ML19241B215
| ML19241B215 | |
| Person / Time | |
|---|---|
| Site: | Wolf Creek  |
| Issue date: | 04/10/1979 |
| From: | Crossman W, Oberg C, Rosenberg A NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19241B213 | List: |
| References | |
| 50-482-79-04, 50-482-79-4, NUDOCS 7907130139 | |
| Download: ML19241B215 (15) | |
See also: IR 05000482/1979004
Text
U.S.fJUCLEARREGULATORYCOMMISSIUN~
OFFICE OF IrlSPECTION AND E
0RCEMEilT
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REGION IV
Report f40. STN 50-482/79-04
Docket No. STN 50-482
Category A2
Licensee:
Kansas Gas & Electric C mpany
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Post Office Box 208
Wichita, Kansas
67201
Facility Name: Wolf Creek, Unit No.1
Inspection at:
Burlington, Kansas
Inspection conducted: Marci; 5-8 and 15, 1979
Inspectors:
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C. R. Oberg, Reactort/ Inspector, Projects Si ction
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A. B. Rosanberg, Reactor Inspector, Engineering -
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Support Section
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A. B. Beach, Reactor Inspector, Engineering Support
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Section
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Approved:
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W. A. Crossman, Chief, Projects Section
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E'. Hall, Chief, Engineering Support Section
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Inspection Summary:
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Inspection on March 5-8 and 15,1979 (Report tio. STil 50-482/79-04)
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Areas Insoected:
Routir a, unannounced inspection involving follow up of
unresolved items relat'ng to the containment base mat concrete (Inspection
Report flo. STf4 50-482/78-13). This report alsc includes information on
flRC visits to PCA to observe testing of cylinder fragment cubes and cement
sample cubes, and results of a ineeting between KG&E and Region IV on matters
relating to a PCA report.
The inspection involved seventy-four inspector-
hours on site by three f4RC inspectors.
Results: One item of noncompliance (infraction - failure to follow procedures)
was identified during the inspection.
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DETAILS I
SITE If1$PECTION, MARCH 5-8, 1979
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DETAILS I
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Persons Contacted
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Principal Licensee Personnel
g nsas Gas & Electric Company (KG&E)
"G. L. Koestar, Vice President, Operations
- J. O. Arterburn, Superintendent, fluclear Development
- M. E. Clark, Manager, Quality Assurance, Site
- G. W. Reeves, QA Engineer
+D, W. Prigel, QA Engineer
- T. C. Newman, QA Engineer
- R. Ayres, QA Engineer
Kansas City Power & Light (KCP&L)
- D. Crawford, Construction Engineer
Bechtel
- G. flutwell, Lead Site Liaison Engineer
Ash Grove Cement Company (Chanute Plant)
J. McMechin, Plant Superintendent
J. D. Shea, Chief Chemist
Daniel International Corporation (DIC)
- L. R. Smith, Regional Manager
- W.
E. Hitt, Project Manager
- V. J. Turner, Project QA Manager
- I. Hussain, Assistant to Project Manager
- denotes those present at the exit interview.
2.
Licensee Action on Previous Inspection Findings
Closed) Unresolved Item (No.1)1/ (STN 50-482/78-13):Adequacy of
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Depth and Scope of KG&E and DIC Audit Program in Area of Concrete
Production and Control.
After review of audit and surveillance
reports and discussions with licensee and constructor QA personnel,
the IE inspector concluded that the depth and scope of the audit
program, in the area of concrete production and contro!, is adequate.
This item is considered closed.
1/ Items No. refers to list of unresolved item in Inspection
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Report STf4 50-482/78-13
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Closed) Unresolved Item (No. 2) (STtt 50-482/78-13):
Review of User
Test Break Sheets for 'JT #10 through 24.
During inspection 50-482/78-13,
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summary information for cement cube user tests were reviewed.
During
this inspection, the cube test break sheets and logs were reviewed for
User Tests 10 through 24 and found to be in accordance with site pro-
cedures and ASTM C-150, with the exception of two items of noncompliance
previously identified in report No. STN 50-482/78-13 and NCR I-146-C.
The nonconformance report was reviewed with no further questions.
This item is considered closed.
(0 pen) Unresolved Item (No. 6) (STfl 50-482/78-13):
Determine if Change
in Admixture Properties Occurred.
During a previous inspection, QA
certifications, which did not reveal chemical or physical properties,
were reviewed for the water reducing admixture (WRA) (Master Builders
type 300N) and air-entraining admixture (AEA), MB-VR standard.
During
this inspection, the manufacturer supflied spectrographs for the ad-
mixtures were reviewed. All the WRA spectrographs reviewcd appeared
to be consistent. The AEA spectrographs
differences.
(2)themaximalat3100cm91at3400cm~{eve
Specificallys (1) the minim
varies approximately 24%;
- ofthegraphstartingat1600cmgroximately12%;and(3)tne
varies ap
cm ] where the variation is approximai.ely 15%.
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diverges to the point 600
The significance or
meaning of these variations is not yet determined.
Tnis matter remains
unresolved pending the determination of the significance of these
variations by the licensee and/or the vendor.
(Closed) Unresolved Item (No. 7) (STN 50-482/78-13):
Review of Cylinder
Break Sheets for Batch Plant Mixer Qualification.
During a previous
inspection, batch plant and truck mixer qualification and unifonnity
tests were reviewed.
During this inspection, the cylinder break sheets
for the mixer uniformity tests werc reviewed and results were found to
be in ac'ordance with requirements of ASTM C-94.
This matter is
considerad closed.
(Closed) Unresolved Item (No. 8) (STN 50-482/78-13):
Review of Computer
User Manual for Statistical Analysis of Cylinder Break Data.
The lE
inspector reviewed the " Compressive Test of Concrete Cylinders System
User Manual" issued by DIC Management Services, Greenville, South
Carolina, on April 4, 1977.
No itels of noncompliance or deviations
were identified. This item is considered closed.
(Closed) Unresolved Item (No. 9) (STN 50-482/78-13):
Review of
Compression Test Report for Cylinder Set No. 567.
During a previous
inspection, a possible transcribing error was identified on the data
sheet for cylinder set 567,
During this inspe-tion, a corrected
compression test reoort was filed with the original report.
This
matter is considered closed.
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(Closed) Unresolved Item (flo.10) (STri 50-482/78-13):
Review of Type
of Breaks Experienced on the Test Cylinders.
During a previous in-
spection, it was determined that the description of the type of breaks
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identified by DIC are at vagjance the type of breaks identified by
PCA for the same cylinders.H
During this inspection, a comparison of
type of break identified by PCA, DIC and f4RQ,was made of forty-eight
cylinders shipped to PCA December ll,1978.H
DIC
NRC (only observed 45)
Cone
2
47
3
Diagonal
35
1
26
Transverse and/or
Longitudinal
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Liot Identified
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' lumber Same
33 of 38
as PCA
48
3
identified
A review of ACI and ASTM standards failed to reveal specific guidance
for determining the type of break or their significance.
Therefore,
due to the subjectivity of this matter, this item is considered closed.
(Closed) Unresolved Item (flo.11) (STN 50-482/78-13):
Review of Batch
Plant Production Rate and Adequicy of Mixing.
During previous inspec-
tions, the mixer qualification test and the concrete production rate
for the base mat concrete were examined.
During this inspection, the
mixer qualifications were re-examined for Design Mix 42-C-1 A-N prior
to the time this mix design was upgraded to a 5000 psi mix at 90-days.
It was observed that a mix time of 45 seconds was consistently used.
There are no further questions at this time.
(Closed) Unresolved Item (No. 12, sSTri 50-482/78-13):
Review of Initial
Test Cylinder Curing Temperature.
During a previous inspectior., tem-
perature documentation for the first twenty-four hours of the base mat
cylinders curing could not be found.
During this inspection, it was
determined that temperatures were not " logged," since the DIC procedure
2/PCA (Shideler) letter to DIC (Phillips), dated April 19, 1978
~3fPCA (Shidelce) letter to KG&E (Koester), dated February 27, 1979
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did not require logging.
However,reviewofD[Cmemo,T.A.Greento
W. Hiti., dated December 13, 1978, indicated that the newly cast cy-
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linders were initially stored in heated sheds near the placement.
The
temperature was monitored periodically by personnel with hand held
thermometers to verify compliance to ASTM C-31.
The results of these
measure"ents were not specifically recorded.
This ma *er is considered
closa'
(Closed) Unresolved Item (flo.13 & 14) (STri 50-482/78-13):
Review of
Lack of Curing Room Temperature Records and I;CRs on Curing Room
Temperatures.
During a previous inspection, curing room temperature
records revealed several occasions,whgre the curing room temperatures
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exceeded allowable limits (73.4 F - 3 F) und one period where no
records exist.
The NCRs relating to some of the out of limit tem-
peratures were reviewed.
During this inspection,flCRs concerning
curing room temperature were reviewed for the period November 1977,
through March 1978.
Three recorded periods of temperatures below
specification and one period where no temperatures were recorded, and
no flCRs or deviation notices were initiated.
The period of no record
occurred over a holiday weekend and was apparently caused by the
recorder pen running out of ink.
Failure to identify discrepant and/or indeterminate conditions indi-
cate an item of ncncompliance with 10 CFR 50, Appendix B, Criterion V,
failure to follow procedures and with the requirements of Daniel
Procedure QCp-1-04, paragraph 3.5, Rev. O.
3.
Stop-Work Order for Safety Related Concrete
On March 8,1979, the IE inspector was infomed by the licensee that
a stop-work order had been imposed on all safety related concrete
on the Wolf Creek site.
The stop-work order was effective at 1:35 p.m.
and had been issued as a result of Daniel QC personnel observing and
reporting that concrete was moved more than five feet with a vibrater
contrary tu specifications.
On March 7,1979, during the initial steps
of an auxiliary building internal wall placement (0C 135 WO6), a tremie
vecamo plugged and ruptured.
The special placement plan was abandoned
b, the foreman and the placement was completed using an alternate tremie.
D2 ring the last of the 18 inch lifts, before topping off, concrete was
noved by vibrators 6 feet from the point of deposition.
The speci-
fication limit is 5 feet.
Placement OC 135 WO6 is a 14 foot, 8 inch
long x 2 foot wide x 12 foot hi9n wall in the main steam penetration
area.
4.
Testing of 28-Day Cylinder Fragments
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During the inspection, the IE inspector was informe1 that twenty c .x
base mat cylinder fragment. had been transported to PCA for cube
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testing, and for petrographic and chemical testing.S/ Cubes will
be formed from as many fragments as possible.
Sixteen fragments
will be given petrographic and chemical analysis.
All fragments
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are the results of the 28-day compression tests.
The following
fragments were identified to the inspector:
Cylinder No.
6411
6513
6604
6700*
6424*
6514
6640*
6706
6448
6531*
6651*
6717*
6483*
6543*
6664
6718*
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6484
5561*
6735*
6490*
6580
6752*
6496
6886*
6771*
6794*
- Petrographic & Chemical Analysis
The results of the PCA testing will be reported to the NRC.
5.
Exit Interview
The IE inspectors met with licensee representatives (denoted in
paragraph 1) at the conclusion of the inspection on March 8,1979.
The IE inspectors summarized the purpose and scope of the inspection
and the findings.
'ihe licensee representative acknowledged the item
of noncompliance.
4/KG&E (Koester) letter to DIC (Hitt), dated Fe.'uary 15, 1979
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DETAILS II
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KC&E/flRC MEETIflG, MARCH 15, 1979
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DETAILS II
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Management Meeting
Kansas Gas and Electric Company requested a meeting with Region IV
personnel to discuss the latest PCA report (dated February 27,1979)
transmitted to the Region IV office on February 28, 1979.
The m eting
was held March 15, 1979, with the following attendeen:
Licensee Personnel
G. L. Koester, Vice President-0perations, .G&E
E. W. Creel, Director Quality Assurar.ce, KG&E
J. L. Sippel, Assistant Project Engineer, Kansas City Power & Light
W. R. Waugh, Consultant
J. Shideler, Director Administrative and Technical Services, PCA
_N. R__C.
K. V. Seyfrit, Director, Region IV (attended for opening remarks only)
W. C. Seidle, Chief, Reactor Construudon and Engineering Support Branch
W. A. Crossman, Chief, Projects Section
R. C. Hall, Chief, Engineering Support section
C. R. Oberg, Reactor Inspector, Projects Section
A. B. Rosenberg, Reactor Inspector, Engineering Support Section
J. I. Tapia, Reactor Inspector, Engineering Support Section
R. C. Hamm, Consultant
The meeting specifically at. dressed and discussed several quastions and
areas of concern by the NRC.
Each specific area was discussed individually
and with KG&E making the following commitments:
a.
Make a programmatic statement relating the testing of concrete
cubes to acceptance criteria of the concrete specifications.
b.
Make a statement relating the sand to coarse aggregate ratio, as
determined petrographically, to the concrete specification.
c.
Furnish copies of ali photographs relative to the PCA testing
program to the NRC.
d.
Provide a conversion factor for 2 inch cube strength cut from the
bottoin of cylinder fragnents developed by KG&E's consultant based
on literature search.
e.
Provide a conversion factor for 2 inch cube strength cut from the
bottom of cylinder fragments developed from field tests.
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Examine approximately ten additional fragments 'petrographically
where the 90-day strength was lower than the 28-aay strength.
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Make a statement indicating that the cube: were tested wet and
in the vertical position.
h.
Provide individual cube strengths for the mortar ctLe tests.
The licensee agreed to provide the additional information as a supplement
to the PCA report of February 27, 1979.
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DETAILS III
SUMMARY OF INSPECTION VISITS MADE TO PCA DURING THE
PERIOD JANUARY 17, 1979, THROUGH FEBRUARY 9,1979
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DETAILS III
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1.
Persons Contacted During PCA Inspections
J. J. Shideler, Director of Administrative and Technical Services
L. M. Meyer, Manager, Technical Services Section
D. H. Campbell, Petrographer
R. O'Neill, Assistant Research Petrographer
KG&E
W. R. Haugh, Consultant
Kansas Corporation Commission
R. D. Sundman, Utilities Engineer I
Daniel
Chris Phillips, Site Civil Engineer
L. R. Smith, Regional Manager
2.
OIE Representatives
Janut.ry 17, 1979 - E. J. Gallagher (RIII)
F. C. Hawkins (RIII)
January 30, 1979 - E. J. Gallagher (RIII)
Febraary 9,1979 - J. R. Harris (RII)
E. J. Gallagher (RIII)
3.
Observation af Base Mat Cylinder Fragments at Portland Cement
Association
PCA)
The IE inspectors visited PCA on January 17,1;'9, to observe the
conditions of the concrete test cylinder fragments from the Wolf Creek
project.
The following observations were made at thet time:
a.
Cylinder End Conditions
The cylinder ends showed no unusual conditions with respect to
parallel ends or planeness.
A PCA representative stated that
the cylinder ends met the ASTM requirements. Any minor irregu-
larities would be corrected by the capping compound.
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b.
Failure Plane
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The IE inspector observed that approximately 70% of the cylinuers
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failed diagonally. Another PCA representative stated that diagonal
breaks are sometimes attributed to eccentric loading.
c.
Storage of Cylinders
The cylinders were in a bascaent hallway on a flatbed.
PCA was
awaiting notification from KG&E/ Daniel to begin preparation for
tests and sawing of 2 inch cubes for compression tests.
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No items of noncomp'.iance or deviations ware identified.
4.
Observation of 2 Inch Cube Tests at PCA
On January 30, 1979, the IE inspector witnessed cement mortar cube
tests and tests of concrete cubes from cylinder fragments at PCA.
a.
Cement Mortar Cube Tests
The IE inspector witnessad the 7-day tests for twelve mortar
cubes, thr.'e cubes from .ach of four samples of the Cement U',er
Tests (CUT).
CUT 15
CUT 18
CUT 2.
( jT 21
The results of tests observed met the strength requirements of
ASTM C-150.
These results were reported in the PCA report, dated
Feb uary 27, 1979. The tests were performed in acccrdance with
ASTM C-109.
b.
Sawed Cube Tests
The IE inspector witnessed the testing of twenty-seven sawed 2 inch
cubes.
These cubes were sawed from sixteen cylinder fragments
salvaged from the Wolf Creek base mat concrete tests.
The actual
cube strengths ranged from 6676 psi to 9331 psi, urcorrected. These
results must yet be corrected a factor yet to be c learly established.
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c.
Test Machine Calibration
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Af ter the testing was complete, the IE inspector observed the
calibration of the test machine, Serial No. 57271.
The PCA
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proving ring No. 212, traceable to the National Bureau of
Standards, was used. The machine was found to be within 1%
accuracy for all loads except 5000 pounds, where the machine
was 1.1% high.
No items of noncompliance or deviations were identified.
5.
Obset vation of Petrographic Examinations
On February 9, 1979, IE inspectors made an unannounced visit to the
PCA facilities to observe the petrographic examination of test
cylinder fragments. The examiaation included: visual examination
of the cylinder remnants; ste-/eoscopic examination of five to seven
inch long lapped side pieces cut parallel to the long axis of the
cylinder remnants; and petrographic examination of thin sections
taken from the laoped side pieces.
PCA personnel indicated no
conditions potentially dcieterious to concrete have been identified.
The results of these exaniinations were reported in PCA report, dated
February 27, 1979.
No items of noncompliance or deviations were identified.
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