IR 05000553/1979002
| ML19289F049 | |
| Person / Time | |
|---|---|
| Site: | Phipps Bend  |
| Issue date: | 03/13/1979 |
| From: | Herdt A, Wright R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML19289F040 | List: |
| References | |
| 50-553-79-02, 50-553-79-2, 50-554-79-02, 50-554-79-2, NUDOCS 7906010143 | |
| Download: ML19289F049 (6) | |
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UNITED STATES
- g* "009
- o NUCLEAR REGULATORY COMMISSION
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g REGION 11 I
E 10fi MARIETTA STREET, N.W.
ATLANTA, GEORGIA 30303 o
Report Nos.: 50-553/79-02 and 50-554/79-02 Licensee: Tennessee Valley Authority 500A Chestnut Street Tower II Chattanooga, Tennessee 37401 Facility Name:
Phipps Bend Nuclear Plant Docket Nos.:
50-553 and 50-554 InspectionatPhippsBendSitenearKingsport, Tennessee Inspect i
l 3/79 R. W. Wright Date' Signed 8 3/7f Approved by:
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A. R. Herdt, Section Chief, RC&ES Branch Dite Signed SUMMARY Inspection on February 5-8, 1979 Areas Inspected This routine unannounced inspection involved 34 inspector-hours onsite in the areas of licensee action on previous inspection findings; training and certi-fication of inspection, examination and testing personnel (other than NDE);
training of protective coating applicators; Unit 1 observation of base mat concrete placement work and inspection activities; audit review and updating on an inspector follow-up item.
Results Of the six areas inspected, no apparent items of noncompliance or deviations were identified in five areas; one apparent item of noncompliance was found in one area.
(Unit 1 - infraction: Replacement of 3 inch aggregate with 1\\ inch paragraph 6).
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DETAILS 1.
Persons Contacted Licensee Employees
- W. P. Kelleghan, Project Manager
- G. Wadewitz, Construction Engineer
- J. C. Coefield, QC - Materials and Civil Supervisor
- D. E. Hitchcock, Site QA Unit Supervisor W. K. Burner, QC Welding Supervisor E. J. Barnett, Project Engineering Mechanics Supervisor P. Edens, Project Engineering Civil Engineer M. Stitt, Project Training Officer J. P. Hartman, QA Training Unit Coordinator Other licensee employees contacted included several construction craftsmen, technicians and office personnel.
Other Organizations E. R. Longstreth - Ameron, Field Service Representative
- Attended exit interview.
2.
Exit Interview The inspection scope and findings were summarized on February 8,1979, with those persons indicated in Paragraph I above. The licensee acknowl-edged the one item of noncompliance discussed in paragraph 6.
3.
Licensee Action on Previous Inspections Findings (0 pen) Unresolved Item 553-554/78-08-03 - Inadequate concrete sampling specification and instruction. This item is under study and review by the licensee, who has not established an official position as yet.
Discussion with re ponsible QCM&C personnel and observations during this
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inspection revealed that during the interim period the site has been complying with ACI 318-71 concrete frequency of sampling requirements (i.e. samples are being taken for strength tests of each class of concrete (design mix) poured that day and for each 150 cubic yards of concrete).
4.
Unresolved Items Unresolved items were not identified during this inspection.
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Training a.
Inspection, Examination and Testing Personnel Construction Engineering Procedure CEP 2.10 is the controlling procedure for qualifying and certifying inspection, examination and testing personnel (other than NDE) prior to performing quality control functions on safety related items. The QC Unit Supervisors have the responsibility to select personnel to be trained (certified)
and ensure that their personnel are qualified.
Personnel are qualified (and certified) to the requirements of quality procedures or to " training modules".
Qualification and certification to procedures or " training modules" involves training and testing to requirements of QCI's, RIS & PM, CEP procedures or " training modules".
The Region II inspector reviewed the controlling procedure and held discussions with the acting QC Materials and Civil Unit Supervisor and the Site QA Unit Training Representative concerning QA training activities.
The Region II inspector reviewed the certification records of six QCM&C inspectors employed in the placement of reactor building pour No. RI-AMOI-IB to assure certification in accordance with CEP 2.10.
Five of the six QC inspectors were found properly certified. The sixth inspector's certification to procedure QCI-201,
" Concrete Placement" had been revoked on March 10, 1978 and the inspector had not been recertified by examination in this area to date. This inspector was one of three placement inspectors observed working together to handle the subject concrete placement. Discussions with the QCM&C unit supervisor revealed he had intentionally assigned the inspector to this placement under the direct supervision of a lead placement inspector to obtain beneficial on the job training prior to his reexamination in concrete placement.
No items of noncompliance or deviations were identified.
b.
Certification of Protective Coating Applicators, CEP 2.13 The Region II inspector reviewed the subject procedure.
This procedure assigns the responsibility of providing a comprehensive training session in surface preparation and protective coating application for selected craf t personnel to the Civil Project Engineering Unit Supervisor or his designee. A QCM&C inspector certifies each candidate as a protective coating applicator based on actual coating application and preparation demonstrations.
The Region II inspector attended a training session conducted by TVA and a field representative for Ameron's product Dimetcote EZ, an inorganic zine coating. Surface preparation, application equip-ment, environmental conditions, application procedure, drying and curing times, and some QC requirements of ANSI N101.4, "QA for 2234 163
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-3-Protective Coatings Applicd to Nuclear Facilities" were discussed.
The program evaluation and written tests taken by the crafts personnel were examined by the inspector. Fifteen craftsmen and two QC inspectors were in attendance.
No items of noncompliance or deviations were identified.
6.
Containment (Structural concrete 1) - Observation of Work and Work Activities, Unit 1 The Region II inspector observed the preparation, delivery and placement, inspection, testing and curing during various phases of the RCB base mat placement No. RI-AMOI-IB. The activities associated with the subject concrete placement were inspected for conformance to the following acceptance criteria:
a.
Sections 3.8 and 17 of the PSAR b.
Work Package No. D002-IC-IB (RI)
C. F. Braun Specification 300-01, " Concrete" c.
d.
TVA Specification G-2, " Plain and Reinforced Concrete" Drawing No. S-001, " Reactor Bldg. Zone I Foundation Mat" Drawing e.
No. S-009, " Foundation Mat Sections and Details" f.
Procedures:
(1) QCI's C-201, C-202, C-204, C-205, C-207, C-208, C-212 (2) CEP 2.10, 9.02,12.01,17.01 g.
ACI 318-71, Section 4.3.1 Forms were tight, clean and level and the minimal rebar in this pour was properly installed and cleaned.
Placement activities pertaining to delivery time, free fall, flow distance, layer thickness and consolidation conformed to specifications.
In process tests for slump, air content, unit weight and cylinder molding were performed in accordance with ACI 318-71 recommended frequency of sampling for concrete strength tests. In addition two complete sets of cylinders were taken and lef t in the field under field curing conditions.
An examination of the batch plant indicated materials were being controlled, accurate batch records were being generated and activities were continuously monitored by a QC inspector.
The specified minimum curing measures (maintaining a temperature in the concrete of 50* F or greater for 3 days) was being implemented, however, QCIR No.10206 was written to identify some in place concrete temperature thermocouple readings than were giving low temperature indications.
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-4-The latest approved C. F. Braun Drawing No. S-009, Revision 5, entitled
" Foundation Mat Sections and Details" specifies the use of concrete class 303 BF (3 inch maximum size aggregate) for a radius less than 64 feet and a 301.5 BF mix (i 1/2 incu maximum size aggregate) for a radius greater than 64 feet. The Region II inspector observed that placement No. RI-AMOI-IB used a 301.5 BF mix for the entire radius of the RCB base mat placement. When questioned about the above mix desigr differences the licensee produced a telecon dated January 5,1977, which references some apparent areas of agreement between GE and TVA for revisions to CF Braun's Specification 300-01. In the first paragraph of the above telecon memo it states, "GE also agreed to provide interim approval for the use of 1 1/2 inch aggregate in lieu of 3 inch aggregate. Applicable drawings will also be revised".
However, no CF Braun Engineering Change Notice to the subject drawing (S-009) was found to exist on site nor was a TVA Field Change Request initiated prior to the placement of pour No. RI-AMOI-IB permitting this aggregate substitution. This item is identified as infraction 553/79-02-01 - Replacement of 3 inch aggregate with 1 1/2 inch.
7.
Independent Inspection Effort a.
Audit Review The FSAR, Chapter 17, Section 17.1A.18.3 titled, "DEC Audits" specifies that the supervisor, Site QA Unit, is responsible to perform planned and periodic audits of all construction activities including site contractors under the direction of the Chief, QA Staff. These audits results are to be documented and reviewed by management.
The following DEC QA audits were examined by the Region II inspector for deficiencies found, corrective actions specified, completeness and their implementation in accordance with the licensee's procedure CEP-18.01:
Audit No.
Subject PB-M-78-03 Handling and Storage of Stainless Steel Piping PB-G-79-02 Procurement Document Control PB-L-78-02 Concrete Activities, Batch Plant, and Placement PB-G-78-08 Document Control Unit PB-G-78-07 Personnel Certification PB-C-78-02 Rebar Receiving, Placing, and Splicing 2234 165
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-5-Within the scope of the audit review, no items of noncompliance or deviation were identified.
b.
(0 pen) Inspector Follow-up Item 553-554//8-08-01 Stellar Manufacturing Company (SMC) - Inspection of weirwall and fuel pool liners.
Phipps Bend was requested by TVA's Design Project Manager (memorandum CEB 781130 012) to perform a visual examination of the welds performed by Stellar on the weirwall structure that had been shipped to them and to report back their findings. Phipps Bend transmitted their conclu-sions of evaluation of the weld quality performed by Stellar in their memorandum (PBN 78 1215 003) to Mr. H. C. Russell. Mr. Russell's latest memorandum (CEB 73 1229 503) has directed Phipps Bend site to proceed to review the subject with the technical engineer (GE and Braun) to ascertain the seriousness of the defective welding identified.
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