ML19260A136
| ML19260A136 | |
| Person / Time | |
|---|---|
| Site: | Crane  |
| Issue date: | 03/21/1972 |
| From: | Folsom S, Howard E, Varela A NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | |
| Shared Package | |
| ML19260A131 | List: |
| References | |
| 50-289-72-03, 50-289-72-3, NUDOCS 7910290752 | |
| Download: ML19260A136 (7) | |
See also: IR 05000289/1972003
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U. S. ATOMIC ENERGY COMMISSION
DI7ISION OF COMi' lit.NOE
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REGION I
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CO Inspection Report No.
50-289/72-03
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Subject:
Metropolitan Edison Company
Three Mile Island Unit No. 1
License No. CPPR-40
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Location: Three Mile Island (near Middletown)
Priority
Category
B
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Type of Licensee:
PWR 2535
(B&W)
Type of Inspection: Special (unannounced)
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Dates of Inspection: February 9 - 10 and 16 - 17, 1972
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Dates of Previous Inspecticn: January 27, 1972
Principal Inspector:
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_5- >/ ~/2,
5. A.
ots 'm\\ Re'actof Inspector
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Inspection Performed by:-
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3-20-71
A.Q'.( hiel'a, Reactor Inspector
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Other Accompanying Personnel: None
Reviewed By:__
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E.' M. Howard, Senior Reactor Inspector
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Proprietary Information: None
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7910290 %7 /"
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SECTION 1
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Enforcement Action
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None
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_ Licensee's Action on ?reviously Identified Enforcement Matters
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Nonconformance in moist cure of freshly placed concrete on contain-
ment building dome. Quality Control work procedures were found to be
clarified at this inspection. This item is considered to be resolved.
(Paragraph 5,Section II)
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_ Unresolved Items
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Status of Previousiv Identified Unresolved Items
Repair is continuing on the ring girder concrete voids in accordance
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with proposal submitted to DRL.
The first of about twenty-two concrete
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replacements was made February 16, 1972. This item remains unresolved.
(Paragraph 4,Section II)
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Design Changes
Not applicable
Persons Contacted
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Metropolitan Edison Comoanv/GPU
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Mr. B. Avers, QA Manager *
Mr. R. Heward, Proj ect Manager *
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Mr. B. Stewart, Assistant Manager *
Mr. M. Stromberg, Site QA Supervisor +*
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Mr. J. Wrigh t, Resident Civil Engineer +*
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Mr. J. Connelly, Assistant Resident Civil Engineer +*
Mr. R. Neidig, Assistant Resident Civil Engineer
Gilbert Associates
Mr. R. Fleming, QA Site Coordinator
+ Attendee at Management Interview 2/10/72
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- Attendee at }bnagement Interview 2/17/72
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UE&C
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Mr. R. Moyer, QC Supervisor *
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Mr. R. Thcmas, Assiatant QC Supervisor
Mr. P. Dailey, QC Inspector, Structural
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Mr. W. Haugen, Ring Girder Repair Supervisor
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Mr. T. Purin, QC' Inspector, Welding
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Mr. J. Malvin, Lead Inspector, Structura't
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Mr. N. Reitzi, QC Inspector, Concrete (PTL)
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Mr. J. Schmidt, Records Coordinator
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Mr. J. Luksic, NDT Supervisor
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Mr. C. Talbot, Mag Part Inspector
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National Mobile Concrete - Batch Plant
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Mr. N. Frazer, Supervisor
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Mr. W. Gaskin, QC Inspector (PTL)
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Mr. N. McCormack, QC Inspector . (PTL)
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Management Interview
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The licensee stated at the February 10, 1972 meeting that GAI had not
approved any part of Ring Girder,180* North, for concrete replacement.
(Section II, Paragraph 4)
The licensee stated at the February 17, 1972 meeting that Task Force
approval as a prerequisite for concrete placement in the ring girder
repair is not required.
(Section II, Paragraph 4)
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SECTION II
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Additional Subjects Inspected, Not Identified in Section I, Where No
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Deficiencies or Unresolved Items Were Found
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1.
Weld Shop Set-up For Restricted and Restrained Qualification Tests
Jig fixtrues used in procedure and welder qualification tests were
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inspected and found to provide restraint in four test positions.
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tricted test fixtures with restraint, appear to simulate field con-
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dicions where welding is required in congested area.
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2.
Shop Set-up For Rebar Notch Studv
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Inspcetion of this eq'tipment disclosed it could provide reliable
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data for the report on ' Reinforcing Steel Defect Size Acceptance
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Criteria' as given in Appendix C, Report to DRL of 12/3/71.
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3.
Concrete Heat Sink-Preheat, Burn and Weld Temperature Study
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UE&C Weld Procedure No. 25, Field Welding of Concrete Reinforcing
Bars requires that when one bar being welded is embedded in concrete,
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concrete temperature shall not be allowed to be raised over 200* F.
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The inspector observed a field laboratory set-up where testing was
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performed by UE&C and PTL on February 5 - 9, 1972. An arrangement
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of eleven thermocouples each on rebars sizes 6, 8 and 11 embedded
in 3000 psi concrete blocks 16" X 16" X 18" deep appear to be ade-
quate for this study.
Details of Subjects Discussed in Section f
4.
Containment Ring Girder Renair
a.
UE&C procedure CCP-9
This procedure provides a sequence and description of events,
refers to existing documents, procedures and their requirements
under which the work will be performed.
Emphasis is placed on
proper execution of repairwork and related quality control and
documentation efforts. The procedure is dated January 31, 1972
and was approved by. Met Ed - GPU February 3,1972.
It appears
to meet the intent of commitments made to DRL in Report of 12/
3/71 and Addendum to Report 1/21/72.
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b.
_ Repair of Ring Girder Concrete Voids
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(1) Status of Work,15' Segment I D218/D224
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Concre'e excavation was completed to sound face.
Three
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verification core borings have been made.
Cadweld splic-
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ing for replacement of damaged rebar is about 40% complete.
About half of vertical and dome tendon conduits have been
Epoxy and Dresser coupling patched but leak test was not
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complete. Grounding copper cable was reinstalled on trum-
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plates.
First butt welding of any rebar will be done here
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and the inspector was informed that radiographic examina-
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tion will be perfermed. Weld repair of rebar with minor
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nicks was not completed.
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(2) Status of Work, 30' Segment I D318/D332
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Concrete excavation was completed and seven verification
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cores taken.
Damaged rebar removal was finished and replace-
ment by Cadweld splicing was under way while weld preparation
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of low stress rebar in areas inaccessible to Cadweld was being
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done.
Some damaged dome trumplate spirals were being replaced
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by one inch square hoops. About ten vertical tendon conduits
were Epoxy patched but leak test was not completed.
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(3) Status cf Work, 30* Segment II Dll8/D132
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Concrete excavation was complete and checked by eight verifica-
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tion cores.
Form work for first of three lif ts of concrete re-
placement , Elevation 443' to about 446' - 9", was being instal-
led when inspected on 2/9-10/72. At this time rebar replace-
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ment by Cadweld splicing, vertical conduit patching, and patched
conduit leak testing was in process.
On 2/15/72 the last con-
duit was patched and satisfactorily leak tested.
But not un-
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til 2/16/72 was all rebar replaced by Cadweld splicing. This de-
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lay was necessitated by inspection access behind haunch and ra-
' dius bars that were re=oved only for access.
Final inspection
and clean out was completed on 2/16/72, rebars replaced by Cad-
weld splicing and, the first lift of concrete was placed that
day.
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(4) Status of Work,15* Segment II D218/D224
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Concrete excavation combined with removal of damaged rebar
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was in process.
No tendon conduits were repaired.
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Record Review on February 10, 1972
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Ce: Stete' documentation was unavailable at this ti7me.
But the
ins; actor was informed by licensee that no concrete would be
placed until records were complete and approval given by Gil-
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bert Associates.
Some records were in transit to GAI request-
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ing approval for repair of damaged rebar. Nat until these were
answered or returned frem GAI's Project Engineer in Reading, Pen-
nsylvania would the records be permanently filed the inspector
was informed.
This procedure was verified by the inspector's re-
view.
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d.
Quality Control documentation required by Repair Procedure CCP-9
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on Ring Girder Repairs for concrete placement Lif t # 1 Segment
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II D119 to D131 was audited and found in conformance to require-
ments. The records are identified, General File and Particular
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File. The former contains records and documentation on repair
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covering the entire circumferential area between D119 and D131
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dome tendons.
It consists of twelve verified and approved in-
spections sheets / check-out sheets covering excavation, damaged
rebar removal and replacement or repair, Cadweld splices, tendon
conduit repair, formwork and cleaning for concrete, application
of Epoxy bonding agent and the required prepour, batching and
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concrete placement inspection sheets.
A sample audit was made of one of ' eleven Particular File Folders,
No. D121 NE.
It contains the following :
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(1) Butt and/or Nick Welding identifies request from the field
and contains approval from Project Engineer for repair of
nicks by welding, on individual bars at location identified
by sketches and. Polaroid photographs.
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(2) QC Inspection Report of request from ;L: field for removal
.of specified rebar to accon=odate removal of unsound concrete.
(3) Check List for repair (CCP-9 sheet of 1 of 13) contains QC
inspectors verification on excavation to sound ccacrete.
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Above records appear complete and without discrerency to the
approved requirements of Repair Procedure CCP-9.
However, the
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inspector inquired if any record showing Task Force approval
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on adequacy of repairs and documentation before concrete was
placed existed. The licensee responded that Task Force approval
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as a prereq:iisite for concrete placement was not required.
Observation of First concrete Placed 2/16/72 on Lif t # 1 Segment
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II D119/131
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All concrete placed on Lif t # 1 was observed by the inspector on
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af ternoon of February 16, 1972. Preplacement requirements for
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check off, readiness and application of Epoxy bonding compound
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were also observed.
In addition the ins pector inspected aggre-
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gate storage, batching controls, delivery trucks, delivery,
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ing and conveying of concrete to the forer,
Photographs were taken
by the inspector before concrete placement of repaired rebar and
Cadwelded replacements, patched tendon conduits, arrangement for
placement and typical weld repair of nicked rebar.
These photo-
graphs are. retained in Region I files and will be available upon
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request.
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A total of seven loads were batched for this placement, the first
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four loads, each 4 cubic yards, were rejected for slump and/or
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air. From three 6 c.y. loads, the last three c.y. were rejected
for overtime. A total of 15 c.y. were placed in first lif t.
No
nonconformance to ACI 301-66 was observed in concrete.
5.
Nonconformance in Moist Cure of Freshly olaced Concrete
The concrete area in nonconformance L6 moist cure, observed by the in-
spector placed 12/16/71 on containment building dome, has been tested
for strength and found not to have suffered detrimental effects. This
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is detailed in reply of February 2,1972 to CO letter of January 5,1972.
In addition Met Ed/GPU's Jim Wright informed the inspector that clari-
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fication of the concrete cure procedure by instruction to UE&C construc-
tion superintendent and PTL inspector were specific.
Instructions limit
any removal of moist burlap only temporarily and only at construction
joint for preparatory work for placenent of next lift.
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