IR 05000546/1981006
| ML20005B049 | |
| Person / Time | |
|---|---|
| Site: | Marble Hill |
| Issue date: | 06/02/1981 |
| From: | Hawkins F, Norton J, Williams C NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML20005B048 | List: |
| References | |
| 50-546-81-06, 50-546-81-6, 50-547-81-06, 50-547-81-6, NUDOCS 8107060259 | |
| Download: ML20005B049 (11) | |
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U.S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT
REGION III
Reports No. 50-546/81-06; 50-547/81-06 Docket Nos. 50-546; 50-547 Licenses No. CPPR-170; CPPR-171 Licensee: Public Service of Indiana Post Office Bcx 190 New Washington, IN 47162 Facility Name: Marble Hill Nuclear Generating Station, Units 1 and 2 Inspection At: Marble Hill Site, Jefferson County, IN Inspection Conducted: April 7-10, 14-17, 21-25, 27-30, May 8, and 12-13, 1981
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Inspectors:
F.
C.
awkins (,/2/6l (April 7-10, 14-17, 21-25,
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May 8, and 12-13, 1981)
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? NY (o1t18(
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(April 7-10, 22-24, and 27-30, 1981)
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Approved By:
C. C. Williams, Chief 4 [.A[
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Plant Systems Section Inspection Summary l
M pection on April 7-10, 14-17, 21-25, 27-30, May 8, and 12-13, 1981 l
(Reports No. 50-546/81-06; 50-547/81-06)
Areas Inspected: Followup on previously identified inspection findings; observation of work and review of quality records with regard to the resumption of safety-related concreting activities; observation of in process concrete repair activities. The inspection involved a total of 210 inspector-hours onsite by two NRC inspectors.
Results: No items of noncompliance or deviations were identified.
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Ei07060259 81060f PDR ADOCK 0500054
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DETAILS Persons Contacted Public Service of Indiana (PSI)
- L. Ramsett, Executive Director - Nuclear Quality Assurance W. Petro, Executive Director - Nuclear Project Management
- C. Beckham, Quality Engineering Manager N. Reichel, Civil Contract Manager
- G. Warner, Civil Construction Engineering Supervisor C. Anthony, Concrete Patching Engineer R. Cramer, Senior Construction Engineer - Civil C. Togni, Chief Civil Engineer M. Patel, Supervising General Engineer
- B. Morrison, Quality Engineering Superintendent - Civil R. Royer, Construction Engineer Supervisor K. Tyger, Quality Engineer - Civil L. Worley, Civil Materials Test Supervisor C. Robinson, Lead Field Concrete Technician R. Mustafa, Second Shift Coordinator K. Richards, Construction Engineer - Civil M. Pratt, Construction Engineer - Civil G. Zipen, Construction Surveillance Specialist - Civil R. King, Construction Surveillance Specialist - Civil B. Palmer, Construction Surveillance Specialist - Civil A. Kennedy, Construction Surveillance Specialist - Civil M. Bright, Construction Surveillance Specialist - Civil Newberg Construction Company (N-MH)
D. Stegemoller, Vice President Power Construction L. Elliot, Project Manager H. Wenzel, CERP Coordinator
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M. Swinford, Special Projects D. Maxwell, Project Quality Control Supervisor R. Oliver, Area Engineer - Auxiliary Building H. Hatfield, Labor Superintendent J. Coffman, Quality Control Concrete Supervisor D. Klingler, Labor Foreman R. Alcorn, Quality Control Inspector J. Mulligan, Quality Control Inspector K. Hevner, Quality Control Inspectoi J. Spann, Quality Control Inspector Whalen-Chilstrom Joint Venture (WCJV)
J. James, Quality Control Inspector W. Brockman, General Foreman-2-
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United States Testing Company (UST)
A. Insignares, Batch Plant Inspector N. Layton, Technician - Concrete D. Higdon, Technician - Concrete R. Gross, Technician - Soils E. Price, Technician - Soils Sargent and Lundy Engineers (S&L)
A. Weiss, Concrete Technologist Other Personnel
- J. J. Harrison, Region III Resident Inspector
- Denotes those attending the exit interview.
Licensee Actions on Previous Inspection Findings (Closed) Noncompliance (546/79-03-03; 547/79-03-03): The resolution of this noncompliance was achieved through the licensee's successful implementation of specifications, procedures, and industry standards as they relate to each specific activity which was cited.
a.
The responsible WCJV QC inspector completed the sign-off of the Placement Check Sheet to signify his acceptance of the reinforcing steel in Placement No. ISS-377-1 prior to removal of contaminants from the steel and prior to l
the steel being properly secured to prevent displacement.
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The resolution of this item is addressed in Sections 1.a.(1)(c), 1.a.(1)(d),
1.a.(1)(h), 1.b.(1)(c), and 1.b.(1)(e) of this report.
b.
The responsible N-HH QC inspector completed the sign-off of the ISS-377-1 Placement Check Sheet to accept clean up of adjacent concrete surfaces, formwork, waterstops, and joint filler material prior to completion of adequate clean up.
l The resolution of this item is addressed in Sections 1.a.(1)(a), 1.a.(1)(f),
1.a. (1)(h),1.b. (1)(a),1.b. (1)(d), and 1.b. (1)(e) of this report.
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c.
The N-MH QC Engineer signed the ISS-377-1 Placement Check Sheet to release the area for placement of concrete prior to the completion of Items a. and b. above.
The resolution of this item is addressed in Sections 1.a.(1)(h) a6d 1.b. (1)(e) of this report.
d.
The responsible N-MH QC inspector failed to adequately inspect concrete
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surfaces after form removal to identify, tag, and repair areas of
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defective concrete in the auxiliary and Unit I reactor buildings.
The resolution of this item is addressed in Sections 1.a.(3) and 1.b.(3)
of this report.
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i The responsible N-MH QC inspector failed to inspect completed concrete e.
repairs to verify proper curing of the repair patches.
The resolution of this item is addressed in Section 2. of this report.
(Closed) Noncompliance (546/79-04-02; 547/79-04-02): The resolution of this noncompliance was achieved through the licensee's successful implementation of specifications, procedures, and industry standards as they apply to each specific activity which was cited.
Immediately prior to concrete placement, the NRC inspector observed the following specific conditions which had not been corrected in two concrete pour areas which had been inspected and released for concrete placement by responsible QA/QC personnel.
At least 12 reinforcing steel 2 hear ties which had not been properly a.
secured.
This item is resolved in Sections 1.a.(1)(c) and 1.b.(1)(c) of this report.
b.
Loose wood pieces, tie wire, duct tape, and other general construct debris.
This item is resolved in Sections 1.a.(1)(a), 1.a.(1)(d), 1.b.(1)(a), and 1.b.(1)(c) of this report.
c.
Standing water.
This item is resolved in Sections 1.a.(1)(a) and 1.b.(1)(a) of this report.
d.
Embedded wood in the horizontal construction joint.
The resolution of this item is identical to Item c. abovc.
e.
Unclean formwork.
This item is resolved in Sections 1.a.(1)(f) and 1.b.(1)(d) of this report.
(Closed) Noncompliance (546/79-04-03; 547/79-04-03): The resolution of this noncompliance was achieved through the licensee's successful implementation of specifications, procedures, and industry standards as they apply to the ac-tivity which was cited.
Unit I reactor building concrete Placement No. ICW - Ext. 6 was not cured in accordance with S&L Specification Y-2722 and N-MH WPN-9 after placement on April 27, 1979.
The resolution of this item is addressed in Sections 1.e.(3) and 1.b.(3) of this report.
(Closed) Noncompliance (546/79-09-01; 547/79-09-01): The resolution of this noncompliance was achieved through the licensee's successful implementation of j
specifications, procedures, and industry standards as they apply to each l
specific activity which was cited.
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The NRC inspector observed the following areas in which PSI subcontractor QC inspection personnel failed to perform adequate inspection of work operations
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to verify quality on Placement Nc. 2SW-377-7B.
a.
July 10, 1979 - Reinforcing steel failed to meet the minimum clear distance to fermed surfaces as specified in S&L Specification Y-2722.
This item is resolved in Sections 1.a.(1)(b) and 1.b.(1)(b) of this report.
b.
July 10, 1979 - Reinforcing steel did not meet the minimum cleanliness requirements specified by ACI 318 and the CRSI Manual of Standard Practice.
This item is resolved in Sections 1.a.(1)(d) and 1.b.(1)(c) of this report.
c.
July 10, 1979 - The horizontal construction joint was not properly prepared to assure good bond as sper.ified in ACI 301.
This item is resolved in Sections 1.a.(1)(a) and 1.b.(1)(a) of this report.
d.
July 10, 1979 - The vertical construction joint contained embedded con-taminants and areas of apparent honeycomb.
The resolution of this item is identical to Iten c. above.
e.
July 17, 1979 - Reinforcing steel failed to meet the minimum clear distance to formed surfaces as specified in S&L Specification Y-2722.
The resolution of this item is identical to Item a. above.
f.
July 17, 1979 - During ;cacrete chipping to remove embedded contaminants from the vertical construction joint on 28 line, a featheredge condition was created. This was not in accordance with ACI 301.
The resolution of this item is identical to Item c. above.
(Closed) Noncompliance (546/79-09-03; 547/79-09-03): The resolution of this noncompliance was achieved through the licensee's successful implementation of specifications, procedures, and industry standards as they apply to each specific activity which was cited.
a.
During the placement of ICW - Ext. 9, responsible N-MH personnel failed to consolidate the preceeding two foot concrete lift prior to depositing fresh concrete in two areas.
This practice is not in accordance with ACI 301 and ACI 304.
This item is resolved in Sections 1.a.(2)(a)2. and 1.b.(2)(a)2. of this report.
b.
During the placement of ICW - Ext. 9, responsible N-MH personnel inserted internal concrete vibrators at about 30 inch intervals. This spacing exceeded the allowable distance specified by S&L Specification Y-2722 and ACI 301.
The resolution of this item is identical to Item a. above.
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No procedural rr.-quirements existed for the mixing, installation, and c.
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inspection of dry pack used in the repair of concrete imperfections.
The resolution of this item is documented in IE Inspection Reports No. 50-546/80-39 and No. 50-547/80-39.
d.
No documented instructions or procedures existed to specify the type of repair, based on void size, configuration, and accessibility, which should be used for any specific area of concrete imperfection.
The resolution of this item is documented in IE Inspection Reports No. 50-546/60-39 and No. 50-547/80-39.
Functional or Program Areas Inspected This report encompasses the Region III inspection effort relative to the resumption of civil / structural construction activities by N-MH.
PSI was authorized on March 27, 1981, by the Director of the NRC Office of In-spection and Enforcement to allow N-MH to resume construction activities within the scope of the March 27, 1981, letter and the May 15, 1980, document entitled Graduated Rescission of Order Dated August 15, 1979.
The following specific areas were reviewed in detail.
1.
Observation of Safety-Related Concrete Work and Review of Associated Quality Records a.
Concrete Placement No. 2SW-377-7C The Region III inspectors observed the in process preplacement, placement, and postplacement concrete work activities for pour No. 2SW-377-7C. The placement was made on April 14, 1981, and consisted of approximately 170 cubic yards of mix design No. 5508 concrete and eight cubic yards of mix design No. 5581 grout.
(1) Preplacement Inspection I
(a) Horizontal and vertical construction joints were properly prepared for concrete placement.
(b) Reinforcing steel was placed in accordance with applicable design drawings and WCWP-2.
(c) Reinforcing steel and embedments were properly secured to prevent displacement.
(d) Reinforcing steel and embedments were free of excessive rust, mill scale, concrete, or other contaminants.
(e) Metal waterstops were located as required by the design drawings.
(f) Formwork was properly cleaned and prepared.
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(g) The Region III inspector attended a meeting on April 9, 1981, which was held to discuss the placement of 2SW-377-7.
The N-MH Preplacement Evaluation Checklist, as specified by WPN-34, was discussed in detail.
(h) The N-MH Preplacement Inspection Checklist and Concrete Placement Release Sheet, both required by QCP 10.02, were properly completed to indicate acceptance of the pour area prior to concrete placement.
(2) Placement Inspection (a) Delivery and Placement 1.
Concrete was pumped to the placement area and then deposited via concrete drop chutes. Lift height thicknesses were verified not to exceed 24 incnes after consolidation.
2.
Concrete was properly consolidated using internal vibrators which had been checked, as required by QCP 10.03, to verify the minimum 8000 cpm required.
The vibrators were inserted at approximately 18 inch spacings and remained inserted until consolidation was complete.
3.
Adequate N-MH QC personnel were present at the placement to assure compliance with the applicable procedures and specifications.
(b) Civil Inspection and Testing Laboratory Activities 1.
In-Process Concrete Testing a.
The Region III inspector observed UST field i
technicians perform slump, temperature, and j
percent entrained air tests, and cast compres-l sive strength cylinders. The tests were
performed in accordance with the applicable l
ASTM standard and at the frequencies specified by S&L Specification Y-2850.
b.
Concrete test equipment was observed to be calibrated and properly tagged to indicate calibration status,
c.
Field curing boxes were inspected and found to j
be suitably equipped to maintain freshly cast l
compressive strength specimens at the initial curing temperature specified by ASTM C31. The l
required 60-80* F initial curing temperature j
was verified during the inspection.
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Batch Plant Inspection - The Region III inspector confirmed that the batch plant inspector was per-fo ming and documenting the required inspection activities in accordance with laboratory procedure g
QCP-1.
(c) Batch Plant Activities - The Region III inspector performed a surveillance inspection of the main batch plant during concrete production on April 14, 1981 and reviewed selected quality records on April 22, 1981. Specifics are as follows:
1.
The main batch plant NRMCA checklist was reviewed and found to be in current status.
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Volumetric batching devices and scales for the main and back-up batch plant were observed to be calibrated and properly tagged to indicate calibration status as follows:
Main Plant Device Calibration Due Date Aggregate Scale 6/4/81 Cement / Fly Ash Scale 6/4/81-Ice Scale 6/4/81 Darex Dispenser 7/5/81 WRDA Dispenser 5/6/81 Back-up Plant Device Calibration Due Date Aggregate Scale 6/5/81 Cement / Fly Ash Scale 6/5/81 Water Meter 6/5/81 Darex Dispenser 7/21/81 WRDA Dispenser 6/2/81 3.
The most recent main and truck mixer uniformity test
l results were reviewed and found to meet the require-l ments of ASTM C94. The test frequency met the six month interval specified by S&L Specification Y-2850.
4.
The water sight gauges for concrete truck Nos. 7, 8, and 9 were observed to be calibrated and properly tagged to indicate calibration status.
l (3) Postplacement Inspection
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The Region III inspectors verified proper curing of 2SW-377-7C l
throughout the specified seven day cure period. Additionally, l
the Region III inspector verified, through review of the N-MH i
Concrete Curing Card, that N-MH QC inspectors physically l
checked curing daily throughout the curing period as required I
by QCP 10.04.
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The concrete forms on the west face of Placement No. 2SW-377-7C, from 28 to 30 line, were removed on April 22, 1981. N-MH QC personnel conducts.d a post placement inspection of the exposed concrete surfaces and documented the results of that inspection in accordance with QCP 10.06.
The surface exhibited well consolidated concrete.
b.
Concrete Placement No. 2SW-377-5A The Region III _nspectors observed the in process preplacement, placement, and postplacement concrete wort activities for pour No. 2SW-377-5A. The steam tunnel wall was placed on April 24, 1981 and consisted of approximately 190 cubic yards of six Design No. 5508 concrete and nine cubic yards of six Design No. 5581 grout.
(1) Preplacement Inspection (a) Horizontal and vertical construction joints were properly prepared for concrete placement. N-MH NCR No. 1157, con-cerning the preparation of horizontal keyways, was reviewed and the disposition verified to be proper.
(b) Reinforcing steel was placed in accordance with the applicable design drawings and WCWP-2. N-MH NCR
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Nos. 11735 'nd 1174S, which both concerned reinforcing steel placement, were reviewed for content and to verify that the final dispositions of both were not contrary to quality.
(c) Reinforcing steel anc' embedments were properly secured to prevent displacement and were free of excessive rust, mill scale, concrete, or other contaminants.
(d) Formwork was properly cleaned and prepared for concrete placement.
(e) The N-MH Preplacement Inspection Checklist and Concrete Placement Release Sheet, both required by QCP 10.02, were properly completed to indicate acceptance of the pour area prior to concrete placement.
(2) Placement Inspection (a) Delivery and Placement 1.
Concrete was pumped to the placement area and then deposited via concrete drop chutes. Lift height thicknesses were verified not to exceed 24 inches l
after consolidation.
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2.
Concrete was properly consolidated using internal vibrators which had been checked, as required by QCP 10.03, to verify the minimum 8000 cpm required.
The vibrators were properly inserted at approximately 18 inch spacings and remained inserted until consolida-tion was complete.
3.
Adequate N-MH QC personnel were present at the placement to assure compliance with the applicable procedures and specifications.
(b) Civil Inspection and Testing Laboratory Activities 1.
In Process Concrete Testing a.
The Region III inspector observed UST field technicians perform slump, temperature, and percent entrained air tests, and cast compres-sive strength cylinders. The tests were performed in accordance with the applicable ASTM standards and at the frequencies specified by S&L Specification Y-2850.
b.
Concrete test equipment was observed to be calibrated and properly tagged to indicate calibration status.
c.
Field curing boxes were inspected and found to be suitably equipped to maintain freshly cast compressive strength specimens at the initial curing temperature specified by ASTM C31. The required initial curing temperature of 60-80' F was verified.
2.
Batch Plant Inspection - The Region III inspector confirmed that the batch plant inspector was per-forming and documenting the required inspection activities in accordante with laboratory Procedure QCP-1.
(3) Postplacement Inspection The Region III inspectors verified proper curing of 2SW-377-5A throughout the specified seveu day cure period. Review of the Concrete Curing Card verified that the N-MH QC inspectors had checked curing on a daily basis throughout the specified period.
The forms on the east face of Placement No. 2SW-377-7C, from 28 to 31 line, were removed on April 29, 1981. N-MH QC personnel conducted a postplacement inspection of the exposed concrete surfaces and documented the results of that inspection in ac-cordance with QCP 10.06.
The exposed concrete surface exhibited well consolidated concrete.
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Concrete Repair PSI began the concrete repair program at the Marble Hill site on April 3, 1981. Work initially focused on twenty general areas of " concrete patches" (CP) and " repair areas" (RA) as defined and identified under the Construc-tion Verification Program Procedure SPP-5.
The twenty arers were chosen to allow PSI the opportunity to implement the approved concrete repair / inspection procedures with verification of the ongoing activities by the NRC. The following N-MH procedures were properly implemented during the course of this work on areas CP-1, CP-21, CP-27, CP-44, CP-111, and RA-179.
WPN 25, Revision 6, Concrete Pa ching
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WPN 41, Revision 1, Concrete CEL ng i
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QCP 10.06, Revision 2, Inspection of Concrete Surfaces
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Exit Interview The inspectors met with staff representatives (denoted in the Persons Contacted paragraph) during and at the conclusion of the inspection. The inspectors summarized the scope of the inspection.
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