IR 05000528/1976004

From kanterella
Jump to navigation Jump to search
Insp Repts 50-528/76-04,50-528/76-04 & 50-530/76-04 on 761214-17.Violations Noted:Concrete W/Slump Exceeding Spec 13-cm-101 Used in Reactor Pit Basemat & Change to Drawing 13-C-FA S-116,DCN 5 Not Distributed
ML20134B280
Person / Time
Site: 05000000, Palo Verde
Issue date: 01/18/1977
From: Kirsch D, Pate R, Spencer G
NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V)
To:
Shared Package
ML17198A269 List: ... further results
References
FOIA-84-293 50-528-76-04, 50-528-76-4, 50-529-76-04, 50-529-76-4, 50-530-76-04, 50-530-76-4, NUDOCS 8508150574
Download: ML20134B280 (12)
v • d • e


Text

.-

_ _ _-

-_.__.__

- _-

_ _. -

_ -. -.

-.

__. - _

-.._. -.-_- __

.-

.

.

.

.

U. 5. h.t EAR REGUI.ATORY COMMISSION

'0FFICE CT INSPECTIoM AND ENFORCEMEN*

.

REGION Y

'

-

i

+

.

IE Inspection Report No. m. : >,' en.c9e en_ew nc-04 Arizona Public Service Company Docket No.50-528. 50-529, Licensee gge..goM.141.142,

'

P. O. Box 21666 143

,

Phoenix, Arizona 85036 Priority

.

A Palo Verda Unit Nos.1, 2 and 3 category

,

Facility Location _ i4aricopa County, Arizona PWR's (CE), 3800 MWt

!

Type of Facility Routine, Unannounced Type of Inspection

_

i December 14-17, 1976 Dates of Inspection

,

September 21-24,1976 Dates of Previous Inspection

.

///7

/

.,

'

Principal Inspector

-

'

/ Date R. J.'Pate, Reactor. Inspector

/-/ f "/

,

-

.

Accompanying Inspectors Date

/

D.'I.*Mrsch,'ReactorInspector

!

L Date

,,

other Accompanyir.s Personnel:

G. 5. Spencer Chief, RC&E5 Br.

O

M

'

if Reviewed by '

>

' Dett G.5. Spencer, Chief,ReactorConspuctionand Engineering Support Branen IE V Foru 219

-

0508150574 050703 i

PDR FOIA

-

LEIGHTD64-293 PDH i

!

.

.

r:

t

-

..

- _ _ - _

-

--

-_

..

. _ _

_. -

".

E SUMMARY OF FINDINGS

"

Enforcement Action 1.

Concrete with slump exceeding the requirements of the Specification No. 13-CM-101 was placed in the Unit No. 1 Reactor Pit Basemat (Lift 1C010-0) contrary to the requirements of Criterion XV of 10 CFR 50, Appendix B.

(Paragraph 4.b.(1)ofDetails)

'

'

2.

The frequencies of testing conerete materials at the placement was less tnan required by the Specification No.13-CM-191 for the Unit

'

No. 1 Reactor Pit Basemat (Lift 1C010-0). This is contrary to criterion V of 10 CFR 50, Appendix B.

(Paragraph 4.b.(2)ofDetails)

3.

The change to Drawing 13-C-ZAS-116. DCN No. 5, was not distributed to the work stations as required by the Bechtel Procedure WP/P 3.0 and Criterion VI of 10 CFR 50, Appendix B.

(Paragraph 8.bof Details)

Licensee Action on Previously identified Enforcement Items The Engineering Testing Laboratory (ETL) QA program had been audited by Bechtel including the equipment calibration records and the qualification records of ETL personnel.

Bechtel personnel stated that the audit l

disclosed that satisfactory corrective action had been taken on these items.

However, the audit report had not been issued and was not available for the inspector's review.

This item will remain open.

(No reference)

,

Otner Significant Findinas A.

Current Findines All significant current findings are included in Enforcement Action.

B.

Status of Previously Reported Unresolved Items The following items which were identified during the previous inspection (neportNo. 50-528/76-03) have been closed.

1.

Champion QA program ard implementation.

(Paragraph 3.aof Details)

i 2.

United-Metro, Inc. QA program and imp?ementation.

(Paragraph 3.b l

ofDetails)

l l

3.

Special precautions for concrete curing in hot weather.

(Paragraph 3.c.(3) of Detatis)

.

!

L

.

.

.

e 2-4.

Sof rust on the rebar in the auxiliary building.

(Para-graph 3.d of Details)

The items which remain open from the previous inspections (Report

,

Nos. 50-528/76-01 and 50-528/76-03) are listed below.

1.

Training records of construction personnel including field engineers.

(Paragraph 3.e of Details)

2.

Provisions for unplanned cold joints.

(Paragraph 3.c.(1) of

Details)

Truck dischar 3.

Sanple location for slump measurement.(Paragraph 3.c.(1), (2) and (3)

'

pump line discharge.

)

,

4.

Use of water with 400 ppm chloride ion content.

(Paragraph 3.c.(2)ofDetails)

5.

Improper filing of quality related records.

(Paragraph 3.fof Details)

Manace?.ent Interview The results of the inspection were discussed with Mr. Van 8 runt and other members of the APS staff on December 17, 1976. The following items summarize the discussion at the exit meeting.

A.

Tne status of previously identified unresolved items was reviewed.

Tne inspector noted the itams that were closed this inspection and briefly discussed the items that remain open. Most of the dis-cussion centered on the adequacy of tne Bechtel procedure for control of unplanned cold joints.

The licensee's management personnel stated that a review of concrete cold joint procedures would be conducted.

(Paragraph 3.c.(1) of Details)

The followup of the enforcement items identified in the ETL QA

.

B.

program will be based, at least in part, upon the Bechtel audit results.

These results were not available.

Therefore, the follow-up of these itras will be completed during a future inspection.

(ho reference)

C.

The inspector noted that the response to Circular 76-02 was over-due.

The licensee's management personnel stated that a response was being prepared and would be mailed in the very near future.

l (No reference)

!

l

.

l

!

.

.

--

- -

-

-

. -

. _ _. _

._ __

.

_.

.

.

-

.

.

-3-D.

The drawing enange, DCH No. 5, to drawing 13-C-2AS-110, Revision 4 was not distributed to the work stations as required.

The licen-see's management personnel stated that corrective action would be j

initiated.

(Paragraph 8.b of Details)

E.

The deficiencies identified regarding control of nonconforming I

,

concrete and concrete sampling frequencies were discussed.

The licensee's management personnel stated that these deficiencies l

would be reviewed and corrective action initiated.

(Paragraph 4.b t

of details)

F.

An item regarding QA and QC review and concurrence of nonconformance resolutions, previously identified by the licensee, was discussed.

The licensee's management personnel stated this item would be resolved.

.

.

e O

l '

l.

- -.

-.

-

.

',

'.

DETAILS 1.

Persons Contacted Arizona Public Service Com:any (APS)

E. E. Van Brunt, Jr., Vice President, Construction Projects and ANPP Director J. A. Roedel, Quality Assurance Manager R. Hand, Site QA Supervisor

-

.

D. D. Webster QA Engineer W. M. Petro, Site Manager Bechtel Power Corporation (Becntel)_

C. Betzhcid, Project QA Engineer

-

J. Maqbool, QC Engineer R. Caldwell, QC Engineer W. F. Sturm, Civil QC Engineer J. Schweers, Civil Constructicn Superintendent A. K. Priest, Project Field Engineer M. Arambel, Field Engineer H. P. Smith, Project Field QC Engineer R. L. Lyknes, QC Engineer D. Wendelle, Concrete Superintendent F. E. Schack, QC Engineer

-

, J. Pfunder QA Engineer D. E. Orcutt, Civil Eng'ineering Superintendent V. Nienstedt, QC Engineer

. L. E. Purcell, Lead Civil Field Engineer E. C. Avila, Warehouse Supervisor R. R. Rosen, Document Control Supervisor F. Hamilton, Carpenters General Foreman C. C. Baker. Carpenters Fereman M. Krei:enbeck, Electrical Superintendent G. Maynard, Electrical General Foreman R. Schumitz, Electrical Foreman A. E. Dunckel, QC Inspector N. Weber, Site Advisor - General Environment J. Dyer, Assistant Field Engineer Champion, Inc. (Chamofon)

P. Halott, QC Engineer K. C. Holman, QC Engineer Encineers Testing Laboratory (ETL)

R. White, Level II Examiner

r o

r-

'

.

.

.

-5-FURG)

D. M. Duffy, Project Engineer V. X. Shupe, Engineering Technician Field Supervisor 2.

Project Status The construction progress was reported as indicated below:

Activity

% Complete

.

Large Pipe Installation

Concrete Placement

Reinforcing Bar Installation

-

Ground Cable Installation

Conduit-Non-metallic Installation

Excavation

3.

Followup of Previously Identified Unresolved Items Champion OA Program and Implementation a.

The Champion QA Program that had been approved by Bechtel on

-

November 3, 1976..was examined.

The inspector noted that Champion had established the duties and responsibilities of

.

.

the QC engineer, a training program, and a system of planned and periodic audits. Also, the batch plant recertification intervals had been changed to conform to the specification re-quirements.

No deficiencies were noted.

Champion has had two Level II examiners on site, but the number had been reduced to one due to attrition.

Champion representatives stated that arrangements had been made with ETL for a backup Level II examiner until a Champion replacement arrives on site and can be certified. The records of certifica-tion for the Champion and ETL Level 11 examiners were examined and appeared to be satisfactory. This item is closed, b.

United Metro, Inc. 0A Program and Implementation A Bechtel audit of United Metro activities, performed on October 13, 1976, was reviewed. Areas aucited included nonconforming material, material identification and segre-gation, and inspection personnel certification.

The audit appeared to be satisfactory in both scope and finding resolu-tion.

The records of qualification and certification for United Metro personnel were examined and appeared satisfac-tory.

This item is closed.

.

w. -

- -.

- - -.

- -.

.

-. -

- -

- -

.. - -

- _ _ _ _ _ _ _. _ - _ _ _. - - - - _ _. - -. _. - _ _ -. _. _ - _. _ - _ _ _ _ _ _ _ _ _ _.. _ _ _ _ _. _... _ - - - _ _ _ _. - _ _ _ _ _ _ _ _. -. _ -. _,

-

. _ _ -.

-

.-

'

.

.

.

.

.

i-6-c.

Bechtel CA Ieptementino Procedures for Containment (Structural Concrete)

The following specifications were examined and appeared satisfactory except as noted.

(1) Specification No.13-CH-101. Furnishina and Deliverino Concrete

.

A Sechtel study has determined that a backup batch plant to preclude unplanned cold concrete joints is unwarranted.

The bases cited by the study are the availability of sufficient spare parts on site, age and operating condi-tion of the equipment, the implementation of a preventive

-

maintenance program, experience at other nuclear construc-tion sites and the assumption that Bechtel can properly

'

form a cold joint.

AnexaminationofAttachmentC(Cold Joint Detail) to Specification fio.13-CM-305 resulted in the following concerns:

.(a) The maximum and minimum angles of the existing concrete to the horizontal are not specified.

'

(b) The questionable validity of the implication that the Specification 13-CM-305, Attachment C detail

.

.

provides adequate resolution for all cold joint locations.

(c) Attachment C is applicable to construction joints in

,

slabs and does not address joints in walls or joints exiting in the vicinity of embedments.

(d) Paragraph 8.6 of Specification 13-CM-305, requiring the 'mplementation of Attachment C. contains no requirement to document the conconforming joint or perform an engineering analysis of the cold joint.

(e) The cold joint detail did not properly implement the requirements of the ASME P&PV Code Section !!!,

Division 2, Paragraph CC-4252.

Licensee personnel indicated that a review of the cold joint procedure would be conducted to determine its adequacy. This is an unresolved item.

,

.-

_

__-

.

.

,

,

-7-The inspector noted that Specification 13-CM-101 (para-graph 0.11.3.5) requires that samples for concrete slump be taken at the point of truck discharge.

An apparent inconsistency exists in the specified sample location for pumped concrete slump as. required by this specification and Specification No.13-CM-305.

(See discussion of Specification No.13-CM-305, Item 3.c.(3) below. ) This item is open.

(2) Specification No.13-CM-191, Testino of Concrete.

Materials anc Reinforcino Steel Bechtel representatives stated that approval of the request for code case allowing water of 400 ppm chloride ion content to be used as concrete mixing water, nad not been received at the site. All water used in concrete for Category 1 structures had been trucked from Phoenix, Arizona. This item is open pending verification that the request for i. ode case has been approved by ASME and accepted by NRC.

' Paragraph 15.1.3 of this specification requires that the sample for slump measurement be taken at the " transport discharge" The licensee's representatives stated that this is interpreted as the truck discharge.

This require-

"

'

ment is inconsistent with Specification No.13-CM-305 (Seeparagraph3.c.(3)below). As this specification and not specification No.13-CM-305 is included in the contract between ETL and Bechtel for testing services, this inconsistency requires resolution.

(3)

Specification No.13-CM-305. Concrete Preplacement, Placement and Postplacement An examination of this specification and WP/P-QC1 54.0 (Concrete Postplacement Procedure) disclosed that adequate This precautions for hot weather curing are specified.

item is closed.

,

Also,the inspector noted that paragraph 19.3 of this specification had been enanged to incorporate the re-quirements of ANSI N45.2.5, paragraph 4.8, to sample pumped concrete for slump measurement at the pump line discharge. This specification was apparently ch.nged as a result of concern identified in Inspection Report 50-

'

528/76-03.

However, the inspector also noted that specifications No.13-CM-101 and No.13-CM-191 had not

!

'

been changed to conform to the requirements of ANS!

l N45.2.5.

Both of these specifications require the sample

'

for slump measurement be taken at the truck discharge instead of the pump line discharge.

.

. -. -

,, - -.

-,. -. _ - - -, -. -

n

- - - -

-.,., - - -,

-,.

, - - - - - -. - -..,.

-

~

'

.

.

.

a 8-d.

Site Dewatering

.

Bechtel personnel stated that the water was removed from the Unit 1 auxiliary building sumps and the reinforcing steel (rebar)hadbeencleaned. The Construction Inspection Data Report (CIOR) for preplacement was complete including the verification tnat the rebar was satisfactorily installed.

This item is closed.

,

The ground water monitoring program was reviewed.

The moni-

.

"

toring records disclosed that the water level in the Unit 2 excavation wds dropping.

However, the recedence may not be sufficient to lower the water below the 882 foot level (bottom of auxiliary building sump) within the excavation schedule.

The dewatering program for Unit 2 will depend on the rate the

'

water recedes and has not been established.

e.

Training of Construction personnel

,

The audits conducted about September 16,1976 by Bechtel of the construction personnel training activities (Nos. S-76-30, 5-76-31, 5-76-32 and S-76-33) were reviewed.

The audit

' records indicated these audits were complete and the correc-tive action had been verified by audit S-76-43.

However,

-

audit S-76-43 addressed the training activities of the OC

,

,

i ers and not the construction personnel. Apparently, a eng):w~ ding error, that was not discovered during the management recor review, prevented the required re-audit to verify the correc-tive action was taken. This item is open.

.

f.

Improper Filinc of Quaf f ty Related Records In a previous inspection APS identified that some of the quality related records had been improperly filed.

This item was held open last inspection (Report No. 50-523/76-03) pending completion of the records review by the licensee.

Followup of

.

this item must be done in the project engineering office.

The engineering office was not visited this inspection.

This item will be held open for a future inspection.

4.

Containment (Structural Concrete}_

a.

Observation of Work and Work Activities Concrete placement activities were observed for the Unit No.1 Reactor pit Basemat (Lift IC010-0) and Unit 1 Tendon Gallery Walls (Lif ts IC03-0 and IC04-0).

The activities inspected consisted of placement preparation, concrete delivery and placement, curing, aggregate and cement storage and batch plant operation.

No anomalies were noted.

I

.

.

.

f

_

'.

.

.

.

- 11 -

,

b.

Desion Engineerino Orawings Tnere are several locations (approximately eignt) on the site where a controlled set of design drawings are maintained in accordance witn WP/P-QCI 3.0.

When a change is made to a drawing, WP/P-QCI 3.0 requires tnat the revised drawing or enange notice be placed in the controlled sets.

Contrary to tnis requirement, the Design Change Notice (DCN) No. S to Drawing 13-C-ZAS-110 Revision 4, dated November 4, 1976, had not been distributed to the controlled sets as of December 16, 1976.

9.

Bechtel QA Audits The Bechtel 0A audit schedule was reviewed. Some minor record keeping errors were noted which were corrected by Bechtel. The audit schedule appeared satisfactory.

,

The records of the Bechtel audits were reviewed.

The audit planning, scope and documentation appeared to be satisfactory, except as noted below.

a.

  • The form entitled Quality Assurance Finding, No. LAO 0663(TP0)

6/76 had no space for signature of the initiator. The con-trolling procedure Quality Assurance Standards and Guide

'

'

'

Lines, Section 6.3 has no requirement for the initiator to sign the form. This deficiency was previously identified by Bechtel and wil1 be corrected in accordance with the QA Program,

_

i b.

The followup audit for the construction personnel training was erroneously marked complete.

(Seeitem3.eabove.)

'

10.

Structural Backfill The records for the backfill for three locations were reviewed including the sieve analysis for the backfill material and the

'

com; action test results. The areas that were backfilled were observed after the work was complete. The records for the follcwing areas were reviewed:

.

.

a.

Electrical Duct Bank Unit 1 first half ramp crossing b.

Tendon Access Shaft Mudmat c.

Auxiliary Building Ramp Unit 1 No nonconformances were noted.

.

.

- - - - - -

-

-

- -

- -

-.

-

..

- -

.-

- -

- -

.

.- -

- -

.

.

-

-

.

.. - -

.. - -..

.

.

-

-

.

'

.

,

.

b.

Review of Guaffty Records

-

The quality recoros concerning preplacemant preparation, concrete celivery and placement, concrete curing, rebar splicing, concrete materials and batch plant operation were examined for the Unit tio. 1 Reactor Pit Basemat (Lift IC010-0). The records appeared satisfactory, except as noted below.

(1) The inspector identified tnat concrete was placed on December 14,1976 with slumps above the maximum spac1-fied, including inadvertency margin, by Specification fio.

13 CH-101, paragraph 0.11.3.3.

Slump tests performed for trip ticket lios. 00611. 00622 and 00634 identified slumps of 4 3/4", 4 3/4" and C 1/4", respectively. The maximum allowable slump for 0-2 class concretc is 4 1/2", in-cluding inadvertency margin.

The nonconforming concrete was placed, contrary to 10 CFR 50, Appendix B, Criteria XV which requires that nonconforming materials be controlled to prevent tneir inadvertent use or installation.

(2) 'The inspector identified that the frequencies of testing of concrete materials at the placement did not conform to

,

specification requirements.

Specification 13 CM 191 (Testing of Concrete Materials) requires that testing for

'

'

air content, temperature and slump be accomplished once for every 50 cubic yards placed (Paragrapns 15.2.2 and 15.3.2,respectively).

The testing frequencies on December 14, 1976 for the Unit fio. 1 Reactor Pit Basemat (Lift IC010-0) were 63 cubic yards between trip ticket tios. 00604-00611; 72 cubic yards between trip ticket tios.

00626 00634 and 00694 00700n 99 cubic yards between trip ticket rios. 00636-00647; 81 cubic yards between trip ticket ilos. 00651-00660 and 00667 00676; and 90 cubic yards between trip ticket fios. 00703 00713.

,

,

Specification 13 CM 191, paragraph 15.4.6, requires that one set of three cylinders, for compressive strength tests, be formed for each 100 cubic yards of concrete placed.

Tne cylinder formation and testing frequencies on December 14,1976 for the Unit tio. 1 Reactor Pit Basemat(Lift 1C0100)were135cubicyardsbetweentrip ticket tios. 00611-00626 and 144 cubic yards between trip ticket tios. 00634-00650 and 00660 0007.

.

- 10 -

,

5.

Re:eivinq Inspection A tour of the QC storage yard and warehouse was conducted.

Attributes observed consisted of material identification, markings, segregation, area access control, <:leanliness and preservation. The procedure for Receiving Inspection (WP/P-QCI 4.0) was examined.

Material certifications for weld rod heat numbers 026926. N33793, N14203, 02L017 and No.18 Cadweld sleeves (Lot dos. 5874 and 5887) were examined.

No deficiencies were noted.

6.

0A Audits

.

Supplier audits by Champion, Inc. of Pacific Cement Co., Consock Inc., United Metro, Lassenite and W. R. Grace Co. were examined.

The audits appeared satisfactory with regard to planning, frequency, scope and finding resolution.

7.

Nonconformance Reports (NCR)

Examination of the NCR file disclosed that Project Quality Assurance personnel.did not sign for review and concurrence on NCR Nos. C-010, C 022 and C 034 and that Project Quality Control personnel did not verify remedial actions on NCR No. C-024.

ThePSAR(Section 17.18.1.6.2.A) requires that the Project Quality Assurance Engineer (PQAE)reviewandconcurinallNCR'sandthattheProjectQuality-

,

Control Engineer (PQCE) verify remedial actions on nonconformances (Section 17.15.1.1.4.E).

It was noted that Bechtel procedure WP/P-QCI5.0(NonconformingParts,MaterialsandComponents) requires tne PQAE to review and concur in only those NCR's dispositioned

" repair" or "use-as-is" and allows the field engineer to verify re edial actions in place of the PQCE, contrary to PSAR co nitment.

Licensee representatives showed that this item had been identified previously and tnat resolution was in progress.

8.

Occu*ent Control a.

Field Generated Desian Drawines The procedure for control of field generated design documents (WP/P 3.1) was examined and numerous field generated design

' documents were examined. The authorization, approvals and revision controls appeared to be in accordance with the procedure WP/P 3.1.

No deficiencies were noted.

l l

,

,

l

.-

-

-

,

Retrieved from "https://kanterella.com/w/index.php?title=IR_05000528/1976004&oldid=4234190"