checks were being used as acceptance criteria, however, the drawings or docu-mentation used as a basis were not being listed. The contractor stated that a training session would be held to instruct the re-ceiving inspectors on properly filling out the fonn. This item will be reviewed during a future inspection.
(50-508/79-03-01)
2313 204
-
.
'
-g_
6.
Containment Base Mat Structrual Concrete a.
Observation of Work and Work Activities The inspector examined the preplacement activities of form erection, reinforcing bar placement, and preparation of construction joints in Unit 5 containment base mat placement 5 BMS-013-335 to ascertain com-pliance with Guy F. Atkinson procedure GFAC0 CP-2 (Reinforcing Bar In-stallation) and GFACO CP-1 (Concrete Placement).
The inspector also examined curing for containment base mat placement 5 BMS-014-335 to ascertain-compliance to the requirements of GFACO CP-1.
No items of noncompliance or deviations were identified.
The inspector observed that an embedded vertical reinforcing bar dowel was bent during the positioning of a prefabricated reinforcing bar mat and a worker attempted to manually bend the bar back.
A nonconformance report was subsequently initiated on this item.
The licensee agreed to investigate the need for training construction personnel regarding bent rebar since ACI-318-71 requires specific engineering approval to bend (back) embedded reinforcing bar.
The inspector had no further questions on this matter.
An examination by the inspector af ring wall dowels for proper spacina (per plan WPPSS-3240-G2320) on placements 5 BMS 013-335 and 5 BMS-014-335 identified that the quality control inspector and the assistant quality control supervisor were uncertain as to the required rebar spacing. They stated that due to difficulty in interpretation of plan requirements for ring wall dowel spacing, the opinion of the resident engineer was relied on to determine acceptability.
The licensee agreed to followup on the contractor stated action to perform additional training of QC personnel regarding interpretation of plan requirements. The item will be examined during a future inspection.
(50-509/79-02/01)
b.
Review of Quality Records The quality records associated with Unit 5 containment base mat placements 5 BMS-004-335, 5 BMS-014-335 and Unit 3 containment base mat placements 3 BMS-013-335, 3 BMS-009-335 and 3 BMS-007-335 were examined for com-pliance with Specification No. 3290-415, Testing and Inspection Require-ments for Concrete Materials and Concrete.
The records examined included preplacement checkoffs, placement checkoffs, concrete testing records, cure records, truck trip tickets, personnel qualification records and nonconformance reports.
The quality records associated with Unit 3 Containment Structure slipforming operations for the first and second shift of February 11, 1979, were examined for compliance with Boecon-Fegles procedures CP 219-004, Construction Joint Preparation and Pre-placement Inspection, and CP 219-006, Concrete Placement and Inspection.
2313 205
-
-10-
-
Records reviewed included placement records, reinforcing bar and embed-ment records, mixing plant batch tickets, curing records, surface repair records, nonconformance reports, and plumb roundness and rotation data.
No items of noncompliance or deviations were identified.
7.
Exit Interview The inspectors met with licensee representatives (denoted in Paragaaph 1) at the conclusion of the inspection on !! arch 15, 1979, and summarized the scope and findings of the inspection.
.
2313 206