ML19262A459

Forwards Special Insp Rept 71-04 on 710706-07 Re Significant Concrete Voids in Tendon Anchorage Area Around Ring Girder. Investigation Delayed Until End of Engineers Labor Strike

ML19262A459
Person / Time
Site:	Crane
Issue date:	08/03/1971
From:	Henderson J US ATOMIC ENERGY COMMISSION (AEC)
To:	Long C US ATOMIC ENERGY COMMISSION (AEC)
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ML19262A460	List: ML19262A459
References
NUDOCS 7910290803
Download: ML19262A459 (2)

Text

_ _ _

i t

f UNITED STATES 4

ATOMIC ENERGY COMMISSION

)

WASHINGTON. D.C. 20545 g*'"5 " /

AUG 3 1971

,i g

C. G. Long, Chief, PWR Project Branch #2, DRL METROPOLITAN EDISON CQ4PANY (THREE MILE ISLAND UNIT HO. 1) -

i DOCKET No. 50-289

' The enclosed report of a special inspection. conducted.on July b and 7 is transmitted for information. The licensee informed CO by phone on July 2 that significant concrete voids existed in the tendon anchorage area in the vic2.nity of the ring girder. A complete assess-ment as to the extent of tne voids could not be determined until the Operating Engineers strike t.ds and the crane was available to remove all of the forms. Le are advised that that strike nas now been j

terminated.

c.

The licensee nas appointed a team of NDT specialists to conduct 1007.

volumetric inspection of the suspected areas.

The licensee will approve the inspection method, the resolution and repair program and the final inspection and acceptance of the repairs.

CO will follow tiiis matter on subsequent inspections.

I y;w.

1

Enclosure:

J. B. Henderson, Chief I

CO Rept. No. 71-4 Reactor Construction Branch Division of Compliance cc:w/ enclosure E. G. Case, DRS(3)

R. S. ' Boyd, DRL(2)

R. C. DeYoung, DRL(2)

D. J. Skovholt, DRL(3)

H. Denton, DRL(2)

A. Giambusso, CO L. Kornblith, Jr., C0 R. H. Engelken, C0 J. P. O'Reilly, CO:I J. G. Davis, CO: II B. H. Grier.. CO: III J. W. Flora, CO:IV R. W. Smith, CO:V VREG Files 7 910290 r03 1489OM

~

i IN,m; U. S. ATOMIC ENERGY COMMISSION DIVISION OF COMPLIANCE REGION I INSPECTION REPORT i

CO Report No.:

71-04

Subject:

Metrooolitan Edison Comoany Docket No.

050-00289 6

I License No. CPPR-40 Three Mile Island Unit 1 t

i Location:

Three Mile Island, Pennsylvania Priority N/A Category A

J Date of Inspec -ion:

July 6-7, 1971 i

Date of Previous Inspection:

June 24-25, 1971 4

Type of Licensee:

PWR, 870 MWe Type of Inspection:

Stecial, Announced.

Principal Inspector:

NN ?./ d.,<.s 7- /3 - 7/

l J. H. Tillou seactor I oector Date Ma 7-[b~)!

h Accompanying Inspectors:

S. A. Folsom, Reactor Inspector Date Other Accompanying Personnel: None h6

@/3-7/

Reviewed by:

E. M. Ifoward, Senior Reactor Inspector Date Proprietary Information: None s

4910290 h y

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SECTION I Nonconformances A.

Excessive voids and porosity observed in three Class I concrete tendon anchorage areas, at elevations 443' - 453'.

(Sea Attachments 1 and 2)

Licensee Action on Previously Identified Items g

1 None l

l Unresolved Items t

l None Status of Previousiv Reported Unresolved Items 4.

Grinnell failure to provide material, etc. records with certain engineered safeguards piping spools. No change.

B.

Concrete pour in fuel handling pool wall at temperature less than 32 etc. No change.

C.

No NUTT tests on material used in fabrication of core flooding tanks. No change.

D.

UT of all reactor vessel shell and nozzle velds prior to installation. No change.

E.

Corrective action on DK coolers, final cleaning by fabricator with chlorinated solvent. No change.

Unusual Occurrences None Persons Contacted Metrooolitan Edison Camoanv Bud Avers, QA Manager Matt Stromberg, Site QA Supervisor John Connally, QA Engineer (Civil and Structural)

'd 1484 003

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William Shepard, Site Resident Engineer James Wright, QC Engineer (Civil)

George Bierman, Three Mile Island Project Manager United Engineers and Constructors J. Fant, Site QA/QC Supervisor l

Paul Dailey, Site QC Engineer (Civil and Structural)

Pittsburgh Testing Laboratory 3

Wallace Braden, Three Mile Island Site Supervisor Management Interview A.

Licensee's Participation In The Defective Concrete Problem Mr. Avers stated Met Ed was vitally interested and that the problem had i

been documented by U&EC on their Deficiency Report No. 0366, which had been officially transmitted to the project. Deficiency Review Board for

>]

resolution.

I t

He further stated that a complete evaluation of all areas encompassed by l

this placement was being delayed by the work stoppage of the operating I

engineers, since cranes etc. are required for removal of forms from this l

ring girder area.

Mr. Avers named a consulting group of NDT specialists from UE&C, GAI and PTL I

who were studying methods and techniques for 100% volumetric inspection of the suspect areas after forms are removed. He stated that, to date, no method had been proposed which could reliably identify porosity or voids in the concrete placed within the complex maze of trumplaces, tendon sheaths, anchors, and the vertical, horizontal, or circumferential rebar located in this area.

Mr. Avers further stated that the Met Ed QA group and project manageaent had formally advised UE&C that they (Met Ed) must approve the concrete inspection method, the resolution / repair procedures developed, and the reinspection program for acceptance of repairs.

In conclusion, Mr. Avers stated that the unofficial preliminary position of Met Ed was that the entire 353 cubic yards involved in Lif t No. 3 would have to be removed.

s 1484 004

r A

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B.

Failure of Licensee To Notify CO:I of Sienificant Construction Deficiencies l

^

Mr. Bierrn (Project Manager) stated that their failure to advise CO:I of the suspected problem was their embarassment over the unresolved CDN regarding concrete placed at temperatures lower than allowed by speci-I fication/ cede, and the fact that their finding to date are preliminary, i

since only three local areas have been inspected.

Mr. Avers stated that their management had belatedly advised him to verbally discuss the problem with C0:I.

(Ref. telecon with E. M. Howard, July 2, 1971).

1 C.

The Breakdown of the Site QA/QC Program for Concrete Mr. Avers and Mr. Stromberg stated they would insist that the UE&C pro-cedure No. QC-30, " Work Stoppage" be revised to require that any concrete i

l pre-placement inspection report which contains omissions, reservations or.totations of deficiencies must be presented to the UE&C site QA super-visor for resolution prior to ordering concrete delivered to the place-ment site.

.]

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N 1484 005

Jo SECTION II Additional Areas Inspected, Not Identified In Section I, Where No Deficiencies or Unresolved Items Were Found General j

1.

A telecon on July 2, 1971 from Mr. Avers, GPU QA Manager, advised Mr.

E. M. Howard of an apparent deficiency in concrete placed in the ring girder area of Three Mile Island Unit No. 1 containment wall.

This information was considered to be of sufficient concern, that a special inspection trip was scheduled by the principal inspector to investigate the details of the problem.

2.

Logs and Records a.

UE&C Deficiency Report No. 0366, June 4, 1971 - This report was re-viewed and identified pcur No. 3 at elevation 443' - 453' and azimuth 1100 - 288.

It stated "Following partial removal of forms, poor 0

f]

consolidation of concrete was observed around the trumplate and rebar j

area resulting in porosity and voids between trumplates, tendon sleeves and complex rebar placement"- " Refer to UE&C Engineering for resolu-j tion and corrective action which must be approved by GAI and Met Ed."

b.

UE&C Concrete inspection Check Sheet, Attachment A - Check-off sheet signed by UE&C Concrete QC Engineer.

c.

UE&C Concrete Inspection Report, Attachment B - This inspection release l

sheet is also signed off by the UE&C Concrete QC Engineer and authorizes production to order delivery of concrete to the placement site.

(Ref.

4 Section I, Management Interview, Item C) d.

UE&C Construction " Concrete Pre-Placement Sign-Off Sheet No. R-249-A" -

This sheet contains ' sign-off entires by the various craft supervisors covering completion of their work, according to drawings, in the pour area. The final report is signed off by the UE&C site civil and structural engineer.

I 1484 006

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PTL "7empression Test Cylinder Report No. R-249" - This report con-e.

tains design mix, concrete class, identity of pour, actual slump, air and weight / unit volume tests, length of cure and results for seven and 28 day curing periods.

Results were well in excess of 5000# design mix requirements.

Report was signed off by PTL site f'

supervisor.

l f.

PTL " Batch Plant Inspection Report No. R-249-A" - Identifies pour,

{

elevation, azimuth, design mix, actual mix, number of truck loads, j

total cubic yards, and daily records on sand and aggregate gradation tests. It further includes the time of start and finish of the pour j

as well as the number of trucks rejected and reasons. This docu-I ment is signed off by the PTL batch plant inspector.

8 An inspection of the batch plant and storage area indiccted that i

i weighing equipment is calibrated on a regular schedule. Materials, I

cement, aggregate and sand are stored and regularly sampled to ASTM j

requirements. Water (and ice) are analyzed on a monthly schedule.

Details of Subiecrs Discussed In Section I 3.

Deficient Concrete Placed in Pour No. 3 of Three Mile Island Unit No. 1 Ring Girder Area.

Ref: (1) Cross-Section Orientation Sketch, and (2.1 Photos of Areas with Forms Removed j

As a production expedient, the UE&C site construction superintendent elected l

to make pour No. 3 at elevation 443' - 453' and azimuth 1100 - 288 in one lift. The UE&C site QC concrete inspector expressed his doubts as to the ability of the crew to properly compact the concrete in this area so con-gested with trumplates, tendon sheats and multi-directional rebar. These doubts and reservations were noted on Attachment B to UE&C " Concrete In-spection Report" as follows, "Due to no access to the pour area, only a portion of this area is visible--absolute cleanliness thus cannot be as-sured." Also under the heading " miscellaneous", he recorded "Due to the mass and arrangement of rebar, etc. in this area, proper consolidation of concrete will be difficult or impossible."

It was stated by W. Braden, the PTL site supervisor, that his inspector also expressed grave doubts regarding the compaction of concrete in this ireg-ularly shaped and congested area. This concern was transmitted verbally by W. Braden to the construction superintendent, who it was reported, con-sidered the warnings as personal opinions and continued with preparations for the pour.

w 1484 007

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-T-I Mr. Connally stated that all concrete was placed with crans and buckets, discharged into tremies equipped with rubber chutes allowing approximately four to five feet of free fall. Test cylinders, slump, air temperatures, and weight per unit volume tests were made at truck discharge chutes.

He furmher stated that, as anticipated, use of vibrators for compaction was almost impossible and completely abortive in the more complex configura-tions and congested areas.

After pouring 353 cubic yards in the azimuth area 110 - 288, the job engineer advised the construction superintendent to remove the rebar in the apper portions of the forms, to allow access for personnel to use the vibrators, and make the balance of the circumferential pour.in two lifts. This was done and the southern henisphere of the ring girder is considered by Met Ed to be acceptably placed.

4.

Breakiown of the UE&C QA/0C Program UE&C QC-30, "Procedare for Work Stoppage" is incomplete, since there is no provision for the inspector to express his concern over practices or workscuship which in his judgement will produce deficiencies, but which

,()

do not specifically violate codes or specifications.

It appears that QC personnel must follow a most circuitous, torturous trail in order to get a job stopped and thereby incur the criticism or wrath of the pro-duction personnel with whom they aust have daily or hourly contact.

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'*'***a-fona 4EC 95 ( Rc. May 14. 494? > AEL 0240 Ncte and return.

i For $4 mature.

For Information.

(Name and unit;

ssTIALS AEMAAKS J. B. Henderson.C0

_ In rerard to the concreta defief ene-r recentiv reported for Three Mile Island Unit 1 (Comp 14=ne=

can Ratert 71-04). we underntand thnt ht-FA inteda 7

to notify Couplianca cf the intended repair orocci. m s.

In view of the i n.a m a to mafety

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TO (Name and u.nt) puTIALS REMAAKS that the eencratu in the affected area has, we Distribution :

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..m14 ;m LE _; L4 w a.a Docket File (50-289) 07the repair plans, also.

PWR-2 Reading D.F. Ross TO (Name ana umt; ireTIALS REMAAES cm FROM (Name and unit)

REMAAKS Charles G. Long, E.af PWR Project Br. No. 2 Div. of Rametor Licensing F ow na em 7317 8/17/71 USE CTMEA SCE FOR A00lTIOm4L REMAAKS ero uses o-ase-eis

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