ML20126H499
| ML20126H499 | |
| Person / Time | |
|---|---|
| Issue date: | 05/17/1985 |
| From: | Merschoff E, Naidu K NRC OFFICE OF INSPECTION & ENFORCEMENT (IE) |
| To: | |
| Shared Package | |
| ML20126H483 | List: |
| References | |
| REF-QA-99901003 99901003-85-01, 99901003-85-1, NUDOCS 8506180361 | |
| Download: ML20126H499 (12) | |
Text
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ORGANIZATION: WESTERN CONCRETE STRUCTURES, INC.
GARDENA, CALIFORNIA REPORT INSPECTION INSPECTION N0.:
99901003/85-01 DATE(S):
3/25-29/85 ON-SITQ0VRS:
54 CORRESPONDENCE ADDRESS: Western Concrete Structures, Inc.
O ATTN:
Mr. A. H. Stubbs President 19113 S. Hamilton Avenue Gardena, California 90248 ORGANIZATIONAL CONTACT: Mr. A. H. Stubbs TELEPHONE NUMBER:
(213) 321-1571 PRINCIPAL PRODUCT: Post-tensioning components and installation services.
NUCLEAR INDUSTRY ACTIVITY: Western Concrete Structures has supplied and installed post-tensioning systems for Nuclear Power Plants.
Current work is limited to non-nuclear jobs.
/
/
/////rf ASSIGNED INSPECTOR:
w K. R. Naidu, Reactive Inspection Section (RIS)
Date OTHER INSPECTOR (S):
T. F. Burns, Brookhaven National Laboratory APPROVED BY:
s?!rs.
E.W.Merschofffhief,RIS,VendorProgramBranch Date INSPECTION BASES AND SCOPE:
A.
BASES:
10 CFR Part 21 and 10 CFR Part 50 Appendix B.
B.
SCOPE: This was a followup inspection relative to the failed tendon anchor heads at J. M. Farley Nuclear Station.
The failed tendon anchor heads were fabricated at Western Concrete Structures and heat treated by their subcontractor Downey Heat Treatment Company.
The inspection included a review of materials and services for the post-tensioning components supplied to Palo Verde Nuclear Power Station.
No items of noncompliance were identified.
PLANT SITE APPLICABILITY:
J. M. Farley Nuclear Station (50-364) and Palo Verde Nuclear Station (50-528).
l 8506180361 850614 PDR GA999 EECWESCS 99901003 PDR
ORGANIZATION: WESTERN CONCRETE STRUCTURES, INC.
GARDENA, CALIFORNIA REPORT INSPECTION NO.: 99901003/85-01 RESULTS:
PAGE 2 of 12 M
A.
INSPECTION FINDINGS:
Tendon anchor head abnormalities were observed at the J. M. Farley Nuclear Power Station (JMFNPS).
INRYC0 (located in Chicago) supplied these anchor heads which were manufactured by Western Concrete Structures (WCS) to JMNFPS. WCS fabricated and installed post-tensioning systems at the Palo Verde Nuclear Generating Stations (PVNG). The inspection objective was to evaluate the WCS QA Program implementation relative to the procurement of material and services as a vendor to INRYC0 for JMFNPS and as a supplier to PVNG.
B.
INSPECTION FINDINGS:
1.
Vio}ations:
None.
2.
Nonconformances:
None.
C.
OTHER FINDINGS AND COMMENTS:
1.
Background Information:
The two unit J. M. Farley Nuclear Power Station is operated by Alabama Power Corporation (APC). APC observed two broken field anchor heads and one cracked field anchor head during January and February of 1985. Each of these anchor heads retains 170 0.25 inch diameter tensioned tendons. The tendon anchor heads were fabricated by Western Concrete Structures (WCS) from steel supplied by INRYCO.
The inspectors visited Downey Heat Treating Company where these tendon anchor heatis were heat treated and selectively reviewed the heat treat-ment furnace charts and furnace calibration records. During this inspection, the NRC inspectors reviewed documents such as furnace charts which were not made available to them during their visit to INRYC0 during the March 4-8,1985 visit.
WCS supplied post-tensioning components to the PVNG Units 1, 2, and 3 which are owned by Arizona Public Service Company.
Bechtel Corporation (Bechtel) is the architect engineer and constructor. WCS recently completed the installation of the post-tensioning systems for the three units. The NRC inspectors reviewed the WCS procurement documents, and field installation checklists, and audits performed on WCS.
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ORGANIZATION: WESTERN CONCRETE STRUCTURES, INC.
GARDENA, CALIFORNIA REPORT INSPECTION NO.:
99901003/85-01 RESULTS:
PAGE 3 of 12 1
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2.
Review of Purchase Orders:
The inspectors reviewed the following purchase orders issued by INRYC0 to WCS to ascertain the adequacy of the technical and quality assurance requirements:
a.
INRYC0 PO to WCS 21T505-5 dated 5/22/73 for the supply of 360 sets of post-tensioning anchors for the J. M. Farley Unit 2 Nuclear Station. The following instructions specified the components.
(1) Supplementary instructions (SI) for certification of 170W1B for field applied anchor head, revision dated 9/1/71 with drawing attached.
? (2) SI for certification of 170W1A for shop applied anchor head, revision dated 9/1/71 with drawing attached.
(3) SI for certification of 170W15 field applied bushing revision dated 9/1/71 with drawing attached.
b.
The sis mentioned in the above paragraph contained the following information:
(1) Paragraph 3.a.1 states " Components to be batched by heat coaes and sent to the heat treater.
Vendor will receive certificate from the heat treater stating that 50% of each batch has been checked for conformance to range."
(2) P.aragraph 3.a.2 states " Vendor to give entire batch 100% inspection in three places 120' apart and report average Rockwell on 'C' scale for each head on certificate of inspection."
(3) Paragraph 6b states "INRYC0 to retain all original certification documents."
During the NRC inspection at INRYCO, INRYC0 personnel informed the inspectors that certification documents were not available and that they (INRYCO) requested WC5 to provide them the infor-mation. The current inspection at WCS was to verify whether these records were available. WCS informed the inspectors that i
ORGANIZATION: WESTERN CONCRETE STRUCTURES, INC.
GARDENA, CALIFORNIA REPORT INSPECTION NO.:
99901003/85-01 RESULTS:
PAGE 4 of 12 they shipped to INRYC0 all the original documents N required by the sis.
c.
INRYC0 PO to WCS 21T 455-53 dated 5/22/73 for the supply of 360 sets of post-tensioning anchors for J. M. Farley Unit 1 Nuclear Station.
d.
INRYC0 PO to WCS 2T 505-395 dated 9/3/76 for the supply of addi-tional quantities of field anchor heads, shop anchor heads and field bushings.
The following supplementary instructions (SI) were referenced:
(1) SI for the fabrication of type 170W1A shop anchor heads y
dated 11/20/73 with drawing dated 6/18/76.
(2) SI for the fabrication of type 170W1B field anchor heads dated 11/20/73 with drawing dated 6/18/76.
(3) SI for the fabrication of type 170W15 field applied bushing with drawing, both dated 6/18/76.
3.
Review of Contractor Quality Requirements The subcontractor quality class Q Programs are addressed in Appendix D11 to Bechtel Specification 13-CM-158 for " Furnishing and Installing Containment Building Post-Tensioning Systems at Palo Verde Nuclear Generating Stations 1, 2, 3."
The Appendix D 11 requires the sub-contractor, in this case WCS, to conform to the quality assurance requirements stated in 10 CFR 50 Appendix B.
Western, Concrete Structures developed and maintained a list of Approved Vendors (AVL) to use as their contractors.
a.
The irfspectors selected Varco International (VARCO) who supplied Heat Treating Services to WCS to ascertain whether WCS followed the requirements in their QA manual to approve VARCO.
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ORGANIZATION: WESTERN CONCRETE STRUCTURES, INC.
GARDEMA, CALIFORNIA REPORT INSPECTION NO.: 99901003/85-01 RESULTS:
PAGE 5 of 12 NL M
A WCS vendor checklist indicates that WCS inspected VARCO cn l
November 3,1978, and verified selected attributes of the VARCO l
QC manual. Based on the results, WCS determined that VARCO was l
capable of meeting the WCS quality and technical recuirerents and placed VARCO on their approved vendors list. The qualification process complies with WCS Quality Procedure No. 7.
b.
The inspectors reviewed WCS QC checklists which were used to verify the quality of the shop anchor heads (SAH). The fabrication of the shop heads is done in three stages. WCS drills into the shop head with machines specially designed for this purpose using gun drills. Then the SAHs are sent to a cachine shop - MAR Machines, Los Angeles, to thread
'/ them. Finally they are heat treated. WCS stated that they conduct inprocess inspections in addition to final inspections at every stage. They stated that all parts return to WCS before going to another subcontractor. The Certificates of Inspecticn - Machine Cocponents - identifies the QC inspector who verified the folicwing attributes for shop anchor heads for compliance to WCS procedure QCP 1.2.5.
(1) Sa: pled 25% of the internal and external diareter (2) Satpled 10t for drilling diareter and drift (3) 100% check on hardness testing - average of 3 values (4) 100% cf external threads "go" tests (5) 25% of external threads *go/no go" tests.
No ite=s o,f noncocpliance were identified in the above area.
l 4.
Review of Quality Assurance Records The inspectors reviewed the quality assurance records relative to the base material. The assurance of quality base caterial is of fundamental importance to the successful performarce of the anchor heads (both shop and field installed) and the bustings. This is i
due to the continuous application of tension on a complex part.
The following certified caterial test reports.were exa=ined to l
x A
_.-___u__
ORGANIZATION: WESTERN CONCRETE STRUCTURES, INC.
GARDENA, CALIFORNIA REPORT INSPECTION NO.: 99901003/85-01 RESULTS:
PAGE 6 of 12 g
M determine if the specification requirements for base material were fulfilled:
Order Date Supplier Quantity Heat No. Specification Cert. Date 4/15/77 Jorgenson 1 Bar 17660 ASTM A 322-76 6/12/78 Gr 4142 4/5/78 Jorgenson 2 Bars 18201 ASTM A 322 6/2/78 Gr 4142 5/10/78 Jorgenson 4 Bars 21072 6/2/78 5/11/78 Jorgenson 5 Bars 18274 6/2/78 l
l This, examination revealed that the material supplied was in conformance with the specification (ASTM A 322, Grade 4142) requirements. Chemical 1
analysis, product form, grain size and manufacturing practice (vacuum degassed) were verified on the applicable test reports. No discrepant items were noted on these reports.
A review of the WCS manufacturing sequence was made to verify that heat identification was maintained. This processing sequence of base material consists of the following steps:
a.
Receipt inspection b.
Color code bar stock, c.
Saw cut, d.
Stamping of Serial Number, 7
e.
- Drilling, i
f.
Machine Outside Diameter, g.
Heat treat, h.
Finish-Inspect, j
i.
Assemble-Ship.
The examination of color code indices, certified material test reports, and assigned serial numbers revealed that material to component traceability had been maintained.
No items of noncompliance were identified.
5.
Corrective Action Taken By WCS WCS informed Bechtel that ?ne of the tendon anchor heads fabricated by them and supplied to INRYC0 for use in the Byron Nuclear Power Station failed in 1979, 10 days after tensioning.
Bechtel
ORGANIZATION: WESTERN CONCRETE STRUCTURES, INC.
GARDENA, CALIFORNIA REPORT INSPECTION N0.: 99901003/85-01 RESULTS:
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reviewed this report and determined that it was not applicable for Palo Verde and hence not reportable. One of the considerations was that the Rockwell Hardness (RC) for the tendon anchor heads specified for Palo Verde was 38 2 versus 40 2 for the Byron Station.
Additionally, WCS conducted additional load tests to confirm the adequacy of the design. The results indicated that the fabrication of the post-tensioning components for Palo Verde were adequate to meet the design requirements.
No items of noncompliance were identified.
6.
Review of WCS Installation Records The/ inspectors selectively reviewed the inspection records for the installation of the post-tensioning system at Palo Verde Unit 3 to ascertain the adequacy of the WCS QC inspections. The following records were reviewed:
a.
Certificates of Inspection - Tendon Installation - identify the following attributes for compliance to procedure PTP 6.8:
(1 Tendon number (2
Location or Buttress number (3
Tendon identification number (4) Tendon length (5) Tendon length checked (6) Wire condition (7) Water removed from sheath (8) Corrosion protection applied (9) Shop head threads protected (10) Shop head orientation correct.
b.
Certificates of Inspection - Installation of Field Anchor Head and Field Button Heading - identify the following attributes for compliance to WCS procedure PTP 7.8:
(1) Tendon number (2) Location or Buttress number (3) Field anchor head oriented correctly (4) Tendon pushed back (5) Tendon temporary protection adequate f
(6) Machine qualified (7) Button head eccentricity and head (8) Size verification I
(9) Inspection for splits.
ORGANIZATION: WESTERN CONCRETE STRUCTURES, INC.
GARDENA, CALIFORNIA REPORT INSPECTION N0.: 99901003/85-01 RESULTS:
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h c.
Certificate of Inspection - Tendon Stressing and Installation of Shims and Grease Caps - identify the following attributes for compliance to WCS procedure PTP-8:
(1) Tendon number (2) Location (3) Calibration of stressing equipment (4) Gage (5) Verification of tendon bearing plate (6) Tendon stressing record complete (7) Grease caps installed (8) Shim stacks installed.
d.
Certificates of Inspection - Tendon Greasing - identify the following attributes for compliance to WCS procedure PTP-9:
(1) Tendon number
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(2) location or buttress number (3) Filler material certification on hand (Viscon rust 2090 P4)
(4) Filler temperature at tank (5) Filler temperature at cap (6) Sheathing purged at drain and vent (7) Caps leak tight at pumping end, far end, and at jumper connection (8) Pipe plug inserted at Y (9) Grease lines blown out.
No items of noncompliance were identified in the above area.
7.
Shop Tour The inspectors conducted a shop tour of the machining area at WCS.
All work currently in progress was of a commercial nature, and these activities were on a reduced scale. The facilities for drilling holes in the anchor heads were examined and found to be state-of-the-art numerically controlled gun drilling machines. The work areas observed were found to be clean and orderly.
No items of noncompliance were identified in the above area.
8.
Audits The inspectors reviewed the audits performed by independent sources and Bechtel on WCS.
ORGANIZATION: WESTERN CONCRETE STRUCTURES, INC.
GARDENA, CALIFORNIA REPORT INSPECTION NO.: 99901003/85-01 RESULTS:
PAGE 9 of 12 N
a.
Independent Audits A review of the independent audits performed on WCS by outside sources was conducted to evaluate their level of compliance with the quality assurance program during the period when work was being processed for the Palo Verde Nuclear Generating Station.
The reports covering periods 1978, 1979, 1981, 1982, and 1983 were reviewed and the following was noted:
Year Location Dates Number of Findings 1978 Gardena, CA February 2 & 3 8
^/ 1979 Gardena, CA October 3 & 4 7
1981 Gardena, CA October 13 & 14 4
1982 Gardena, CA December 13-16 12 1983 Palo Verde Site December 13 & 14 11
~
These audits were predominately of a programmatic nature.
Corrective action was taken on all findings except for the period of 1981. WCS could not locate the records which detailed the corrective action taken during that period.
b.
Purchaser Audits The inspectors reviewed the audits performed by Bechtel Corporation (PostTensioningSystem-P.O. 10407-13-CM-158) for the periods 1978 through 1981 for the Palo Verde Nuclear Station.
No deficiencies were identified as a result of the audits of 1979, 1980 and 1981. Two "nonconformances" were identified in the 1978 audit which were program rather than hardware related.
No it* ems of noncompliance were identified in the above area.
9.
Review of Heat Treating Facilities There were two heat treating facilities that were involved in the performance of hardening and tempering of the anchor heads (shop and field). The inspectors visited each facility to evaluate their compliance to MIL-H-6875F (specification which establishes the heat treating process and equipment controls).
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ORGANIZATION:
WESTERN CONCRETE STRUCTURES, INC.
GARDENA, CALIFORNIA REPORT INSPECTION NO.:
99901003/85-01 RESULTS:
PAGE 10 of 12
's a.
Varco Heat Treating Company 774 North Eckhoff Street Orange, California 92668 This facility had recently been sold by Varco International of which it was the heat treating subsidiary. While a subsidiary of Varco International, it was customary practice to solicit outside work to fill available heat treating capacity.
Purchase orders for heat treatment which were issued to Varco by WCS were as follows:
P. O.
Date Part Quantity Material
,3715 11/20/78 Bushing 700 ASTM A-519 Gr. 4140
' 3813 1/9/79 Field Head 720 ASTM A-322 Gr. 4142 2723-R1 12/5/79 Shop Head 720 ASTM A-322 Gr. 4142 These items were to be heat treated to a Rockwell "C" hardness of 36/40 "per MIL-H-6875F."
Selected instrument and furnace calibration records required by MIL-H-6875 were reviewed for the periods 1979, 1980, and 1981 with the following results:
Temperature Controlling Instrumentation Date Furnaces Not Tested 7/16/79 9D, 140, 150, 16D 8/15/79 All were tested.
9/18/79 9D, 14D, 150, 16D 1/9/80 9D 2/13/60 90, 14D, ISD 3/17/80 28, 2AD, 80, 9D, 140, ISD, 16D 4/22-28/80 14D, ISD, 16D 6/26/80 90, 14D, ISD 7/26/80 All were tested.
8/27/80 9D, 140, 150, 16D, 2AD 10/10/80 2AD 11/19/80 28, 2AD 12/12/80 28, 2AD 1/16-29/81 2B, 2AD 7/1/81 All were tested.
ORGANIZATION: WESTERN CONCRETE STRUCTURES, INC.
GARDENA, CALIFORNIA REPORT INSPECTION N0.: 99901003/85-01 RESULTS:
PAGE 11 of 12
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M Furnace Temperature Uniformity Surveys
Furnace No. 2B (Used for Anchor Head Hardening)
Tested on 2/27/85, 11/27/84, and 8/3/84 - no prior records were available.
Tempering Furnaces (Used for Anchor Heads) 8D 9D 14D ISD 16D 2/5/85 12/3/84 1/14/85 1/10/85 6/18/82 7/26/84 4/12/84 9/23/82 6/18/82 3/12/82 1/11/84 8/30/82 3/26/82 10/7/81 9/14/83 6/2/82 1/11/80 2/27/81
?
6/9/83 3/4/82 12/12/79 5/14/B0 3/3/83 8/28/81 3/22<79 6/21/82 3/18/81 3/29/82 2/24/81 9/22/81 12/7/80 9/15/81 2/28/80 Prior records were not available.
An effort was made by the Varco Quality Control Manager to locate prior test results of furnace instrument calibration and temperature uniformity surveys, but this effort was unsuccessful. The Quality Control Manager had been on temporary layoff for over a year and had only recently been recalled to work. He stated that the records were complete as of two years ago but had been misplaced or lost during his absence. Also, it was during this time frame that the heat. treating subsidiary was sold by Varco International.
In these two areas, the records (or absence of them) indicates a failure to completely comply with the imposed requirement of MIL-H-6875F, governing the heat treating equipment.
b.
Downey Heat Treating Company 9629 Nance Street Downey, California 90241
ORGANIZATION: WESTERN CONCRETE STRUCTURES, INC.
GARDENA, CALIFORNIA REPORT INSPECTION NO.:
99901003/85-01 RESULTS:
PAGE 12 of 12 t
M This facility is an independent heat treating organization of relatively small size.
Only limited work was performed by this organization for WCS.
Purchase orders for heat treatment issued to Downey by WCS were as follows:
P.O. 3644 10/3/78 20 Bushings 2940 6/3/76 2 Field Heads 2933 4 Bushings 3 Field Heads 2933 3 Shop Heads 2933
.The items for heat treating on Purchase Orders 2933 and 2940 were
' identified as prototypes.
The requirements of MIL-H-6875F were also imposed on this heat treating organization by WCS.
However, due to limited time at this facility, the inspectors examined only the temperature uniformity survey results for the equipment which was used to perform the hardening of the post tensioning hardware.
These records covered the period of 1976 to 1978 and were found to be in compliance with the requirements of MIL-H-6875F.
For this period, the temperature uniformity surveys were performed within the required time frame and temperature variations were found to be within specification requirements.
No items of noncompliance were identified in the above area.
D.
PERSONS CONTACTED:
a.
Western Concrete Structures (WCS)
A. H. Stubbs, President b.
Varco Heat Treating Company (VARCO)
R. Durham, Quality Control Manager, 774 N. Eckhoff Street, Orange, California 92668.
c.
Downey Heat Treating Company (Downey)
J. R. Patterson, Vice President and Sales Manager, P. Cresswell, Manager, 9629 Nance Street, Downey, California 90241.
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