ML20137Y317
| ML20137Y317 | |
| Person / Time | |
|---|---|
| Issue date: | 09/11/1985 |
| From: | Merschoff E, Naidu K NRC OFFICE OF INSPECTION & ENFORCEMENT (IE) |
| To: | |
| Shared Package | |
| ML20137Y301 | List: |
| References | |
| REF-QA-99901007 99901007-85-01, 99901007-85-1, NUDOCS 8510070296 | |
| Download: ML20137Y317 (7) | |
Text
ORGANIZATION: PRESCON CORPORATION SAN ANTONIO, TEXAS REPORT INSPECTION INSPECTION N0.: 99901007/85-01 DATE(S): 6/10-12/1985 ON-SITE HOURS: 48 CORRESPONDENCE ADDRESS: The Prescon Corporation ATTN: Mr. J. Oiknine, President 1338 North WW White Road San Antonio, Texas 78220 ORGANIZATIONAL CONTACT:
Howard E. Williams TELEPHONE NUMBER:
512-662-8500 PRINCIPAL PRODUCT:
Post-Tensioning Components - Supply and Installation NUCLEAR INDUSTRY ACTIVITY:
Prescori is currently installing a containment post-tensioning system at the South Texas Project, and intends to participate in tendon surveillances for nuclear power plants.
A ASSIGNED INSPECTOR:
be k23[K u
K. R. Naillu, Reactive Inspection Section (RIS)
Da te' OTHER INSPECTOR (S):
T. F. Burns (BNL)
J. Harper, IS O
APPROVED BY:
I f
f E. W. MerschofVfhief, RIS, Vendor Program Branch Date l
INSPECTION BASES AND SCOPE:
A.
BASES:
10 CFR Part 21 and 10 CFR 50 Appendix B.
B.
SCOPE:
Inspection of post-tensioning components for South Texas Project including verification of documentation and selective verification of QA program implementation.
I PLANT SITE APPLICABILITY:
South Texas Project 50-498.
l 8510070296$hhESC PDR GA999 PDR 9991007
ORGANIZATION: PRESCON CORPORATION SAN ANTONIO, TEXAS REPORT INSPECTION N0.:
99901007/85-01 RESULTS:
PAGE 2 of 7 A.
INSPECTION ISSUES The Prescon Corporation (Prescon) is currently installing the post-tensioning system at the South Texas Nuclear Power Plant (STP). The purpose of this inspection was to ascertain whether the implementation of Prescon's QA program relative to the fabrication of post-tensioning components meets the requirements of 10 CFR 50 Appendix B and STP's technical specifications.
B.
BACKGROUND INFORMATION Prescon, a division of Compenon Bernard Group (France) and a member of the Freyssinet International Group, specializes in the application of prestressed technology. Prescon has furnished engineering services and specialized construction systems and post-tensioning systems for major construction projects including nuclear power plants in the U.S. and other countries.
Prescon fabricated post-tensioning components to technical specification 2C239CS003 issued by Brown & Root, the then Architect Engineer (AE) for STP.
In October 1981, Bechtel Energy Corporation (BEC) assumed the AE responsibilities and issued a revised specification 2C239CS0003, Revision 0, on 9/24/82. Due to delays in construction, the first batch of tendons was fabricated and stored for an extended period of time. This material was scrapped due to excessive rust. A second batch was fabricated and stored under controlled atmospheric conditions.
Recently, problems have been identified with the post-tensioning equipment supplied and installed by Inryco at the J. M. Farley nuclear power plant in Alabama. Although these problems were ultimately found to be caused by a hydrogen embrittlement mechanism not associated with fabrication, a followup inspection at Inryco revealed several deficiencies in the implementation of their quality assurance program.
l The purpose of this inspection was to ensure that similar quality l
assurance problems do not exist with regard to the implementation of j
Prescon's quality assurance program.
l.
C.
INSPECTION FINDINGS 1.
Violations a.
Contrary to section 21.21 of 10 CFR Part 21, Prescon did not develop a procedure to review and evaluate deviations for reportability (85-01-01).
1
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__.s._
ORGANIZATION:
PRESCON CORPORATION SAN ANTONIO, TEXAS REPORT INSPECTION NO.:
99901007/85-01 RESULTS:
PAGE 3 of 7 D.
INSPECTOR OBSERVATIONS AND OTHER COMMENTS 1.
Shop Tour The inspectors toured the shop area and observed post-tensioning components being prepared for shipment to the job site. Shop anchor heads were being prepared with tendons cut to specified lengths and button heads were being formed. A designated area was assigned to segregate and store nonconforming material. Calibrated measuring devices were being used during the fabrication and inspection process.
No nonconformances were noted during this portion of the inspection.
2.
Review of Test Documentation The inspectors reviewed the documentation on the dynamic and static tests performed by Prescon and determined the following:
a.
Static Testing i
Prescon tested a tendon system consisting of 186 1/4" diameter wires at their Simpsonville, South Carolina facility on August 29, 1974. The purpose of the test was to demonstrate that the tendon to be used to post tension Arkansas Nuclear One, Unit 2, would conform to the technical specification. The acceptance criteria was:
(1) The tendon will reach a minimum of 100% of the guaranteed ultimate tensile strength with no more than 2% of the wires failing during the test.
(2) The percent elongation of the tendon under maximum load shall not be less than 3%.
The conclusion of the test was that the test tendon reached a capacity of 2298 kips (104% of the guaranteed ultimate tensile strength) and achieved an elongation of 3.04% prior to the fourth wire break. The tendon performed in accordance with the specifications.
b.
Dynamic Testing A test program was conducted ta fulfill specified requirements related to the fatigue life of unbonded button headed wire tendons used for post-tensioning concrete structures. During
ORGANIZATION:
PRESCON CORPORATION SAN ANTONIO, TEXAS REPORT INSPECTION N0.:
99901007/85-01 RESULTS:
PAGE 4 of 7 the test, one 20 wire tendon was loaded between 40% and 80% of the guaranteed ultimate tensile ~ strength (GUTS) for 80 cycles.
Two 20 wire tendons were loaded between 60 and 66% of the GUTS for 427,000 and 505,000 cycles respectively. Trinity Testing Laboratories, an independent testing laboratory, witnessed the test once a day between September 23, 1977 and January 17, 1978.
The random inspection was to determine that at those times witnessed, the test apparatus was performing according to the specifications.
The test concluded that the specified requirements had been met.
The tests indicated that alignment of the specimen in the test frame, effects of side loading and the fretting that resulted must be considered. With a stress range between 60 and 66 percent of the tendon capacity and adequate control over these factors, the tendons should be capable of consistently with-standing cyclic loading in excess of 500,000 cycles without failure.
3.
Review of Audits Performed on Prescon The inspectors reviewed the following audits performed on Prescon:
a.
Bechtel Power Corporation, San Francisco, September 14-15, 1983 b.
Bechtel Power Corporation, San Francisco, February 26-28, 1985.
c.
Florida Power & Light Company, March 28, 1985 d.
Duke Power Company, May 28-29, 1985 The review indicated that Bechtel identified one programmatic deficiency relative to inadequate provisions in the manual to control obsolete drawings. Bechtel reaudited Prescon on April 21, 1985 and verified that the corrective actions taken by Prescon to revise and implement the procedure were adequate. No unacceptable findings were identified by the other audits. No nonconformances were noted during this portion of the inspection.
4.
Review of Grease Filler Cap Gasket Certification A gasket is used to retain the grease in the filler cap assembly.
The inspector reviewed the certification on this gasket to ascertain whether the gasket will meet the service conditions.
.r. -
ORGANIZATION:
PRESCON CORPORATION SAN ANTONIO, TEXAS REPORT INSPECTION N0.:
99901007/85-01 RESULTS:
PAGE 5 of 7 Prescon's purchase order 6032 dated December 22, 1978 to Corpus Christi Gasket Company, Corpus Christi, Texas ordered 1050 filler gap gaskets made of Nitrile Base Rubber Compound and drawing TP-1002 which provided technical details. The Corpus Christi Gasket Company provided test results for the gasket and certified that the gaskets will withstand the service conditions and environment involved in the required application for a period of 50 years.
No nonconformances were noted during this portion of the inspection.
5.
Review of Part 21 Requirements Bechtel Energy Corporation (BEC), who assumed the AE responsi-bilities in 1981 from Brown and Root, issued Technical Specification 2C239CS0003 Revision 0 on 9/24/82, including the requirements of general contract 14926-C-0067.
Paragraph GC-8 on page A-3 of this contract imposes 10 CFR Part 21 requirements on Prescon.
Prescon had not developed a Part 21 procedure establishing the steps to be taken to identify, evaluate and report a significant noncon-forming condition. The inspectors informed Prescon that failure to develop and post 10 CFR Part 21 Reporting Procedures was a violation of NRC rules and regulations (Violation 85-01-01 identified in section C of this report).
6.
Review of Personnel Training A review of training activities indicated that Prescon established and implemented a training program for quality control inspection personnel. Section 2.4 and 2.5 of the Prescon QA manual addresses basic indoctrination and on-the-job training for new employees and engineering personnel, houdver, there was no objective evidence to verify this activity. The inspectors informed Prescon that the training program should include personnel affecting quality, such as individuals in procurement, engineering, and production since they should be able to recognize the customer's quality requirements and the appropriate provisions of the Prescon quality assurance manual.
In a letter dated July 23, 1985, Prescon stated that they will develop a program with input from the Shop Manager and Director of Engineering and that the QA program will be revised to reflect this requirement.
Files will be kept on individuals to reflect 1985 training received. Corrective action is expected to be completed by August 22, 1985.
No nonconformances were noted in the above area.
ORGANIZATION:
PRESCON CORPORATION SAN ANTONIO, TEXAS REPORT INSPECTION NO.:
99901007/85-01 RESULTS:
PAGE 6 of 7 7.
Review of Procurement Activities a.
The inspectors reviewed Purchase Order (P0) 5394 dated 10-17-77 to National Flame and Forge for the supply of 999 pieces of 186 wire stressing washers (also referred to as anchors). The applicability of 10 CFR Part 21 requirements was not referenced in the P0. Prescon personnel acknowledged the finding and agreed to issue an amendment to cover future shipments.
Subsequent to the inspection, Prescon issued an amendment to P05396 to National Flame and Forge imposing the requirements of 10 CFR 50 Appendix B and 10 CFR Part 21.
b.
The Prescon QA manual addresses the selection and qualifica-tion of vendors in Section 7.1 and the performance of audits in Section 18.2.
These sections will not prevent a vendor being placed on the Approved Vendors List (AVL) prior to an audit being performed. Subsequent to the inspection, Prescon informed this office that they revised Sections 4.2 and 7.1 of their QA manual to state that purchase orders will not be issued prior to performing an audit on the vendor and placement of the vendor on the AVL.
c.
Prescon did not, in all cases, have the original Certified Material Test Reports (CMTR).
Presently, the CMTRs provided are actually from the fabricator of the washer and the data therein have been transposed from the manufacturer's CMTR. This was an item of concern since it was stated that the mill (manufacturer) performed the heat treatment and not the fabricator. Prescon in their letter dated July 23, 1985, stated that they received the original CMTRs on July 11, 1985.
No nonconformances were noted in the above area.
1 E.
Exit Meeting The inspectors met with representatives from Prescon identified in Section F and discussed the scope and findings of the inspection.
F.
Persons Contacted Prescon Corporation
- J. Oiknine, President
- H. E. Williams, QC Manager
- J. Kelly, QC Supervisor
ORGANIZATION: PRESCON CORPORATION SAN ANTONIO, TEXAS REPORT INSPECTION NO.:
99901007/85-01 RESULTS:
PAGE 7 of 7 Bechtel Energy Corporation N. A. Joonejo, Civil / Structural Engineering Supervisor B. Bitner, Engineer
- Denotes those individuals who participated in the exit meeting conducted on June 12, 1985 at the conclusion of the inspection, t
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