ML19276H324
| ML19276H324 | |
| Person / Time | |
|---|---|
| Site: | Crane  |
| Issue date: | 01/29/1969 |
| From: | Cantrell F, Whitesell D US ATOMIC ENERGY COMMISSION (AEC) |
| To: | |
| Shared Package | |
| ML19276H275 | List: |
| References | |
| 50-289-69-01, 50-289-69-1, NUDOCS 7910160666 | |
| Download: ML19276H324 (13) | |
Text
J. & <T U.
S. ATOMIC ENERGY COMMISSION 9
REGION I DIVISION OF COMPLIANCE Report of Inspection CO Report No. 289/69-1 Licensee:
METROPOLITAN EDISON COMPANY (Three Mile Island Nuclear Station No. 1)
Provisional Construction Permit No. CPPR-40 Date of Inspection:
January 7, 1969 Date of Previous Inspection:
September 18-19, 1968
' Wl& 11 [o-
/
f f Inspected By:
/
F.
Cantrell, Redctor Inspector
'Date Y
/= f'1 = ls ?
D.
E. Whitesell, Reactor Inspector (Constr)
Da te 84 A df M '. Moseley, Reviewed By:
N.
C S'enicr Reactor Inspector
' Date SCOPE A special announced inspection was made at the 2452 Mwt Pressurized Water Power Reactor under construction on Three Mile Island near Middletown, Pa.
The purpose was to inspect the concrete voids uncovered when the forms were removed from the ceiling of tne tendon galley.
Mr. D. Whitesell, Reactor Inspector (Construction),
Region I, acc'ompanied the assigned inspector and wrote portions of this report.
1419 233 7910160666
- 7. $' '
SUMMARY
An inspection of the tendon galley after the void areas had been chipped back to solid concrete, showed that in three areas the void extended up into the concrete more than one inch.
These three areas penetrated the concrete from twelve to sixteen inches (Attachment No. 1 and 2).
The affected areas were between the tendon bearing plates, and in only one area wa's the concrete chipped out from behind the bearing plate.
The space behind the bearing plate was approximately 1" wide, 3" deep, and 12-15" long.
The total void volume, including the chipping, is estimated ro be 4-5 cubic feet.
The cause of the voids was wood and mud left in th form prior to pouring concrete.
MET-ED and Gilbert Associates, Inc. (GAI) have completed their review and approved the United Engineers and Constructors (UE&C)
Repair Procedure.
A copy of the Procedure (Attachment No. 3) was sent to Compliance for review.
Repairs to the voids around the 170 wire tendon plates will be delayed to permit Compliance review 9
of the Repair Procedure.
Repairs around the unused trumpets (90 wire system) will be made as necessary in order to not cause a delay in the schedule.
The Chicago Bridge and Iron (CB&I) welding procedures for the containment liner were reviewed and found to be adequate, except that the quality control procedures were not included.
Sub-sequently, MET-ED reported that CB&I had agreed to provide copies of the quality control procedures to MET-ED and UE&C.
Compliance was given copies of the following Quality Control Procedures:
Structural Concrete (Attachment No. 2)
Site Quality Control Plan Receiving and Material Control Storage Liquid Penetrant Examination Magnetic Particle Examination
]/}j')f Radiographic Examination Ultrasonic Examination Leak Test Region I will evaluate these procedures and will repo.rt the evaluation in the next inspection report.
%GD Results of Insoection A. Persons Contacted Vernon Steubner, Resident Engineer, MET-ED B. G. Avers, Manager, Quality Assurance, GPU Dick Mason, Job Engineer, UE&C D. A. Godfrey, Structural Engineer, GAI R. M. Eshbach, Field Quality Control Inspector, GAI M. B. Prisota, Field Quality Control Engineer, UE&C Karl Brooks, Welding Inspector, UE&C B. Concrete 1. On December 16, 1968, Vern Steubner, of MET-ED phoned the assigned inspector to report that some voids had been discovered in the concrete in the ceiling of the tendon access' galley. He stated that the voids had been created by dirt and pieces of wood left in the forms. He informed the inspector that the areas had been cleaned and 9 the concrete had been chipped out to clean solid material. The total voids were estimated to be approximately 4-5 cubic feet. 2. The' inspectors examined the void areas and found that there was a total of seven (7) areas where dirt and bits of wood had been found. Of the seven areas, four (4) were found to penetrate into the concrete a distance of 1" or less, and could be easily patched. 3. The three remaining areas had been created by pieces of wood and penetrated into the concrete for depths of twelve to sixteen inches (12"-16") and would require repairs. All areas affected were between the tendon bearing plates and at only one place was the concrete chipped out from under the bearing plate and this constituted an area of approx-imately 1" wide by 3" deep and 12" to 15" long. (Location shown in Attachment No. 1, photographs of void areas in Attachment No. 2.) O IA19 235
"Z k 9 _4_ 4. UE&C has prepared a written procedure for repairing these areas (Attachment No. 4.) Tha procedure has been approved by GAI and MET-ED. 5. The inspector traced the concrete records for placement in the two worst areas (Section 5 & 6). Sections Involved: 3, 4, 5 and_6 (Attachment No. 1) Dates of Pours: 9/9, 9/19, 9/16, 9/26 Height of Pour: 8' 6" continuous pour Slumps: 2 3/4" to 4" Temperature of Batch: Average 65 F (one batch was used with Temp. of 710F. 6. The forms were inspected prior to the pour by the testing laboratory inspectors, UE&C Engineers and GAI engineers per QC Procedure No. 1 for Structural Concrete (Attachment No. 31) During the pour, " slump" and temperature was measured on each batch. Two testing laboratory inspectors G were assigned to each pour point. UE&C and GAI engineers were also assigned overall inspection responsibilities for observations of vibrations and overall progress. 7. Pittsburgh Testing Laboratory replaced U. S. Testing Laboratory on October 1, 1969 Insufficient manpower to adequately cover the jobs in progress was reported by MET-ED to be the prime reason for the change in test laboratories. 8. In discussing the probable factors contributing to the cause of these defects, the inspectors learned that a part of the concrete placement was delayed by a rainstorm which occurred after the placement area had been cleared.
- Also, the areas where wood was found in the concrete occurred at the points where bulkheads had been erected to form the pie shaped placement areas.
The wood scraps could have been overlooked due to poor visibility of the area in the vicinity of the high density of steel. O 14l9'236
"w 6 t' S 9. Mr. Avers stated that, although all the containment base slab was completed, the incident had alerted them to the need for closer inspection of all contact surfaces immediately prior to and during all future concrete placements, and they had in fact implemented a more stringent inspection program. 10. The inspectors visited the Testing Laboratory constructed on the site by MET-ED and operated by Pittsburgh Testing Laboratory for monitoring the concrete work. The Laborator; is equipped with a steam curing rocm where the temperature and humidity are monitored with recording instruments. The laboratory also is equipped for making the cylinder break tests and for checking cadweld splices, and verifying the yield and ultimate strength of the rebars. 11. The inspectors observed a portion of the placement of concrete in one of the turbine ped'stals and found the area to be protected by canvas wind u.2akers and several heaters. The forms were insulated and the surface of the fresh concrete protected by approximately two feet (2') of straw. C. Liner Plate 1. Materials The mill certificates for the liner plate material was reviewed and found to conform to the materials specified in the PSAR. 2. Weldinc Procedures a. Th welding procedures examined were developed by Chicago Bridge & Iron (CB&I) and approved by United Engineers and Constructors (UE&C) as follows: (1) Procedure 9V was for joining base metals classifie as P-1 to P-1 in Table Q11.1 in Section IX of the ASME code by using the shielded metal arc using F-3 electrodes. G 1419 237
%d 'd
- (2)
Procedure 491 which was for joining P1 to P1 using F4 electrodes. (3) Procedure 25 which was for joining P1 to P1 using a submerged arc with Linde 29 wire and grade 50 flux. (4) Procedure 171 which was for joining stainless steel to stainless steel with a shielded metal arc and using E308-16 electrodes. (5) Procedure 473 which was for joining stainless steel to carbon steel with a shielded metal arc using E309-16 electrodes. b. Each of the above procedures provided for joint preparation, current characteristics, cleaning, visual inspection, staggering of the start and stop points for multiple passes, repairs of defacts, and each procedure e was accompanied by a sketch showing the pass sequence. Each welding procedure had been qualified in the flat, c. vertical, horizontal and overhead positions, and charpy notch tests of the weld metal and heat affected zones had been made all in.accordance with section IX of the ASME Code. d. An examination of the welder!$ qualification tests re-vealed that nine welders had qualified on procedures 9V, 491 and 25 in all posi'. ions. No welders had been qualified on procedures 171 and 473. The inspector inquired if CB&I had submitted any e. written quality control procedures that would be imple-mented for the control of their field fabrication. (1) Mr. Avers, of GPU, responded that th3y had re-ceived a copy of a letter from CB&I to UE&C where in CB&I stated that thair intention was to use their Field Engineer and Welding Supervisor to 9 handle the quality control of their fi ald fabrica tion, and anything more than this would result in an addition to the contract in the.ameunt of twenty-thousand dollars ($20,000.)
~ b6L7 (2) Mr. Avers stated that c1ET-ED's response to the above was with a letter vritten December 30, 1968 a quote from CB&I for directing U.3&C to obtai:1 written proc 3dures cove.ing radiography, liquid penetrant inspection, ultrasonic inspection, and general installation procedures including the storage and control of electrodes, all in conjunc-cion with GAI specifications SP-5490 and SP-5489. f. Mr. Steubner phoned January 17',. 1969 to report that CB&I had agreed to supply the requested quality control procedures. D. Plant Pioing -1. The purchase specification number 5544 was reviewed and the inspector noted that the specifications covering shop fabrication. required the following procedures. O a. Receiving inspection for cleanliness, damage or discrepancies, b. Stainless steel to be stored separate from carbon steel Welding procedures and qualification tests to be c. available in shop d. Welder's qualification tests available in shop for review All welding to be in accordance with Section IX of e. the ASME Code f. All fabrication work to conform to Sections I, VIII ano IX of the ASME Code as a minimum, unless other-wise noted. g. Stress relieving and/or heat treating to be by electrical induction, or in a furnace. O .e !A19 239
76? 2. The specifications contained provisions for 100% radio-graph and 100% magnetic particle or dye penetrant in-spection of all girth and longitudinal butt welds, seal welds and branch welds 4" and over,and 100% magnetic particle or dye penetrant examination of all fillet welds; under Table N1, defined "as sever nuclear in-cident" and Table N2, defined as " causing hazard to the plant." The specification further, requires the fab-ricator to have a quality control procedure to control ~ the following: (a) Raw Materials - including inspection, identifica-tion and certification. (b) Purchased Parts - Inspections and tests. (c) Fabrication Process - Qualification tests, cleaning tools and fixtures. (d) Inspection and Test Ecuipment - Calibration of 9 instruments and gages. (e) Packacinc & Shippinc - Final inspection, releases and maintenance. (f) Control of Chances - Drawings, specification, etc. (g) Material Identification - Marking, tagging, and inspection status. (h) Disposition of Nonconforminc Items - including re-pairs, rework, retests or identification to prevent inadvertent use. (1) control and Storace of Inspection and Test Records 4%. e a. 3. It was not determined as to how the vendor is informed as to whether his work involves a system that falls under Table N1 or N2.. This will be pursued on the next visit. O O !419 240
LM E. Exit Interview Portions of the exit interview were conducted by phone after the inspectors returned to the Region I office. 1. Concrete The inspectors stated that they would like to review the repair procedure for the voids in the concrete before the Steubner stated that he would repair work is started. Mr. send a copy of the repair precedure to Compliance as scon as the procedure had been approved by GAI and MET-ED. 1969.) (The Procedure was received by Region I on January 20, He stated that it would not affect the construction schedule in the vicinity of the 170 wire tendon to delay the repairs trumpets while Compliance was reviewing the repair procedure He stated that MET-ED needs'to make repairs in the vicinity of the trumpets that are to.be plugged (No. 90 wire tenden system) right away in order to avoid a delay in starting up 9 with the concrete for the containment wall. Mr. Steubner stated that MET-ED and GAI were On questioning, satisfied that the voids had been adequately investigated and that no further testing was planned on the reactor building mat for the following reasons : found were minor and were explained by the a. The voids mud and wood found when the forms were removed. Enough chipping has been done around the voids to assur b. that there is solid concrete. The placement and vibration of the concrete was observe c. by himself, UE&C and GAI and was deer.ied adequate. The calculated amount of concrete or more was used in d. each section which indicated the concrete was adequatel-compacted. O O I 419 24)
2b[ 2. Quality control Procedures for the Containment Liner Mr. Avers stated that the CB&I plan for erecting the con-liner referred to procedures for radiography, tainment liquid penetrant inspection, weld rod control, ultrasonic Mr. Avers inspection, but did not include the procedures. showed the inspectors copics of letters between CB&I and UE&C about the above procedures. Mr. Avers stated that MET-ED would get the procedures even if they had to pay Steubner subsequently reported that extra for them. Mr. he attended a meeting with CB&I in Memphis in which they agreed to give MET-ED the procedures. 3. Procedures Mr. Avers and Mr. Steubner gave the inspector copies of the following procedures: Site Quality Control Plan 9 Receiving and Material Control Storage Liquid Penetrant Examination Magnetic Particle Examination Radiographic Examination Ultrasonic Examination Leak Test Structural Concrete Mr. Avers stated that procedures were available for all work being done at present, and procedures would be available prior to the start of additional work. Region I will evaluate the above procedures and will report the evaluation in the next inspection report. O 1419 242
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