IR 05000518/1979009
| ML19246B419 | |
| Person / Time | |
|---|---|
| Site: | Hartsville  |
| Issue date: | 05/09/1979 |
| From: | Bryant J, Swan W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML19246B416 | List: |
| References | |
| 50-518-79-09, 50-518-79-9, 50-519-79-09, 50-519-79-9, 50-520-79-09, 50-521-79-09, NUDOCS 7907130443 | |
| Download: ML19246B419 (6) | |
Text
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UNITED ST ATES t '"80uq k
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Report No. 50-518, 519, 520, 521/79-9 Licensee: Tennessee Valley Authority 500A Chestnut Street Tower II Chattarooga, Tennessee 37401 Facility Name: Hartsville Nuclear Plants A & B Docket Nos. 50-518, 519, 520, 521 License Nos.:
JPPR-150, CPPR-151, CPPR-152, CPPR-153 Inspection at Hartsville Sit
.2ar Hartsville, Tennessee
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Inspector:
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Late Signed
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W. B. Swa Approved by:
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'ection Chief, RC&ES Branch Ifate Signed SUMMARY Inspection on April 17-20, 1979
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Areas Inspected This routine unannounced inspection involved 32 inspector hours onsite in the areas of Category I concrete; spray ponds; and steel structure and supports.
Results No apparent items of noncompliance or deviations were identified.
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DETAILS 1.
Persons Contacted Licensee Employees
- R. T. Hathcote, Project Manager H. S. Sheppard, Assistant Construction Engineer, Plant B
- G. A. Gonsalves, QA Supervisor
- J. W. Davenport, Civil / Materials QC Supervisor, Plant A W. W. Davis, Materials Engineer, Plant A M. B. Rodgers, Materials Engineer, Plant B
- A. G. Debbage, QA Audit Supervisor
- W. T. Quinn, Construction Engineer, Plant B
- W. R. Brown, Construction Engineer, Plant A
- L. H. Jackson, Assistant Construction Engineer, Plant A J. W. Henry, Supervisor, Mechanical QC, Plant B
- B. E. Huffaker, Civil / Materials QC Supervisor, Plant B G. England, DCU Supervisor, Plant A R. C. Nixon, Document Control Supervisor, Plaot B K. McLean, Project Geologist
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J. T. Dorman, Assiscant Construction Engineer, Second Shift R. L. Long, Materials Engineer, Plant A
- Attended exit interview
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2.
Exit Interview The inspection scope and findings were summarized on April 20, 1979, with those persons indicated in Paragraph I above. A second interview was held with the project manager and QA-QC people to acquaint the inspector with a licensee Cadwelding finding discussed in paragraph 7 below.
3.
Licensee Action on Previous Inspection Findings Not inspected.
4.
Unresolved Items
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Unresolved items were not identified during this inspection.
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5.
Independent Inspection Effort Inspection, review and discussion effort was expended in the following j
ways:
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Study of construction schedule for NRC inspection " windows".
a.
b.
Observation of work activities in auxiliary structures in Plants A and B power block areas.
c.
Inspection of completed work in raw makeup water inlet pumping station.
d.
Discussion of QA unit auditing record and schedule.
e.
Observation of placement of rebar and embedments in the B-2 power block structures.
f.
Inspection of the completed concrete floor for the B-2 aexiliary bcilding.
g.
Inspection of recently placed concrete floor mats for control buildings for Units A-1 and B-1.
h.
Inspection of completed placements in the containment shield wall of Units A-1 and B-1 and observation of forming for additional placements in these walls. The quality records for the completed placements were reviewed. The findings of this unassigne6 inspection ef fort are detailed in paragraphs 8 and 9 below.
6.
Lakes, Dams, and Canals - Observations of Work and Work Activities -
Spray fonds A-1, B-1, A-2, and B-2
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The inspector observed excavation of earth and Hermitage rock down to bedrock Carters limestone in the south portion of the basin for spray pond B-2.
This additional excavation was directed by TVA memorandum dated April 2, 1979, Russell to Hathcote, in response to the findings of geologic-soil engineer team's site visit on March 14, 1979. Criteria afor treatment of the rock exposed by this excavatien will be provided in a revision to the Hartsville Construction specification N6C-875.
The inspector observed curing operations on newly placed concrete for the base of the A-2 spray pond pump house and completed concrete place-ments for the pump houses of spray ponds B-1, B-2 and A-1.
Concrete quality for these pump houses and auxiliaries is being controlled by the Stride Specification and QC Procedures for other Category I concrete for the Hartsville Project.
No noncompliances or deviations were identified.
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7.
Containment (Structural Concrete I) - Basemat of Unit A-2 Follow on observations were made of preparations for the next placement, Pour A2R-1C, in the basement of Unit A-2.
These activities included forming for the periphery, placement of embed-ments, Cadwelding of vertical #18 shear rebars, and cleaning.
These operations are largely controlled by the construction drawings for rebar and embedments, by TVA Specification G-2, and by the Cadweld Manuf acturer's hanual.
No noncompliances or deviations were identified during these obser-vations.
At a second exit interview, requested by the licensee, the licensee revealed that a TVA quality control inspector had discovered an unacceptable deviation by a Cadwelding team for welds on the vertical
- 18 shear rebars.
When the welding team judged that insufficient fill had been achieved to permit acceptance of the weld by QC, the joint was removed by gas torch cutting off the sleeve without notice to QC, and a new weld was made with the same rebar and a new sleeve. Accepted procedure required that the faulty weld be removed by cutting the rebar above and below the veld. Replacement required a new weld using a longer upper length of #18 rebar. The improper weld had been discovered by the QC inspector when he noticed that deformations on the lower rebar had been removed by the cutting operation.
The. weld was removed and sliced
, longitudinally. This exposed additional cutting damage to the rebars.
The NRC inspector was told that two welders had been terminated and that
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all welds made by the team, siace 100 percent inspection during welding had been discontinued, would be examined and replaced if any indications of unauthorized cutting is found. A written report of findings will be made by the licensee.
8.
Containment (Structural Concrete II) - Observation of Work and Work Activities for Shield Wall - Units A-1 and B-1 For Unit A-1, completed shield wall placements AIR-2A and AIR-2B were inspected. The first placement had been made on December 12, 1978 and the second in two stages on March 8 and April 2,1979.
Placement A2R-2A for Unit B-1, placed on March 20, 1979, was also inspected.
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Forming and other preparations for an additional placement for each unit were observed.
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Visual inspection and review of quality records (detailed in paragraph 9) gave evidence that adequate quality control had been imposed during preparation for placement, manufacture, pouring and curing.
No noncompliances or deviations were identified.
9.
Containment (Structural Concrete II) - Review of Quality Records -
Shield Wall of Units A-1 and B-1 The pour cards and other quality records required by the specifications and by procedures C-201, C-204, C-208 and referenced ASTM-ACI Standards were reviewed. The records covered preparation for placement, mixing, delivery, placement, curing materials testing, batch plants A and B operation, qualification of inspection and test personnel, and auditing of testing. For Unit A-1, 510 cubic yards had been placed on December 22, 1978, Pour AIR-2A. Placement AIR-2B was made in two lif ts: 270 c.y. on March 28,1979 and 210 c.y. on April 2,1979.
The designated mix requires the attainment of 4,000 psi compressive strength in 90 days. Concrete cylinders f r om placement AIR-2A attained an average strength of 5510 psi at 90 days, 38 percent above requirement.
Three day test cylinders for the first lift of AIR-2B yielded an average t
only 1026 versus a minimum of 1100 psi required by the mix design.
The results of testing of cylinder sets at 28 days were:
Cylinder Set Strength
Number Attained 1514 2759;2759 1515 4138;4067 (Above reg'd. 90 day strength)
1517 2865;2900 1518 3325;3289 (In satisfactory range for 28 days)
Sets of 1514 and 1517 failed to meet desired strength at 28 days. A QCIR has been prepared for engineering evaluation if 90 days strength for these sets fails to reach 4000 psi. NRC follow up item 50-518/79-01 has been assigned on this matter.
The cylinders for the second lift of AIR-2B, made on April 2, 1979, had
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an average strength of 1821 psi, well above the target of 1300 + 200 psi.
For placement BIR-2A the 3 day strengths averaged 1385 psi and the 28 day strengths averaged 3348 psi; within the mix design curve values.
The reviewed records reviewed reflected adequate quality control.
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t-5-No noncompliances or deviations were identified.
10.
Containment (Structural Concrete I) - Review of Qaality Records -
Unit B-2 Basemat A partial repeat review was made of records of auditing and qualifications of batch plant QC inspectors. The preliminary report for audit If f-6-78-01 for concrete sampling and testing was reviewed. The final report is due May 4, 1979.
The qualification record for inspectors involved in concrete manufacture, placement and curirg shows that inspectors used in the first two basemat placements were qualified.
No noncompliances or deviations were identified.
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