ML20054D569

Final Deficiency Rept Re Five Star Special 150 Grout Used in Facility Containment Const Opening.Condition Determined Not Reportable Per 10CFR50.55e Requirements

ML20054D569
Person / Time
Site:	Palo Verde
Issue date:	04/07/1982
From:	Van Brunt E ARIZONA PUBLIC SERVICE CO. (FORMERLY ARIZONA NUCLEAR
To:	Bishop T NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V)
References
10CFR-050.55E, 10CFR-50.55E, ANPP-20645-GHD, NUDOCS 8204230146
Download: ML20054D569 (6)

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,; ' Docket Nos. $0-528/529/530 J 'g(> yo.55(e) Report

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• PHOENIX. ARIZON A 85036 April 7, 1982 ANPP-20645-GHD/BSK U. S. Nuslear Regulatory Commission Region V S g Creekside Oaks Office Park RECEIVED 1450 Maria Lane - Suite 210 - ..

Walnut Creek, California 94596-5368 t APR 22ig82 y Etuum asauarrunum Attention: Mr. T. W. Bishop, Chief NMer ummeg g Reactor Construction and E E //

Engineering Support Branch

~

Subject:

Final Report - DER 82-7 A 50.55(e) Report Relating to Five Star Special "150" Grout Used in Unit 1 Containment Construction Opening File: 82-019-026 D.4.33.2

Reference:

(A) Telephone Conversation between J. Berdoin and J. Cook on March 3, 1982 (B) Telephone Conversation between J. Eckhardt and G. H. Duckworth on April 6, 1982 (Time Extension)

Dear Sir:

Attached, is our final written report of the deficiency referenced above, which has been determined to be Not Reportable under the requirements of 10CFR50.55(e).

Very truly yours,

( \ -

/ M L LC ^

(( Q E. E. Van Brunt, Jr.

APS Vice President Nuclear Projects ANPP Project Director EEVBJr/GHD:ske Attachment cc: See Attached Page 2

\ED s204230146 820407 gg t PDR ADOCK 05000528 S PDR g ,7

U. S. Nuclegr $23ulatory Commission l t Attention: Mr. T. W. Bishop, Chief

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\ ANPP-20645-GHD/BSK April 7, 1982 Page 2' 1

cc: Richcrd DeYoung, Director

, Office 'of Inspection and Enforcement U. S. Nuclear Regulatory Commission

, Washington,'D. C. 20555 J. A. Roedel

- D. B. Fasnacht G. C. Andognini A. C. Rogers B. S. Kaplan W. E. Ide J. Vorees l J. A. Brand A. C. Gehr W. J. Stubblefield W. G. Bingham R. L. Patterson R. W. Welcher R. M. Grant D. R. Hawkinson L. E. Vorderbrueggen R. L. Greenfield Assistant Attorney General Bataan Memorial Building Santa Fe, New Mexico 87503 Ms. Patricia Lee Ecurihan

' 6413 South 26th Street Phoenix, Arizona 85040 T

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FINAL REPORT - DER 82-7 DEFICIENCY EVALUATION 50.55(e)

ARIZONA PUBLIC SERVICE COMPANY (APS)-

4 PVNGS UNIT 1 I. Description of Deficiency e Five Star Special "150" Grout, Lot #VWJ 83080, was manufactured on August 30, 1980, and was received at the Palo Verde jobsite  ;

on September 3, 1980. It was used in seven placements (Table 1, Placements #1-#7) prior to obtaininh the Preliminary Certifica-tion (Tests conducted per ASTM C109 and CRD 76) for the "150" grout. The Preliminary Certification for Lot #VWJ 83080 was received approximately September 26, 1980, with no apparent deficiency based upon the submitted seven-day results.

Final Certification for Lot #VJW 83080 was received on the

jobsite October 3,1980. The cover letter indicated that the material met the minimum requirements of the U. S. Grout Corpora-tion. Three subsequent placements using Five Star "150" Grout, Lot #VWJ 83080, were made (Table 1, Placements #8, #9 and #10) on October 3, 1980, February 19, 1981 and November 11, 1981.

On November 11, 1981, while obtaining compressive strength samples from the Unit 2 Radwaste Construction opening, partial placement 1R024 (Table 1, Placement #10), field lab personnel observed a significant amount of separation in the grout sample over a period of time. The grout sample segregated into two layers; the bottom portion was rather viscous, while the upper portion appeared diluted and watery in nature. Test samples were taken from the top and bottom portion of the special test block for comparison testing. The results (Table 1, Placement

1. 11) from the "special" test indicated significant strength variation - whence Stop Work Notice No. 81-3 on use of Five Star "150" Grout was issued December 14, 1981.

The APS Quality Assurance Stop Work Notice No. 81-3 required the following actions: (a) identify all areas where "150" Grout was used, (b) investigate stratification by coring and testing the top areas placed with "150" Grout, and (c) remove "150" Grout from the approved list. All areas are identified on

, Table 1.

A test block 1.5' x 2,0' x 2.5' was made January 21, 1982 to simulate the largest placement of grout (Table 1, Placement #10)

- used on the jobsite. Note that at this time no bags of Lot

1. VWJ 83080 remained,and that the test used Lot #VWJ 01882. Cores were taken, ' top and bottom, and were tested at an age of six days.

The results indicated approximately 1,680 psi difference between the top and bottom.

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Final Report - DER 82-7 Page 2 Nonconformance Report No. CR3179 was written January 22, 1982, initially against the radwaste partial placement 1R024 (the Containment construction opening was included later). The interim disposition was to take several top and bottom core samples and test for strength requirements. Cores were taken February 10, 1982, from the Radwaste Building Placement 1R024 and tested February 11, 1982. The results are as follows:

Top Average = 4,970 psi; Bottom Average = 6,580 psi. This difference is due to the size of the placement which has a depth of three feet. The required strength is 4,000 psi for the Radwaste Building.

The Deficiency Evaluation Report was written February 19, 1982, indicating that Radwaste cores met the 4,000 psi requirement.

The top of the Containment construction opening has since been tested to verify that the strength of the grout met the 6,000 psi strength criteria. The Containment construction opening (Table 1, Placement #1), which has a placement depth of fifteen inches, was cored at the uppermost portion where test results, to date, indicate that the weakest grout material would probably exist. The average test results of three top cores is 7,930 psi at an age of 547 days.

Note that all compressive strength tests (Table 1, Placements

1. 1-#10), done in accordance with ASTH C109 (two-inch cubes),

were all in excess of 5,000 psi at twenty-eight days with the average compressive strength at twenty-eight days equal to 6,890 psi.

II. Analysis of Safet3 Implications This condition is evaluated as Not Reportable. Based upon the test data accumulated and core samples taken, it is concluded that the largest grout placement (Radwaste IR024) and the Con-tainment construction opening placement have the required strength.

For the remainder of the areas where "150" Grout was used and core samples not taken, it is our judgement that, due to their size, quantity, thickness of grout, time elapsed since placement, and their respective strength criteria, the strength of the grout is adequate. Had this condition remained undetected, it would not have represented a safety significant condition.

III. Corrective Action The following actions will be implemented to prevent recurrence:

1. The Work Plan Procedures (WPP/QCI) will be revised to require the Field Engineer to review the manufacturer's final certification and acknowledge his release prior to use of that batch of grout.

Final Report - DER 82-7 Page 3

2. Remove Five Star Special "150" Grout from the approved list.

3. Limit the maximum depth of grout placement to six inches to minimize segregation.

1

's TABLE 1 DER 82-7

• FIACEMENTS USING FIVE STAR "150" CROUT Flacement Length of Quantity 284 UNO Cores obtained by 3" Dia.

i Number. Time E gg of Comp. Str. Avg. Compressive Str. (pei) Quantity Location of Lot # WJ 83000 & Commsente Date deve Water /Bam 2"s2"x2" Too Botton Bene Lot # WJ 83080 Manufactured 8/30/40 (1) 9/10/80 8 7480 f2 7 7930 -

250 U-1 Containment construction opening - E1.145' (2) 9/11/80 8 9 7240 - -

2 U-2 Control drill & grout reber - 44 Fanels - E1. 178'

! (3) 9/12/80 9 8 6100 - -

2 U-2 Containment s-1 tank leveline not blockout - 31.105 (14 9/15/80 12 8/9 6840/6130 - -

10 U-2 containment reactor vessel col. supporte (voide left ,

after let grouting) E1. 78' - 2 Flecamente (5) 9/16/80 13 7 7070 - -

1 U-1 Fuel Bldg. stair-stringer - El. 140' (6) 9/18/80 15 8 7900 - -

15 U-1 Containment RCP supports IB & 25 - 31. 81' (7) 9/24/80 21 8 7000 - -

3 U-1 Radweste well penetration - E1. 140' (8) 10/03/80 30 8 7070 - -

1 U-2 Turbine grouted anchor bolts - E1. 112' (9) 2/19/81 169 9 5710 - -

27 U-1 Radvaste pipe chaea - E1. 114'

1. 3 #3 (10) 11/11/81 434 9 7300 4970 6580 30 U-2 Radweste construction opening 18024 - 51. 152' (11) 11/11/81 434 9 See - -

Field lab specist testing (Bucket sampled) cube samples co m oto - 2" x 2" x 2" at 28 days Comp; Top - 3480 Bot. - 8480

1. #4 (12) 1/21/82 -

9 8480 5560 7590# ' -

Test block - uimilar to #10 - used Lot i WJ 01882 -

cores taken.

Sum 341 Notes:

fl Length of time from receipt of material on jobeite - Received 9/03/80.

1. 2 Av3. of 3 core samples, age tested = 547 daye

1. 3 Top Avg. of 4 cores, age tested = 92 days Bot. Av3. of 3 cores, age tested = 92 days.

1. 4 Dif ferent Lot - Av3. of 3 cores, age tested = 6 daye

1. 5 Different Let (Lot # WJ 01882)

1. 6 Total base received - 510 base: 510 - 341 = 169 base The 169 base were used as concrete spacers.

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