ML19261A419

Forwards 790111 10CFR50.55(e)rept Re Concrete Void in 6th Lift of Reactor Containment Bldg Noted During Const.Final Rept Will Be Provided After Completion of Repairs.W/Encl Ltr from Daniel Const Co Dtd 790111

ML19261A419
Person / Time
Site:	Wolf Creek
Issue date:	01/12/1979
From:	Koester G KANSAS GAS & ELECTRIC CO.
To:	Seyfrit K NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV)
References
NUDOCS 7901180156
Download: ML19261A419 (11)

Text

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KANSAS GAS AND ELECTRIC COMPANY ss

, THE E'LRCTen*C COnenuNY e*

GLE N N L MOE S T( H

.'CE pa t h ila t es t O*a ma t omsg i January 12, 1979 Mr. Karl V. Seyfrit Director, Region IV Office of Inspection and Enforcement U.S. fluclear Regulatory Commission 611 Ryan Plaza Drive Suite 1000 Arlington, Texas 76012 Re: Docket !!o. ST!! 50-482 Sub: 50.55(c) Report Regarding Concrete Void

Dear Mr. Seyirit:

On December 14 we reported to your Region IV Office that a concrete void was revealed when the fo rms for the sixth lif t of the Wolf Creek reactor containment building were lifted.

Subsequent to this initial report, we concurred with you that a wri tten 50.55 (e) report would be prepared for this void. Accordingly, please find attached two (2) copies of our interim report dated 1/11/79. A final report will be submitted after repairs have been co:nple t ed .

Also attached as part of the report is Mr. H.W. McCall's letter dated 1/11/79 which transmitted the final Ad !!oc Committee findings and recommendaticas to tre. These correspond to the eleven items of your letter of December 19.

We will review this report with Region IV personnel in Arlington, Texas on Saturday, January 13, 1979.

Please advise if you need additional information.

Yours very truly, dI /d j,'JL&b/)5'b[D

./,

GLK:bb Attach cc: Director, Office of Inspection & Enforcement c/o Distribution Service Branch, DDC, ADM U.S. !!uclear Regulatory Commission 79011866(

Washington, D.C. 20555 (Attach 15 copies) 20! IV. Market - Wichda, Kansas -- Ma l Address: P. O. Box 2C8 ! Wichita, Kansas 67201 - Telephone- Area Code (316) 26#1111

1/11/79 RFPORT OF CC:! CRETE VOID This interim report is made pursuant to 10CFR50.55(e) regarding a concrete void in the Wolf Creek Reactor Building.

(a) Description of the Deficiency On December 13, 1978, when the form for the sixth ring pour of the Wolf Creek heactor Containment Buildina was raised, a void beneath the equipment hatch was revealed. The void extends downward from the bottom of the equipment hatch to the top of the fifth ring pour at elevation 2043'-10" The sides of the void slope upward away from the hatch centerline. The width of the void is approximately six feet and the depth of the void extends through the thickness of the wall.

(b) Identi fication of the Firm Constructing the Facility Concrete production and placement far all Power Block Buildings at Wolf Creek is performed by Daniel International.

(c) Analysis of Safety Implications Because of the dimensions and location of the void described above, it is impossible that the void could remain unseen and thus remain unrepaired until the structure would go into service. Iloweve r, if it is postulated that the void renained undetected, it would have most probably been detected at the time of tendon tensioning (which occurs prior to opera tion) because of excessive deformations as a result of tendon load. Repair of th. void will meet all design requirements and no adverse effect to te health and safety of the pub)ic will result because of this voic (d) A Description of the Corrective Action, organization Reaponsible for the Action, Measures to , Prevent Reoccurrence The occurrence of the void has been docurented on !;onconformance Report 1Stio719C by Daniel and forwarded to the A/E, Bechtel Power Corporation, for dispositioning in the established manner. As of this date the details of how the repair will be made nave not been forwarded to the site by the A/E. When the A/E approved disposition is received, it will be reviewed with !JRC Region IV personnel prior to proceedinq with the repair work.

The repair work will be performed by Daniel.

To enhance the ef fecti veness of the Wolf Creek QA Program and especially to reduce the likelihood of additional concrete placement problems

Report of Concrete Void 1/11/79 the eleven step program as described in Mr. K.V. Seyfrit's letter to Mr. G.L. Koester dated December l'), 1978, has been undertaken. The attached report indicates the status of all eleven items and describes the findings of Daniel's Ad Hoc Committee. This report and Mr. H.W. McCall's letter of January il, 1979, also indicate the actions which hace been and are being takea as a result of the Committee's review.

To provide a further review of the QA Program as carried out by KG&E and Daniel, an independent consultant will be retained by YG&E/KCP' to make a long term investigation of the construction QA Program, its implementation and its effecti*leness. The con-sultants work will include recommending changes to correct any inadequacies which might be identi fied. It is planned to start this independent review as soon as a suitable consultant can be selected.

D ANIEL CON STRUCTION COM PANY, I NC.

DANIEL SulLDING GREENVILLE, SOUTH CAROLINA 29602 H. W. McCALL P ESIDENT Para o==* January 11, 1979 Mr. G. L. Koester Vice President Kansas Gas and Electric Company 201 North Market Street Wichita, Kansas 67201

Dear Glenn:

Confirming our discussion at the Wolf Creek site on January 9 and 10, I am pleased to transmit the Ad Hoc Committee's final ~ report on the placement and consolidation of the concrete on the Wolf Creek Project.

This report includes recommendations and actions deemed necessary to release work-hold agreement #3. D. M. McAfee has been assigned the responsibility to follow up all the recommendations and see that they are implemented.

In addition, we have enclosed a copy of the existing WP-IV-106 and QCP-IV-106 with the Applicable Draft Interim Change Pr.ocedures recommended by the Committee.

A Technical Service Representative from our Greenville-based Tech-nical Service Division will be on the site to fulfill a newly created position of Technical Superintendent-Concrete until a per-manent superintendent is assigned to the project.

The additional training of the craft in the field has been started and will be documented. A formal program for training responsible personnel in project procedural requirements shall be completed by February 19, 1979.

Subject to your review of our response and your verification of the actions called for therein we ask that you ign and release work-hold agreement #3.

incerely, cc: J. O. Arterburn L. W. McGri ff R. A. Bradshaw D. M. McAfee M. E. Clark D. T. McPhee E. W. Creel is e ?EO7 L. R. Smi th W. E. Hitt ~v' B. E. Wells

. a DANIEL INTERNATIONAL CORPO:MTION DANIEL BUILDING GR E ENVILL E. SO UTH CAROLINA 296o2 18o3)299-2500 TO: H. W. McCall DATE: January 10, 1979 FROM: Ad Hoc Committee

SUBJECT:

Placement and Consolidation of Concrete on Wolf Creek Project

REFERENCE:

1. Letter from H. W. McCall to Distribution, Dated December 16, 1978 same subject.

2. Letter from USNRC, to Kansas Gas and Electric Company, Dated December 19, 1978.

In accordance with your directive stated in reference #1 above, the Ad Hoc Committee has completed their review of safety related con-crete placement, consolidation, testing and inspection at the Wolf Creek Project.

The following are the results of the review. This report is keyed in the left hand margin to both reference #1 and #2 above. A sum-mary of recommendations is shown at the end of the report.

Reference 1 2 para.1 Immediately halt further placement of concrete in safety related structures until the following proposed reviews and corrective measures have been completed.

A Work Hold Agreement Number 3 was issued by Kansas Gas & Electric Company for safety related concrete on December 18, 1978, para,1 para.2 Completely review concrete placement and related work procedures to assure their adequacy for the placement and consolidation of concrete.

The results of the above review indicated the procedural controls for placement and censolidation of concrete are adequate and are in compli-ance with project requirements. However, to strengthen the procedural controls a change to WP-IV-106, (Concrete Pre-Placement, Placement and Post Placement) is recommended to include a section addressing pre-planning activities for difficult concrete placement.

January 10, 1978 Page Reference 1 2 para.2 para.3 Completely review quality control, inspection and testing procedures to confirm their adequacy.

The results of the above review indicate the procedural controls used by quality Control for testing and inspection of placement and consoli-dation of concrete are adequate and meet project requirements. To be consistant with the recommended change to WP-IV-106 it is recommended that QCP-IV-106 (Concrcte Pre-Placement, Placement and Post-Placement) also be revised to address the Quality Control Department's participat-ion in the preplanning effort and implementation of the plan.

Reference 1 2 para.3 para.4 Assure all persons in construction engineering, construction, and quality control are fully cognizant of these procedures, or any modifications to these procedures and that Quality Assurance verifies that the appropriate persons are trained in these procedures,

a. The Committee's review to assure that personnel in Construction Engineering and Construction are fully cognizant of concrete place-ment and related work procedures and modifications thereto resulted in the following:

Responsible Construction Engineering and Construction per-sonnel are cognizant of concrete placement an1 consolidation procedure requirements; however, there is a lack of documen-tation attesting to procedural review or training by either Construction Engineering or Construction, A standardized program has not been implemented for orientation and training of personnel relative to procedural requirements and contents.

A standardized program has not been implemented to assure that personnel are cognizant of either new procedures or revision to existing procedures,

b. The Committee's review to assure that personnel in Quality Control are fully cognizant of the requirements of quality control, testing and inspection procedures including modifications resulted in the following:

Quality Control personnel have a generally good working know-ledge of both the purpose and contents of QC Procedures al-though familiarity with the procedure itself was apparently limi:ed in some cases.

January 10, 1979 Page Reference (con't) 1 2 para.3 para.4 A standardized program has not been implemented for orientation and training of personnel relative to procedural requirements and contents.

A standardized program has not been implemented to assure that personnel are cognizant of either new procedures or revisions to existing procedures.

c. The Committee's review to assure that Quality Assurance verifies that appropriate persons are trained in procedures related to place-ment and consolidation of concrete indicated that the Orientation and Training is being audited and the results of the audits were satis-factory. Audits of On-Going Training of Craf t Personnel invol' nd in safety related work have not been accomplished to date.

In conclusion, these reviews indicate that project personnel inter-viewed are generally cognizant of the procedure requirements, how-ever, to assure that responsible personnel are knowledgeable of appropriate procedural requirementa additional training should be provided to Construction supervision, Engineering and QC personnel.

Specific training of concrete placement craft personnel should be provided as specified by the Technical Superintendent-Concrete.

Reference 1 2 para.4 para.5 ~~ Review the adecuacy of the quality assurance program for verifying the satisfactary placement and consolidation of concrete to meet project requirements.

The Committee reviewed the adequacy of the quality assurance pro-gram with the following results:

The Quality Assurance Program for assuring the satisfactory place-ment and consolidation of concrete to meet project requirements is adequate. The implementation of the program is adequate and ef fect-ive with the exception of documented training of personnel. To assure that project personnel are provided adequate training to per-form their assigned functions, the Department Managers shot td specify the required class room training for personnel under their direction.

Tids training should be conducted and documented for supervisory con-struction engineering and quality control personnel. In addition special formal and informal training of craf t personnel shoald be conducted and documented as specified by the Technical Superintendent -

Concrete.

January 10, 1979 Page Reference 1 2

--- para. 6 Review the adequacy of the quality control program for verifying the satisfactory implementation of the procedures.

The Quality Control Program was reviewed by the Committee and included the checks and balances of the Quality Control Program such as Procedures, Inspection Reports, Deficiency Reports, Non-conformance Reports and Audit Reports. The results of this review indicated that the QC Program has the necessary controls for verify-ing satisfactory implementation of the procedures.

A weakness was identified with documented procedural training which is addressed above. Also, it is recognized that better preplanning would provide additional assurance of the success of difficult con-crete placements. This is addressed in the review of the specific void as follows.

Reference 1 2 para. 5 para.7 Review the specific void in the concrete under the equipment hatch in the reactor containment wall to determine probable cause and corrective action.

A review was conducted by the Committee to determine the probable cause of the void.

The pour started on north side of Equipment Hatch with adequate vibrator crews working concrete from the north side flowing con-crete under the Equipment Hatch sleeve toward the south side.

Vibrator crews were also on the south side helping to flow the concrete. The concrete Q.C. Inspector and the concrete foreman were visually observing the face of the concrete with the aid of flash lights from approxiaately 20 feet from the center line of the sleeve and was considered sealed, they authorized finishing the pour from the south side of the Equipment Hatch sleeve. The probable causes are:

1. Delay ir. the pour around the Equipment Hatch on the north side to havirg to replace styrofoam which had broken loose. The delay of approximately 30 minutes could have reduced the plastic-ity of the concrete face.

2. Lack of windows in the forms to f acilitate placement and inspection.

3. Due to the heavy congestion of the rebar and tendon sheathing around the Equipment Hatch sleeve it was extremely difficult for personnel to get closer than 15'-20' from the centerline of the sleeve.

4. The centerline of the sleeve was not visually identified to aid Quality Control and Construction personnel in determining the location of the concrete face in relation to the centerline.

January 10, 1979 Page Ref+rence 1 2 '~

para.5 para.7 5. Absence of weep holes in the forms contributed to trapping air and preventing flow of concrete.

In conclusion elimination or mitigation of these probable causes thru better preplanning would have prevented the void.

Corrective Action to reduce the possibility of voids in congested areas.

The implementation of the Committee's recommendations at the con-clusion of this report should eliminate or mitigate the occurrence of voids as well as improve the overall concrete placement and consolidation program.

Reference 1 2 para.6 para.8 Review and confirm the independence of incpection and verification organizations.

This review was conducted by the Committee and the results confirm the independence of the inspection and verification organizations.

A thorough review of the management commitments at the Wolf Creek Project which included Section 17.Bl. of the PSAR, the DIC Quality Assurance Program-Nuclear and the organization alignment and res-ponsibilities defined in Construction Procedure AP-II-01, (Site Organization and Position Description) revealed that the management system for the project provides adequate independence for the inspec-tion and verification organization.

Interviews with Quality Control supervisors and inspectors confirmed that the implementation of the management commitments in the PSAR, DIC Quality Assurance Program - Nuclear and Project Construction Procedures is satisfactory.

Personnel interviewed feel that Quality is not being sacrificed in favor of schedule or cost.

The interviews revealed that a communication gap exists within Quality Control and between Quality Control and the remainder of the project.

It is recommended that Quality Control manageaent should be included in the project planning meetings and they should conduct regular meet-ings with their subordinate supervision to discuss work forecasts and potential and real problem areas. Effcrte should be made to reaffirm all personnel in the Quality Control Department are informed of their independence and authority.

, January 10, 1979 Page Reference 1 2 para. 7 para.9 Establish a Daniel Construction Company Ad Hoc Committee cotprising David M. McAfee, Chairman, Leo R. Smith; Richard A. Bradshaw; and William E. Hitt to review, evaluate, and attest to the adequacy of the above action items prior to further placement of saf ety related concrete.

Kansas Gas and Electric Company will be represented at each Committee meeting by at least one individual from its Quality Assurance group.

The Ad Hoc Committee was formed in accordance to the above statement and this report comprises its findings and recommendations.

Reference 1 2 para.8 para.10 David M. McAf ee, Committee Chairman, is to report to Mr. H. W. McCall, President-Power Group, Daniel Construction Company, on a daily basis as to the progress being made on these actions. Mr. H. W. McCall, in turn, will keep you informed, daily, of the committee's significant findings.

D. M. McAfee did report to H. W. McCall to discuss progress and find-ings of the Committee on a daily basis. This progress was reported to G. L. Koester on a regular basis.

Reference 1 2 -

para.11 Discuss with Region IV personnel the completion status of the reviews and corrective measures identified above, along with any significant findings, prior to resumine the placement of concrete in safety re-lated structures .

A meeting is scheduled with Region IV personnel on January 13, 1979, to present this report.

RECOMMENDATIONS: 1. Implement a formal program for training responsible personnel in project procedural requirements.

2. Provide additional training of concrete placement and consoli-dation requirements to applicable construction and quality con-trol personnel to assure their knowledge for placing and con-solidation of concrete.

3. Assign Technical Superintendent-Concrete for the project to direct Ccnstruction personnel in preplanning their work.

January 10, 1979 Page RECOMMENDATIONS (con't)

4. Q.C. Management conduct regularly scheduled meetings with their subordinate supervision to discuss work forecasts and potential and real problem areas. Also, Q.C. Management should be required to participate in roject planning meet-ings.

5. Revise WP-IV-106 and QCP-IV-106 (Concrete Preplacement, Place-ment and Post Placement) to address preplanning and special written instructions for difficult concrete placement act-ivities.

6. A Quality Assurance audit of on going training of craf t personnel sould be conducted in the near future.

7. Additional special formal and informal training for craft personnel should be conducted and documented as specified by the Technical Superintendent-Concrete.

8. The Project Manager and the Regional Manager, Power Group should meet with Q.C. personnel to reaffirm their independence and authority.

9. Add to the Daniel Quarterly Quality Assurance Committee Meeting agenda an item to review the independence and authority of the Q.C. Department. This meeting is a joint meeting between the licensee and Daniel.

10. Submit formal requests to the Architect Engineer when required to facilitate placement of concrete.

/

D. M. McAfee