ML19329B244
| ML19329B244 | |
| Person / Time | |
|---|---|
| Site: | Davis Besse  |
| Issue date: | 06/13/1976 |
| From: | NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | Henderson J US ATOMIC ENERGY COMMISSION (AEC) |
| Shared Package | |
| ML19329B241 | List: |
| References | |
| 720613, NUDOCS 8001310592 | |
| Download: ML19329B244 (21) | |
Text
{{#Wiki_filter:- F'O r. y - TCLEDO v D3 Q'"' S 1 > TA w u kt GLWs J. SAusscN March 6> 1972 v.c. pr...c. go.., s ~ - - " + - ', - '.. '"..a'."- [ l .t au ::ou nt ELiv 1 n.,.....,.... i er u. r..<.. 4 n. i u, ,,u., m, ;.. i.....u i si o .o e s s Igd (*g a.ite .T J u.ba:) 1ha fl AL$ elLMAAks ".p. .'-~.',3 J. 3. Handerson, R0
SUBJECT:
TOLEDO EDI. SON COMPANY DOCKET No. 50-346 /.< ; R. H. Engelken, R0 ~ cArc 'r, ?. A. Morris, R0 l e \\ ! TO sName 2.TJ wast) IMII Aa $ AEuARASAttached are the enclosures to applicant's i R0 Files DR Central Files letter dated March 6, 1972, which were not sent = Art l ?DR I to vou with our letter dated March 13, 1972. TV "*pe and un.t) ihiT;ALS ALMAAxS / \\ 'N //1 ?DR NSIC 1 OATE t DTIE i jnewAaxs i rao v. (s..v...no on.c3 'LhL - sY, >< s d O b u' N h ef <?A/'-4 H RO:1IT // f $ YkdA&f) bW) n M d 4a b A' Y Y \\ a 1 tL/d/ & lG'.fu% b - .M feONE h0. g CATE l 6-13-72 Lss or,ca sice son Accirica aculad ......-a... ~ ~ " " ~ aeveloped at 90 days is determined. Yours very truly, of ,u. .; /, sm,6/r GJS.r 8001310 h Attachment's 'iAR 101972 l THE TCLEDO EDlSON CCMPANY EDISON PLAZA 300 MADISON AVENUE TOLEDO. CHIO 43652
dk g Bechtel Corporation (g. V Inter-office Memorandum T* H. W. Wahl-Dam January 21, 1972 SAect Concrete Investigation Fmm M. R. Stephens Of Construction e capeito A. Bingham wo/a A Davis-Besse Power Station J. Scull wo/a FMB-594 S. Helms w/a J. Lenardson w/a J. Corder. wo/a P. Cotter wa/a J. Varela wo/a A. Martin wo/a As you are aware on December 28 and 29, 1971, concrete was placed in Bentley Pour Numbers 550, 552, 551 and 555 respectively. The 7-day breaks of this concrete received on January 4 and 5, 1972, indicated low early strength gains as compared to normal 7-day cylinder strengths previously obtained. This prompted investigation into the possible s ) cause, and it was determined that minor inadequacies existed in the first / 24-hour curing period of the cylinders in question. However, additional 7-day cylinder strengths received on January 6 and 7, 1972, indicated improper curing was not the cause, and prompted further investigation as indicated in the attached chronological history of the events. Meetings were held with all parties involved, namely PTL, Medusa, Bechtel and TECo. Medusa Cement Company's expert indicated the pro-bable cause was a chemical change in the cement composition which caused low early strength gains, but did not violate the chemical requirements of ASTM, C-150. As a matter of fact, User's Tests proved that the cement in question did, in fact, comply in all respects with the requirements of C-150, but the 7-day morter cube strengths were much lower than the usual. Medusa further indicated that from pre-vious experience and past history, coupled with the information pre-sently available, the concrete in question would meet or exceed the specification requirements for strengths in 28 days. On January 12, a stop order was issued to Nicholson Ccacrete Company prohibiting further concrete production until it could definitely be established that this, in fact, would be the case, because Medusa Cement Company's expert indicated that the chemical C s was responsible 3 for low early strength gains and subsequent Users Tests taken as a result of this problem, proved this to be true. Additional cylinders were tested to determine whe:her the strength increase was in fact occurring as was indicated by Medusa's expert. These were 22-day [, results representing the pours in question. All strengths were ade- $s 's,, quate and indicative of satisfactory 28-day strengths. A significant number of strengths were above the design requirements. Based on this information on January 20, tha stop order written on the production of l I ( ene a....
concrete was removed to allow production to commence on January 24, C. (f s tS72. _j The following action items were implemented immediately. Procedures will be written to cover these areas and submitted to Engineering for approval at a later date. 1. Medusa cement Company commited to sampling and testing the :ement loaded into each rail car (Approximately 400 barrels) to determine the 3-day cube strength results in order to determine if the cement will produce satisfactory 7-day concrete strengths at the jobsite. The 3-day cement cuba strength results will be used to determine if the rail car can be unloaded at the Bayview, Ohio Storage Facilities, and will be coo dinated within Medusa. c Information will be forwarded to the Bayview Storage Facility, including the rail car number, to allow unloading into the silo set aside for Davis-Besse jobsite. ~ 2. Nicholson has been advised to review their QA Program to incorporate these requirements and include means of verifying that the un-loading of rail cars at the Bayview Facility is in accordance with - Medusa's commitments.
- 3. ' PTL has been advised to incorporate in their QC procedure a r
- - surveillance function to verify that Medusa Cement Company is - ',,'indeed complying with their commitment at the Medusa Facility N in Wampum, Pa. In addition, PTL will take cement random samples at ) - Wampum and perform cement cube strength tests verifying Medusa's ~~ test results. The frequency of sampling has not been firmed up at .,,this time. PTL at the jobsite will verify that Nichcison Concrete -- Company is maintaining surveillance of the Bayview Facility. '^ . t.. s2 & & )l.t 1- 'M M. R. Stephens MRS:DE/mm AtUchments ht) Li*. e g. e e e , e# ( (m/ m_ .a m.
es N / INVESTIGATION & ACTION fi ) %'8 J The following is a chronological history of events to determine the reason for low 7-day strength test results on the concrete placed in the attached pours. W*odville Lime & Chemical Company - Aggregate Supplier Talecon with Mr. J. Urshel, questioning the possibility of contanination of the d: livered aggregates proved negative. Mr. J. Urshel stated that no changes had been made in their processing or handling operations. Pittsburgh Testing Laboratory - On-Site Test Lab. Investigated areas including curing tank temperatures. Visual inspection of stock-piled aggregate, batch ticket quantities, mixing water visual quality, errors in ttseing nachine use or calibration, cylinder caps, making of cylinders. All items approved acceptable.
- pvised PTL to sample and test concrete ingredients as follows:
k_ a) Mixing water for algae, salt, oil. b) Cement for full lab tests to determine compliance with ASTM C-150. c) Fly ash for full lab tests to determine compliance with ASTM-618. d) Tests in item b and c above to be made with mixing water from jobsite and standard water as required. e)" Pozzilith 200N for verification. f) Daravair for verification. It ems a,b, e, & f will be forwarded when received. Toledo Edison Co. 's Requested and obtained fly ash carbon and fineness results on tests presently in TECo lab. Results attached as Ited 1. NicholsonConcrete&SupplyConlcenv-BatchPlant 5 Contractor. SJabnormaleventsormalfunctionoccurred. cussions were held with plant operating personnel. Questioned plant operation. Calibrated all weight hopper scales. Results proved no'descrepancies existed. 1
.+ Pittsburgh Testing Laboratorv - Pittsburgh, Pa. 1econwithlabandrequestedresultsofuserstestpresentlyintheirpossession. Tasting was not yet. complete. Advised PTL to perform full chemical and physical tests cn cement and fly ash and report results immediately by telephone. Results tabulated and attached as Item 2. _Pittsburgh Testing Laboratory - Cleveland, Ohio Talecon with G. Bigham in Cleveland advising of testing requirements and requesting expedi.tious completion on 24 hour basis. Medusa Cement Company - Cleveland, Ohio Attempt to contact Mr. W. Copenhefer proved unsuccessful. Advised Mr. Gulyas of problems in,, concrete strength and requested Medusa support immediately. Note: A.telecon with PTL's J. Artuso indicated that the cement was suspect. Mr. Artuso stated that possibly the chemical composition has changed sufficiently to give low 7-day strength characteristics but most probably would produce satisfactory 28-day { ingths. Mr. Arturo indicated experience with this problem before and would be able to confirm this after the chemical tests requested were completed. Tha following concrete test batches were made in 5 yard quantities for further infor-mation at a later date. Results attached as Item 3. Eight cylinders were cast from ecch batch;at the locations indicated. Unit Araa., - ::Cyl. No. Mix Slump Air Temp. Weight Batch- __.Q-1-P ..--..C-1-3A 2-1/2 3.7 68 92.65 Plant r_= Lab. Q-I-L = C-1-3A 1-3/4 3.0 64 Sfti - ~~Q-1-S C-1-3A 1-3/4 2.4 64 Br.tch' Plant Q-2-P ~ C-1-3ANTA 2-1/4 4.8 64 91.75 Lab Q-2-L C-1-3ANFA 2-1/4 3.8 63 Sita - " Q:2 ~~ C-1-3ANFA 2-1/4 3.2 62 I 2
r~*7cylin'ders~of'eachsetwere'steamcuredfor72hoursaftertheinitial2Qt4 hour ~ (.dringtime. Test results are enclosed as Item 3.
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'J,/13/72 Centacted Medusa Cement, Mr. W. Copenhefer. Advised hid of low strength problem and ,rsquested immediate assistance in solving the problem. Mr. Copenhefer advised his imme'diate" departure for~the jobsite and would send Mr. K. Rupp to the jobsite in ~ he interim. t A. meeting was chaired by Bechtel with Nicholson, Medusa, PTL, & TECo to discuss present condition of concrete in place; and further action to be taken. . Discussion centered on the probability that concrete strengths at 28-days would be catisfactory. However, all were agreed that sufficient evidence was not available at .theEtime for any conclusions. The test results received from PTL, Pittsburgh via J. Artuso indicated that the cement was in question. 'The 7-day test results for samples taken on December 27, 1971 and December 30, 1971 \\ ,(' ficated low strengths were obtained as indicated below. 1 _ Sampled 12-27-71 Fly Ash Users Test !7-day. control 2230 PSI (Cement only) 3520 PSI (Cement and fly ash) _7-day test 1 < Sampled 12-30-71 --- Fly Ash Users Test .7-day control _ 2230., PSI (Cement only) 17-day test 3350., PSI , (Cement and fly ash) Nermal strengths obtained previously are as follows: Sampled 10-21-71 Fly Ash Users Test 3: :. 7-day control 3610 ~ (cement only) 1 :. . _ "~ (cement and fly ash) 7-day test 5000' Simpled 12-3-71 Fly Ash Users Test "-fay control 3450 ~ ~~ (cement only) ( ) km '~<oday test 4970 (cement and fly ash) 3
.'Rupp agreed that this did indicate a significant change. However, Mr. Copenhefer @ uld be more qualified to explain this situation. .All parties agreed to expedite the supply of acceptable cement. Mr. Rupp indicated he wsuld contact Mr. Copenhefer as soon as possible and commence necessary action. Bechtel advised all parties that che concrete in' place was questionable and no further W ucrete placements would occur antil Medusa and Nicholson could assure acceptable cement through additional testing prior to use. Buchtel requested and Nicholson agreed to supply sufficient Huron Type II cement to commence qualification tests for an alternate supply of cement as a backup in the svent Medusa Cement proved unacceptable. Nicholson was also requested to empty Bin #2 for inspection to determine if leakage was present from the fly ash Bin #1. (It was agreed later that TECo would pay this cost if the cement proved acceptable and _Nichols'on would pay the costs if the cement proved unacceptable.) heel and PTL agreed to establish a testing program at Medusa, Wampam, Pa. plant x~ v o insure acceptable cement was delivered to the Bayview silos for use on this job. a.;. TECo requested that Nicholson separate the fly ash from the common cement-fly ash , compartmented silo to prevent possible fly ash to cement leakage. Nicholson agreed. NiCtolson Concrete & Supply Co. - On-Site Batch Plant .. _. ~. _ _ _. _. _ incholson removed and wasted 58,047 lbs. of cement from Bin #2. Samples were taken by the on-site PTL test lab at approx. 6300 lbs. intervals for future tests. 1/14/72 Inspection of Bin #2 at the batch plant indicated no leakage of fly ash into the cement was present. Euron Type II cement was delivered and installed. 10 test batches were made and cylinders , cast for all mix designs presently in use.
- Li. :..
... ~. - - ' Test results are attached, as Item 4. t(J 4 ,,, - - - -, ~ - ,----------,,,,---s
~ A meeting was chaired by Bechtel with Nicholson, PTL, Medusa and TECo. { (,)ihtel indicated Nicholson had established a means of separating th common cement-fly ash compartmented silo. The plan is to erect another bin alongside tha existing silo and provide a screw conveyor for feed.of fly ash to the weight h:pper. This could be obtained from Rex Chainbelt in Milwaukee, Wis, rapidly, and was presently under fabrication for another job. Rex had agreed to divert this unit to this job. Approximate shipping date is January 28, 1972. Medusa indicated that the cement chemical composition has evidently changed signifi-cantly to indicate low 7-day strengths, but was actually a better Type II cement than hcd been supplied. Supplies previously were closer to a Type I cement in strength gains. Although the Type II specifications were met as evidenced by the users r taats performed, Medusa was confident that the 28-day strengths would be adequate. Medusa expressed a desire to obtain core samples to ascertain the strength of the m erete in place, at their cost. htel agreed to obtain engineering information on January 17,.1972 to determine the locations and number of samples to be taken as Item 12. Medusa made the following committments and Bechtel agreed: ~;1--. 1_ a) Each rail car of cement loaded at the Wampum, Pa. plant would be tested for acceptable results based on what Bechtel was accustomed to, b) The rail cars would then be transported to the Bayview silos designated for the Davis-Besse job and would not be unloaded until test results taken at Wampum indicated acceptable strengths. Probably, 3-day results on cube strengths would be sufficient. The time in transportation would be approx- , imately 6-7 days and 7-day results may be available. c) The Bayview personnel would be advised of what cars, by number, were acceptable for this job and only those cars would be unloaded into a silo w ) reserved for this job. Medusa will make additional silos available .s re-(- ), quired. s 5
.. tel requested PTL to provide an acceptable inspection criteria at Wampum to verify g. L is operation with spot check sampling to insure compliance with this criteria.
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PTL agreed. 11 was in agreement that Medusa was to coordinate core sampling with PTL. PTL would provide all necessary equipment. Nchtel would obtain the necessary information n the location of the samples to be taken. EhhintentistocbtainthesesamplesbyJanuary 18, 1972 and compare the results with .2 :. cylinder strengths available from cylinders presently under norms.1 curing conditions. 1/18/72 PTL obtained core camples for Medusa Cement Company in the areas indicated by Bechtel c$tgineering on the enclosed drawing. The results of the core samples are indicated balow. TitAs'e~ core samp1;y were taken from concrete pours involved in the investigation.
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CORE SAMPLES TAKEN ON 1/18/72 AND TESTED ON 1/21/72 N o.. 1 Top _ 2250
- No. 2..
... Top. - 2910 Bottom 4520 Ns. 3 -Top 1910 No. 4 ..:.; :::.. Top 2750 No. :5 ' . Top. 2680 No. 6 2 Top. 2360 1
- .-- ;- Top
- 3540 Bottom 3550 Ns. 7 Ns. 8 Top. 2420' No. 9 Top 2180 Ctnerete represented 1 thru 6, placed on 1/4/72 t l Cincrete represented 7 thru 9, placed on 1/7/72 (([hm) 6
1/20/72 Additional representative cylinders were tested at 22 days for pours 550, 551, 552, and 555; test results are attached as Item 5. These are containment building pours 10 and 11.~ Received 3-day cube strength test results taken on 4 rail cars from Medusa Cement ~~~ Company at Wampum. Pa. Results are indicated below: ' * ~ Car No. 3-Day Test 255942 2360 psi 881000 2460 psi 382465 2330 psi 882168 2500 psi All parties were agreed that the 3-day results indicat4d acceptable cement. ~ ' Additional Attachments ~ ^ It'ma 6 represents cylinders which were steam cured for strength gain determination. Item 7 represents cylinders under normal laboratory curing waiting additional i ..z2 testing. ( ) Item 13&14_representstabulatedtestresultsofeachmir.designindicated.
== Conclusion:== ,The aforementioned events produced an acceptable end result allowing continued concrete placement. It is anticipated that the 28-day strengths will prove , acceptable and no further action is deemed necessary at this time. i ~. : - ~ ~*; I, -e -7
Swiss Hammer Readings For Concrete Pours 550, 551, 552 & 555 Pour 4550 1/11/72 4270 PSI represented by Item 11 Area 1 16 20 18 20 Area'2 17 18 15 15 20 17 15 17 17 18 17 15 19 19 19 18 13 13 16 16 20 18 19 18 15 18 19 15 Area 3 20 16 18 18 Area 4 29 31 30 32 19 18 20 21 32 36 30 30 17 12 18 16 31 33 30 36 17 19 22 22 36 30 35 35 29 32 34 Area 5 31 31 29 29 Area 6 26 33 31 32 26 29 28 32 55 34 36 24 26 27 31 28 36 29 36 25 28 26 26 25 30 29 28 34 30 31 32 29 31 30 31 represented by Item 8 Area 1 28 28 28 28 Area 2 27 28 27 29 30 26 28 25 30 28 28 27 26 27 26 26 27 29 33 27 28 26 28 28 28 27 29 28 28 29 32 30 28 Area 3 26 29 26 26 30 28 28 30 27 27 28 36 27 26 28 28 26 25 28 Pour #552 1/10/72 4850 PSI represented by Item 10 Area 1 20 25 25 24 Area 2 21 22 24 21 21 24 20 20 20 23 22 25 20 21 22 20 20 22 24 21 22 22 20 20 20 20 20 23
- N s
l 8
o ~ our #555 1/10/72 6500 PSI represented by Item 9 b' Area 1 39 42 21 39 Area 2 34 32 43 38 37 42 39 26 36 36 36 38 4'1 39 36 36 39 44 34 36 39 40 50 46 36 38 36 36 38 38 36 Area 3 31 32 33 43 Area 4 34 38 40 38 ' ~ 32 40 34 30 40 36 38 40 38 35 34 35 38 39 36 34 36 32 36 34 36 35 36 36 48 42 33 29 34 40 38 38 30 33 38 ..z. NOTE: Areas 1, 2 & 3 for Pour 550 and Areas 1 & 2 for Pour 552 were made with one Swiss Ha=mer. Readings for all other areas were taken with ~ ~ ~ ~ anothe,r Swiss Hammer. Thus, the difference in average readings. Indicated, strengths are shown by each pour number. (,. c ~ - .t t O ee - b b ?- l ~ .c.= - .v h. D = h. Y \\.) 1 * (J/ l e .- 9.-
~ Date'of Pgur # Pour ( 550 condensate storage tank slab 12-28 551 Transfer tube' slab and wall 12-29 552 Pour #10 under cont. vessel, 210 degrees-39 der;rees 12-28 555 Pour #11 in cont. vessel, O degrees-90 degreea 12-29 556 North hald MFWP fcundation 1-3 557 Duct _ Banks detween T/G pedestal and P.H. 1-3 557 Pour #11 Cont. Blog. 254 degrees - 360 degrees 1-4 558 Condensate pump equip. pad 1-3 569 585 diesel gen. slab. 1-6 562 585 slab aux. bldg., Area 7, G line to 5 line 1-5 564 Col Cap, B-8 1-5 565 Grade beam between cols. B-3 and A-3 1-6 [ } Elect. M.H. 3101, foundation slab l-5 /- (_ \\d 569 585 diesel gen. slab 1-6 571 Four #11, Cont. Bldg. 199 degrees to 254 degrees le7 572 Col. caps C-9, D-9, D-10; Grade beams E-9-D-9, D-9-C-9, C9-C10, C10-D10, D10-D9, D10-E10, A4-B4. 1-10 573 . Elect. pit bottom slab 1-11 574 Duct bank into west wall of pumphouse 1-10 576 Grade beam Al-B1 1-11 / N ( \\ e 10
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CL-3300 ctussons on sarascrs reos on assamosas oua naroats is assansso panoins cua waitTan aremovak. January 21, 1972 The Toledo Edison Company and The Cleveland Electric Illuminating Comoany Post 0 ffice Bos: 929 ( Toledo, Ohio 46301 ne: CL-BS00 Materials Testing Cement and Fly Ash Tests
Dear Sir:
O t "') indicating the dates sampled. Attached are following reports of Fly Ash Tests and Cements ( Test of Cement-Laboratory No. 722353-Sampled 1/12/72 Test of Cement-Laboratory No. 723224-Sampled 1/4/72 Test of Fly Ash-Laboratory No. 727354-Sampled 1/12/72 ) Test of Fly Ash-Laboratory No. 723076-1-Sampled 12/27/71 Test of Fly Ash-Laboratory No. 7230 78-2-S amp led 12/30/71 The cube strengths of the cement sampled on l'/4 and 1/12 were about 3000 P.S. I. at 7 days. This compares with about 3500 P.S.I. that was l experienced previously. This is attributed primarily to the recuceu C s content of the cement which resulted in a higher C,S. This condition 3 would cause ultimate strength to develop later at 26 days or 90 days. This would result. in lower cylinder stren;;ths in the field,and the strength development of the cylinders would also be retarded with the ultimate strength developed at 26 or probably 90 days. i A e i \\ v
- PrTTreuROM NEw YONE SOSTON PM4AOE ' Mea CLEVELANO OETROIT s f. Louis suPFaLO GREENseORO LOutsysLLE M E M PMit salt LAEE CITY sam FRaNCJSCO setw (erLEANs staTTLE Pom fLaNO gemMONGMaae saf0M mouGE LaFATETTE Mekw aum E E sNDiaNaPOWs ATLANTA MOusf0M OALLas sacKsONviLLE Tea *Pa se + 4 an e CNicaeo eTaacust faLLawassEE EuCENE NasaveLLE acaNOaK CsaTTaNOOoa OaTTONa CaLANDO nOCMEste n spoua=E assoc 8af ts afi Los ANGELES TONONTO MONTAEaL LONOOps. ENGLAND
The Toledo Edison Company and The Cleveland Electric Illuminating Company January 21, 1972 Although there would be a reduction in strengths with the above cements, these would not be as appreciable as the cements that were sampled on 12/27 with the fly ash as shown in tre fly ash reports 723076-1 and 2. The seven day cube strengths of the cement (Standard ASTM C-109 J. stb 1 C-150 without Fly Ash) was 2230 P.S.I. at seven day. This is appreciably lowe., and the concrete made from this cement would'be significantly 1:.er. This apparently is cue to a sharp
- 'timate strengths should be comparable reduction in the C 8' 3
however at later ages c:. _ v, and possibly 28 days. It is recommended that tne quality of cement be established as ~ that used in the original mix designs or new designs made with the cement quality and then the cement quality maintained by normal testing rate specified in ASTM C-150 and the silo tested and sealed prior to-use. O Very truly yours, PITTSBURGH TESTING LAIK)RATORY ,.y-x-l- } f/ h cf.nze i f Joseph F. Artuso, ^ Assistant to the Vice President JFA/mb cc: Mr. J.D.Lenardson Mr. Neil dadsworth Mr. F. Lohnes Mr. Don Eisenhart Bechtel Company PTL, Cleveland I i Enclosures (w/
N h.% e ggp. -41 p, g i ~[. -,.. I Eg Q COMRANY D f S '()(V @ (Q OFFICE MEMORANDUM - U* .1 ] p? .A \\* c J n. y 'j-{ hy December 14, 1971 d i La a u . c,,,~, c-, d., NCl 519n O. p' TO: J. D. Lenardson 'N. FROM: G. W. Eichenauer
SUBJECT:
Observing and Auditing of Medusa Cement Company (Bay Bridge Storage Silos) Bay View, Ohio. An inspection visit was made at Medusa Cement Company, Bay View, Ohio, on December 7,1971, by the writer, and acco=panied by George F. Bigham, District Manager, Pittsburgh Testing Laboratory. Principal contact during the audit - Wm. Bluhm, Manager. Items and areas covered were as follows: 1. Audited bill of lading from Wampum, Pennsylvania Plant, as (] to type of cement, quantity and against railroad car nu=bers t, being unloaded, w 2. Observed unloading cars by blower system to various silas. 3. Checked master mill test reports for e ch lot delivered from Wampum, Pennsylvania, wha.ch has been tested in ac-cordance with ASTM C-150 and certified for use on Davis-Besse Project. 4. Silos were tight and provide for free movement to discharge ~ opening. Each silo is nu=bered according to type of ce=ent stored. Type II Cement stored in #17 silo is reserved for the Davis-Besse Project. 5. Checked temperature records which revealed highest readings at 120
- average 75 to 80.
6. Lat'est calibration of scales was October 31, 19 71, by " Col'. Indus tries". COMMENT: The bill ofj lading appears to be indefinite in regard to from which silo bf lot at Wampum Plant, cement is being delivered totheBayhridgestoragesilos. Where storage is provided for differeht types of ce=ent or ce=entitious materials, it n is essential the above be indentified for traceability.
s, ) s <~ o.. TO: J. D. Lenardson .a b' December 14, 1971 i SUFJECI: Observing And Auditing of Medusa Cenent Comparv (Bay Bridge Storage Silos) Bay View, Ohio. (CONTINUED) 1 Since Nicholson Concrete and Supply Company is responsible to their Qualir, Control Program covering receipt of material for the Davis-Besse Project, it is recommended a follow-up be made regarding this comment. f/ D fyg',,,alg.d8 c GEORGE W. EICHENAUER 1 GWE:jp [ N. L. Wadsworth (J./i-cc: A. S. Martin l Nicholson Concrete & Supply Company e 9 f r ~-
'*I. 12-17-71 n-fjh(([':*M'b
- i 'U~i i' l' * {
d FOLLOW UP AUDIT:!GDteAh A telephone-eall, 12-17-71, to Howard Wahl, Project Engineer, from A.S. Martin (Bechtel), in regard to a Q. A. program by Medusa Cement Co. was not necessary as long as Nicholsons received the proper certifications. Mr. Wahl stated this was the same procedure being used on all their Nuclear Power Plants. Jr* w g .g ft j r 4 O ..Er Geo'rge Eichenauer 7l Y t -'.pl GWE:bac i I I a i. i i
73 C -J raz Tor. zoo _j : @ (iT 0( cose.sv fl OFFICE MEMORANDUM y !?'. [lfa p y a p (di/d[dU\\d.J}Oc\\dj'%r:m, V l fj,'p
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ui i h February 17, 1972 TO: J.D. Lenardson FROM: G.W. Eichenauer
SUBJECT:
QA visit at Medusa Cement Company, Wampum, Pennsylvania. An inspection visit was made at Medusa Cement Company, Wampum, Pennsylvania, on February 10 & 11, 1972 by the writer, accompanied by Mr. Mike Nicholson and Mr. Verl Smith of Nicholson Concrete and Supply Company Toledo, Ohio. The primary purpose of the QA visit was to determine the traceability of cement from Wampum's Manufacturing plant to the distribution silos at Bay View, Ohio to the Davis-Besse project; methods and frequency of sampling and adequacy of Medusa's Quality Control Program. Principal contacts during the visit: Wm. Copenhefer Quality Control Medusa R. Eberhardt Plant Manager Medusa () Charles Solbrig Chief Chemist Medusa Geo. Bigham District Manager Pittsburg Testing Laboratories The processing of cement was observed during a tour of the plant. Limestone and shale is obtained from nearby Company owned quarries and glacial gravel is purchased from a nearby pit for additional silica. Purchased sintered pyrites provides the required iron content. After crushing, the various raw materials are combined in the right prop-rtions so that the cement =ade from them will be of the right composition and of uniform quality. Once mixed, the crushed raw materials undergo a process Ealled fine grinding which mixes the various materials more thoroughly and reduces them further in size in preparation for the kiln. Coal fired kilns are used for clinker production. The clinkers are air quenched and transferred to a covered clinker storage area. When there is sufficient clinker "a11able, the clinker is withdrawn from the bottom and transferred to.. closea circtic finish mill, where it is interground with approximately 4% of New York State gypsum rock. Upon leaving the milling circuit the cement is pneumaticall'y pumped to the silo banks. Initial blending is controlled by mill chemists first analyzing the rock and other materials to determine their =ineral content. Then, by means of mathematical formulas, they determine how =uch of each kind of material stage help control the aml ounts of key chemical, compounds, such as tricalcium should be use'd to obtain the uniform final prodt Formulas used at this .w. silicate, dicalcium silihate and tricalcium althinate, found in the finished t ) cement. \\_.../
!i-g ( 6 Ti i.3 y y (i ;f hr.y'1 s ~g i.: n TO: J.D. Lenardson y 'n y g 7-i, ) Page 2 v' February 17, 1972 SUBJECI: QA visit at Medusa Cement Company, Wampum, Pennsylvania. The Quality Control of cement production is checked throughout the manufacturing process. Production samples are composited daily for analytical survey. Each three hours samples are collected from the cement receptacle of a period. - sa=pling device. Periodic Control tests for specification conformity of the cement are sulfur determination and fineness. Chemical and physical testing is performed daily on the cement composite to determine all other values related to ASTM specification. Fineness of the mix is monitored by te=perature, pressure, and rate meter devices. Burning results are checked by periodic testing of clinker-free line content. During the exit meeting, procedures to establish a program at Medusa, Wampum plant to insure acceptable cement delivered to Bay View silos for use at the Davis-Besse site was discussed. It was-agreed that all Type II cement transferred from Wampum silos to railroad cars for the Davis-Besse project will be documented and will indicate which silo from their bank and certification of the lot. This will provide identification for traceability on cement. (See comment on previous TECo Audit 12-7-71 at Bay View). Each cement car loaded at the Vampus plant designated for the Davis-Besse project will be sampled and 7 day results on cube strength will be reviewed by Q Wampum personnel for acceptsble strengths. The Bay View personnel will be i, ) advised of what cars, by nuaber, were acceptable for the Davis-Besse project and b' only those cars will be unloaded into the Davis-Besse reserved silo at Bay View. All records and test reports from Wampum plant will be forwarded to Nicholson Concrete & Supply Company each month for specification conformity of the cement. COMMENTS: The layout chart of the silo storage bank regarding identification for different types of cement was not clearly marked. This was discussed with Medusa personnel, and a revised chart will be made for clarification. e Since Nicholson Concrete & Supply Company is responsible to their Quality Control Program covering receipt of material for the Davis-Besse Proj ect, it is recommended that a _ollow-up by Nicholson be made regarding this comment. It is also recommended that Nicholson Concrete Co. maintain close surveillance over Medusa Cement Company's QA program in order to comply to the 18 point criteria according to TECo contract 7749-4 Section 12. .s ge //. f % s-m f / 0 l-p.& ' YGEORGE W. EICHENAUER p j GWE:bac 4[g r CC: GJS ' G.B. Nicholson Concrete hL gM h ic
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