IR 05000508/1982006
| ML20052J010 | |
| Person / Time | |
|---|---|
| Site: | Satsop |
| Issue date: | 04/22/1982 |
| From: | Albert W, Dodds R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V) |
| To: | |
| Shared Package | |
| ML20052J003 | List: |
| References | |
| 50-508-82-06, 50-508-82-6, 50-509-82-03, 50-509-82-3, NUDOCS 8205240307 | |
| Download: ML20052J010 (29) | |
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. . U.S. NUCLEAR REGULATORY COMMISSION
REGION V
50-508/82-06 Report No.
50-509/82-03 Docket No.
50-508/50-509 License No. CPPR-154, -155 Safeguards Group Licensee: Washington Public Power Supply System P. O. Box 1223 Elma, Washington 98541 Faci 1ity Name: WNP-3/5 WNP-3/5 Construction Site Inspection at: Inspection conducted: March 1-31, 1982 , 4-/2 2/F-2._ Inspector: Date Signed W. G. Albert, Senior Rer.ident Inspector Approved by: b /d ZZ[P2-J R. T. Dodds, Chief, Reactor Projects Section 2 Date ' Signed ' Reactor Construction Projects Branch Summary: Inspection during March 1982 (Report Ncs. 50-508/82-06 and 50-509/82-03) Areas Inspected: Routine unannounced inspection by the resident inspector of construction activities on Unit 3 and layup of Unit 5.
Included were licensee
l actions on construction deficiencies reported to the-NRC (10 CFR 50.55(e)) and licensee action on items of noncompliance and unresolved issues; welding of reactor coolant pressure boundary piping and other safety related piping; concrete placement and preparations; electrical cable tray observations and preventive maintenance systems for control of stored equipment in the Unit 5 Reactor Auxiliary Building.
l The inspection involved 105 inspection hours onsite by one NRC inspector.
, Results: Of the principal areas inspected, one item of noncompliance was identified l in the preventive maintenance systems for Unit 5 equipment (paragraph 7).
I \\ l - 8205240307 820426 PDR ADOCK 05000508 G PDR L
.__ _ - . DETAILS 1.
Persons Contacted The inspector interviewed various engineering, management, in-spection, and construction personnel of the organizations listed below.
Key personnel, including those who attended the exit interview are specifically identified below: a.
Washington Public Power Supply System (Licensee or Supply System)
- R. S. Leddick, Program Director, WNP-3/5
' T. Beers, Quality Assurance Engineer N. F. Blaise, Senior Project Quality Engineer D. R. Coody, Project Quality Engineer
- R. A. DeLorenzo, Program Director WNP-4/5 Termination
- C. E. Love, WNP-5 Termination Manager
, N. C. Kaufman, Project Start-up Manager D. J. Lagrou, Engineering Supervisor R. J. Marzano, Chief, Site Security J. A. Puzauskas, Quality Assurance Engineering Supervisor
- E. L. Stephens, Senior Project Quality Engineer s
C. H. Tewksbury, Quality Assurance Surveillance Supervisor
- 0. E. Trapp, Project Quality Assurance Manager
- J. A. Vanni, Senior Project Quality Engineer J. M. Walker, Senior Quality Assurance Engineer (corporate office)
b.
Ebasco Services, Inc, (Ebasco) R. E. Abel, Project Quality Engineer L. A. Bast, Quality Assurance Engineering Supervisor A. M. Curtona, Quality Program Site Manager P. Gosselin, Resident Engineer A. W. Hahn, Warehouse Supervisor - M. R. Harris, Project Quality Engineer
J. W. Hassett, Project Quality Engineer W. J. Lear, Nondestructive Examination Specialist
- R. G. Peck, Project Quality Engineer
.' c.
Combustion Engineering (CE) W. G. Douglass, Nuclear Site Manager W. Pratt, Site Representative d.
Peter Kiewit & Sons Inc. (PKS) T. Miller, Equipment Maintenance Supervisor , S. Scott, Quality Control Supervisor T. Smith, Equipment Installation Supervisor E. Tosh, Quality Assurance Supervisor l . _ . . _ _ _ _ _ > . . -2-e.
Morrison-Knudsen (MK) R. Polley, Lead Quality Control Inspector f.
Morrison-Knudsen/ESI/ Lord (Joint Venture) H. Bironski, Project Welding Engineering Manager W. Holcombe, Project Quality Assurance Manager T. Kirkland, Training Manager L. Murray, Welding Superintendent K. Souder, Project Quality Control Supervisor J. Sowers, Project Quality Director A. Walcutt, Project Quality Engineering Supervisor
J. A. Jones Inc. (JAJ) , J. Jeatran, Quality Verification Supervisor G. Wickliffe, Project Quality Assurance Manager h.
State of Washington (State) G. Folta, Deputy Boiler, Inspector R. Miller, State Electrical Inspector
- Designates those attending exit interview on March 31, 1982.
2.
Independent Inspection and Tours Daily tours of s9me portions of the Unit 3 construction site were normally conducted by the resident inspector during each on-site work day. Tours during this month included the Ranney Wells, haul road, and barge slip area.
Tours of Unit 5 included observations of that equipment selected as a random sample for examination of the prevention maintenance systems. Although this sampling resulted in one item of noncom-pliance as described in paragraph 7 below, the tours, per se, did not reveal any canditions of safety significance.
3.
Project Construction Status - Unit 3 At the end of the report period, project site construction had reached 50% completion.
Concrete placement for the roof slabs at the 463' level (highest roof) of the Reactor Auxiliary Building (RAB) had started.
Initial installation of electrical penetrations began during the month.
4.
Licensee Organization Change On March 9,1982, the licensee announced that a Director of Projects i had been named to whom the Program Directors for WNP-1, 2, and 3 i i - - - - ., - --,,
._.
- - _ - ~ . 'l ' -3-now reported, rather than reporting directly to the Managing Director of the Supply System, as was done previously.
5.
Licensee Action on 10 CFR 50.55(e) Construction Deficiencies
a.
Concrete Consolidation in Shear Wall of Reactor Auxiliary Building, Placement ABW-19-21, 428.50 The final report of the NRC's consultant retained to provide physical evidence of the structural integrity of the repaired wall, has been forwarded by the task contractor, Parameter Inc. of Elm Grove, Wisconsin. This report, numbered CECL-0347, is acceptable to the NRC with the exception of attachment 6 which does not accurately depict the repaired areas of the wall.
The consultant's report is incorporated in this report as an appendix. The consultant's report was previously discussed i with the licensee with regard to one area of the wall which
produced lower sound velocities and thus provided less evidence of concrete integrity.
(See IE Inspection Report 50-503/80-02).
As a result of these discussions, the licensee undertook additional investigation of the wall in this questionable area by the drilling of two 1-1/4" core holes to a depth of 40".
They were drilled at the approximate locations of test points 4-E and 4-D as described in the consultant's report.
The holes were cored in the south face of the wall at a down angle of 11* to facilitate repair of the holes. Hole 4-E was located 31" east of the intersecting wall and 111" above the floor.
Hole 4-D was located 33-1/2" east of the intersecting wall and 88" above the floor. The location of the holes in relation to the original area of repair in this section of the wall is shown in the figures on page 5.
Figures 1 and 2 illustrate the south face of the wall in the area of concern.
At the time of these two photos, the wall had been chipped back to sound concrete. The reinforcing steel on the left of figure 2 is that of the intersecting wall.
Concrete had not been placed in the intersecting wall at that time.
Figures 3 and 4 illustrate the location of the cored holes.
At this location the wall was 54" thick. Therefore, the 40" depth of the holes explored the wall through to the outer reinforcing steel curtain on the north side of the wall. The north side of the wall had also been chipped back and repaired in this area and hole 4-D penetrated into what appeared to be repair material.
The cores removed from 4-D showed good bonding of the repair to the base concrete. The cores removed from hole 4-E did not produce significant information because of difficulties with coring equipment.
On March 16, 1982, the cored holes , were examined using a fibre optics borescope. This examination ,
~ ... -
- -,, -. - - - - -,,,, _,, , -. - -,, , .,, _-. -,
' . , -4-was performed by the NRC resident inspector, Ebascc Quality Assurance ard Etasco Resident Engineering.
The inspection revealed that the concrete was generally sound throughout the 40" depth of the cored holes.
No voids exceeding 1" in dimension were noted, with the majority of the discontinuities being of " popcorn" size.
Distance between discontinuities was sufficient to preclude their interference with the structural soundness of the wall.
Based on the previously submitted reports of the licensee, the.
examinations of repairs and repair methods, the report of the . NRC's consultant (attached) and the results of the coring, it is concluded that the disposition of this deficiency'is^ satisfactory. The item is closed.
6.
ActiononPreviogyUnresolved, Follow-up,andEnforcemeniItems a.
(Closed) Follow-up Item (50-508/81-08/01)(50-509/81-08/01) Time to Achieve QA Program Consistent _with Actual Operations During the team inspection.of April 13-23, 1981, the NRC stated that the failure of the licensee to support the documented quality program with the needed changes to policy and procedure documents in a timely fashion constituted a significant weakness in management performance. The majority of these changes were necessary because of the new division of responsibility between the licensee and the construction manager (Ebasco).
In response, the licensee stated in his letter of October 30, 1981 that although updating of all the remaining affecting procedures had not been completed at the time of the April 13-23, 1981 inspection, a comprehensive program to assure timely completion, consistent with the new organizational structure, had been established and implemented.
During the month, the inspector examined the current status of Project Site Procedures (PSPs) against the status of these procedures as shown in the Supply System's revised program of August 18, 1981, titled " ASP / PSP Manual Conversion Plan Update." ASPS are being phased out and only a few affecting non-quality related activities remain.
The inspector accounted for procedure deletions and additions by tracing coverage of the functions included.
A sampling from the actual procedure file was checked against the PSP status report on revisions dated February 10, 1982 and found to conform. The inspector found that quality affecting procedures had been revised and implemented to confonn with the latest PSAR deviation (WP-28) by October 15, 1981. The Supply System had stated in their letter to the NRC of October 30, 1981, that the work was accomplished by the date of that letter. This item is close ~ pT ~*. yyur==m e--2 6 cgf p . ---a,_ b [.M [)gW p k ph k h hy a '
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i m, p . ' {$ _ _ _ - ' Fig. 1 - Aug 1981 Fig.:2 - Aug 1981 Hole 4-0 would be located Shows general view of the area approximately as shown by of concern after removal of red "X" unsound concrete.
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y% ' <, h ^ yys i& mu m ~i _& " m , Fig. 3 - Mar 1982 Fig. 4 - Mar 1982 Holes 4-E and 4-D circled.
Holes 4-E and 4-D circled.
"T" shaped trenches were cut in Protrusion from each hole is the wall to positively locate rolled burlap.
outer rebars prior to coring.
USNRC Photos
, -6-b.
(Closed) Unresolved Item (50-508/81-08/02)(50-509/81-08/02) Project Quality Assurance Manager Reporting Relationship In IE Report No. 50-508/509/81-08, the NRC questioned the lack of a direct reporting relationship between the site and the corporate Quality Assurance Director, stating that this has the potential for nonuniform administration of the quality assurance program and policy. The NRC noted that the PSAR states that the corporate Quality Assurance Director is responsible to develop and administer the corporate quality assurance program for the Supply System.
The item was to be further examined by the NRC.
The relationship between the site quality assurance organization and the corporate quality assurance organization was examined during the month by the NRC resident inspector. The object of this examination was to establish the extent to which the corporate quality assurance organization oversees and controls the program and activity of the project quality assurance organization. The following was established: (1) The corporate office conducts yearly audits of the project quality assurance program.
Further, the corporate office maintains an on-site resident quality assurance engineer for conducting audits, investigations, and surveillance as directed by the corporate office.
Currently, this individual is also responsible for administering the licensee's " hot line" program which is a system that allows any individual to register anonymous complaints about quality control matters or the admini-stration of the quality assurance / quality control programs.
The functioning of the " hot line" program has been examined periodically by the resident inspector.
(2) The corporate office examines and concurs in all com-munications to the NRC concerning matters of enforcement or deficiency reporting (10 CFR Part 50.55(e) and Part 21).
However, minor changes to the content of submittals, dealing with such matters as dates for completion, do not receive concurrence from the corporate office.
(3) Project Site Procedures (PSPs) apply to the activities of many diverse organizational elements. Those PSPs con-trolling the activities of the Supply System site quality assurance organization are approved.by the corporate office.
(4) The corporate office reviews and concurs in all deviations to the quality assurance program as described in Section 17 of the PSAR. The inspector questioned the absence of corporate review of section 3 deviations relating to
I . . . l-7-i changes in the quality classification of equipment and structures. The licensee stated that although no such 1 - changes had been made, it was the licensee's intent to include these among the changes examined by the corporate '
office.
Instructions regarding this would be clarified.
(5) The corporate office certifies all audit team leaders for Supply System quality assurance organizations.
(6) The corporate office reviews and concurs in all Quality Assurance Instructions (QAls). -These instructions control the activities of the licensee's site quality assurance organization.
, (7) The corporate Quality Assurance Director holds regular (usually monthly) meetings with the site Quality Assurance Managers and in addition examines quality assurance , problems on-site periodically.
_ (8) The site Quality Assurance Manager's. monthly report'is also submitted to the Corporate Quality Assurance Manager as well as the Program Director.
Based on the examination of the above items, it appears that the reporting relationship established for the WNP-3/5 Project Quality Assurance Manager is satisfactory in the framework of existing management controls. The item is closed.
c.
(Closed) Noncompliance (50-508/81-08/05) Ebasco Control i j of Measuring and Test Equipment I In a letter of August 19, 1981, the licensee stated that the '. disposition of the item had been to recneck the torque wrench for the loading range previously used and establish that it was within limits while being used in the damaged condition.
Regarding corrective action, the licensee stated that the procedure governing the issuance of tools had been clarified ' and that training was conducted.
The inspector reverified the disposition by examination of calibration reports.
Corrective action was verified by examination of Rev. I to procedure PSP-MM-11-9. Training in the revised procedure was verified from existing records. The item is closed.
! d.
(0 pen) Noncompliance (50-508/81-08/18) (50-509/81-08/18) . Failure to Bend Reinforcing Steel as Required by Specification i In the reply of August 18, 1981, the licensee committed to the l following corrective actions with regard to this item:
(1) procedure revision, (2) craft training, (3) marking of field bending pins, and (4) provision of a set of templates in ' the field.
, !
. -8-In the examination of this item, the inspector found that Morrison-Knudsen procedure CP-15 had been revised, craft and quality control training records indicated that the necessary training was accomplished, field pins had been marked, and that a set of templates was available for measuring bend diameters. However, the inspector found that the same pin was used to bend both #4 and #5 reinforcing steel and that 180* bends with this pin on #5 reinforcing steel resulted in diameters of bend which did not match the template provided.
The inspector also examined the " accept-as-is" disposition of bars which had been bent prior to corrective action being taken. The " accept-as-is" disposition was based on the results of pull tests of embedded reinforcing steel.
Surveillance reports of this item by both the Supply System and Ebasco were examined.
This item remains open because the inspector has questioned the efficacy of corrective action which permitted the one size of bar (No. 5) to be bent to a diameter smaller than the templates provided for field use.
Ebasco, in turn, stated that the matter was covered by overriding specification requirements which required the No. 5 bars to be bent smaller in order to provide adequate concrete cover in smaller wall sections. At the end of the report period, documentary follow-up was still incomplete. The item remains open and the subject of the adequacy of corrective action is unresolved.
e.
(Closed previously) Follow-up Item (50-508/81-10/03) (50-509/81-10/03) WS-Employee Freedom to Express Quality Concerns In paragraph 3.g of IE Inspection Report 81-11, the licensee had made a commitment to seek an i1RC legal opinion with regard to the Wallace-Superior employee instruction which had sub-sequently been addressed in a court decision.
At the request of the licensee, the resident inspector reviewed this with regional personnel and informed the licensee that the commitment was no longer considered active because of the court action and the matter should be dropped.
See IE Inspection Report No. 50-508/82-01 for actual close-out of this item.
l f.
(Closed) Unresolved Item (50-508/82-02/01) f1K/ESI/ LORD - Control l i of Nonconforming Conditions - Procedure FQP 15.1 ! During the past two report periods, the resident inspector had ! i found instances in which the use of the tagging provisions of l procedure FQP 15.1 had been misunderstood by Joint Venture personnel. Although no specific instances had been found in ' which misuse of the tags adversely affected safety related { l. _. - . - . l _g_ equipment, it did appear that the potential for working through nonconformance report hold points existed because personnel did not understand the use, meaning, and application of the various tags (NCR, Prohibited Work, Permitted Work and ' Conditional Release).
Because of these observations by the NRC inspector, a procedure change had been made which assured that hold points on travelers included those associated with l nonconformance reports. Also, the licensee committed to providing training on this subject to all joint venture personnel "down to the foreman level" by March 17, 1982.
During the month, the inspector confirmed that 122 joint venture personnel were provided with the training. Monitors reported a definite class interest in understanding the system. The item is closed.
7.
Extended Construction Delay - WNP-5 On March 25, 1982, the NRC resident inspector initiated an ex-amination of the system and records which controlled the inspection and preventive maintenance of equipment stored in the Unit 5 Reactor Auxiliary Building. To determine system effectiveness, the inspector selected seven items of equipment as follows: ~ North and South Motor Driven Auxiliary Feedwater Pumps . North and South Turbine Driven Auxiliary Feedwater Pumps . " Let Down Heat Exchanger . North and South Shutdown Cooling Heat Exchanger (SDCHX) . The inspector was informed that custody of these seven items was with PKS. An examination of PKS procedure CP-1, " Care and Main-tenance Instruction Procedure" and equipment specific procedures, WI-A-131, WI-A-133, WI-B-109, and WI-B-101 for the equipment in the sample, showed that the procedures covered the manufacturer's specifications, Ebasco requirements, and met ANSI N45.2.2 where applicable.
An examination of the actual records for the equipment revealed the following: (1) PKS had no record for care and maintenance of the SDCHXs since June 1980 when the custody of these units had been returned to . Ebasco because of a need for rework by the nimnufacturer, Ametek Inc.
(2) Records were not readily retrievable without the direct involvement of the single individual responsible for the administration of the system.
-. - -- . - --
. -10-(3) Certain care and maintenance tasks are assigned to another contractor (Fishback and Moore). The task assignment sheets had been returned with only the notation "0K" and date.
Although the basic PKS system appeared to be functioning in a satisfactory manner, the current absence of the SDCHXs from the system could not be explained by PKS since PKS stated that custody of this equipment had not been turned back to them after rework by the manufacturer and return to the site.
The inspector next examined the records of the Combustion Engineering site representative and determined that the two SDCHXs had been returned to the site on August 26, 1981 at which time there had been a deliberate interchange of the SDCHXs between Unit 3 and 5 in order to expedite construction.
CE records showed that the North SDCHX had been turned over to Ebasco on September 18, 1981 and the South SDCHX was turned over on February 23, 1982.
CE has no system for performing routine inspection and maintenance although CE personnel stated that they did monitor.the condition of equipment still in their custody and they would request Ebasco to perform any maintenance necessary.
Ebasco warehouse records showed that they had received custody of the North SDCHX on December 10, 1981, nearly three months after CE records showed the equipment turned over to Ebasco.
Further, Ebasco records show that the North SDCHX was turned over to PKS (Row #8858) on January 26, 1982.
ihere was no record of the North SDCHX in the Ebasco care and maintenance system.
The South SDCHX is recorded as having been received by Ebasco on February 24, 1982 but was not entered into the Ebasco care and maintenance system until NRC inquiry was initiated as described herein.
All seven items of equipment were examined in the field. To the extent which could be observed, no deviations from manufacturer's care and maintenance instructions were noted.
The absence of specific preventive maintenance control over the two Shutdown Cooling Heat Exchangers by any of the three site organizations responsible for their care and maintenance during the seven months following their return to the site on August 26, 1981, is considered to be a violation of 10 CFR Appendix B Criterion XIII, Handling, Storage and Shipping.
Noncompliance (50-508/82-03/01).
8.
Electrical Cable Boxes ! On March 19, 1982, the NRC inspector was advised by the electrical inspector for the State of Washington that he had found certain
deficiencies in boxes which are used to convey wire from one cable ' tray to other cable trays.
l l l
. . -11-These deficiencies were examined as well as the documentation and proposed disposition. The NRC inspector determined that problems were being addressed but questioned the absence of a nonconformance report for controlling the observed deficiencies.
NCR No. 14275 was subsequently prepared which addresses the questions raised by the State inspector. The State will observe the resolution of those deficiencies and advise the NRC regarding any further con-cerns.
9.
PKS Weld Material Control PKS procedure WI-701, " Filler Metal Control," was examined against the criteria of ASME Section IX, Ebasco Specification 884-WA-80 and AflSI N45.2.2 (Reg. Guide 1.38).
Questions from the examination were discussed in a meeting between the NRC, licensee, and Ebasco and satisfactorily resolved.
Field observations of weld rod withdrawal indicated conformance to the PKS procedure as did the daily records available in the one rod issue room examined.
No items of noncompliance were identified.
10.
Reactor Coolant Pressure Boundary Welding The periodic surveillance of machine welding, preheat, interpass temperature, and material controls was continued by the resident inspector during the month.
No items of noncompliance were identified.
11.
Safety Related Structures - Contract 263 - Morrison-Knudsen Questions were addressed by the NRC resident inspector with regard to the inspection criteria used by MK inspectors for reinforcing steel lap splices. The NRC observed that most Ebasco drawings provided a table which specified lap length while a few did not.
Ebasco personnel later stated that where splice length was not specified by drawing, it was left to the detailer to insure that the necessary development length was available in the bars as cut and bent by the supplier. Therefore, the splices per se were not to be inspected by MK quality control personnel, but rather they were to simply assure that the identified reinforcing steel of the detail drawing was properly located. This opened the questions as to why some drawings did specify lap length and quality control personnel were inspecting all floor splices for the proper lap and why detail drawings were being used for final acceptance.
The matter of inspection criteria for splice development will i remain open pending follow-up by the inspeJor.
Follow-up item (50-508/82-06/01).
i
l . -12-12.
Safety Related Structures - Contract 265 - J. A. Jones Procedures for quality control of structural steel were examined and discussed. The inspector noted that JAJ procedure, WE-WP-4, " Handling, Storing, and Erecting Structural Steel," did not address a provision of the governing AISC specification which required the measurement of the " nut turn" to produce minimum tension in the periodic setting of job inspection torque wrenches. The inspector also noted that the system for records did not provide a general inspection checklist which addressed the erection of the steel and the fit of structural steel members (system'was completely oriented , tojoints).
These items were discussed with JAJ personnel. JAJ initiated-changes which will be followed by the regional based inspector as part of other examinations concerning JAJ structural steel work.
No items of noncompliance were identified.
13.
Unresolved Items Unresolved items are matters about which more information is required to ascertain whether they are acceptable items, items of noncom-pliance, or deviations. An unresolved item disclosed during the inspection is discussed in paragraph 6.d.
14.
Exit Interview On March 31, the NRC inspector met with the WNP-3/5 Program Director and other members of his staff. The items of this report were either suninarized or referenced to the weekly discussions.
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. .:.:.v -- .. CECL# 0347 February 22, 1982 APPENDIX USNRC REPORT N0.
50-508/82-06 i FINAL REPORT OF , SONIC TESTING OF CONCRETE ' FOR l PARAMETERS, INC.
13380 Watertown Plank Road < Elm Grove, Nisconsin 53122
PROJECT: Washington Nuclear Project No. 3 Elma, Washington SCOPE OF SERVICES: Provide the NRC Office of Inspection and Eiiforcement, Region V, Nondestructive Sonic Testing Services, ~ e of concrete structures at subject plant to determine the consolidation and integrity of the structures.
STFUCTURES TESTED: Auxiliary Builfing, wall identified as ABW-OlT/62T 4~2E5 and Auxiliary bailding, wall identified as ABW-5/7-428.5.
< DATE OF TESTING: November 9 through November 23, 1981.
l ! CONTACT: Mr.
W.
G. Albert, NRC Senior Resident Inspector at WNP-3.
ATTACIIMENTS :
- 1 - ABW-019/021-428.5 - Sonic Data
- 2 - ABW-5/7-428.5 - Sonic Data
- 3 - ABW-5/7-428.5 - Plan Detail 84 - ABW-109/021-428.5 - Plan Detail
- 5 - ABW-5/7-428.5 - Coordinate Sketch
- 6 - ABW-19/021-428.5 - Coordinate Sketch
' 97 - Oscilloscope Curves comparison -
- - _ - _ _ _ -- _. - _- , -2- - . . GENERAL The sonic test method was in accordance with ASTM C-597.
This method was the pulse through method of sonic testing using A James Electronic "V" meter.
Time measurements are made of the travel of a pulse or train of waves through a measured path length using a sending transducer on one side of the concrete surface and receiving transudcer on the other side.
A Tektronics oscilloscope a was used as an adjunct to observe the shape of the curve produced, smooth curve results when the sound passes through monolithic a and sound concrete.
An irregular curve or a straight line is pro-c - duced on -no oscilloscope when a defect is encountered.
The oscilloscope contains a memory feature so ' hat a curve of a good t velocity can be compared with any questionable readings.
A sample e photograph is shown in Attachment #7.
The velocities determined in this method are a measure of the soundness of the concrete along the path line.
Voids and cracks of significant size will interrupt the transmission so that either no velocities can be determined or i the void is circumvented and will then produce a significantly , lower velocity.
Other factors that may severely interfere with the transmissions are dense reinforcement (many interferences), surface roughness and subsurface micro cracking.
Therefore, evaluation of the data must include an allowance for these con-
' ditions.
A two foot grid was placed on the walls and all readings were taken as shown in Attachments #5 and #6.
Readings that could not be taken because of interferences such intersection walls, plates, openings and/or chip' ped concrete surfaces are indicated as "N/A".
i TEST 4RITERIA , l t he wall ABW-019/021-4 28. 5 was severely honeycombed during
. construction.
The wall was repaired in accordance with an l l approved procedure.
The sister wall, ABW-5/7-428.5, was placed subsequently with corrective actions to provide for complete con-solidation and the visual examination after form removal indicated (I proper integrity.
,? '. i , .
, v --4 - -. -- - . . - - _ _. _ _ - - _ _ _ -. . , - _ -.
_ _ _ _ __ _ , -3- - . . . TEST CRITERIA (CONTINUED) : < The sonics test procedure was used on both walls to provide a comparative analysis as well as establishment of integrity by ' individual velocity determinations.
Generally, velocities in the j magnitude of 10, 000 to 14,000 ft./sec. are considered evidence i of dense-void free concrete for this type of highly reinforced . $ concrete structure.
I EVALUATION: The sister wall ABW-5/7-428/5 had a mean velocity of 13,799 , ft./sec. and a standard deviatian of 1064 ft./sec, which results l, in a coefficient of variation of 7.7%. As shown on Attachment #3, ll ' the west end portion was not tested because it was not considered necessary for the comparative purposes.
The velocities were in ' .. a general range of 11,000 to 13,000 ft./sec.
There were three it isolated grid points where velocities could not be determined.
'j Two of the grid points, 38-A and 42, were near the bottom construction i joint.
It is our opinion that the lack of reading was due to either j ' surface roughness or dowel congestion.
Velocity of the other point, 28-C, could not be determined.
This may be due to the causes given in the general discussion such as subsurface micro-cracking or congested rebar interfaces.
In any event, the overall consolidation
< I is considered good because more than 95 percent of the grid points I indicated high velocities.
The repaired wall ABW-019/021-428.5 had a mean velocity of l t 12,496 ft./sec. and a standard deviation of 1067 ft./sec. which
results in coefficient of variation of 8.5%. The velocities in a general range of 10,000 to 13,000 ft./sec.
There were were
three isolated grid points where velocities could not be determined, l-22-D, 26-E and 36-B.
Since these are isolated, it is our opinion that they are not significant and may be the result of subsurface micro-cracking or congested rebar interfaces.
Also, since velocities at more than 95% of the grid points could be determined, the over- ' all quaiity of the concrete is considered acceptable.
However, there was an area, grid points 4-E and 4-D, where signficantly , - _. - _,, - - -. - - , _, __- -
-4- . EVALUATION (CONTINUED) : lower velocities were produced.
This was in the general area of a penetration and embedded plates which may have affected con-solidation.
Therefore, this area requires more investigation and analysis.
The evaluation of the data and relative good uniformity of sonic readings indicates that there are not major voids or dis-continuities in either wall.
c h oepy p! Artuso RESIDENT, C.E.C., INC.
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