ML19347B504

Final Deficiency Rept Re Concrete Placement QA Program & Revised Procedural Requirements.Inspector Added to QC Staff. Personnel Reinstructed in Proper Consolidation of Placement. Procedures Rewritten W/Involvement of Supervisors

ML19347B504
Person / Time
Site:	South Texas
Issue date:	09/04/1980
From:	Oprea G HOUSTON LIGHTING & POWER CO.
To:	Seyfrit K NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV)
References
10CFR-050.55E, ST-HL-AE-524, NUDOCS 8010150188
Download: ML19347B504 (12)

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'The Light Company n_,,, uurim,m m a.,mm s-,,i. r~s m,unees.mn September 4, 1980 ST-HL-AE-524 SFN: V-0530

'tr. Karl Seyfrit Director, Region IV Nuclear Regulatory Commission 611 Ryan Pla:a Drive, Suite 1000 Arlington, Texas 76012

Dear Mr. Seyfrit:

1 South Texas Project J Units 152 Docket Nos. STN 50-498 STN 50-439 Final Report Concerning the Quality Program for Concrete Placement CIl-W90 l

On June 4, 1980, pursuant to 10CFR50.55(e), Houston Lighting 5 Power Company notified your office of a deficiency concerning a breakdown in the quality program for concrete placement CIl-W90 (Steam Generator Secondary Shield Wall in the Ur.it 1 Reactor Containment Building) . Interim reports on this subject were submitted to your office on July 3,1980 (ST-HL-AE-492) and August 1, 1980 (ST-HL-AE-504). This report constitutes a final report on this deficiency.

If there are any questions, please contact Mr. Michael E. Powell at (713) 676-8592.

Very truly yours ,

[7.N . A:wre,a, A - .

Execdtive cice President MEP/ngb Attachments U G101 ao l4,q,

. ston toteg & %e compsnv September 4,1980 ST-HL-AE-524 SFN: V-0530 Page 2 cc: D. G. Barker C. L. McNeese H. R. Dean R. L. Waldrop G. B. Painter A. J. Granger R. A. Frazar

M. D. Schwarz (Baker & Botts)

R. Gordoti Gooch (Baker & Botts)

J. R. Newman (Lowenstein, Newman, Reis, Axelrad & Toll)

Director, Office of Inspection & Enforcement Nuclear Regulatory Conmission Washington, D. C. 20555 M. L. Borchelt Executive Vice President Central Power & Light Company P. O. Bcx 2121 Corpus Christi, Texas 78403 j R. L. Range Central Power & Light Company i

P. O. 2121 Corpus Christi, Texas 78403 R. L. Hancock Director of Electrical Utilities City of Austin P. O. Box 1088 Austin, Texas 78767 T. H. Muehlenbeck City of Austin l P. O. Box 1088 l

Austin, Texas 78767  :

J. B. Poston Assistant General Manager of Operations City Public Service Board P. O. Box 1771 San Antonio, Texas 78296 A. vonRosenberg City Public Service Board P. O. Box 1771 San Antonio, Texas 78296 1

ston tg5 ting & f5m company

.HL-AE- 524

ge 3 Charles Bechoefer, Esquire Chairman, Atomic Safety & Licensing Board U.S. Nuclear Regulatory Commission Washington, D.C. 20555 Dr. James C. Lamb, III 313 Woodhaven Road I Chapel Hill, North Carolina 27514 1

Dr. Emmeth A. Luebke Atomic Safety & Licensing Commission U.S. Nuclear Regulatory Commission i Washington, D.C.20555 Steven A. Sinkin, Esquire 116 Villita Street San Antonio, Texas 7820S Citizens for Equitable Utilities c/o Ms. Peggy Buchorn Route 1, Box 432 Brazoria, Texas 77 Ze Richard W. Lowerre, Esquire Assistant Attorney General for the State of Texas P. O. Box 12548 Capitol Station Austin, Texas 78711 Henry J. McGurren, Esquire Hearing Attorney Office of the Executive Legal Director U.S. Nuclear Regulatory Commission Washington, D.C. 20555 l

l ATTACH 3ENT 1

. Final Report Concerning the Quality Program for Concrete Placement CIl-W90 September 3, 1980 DESCRIPTION'0F DEFICIENCY During a Brown 6 Root internal audit conducted from April 7-10, 1980 or, concrete placement activities, an in-depth review was performed on all activites and documentation relating to concrete placement CIl-W90 (placement made 10/29/79).

This placement was randomly selected by the auditors as representative of a complex j safety-related concrete pour d ring late 1979. The findings of this audit, as documented in Brown S Root Audit Deficiency Report (ADR) ST-36.7, raised numerous questions concerning Brown 5 Root meeting their specification and procedural requirements for pre-placement, placement and post-placement documentation. The documentation for this placement, which was reviewed by the auditors, appeared

< inadequate to conclude that satisfactory consolidation was achieved in this place-ment. Proper vibrator spacing could not be obtained using internal vibrators during the placement thus internal vibration was replaced or supplemented by form

, vibration. The documentation appeared inconsistent regarding the acceptability of I the vibration techniques actually employed for this placement. The auditors felt that the failure to meet the specification and procedural documentation require-ments indicated a breakdown in the quality program which caused the physical quality of concrete placement CIl-W90 to be indeterminate until proven otherwise.

SAFETY EVALUATION In lieu of attempting to perform a safety evaluation on an indeterminate deficiency, this placement was identified to the Brown 6 Root Task Force for Concrete Verification (NRC Order to Show Cause, Item 3.b). As described in the Concrete Verification Program - Status Report dated August 15, 1980 (ST-HL- AE-513) ,

the Task Force investigated this placement using visual inspection and Ultrasonic Testing. The Task Force investigated placement CIl-W90 for underconsolidation in the area of the 42 inch diameter pipe sleeve, under the embedded plates in the top of the wall, and in the area where form vibrators were used during the place-ment. The Consultant Panel and the Task Force have determined from their inspections and testing that th placement is structurally sound.

CORRECTIVE ACTION Since no physical defect has been identified in the placement, no corrective 4

action is required concerning the structural integrity of the placement. Cor-rective action concerning specification and procedural recuirements for pre-place-ment, placement and posc-placement documentation has been addressed under

" Recurrence Control".  ?

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ATTACHMENT 1 (Cont.)

RECURRE!!CE CONTROL Improvements for the concrete placement program have recently been identified to the NRC (see Attachment 2, HLSP Response to Items n# " n-compliance, dated May 23, 1980, Item A-7 Concrete Placement Activities; and Attachment 3, HL5P Response to Order to Show Cause, dated July 28, 1980, page 12, Complex Concrete Placement). These improvements will assure against recurrence of a similar concrete placement problem.

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ATTACHMENT 2

• I T F.F. A - 7 Concrete Placement Activities A. Summarf concrete placement activities preblems previously identified had not been corrected in accordance with prior cc::ctit=ents.

These continuing proble=s involved proper consolidation practices, poor lighting, lack of adequate numbers of inspection personnel, production pressures and excessive lift thicknesses. These are matters previously identified as placement problems and, contrarf 4

to prior commitments, corrective action has not been incorporated 1

into concrete placement procedures.

B. Replv (1) Affirmation or Denial The item of noncompliance is substantiated.

(2) Reason for the item of noncompliance Analysis of this noncompliance shows that the problems identified above are a result of insufficient training, unsatis-factory procedures and production pressures.

i (3) Corrective action to date and results achieved The following corrective actions have been taken:

a. Production Pressure - Additional QC inspectors have been added to the Quality Control Staff to assure that

• This has been extracted from the May 23, 1980 letter from G. W. Oprea to Victor Stello, "HL&P's Response to Items of Non-comoliance."

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preplacement inspections are conducted in a thorough manner.

Procedures have been revised to require the comoletion of  !

preplacement inspection and sign off of the pour card by the B&R QC inspector prior to the delivery of concrete to the construction area. Other measures described in the response to Item 1, above, have been taken to eliminate the' production pressures which might be perceived by the QC staff.

b. Inadequate lighting - Construction procedure CCP-4 has been revised to add placement lighting to the preplacement/ place =ent checklist. This requirement is applicable to all safety-related pours.

c. Reinspection - Revisions to Site Procedures A040K?CCP-3, 4, 8, 12, 19 have been made which instruct the inspector that after he has inspected and accepted an item, if additional activity should occur in that area that would make quality of that item indeterminate or unacceptable, he shall reinspect that item and document his results on the applicable examination check.

d. Supervision - Placement foremen, field engineers and QC inspectors have been reinstructed on their obligation to identify any improper consolidation practices and to

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ensure that the placement receives proper consolidation.

e. Training - Procedure CCP-4 revised March 7, 1980, requires consolidation training every 90 days for consolidation placement craft. The most recent class was held April 18, 1980. These training classes emphasize consolidation procedures and ACI recom= ended practices.

f. Placement meetings - Construction procedure CCP-4 has been revised to require formal preplacement and postplace-ment meetings. The required agenda for preplacement meeting includes review and discussion of the specific placement method to be undertaken and the sequence of activities.

The prescribed agenda for postplacement meetings includes discussion of all deviations from the placement as planned, including delays and required changes in the sequence of activities.

g. Proced6:es - Procedures are being rewritten in a new format with the involvement of the craft supervisors.

These rewritten procedures will contain all relevant informa-tion from specifications, technical reference documents, l l

codes, standards and regulauory documents. They are being I 1

vritten in such a way that they can be easily understood by

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craft personnel. Technical terns are being rep, laced, whenever possible, by sinpler terns or phrases.

(4) Corrective steps which will be taken to a, void further items of nonec=cliance As noted above, a nunber of significant corrective actions have already been initiated. These efforts will continue f throughout the duration of construction. Procedure CCP-4 will be revised by June 2, 1980, to reflect the requirement to discuss.

l adherence to the specified lift thickness during each preplacement i

meeting. As i= proved methods of placing concrete are identified, they will be evaluated for incorporation into project construcrion procedures and training manuals.

(5) Date when full comcliance will be achieved Actions a. through f. in Section (3) above have already l been accomplished. Action g. will be completed by July 21,

~i 1980. The actions discussed in Section (4) will be an on-going project activity.

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l ATTACHE'fENT 3 i

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• C. Complex Concrete Placement

1. Revisicn and reissuance of concrete placement procedures.

2. Training of personnel in the revised procedures.

Specific complex placement provisions will be addressed in separate training sessions.

3. Construction, Engineering and QA management will review the results of the Unit 1 Reactor Containment Building Concrete Task Force investigation for impact on existing procedures and methods and will make modifications in these procedures and methods as necessary.

4. Assignment of complex pour coordinator from Con-struction to oversee complex concrete placement operations i

until such time as Construction management determines that performance is satisfactory.

5. Assignment of a complex pour coordinator from QA

' to oversee concrete placement inspection activity on these pours until QA management deter =ines that QC performance is satisfactory. l

6. Verification of the availability of qualified

' Pittsburgh Testing Laboratory concrete testing personnel.

7. Reconfirmation of the qualification and certification l of QC inspection persennel. 1 J

8. Review of the concrete supplier's quality program l

to assure there are no unresolved quality program deficiencies.

• This has been extracted from HL&P's Response to Order to Show  !

Cause, dated July 28, 1980.

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9. Reverification of the availability of adequate concrete placement equipment and personnel.

10. Resumption of co= plex concrete placement to begin with those pours already formed, proceeding from simpler to more difficult pours as follows:

(a) North valve room walls and second shield EL -2' to +9'3" CI2 W24 - 160 cu. yds.

(b) South EX walls El -2' to +9'3" CI2 W22 - 208 cu. yds.

(c) Southeast secondary shield wall EL -2' to +9'3" CI2 W23 - 40 cu. yds.

(d) North valve room walls / slabs EL 61'3" to 68'0" CIl S68 - 102 cu. yds.

(e) Containment shell EL +53' to +63' CS2 W8 - 580 cu. yds.

(f) Dome pour EL 150' to 155' CS1 W18 - 375 cu. yds.

(g) North valve room walls and secondary shield walls .

EL 9'3" to 16'0" CI2 W27 - 137 cu. ycs.

(h) Southeast exchange wall and secondary shield walls EL 9'3" to 16' CI2 W28 - 129 cu. yds.

(i) Southeast secondary shield walls EL 9'3" to 16' CI2 W26 - 32 cu. yds.

11. Review of the quality of the placement and documenta-tion of the work for conformance with requirements.

12. After the processes described in the above items have been completed, the complex concrete placement program will be expanded into other areas as additional personnel are qualified.

QA management will review the implementation of these steps to verify that the quality program is functioning properly. Resumption of the work will begin gradually, with l

specific QA management assurance that all procedures and t

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check lists are in place and the requisite number of qualified QC inspectors are available for each construction activity.

Each step of the resu=ed work will be carefully monitored; and only after B&R & EL&P QA management and Construction management have assured themselves that the resumed construc-tion activities are being done correctly, and the QA/QC system is working effectively, will ute work in these activi-ties be increased.

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