ML20147C123

Responds to 781017 NRC Ltr Re Violation Noted in Inspec Rept 50-363/78-12.Corrective Actions:Personnel Reinspected & Retested;Inspector Assigned to Inspect Status of Concrete Curing

ML20147C123
Person / Time
Site:	05000363
Issue date:	11/13/1978
From:	Finfrock I JERSEY CENTRAL POWER & LIGHT CO.
To:	Grier B NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I)
Shared Package
ML20147C098	List: IR 05000363/1978012 ML20147C123
References
NUDOCS 7812180161
Download: ML20147C123 (3)

Text

__________-____ -

. *4 . . ,

( ) {. File: 2421.10

. hc- 7.f 4""

() Jersey Central Power & Light Company Madison Avenue at Punch Bowl Road Nkyristown. New Jersey 07960 (201)455-820)

November 13, 1978 v

Mr. Boyce H. Grier, Director Office of Inspection 5 Enforcement, Region I U.S. Nuclear Regulatory Commission 631 Park Avenut King of Prussia, PA 19406

SUBJECT:

LICENSE NUMBER CPPR-96 INSPECTION NUMBER 78-12 DOCKET NIIMRER 50-363 This letter responds to the subject inspection report which presents an infraction uncovered by Mr. A. A. Varela during his inspection Sep-tember 12-15, 1978. Below is our response to the infraction cited in the subject inspection report.

Infraction 10 CFR 50 Appendix B, Criterion V states, in part, that " Activities affecting quality shall be prescribed by documented instructions, procedures, or drawings .

and shall be accomplished in accordance with these instructions, drawings, and procedures ...."

The licensee's Quality Assurance Plan, Revision 9, Section 5.0 states, in part, the Forked River Unit Quality Assurance Program requires that:

" Quality related activities be prescribed by appropriately documented instructions, procedures and drawings", and "The activities be accomplished in accordance with such documents.

1. Morrison-Knudsen (M-K) Construction Procedure CP-11-FR, Revision 1,

" Placement and curing of Concrete",Section VI.N Preservation of Moisture, requirer:

For concrete surfaces not in contact with fo .s, one of the following procedures as applicable s' .11 be r.pplied immediately after completion of placement and finishing:

(a) Ponding or continuous sprinkling.

(b) Application of absorbtive mats or fabric kept

-continuously wet.

Jersey Central Power & Light Company is a Member of the Genera! Pubhc Utitres System

Y . .

. *Mr..Boyc'e H. Grier November 13, 1978 (c) Application of sand kept continuously wet.

(d) Application of an approved waterproof sheet material.

(e) Application of other moisture-retaining ,

covering as approved or in specification.

(f) Application of an approved membrane curing compound.

(g) Continuous application of steam or mist spray.

Ccntrary to the above, containment basemat concrete placements number LSK 104-B and 103-A completed on the afternoon and evening of Sep-tember 11, 1978 were observed on the afternoon and evening of Sep-tember 13, 1978 to have no application of absorbtive cover and/or water on horizontal surfaces. On the morning of September 14, 1978, approximately 30% of horizontal finished surface and construction joints were dry when hand tested. On the morning of September 14, 1978, vertical forms on pour 104-0 were ren.9ved, draped with plastic but not scaled. Vertical concrete at midday was observed to be surface dry and remained without moisture application until late in the afternoon.

2. Morrison-Knudsen Construction Procedure CP-11-FR Revision 1,Section XI.C, Inspection and Test Requirements, prescribes:

The Quality Control Inspection will verify that the concrete curing method is properly applied and maintained for the minimum curing period.

Contrary to the above, containment basemat concrete placements LSK 104-B and 103-A completed on the afternoon and evening of September 12, 1978 were ,

not verified by the QC Inspector for adequacy of curing on September 13 and 14, 1978.

Corrective Action Taken

1. GPUSC-QA through disposition to Non-Conformance Report No. 0371 directed that M-K " Maintain exposed surfaces (Placements 103-A and 104-B) under wet cure until October 16, 1978."

2. M-K personnel were reinspected by GPUSC-QA to the requirements of M-K procedure CP-11-FR with respect to curing requirements and documentation.

M-K's inspector was retested on September 25, 1978 and obtained a grade of 79.5% on a written examination. Based on this,M-K was allowed to continue work in the containment area.

• R Mr: Boyce H. Grier November 13, 1978 Corrective Steps to Avoid Further Infractions As of October 5,1978, a Morrison-Knudsen Inspector has been assigned, full time, to inspect the status of concrete curing and to take and record temperatures. This assignment will be continued until it has been satis-factorily demonstrated that it is no longer required.

Additionally, training sessions were held by M-K on September 25, 1978 and October 12, 1978 on the ACI requirements goveIming the curing of concrete.

This means of additional instruction and training will be continued on a scheduled basis.

Very truly yours, l j l1,h' f :.?  :/

Ivan R. Finfrqpk, Jr:

Vice President asb

• .. +

1. " "I W UNITED STATES

f. . . .% NUCLEAR REGULATORY COMMISslON f " "A ( $ REGION i E 631 PARK AVENUE 7, $p g f ': ,8 KING OF PRUSSI A, PENNSYLVANI A 19406 o,s a ,

• a,e Docket No. 50-363 Jersey Central Power & Light Company ATTN: Mr. I. R. Finfrock, Jr.

Vice President 260 Cherry Hill Road Parsippany, New Jersey 07054 Gentlemen:

Subject:

Inspection 50-363/78-12 This refers to the inspection conducted by Mr. A. A. Varela of this office on September 12-15, 1978, at the Forked River Nuclear Station, l Unit 1. Forked River, New Jersey, of activities authorized by NRC License No. CPPR-96 ard to the discussions of our findings held by Mr.

Varela with Mr. S. Levin of your staff at the conclusion of the inspection.

Areas examined during this inspection are described in the Office of Inspection and Enforcement Inspection Report which is enclosed with this I

letter. Within these areas, the inspection consisted of selective examinations of procedures and representative records, interviews with personnel, and observations by the inspector.

Based on the results of this inspection, it appears that one of your l

activities was not conducted in full compliance with NRC requirements, as set forth in the Notice of Violation, enclosed herewith as Appendix A. This item of noncompliance has been categorized into the levels as described in our correspondence to you dated December 31, 1974. This notice is sent to you pursuant to the provisions of Section 2.201 of the NRC's " Rules of Practice," Part 2, Title 10, Code of Federal Regulations.

Section 2.201 requires you to submit to this office, within twenty (20) days of your receipt of this notice, a written statement or explanation in reply including: (1) corrective steps which have been taken by you and the results achieved; (2) corrective steps which will be taken to avoid further items of noncompliance; and (3) the date when full compliance will be achieved.

l 2 O2 k/

7813.15

Jersey Central Power & Light 2 Company In accordance with Section 2.790 of the NRC's " Rules of Practice," Part 2, Title 10, Code of Federal Regulations, a copy of this letter and the enclosures will be placed in the NRC's Public Document Room. If this report contains any information that you (or your contractor) believe to be proprietary, it is necessary that you make a written application I within 20 days to this office to withhold such information from public l

disclosu,re. Any such application must be accompanied by an affidavit executed by the owner of the information, which identifies the document or part sought to be withheld, and which contains a statement of reasons which addresses with specificity the items which will be considered by the Commission as listed in subparagraph (b)(4) of Section 2.790. The information sought to be withheld shall be incorporated as far as possible into a separate part of the affidavit. If we do not hear from you in this regard within the specified period, the report will be placed in the Public Document Room.

Should you have any questions concerning this inspection, we will be pleased to discuss them with you.

Sincerely, A

Robert T. Carlson, Chief Reactor Construction and Engineering Support Branch

Enclosures:

1. Appendix A, Notice of Violation

2. Office of Inspection and Enforcement Inspection Report Number 50-363/78-12 cc w/encis:

M. K. Pastor, Project Manager

O APPENDIX A NOTICE OF VIOLATION Jersey Central Power and Light Company Docket No. 50-363 Based on the results of the NRC inspection conducted on September 12-15, 1978, it appears that one of your activities was not conducted in full compliance with conditions of your NRC Facility License No. CPPR-96 as

.indicateo below. This item is an infraction.

10 CFR 50, Appendix 8, Criterion V, states, in part, that" "Acti-vities affecting quality shall be prescribed by documented instruc-tions, procedures, or drawings...and shall be accomplished in accordance with these instructions, drawings, and procedures. . ."

The licensee's Quality Assurance Plan, Revision 9, Section 5.0 states, in part, the Forked River Unit 1 Quality Assurance Program requires that:

Quality related activities be prescribed by appropriately documented instructions, procedures and drawings," and

. "The activities be accomplished in accordance with such docu-ments."

1. Morrisor.-Knudsen Construction Procedure CP-11-FR, Revision 1,

" Placement and Curing of Concrete",Section VI.N, Preservation of Moisture, requires:

For concrete surfaces not in contact with forms one of the following procedures as applicable shall be applied immediately after completion of placement and finishing:

a. Ponding or continuous sprinkling

b. Application of absorptive mats or fabric kept continuously wet

c. Application of sand kept continuously wet

d. Application of an approved waterproof sheet material 781218-1

a Appendix A 2

e. Application of other moisture-retaining covering as approved or in specification

f. Application of an approved membrane curing compound

g. Continuous application of steam or mist spray Contrary to the above, containment basemat concrete placements number LSK 104-B and 103-A completed on the afternoon and evening of September 12, 1978 were observed on midday September 13 to have no application of absorptive cover and/or water on horizontal surfaces. On the morning of September 14, approximately 30% of horizontal finished surface and construction joints were dry when hand tested. On the morning of September 14, vertical forms on psur 104-B were removed, draped with plastic but not sealed.

Vertical concrete at midday was observed to be surface dry and remained without moisture application until late in afternoon.

2. Morrison-Knudsen Construction Procedure Cp-ll-FR, Revision 1, in Section XI.C, Inspection and Test Requirements, prescribes:

l The Quality Control Inspector will verify that the concrete curing method is properly applied and maintained for the minimum curing period.

Contrary to the above, containment basemat concrete placements LSK 104-B and 103-A completed on the afternoon and evening of September 12, were not verified by the QC inspector for adequacy of curi.ig on September 13 and 14.

U.S. NUCLEAR REGULATORY COMMISSION Q OFFICE OF INSPECTION AND ENFORCEMENT Region I Report No. 50-363/78-12 Docket No. 50-363 l License No. CPPR-96 Priority --

Category A Licensee: Jersey Central Power and Light Company 260 Cherry Hill Road Parsippany, New Jersey 07054 Facility Name: Forked River Nuclear Station. Unit 1 Inspection at: Forked River, New Jersey Inspection condtreted:] Septembe 2-15, 1978 Inspectors: / /

7 A_ hCR'k'T 2, li76 W. G."Varela, Reactor Inspector date signed date signed date signed Approved by: k/)- M , /d 76 f D. Ebneter, Chief, Engineering Support dats signed Section No. 2, RC&ES Branch Inspection Summary:

Inspection on September 12-15, 1978 (Report No. 50-363/78-12)

Areas Inspected: Routine, unannounced inspection by a regional based inspector of reinforcing steel installation and cadweld splicing for the containment basemat. Concrete mixing, delivery, testing, placement, finishing and curing for containment basemat was observed. The inspector also observed backfill placement, compaction and testing, and reviewed records on maintenarce of de-watering, pressure relief and slope stability of the excavation. A site tour inspection was performed and previously identified unresolved items were reviewed.

The inspection involved 30 hours3.472222e-4 days <br />0.00833 hours <br />4.960317e-5 weeks <br />1.1415e-5 months <br /> onsite by one NRC regional based inspector.

Results: Of the six areas inspected, one item of noncompliance was identified in curing of concrete.

$5 Y 781 Q5 Region I Form 12 (Rev. April 77)

i DETAILS

1. Persons Contacted General Public Utilities Service Corporation (GPU)

J. J. Barton, Project Site Manager J. W. Davis, Resident Civil Engineer

• R. F. Fenti, Senior Site QA Auditor J. W. Griest, Project Construction Manager

• S. Levin, Supervisor Site Engineering

• J. C. Thompson, Site Quality Control Supervisor J. E. Wright, Site Quality Assurance Manager Stone and Webster Engineering Corporation (S&W)

J. Adachi, Concrete Testing Site Manager (PTL)

L. Brown, Construction Superintendent S. Deyo, Construction Engineer W. G. Dick, Area Superintendent S. D. Morris. Quality Control Engineer G. Noons, Area Engineer

• B. Officer, Assistant Superintendent of Construction

• K. Platte, Resident Engineer F. Puffer, Quality Control Engineer A. Pir,ter, Quality Control Engineer

• R. L. Wagner, Superintendent of Construction Morrison-Knudsen (M-K)

R. Barnes, Quality Control Engineer R. Colasardo, Soil Test Engineer, (U.S. Testing Company)

N. Corbi, Reinforcing Steel Superintendent L. Grandpre, Construction Superintendent H. Haney, Area Superintendent

• D. Kivisto, Assistant Project Manager D. Richards, Quality Control Engineer

• R. Stauber, Site Quality Assurance Manager D. Sleeper, Quality Control Cadwel Inspector

3 Burns and Roe Inc. (B&R)

T. Hayes, Geotechnical Engineer S. Lazorchak, Site Field Engineer E. Zisman, Senior Geotechnical Engineer Eastern Shore Transit Mix (EST)

R. Johnson, Quality Control Manager V. Nagee, Quality Control Engineer F. DeCessaro, Batch Plant Operator A. Vendrasco, Vice President l

l

• denotes those present at the exit interview.

The inspector also interviewed other licensee and contractor employees during the inspection, including quality control and construction crafts.

2. Plant Tour The inspector made a tour of the construction site to observe work activities in progress. The inspector examined work items for any obvious defects or noncompliance with regulatory requirements and for evidence of quality control of the work. Specific activities observed by the inspector included installation and cadwelding of reinforcing steel for the reactor well basemat, placing, compacting and testing of structural backfill, mixing, transporting, testing and placing concrete for the containment basemat and laboratory tensile tests on vertical #18 cadweld splices to qualify operators.

As identified in Paragraph 4 concrete placement practices observed, at start of work on the containment basemat pour, LSK 104-B appearing as poor practice was corrected. Paragraph 5 identifies a noncompliance in post placement concrete curing. Except for these items, other construction site work activities were observed to be without items of noncompliance.

4

3. Licensee Action on Previous Inspection Findings (Closed) Unresolved Item (363/78-08-02): Procedure on mechanical splicing of rebar requires corrections for clarity and specificity.

Procedure CP-12-FR on mechanical splicing of reinforcing steel bars was revised by M-K June 21, 1978 and revision number 3 was approved and released for construction on June 26, 1978. The inspector re-viewed CP-12-FR revision 3 and observed specific changes in detail provided adequate clarity. Also additional inspection criteria and forms for quality control documentation are provided.

4. Corrective Action Taken in Concrete Placement of Containment Basemat Block LSK 104-8 The inspector observed concrete placement of containment basemat block LSK 104-B shortly after start of the placement at midday September 12, 1978. He observed that method used in depositing concrete from conveyor vertically through about 25' of telescoping plastic drop chutes caused separation of the aggregate from the mortar and scattering of the three-quarter inch, maximum size aggregate. The placement and practice could have caused segregation of the aggregate in the mix. The inspector discussed this with S&W and M-K QC personnel with the result that the concrete placement was delayed. Changes were made to the drop chute to provide a section of chute with reduced diameter to control the concrete velocity at exit, and to extend the chute to deposit concrete as close as possible between rebar to its final position in the forms. Continuation of concrete placement complying with requirements was observed by the inspector to complete block LSK 104-B. No undue scattering of aggregate or segregation was observed in remainder of pour.

5. Noncompliance in Concrete Cure of Containment Basemat Blocks LSK 104-8 and 103-A Concrete placements LSK 104-B and 103-A for the containment tendon gallery basemat were completed mid afternoon and evening, respec-tively, September 12, 1978. M-K construction procedure CP-ll-FR, requires in Section VI.N, Preservation of Moisture:

5

1. For concrete surfaces not in contact with forms, one of the following procedures as applicable shall be applied immediately after completion of placement and finishing:

a. Ponding or continuous sprinkling

b. Application of absorptive mats or fabric kept continuously wet

c. Application of sand kept continuously wet

d. Continuous application of steam or mist spray

e. Application of an approved waterproof sheet material

f. Application of other moisture-retaining covering as approved or in specification

g. Application of an approved membrane curing compound The inspector observed on the afternoon of September 12, following completion of concrete placement on pour 104-8 that horizontal con-struction joint areas were not provided with any above methods for moisture preservation or moisture addition. On the morning of September 13 and thoughout that day, moist cure was not applied to pour 104-B or 103-A until late in the afternoon. However, on the morning of September 14 about 30 percent of both areas were surface dry. Vertical wall wooden forms were stripped from 104-8 on the morning of September 14 but plastic sheet covering was not sealed to prevent loss of moisture, and surfaces were dry in the afternoon before water was applied. Additionally, M-K construction procedure CP-11-FR requires in Section XI.C:

"The QC inspector will verify that the concrete curing method is properly applied and maintained for the cure period."

The NRC inspector observed that M-K QC did not verify cure method on pours LSK 104-B and 103-A on September 13 and 14.

/ 6 Failure to provide concrete surfaces not in contact with forms with a method for preservation of moisture immediately after completion of placement and finishing, failure to continuously maintain moisture on concrete, and failure by QC to verify that cure method is pro-perly applied is considered to be in noncompliance with Criterion V of 10 CFR 50, Appendix B. (78-12-01)

6. Observation of Concrete Placement of Containment Basemat Block LSK 104 Preplacement Activities for Block LSK 103-A and Rebar Installation.and Cadwelding for Reactor Well Basemat The inspector observed placement preparation and concrete placement of containment basemat blocks LSK 103-A and 104-8 respectively, on September 12, 1978, and QC inspection performed in connection with this work. These activities were inspected for conformance to the following:

Forked River Nuclear Station, Unit 1, PSAR Section V and Appendix SD.

B&R Specification 2700-206, Rev. 6, " Substructure" B&R Specification 2700-202, Rev. 8, " Production and Delivery of Concrete" GPU Specification 202-003, Rev. 3, " Specification for Per-formance of Owners Site Civil Testing"

-- GPU QC Procedure FR-1-10-04, Rev 0, " Site QA/QC Surveillance Procedure" M-K Construction Procedure CP-ll-FR, Rev.1, " Placement and Curing of Concrete" The inspector determined the following activities were accomplished according to applicable specifications, codes, standards and pro-cedures:

7

a. Placement Preparation for Block LSK 103-A - forms properly secured, tight and clean; rebar and other embedments properly placed, secured, clean and specified distance from forms; preplacement inspection completed prior to concrete placement; construction joints and water stops prepared as specified and/or approved.

b. Delivery and Placement - proper mix specified and delivered; controlled mixing and delivery time; testing at truck dis-charge properly performed using calibrated equipment; properly controlled concrete remixing in truck when approved water added at truck discharge; adequate crew, equipment and tech-niques prevented segregation; adequate consolidation with tested vibrators; inspection during placement.

c. Aggregate and Cement Storage - aggregate of different sizes in separated storage bins; cement adequately protected; inspection of all concrete ingredients conforms to requirements for scope and frequency.

d. Rebar Installation and Cadwelding - number 18S rebar installa-tion for the reactor well basemat block conforms to specifi-cation 206, engineering drawings S745, S746 and S747 and pertinent rebar detail layout drawings; horizontal rebar splicing of #18 splices were observed in preparation, fabrication and checked after firing to conform to requirements. Tensile Testing of veritical #18 splices were observed in the site testing laboratory for qualification of operations.

e. Batch Plant Operation - accuracy of material control and temperature control; inspection, generation and control of batch plant print-out records and truck tickets; inspection of materials and batching by qualified QC inspection personnel.

No items of noncompliance, other than that identified in Para-graph 5, were identified.

7. Observation of Installation-Compaction and Testing of Structural Fill Around Engineered Safety Features Compartments The inspector observed installation and testing of Class I fill at the west and south sides of the ESFC from about evelation -11' to -

8', and removal / replacement of reject fill at the 48" diameter sumps south of ESFC. These activities were inspected for conformance to the following:

l

8 l

Forked River r!uclear Station, Unit 1, PSAR Appendix SD B&R Specification 2700-206, Rev. 6, " Substructure" M-K Construction Procedure CP-01-FR, Rev. 3, " Placement and Comp 3ction of Class I Backfill" GPU Procedure FR-1-10-04, Rev. O', " Site QA/QC Surveillance Procedure" Performance of the following activities was observed:

a. Backfill release form was signed by construction manager.

b. Placement of approved fill in 8" (loose) layers rolled four passes with approved 25 ton vibro-roller over each lift after application of water to each layer (prev'.ous tests established no maximum limit on moisture).

c. In-situ density tests, using a calibrated instrument (Washing-ton 1/10 cubic foot densometer), conducted by a qualified US Testing Company technician under surveillance of S&W QC engi-neer, tests #127 - 130, fullfilling requirements of ASTM 0 2167-72.

d. Frequency of in-place density testing exceeded minimum re-quirements of one in-situ test for every full shift of com-paction operation, or one test for each foot thickness of compacted backfill over an area of 18,000 square feet.

e. Laboratory determination of natural dry density, maximum and minimum densities on soil obtained for each sample identified above, and computation of relative density of cohesion less soils, as required using ASTM D 2049-74,

f. Relative density results fullfilled requirements that average of all tests have minimum value of 90% and none fall below 75%.

No items of noncompliance were identified.

9

8. Review of Ground Water and Slope Stability Records for Maintenance of Dewatering and Safety of Excavation Slopes The Moretrench American Corporation (MTA) has contract for installa-tion and maintenance of the dewatering system surrounding and within the excavation for the Forked River Unit 1 facility. This is not a safety related activity and, therefore is not required to conform to 10 CFR 50, Appendix B. However, maintenance of the required level of ground water within the slurry trench cut-off wall to permit construction in the dry is controlled by MTA in accordance with dewatering requirements established by B&R. MTA personnel provide assurance in control of dewatering by daily water level, pressure and flow readings as well as installation and maintenance of additional equipment as needed to assure safety of the excavation.

Additional procedural requirements of the AE are imposed on the construction r aanger (S&W) for monitoring dewatering of the upper __

unconfined aquifer and the lower confined aquifer to ensure that construction proceeds within safe limits relative to consideration of ground water pressure and stability of excavation slopes.

Construction manager personnel, independent of MTA, daily obtain readings on piezometers, observation wells, inclinometers and em-bankment slope stakes. These are submitted daily to B&R site geotechnical engineer for compilation, analyses and weekly summari-zation. The inspector reviewed these records for period August 4 to September 15, 1978. The records indicate conformance to criteria -

identified in B&R Procedure W0 3700 for Monitoring Instrumentation to Control Dewatering and Excavation.

No items of noncompliance were identified.

9. Exit Interview At the conclusion of the inspection on September 15, 1978, a meeting was held at the Forked River site with representatives of the licensee and contractor organization. The inspector summarized the results of the inspection as described in the report.

._ ._ _.-