ML19344A807

Forwards Section 5, Concrete Surface Irregularities of Util Const Verification Program Per Util 800228 Commitment

ML19344A807
Person / Time
Site:	Marble Hill
Issue date:	07/18/1980
From:	Shields S PSI ENERGY, INC. A/K/A PUBLIC SERVICE CO. OF INDIANA
To:	James Keppler NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
References
NUDOCS 8008220234
Download: ML19344A807 (18)

Text

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PUBLIC SERVICE INDIANA July 18, 1980 S. W. Shields Vice President Electric System Mr. James G. Keppler, Director Docket Nos.: STN 50-546 U. S. Nuclear Regulatory Commission STN 50-547 Region III Construction Permit Nos.:

799 Roosevelt Road CPPR - 170 Glen Ellyn, Illinois 60137 CPPR - 171 Marble Hill Nuclear Generating Station Units 1 and 2 l

Dear Mr. Keppler:

As part of PSI's program to provide assurance that the work already completed is sound and meets applicable safety requirements, PSI is conducting the Construction Verification Program as committed in the

" Description of Licensee Activities Addressing Order Confirming Suspension of Construction", dated February 28, 1980.

Pursuant to that commitment PSI is transmitting section 5.0, Concrete Surface Irregularities, for your review. Section 5.0 is based on the physical verification of Category I concrete surfaces in accordance with Special Process Procedure, SPP-5.

In total there will be twelve sections to the final report on the PSI Construction Verification Program, of which Concrete Surface Irregularties is one section. The remaining sections will be transmitted individually as they are completed.

If you have any questions on this subject, please feel free to contact me.

Sine rely, S. W. Shields Senior Vice President Nucle..r Division TB:dc cc: E. R. Schweibinz, P. E.

J. J. Harrison F. hawkins Mdf JUL 21 N 7 - M - 0 p u 3 tT C 1000 East Main Street. Plainfield, Indiana 46160 317 . 839 .9611 8 0082 20 My - - __

r 5.0 CONCRETE SURFACE IRREGULARITIES 5.1 Abstract- ,

This section describes the completion and results of an extensive inspection program conducted by Public Service Indiana (PSI) and Newberg-Marble Hill (N-MH) on accessible surfaces of Category I concrete structures at the Marble Hill Nuclear Generating Station, and the resulting conclusions and proposed follow-up action to be taken in assuring the appropriate removal and repair of unsound concrete. This program consisted of extensive documented visual examinations conducted by specially qualified and trained teams in accordance with the approved Special Process Procedure, SPP-5. The extensive visual examinations were documented both on drawings and physically marked with an enamel paint on the actual concrete surfaces as described in Paragraphs 5.3.5 and 5.3.6.

Based on the results of these examinations, PSI will take corrective measures to remove and replace existing patches and unsatisfactory concrete upon restart of safety-related construction activities. In addition to the immediate corrective action to replace concrete patches and repair unsound concrete, PSI and Newberg-Marble Hill will conduct a comprehensive training program for production and inspection personnel. This training program will be structured to identify the probable causes which directly or indirectly led ta surface irregularities and honeycomb, and to instruct personnel now to eliminate or ninimize conditions which lead to unsound concrete (i.e., Paragraph 3.3.9.3).

5.2 Introduction The information discussed herein summarizes the measures taken to identify surface irregularities of the in place Category I concrete and to determine the necessary corrective measures. These measures consisted of the following and are described in subsequent l paragraphs of this section:

5.2.1 Preparation and approval of a procedure for physical inspection and verification of Category I concrete surface irregularities.

5.2.2 Establishment and Qualification / Training of Physical Survey Teams.

5.2.3 Compilation of Sargent & Lundy-(S&L) structural drawings for use in mapping irregularities.

5.2.4 Physical inspection of visible Category I concrete surfaces.

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because of questionable circumstances s,uch as an adjacent rock pocket, then the Physical Surveyors marked the area as a concrete patch. Obvious form-tie patches were not considered as concrete patches. A copy bf the procedure (SPP-5) is contained in Attachment 5.6.1.

5.3.2 Establishment of Physical Survey Teams Physical Survey Teams were established by the PSI construction Manager with the concurrence of the PSI Project Engineering Manager and the PSI Quality Assurance Manager. Physical Survey Teams worked under the supervieion of a Team Leader. Each Team Leader was a PSI Engineer experienced in concrete construction. Physical Survey Team membership consisted of at least one PSI QA Engineer / Inspector qualified to Level II and a N-MH QA/QC Inspector qualified to Level I in accordance with the requirements of ANSI N45.2.6-1973, as defined by PSI Project Management Procedure (PMP) 3.01. In addition, each member of the Physical Survey Team attended a documented training session which dealt specifically with the SPP-5 procedure.

5.3.3 Compilation of Survey Data Prior to starting inspections, a plan print of each S&L structural .

drawing of in-place Category I concrete was obtained for use in the survey. Developed elevation dcawings were used for the containment '

exterior and primary and secondary shield walls. These prints were used as the basis for dividing areas into survey units.

5.3.4 Physical Inspection Once prints were obtained, the teams conducted the physical inspection of visible areas. This activity was performed between February 6, 1980 and April 18, 1980.

The visual surface examination included the following:

5.3.4.1 The bottom and side surfaces of accessible beams and slabs )'

indicated on the plan drawings.

5.3.4.2 The vertical surfaces of accessible walls and columns indicated on the plan drawing, and extending from the top of the slab on the

. plan drawing to the bottom of the slab / beam directly above.

Inspections took place under adequate lighted conditions. Ladders or scaffolding were utilized where required and each visible surface was illuminated using construction floodlights when needed.

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• 0 5.3.7 Identification of Inaccessible Areas Formed areas which remain inaccessible for visual inspection were recorded as described in Subsection 5.3.5 and have been reported to ,

the NRC. Locations covered by formwork will be examined as formwork is removed after the resumption of safetf-related construction activities.

PSI plans to address surfaces which are inaccessible due to backfilling in the following manner:

Upon the Nuclear Regulatory Commission's authorization to resume Category I concrete work, patched areas shall be removed to sound concrete. The inspection of each patch will be documented in accordance with approved procedures. Tatches will be grouped into separate categories to enable PSI Project Engineering to evaluate the effect of each category of patch on the integrity of the structure to perform as designed. Based upon the inspection of patches and the evaluation of these categories of patches, PSI Project Engineering will evaluate areas which were inaccessible for surface inspection due to engineered backfills or other physically inaccessible surface areas.

5.3.8 Preparation of Corrective Action Requests (CARS)

Using the documentation obtained during the inspections, PSI has generated CARS to procedurally identify the presence of surface irregularities for evaluation, repairs and to establish corrective actions to prevent recurrence. These CARS are grouped into three categories as follows:

5.3.8.1 Concrete patches (See Figure 5.6.2-1) 5.3.8.2 Potential repair areas except those located on exposed construction o joints (See Figure 5.6.2-2) 5.3.8.3 Potential repair areas located on exposed construction joints (See Figure 5.6.2-3)

Note: Separate CARS, as defined in 5.3.8.3 were written as an added precaution to assure that repair areas located on an exposed construction joint will not be covered by a subsequent concrete placement before corrective action can be completed.

5.3.9 Concrete Patches 5.3.9.1 PSI has made the commitment that previously completed concrete patches will be removed whether or not it is evident that the patches had been correctly installed. Patched areas have been identified and will be removed to sound concrete. Conditions found will be evaluated and repaired in accordance with procedures reviewed and approved by the Contractor and PSI.

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occurrence of this localized unconsolidated concrete cannot be  :

eliminated, but can be minimized.  ;

The occurrence of rock pockets and honeycombs is caused.by a lack of vibration in these areas. Due to the large amount of reinforcing steel, proper vibrator insertion and vibration duration is extremely important to force the plastic concrete through and around the reinforcing curtain to the form surface. . Again, the occurrence of honeycomb and rock pockets can be minimized, but not  !

eliminated, by adequate careful vibratton.

i Further steps to be used in combinction with or in addition to those discussed above are as follows:

5.3.9.3.1 Supplementation of Quality Assurance / Control, Construction, Engineering, and Production staffs with personnel qualified in concrete-related work for nuclear power plants.

5.3.9.3.2 Revision of existing procedures and development of additional procedures.

5.3.9.3.3 Addition of procedural " Hold Points" to allow ef fective inspection of work-in-progress.

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5.3.9.3.4 Development and implementation of an extensive indoctrination and j training program in concrete-related work for inspection and production personnel.

5.4 Conclusions Through this extensive visual concrete surface examination at the Marble Hill Nuclear Generating Station, concrete patches and potential repair areas on visible concrete. surfaces have been identified and located. Potential repair areas such as honeycomb, rock pockets, and other voids which expose reinforcing steel will be repaired. These future repairs, combined with the engineering evaluation to be performed on the inaccessible surfaces, will assure that the in place safety-related concrete is structurally adequate and meets the requirements of applicable codes and standards.

In addition, training of personnel in concrete work, augmenting of staffs with more qualified personnel, provision of new and improved procedures to govern such work, and increased controls through witness and hold points to assure proper preparation for and performance of work will improve the quality of future concrete placement.

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SUMMARY

OF REVISIONS PROC. NO. SUSJECT

. SPP-5 CATEGORY I CONCRETE SURFACE IRREGULARITIES RE SION REVISION DESCRIPTION 0

1 Revised paint requirements , Paragraph 3.2-6.

2 Revised responsibility of team assignment, Paragraph 3.2.

Revised responsibility of PSI Project Engineering Manager, Paragraph 3.1.

Revised PSI /NRC communication channels, Paragraph 3.1.

3 Revised supervision responsibility of Team Leader, Paragraph 3.1.

Revised drawing requirements, Paragraph 3.2.

4 Revised " Repair Area" and " Concrete Patch" definitions, Paragraph 3.2.

5 Revised qualification requirements of Team Leader, Paragraph 3.1.

6 Revised paint requirements, Paragraph 3.2-6.

.7 Revised responsibility c.f team assignment, Paragraph 3.1L.

Revised issuance of nonconformances, Paragraph 3.2-6.

i REVISION AUTHORIZATION l REVISION NUMBER 7 DATE ISSUEo 05-22-80 PREPARED /

BY ( [ d L, CHECKED . s BY , M a> 4 SEC ION G l APPROVED k Q.A. MGR. , _ ,jt(h'[h APPROVED PROJ. DIR. -

Putdc Service Indiana LF 61 175 2/80 .

i MARBLE HILL GENERATING STATION Date 05-22-80 PUBLIC SPECIAL PROCESS PROCEDURE Revision 7 2 of 8 SERVICE

(; INDIANA

Title:

SPP-s CATECORY I CONCRETE SURFACE IRREGULARITIES -

1.0 SCOPE This procedure establishes a systematic method for the identification, location, and documentation of all concrete patches and unrepaired concrete surface irregularities located in all visible Category I areas.

2.0 DEFINITIONS AND ABBREVIATIONS N-MH - Newberg - Marble Hill NRC - Nuclear Regulatory Commission PSI - Public Service Indiana Physical Surveyor - An individual who performs the inspection work involved in the verification procedure.

PST - Physical Survey Team - A group of individuals, including a Team Leader and Physical Surveyors, who are responsible for the performance of

(,' the visual inspection and documentation.

S 6 L - Sargent & Lundy Engineers Surface Irregularity - A concrete patch or repair area.

Team Leader - An individual who is a member of the Physical Survey Team and supervises the work of the Physical Surveyors.

3.0 INSTRUCTIONS 3.1 Establishment of Physical Survey Team The establishment of the Physical Survey Teams shall be the responsibility of the PSI Construction Manager with the concurrence of the PSI Project Engineering and Quality Assurance Managers. All Physical Survey Teams shall work under the supervision of a Team Leaders. Each Team Leader shall be a PSI engineer who satisfies one of the following qualifications.

1. BS degree plus one year experience in concrete related work.

2. Five years experience in concrete related work.

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I MARBLE HILL GENERATING STATION Dan 05-22-80 PUBLIC SPECIAL PROCESS PROCEDURE Revision 7 SERVICE

Title:

( INDIANA SPP-5 CATEGORY I CONCRETE SURFACE IRREGULARITIES hammer. If the hammer sound is similar to the surrounding concrete, this indicates solid material and these locations shall not be identified as patches. However, if the area seems suspect because of questionable circumstances such as an adjacent rock pocket, then the Physical Surveyors shall mark the area as a concrete patch. Obvious patch form-tie locations shall not be considered as concrete patches As the inspection progresses, the plan drawing defining the area shall be marked in the following manner:

1. Any area that has been visually inspected shall be clearly indicated by marking the drawing.

2. If any area cannot be visually inspected, then a note describing the area and the reason for inaccessibility shall be clearly indicated on the drawing, e.g., formwork-in place, backfill, bottom surface of a grade slab, etc.

(m When formwork prohibits the visual inspection of a concrete surface, the

\ Team Leader shall notify the PSI Construction Manager (or his delegate),

who in turn will communicate with the PSI Project Engineering Manager.

It is intended ' at all PSl/NRC communications associated with implementation of the verification program go through the PSI Project Engineering Manager. The removal of formwork shall be handled on a case-by-case basis with the exception that the formwork for the 9th lif t of the Containment Exterior - Unit 1, shall not be removed until required in the normal course of events following the resumption of work. This surface area shall then be inspected using normal QA surveillance as the formwork is removed.

3. Surface irregularities shall be approximately located on the plan drawings using the follo..-... ..vLoi vii.

- Concrete Patch (1/4" diameter)

- Repair Area (each leg 1/4" in length)

Note: Developed Elevation drawings shall be used for the containment exterior, secondary shield wall and primary shield wall.

4. Each surface irregularity shall be given a unique (

identification number using the following format:

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$ where ID!E CP for Concrete Patch 8

5

F MARBLE HILL GENERATING STATION Date 05-22-80 7

PUBLIC SPECIAL PROCESS PROCEDURE Revision

" 5 of 8 SERVICE

Title:

( -- INDIANA SeP-5 CATEGORY I CONCRETE SURFACE IRPSGULARITIES 2iERA for Repair Area X 2 Sequential Number Starting with "1" for each drawing For example, if on drawing S-673 five concrete patches and ten repair areas have been found, then the first and last identification number for each type would be CP-1 and CP-5 for concrete patches and RA-1 and RA-10 for repair areas.

In addition, when the next drawing is used for inspection, the first concrete patch discovered shall be labelled CP-1, etc. All marked up drawings shall contain the names of the Physical Surveyors and Team Leader and the date of the inspection.

5. In addition to locating the surface irregularities on the drauing, the following forms shall be completed at the time that the inspection is being conducted:

Form SPP-5-3.2-1 Concrete Patch Data Sheet Form SPP 5-3.2-2 Repair Area Data Sheet

> The dimensions input on the above forms shall be to the approximate center of the surface irregularity. The accuracy of the location dimensions shall be such that any surface irregularity can be readily located by using the marked up drawing and the corresponding data sheets.

6. The perimeter of each concrete patch shall be clearly marked using red spray paint; whereas, the perimeter of each repair area shall be clearly marked usit.g yellow spray paint. The yellow and red spray paints shall be used for all Category I areas except for the exterior of the Containment Building.

For the exterior of the Containment Building, the perimeters of repair areas shall be marked using a light gray spray )

paint and the perimeters of concrete patches shall be marked using a dark gray spray paint. All spray paints shall be an l exterior enamel type, i It shall be the responsibility of the P.S.T to originate any l deficiencies with design requirements in accordance with PMP l 1.07 on a Corrective Action Request (CAR). The PSI Level II Inspectors are responsible for assuring that the nonconformances are documented accurately with the findings of the P.S.T and are responsible for signing the signature

( block labeled " Initiator". NOTE: For SPP-5 deficiencies it

'- @ shall be noted in the " Method of Discovery" block on the CAR h Form that the deficiencies were discovered by SPP-5 P.S.T.,

The control of the nonconformances (CARS) shall be in b

f MARBLE HILL GENERATING STATION Date 05-22-80 PUBLIC SPECIAL PROCESS PROCEDURE Revision 7 SERVICE

"'" 7 of 8

Title:

(_ INDIANA SPP-5 CATEGORY I CONCRETE SURFACE IRREGULAR 1 TIES 4.0 FLOWCFLART 3.1 Establish PSTs PSI o

3.2 Obtain Reduced Prints of PST Category I Areas k

3.2 Visually Examine Concrete Surfaces, Mark Prints to PST Indicate Surveyed Areas and to Indicate Concrete Surface Irregularities, Complete Data Forms f 3.2 f Output Document (Typ.)

f PST 7

3.2 Process Nonconformances PST h

3.3 Maintain File of All Documents PSI k' o R

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CONCRETE PATCl! DATA SHEET

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Signztt..as of Physical Surysyors S&L Dvg. No.: <

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.i Building:

Concrete' Dimensions From Column Lines 1 . Approximate Approximate .

Patch' Comment Elevation Size,SQ.FT.

I,p, no, North - South 2 East - West 2 __

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o 1 For Containment Exterior Wall, Secondary Shield Wall,.and Primary Shield Wall useAzimuths 2 Dhaensions shall be indicated as counterclockwisc-CCW and clockwise-CW when Azimuths are used for reference

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• ATTACHMENT 5.6.3.3 Exattple of a Repair Area Data Sheet RIPAIR V"A PATA FHEET p g,. O ME 3- M Signatures of Phvsical Surveyors S & L Dvs. No. S-709. Fev. C Building: Auxiliary Tunnel E1 pair Dirensions From Colurn Lines 1 \pproximate Approxirate Corrrent Area T. P. No. North - South 2 East - West 2 Elevation S iz e , SO. FT.

N. face ot vall la' d RA-1 of 10 line 6' W. of N line 357-6" l'Hx?"V Interriminent - uncon. are on N. face Rock pocket in form seam on RA-2 I f)

• W. of N line 358 4'Vxt"H N. face RA-3 3' S. of 10 W. face of N. If ne val 362 2'Px1'V l'ncon area on W. face S. face of 10 line RA-4 vall 2'-6" V. of N 361 3"Hx1'V t*neen. area on S. face Rock pocket in horizontal form seam PA-5 8' W. of N line 361 11'Hxl'V and includes uncon. area Pock pocket along form seam at top RA-6 12' W. of N line 363 3'Hx1"Y of vall Rock rocket along er. bed on 5.

PA-7 4' N. of 6 line 7' E. of Q line 369 2-l'Vxt"H face of vall RA-8 7' N. of 5 line 7' E. of Q line 373 l'Hx6"V Void at t on o f vall S . face of vall RA-9 " "

o 9' N. of 5 line 372 l'Hx6"V t*ncen. area on S. f ace of vall

'f Suspect areas on slab step-down

', RA-10 5 line 5' E. of 0 line 360 ---

W. face J. W. face of vall 5' W.

RA-11 4' S. of 5 line of P line 369 l'Hx6"V Suspect area around conduit W. face of wall 5' W.

RA-12 3' N. of 5 line of P Ifne 369 l'Hxl"V Pnck pocket alone bottom of vall RA-13 r,' N . o f 5 I f ne " "

371 3'Hx2'V Rue hole area

" RA-14 13' S. of 8 line " "

369 2'Fx2'Y Pug hole area 7 E. face of vall 7' E.

T RA-15 13' S. of 8 line of 0 ifne 370 3'Vx1'M Bug hole area RA-16 12' S. of 8 line " "

366 2'lix1"V Rock pocket along form seam E

5 1 For Containment Exterior Wall. Cecondary Shield Wall and Primary Shield Wall use Azi'suths 2

Dimensions shall be indteated as counterclockwise-CCW and clockwise-CW vhen Azimuths are used for reference 1

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