ML19260A422
| ML19260A422 | |
| Person / Time | |
|---|---|
| Site: | Marble Hill |
| Issue date: | 10/01/1979 |
| From: | NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML19260A418 | List: |
| References | |
| 50-546-79-09, 50-546-79-9, 50-547-79-09, 50-547-79-9, NUDOCS 7911210086 | |
| Download: ML19260A422 (4) | |
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Appendix A NOTICE OF VIOLATION Public Service of Indiana Docket No. 50-546 Docket No. 50-547 ased on the results of an NRC inspection conducted on July 9-13, 17-20, and 23-27, 1979, it appears that certain of your activities were net conducted in full compliance with NRC requirements as noted below.
Items 1-5 are infr ctions.
1.
10 CFR 50, Appendix B, Criterion X, requires that a program for inspection of activities affecting quality shall be established and executed by or for the organization performing the activity to verify conformance with the documented instructions, procedures and drawings for accomplishing the activity.
The Marble Hill PSAR, Chapter 17.0, Section 17.1.10.1(b) requires that, " Inspections or tests are performed for each work operetion as necessary to verify quality."
Contrary to the above, the inspector identified the following areas in which PSI subcontractor QC inspection personnel failed to perform adequate inspection of work operations to verify quality on placement number 2SW-377-7B.
a.
July 10, 1979 - Reinforcing steel failed to meet the minimum clear distance to formed surfaces as specified in Sargent &
Lundy (S & L) Specification Y-2722, Section 412.
b.
July 10, 1979 - Reinforcing steel did not meet the minimum cleanliness requirements specified by ACI 318-71, Section 7.2.1 and the CRSI " Manual of Standard Practice", Chapter 8. as required by S & L Specification Y-2722, Section 412.
c.
July 10, 1979 - The horizontal construction joint was not properly prepared for bond as qmcified in ACI 301-72, Chapter 6, as required by S & L Specification Y-2722, Section 411.
d.
July 10, 1979 - The vertical construction joint contained embeeded contaminants (i.e., visqueen and styrofoam material) and areas of apparent honeycomb extending from the top of the vertical construction joint to the bottom around the projecting horizontal reinforcing steel.
e.
July 17, 1979 - Reinforcing steel failed to meet the niinimum clear distance to formed surfaces as specified by S & L Specification Y-2722 Section 412.
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b S19 Appendix A f.
July 17, 1979 - During concrete chipping to remove contaminants from the 28 line bulkhead, a featheredge condition was created.
This condition is not in accordance with ACI 301-72, Chapter 8, as referenced by S & L Specification Y-2722.
p.
10 CFR 50, Appendix B, Criterion III, requires that measures shall include provisions to assure that appropriate quality standards are specified and included in design documents and that deviations from such standards are controlled.
The Marble Hill PSAR Chapter 17, Section 17.A1.3 states that,
" Appropriate quality requirements and standards are specified and included in design documents by those assigned responsibility for these items."
Contrary to the above, the following instances were noted in which design documents do not include appropriate quality standards, in that:
a.
No definitive requirement which specifies the maximum allowable lateral movement of fresh concrete during placement presently exists.
b.
The 7 day cure requirement for concrete is not adequately defined in S & L Specification Y-2722 to assure the proper curing time.
c.
S & L Specification Y-2722, Section 413.6 h. does not prevent the continued rapid discharge and placement of concrete during tightened sampling initiated as a result of concrete which does not meet specification.
d.
S & L Specification Y-2850, section 406.3 does not provide adequate control to prevent the inadvertent use of noncomforming aggregate in that test results are not available prior to the use of such aggregate.
3.
10 CFR 50, Appendix B, Critierion V, requires that activities affecting quality shall be prescribed by documented instructions, proc 2dures, or drawings, of a type appropriate to the circumstances and shall be accomplished in accordance with these instructions, procedures, or drawings.
Marble Hill PSAR, Chapter 1, Section 1.7, commits to Regulatory Guide 1.28 (June 7, 1972) and therefore to ANSI N45.2-71. ANSI l_
N45.2-71, Section 6, states that, " Activities affecting quality shall be prescribed by documented instructions, procedures,.or 1381
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OC7 c m3 Appendix A '
drawings, of the type appropriate to the circumstances and shall be accomplished in accordance with these instructions, procedures, or drawings."
Contrary to the above, the RIII inspector observed the following:
(Placement Number ICW-Ext.-9) Failure to consolidate the preceeding a.
2 ft. concrete lift prior to depositing fresh concrete in two ACI 301-72 and ACI 304-73, specified by S & L Specification areas.
Y-2722, Section 413.2, requires that concrete be placed in horizontal lifts not exceeding 2 ft. in depth and be consolidated by vibration.
b.
(Placement Number ICW-Ext -9) Internal concrete vibrators that were inserted at about 30-inch intervals, exceeding the allowable distance of about 18 inches specified by S & L Specification Y-2722 and ACI-301-72.
No procedural requirements exist for the mixing, installation, c.
and inspection of dry pack material used in the repair of defective concrete.
d.
No documented instructions or procedures exist to specify the type of repair (i.e., dry pack, concrete pour back, grout pour back, pressure grout, or gunite) which should be used for any specific defective area; based on the void size, configuration, and accessibility.
4.
10 CFR 50, Appendix B, Criterion XVI, requires that measures shall be established to assure that conditions adverse to quality are promptly identified and corrected.
Marble Hill PSAR, Chapter 1, Section 1.7, commits to Regulatory Guide 1.28 (June 7, 1972) and therefore to ANSI N45.2-71.
ANSI N45.2-71, Section 17 states that, " Measures shall be established
. to assure that conditions adverse to quality... are promptly identified and corrected.
Contrary to the above, the RIII inspector observed or confirmed:
Two honeycomb areas which were not identified, tagged, or a.
repaired as required by QAPN-10.
b.
Thirty defective concrete areas containing either minor or major honeycomb, and/or various contaminants, which were super-ficially patched before complete removal of all defective material. These areas were not identified or tagged as required by QAPN-10.
1381 17s
Appendix A
- The availability of nonconforming " dead cement" for use in c.
making concrete repairs, originally identified on June 26, 1979, was not yet corrected on July 19, 1979.
5.
10 CFR 50, Appendix B, Criterion 11 states in part that, "This program shall provide for the indoctrination and training of personnel e
A performing activities affecting quality as necessary to assure that suitable proficiency is achieved and maintained.
The Marble Hill PSAR chapter 17.0, Section 17.1.2.5, states in part that, "An integral part of the PSI quality assurance program is its provisions for the training and indoctrination of project personnel and quality assurance personnel... The training program applies to all personnel who perform project related activities."
Contrary to the above, on July 20, 1979, it was determined by personnel interviews and observation of work that contractor supervision, concrete finisher craftsmen and QC inspection personnel were inadequately trained and indoctrinated as demonstrated by numerous concrete repairs which were completed:
(1) without benefit of QC notification, (2) without adequate patch preparation, (3) using nonconforming materials, and (4) without of adequate procedures.
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