ML19319B997
| ML19319B997 | |
| Person / Time | |
|---|---|
| Site: | Davis Besse  |
| Issue date: | 05/16/1972 |
| From: | Hayes D, Rohrbacher R, Vetter W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML19319B996 | List: |
| References | |
| 50-346-72-02, 50-346-72-2, NUDOCS 8001290724 | |
| Download: ML19319B997 (9) | |
See also: IR 05000346/1972002
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U. S. ATOMIC ENERGY COMMISSION
DIRECTORATE OF REGULATORY OPERATIONS
REGION III
RO Inspection Report No. 050-346/72-02
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Subject: Toledo Edison Company
License No. CPPR-80
Davis-Besse
Priority: N/A
Oak Harbor, Ohio
Category: A
Type of Licensee:
Type of Inspection:
Routine, Unannounced
Dates of Inspection:
April 10 - 12, 1972
Dates of Previous Inspection: January 11 - 12, 1972
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Principal Inspector:
D. W. Hayes
8 -/ 8' 7Z
(Date)
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Accompanying Inspector:
R. A. Rohrbacher
S -/S - 7 L.-
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(Date)
Other Acccmpanying Personnel. None
Reviewed By:
W. E. Vetter, Senior Reactor Inspector
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(Date)
Proprietary Information: None
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SECTION I
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Enforcement Action
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A.'
Noncompliance: None
B.
Nonconformance: None
C.
Safety Items: None
Licensee Action on Previously Identified Enforcement Matters
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No previously outstanding enforcement matters exist.
Unresolved Items
A.
Cas Waste Decay Tanks
Material certification records for the flange bolts on the waste gas
decaj tanks were not available for review.
(Paragraph 7)
B.
Material Storage
Several metal components for Class I structures were observed to be
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in contact with the ground.
(Paragraph 6)
C.
Steam Generator Supports
Records were not available to verify the required qualifications of
NDT technicians performing shop ultrasonic examination on 24 of the
steam generator support structure components.
(Paragraph 8)
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Status of Previously Reported Unresolved Items
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A.
Possible Low Compressive Strength Concrete (Report No. 346/72-01)
Low seven-day compressive strength test results on test cylinders,
representing concrete placed December 28 and 29, 1971, and
January 6 and 7, 1972, indicated that the 28-day strength requirement
may not be met.
Consequently, a concrete production stop order was
issued on January 12, 1972, to be in effect until the cause of the
problem could be identified.
Subsequent investigations indicated
that the cause of the low seven-day test results was the cement.
The tricalcium silicate (C S) concent of the cement, although within
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specifications, was lover than normal, ano the cement exhibited Type V
characteristics,
i.e.,
low early strenth and high-late strength, rather
than the early strength development expected for Type II cement specified.
Although the 28-day compressive stength test results for 4 of 15 test
cylinders representing an 810-cubic yard pour (No. 557) did not meet
the specified design strength of 5,000 psig, the 90-day test results
established that all the concrete in question developed strengths above
the design requirements.
Bechtel Corporation engineering personnel,
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in consultation with Toledo Edison Company and the Medusa Cement Company,
reviewed these and other results of the investigation and accepted the
structure "as is".
The concrete productisn stop order was rescinded on January 24, 1972,
following replacement of all cement stocks onsite and at the Medusa
Bay bridge storage yard, initiatJ.on of revised sampling and testing
procedures, and verification through a series of tests that acceptable
concrete could be produced at the site.
As of April 12, 1972, the final, approved copies of the revised sampling
and testing procedures had not been received from the Bechtel design
engineer. Consequently, this aspect of the marter remains open pending
a review of the approved procedures.
(Paragraph 5)
B.
Valve Design Verification (Report Nos. 346/71-02 and 346/72-01)
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Only one purchase order for Class I cast valves has been issued to date
by Babcock & Wilcox (to Crosby Valve for two pressurizer cafety valves).
J. D. Lenardson, TECO/QAE, told the inspector that wall thickness
measurements of these valves will be checked against specifications
prior to use.
Moreover, Mr. Lenardson stated that, if any additional
Class I cast valves are ordered for the Davis-Besse facility, they
would be subject to measurement checks.
This item is considered to
be resolved.
Design Changes
No design changes were reported or observed.
Unusual Occurrences: None
P ersons Contacted
The following people, as well as other personnel listed under the Management
Interview Section of this report, were contacted during the inspection:
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Toledo Edison Company (TECO)
J. A. Lenardson, QA Engineer (Site)
W. G. Moring, Jr., QA Engineer (Mechanical)
E. M. Wilcox, QA Engineer (Welding NDT)
Bechtel Corporation (Bechtel)
A.
S. Martin, QA Engineer
M. R. Stephens, Project Construction Manager
R. L. Lykens, QC Engineer
H. A. Ablondi, QA Engineer
Grinnell Corporation (Grinnell)
D. R. Giguere, QA Manager (Site)
Management Interview
Personnel in Attendance
Toledo Edison Company (TECO)
G. J. Sampson, Vice President - Power
J. E. Seward, Engineering Division
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W. H. Schultz, Engineering Division
J. A. Lenardson, QA Engineer (Site)
B. R. Beyer, Operations Maintenance Manager
W. G. Moring, Jr., QA Engineer (Mechanical)
E. M. Wilcox, QA Engineer (Welding NDT)
Be:htel Corporation (Bechtel)
D. L. Reddick, Field Project Engineer
R. L. Lykens, QC Engineer
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A. S. Martin, QA Engineer
G. A. Sullivan, Field Coordination
Items Discussed
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A.
Possible Low Compressive Stengch Concrete
The inspector stated that he had reviewed the Bechtel investigation
packet concerned with low compressive strength concrete and agreed with
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the final disposition of the nonconforming concrete. The inspector
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added that the final resolution of the " cement problem" would follow
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review of recently completed procedure changes which were now in effect
but not yet approved by the Bechtel design engineer.
(Paragraph 5)
B.
Material Storage
The inspector stated that several components for Class I structures were
observed, apparently due to inadequate shoring, to be stored in contact
with the ground. The licensee stated that this situation would be
corrected immediately.
(Paragraph 6)
C.
Class I Piping
The inspector said that, according to Mr. Stephens, erection of Class I
piping (originally schaduled to start in early thy 1972) may be delayed
pending final approval of some sections of the Grinnell Field QA/QC
Manual and further refinement of the contract with Grinnell.
According
to Stephens, the inspector added, contract refinement relates to the
interface between the piping work to be performed by Grinnell and that
to be perfor=ed by Babcock and Wilcox.
The licensee could add no
additional information with respect to this matter.
The inspector
said that this item would be reviewed during subsequent inspections.
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D.
Waste Gas Decav Tanks
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The inspector stated that he had completed a review of the quality
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documentation for the waste gas decay tanks and, although installation
had not been started, he noted that the material certification records
for the flange bolts were missing.
Mr. Martin said that a search for
the missing record had been unfruitful but that another copy would be
obtained and would be available for review during the next inspection.
(Paragraph 7)
E.
Steam Generator Supports
During a review of the material certification records for the steam
generator support components, the inspector stated, it was impossible
to establish the qualification of the NDT technician (s) performing
shop ultraconic examination on 24 of the components.
Mr. Martin said
that the qualification records had been reviewed by the Tachtel shop
inspector, but this fact had not been documented.
He add 2 that the
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missing documentation would be obtained and made available for review
at the site during the next inspection.
(Paragraph 8)
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SECTION II
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Additional Subjects Inspected, Not Identified in Section I, Where No
Deficiencies or Unresolved Items Were Found
1.
General
Construction Status as of March 31, (972
a.
Engineering - 79% complace (overall)
Construction - 18% complete (overall)
b.
Personnel Changes
Mr. D. P. Eisenhardt, previously a Bechtel QC Engineer, transferred
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to the position of Mechanical Coordinator in the Field Coordination
group. A Mr. R. L. Lykens has replaced Mr. Eisenhardt.
Mr. H. A. Ablondi, a QA Engineer specializing in piping and
welding, was recently hired by Bechtel and has now been assigned
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to the site.
2.
Class I Concrete
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a.
Record Review
(1)
Concrete Strength Tests and Slump Tests
(2)
Proper Mix Specified and Delivered
(3) Mortar Cube Test Results
(4)
Batch Plant Inspection Reports
(5) Cement Test Reports
3.
Other Class I Structures - Steam Generator Support Structure Embedments
a.
QC System
(1) Material Chemical Composition
(2) Material Physical Characteristics
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(3) Material NDT
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(4) Handling of Nonconforming Material
(5)
Storage Identification and Control
b.
Review of Records
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(1) Material Certification
(2) Material NDT Records (excluding technical qualifications)
(3)
Purchase Specifications
(4) Receiving Inspection Reports
(5)
Shop Inspection Reports
(6) Nouconformance Reports and Resolutions
c.
Observation of Work
(1)
Quarantine of Nonconforming Components
(2)
Protection of Components in Storage
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4.
TECO QA Audit Reports - Site
TECO reports for five audits of the Pittsburgh Testing Laboratory site
facility, covering the period from December 17, 1970, to January 26,
1972, and one audit report on Bechtel site receipt inspection of the
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steam generator support embedments were reviewed.
Details of Subjects Discussed in Section I
5.
Possible Low Compressive Strength Concrete
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Following the previous inspection in regard to this item, TECO notified
the RO:III office that Bechtel, in consultation with TECO and the
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Medusa Cement Company, had traced the cause of the low seven-day concrete
cylinder test results to low tricalcium silicate content in the cement.
As a result of this finding, cement stocks were replaced, and revised
sampling and testing procedures were placed into effect to prevent
reoccurence (see Report No. 346/72-01).
During the current inspection,
implementation and results of these changes were reviewed.
In addition,
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the compressive strength test results for two Class I concrete pours
made after the concrete production stop order was. rescinded were
reviewed and were found to meet specifications. The concrete produc-
tion stop order was rescinded on January 24, 1972.
Nonconformance report No. 43 was issued by Bechtel when it was found
that the 28-day compressive strength test results for 4 of 15 test
cylinders, representing the 810-yard pour, No. 557, did not meet the
specified design strength requirements of 5000 psig. The disposition
of the nonconformance report waa reviewed and found to be in agreement
with established procedures. The concrete (pour No. 557) was accepted
"as is", based on the fact that the 90-day test results exceeded the
design requirements and that the test results from the investigation
supported the conclusion that the cement used exhibits Type V
characteristics,
i.e.,
low early strength and high late strength.
Production of concrete to requirements is no longer questioned. However,
the final approved copies of the revised sampling and testing procedures,
approved and in use on an interim basis, had not been received onsite
at the time of the inspection. This item remains open pending review of
the final approved procedures.
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6.
Material Storage
During the current inspection, the inspector noted that some components
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for Class I structures were stored in contact with the ground. Apparr-*1y,
shoring below the.se components had sunk into the ground.
The components
included the main air lock door penetration, reinforcement steel, and
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domed sections of containment vessel plate.
Prior to the conclusion of
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the inspection, corrective action was in progress and correct storage
was completed within two weeks.
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7.
Waste Gas Decay Tanks
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A follow-up inspection of the waste gas decay tact.s (T-24, T-25-1, 2,
and 3, currently in storage) was made to complete a review of material
certification records which had been started during the inspection of
January 11 - 12, 1972.
During the current inspection, it was noted
that the material certification records for the flange bolts were missing
for all four tanks.
The bolt material specification is ASTM A-307.
The receiving inspection report, signed by Mr. Arenson, indicated that
the bolt material records had been received, but a search by Bechtel
was unsuccessful.
Mr. Martin said that additional copies would be
obtained and that they should be available for review during the next
inspection.
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8.
Steam Generator Supports
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A review of the material nondestructive test records (NDT) and the
Bechtel shop inspector reports could not verify that the NDT tech-
nician(s) performing the shop ultrasonic examinations en 24 components
for the steam generator supports were properly qualified.
The com-
ponents involved were the sole plates (two pieces), anchor ring plates
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(two peices), reinforcing bars (four pieces), and the , anchor plates
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(sixteen pieces). The NDT technician (s) in question varked for the
Arnold Greene Testing Laboratory, and the UT examination was conducted
in accordance with ASTM A-435.
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Mr. Martin stated that he was sure the qualfication records had been
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reviewed by the shop inspector but that he evidently had failed to
document the fact. He added that the missing documentation would be
obtained and made available for review during the next inspection at
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the site.
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