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March 12, 1982 MEMORANDUM FDR: Uldis Potapovs Chief. Vendor Program Branch, Region IV James E. Gagliardo, Director, Division of Resident, Reactor Pro.jects and Engineering Programs, Region IV Lawrence P. Crocker, LQB, Divis6cn of Human Factors Frank J. Miraglia, Chief. LB3, Division of Licensing
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FROM:
Karl V. Seyfrit, Deputy Regional Administrator, Regfon IV
SUBJECT:
MANAGEMENT EVALUATION AT SOUTH TEXAS It is qy mderstanding.that the addressees have been selected to serve on a team to evaluate the interfacing of the new management team at the South Texas facility. Now that a new constructor has been named, we need to begin planning for our effort. We will be looking at the working / organizational interfaces, responsibilities, and controls among HL&P, Bechtel, Ebasco, and Westinghouse.
To this end, I am requesting the addressees to attend a meeting in Region IV on April 8 and 57to discuss areas to be covered and a plan to accomplish the task. The actual evaluation effort is to be conducted during the week of May 3-7,1982.
Please inform me promptly if you cannot meet the scheduled dates.
" Ort:;inal Signed by:
K. V. sEYFRIT".
Karl V. Seyfrit Deputy Regional Administrator cc:
J. T. Collins, RIV D. G. Eisenhut. DL 8506070570 840620 PDR FDIA QLASSPIB4-393 PDR smer yl..DRA..RI V
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UNITED STATES
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NUCLEAR REGULATORY COMMISSION
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June 22* 1979 i
Dochet No. 50-493 30 t,99
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.'.1.v This refers to the telephone conversation between you and Mr. W. C. Seidle of
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this office on June.22,,1979, concerning voids in the concrete that were dis-covered in lift,.8..of the South Texas Project, Unit 1 containment vall and the iz: pact of thE presence of the voids on other safety-related concrete placanents at the site.
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Based on the June 22, 1979, telephone conversation, we understand that you have, or plan to:
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Issue an order effective June 22, 1979, to stop placement of safety-related q'.
concrete at the South Texas Project site.
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Review concrete plar -t procedures to determine if inadequate procedures s
nay have contributed to the formation of voids discovered in Lif t 8.
3.
Review the adequacy of the mix design used for the contain:nent walls.
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Review the adequacy of the ratio of Quality Control personnel to construc-tion personnel assigned to placement activities. ~
5.
Review the adequacy of the ratio of supervisory personne'l to placement I
personnel.
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Review the adequacy of concrete preplacement planning.
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Review the adequacy of lighting provided at the point of placement.
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Contact the Region IV office prior to resumption of placement of safety-related concrete.
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[CERTIFIEDMAIL-RETURNRECEIPTREQUESTED j
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Houston Lighting and Power Company June 22,19,79
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If your understanding of this r.atter is inconsistent with the above, please contact this office in: mediately.
Sincerely, I.,
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This document is writte'n to confirrs our telephone conversation' f *
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With reference to our stop work ' order of June 22,1979, on
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the placement of safety-related concrete at the South Texas Project, please be advised that we have completed an extensive review of the items identified in said letter.
As a result of this review and because of the confidence developed on pait'iio'@RCB exterior shell wall placements we intend v-to issue a partial release of our stop work notice which will allow
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for placemnt of all safety-related concrete with the exception of the F.CB extarier shell walls.
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We will continue our hold on the RCS exterior shell wall placer.wnts because of the complexity and configuration of this type concrete placement. Also. our evaluation of the RCB exterior wall has not been cormleted. We intend to release the stop work on the RCB exterior.shell walls only after the results of our evaluatica.
. tre known and corrective acti,n "if anyfis jiresented '
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~ Dur decision issths. result of a thorough review of the. areas of concern identified in the stop work notice of June 22.1979, as they relate to non-RCB exterior shell well placements of safety-related concrete.
Specifically:
1.
Engineering has reviewed the design mixes currently used on site and have found thers to be acceptable for the various safety-related structures.
2.
The pre-placement meetings and the topics address'ed in these sessions have been reylewed andhave been found adequate for non-RCS exterior shell walls.
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The present inethod of providing lighting for non-RCB 1
exterior shell walls has been reviewed and found l
adequate especially for.those personnel who must be.
inside the fotwed area.
The present nethods and equipment utilized to consN.
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lidate concrete have been re-examined as well as the QA/QC inspection techniques and both are achieving adequate results in ~non-RCB exterior shell walls.
5.
The present system for training both construction and QA/QC personnel is adequate to ensum proper implementa-tion of specification requirements. Additionally,.
special sessions were held June 26,1979, to rc-c.giiasize.
the procedural details of concrete placement to both construction and QA/QC personnel.
- 6. The ratio of construction supervision to placement personnel has been evaluated and has been found adequate
- .for non-RCB exterior.shell wall placements. However, no fixed ration of QC inspection personnel to placement personnel exists. Rather an evaluation on many factors f'..
is conducted to determine the appropriate number of QC inspection: personnel for any given concrete: placement.
This present method has been reviewed and is adequate for non-RCB exterior shell wall placements.
If you have any questions and/or comments on the above,.
. please. advise.
.4 Yours very
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cc:
ssrs. M. Borchelt (CPal.)
J. Poston (CPS))
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ARLINGTON, TEXAS 76012 s.;.;.?
June 29, 1979 Docket No. 50-498 50-499
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," This refers to your 1etter dated June 28, 1979, which was~ ' transmitted to this office by facsimile on June 29, 1979. Your letter states that, based on your review of concrete placemen concerns identified in your stop-work notice, dated June 22, 1979, you intend to issuai a partial release of your stop-work -
notice which will allow for placement of all safety-related concrete at the South Texas. Project with the exception of the, Reactor Contninr=nt Building (RGB) exterior shell walls.
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We understand that you will continue your stop work on the RCB exterior shall
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wall placements)ecdiii$ ' completion of your. evaluation of the RCB exterior o
shall wall and, further, that you will release the stop work on the ECB exterior shell wall placanents only af ter the results of your evaluation are known and this office is infomed of your plans' prior to resuming these placements.
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If your understanding of this matter is inconsistent with the above, please contact this office 4-ediately.
Sincerely,
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K. V. Seyfrit Director f' C"'
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RErmtN RECEIPT REQUESTED W
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Electric Tower July 16,1979 IS--i RC1 Box 1700 ST-HL-AE-362 ii
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Houston. Texas 77001 SFN: V-0100 u
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Office of Inspection and Enforcement 7
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Dear Sir:
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%y South Texas Project S 4 3" Units 1 & 2 kap' Docket Nos. STN 50-498, STN 50-499 Interim Report on the. Reportable Deficiency Concerning Concrete
- Voids in the Eighth Lift of the Unit 1 Reactor Containment Building On June 18, 1979, pursuant to 10 CFR'50.55(e) (2), Houston Lighting & Power Company notified your office of concrete voids behind the liner plate in the eighth lift of the reactor building exterior wall. - A thorough and detailed plan for investigating the entire eighth lift has been prepared. A more complete report should be,available onjr about _ August 15, 1979.f - ~~
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Lift 8 has been entirely mapped by sounding techniques to locate those areas with apparent lack of contact of concrete with the steel liner.
Eleven holes have been drilled in suspect areas around the equipment hatch area and an additional 138 holes will be drilled in other areas of the liner. Three voids have been detected thus far.
Further questions on this incident should be directed to Mr.
D. G. Barker at (713) 676-8891.
Very truly yours,
.O W
E. A. Turner Vice President Power Plant Construction
& Technical Services LRJ:bf
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cc: Charles Bechhoefer, Esquire Chairman, Atomic Safety and Licensing Board U. S. Nuclear Regulatory Commission Washington, D. C.
20555 Dr. James C. ' Lamb III
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313 Woodhaven Road Chapel Hill, North Carolina 27514 Dr. Emmoth A. Luebke Atomic Safety and Licensing Board U. S. Nuclear Regulatory Commission Washington, D. C.
2055S Steven A. hiinkin, Esquire
'116 Villita Street San Antonio, Texas 78205 Citizens for Equitable Utilities c/o Ms. Peggy Euchorn Route 1, Box 432 Brazoria, Texas 77422 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 Charles Thrash Baker 4 Botts One Shell Plaza Houston, Texas 77001 R. Lowenstein Lowenstein, Newman, Reis, Axelrad & Toll 102S Connecticut Avenue, N.W.
Washington, D. C.
20036 R. Gordon Gooch Baker & Botts h
1701 Pennsylvania Avenue, N.W.
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Company August 15, 1979 h Tm ST-HL-AE-369 R Q Bax1700 SRI: V-0100 n
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Director, Region IV Office of Inspecticn & Enforcement 611 Ryan Plaza Drive, Suite 1000 Arlington, Texas 76102
Dear Sir:
South Texas Project Units 1 & 2 Docket Nos. STN 50-498, STil 50-499 Second Interim Report on the Reportable Deficiency Concernihg Concrete Voids in the Eighth Lift of the Unit 1 Reactor Containment Building l
On July 16, 1979, pursuant to 10CFR50.55(e), Houston Lighting &
Power Cc pany provided your office with an interim report concerning e
concrete voids behind the liner plate in the Eighth Lift of the Reactor Building exterior wall. The letter indicated that a more complete report would be submitted on or about August 15, 1979.
The attached report provides a description of the deficiency, the investigation of the deficiency, and the current corrective action being taken. The tentative date for completion of the repair is January 19, 1980, followed by a final report one month later.
Additional discussion or questions should be directed toward Mr.
L. R. Jacobi, (713) 676-7953.
V ry truly yours, m
E. A. Turner l
Vice President Power Plant Construction
& Technical Services l
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D..- C-. Barker cc:
A. J. Granger
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R. A. Frazar M. D. Schwarz-(Baker & Botts)
R. Gordon Gooch (Baker & Botts)
J. R. Newman (Lowenstein, Newman, Reis Axelrad & Toll)
Director, Office of Inspection & Enforcement Nuclear Regulatory Comission Washington, D.C. 20555 Charles Bechhoefer, Esquire Chairman, Atomic Safety & Licensing Board U.S. Nuclear Regulatory Comission Washington, D.C. 20555 Dr. James C. Lamb, III 313 Woodhaven Road Chapel Hill, North' Carolina 27514 Dr. Emmeth A. Luebke Atomic Safety & Licensing Comission U.S. Nuclear Regulatory Comission e
Washington, D.C. 20555
... w Steven A. Sinkin, Esquire 116 Villita Street San Antonio, Texas 78205 Citizens for Equitable Utilities c/o Ms. Peggy Buchorn Route 1 Box 432 Brazoria, Texas 77422 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 Comission Washington, D.C. 20555
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l-l INTERIM REPORT
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ON THE STPEGS RCB NO.1 LIFT 8 CONTAINMENT VOIDS I
t INTRODUCTION On June 5,1979, Houston Lighting & Power Company submitted a final report on the void deficiency that had occurred on the 1Eth lift of Unit 1 RCB Containment Shell. This report contained a description of the methods.that were used to identify, analyze, and repair'these voids. The report also
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contained information on those actions taken to preclude the recurrence of this deficiency. Prior to the preparation of this final report, information was obtained from site personnel which led to the ' concern that voids might' exist in the 8th lift of the Unit 1 RCB Containment Outer Shell. Soundings
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were begun and.it.was, determined by drilling that voids did indeed exist.
On June 18, 1979 HL&P notitied the NRC that the condition was reportable under the requirements of 10CFR50.55(e). At this time, a stop work notice was issued for the placement of all concrete in the Unit 1 and Unit 2 RCB Containment Shells. ~ At this time, a significant amount of investigation has been performed towards the resolution of this deficiency; however, 0,:
I work has not been completed. Thus, this interim report will provide the status of this activity and will provide information on the work yet to be com-l plated, including an estimated schedule for the completion of these activities.
l INVESTIGATION f
The investigation of this deficiency was two-fold. One facet of the in-i vestigation was directed toward determining the extent of the voids. The w-
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other facet of the investigation was directed toward detemining the cause and providing sufficient corrective action so that the placing of concrete in the RCB Outer Shells could resume. A logic diagram was prepared so that this work could proceed in a planned and orderly manner. A copy of this logic diagram is contained in Figure 1.
Initially, B&R Construction placed a 2' x 2' grid on the steel Containment
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liner from El. 57'0" to E1. 67'0" for the full circumference of the Con tainment. The liner was then sounded for the purpose of detecting potential void areas, using procedures that were developed during the investigation on Lift 15. All of this' activity was conducted under Quality Control sur-veillance.- This procedure involves the tapping of the liner using a metal
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hanner and identifying areas of "non-contact" between the liner plate and the concrete based upon the sounds as detected by the human ear. The areas of "non-contact" were physically marked on the liner plate and th'is informa-tion was then transferred to drawings and transmitted for evaluation.
Draw-ings of the liner were prepared showing all penetration and liner stiffening systems. Based upon these drawings, direction was provided to drill holes in the liner plate to determine if the "non-contact" areas were indeed voids.
A total of 158 holes were drilled and investigated. As the result of this investigation,12 areas were identified in which voids existed. The voids were then explored using probes and a fiber scope to' determine the extent of "non-contact". These void areas are shown in Figure 2.
The majority
{of the "non-contact" areas were attributed to temporary welbients attached fh t
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Interim Report
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Page'3 to the liner, normal concrete settlement / shrinkage, and liner movement.
These findings were consistent with the conclusions obtained during the investigation of the Lift 15 deficiency.
The investigation to determine the cause of this deficiency and to provide recurrence control for future pours was conducted in the following manner.
A review of the pour packages (which included inspection reports, test data.
and non-conformance reports) which were applicable to Lift 8 was conducted.-
This investigation,was performed for the purpose of identifying any un-expected conditions which may have occurred during the course of the place-ments and thus, could have contributed to the problem. The information d
obtained during this investigation was combined with information obtained during interviews with construction and inspection personnel to provide a basis for assessing the procedures being utilized to control the activities
. 1 during these complex concrete pours.
During the investigation to detemine the locati'on of the voids, it was ascertained that the voids of significance were located under the horizontal 8" channel and 1" x 8" plate stiffeners in the vicinity of added reinforcing steel around penetrations.. Such areas require an additional amount of attention and vibration during the consoli-dation of the concrete.
During this pour, these areas were at the approximate 5' mark of the 10' pour and their. accessibility for inspection'and vibration was poor. As the result of these investigations, it was determined that recurrence could be affected by providing for better accessibility to those areas of congestion where additional inspection and vibration is required.
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. Interim Report c y, Page 4 r
h'h, and by strengthening the construction and quality control procedures. A list of recomendations for corrective action was prepared and was reviewed and approved by both. Brown & Root and Houston Lighting & Power Companies.
i A sumary of these recomendations is contained in Table 1.
Construction and inspection procedures and engineering design documents are currently being revised to accommodate for the implementation of these reconssendations.
CONTINUING ACTIVITIES Based upon the information obtained during this investigation of the voids l
in Lift 8, it was concluded that other void areas could exist beneath pene-
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trations and the 8" channel and plate stiffeners where additional reinforcing a...,...
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steel is located. Therefore, additional soundings will be made in three general penetration areas of high stress regions and congestion:
- 1) the equipment hatch, 2). personnel air lock, and 3) the main steam and' feedwater i
lines. The current areas of investigation are shown in Figure 3.1 and 3.2.
l The logic diagram and plan for the completion of this acti~ ity is contained v
in Figure 3.3.
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The use of alternate methods of sounding the liner was investigated. This investigation consisted of reviewing utility reports to the NRC for similar occurrences on the Wolf Creek, Edward Hatch, and VC Summer nuclear power plants. These reports described similar problems and methods of detecting j
voids behind the liners. The merits and effectiveness of the alternate i
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methods contained in these reports were discussed with industry personnel Sk.?
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directly involved with their use.
It was concluded that physically sounding the liner surface and selectively drilling holes to interpret and verify the soundings is as reliable as other more sophisticated techniques used for void detection. To properly interpret the soundings, the geometry of the liner stiffeners, penetrations, and a general configuration and congestion of this reinforcing steel must be considered.
At the present time, activities are underway to resume the placement of concrete in the RCS Containment Shell.
Construction and inspection procedures are being revised to upgrade the control of the concrete placement during the shell placements.
In addition, design drawings are being revised to provide for additional accessibility to areas where additional inspection and vi-7 k
bration is requ' ire'd."'The plan and logic diagram for this activity is also g,
contained in Figure 3.3.
It has been determined that the methods used to repair the voids observed on Lift 15 are appropriate and suitable for use to repair the voids found on Lift 8.
Final evaluation of the material used in the repair of Lift 1.5 will be performed after all information relative to the actual Lift 8 voids is available.
t It is estimated that this deficiency, including repair, will be closed out on or before January 19, 1980. The final report will be submitted to the NRC within 30 days thereafter.
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TABLE I V
RCB SHELL CONCRETE PLACEMEtlT RECURRENCE CONTROL l
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PROBLEM RECOMMENCED SOLUTION 1.
Concrete-Uniformity A.
Buy all produced concrete (batch 0 6").
.B. Area Engineer to visually monitor slump consistency at hopper.
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Use of grout at penetrations as. determined by Engineering.
D.
Aggregate Moisture - Control for coarse aggregate.
2.
Preplacement Planning A.
Drawing and meeting on each placement and document.
B.
Define workable section on placement plan.
3.
Inspection A.
Training of QC inspectors.
B.
Increase number of inspectors to 4 to 6
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per pour.
C.
Advise foreman of inspectors' authority.
D.
Have specific vibrator inspector (s) on l
pour.
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Equipment Breakdown A.
Back-up equipment, one to one, located at the pour.
B.
Preventive Maintenance Program identified
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and followed.
5.
Access /VisibilityVroblem A.
Reduce Lift #7 to approximately 6'-0, with channel at top; subsequent lifts
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to be 10'-0.
B.
Selective shear bar relocation to increase accessibility (10'-0 c. to'c.).
L C.
Lighting available on the form.
D.
Engineering to review tie attachment at liner for lifts, at top of form.
6.
Fatigue Start by 9:00 or scrap pour.
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7.
Vibration A.
Crew deposit and vibrate simultaneously, responsible for each workable section.
B.
Pre-training of vibrator operators.
C.
Pencil vibrators at each work section'for inside and outside face and at penetrations (2 pencil vibrators).
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D.
Vibrators set-up for each section.
E.
Vibrator / Placement Method written by Construction, including assignment of l
vibrator operators to each section.
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8.
Training A.
Vibrator-Placement Foreman - one training I
placement program on technical aspects.
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Vibrator training field class, demonstrating
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and explaining technique.
C.
Meeting with crews prior to placement after prepour meeting, Pour Card signed by the
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Production Pressure; At prepour meeting, inspector (s) explain "how" identified problems are to be interfaced and solved during the placement.
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Records Document post-placement interviews.
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INVESTIGATION i e i e i >s e 2 7e s 3 7s e a is e II rs e is is a la is tvESI (12-1e-19) (1.is.791 l O LOCATE susmif SPECIFIED APPROVE Drill. REPORT EVALUATE REPAlnAS O AREAS O M" FREA SIGNIFICANT VOlGS REQUIRED q llOLES p HOLES g g, =O f ~ v u l,.EO l.<. PER FREA I-C-3440 EST. 14 WK5. EST. 5 WKS. [10 88 79) ~ I PROVIDE
SUMMARY
PROVIDE
SUMMARY
REPORT NO s 16 19 92079 [EPORT ON LIFT No.s ON FENETRATION AREAS A. l C u I i s 3 19 e G 79 F KA 1-C-344s EXP4h05 Liff a llIVESTIGAfl0E To IllEttalt a EQUIPMENT leATCM AREA ELEV. 40' to 130' 6 PERSONNEL Altt0CE AREA ELEY. 35' to 95* j c, R41N STEAM /flEDWATER LINE5 ELEf. 40' to 65' RESUME SHEl.L CONCRETE 72779 a 379 CONSTRUCTIONf0A e IO 79 INCORPORATE TO TRAIN / REVISE PROvlOf FORM TIE /SNEAR GUIDEEINES PROCE DURE S/IMPL EMENT RESPOND LIFT POUR TIE / GROUT GUIDE LINES INTO PROCEDURES R E COMMENDA TIONS TO NRC S W.N.' LIFT No. h O A m -v v i i a e is a 10 7e EONSTRUCTION REVISE REVI wI 0VE FREA ON LIFT No. r (REA INCORPORATING RECOMMENDATIONS =) tecmeeamo Acevivity NOTE: The dates shown are intended for i 8"^"'"^"""v'5"**"""'"- internal planning and scheduling only. FIGURE 3.3 l}}