ML19254F216
| ML19254F216 | |
| Person / Time | |
|---|---|
| Site: | Washington Public Power Supply System |
| Issue date: | 10/08/1979 |
| From: | Renberger D WASHINGTON PUBLIC POWER SUPPLY SYSTEM |
| To: | Spencer G NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V) |
| Shared Package | |
| ML19254F215 | List: |
| References | |
| GO1-79-515, NUDOCS 7911070377 | |
| Download: ML19254F216 (9) | |
Text
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Tp Washington Public Power Supply System A JOINT OPERATING AGENCY P. O. Bo x 9 6 8 3000 Ge o. WasMING row Way Rac HLa h o. Wa9MtNG TON 99352 Pwawa ( 509 6 3 7 5-5000 October 8, 1979 G01-79-515 g
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97 NEO h Cg[-[g ggg3 %,=.;
Nuclear Regulatory Commission Region V
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T,$'I s Suite 202, Walnut Creek Plaza 1990 N. California Boulevard
-k Walnut Creek, California 94596 y
Attention:
Mr. G. S. Spencer, Chief Reactor Construction and Engineering Suppc t Branch
Subject:
WPPSS NUCLEAR PROJECTS f40S.1 & 4 TRANSMITTAL OF REQUESTED INTERIM REPORT AWSH REINFORCING STEEL
Reference:
Telephone conversation between G.S. Spencer and T.J. Houchins on September 20, 1979 As requested during the referenced telephone conversation, the attached AWSH Reinforcing Steel Interim Report is submitted.
If you have any questions or comments, please advise.
Very truly yours, b
D. L. Renberger Assistant Director, Technology Attachment cc:
CR Bryant - BPA SB Barnes - UE&C, Phil.
BD Redd - UE&C, Phil.
J. Freeman - UE&C, Phil.
1290 103 7911070 3 7 7 7'/- o 3
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ATTACHMENT A INTERIM REPORT OMISSION OF REINFORCING STEEL I.
INTRODUCTION During a July 31, 1979 project meeting involving Project Engineering, Project Quality Assurance and Atkinson-Wright-Schuchart-Harbor (AWSH)
Quality Assurance, a problem was identified regarding the omission of reinforcing steel from several concrete placements.
It was further noted, during the meeting, that the apparent cause of the problem was inconsistencies between the reinforcing steel placing drawings and the UE&C design drawings.
An inquiry has been initiated in order to determine the extent of the omitted reinforcement and identify those actions required to alleviate the condition.
Based upon the initial portion of the inquiry, the condition was identified as being potentially reportable under the provisions of 10CFR50.55(e). The condition is still under evaluation in order to ascertain its reportability status. This report is sub-mitted in the interim to provide insight and information on the con-dition which has been gathered to date and to identify those actions taken by the Supply System and AWSH to properly control the placement of reinforcing steel.
During the inquiry, four (4) factors have been identified which in-fluence the omission of reinforcing steel:
o Klinger Steel (9779-136) placing drawings are not updated to indicate the latest approved configuration as depicted on the design drawings.
(i.e. Klinger, the rebar detail and supply contractor, has completed his work. The detail drawings are no longer updated).
o Failure of AWSH to perform an adequate comparison between the UE&C design drawings and the placing drawings, developed by Klinger and AWSH, to assure compatible detailing.
o AWSH inspection personnel utilizing placing drawings, both Klinger and AWSH, for the performance of their inspections.
(Specification requirements dictate that both the placin the design drawings are to be utilized for inspections.)g and o
Errors in transposing the design details to the placing drawings.
(minimal)
II.
EXTENT OF OMITTED REINFORCING STEEL The determination of the extent of the missing reinforcing steel is con-tinuing to be perfonned. As evidenced in section III of this report, the control ef fort being conducted is dependent upon the applicable 1290 004
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Attachment A Page 2 II. EXTENT OF OMITTED REINFORCING STEEL (Cond)
AWSH contracts (i.e. 9779-253, Containment, ASME Section III Division 2; 9779-253, Containment, Non-ASME Section III Division 2 and 9779-254, General Service Building, Non-coce). To date, there have been 218 placements made for 9779-253 and 851 for 9779-254.
A.
9779-253; ASME Section III Division 2 - Containment The Project ASME organization was made aware of the potential for missing reinforcing steel in SME work based upon the condition identified in the area of AWSh non-code concrete placements. The ASME organization initiated a t andom comparison of design and placing drawings. The comparisor, resulted in the identification of two (2) instances where reinforceg steel (#6) diagonal trim
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stecl required around penetrations) was nearly omitted in concrete placements. However, prior to the concrete placements, Field Change Notices (FCNs) were 'nitiated and MSH fabricated and installed the required additional reinforcing steel.
B.
9779-253; Non-ASME Section III Division 2 - Containment For that portion of the 9779-253 contract which is non-code related, from July 1978 to the present, there have been four (4) instances identifying the omission of reinforcing teel. The bars varied in size from number eight (#8) to number i_
en (#14) and in quantity of bars from four (4) number eights (#8's) to fourteen (14) number elevens (#11's). Each of the four (4) instances have been disposi-tioned by Engineering and the applicable disposition achieved.
(e.g. detailing, fabricating and installing additional bars; use-as-is for non-critical reinforcement or adjusting in-place reinforcing steel). Attachment 1 lists the Contractor initiated Nonconformance reports (CNCRs) and associated data.
C.
9779-254; Non-Code - General Service Building From July 1978 to present, of the 851 concrete placements made there have been twenty-six (26) instances in which reinforcing steel has been omitted.
The omitted steel varies in size from number four (4) to number eleven (#11) and in quantity of bars from one (1) number eight (#8) to thirty-three (33) number eleven', (#11's). Attachment 2 lists the CNCR's and associated data.
Each of these conditions are being or have been evaluated on a case by case basis to determine the safety implications and the applic-able disposition.
(e.g. chipping out affected area of placement and fabrichting and placing required reinforcing steel; drill and grout required resteel in place, etc.)
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Attachment A Page 3 III. ACTIONS TO CC?
ON-G0ING CONSTRUCTION ACTIVITIES As indicated in section II above, the efforts for the control of the day to day construction activities is based upon the particular contract or portion thereof.
In additien, factors such as the incidence of omitted reinforcing steel, the rate of construction activities and the degree of the use of standard reinforcing steel configurations regulate the need and intensity of a special control program.
A.
9779-253; ASME Section III Division 2 - Containment The general design configuration of the code concrete placements utilize, for the most part, a standard detail of reinforcing steel.
The omission of reinforcing stee s from the standard array is easily identifiable.
The only instances of missing reinforcement identified were corrected prior to placement; therefore, no special control syster; has beeninitiated.
However, both project Code QA and AWSH personnel have been made aware of the identified problem.
Section VI of this report, outlines the actions initiated to effectively control the placement of reinforcing steel.
B.
9779-253; Non-ASME Section III Division 2 - Containment (Cont'd)
The complexity of the design for the non-code portion of the con-tainment is such that the design drawings must be continually reviewed, thus reducing the possibility of omitting reinforcing steel.
The non-code preplacement inspections by AWSH are being monitored through Project Quality Assurance surveillance. The project sur-veillance personnel and the AWSH inspection personnel have been made aware of the identified problem. Again,Section VI of this report, outlines the actions initiated to effectively control the placement of reinforcing steel.
C.
9779-254; Non-Code - General Service Building It can be notN that the majority of missing reinforcing steel has been identified in the 9779-254 General Service Building placements.
Therefore, a more attentive control program has been initiated in that area.
The program consists of a special QA task force assigned to assure compliance to the design drawings. This task force consists of Project Quality Assurance Engincers, highly cualified in the civil discipline, and certified as level II Surveillance Engineers 1290 006
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Attachment-A Page 4 III. ACTIONS TO CONTROL ON-G0ING CONSTRUCTION ACTIVITIES (Cont'd)
C.
9779-254; Non-Code - General Service Building (Cont'd) in accordance with ANSI N45.2.6.
Member (s) of the task force accompany the AWSH Quality Control inspectors during their daily preplacement inspections.
During these "in concert" inspections, assurances are made that reinforcing steel has been properly placed prior to the initiation of the concrete placement.
This effort will cont.nue until a level of confidence can be obtained in the contractor's reinforcing steel placement effort and the draw-ing inconsistency problem resolvei. (See section VI of this report.)
IV. ACTIONS TO ASSURE PROPER INSTALLATION OF RESTEEL IN PREVIOUS PLACEMENTS One of the functions during the control program inspections by the afore-mentioned special QA task force is to examine previous placemer.ts to assure that reinforcing steel required to protrude into adjacent placements is in place.
If it is found to be omitted, the circumstances are researched (i.e. a review is performed of design change documents to see if steel was deleted by design change) and if no evidence of design changes exist AWSH or Project QA personnel initiate a nonconformance report for Engineer-ing disposition.
In addition to the special QA inspection task force, a second task force was organized for the purpose of reviewing design drawings and reinforcing steel placing drawings for owner-furnished reinforcing steel, supplied by Klinger.
The second task force was comprised of qualified personnel in the civil discipline from Project Engineering, Construction Management and Quality Assurance. The task force compared design drawings to placing drawings and assessed any differences. When differences were identified research was conducted to assure that t!.e proper design change documents were on file indicating that the required changes were conveyed to the contractor.
The drawing comparison and assessment was performed for all owner furnished reinforcing steel detail s nd design drawings for Contracts 9779-253 and 9779-254 for both Unit i and Unit 4.
The drawing comparison and assessment effort was completed on September 14, 1979.
Reinforcing steel furnished and detailed by AWSH is governed by AWSH detail drawings. As such, AWSH has been directed to verify that UE&C design and AWSH detail drawings are consistent.
This effort was initiated by AUSH for both 9779-253 and 254 on September 10, 1979, and is scheduled for completion on November 9,1979.
1290 007
Attachment A Page 5 V.
ACTIONS TAKEN TO CORRECT IDENTIFIED DEFICIENCIES As deficiencies are identified through actions taken in Sections III & IV above, they are appropriately documented on a nonconformance report or requests for information (RFI) and submitted to the Engineer for disposi-tion.
Each is evaluated for safety implications on a case by case basis.
VI.
PROPOSED ACTIONS TO PRECLUDE RECURREi1CE The following corrective actions have been initiated and should preclude recurrence.
For those actions required of AWSH, letter UEAT-79-5416(253)/
UEAW-79-5257(254) was transmitted to AWSH on September 24, 1979.
AWSH was directed to take appropriate < orrective action as outlined below, and to submit an action plan on or before October 10, 1979.
A.
Comparison of Design and Placement Drawings AWSH has been directed to perform a comparison of AWSH reinforcing steel placing drawings and UE&C design drawings to assure that they are consistent. Any inconsistencies noted shall be documented and resolved. This comparison will allow for; 1)
Craft to install the reinforcing steel in accordance with the latest approved design, and 2)
A minimized opportunity for the contractor's inspection personnei to overlook missing reinforcing steel.
B.
Performance af Inspections to Design Drawings and Placing Drawings The contractor shall comply with specification requirements regarding the utilization of both design drawings and placing drawings for tne performance of his preplacement inspections.
This practice will be further enhanced by the performance of the aforementioned drawing comparisons.
C.
Performance of Meaningful Training Sessions Both Contractor craft personnel and inspection personnel shall be subjected to meaningful training sessions covering the technical requirements involved in reinforcing steel placement.
D.
Performance of Additional In-Process Inspections AWSH Inspection techniques shall be revised to include more frequent "in-process" inspeci. ions in order to detect any suspect areas in which reinforcing steel nay be in question.
1290 008
Attachment A Page 6 VII.
SUMMARY
The extent of reinfc cing steel omission varies according to contract and area.
The cause of this omission can be defined as inconsistencies between placing drawings and design drawings and the performance of inspections to the placement drawings without comparison with the design drawings.
To alleviate titis condition actions were taken to control the on-going construction activities, to assess the acceptability of previous place-ments and to correct ar" deficiencies identified.
Finally, corrective actions have been initiated to preclude the recurrence of the identified condition.
1290 009
ATTACHMENT 1 INSTANCES OF OMITTED REINFORCING STEEL; 9779-253 NON-ASME Placement Additional No. of Instances Omitting Affected Omitted Bar (CNCRs)
Reinforcing Steel Placements
- Bars Size 1-CNCR-253-323**
C-1014 C-1011 6
11 558 C-1039 C-1041,C-1006 4
8 628 CG-204 CG-204 14 11 772 C-1034,C-1034A C-2001,C-2002 C-1051 C-2001,C-2002 C-2005,C-2008 4
14
- Note - Placements affected in some manner by the missing reinforcing steel (e.g. continuous bar required to protrude into another placement etc.)
- Note - These bars identified near completion of placement end were even-tually installed but lack three (3) inch embedment length.
1290 010
ATTACHMEllT 2 IrlSTANCES OF OMITTED REINFORCING STEEL: 9779-254 Placement Additional No. of Instances Omitting Affected Omitted Bar (CitCRs)
Reinforcing Steel Placements ***
Bars Size 1-CNCR-254-39 1914 S
6 46 1214 7
6 168 1360 1939 12 6
188 1353 4
6 233 201'4 4
8 235 930A 12 v
304 3608 2
8 393 3607 3614 1
8 400 2020 2944 2
6 4C5 2008 2957 3
8 420 1992 2048 10 11 450 2628 2900 2
11 2
8 455 2046 2926 4
6 463 2628 26T.3 1
11 2626 2900 1
8 469 3025 Block Wall 8
5 479 3025 3857 2
5 486 3036 Curb 10 4
495 3005 3019 4
5 2
6 16 5
504 2900 2959 2
6 610 2903,2907,2911 33 11 2915,2919,2923
+
2927 2309A,2929C 612 3005 3011 2
6 633 1937 2864 12 6
647 3011 3005 1
6 606 2309A 2929C 10 9
823 3025 3868 2
6 829 2020A 1
6
- tiote :
Placements affected in some manner by the missing reinforcirg steel (e.g. continuous bar required to protrude into another placenent etc.)
FNote:
One (1) NCR (1-NCR-254-15) identi fies 14 1514 bars missing from place-ments G-2354, 2854A, 2214 end 2214A.
This gives a total of 27 instances.
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