ML20031C643
| ML20031C643 | |
| Person / Time | |
|---|---|
| Site: | Callaway  |
| Issue date: | 09/23/1981 |
| From: | Neal P DANIEL INTERNATIONAL CORP. (SUBS. OF FLUOR CORP.), UNION ELECTRIC CO. |
| To: | |
| Shared Package | |
| ML20031C639 | List: |
| References | |
| ISSUANCES-OL, NUDOCS 8110070378 | |
| Download: ML20031C643 (19) | |
Text
_ _.
s UNITED STATES OF AMERICA NUCLEAR REGULATORY COMMISSION BEFORE THE ATOMIC SAFETY AND LICENSING BOARD In the Matter of
)
UNION ELECTRIC COMPANY Docket No. STN 50-483 OL
)
(Callaway Plant, Unit 1)
)
AFFADAVIT OF R.
DAVID NEAL
. ~..
IN SUPPORT OF APPLICANT'S MOTION FOR
SUMMARY
DISPOSITION OF JOINT INTERVENORS' CONTENTION NO. 1B (CONCRETE CRACKS)
County of Callaway
)
ss:
State of Missouri R. CAVID NEAL, being duly sworn, deposes and says as follows:
1.
I am the F' ject Civil Engineer, Callaway Plant, Daniel International Corporation (" Daniel").
My business address is P. O. Box 108, Ful ton, Mi ssouri, 65251.
A summary of my professional qualifications and experience is attached hereto as Exhibit "A".
I have personal knowledge of the matters stated herein and believe them to be trua and correct.
I make this affidavit in support of Applicant's Motion for Summary Disposition of Joint Intervenors' Contention No. 1B (Concrete Cracks) in this proceeding.
2.
Daniel is the constructor for the Callaway Plant.
Headquartered in Greenville, South Carolina, Daniel is engaged k$dOk[8lK05000483-78 81100i' g
PDR s..-
-a
e in engineering, construction and industrial maintenance projects throughout the United States and in many foreign countries.
The power group of Daniel specializes in provid-ing management and technical expertise to utility clients for power plant construction.
As indicated in the Callaway Plant Addendum to the SNUPPS FSAR, section 1.4.8, the Daniel power group has recently constructed or has current contracts for eleven nuclear units, four fossil units and two hydro-electric plants with a capacity in excess of 16,000 MW.
3.
The purpose of this affidavit is to demonstrate that the quality control programs at Callaway perfor.med properly in detecting and dispositioning the cracks in the Control Building walls.
4.
On February 8, 1978, a Nonconforinance Report, NCR 2-2081-C,A, was written by Daniel, documenting fif teen (15) cracks in the concrete in the Control Building walls.
( A copy of NCR 2-2081-C-A is attached as Exhibit "B". )
i Upon information and belief, th's NCR was written at the t
request of NRC inspectors following an investigation into an anonymous allegation that a concrete pour had been made for a portion of the Control Building wall on top of a por-tion of the wall containing a visible 12 foot long and 8 inch deep crack.
See NRC Inspection Report No. 50-483/78-01, p.
- 70....
r 5.
The NCR contains sketches showing the size and location of the fif teen (15) cracks.
Four (4) of the cracks do not exceed 1/16 inch in width at their widest point; six (6) cracks do not exceed 1/32 inch; and five (5) cracks are hairline cracks.
Several of the cracks extend beyond one pour.
Tne NCR indicates that only three of the cracks (Nos.
11, 13 and 15) are considered to be a reportable condition.
6.
After evaluation of the cracks by Daniel and the architect / engineer, Bechte1 Power Corporation ("Bechtel"),
NCR 2-2081-C-A was superceded by NCR 2-2173-C-A on February 21, 1978.
( A copy of NCR 2-2173-C-A is attached as Exhibi t t'C". )
The new NCR includes only crack Nos. 11, 13 and 15.
-(Crack No. 12 was also included in this NCR only because it appears on the same sketch as do cracks No. 11 and 13.
Since it was a hairline crack, Crack No. 12 was not deemed to be reportable.)
ihe other cracks were determined by Daniel and Bechtel not to be structurally significant nor otherwise to constitute noncon-formances.
Daniel's recommended disposition for the remaining cracks was "use as is" since the cracks "will not impair the structural integrity of the walls."
Bechtel's revised dis-position calls for repair of the three cracks with an approved e: 1xy grout.
7.
Of the fif teen cracks, three -(3) were found in a portion of the wall poured on January 25, 1978, ten (10) were located in a portion poured on January 12, 1978, and one l
(1) each were found in portions poured on January 11, 1978 and December 23, 1977.
Four (4)-of the cracks extended into previous aajacent pours.
l l
l 8.
Daniel Work Procedure WP-109, " Concrete Place-ment, Grouting and Post-Pnur", Revision 7 (dated November 3, 1977), section 4.10, requires a Daniel Civil Quality Control l
Inspector to conduct a post-pour inspection of a concrete placement approximately 30 days after the pour and to note any cracks which have occurred.
Although not mandated by n e-WP-109, inspections are also made by Quality Control In-spectors at other points in the post-pour curing process, particularly at the time of form removal.
WP-109, devision 7, required that only cracks greater than 1/16 inch in width must be reported to the Daniel Area Civil Engineer.
The 30-day inspection and the greater than 1/16 inch reporting criteria are also mandated by Daniel Quality Control Procedure QCP-109, " Concrete Placement, Grouting and Post-Pour", section 4.9.9.
When a crack greater than 1/16 inch is reported, the Area Civil Engineer is required by WP-109, section 4.10, to inspect the crack area to determine its extent and to determiner what effect the crack appears to have on the function of the structure considering the following questions:
a.
What is the effect on structural capability?
b.
If exposed, will water intrude or l
leak through?
c.
Will weathering ravel and deteriorate the concrete in the vicinity of the crack? !
O 8.
continued d.
If the cracks are random and unsightly, is cosmetic repair desirable?
If the crack appears to affect structural integrity, an NCR must be wri tten.
These criteria for reporting potentially significant cracks were developed jointly by Daniel and Bechtel and represent a conservative standard.
9.
None of the fifteen cracks, identified in NCR 2-2081-C-A on February 8, 1978, exceeded 1/16 inch in width and therefore none would have been reportable by the Civil 4
Quality Control Inspector under the criteria of section 4.10 i
of WP-109.
Furthermore, it'is important to recognize that the development of such minor cracks resulting from drying shrinkage during curing is a dynamic process.
Cracks can appear practically overnight.
In February of 1978, when the NRC made its inspection and NCR 2-2081-C-A was wri tten, less than 30 days had elapsed since the placement of the concrete pours in which 14 of the 15 cracks (including Nos.
11, 13 and 15) were discovered.
Accordingly, some or all of the cracks identified in the NCR on February 8,1978, may not have existed at the time of earlier Daniel inspections.
There is, therefore, no basis for concluding that these cracks were overlooked or ignored by Daniel Quality Control Inspectors since the cracks did not exceed the reportability threshold and may not even have existed during earlier inspections.
l 1
I 10.
Finally, none of the cracks were determined by Daniel and Bechtel to be of any structural or safety significance.
Crack Nos. 11, 13 and 15 were deemed to be potentially significant enough that they were reported in NCR 2-2173-C-A.
Their significance, however, was not related to the question of structural integrity and they were repaired pursuant to the Bechtel approved disposition because they were determined to be cosmetically undesirable.
The order of priorities for construction was such that the repair work was not completed until June, 1979.
Normally, repairs of a minor nature, such as these, are performed when several are avail-able for work at the same time.
The repair work was in no way 4
hindered by the fact that subsequent lif ts of the wall had been placed on top of that portion containing the cracks.
f O
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Nw/
9!'Z3)T/
t a
i.. David Neal '
/
/
, NOTARIZATION Subscribed and sworn to befere me, the undersigned dayofdgwfu,)
officer, this c23
, 1981.
w ? r) l No taryf?uf yi c My Commission Expires:
3),/992 l l
l'ElvmAL RCSUS:E ROBERT DAV!D f:FAL TITLE PROJECT. CIVIL ElGI!EER
~
DATE OF BIRTH JAllUARY 30, 1953 E0'.'CATIO!!
UtlIVERSITYOFS0JTHFLORIDA,SEPTEi:CLR1971toMAYiS2 UtlIVERSITY OF ILLIt:0IS - 1972 to 1975 B. S. Ill CIVIL Ei:GII;EERIliG. - 1975 SUIStARY OF EXPERIEtiCE:
Six (6) years of heavy construction engineering and supervisory experience including tenparary facility and falsework design, material procurement admini'stration, and the administration and interpretation of Design Specifications, Procedures and applicable Quality Control methods.
Management experienca includes the management of a fifteen (30) mc=ber Civil Engineering Departcer.t providing engineering and procurement support to Construction forces during the construction of a 1150 MU lluclear Power Plant.
SPECIAL TRAltlIf;G:
1.
Welding Technology for Supervisces and Engineers (1 week seminar) October,1979 Hobart School of Welding Tecnnology, Troy, Ohio, 2.
Supervi: cry Develcpment Seminar - September,1978
.(Held at the Callaway jobsite).
3.
Purchasing and Contracts Seminar May, 1978
-(Held at the Callaway jobsite).
4.
General Electric " Management Practices Course" One-week Seminar - October, 1980
-Center for Continuing Education, Boone, North Carolina 5.
" Managing Management Time" One-day Seminar - June,1981
. Flaming Pit Banquet Center, Columbia, Missouri
~..
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Page 2 k.*'.PLOYMENT JOB TITLE /EltPLOYER DUTIES t, RESPONSIBILITIES Jun2, 1981
. Profcct Civil Engineer Type of facility - tw1 :: nit to Present Callaway Nuclear Power Plant Nuclear Power Plant Daniel International Corp.
Fulton, Mo.
65251 Project Description - First of two 1150 MW Pressurized Water Reactors; Combined Capital Value - $3.2 Billion
~,_
Technical Expertise -
Extensive knowledge of Work Procedures, Specifications, Codes and Standar'ds.
Design capabilities for tempor W works, falsework, and heavy rigging.
Specific Responsibilities -
Rcport to the Construction Engineering Manager and, supervise and manage the tctal Civil Construction Engineering effort for the project.
Responsible for the authoritative interpretation of the design documents and for the technical support required to assist Construction in confonning to Design and applicable Code requirements.
Initiate and
- prepare requisitions for procurement of subcontract materials and equipment; interface with the Material Control Manager concerning the 5
handling, storage, preservation and disbursement of materials and equipment with specific emphasis on Code-related items.
Participate in and monitor estimating, planning and scheduling efforts to the extent of providing engineering infonnation input from inception through completion. Communicate and cooperate with other discipline engineers in the pursuit of mutual responsibilities to the Project and develop effective methods of
-~
accomplishing the required work-activities.
e
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(MPLOYMEt:T_
JOB TITLE / EMPLOYER DUTIES t. RESP 0tlSIBILITIES f{ovember.1978 Lead Civil Engineer i-Type of facility -
I to June, 1981 Daniel Constructi,on Co.
Two Unit fluclear Power Plant Callaway fluclear Pcwer Plant Fulton, Mo.
65251 Project Description -
First of two (2) projected 1150 MW pressurized water Reactors; combined Capital
. Valt.e $3.2 Billion Technical Expertise -
i Supervisory responsibility for meeting engineering needs to support construction in
)
assigned areas.
Specific Responsibili' ties -
Reporting directly'to the i
Project-Civil Enginee'r with overall direct supervisory j
responsibility for five (5) engineers involved in providing
]
Civil Engineering support for
. construction activities.
Detailed duties include providing technical guidance, determining work assignments and priorities, coordinating speci'al investigations and
" studies when requ' ired by A/E, Client or regulatory bodies,
~
and handling.of all i
administrative functions t
related to assigned employees.
Assigned areas include Turbine, 4
Radwaste, Auxiliary, Control, Comunications Corridor, and Diesel Generator Buildings in l
addition.to previous responsibilities over structural engineers.
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Perstnal P.ctumo, Cont.
Robert David !* cal Page i
e EST '.OYME'.I JOB TITT.E/CIPI. OYER DUTIES & RESPONSIBILITICS i
March, 1973 to Lead Structural Ent'.ineer Type of Facility -
Nover.her, 1973 Daniul Constructivu Co.
Tuo (2) Unit Nucicar Power Callaway Muc1 car Plant Plaat..
Fulton, Mo.
Project Description
~~
~
First of two (2) projected 1150 MW pressurized vater Reactors; ecchined capit.21 value $3.2 ?.illion
~
Technical Expertise -
Technical knowledge of l
implemented structural construction codes and interpretation of drawing requirements.
Specific Resjocsibi11 ties --
~ g Reporting directly to the 2.
Project Civil Engineer with overall supervisory responsibilitics for three (3) engineers involved uith
~-
.s.tructural and reinforcing
.Estec1 place =ent, providing priority assign = cat and a
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technical review of their
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Coordination of construction procedures and
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... !?!Pt.C U T !T JOB TITT.E/E*tP!. OYER DUTIES t. RESPO:*SICII.1T.!_i:.0 AuCust,1977 te
' Ares Civil Engineer Type of Facility -
?f.,rch, 1973 Danici Countruction Co.
Two (2) Unic !*ucicse Pevur Plan Ca11susy !!ucicar Plant Fulton, Mo.
Project Description -
First of two (2) projected j
1150 int pressurised v:.ccr Reactors; corSined espits1 I
value of $3.2 Sillion Techniesl Expertise -
I Review snd dispo ition of Nonconfor=ance Reports relstad to structural and reinforcing stccl.
Specific Responsibil'itics -
I Reviewing sud perfor=ing engineering checks on design an fabrication drawings for struct and reinforcing drawings - chec'
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them for confor=ance to the das drsvings; =aintain.'.;;. concise a current =sterial receipt record
' provide infor=cd enginscrin-
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3 dispositions on struerursi and reinforcing reisted Nonconfor=s ;
~~
Rep 6rts.
January, 1976 StructuralSteel$ngr.,
.Typh of Facility -
to August, 1977 Pull =an Kellogg, Inc.
Petro-che=ical co= plex includin Houston, Texas process structur'e, yard piping tank farm.
~'
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Project Description -
.t.. n....... ; r. s' Herbicide Production Plant -
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capital value of $90.511111on
. Technical Expertise -
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Coorslination and erection of L..
structu.al secc1 process scruet f.
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for herbicide production
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Specific Responsibilities -
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Engineering dutics included. the,
's...'.3 deter =ining of =sterisi f."
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availability and erection.statu 2
deter =ining erection sequence, inspection of crected seccl and verification and correction of J
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design and fabrication errors.
SuPcrvision dutics con :isted of det'cr=ining crection prioritics and crew pisec=ca't, ordering
~ '
material, and responsibility ic fN l
accursey of craft ti=c ch.trSed
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job budget.
Personal Renuce, Cont.
-Kobert David Neal race 6
-_M.PLOYMENT
- JOB TITT,E/C:PT.0YER DUTIES & RESTO"SIBILITIES E_
1 Sum er, 1975 Encfncering Technician Illinois Dept. of Transl'ortst19n m.
Interstate 72 Project Orcana, Illinois i-Sum =ce, 1974 Ass' t. Laboe Foec= sri Demetree Builders, Inc.
Apartment Construction Orlando,. Florida
~
Ass,'t. Field Engineer Su==ce, 1973 ~
McDevice & Street Co..
' s '-T -' e -
Construction of Seaworld
~ -
i Orlando, Florida
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1 ctAun Robert David Neal
. July 13. 1981.
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-rrepecs tearnesNumoor Acuom Age Srs O
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he&.Nunoor aus.4y nts4 2/14/78 foF8 I
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lienorienneo or A,ea saa tiem Control Building
['"S5-15 sutem to N/A Wall pours 2C351WO1, 2C361W01, 2C361WOS, JC351WO3, 2C361WO3, 2C361WO2, 2C361WO6 -
~
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Cracks in concrete walls.
controisne o.eument.t.
3echtel Drawings C-OC3901, revision 8; C-0C3902, revision 8; C-0C3903 revdsion 6 and C-0C3904, revision 7:
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Desedation af Nasconforvaaneet j
lc" e-7-79 See Sheet Number 2 N
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AAr 9/qrrq (VTSUAL)
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Recorarmended Dirnestaten in Basis for Recorareendation
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gs, Bechtel $ rece=nend disposition and basis for C A****
reccamendation.
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cause of Nonconformance and Aettoa to Prevent Recurr=neer O v.e 1 1.
3echtel to provide cause of nonconformance and ac:1on to C Reject j
prevent recurrence.
No further Daniel action required. ;.wy ;,,p,9 i
j Action Takest to Control Nonconfortnamoet Place hold tags. Work may proceed on adjacent lif ts to the poinc of concrete V
placement.
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L ue Qaa Discorition:
iriseet statement inefuded C Yes O 8.
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n co,a,.en ed O minoeinuon aevt.ed a reno.
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~ooeuments to be newtsed:
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A,T. Approvat Title Data SNUPPS or Uutsty Approval Ttue o gs.
Statement of Cornoleted Actions 1XHIB;TB 1
Action Como6etes Taue Date Action Ventred fitle Date Dutnuution:
J. I.. Turdera N. A. Petrick W.
'd. Weber M.
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C Aa.11
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T h... m e n r e,,1,so A.
S. Mart.n C. J. Plows l
Steve Mills t
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Callaway / 7186 2/14/78 I
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DESCH7 TION OF NONCONFORMANCE:
', ' ~ ~ ~ ~
~~
~*
Cracks have been observed in the ref e enced vall pours with size and location as shown sa the attached sketches.
In the judgement of Daniel Engineering only cracks 11,13 and 15 are considered to be a reportable. condition.
Other cracks are shown for information and to indicate a recurring problem.
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=cm Control Building s,, ea to N/A Wall Pours: 2C361WO3 and 2C351WO3 - -- -- ' -
Cracks in concrete valls.
.fhis.NC2 supercedes NCR 2-20*1-C-A c.3==ctaeo.e =e=ur e
3echtel Draving.C-0C3901 Rev. 8..-
'Q R ig i n sM.t. y IS S U =~ h n - ese...ex. u..t.--
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z-a3.78 z.-M-78 Cracks have been observed in the referene:i
~ # -70 vall pour with size and location as shown on attached sketch. Crack depths cannot be determined at this c'ime.
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Aars Ace des oL-sessan t Zama far As.:n
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Use as is.
Cracks v1J1 coe impair the struc::.ral C **====
intes:1:7 of the walls..... J -
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camas of Nessetter=aase s.34 Aetas t. % Reen.=esmet
,ggg Cracks apparently due to concrete shrinkage'." No '
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further Daniel action ree.uired. I.u.d4 r..t 4, a..
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h Place hold tags (1 of 2 through 1 of 2).
This NCR is not to afhet any adja' cent pours.
[M N, d _ d h 0C 1 74. 79 l n as s s
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Saw cut cracks to 1/2" vidth and 1" depth. Repair with f'
an approved e'poxy' grout. The repaired structure vill serve.its intended function.
E.F.Eeckett CSE 3/14/73
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3/13/78 Robt. White (for SNU??S) Nuc. & Fuel E=g.3/l >/7 A.m An= u ns.
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