ML20137F989

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Forwards Answers to Two Questions Re Public Safety Given Violations of Plant Spec & Breakdowns in QA Programs,Per 841228 Telcon Request.Related Info Encl
ML20137F989
Person / Time
Site: Comanche Peak  Luminant icon.png
Issue date: 12/29/1984
From: Philleo R
PHILLEO, R.E.
To: Jeng O, Shao L
NRC
Shared Package
ML17198A292 List: ... further results
References
FOIA-85-59 NUDOCS 8512020119
Download: ML20137F989 (39)
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{{#Wiki_filter:..,,. i s vas.aPMONE DOSS 350 4108 ROBERT E. PHILLEO P.E. 7 d \\ . - ~. - -. - 7420 ANNANWOOD COURT ANNANDALE, VIRGINIA 22003 December 29, 1984 i Mr. David Jeng c/o Mr. L. Shao + U. S. Nuclear Regulatory Commission MS 5650 NL Washington, D. C. 20S55

Dear Dave:

Enclosed are answers to the two questions on safety which you requested by teleph6ne on December 28, 1984. s Sincerely, Robert E. Phille'o O enc 1. s 4 i \\ s. ,1 D se 9 a i V 8512O20119 851106 1hf G DE 59 PDR-Cr609 ) i s \\ 5 z s. 4 I I

'.y 5, s QUESTIONS ON SAFETY OF COMANCHE PEAK STEAM ELECTRIC STATION Robert E. Philleo, P. E. 1. Given the documented violations of specifications and the breakdowns in the quality assurance program, are the structures at Comanche Peak safe and will the public safety be adequately protected if the plant is permitted to operate? Except for an evaluation of the potential consequences of the open iesues yet to be resolved, the plant is safe. The alleged violations which cannot be adequately evaluated have been listed as open issues, and the applicant is being required to carry out additional work in order to obtain data necessary for evaluation. A substantial amount of confidence can be placed in the results of the structural integrity test of the containnent structure for Unit 1. Not only did it establish the. capability of the containment structure to withstand 115% of the design internal pressure, but it established the general level of quality of the reinforced concrete construction throughout i the project. The construction dccumentation indicates that the quality of construction on the containment structure was typical of that for the project as a whole. Although there were breakdowns in quality control.and quality ? } assurance procedures on specific occasions, the project as a whole is i well documented. The concrete delivered to the forms was of uniformly high quality, as measured by the compressive strength of test cylinders. There are, to be sure, allegations of falsified cylinder test results for a small part'of the project, and these allegations must be investigated by-tests of the concrete in place. If the investigation proves that the quality of concrete during the period of alleged falsification is equal to that of the rest of the project, then it will have been established that all the concrete was of high quality as it entered the forms. If not, it will be necessary to investigate a small portion of the concrete in detail and to perform structural analyses of those portions found to have deficient concrete. The quality of the placing did not match the inherent quality of the concrete, although the frequency of "honeycombing" is not excessive for a project of this size. While the quality assurance program concerned with consolidation of the concrete had deficiencies, the quality assurance program appeared to work well in identifying and repairing areas with poor consolidation. The procedures were well documented, and where necessary rather elegant procedures were employed. A walk-through inspection of the project reveals no missed areas. The question may be asked as to whether there are internal voids which cannot be seen. Long experience with concrete construction has indicated that the formed surface is the most difficult area to consolidate. If there are not' excessive unconsolidated regions j' 4 .YId

I l.a.. a --h..a:,,here.wromueve:;er-a +ws sm.-unawa n.s.wa..-% =mw.us - l on the surface, it is unlikely that there are many voids in the interior. A few interior voids can be tolerated. A few suspect areas of concrete were tested ultrasonically at Comanche Peak to determine whether internal voids existed. Only one had to be repaired. It is apparent that there were a number of disgruntled employees on the project willing to supply evidence of construction irregularities. It is likely that nearly every expample of failure to comply with specifications was contained in allegations so that a ctudy of the allegations should provide a good basis for judging the quality of concrete construction. Many allegations concerned cold-weather protection. Very few, however, were concerned with the critical early hours immediately after placing. Those that were concerned with early protection were investigated by tests of the hardened concrete, and the concrete was found satisfactory. Failure to comply at later ages, while constituting a quality assurance deficiency, does not impair safety. Concrete which does not receive its design load at an early age, such as the concrete at Comanche Peak, will attain its desired strength during warm weather. The Comanche Peak specifications cited the more stringent requirements for concrete which does receive its design load at an early age. There were several allegations of misplaced or missing reinforcing bars. In some cases bars were added by drilling and grouting. In other cases structural analyses demonstrated that the structure was satisfactory without the missing bars. In another, shores were left in place for an extended period of time until the structure in the as-built condition was safe for carrying the design load. In other cases it could not be determined from existing data whether the as-built condition is safe. For these the applicant is being required to perform ~ analyses and, if necessary, corrective action. Except for those items still remaining to be resolved, the concrete structures in the as-built condition have been demonstrated to be adequate both in quality of concrete and structural configuration. 2. How does the quality of concrete construction in Comanche Peak compare with other examples of heavy construction, particularly that of other nuclear power plants? The Comanche Peak construction compares favorably with most non-nuclear heavy construction. Even if all the suspect test results are eliminated, the documentation at Comanche Peak far exceeds that of most non-nuclear projects. The only area in which it might suffer in comparison with other projects is that of consolidation of concrete. Most non-nuclear projects, however, are less-heavily reinforced than nuclear projects so that consolidation is easier. The writer's experience on nuclear projects is limited. However, it j may be stated that there is nothing at Comanche Peak that ecmpares with the incidence of honey-combing in the basemat of Unit 3 at Iurkey Point. Both documentation and visual examination indicate that the Comanche Peak concrete is as good as that at Waterford. (

y AGENDA NRC-TRT MEETING 1/07/85 I. OVERALL CPRT INITIATIVES / PHILOSOPHY - LEVIN /HOOTON II. CONCRETE 1) Introduction to Action Plan - Levin

2) Gridding Procedure - Harrison / Webster
3) Description of Test Procedures / Traveler - Harrison
4) Description of Statistical Evaluation - Webster III. CONDUIT 1)

Introduction of Action Plan - Levin

2) Sample Selection - Wright /Mortgat
3) Description.of Engineering Instruction /

Qualification of Personnel - Wright

4) Description of Walkdown Documentation - Wright
5) Overview of G&H Analytical Effort /

p and Third Party Review - Mortgat IV. CONTROL ROOM CEILING 1) Introduction to Action Plan - Levin

2) Objective / Philosophy of Design Changes - Levin
3) Experience in Earthquake /What's Important - Swan
4) Physical Description / Photos - Swan
5) EQE Recommendations - Swan
6) Design Details - Wells
7) Third Party Activites - Witt V.

FIELD WALKDOWN ~ VI. DISCUSSION h h e

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