IR 05000546/1980036
| ML19345A740 | |
| Person / Time | |
|---|---|
| Site: | Marble Hill |
| Issue date: | 10/20/1980 |
| From: | Gallagher E, Hayes D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML19345A736 | List: |
| References | |
| 50-546-80-36, 50-547-80-36, NUDOCS 8011250062 | |
| Download: ML19345A740 (9) | |
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U.S. NUCI. EAR REGULATORY C0teilSSION
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OFFICE OF INSPECTION AND ENFORCEMENT
REGION III
Reports No. 50-546/80-36; 50-547/80-36 Docket Nos. 50-546; 50-547 Licenses No. CPPR-170; CPPR-171 Licensee:
Public Service of Indiana Post Office Box 190 New Washington, IN 47162 Facility Name:
tiarble Hill Generating Station, Units 1 and 2 Inspection At: ?!arble Hill Site, Jefferson County, IN Inspection Conducted:
October 6 - 9, 1980 7*'
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E. J. Gallagher
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Approved By:
D. W. Hayes, Chie
/O 2o So Engineering Support Section 1 Inspection Summary Inspection on October 6-9, 1980 (Reports No. 50-546/80-36; 50-547/80-36)
Areas Inspected: Review and evaluation of construction verification pr ogram No. SPP-13, Category I Concrete Pour Packages, Concrete Constituent flaterials and Embedded Metals Records Review, and related corrective action reports.
The inspection involved a total of 24 inspector-hours by one NRC inspector.
Results:
No iteras of noncor.:pliance were identified.
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DETAILS
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Persons Contacted Public Service of Indiana (PSI)
- L. Ramsett, Quality Assurance Manager
- W.- M. Petro, Project Director
- C. Beckham, Quality Engineering Manager
- G. Warner, Superintendent Civil Quality Engineer
- D. B. Ingmire, Construction Verification Coordinator
- T. R. Burns, Project Engineering Manager
- T. D. Geib, Project Licensing Engineer
- M. Juvick, QA Administrative Assistant NRC Personnel
- J. Harrison, RIII Resident Inspecto,r
- E.
Schweibinz, RIII Project Inspector
- Denotes those in attendance at the exit meeting on October 9, 1980.
Functional or Program Areas Inspected 1.
Construction Verification Program Final Report (SPP-13)
The purpose of the inspection was to perform a review and evaluation of Section 12.0, entitled, Category I Concrete Pour Package, Concrete Constituent Materials and Embedded Metals Records Review of the PSI Construction and Material Verification Program Final Report, transmitted to the NRC by the PSI letter of September 12, 1980. The review and evaluation consisted of a review of the acc.eptance criteria established in special process procedure SPP-13, a review of the licensee's findings during implementation of the procedure, and an evaluation of the correc-tive action reports.
The inspector concluded that Section 12.0 of the PSI Construction and Material Verification Program Final Report is complete in identifying the records and material deficiencies and provides acceptable corrective action dispositions with the exception of CAR No. PC-0469 which is discussed in paragraph 3 of this report.
In most cases the corrective action can not be completed until after resumption of Category I work activities. The inspector identified to the licensee, differences between the established acceptance criteria and code requirements as discussed in paragraph 2 of this report.
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2.
Review of Special Process Procedure SPP-13 The initial review of SPP-13, regarding Category I concrete pour packages, concrete material and embedded steel records review was documented in previous NRC Inspection Report No. 546/80-21; 547/80-21, paragraph 2.
A further review of SPP-13, Revision I was performed to verify that it included appropriate acceptance in reviewing the concrete data packages. The following comments were brought to the attention of the licensee.
SPP-13, Attachment 6.18, (acceptance criteria for water) specifies a.
the maximum chloride ion (ASTM D512) content te be 500 ppm.
ASME B&PV Code Section III, Division 2, Article CC-2223 specifies a maximum limit on chloride ion in mix water to be 250 ppm.
In addition, AC1 318-71, commentary Section 3.4.1 states, "that chloride ion greater than 400 or 500 ppm might be considered dangerous and ACI Committee 222, Corrosion of Metals in Concrete, recommends that levels well below these values be maintained.
The inspector indicated to the licensee that the acceptance limit in SPP-13 is unacceptable and without code basis. However, the actual chloride content in the mix water used at ::arble Hill has been tested and found to be below the 250 ppm code limit.
This item is considered open pending licensee review and response (546/80-36-01; 547/80-36-01).
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SPP-13, Attachment 6.14, (Acceptance Criteria for Cement Material)
indicates cement strength (ASTM C109) to be minimum of 1500 psi in three days and 2500 psi in seven days.
ASTM C150-77 (and currently 1980) requires cement to be 1800 psi in three days and 2800 psi in seven days. The licensee indicated that the values established are in accordance with ASTM C150-73. The RIII inspector indicated to the licensee the most current industry standard for quality of cement and requested that consideration be given to revising the specification to improve the quality of the material being supplied.
SPP-13, Attachments 6.10 and 6.12 provide the acceptance limits c.
on slump and air content for concrete mixes. The inspector requested the concrete mix design qualification records in order to verify that the mixes were qualified at the extreme limits.
ACI 318-71, Section 4.2.2 which requires mix designs to be developed using the extreme slump and air content permitted by the construction specification. The licensee indicated that the requirements of ACI 318 had not been met, however, CAR No.
PC-0193_had identified this deficiency. The original mix designs had been approved by Sargent and Lundy Engineers.
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CAR No. PC-0193 was reviewed by the RIII inspector.
It was i
determined by the inspector that Sargent and Lundy Engineers'
technical justification for acceptance was not acceptable.
The technical justification given was that the average concrete strength produced to date is above the minimum strength required.
This disposition does not address the qualification of concrete strength at the extreme limits. The " average concrete strength" to date is a composite of the entire range of air content and slump limits, not extreme limits.
The disposition does not demonstrate that at extreme limits the required strength can be achieved. The licensee's representative indicated that a CAR PC-0193 would be ammended to address the deficiency identified and failure to comply with ACI 318-71 building code requirements for mix design qualifications. This item is considered open pending a review of the licensee's revised disposition.
(546/80-36-02; 547/80-36-02)
3.
Review of Corrective Action Reports (CAR's)
A review was performed of corrective action reports identified by the licensee during the review of concrete pour packages in order to determine whether each finding had been correctly identified and to evaluate the adequacy of the corrective action to be taken.
Implementation of the corrective action for a number of the CAR's is to take place after resumption of safety-related work activities.
Table 1 attached to the report provides a summary of the CAR's identified by the licensee in implementing SPP-13. The table also provides whether corrective action has been implemented as of this inspection and the RIII inspector's evaluation of the adequacy of the corrective action report.
The identified corrective action of CAR No. PC-0469 relative to inadequate curing records for concrete placements was determined by the RIII inspector to be unacceptable as written.
The proposed resolution was to perform a rebound hammer nondestructive test (Swiss llammer Test) on the surface of the concrete to demonstrate the in place material provides adequate strength.
Procedure QCP-10.10 has been developed to implement this program. The inspector indicated that the rebound hammer test would not be adequate to demonstrate in-place concrete strength.
The licensee's representative committed that a revised response would be provided to amend paragraph 12.3.4.2.4 of Section 12 of the Construc-tion Verification Program. The response was to include an evaluation of concrete core compressive strength results on placements for which adequate curing could not be verified. This item is considered open pending a review of the licensee's revised disposition.
(546/80-36-03; 547/80-36-03)
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Corrective Action Report Nos. PC-0716 and PC-0719 could not be com-
pletely reviewed since the required documentation from the reinforcing steel supplier and air-entraining admixture supplier.had not been furnished at this time. These items are to be reviewed at a subsequent inspection. (Sh6/80-36-ok; 547/80-36-0h and Sh6/80-36-05;. sh7/80-36-05 reppectively.).
Corrective Action Report Nos.-PC-0722 and PC-0731 relative to cadweld test frequencies and cadwelder qualifications were reported in accordance with the requirements of 10 CFR 50.55(e). Final report was received i-by RIII on September 29, 1980 and refers to the final report and evaluation of SPP-6 of the Construction Verification Program.
The final report for SPP-6 (cadwelds) is currently under review by RIII NRC office. Final NRC evaluation of the related CAR's will be
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resolved asfpart of this review.
Exit Meeting
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The inspector and the RIII resident inspector met with site staff representa-tives (denoted under Persons Contacted) at the conclusion of the inspection on October 9, 1980. The inspector summarized the scope and findings of the inspection.
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Attachment:
Table 1: Review of corrective action reports for SPP-13
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0 TABLE 1
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Car No.
Description Corrective Action Implemented Remarks PC-03/2 8 concrete Yes; spec. revised to take corrective placements samples each 100 cu. yards action where compress-acceptable ive strength samples not taken at required frequencies PC-0373 43 slump tests Yes; concrete samples of each Corrective exceed spec.
excessive slump concrete meet action requirements concrete strength required acceptable; technical justification acceptable PC-0380 Documentation Yes; entry corrected Corrective error in one pour action package acceptable PC-0469 410 concrete No; (180 day after restart)
See placements that licensee proposed to use inspector's records do not nondestructive tests (Swiss comments on provide evidence Hammer Test) to demonstrate test program that concrete was adequate strength in paragraph properly cured 3 of this report PC-0470 Errors in Yes; calculation corrected on Corrective calculation of data sheets action concrete acceptable compressive strength; and test frequency PC-0660 Sampling Yes; review of previous and Corrective frequencies for subsequent tests found acceptable action in process tests on acceptable fly ash material not met PC-0661 Sampling Yes; review of previous and Corrective frequencies subsequent tests found action for in process acceptable acceptable tests on cement material not met i
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CAR No.
Description Corrective Active Implemented Remarks
PC-0692 Clerical error; Yes; report corrected to Corrective incorrect ASTM identify mix water test as action reference.for ASTM C191 acceptable mix water test PC-0715 Incorrect weight Yes; error on data report, Corrective of No. 11 corrected on weight of bar; action reinforcing'bar; retest for elongation meets acceptable out-of-spec.
ASTM A615 requirements elongation for No. 11 bar PC-0716 Documentation not No; Newburg to obtain Open, pending available to documentation from steel review of demonstrate testing supplier documentation; of reinforcing planned steel each 50 tons corrective per heat of steel action acceptable PC-0719 Air-entraining No; Newburg to obtain Open, pending admixture CMTR documentation from admixture review of did not conform supplier documentation; to spec.
planned requirements corrective action acceptable PC-0722 Test freouencies Yes Reported in for testing accordance with 50.55(e);
review of final report on SPP-6 to resolve cadweld issue PC-0724 Concrete placed Yes; actual samples of out-Corrective which exceeded of-spec. material tested and action slump, temp.,
determined to meet strength acceptable and air content requirements PC-0726 Grout material Yes; spec. Y-2722, Sect.
Corrective not tested 414.1 revised to specify action test frequency for grout acceptable material-2-
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Description Corrective Action Implemented Remarks
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PC-0731 Cadweld test Yes Reported in frequencies for accordance production splices with 50.55(e);
not met review of final report on SPP-6 to resolve cadweld issue PC-0367 Missing information No (180 days after restart)
Planned on records action acceptable PC-0368 Clerical Yes Corrective action acceptable PC-0369 Documents missing No (90 days after restart)
Planned from data packages action acceptable PC-0370 Clerical Yes Corrective action acceptable PC-0371 Illegible entries No (90 days after restart)
Planned on records action (clerical)
acceptable PC-0374 Incomplete data No (90 days after restart)
Planned packages action acceptable PC-0375 Incorrect No (90 days after restart)
Planned entries in action pour packages acceptable PC-0376 Incomplete No (90 days after restart)
Planned documents action acceptable PC-0377 Missing No (90 days after restart)
Planned approval action signatures acceptable PC-0378 Data on No (90 days after restart)
Planned records action i
cut off acceptable during reproducing-3-
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CAR No.
Description Corrective Action Implemented Remarks
PC-0379 Nonconformance No (90 days after restart)
Planned report not action referenced in acceptable data package
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