ML19326A110
| ML19326A110 | |
| Person / Time | |
|---|---|
| Site: | Davis Besse  |
| Issue date: | 11/10/1971 |
| From: | Hayes D, Clint Jones, Vetter W US ATOMIC ENERGY COMMISSION (AEC) |
| To: | |
| Shared Package | |
| ML19326A100 | List: |
| References | |
| 50-346-71-03, 50-346-71-3, NUDOCS 8001310671 | |
| Download: ML19326A110 (10) | |
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U. S. ATOMIC ENERGY COMMISSION DIVISION OF COMPLIANCE REGION III CO Inspection Report No. 050-346/71-03
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, Announced i
Dates of Inspection:
October 13-15, 1971 Dates of Previous Inspection: June 8-10, 1971 Principal Inspector:
D. W. Hayes
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CE nau Accompanying Inspectors:
C. E ones
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(Date)
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R. A. Rohrbacher (Date)
Other Accompanying Personnel: None
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Reviewed By:
W. E. Vetter, Senior Reactor Inspector (Date)
Proprietary Information: None O
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SECTION I Enforcement Action Noncompliance A..
Approved procedures were not followed in regard to the lateral movement of concrete.
In addition, vibrators were used in a manner contrary to recommended practices..(Paragraph 8)
Nonconformance B.
Strength cylinder samples for pumped concrete were not taken at the pump discharge in accordance with ACI Standard 301 referenced in the PSAR.
(Paragraph 9)
Safety Items: None Licensee Action on Previously Identified Enforcement Mattet; A.
Fly Ash Quality Documentation (C0 Report No. 346/71-2)
During the previous inspection, it was noted that fly ash was received and used without the quality documentation required by Bechtel's Technical Specification (7749-C-25) and Nicholson's
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QA/QC Manual.
" Users" tests are now being taken in accordance with the 100-ton, minimum sampling frequency required by ASTM C-311 Specification.
These tests are in addition to the less frequent tests mado by the fly ash suppler (Detroit Edison Company). Approved modifications are being made to Bechtel's 7749-C-25 Specification and the affected QA/QC Manuals and procedures to bring them into agreement with the revised policy. Thic item is now resolved.
B.
Failure of Quality Control System (C0 Report No. 346/71-2)
Shortcomings in the quality control effort were found during the i
last inspection in that several yards of concrete were placed at a pour site other than that for which it was intended.
The licensee's response in regard to this item has been received and is considered to be adequate. However, further review of field implementation is planned in consideration of the enforcement items identified during the current inspection.
(Paragraph 8)._
Unresolved Items: None Status of Previously Reported Unresolved Items A.
Valve Design Verification (C0 Report No. 346/71-2)
Mr. Lanardson stated that TECO had discussed conformance and verification of valve casting wall thicknesses to the drawings and specifications with Babcock and Wilcox but that details for accumulating the required information have not been worked out.
This item remains on our follow-up list.
B.
Shield Building Wall Plumbness (CO Report No. 346/71-2)
Previously requested detailed erection data and the results of an engineering analysis and evaluation concerning the plumbness of the cylindrical walls of the shield building were reviewed.
This item is now considered to have been resolved.
(Esragraph 10)
C.
Curing Provisions and Temperature Control for Concrete Strength Cylinders (C0 Report No. 346/70-4, II.b.6.)
New Pittsburgh Testing Laboratory expanded site facilities for curing concrete strength cylinders were examined and found to be
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consistent with applicable standards. This item is being removed l
from our follow-up list.
D.
Pumped Concrete (CO Report Nos. 346/70-4 and 346/71-2)
Mix designs, including lubricating grout for pumped concrete, have y
been approved and qualified. Approved procedures for pumped concrete have also been developed; however, the procedures do not specify that the strength cylinder samples be taken at the pump discharge as required by ACI Standard 301.
(Paragraph 9)
E.
Fegles-Power Service, Incorporated, QA Manual (C0 Report No.
346/71-1 The Fegles' QA Manual was reviewed to verify that revisions to the manual more clearly define the QC inspector's duties and remove any reference regarding.his function as a supervisor. This iten is considered closed.
b.
N Design Changes 1
No design changes were reported or observed.
Unusual Occurrences: None Persons Contactgi The following people were contacted during the inspection:
Toledo Edison Company (TECO)
J. A. Lenardson, QA Engineer (Site)
G. W. Eichenauer, QA Engineer (Civil)
W. G. Moring, Jr., QA Engineer (Mechanical)
E. F. Doerr, Construction Coordinator Bechtel Corporation (Bechtel)
' G. A. Sullivan, Assistant Project Construction Manager A. S. Martin, QA Engineer D. C. LaVc.lla, Assistant QA Engineer D. P. Eisenhardt, QC Engineer R. L. Lykens, QC Engineer W. B. Baley, Welding Engineer s
Nooter Corporation (Nooter) 1 J. D. Rainwater, General Foreman M. C. Hamilton, QC Engineer i
Chicago Bridge and Iron Company (CB&I) i W. F. Hiser, Project Welding and QA Supervisor R. A. Wehrle, Construction QA Manager Nicholson Concrete and Supply Company (Nicholson)
J. M. Nicholson, Project Manager Pittsburgh Testing Laboratory (PTL)
F. W. Lohnes, Project Supervisor (Site)
R. (NMI) Oliver, Plant QC Inspector Michigan Testing Engineers, Inc. (MTE)
D. (NMI) Ponka, QC Supervisor (Acting for A. Bentley and Sons)
J. (NMI) Sheahan, QC Inspector D :
'N Management Interview Personnel in Attendance Toledo Edison Company (TECO)
G. J. Sampson, Vice President - Power L. E. Roe, Project Engineer N. L. Wadsworth, General Superintendent J. A. Lanardson, QA Engineer B. R. Bayer, Operations Maintenance Manager G. W. Eichenauer, QA Engineer W. G. Moring, Jr., QC Engineer E. F. Doerr, Construction coordinator Bechtel Corporation (Bechtel)
M. R. Stephens, Project Construction Manager M. G. Nelson, QC Coordinator (Gaithersburg)
D. L. Reddick, Project Field Engiacer A. S. Martin, QA Engineer D. P. Eisenhardt, QC Engineer Items Discussed A.
In reference.to strength cylinder samples for pumped concrete, Messrs.
Lecardson and Martin stated that the procedure and sampling location would be immediately changed to conform to ACI Standard 301.
(Paragraph 9)
B.
Messrs. Stephens, Martin, and Lenardson agreed that further effort was needed in regard to concrete placement and that this area would receive additional attention.
(Paragraph 8)
C.
Those present were advised that Mr. C. E. Jones had been reassigned to other facilities and that, effective October 1, 1971, Mr. D. W.
Hayes assumed responsibilities as the construction unit principal inspector for the Davis-Besse Plant.
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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 a.
Construction Status Engineering
- 68% complete (overall)
Civil
- 68% complete Electrical
- 65% complete I&C
- 62% complete Mechanical
- 67% complete Architectural-84% complete Construction
- 13% complete (overall) b.
Personnel Additions TECO has assigned Mr. E. M. Wilcox to the site as a welding NDT QA Engineer.
Bechtel has added Mr. D. C. LaValla as an Assistant QA Engineer and Mr. R. L. Lyken as a QC Engineer.
N 2.
Other Class I Structures - Spent Fuel Pool Liner Assembly and material records pertaining to the north and east walls of the spent fuel pool liner were reviewed in detail. Records for the floor and the south and west walls were reviewed in general.
Plare Nos. 47, 48, 56, and 57 and the welds between these plates were used for traceability.
a.
Records Reviewed (1)
Visual inspections including alignment, joint preparation.
root gap, environmental controls, and completed welds (2)
Defect removal and repairs (3)
NDT (4)
Materials (5)
Welder qualification (6)
Current list of qualified welders \\
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b.
Observations (1)
Use of proper weld procedures' (2)
Identification of weld, welder, and inspector (3)
Control of weld material 3.
Concrete - Containment vessel Support a.
QC Systems Piping used for pumped concrete, b.
Records J
(1)
Pour site inspection and release authorization (2)
Proper mix specified and delivered (3)
Adequate placement crew and tools (4)
Delivery tickets and QC review (5)
Slump and air entrainment measurements (6)
Strength test cylinders and curing tank temperatures (7)
Temperatures and mix and placement times (8)
Batch plant equipment inspection and calibrations (9)
Fly ash and aggregate tests c.
Observations (1)
Preplacement QC inspection (2)
Slump, strength, and air entrainment tests (3)
Proper delivery of concrete (4)
Rebar splices 4.
Containment Vessel a.
QC Systems Reviewed the qualifications of weld procedures, welders, NDT techniques and technicians, and examined identification of welders and weld procedures, NDT technicians, NDT procedures, and results.
In addition, QC systems for the following disciplines were reviewed:
(1)
Radiograph quality (2)
Weld quality (3)
Magnetic particle and dye penetrant examinations (4)
Correlation of records to welds (5)
Defect removal verification (6)
Acceptance of repair (7)
Material receipt verification (8)
Pre-issue storage conditions (9)
Issue control and disposition of unused materials (10)
Post-issue environmental control s
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s Other areas reviewed were the identification of the QC inspector (s) procedural requirements for visual inspections (requirements are established in the QA manual and welding procedure) and the QC system for preheat and interpass temperatures, post weld controlled cooling and stress relief.
l b.
Records i
Reviewed the in.pector's records for visual inspections, in addition to othar items reported above. Visual inspections are made, but not all are recorded.
Preheat temperatures are measured prior to release for welding, but temperatures are not recorded for each seam. NDT records were examined.
Records of material receipt, storage conditions, issue control, environmental control, and disposition of unused material were also examined. The listing of currently qualified welders was verified against the welder qualification records and weld map data.
c.
Observations Observations in the field indicated the work was being performed in.accordance with approved, qualified weld procedures by qualified welders. Radiographs of completed welds and repairs
[\\s_ h were reviewed by the representatives from the contractor,
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applicant's representative, and the Insurance Code Inspector.
The control of the weld materials was observed to conform to the QC requirements.
5.
Electrical Preliminary discussions were held with both Bechtel and TECO in regard to the QC systems planned for electrical work, including cable installation.
Mr. Lanardson stated that Bechtel's EE 553
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program will be used for the installation of wireways and cable and that the provisions of IEEE 279 Criteria will be followed for protective systems. TECO is also considering imposing upon the yet to be selected electrical contractor, the requirements of the IEEE draft standard, " Installation, Inspection, and Testing Requirements for Instruments and Electrical Equipment During Construction of Nuclear Power Generating Stations," (IEEE/JCNPS AH.3-ANSI-N45 3.4).
However, a final decision has not been made.
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6.
Class I Piping The Grinnel Corporation has been selected to fabricate and erect the Class I piping at Davis-Besse. One exception is the primary piping which will be fabricated by the NSSS supplier (Babcock and Wilcox). A contract for the erection of the primary piping has not been issued.
Grinnel's shop fabrication and field construction QA/QC manuals, were reviewed. The manual had just been received by TECO. With minor exceptions, both appeared to meet the requirement of the 18 Criteria.
Further review is planned by the inspector, following approval of the manuals by Bechtel and TECO.
7.
Material and Equipment Storage Facilities Plans and facilities for the storage of Class I materials and equipment were reviewed and were considered adaquate to meet the needs for the control and protection of these iters. Most storage will be in heated warehouses.
Details of Subjects Discussed in Section I 8.
Concrete Placement Practices
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Observations of a Class I concrete pour (pour No. 397), under the containment vessel, revealed placement practices not in accordance with required procedures. The inspectors noted concrete being moved laterally about 15 feet from the point of deposition, which is in excess of the five-foot limit imposed by Bechtel's Specification 77/ 9 C-26A, Paragraph 6.7, and contrary to good 1
practice.
I The pumped concrete was being placed on a sloping surface and was not deposited on the lower end first.
Instead, it was deposited about midway along the sloping surface and then allowed or caused to flow to the lower area. Moreover, vibrators were observed being used in a horizontal or a near horizontal position and in a manner that could cause excessive separation of the cement and aggregate.
The inspectors brought the discrepancies to the attention of Messrs. Moring and Eichenauer but, independent of this, corrective i
steps were taken by the concrete placement crew. t
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9.
Strength Samples for Pumped Concrete During the review of concrete strength test results for Class I pours, specifically, concrete placed under the reactor containment vessel by pumping (2,226 cubic yards as of October 14, 1971) the inspector noted that, except for the initial sample, concrete strength cylinders were not taken at the pump discharge as required by the ACI Standard 301 which is referenced in the PSAR. The samples were instead being taken at the batch plant. Messrs.
i Eichenauer (TECO) and Eisenhardt (Bechtel) confirmed this omission.
I Both Messrs. Eichenauer and Eisenhardt stated, and it was later confirmed by Messrs. Martin and Lenardson, that the procedures a
would be immediately changed and that future strength sampling of pumped concrete would be at the pump discharge.
10.
Shield Building Wall Plumbness During the previous inspection, a preliminary review of available data indicated that the specified tolerance for plumbness of the vertical wall of 1 inch in any 25 feet had been exceeded.
Subsequent plotting of the raw data indicated the out-of-plumbness tolerance limit for 25 feet of wall had been exceeded by approximately 2 inches.
However, the overall out-of-plumbness tolerance of 4 O
inches was not exceeded.
Bechtel engineers analyzed the as-built data and concluded that the effects of this amount of out-of-tolerance on the shield building structural integrity were insignificant. Bechtel Engineering recommended that all interface work be adjusted to meet the as-built alignment of the structure and that the structure be accepted.
TECO stated that their engineering review agreed with the Bechtel analysis and recommendations. Furthermore, TECO said that information regarding the as-built structure, in terms of plumbness, would be included in the FSAR.
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