ML20154E785

Insp Rept 50-275/69-07 on 690916.No Nonconformance Noted. Major Areas Inspected:Review of Const Organization & Relationships Between Util,Prime Const Contractor & Several Subcontractors & Currently Developed QC Procedures

ML20154E785
Person / Time
Site:	Diablo Canyon, 05000000
Issue date:	10/10/1969
From:	Crews J, Andrea Johnson, Spencer G US ATOMIC ENERGY COMMISSION (AEC)
To:
Shared Package
ML20154C370	List: ML20154C367 ML20154D294 ML20154D425 ML20154D452 ML20154D528 ML20154D575 ML20154D594 ML20154D647 ML20154D736 ML20154D846 ML20154D855 ML20154D869 ML20154E066 ML20154E143 ML20154E188 ML20154E240 ML20154E258 ML20154E356 ML20154E392 ML20154E431 ML20154E484 ML20154E507 ML20154E577 ML20154E597 ML20154E600 ML20154E634 ML20154E666 ML20154E684 ML20154E762 ML20154E785 ML20154E809 ML20154E821 ML20154E871 ML20154E878 ML20154E908 ML20154E958 ML20154E967 ML20154E977 ML20154F001 ML20154F024 ML20154F073 ML20154F094 ML20154F104 ML20154F116 ML20154F123 ML20154F135 ML20154F145 ML20154F153 ML20154F156 ML20154F390
References
FOIA-88-156 50-275-69-07, 50-275-69-7, NUDOCS 8805200327
Download: ML20154E785 (14)

Text

... - - . - .- _ _ . - - _ .

I

. I 4

(.  ;

5 U. S . ATOMIC ENERG'.' CO.W.ISSION q

DIVISION OF COMPLIANCE I REGION V l J

i Report of Inspection l CO Report No. 50-275/69-7 i i i l i I

. Licensee Pacific Gas & Electric Company (

Construction Percit No. CPPR-39  ;

l

- Category A t

i Date of Inspection: Septecher 16, 1969 Date of Previous Inspection: June 26 and 27,1969 l 4

l I

Inspected by:

W# X'/a/f/ l A. D. J,chnson }

3 Reactor '

Inspector (In-charge) l

/i r . ,

'l f/

. i

? i

\ /O. / .!912% l j

J; I?.' Crews ((bifs[;'!

/ /-  ;

Reactor Inspector ,

\)

Reviewed by: MAMV /

C. S. Sp'dncer i

! Senior Reactor Inspector f j Proprietary Information: None  ;

i 1 l I

SCOPE l .

1 l

{

Type of Facility: Pressurized Water Reactor l l

Power 1.evel 3250 1:vt  ;

! l 4 1 l

1 8805dOO327 000156 IL t p156 M i

j

(

2 Loc a t ion: Diablo Canyon, San Luis Obispo County, calif ornia Type of Inspection: Routinc Announced Accompanyinn Personnel: None Scope of Inspection: Thc inspcetion effort included a review of (1) the construction organi:ation cnd relationships botvcen PC&E, the prima construction contractor and the ceveral sub-contractors, and (2) the currently dcveloped QC procedures rels:ed to the construction of the contair.acnt buildin; cad other Class 1 civil structurcs.

SCOM'l Safety Iters - None Nonconforrance Items - None Status of Previously Reported Problems -

None Other Significant Items .

1. Detailed quality control procedurcs have been formulated concerning construction of the containncat building and other Class I structures. The procedures related to nonconforming coeponents and/or esterial did not cicarly delineate responsibilities and approval authority for final disposition. PG&E indicated additional consideration would be given to the adequacy of these procedures.

2. The initial placement of reinforcing secel for the containment ba se ro t is scheduled to commence in early October. A labor dispute which delayed the start of construction activitics for approxinately six weeks has been settled.

1 l

l

Management Interview -

At the conclusion of the visit, the inspectors met with Messrs. Kelly and Lindblad to review the scope and findings of the inspection effort. Mr. Kelly indicated that the items concerning clarification of approval authority for final disposition of nonconforming catorials and complete documentation related to placccent and curing controls for concrete would be given appropriate consideration to assure adequacy of the procedures.

DETAILS A. Persons Contacted D. V. Kelly -

Project Engineer J. O. Schuyler -

Senior Mcebenical Engineer W. J. Lindblad -

Mcchanical Engineer M. H. Chandler -

Panager, Station Construction R. S. Bain -

Construction Superintendent W. R. Hersey -

Project Superintendent L. H. Carr -

Quality Assurance Engineer, Cencral Construction Department R. R. Friedrichs -

Resident Civil Engineer A. J. PleweJ -

Construction Engineer K. A. Beede -

Engincar, Department of Engineerin; 2cscarch R. Mayers -

Inspection Engineer J. H. Searle -

Senior Faccrials Inspector J. L. Murin -

Civil Engineer, Q-A F. W. Brady -

Civil Engineer, Q-A J. Zipperer -

Q-A Spec ia lis t , Engineering Departrant W. N. Harris -

Q-A Engincer, Guy F. Atkinson Company i B. Concrete (Containment)

1. Implementation of Quality Assurance Program Mr. Bain outlined the licensce-contractor line and quality control organizations for concrete manufacture, testing, placement and curing. The stru .ture of PG&2's organization responsible for -

onsite supervision of contractor activities conforms to the organization table shown in Appendix B of CO Report No. 50-275/69-1. I Mr. R. R. Friedrichs has been namad the Resident Civil Engineer 4 responsible to the Project Superintendent, Mr. Hersey, to assurc '

that the contractors perform civil construction activitics in accordance with the conditions of the contract.

, . - - _ . _ -s _ _.

l I

i 4-Mr. Harris, representing the Guy 7. Atkinson Company, explained that Atkinson will perform the concrete work; however, sub-contractors have been employed to install the reinforcing secci, embedded piping, tanks and containment liner. I Harris outlined Atkinson's onsite construction organization as l follows:

I Proicet Mananer l l

i l A I Basiness Sa fety Concral Snoerintendent Eneincaring OA i

l l j s 4 0 Batch Plant Concreto Rincers Labor Pipinn Etc.

Concerning the relationships of the licensec-contractor, Mr. 2ain explained the duties of each as follows:

a. Atkinson is to nanufactura, placc and cure the concreto I in accordance with the contract specifications.

l

b. Atkinson is to receive all concroce catorials, assure that appropriate certification documents accompany all materials, confirm that materials as cortified conform to the appropriate code requirements, and provide a copy of the documents along i with material sampics to PG62 representatives.

c. Atkinson is to preparo drawings of each concrete lif t for ,

PG6E 's approval. These detailed "lif t drawings" are to shov l the complete layout of the lift indicating dimensions,

• eleva tions , and loca tion. Embedded items are to be shown ,

such as anchor bolts, water stops and miscellancous metals. l The shop drawings will be used for placement of reinforcing steel, electrical conduit and piping. The lif t drawings are to also show the class of concretc and all finishes. A "Bill of dbterial" listing all materials or equipment required for the lift is to be included on each drawing.

d. PG&E hos the responsibility and authority to inspect all constraction activities to assure contract conditions are being satisfied.

e. PG&E is responsibic to obtain samples, test and evaluated results of roterials used in the construction of the facility. PG&E is also responsible to sampic and test the manufactured concrete to confirm that the manufactured product conforms to the coatract specifications,

f. PG&E has the responsibility to inspect and verify that proper procedures are followed in placement and curing of the concrete as prescribed by the contract.

g. PG&E inspectors are responsible to thoroughly understand the requirements of the contract specifications and applicable standards or codes pertaining to the work in progress. An inspector also has the authority to stop or reject all work which in his opinion is below specified quality standards if Atkinson does not take proper action to document such deviations as well as initiate the proper corrective measures. Such items and activitics are required to be noted on the inspector's daily report of activitics to the Resident Civil Enginecr.

2. Review of Quality Control System

a. Mix Design According to Mr. Friedrichs, concrete trial batches containing various amounts of materials have been tasted and evaluated in accordance with the standard ASTM procedurcs. To date sufficient data have been accumulated to enable selection and approval of an appropriate mix for 3,000 psi concrete (Class B). According to Mr. Becde, this mix design was determined in accordance with method 2 of ACI 313-63 section 502. However, the mix for 5,000 psi concreto (Class A) has not yet been approved. The Approved Class B mix design was stated to be as follows:

Strength - 3,000 psi in 28 days Slump - 3 inchos Ingredient Ucipht - Pounds / cubic vard Water 291 Cement 498 Sand 1,330 3/4-inch aggregate 820 1 -inch aggregate 890 Air entraining agent (-) 12.5 11. oz.

Water reducing agent ( _ . 42 fl. oz.

b. Temperature Limits The contract specifications include appropriate limits concerning temperature and delivery timo as reported in CO Report No. 50-275/69-6.

The batch plant is fully automated with its operation and batching cycle initiated by a mix card inserted into the control consolo. The card is checked by the ?GLE batch plant inspector to assure that che proper mix is used for the concrete placement in progress. Each concrete mix will' have an identifying number along with the design strength and the structure or structures for which its use is intended.

The plant is equipped with an autc=stic digital recorder which provides a record on tape of materials, time and temperature of the batch. The inspector is responsibic for verifying that the manufactured concrete conforer to the contract requirements. ?G&I's QC procedure also inscructs the inspector at the piscoment point to confirm from the bacch ticket that (1) the mix is proper for the locacion and (2) ,

the age of the batch is Icss than 45 minutes. Mr. Friedrichs stated that in view of the closeness of the batch plant to the work area, the age of the concrete at time of pouring should average approximately 15 minutes. he also added that the ambient temperature in the area seldom drops below 350 F in the winter or rises above 900F in the su=scr.

c. Slump, Stronnth and Air Entrainment Tests The contract provides appropriate procedures and requirements '

concerning these tests as reported in CO Report No. 50-275/69 6.

PG&E's QC procedures include provisions establishing the frequency of tests and the standard ASTM proceduros to be followed in performing and evaluating the tests. The  ;

procedures require test cylinders to be taken on a minimum '

frequency rate of 1 set for cach 100 cubic yards of concrc:' i ma nufac tured. These cylinders of concrete are to be used to determine the strength characteristics of the concrete 1 placed in the structurcs. The procedurcs also require that during the early stage of construction cylinders be cast at ,

time of placement to provido data to correlate strength '

characteristics of the concrete as mixed at the plant and after transportation to the placement site.

~7--

Slump and air entrainment tests are to be performed in conjunction with the casting of all test cylinders. In addition, the procedures require additional checks of slump and entrainment between casting cylindors. Also, clump is to be checked by the laboratory personnel should the placement inspcetor observe variations in the concrete being placed.

Documentation of all concrete test results is to be made on approved forms. All tests are to be identified as to the structure, placement and batch number for future re ferenc e.

d. Curing Procedurce The contract requirements concerning curing of ccacreto have been documented in C0 Report No. 50-276/69-6. ?O&E 's QC procedures designate the placemant inspector as the responsibic individual to confirm that Atkinson follows the appropriate procedures as prescribed in the contract specifications,

e. Placement Control -

Both Atkinson's and ?G&E's QC procedurcs requira that prior i to concrete placement , the particular area will be inspected l by representatives of both PG&E and Atkinson. Each represen- l tative is to sign the placcment card (checklist) indicating that the area has been inspected and approved. Itecs to be inspected and approved included: (1) cleanup, (2) line and grade, (3) forcs and blockouts, (4) reinforcing steel, l (5) inserts, (6) anchor bolts, (7) embedded metal (8) water i stops, (9) joint filler (10) piping and (11) cicetrical.

The inspector commented that the checklist contained no pro-visions for documenting confiraation that adequate personnel and equipment were available for the placement operation.

Both Harris and Friedricks indicated these items would be i added to the list along with a provision for the PG4E l placement inspector to document the fact that proper curing procedures have been implemented subsequent to placement.

The procedure for insuring that proper concrete is delivered to the proper location in the time required is keyed to the batch ticket which contains a mix design number and the time the batch was manufactured. The placement inspcetor is responsibic for verifying that the mix design number

8-is consistent with that shown on his lif t drawing. He is also required to verify from the time shown on the ticket that the age of the concrete is less than 45 minutes prior to authorizing placement.

3. PG&E Inspector Qualifications Provisions in the onsite quality assurance plan concerning qualification of inspectors require that:

a. A record of the job experience and training of each inspector working at the construction site shall be filed with the quality assurance records,

b. PG&E is to certify that the individuals are suitable for the assigned responsibilities.

c. The following requirements are to be used in selecting inspectors.

(1) BS degree or equivalcat academic training in engineering or five years experience in construction prac t ic e.

(2) Thorough knowledge of applicable codes and specifications. l (3) Certificate from an organization which specializes in nondestructive testing training.

Mr. Chandler, Manager, Station Construction, stated that the inspectors will be drawn from organizations within the General Construction Department cf the Company. He did not expect i difficulty in filling the needed inspector positions from the j 4,700 employees in the Department. He added that if sufficient ,

qualified personnel were not available within the company, ~

l' qualified personnel would be hired from other labor sources.

C. Reinforcing Steel (Containment)

Quality control procedures relating to the manufacture and placement of reinforcing steel were reviewed, and discussions were held with Messrs. Lindblad, Carr, Harris and Bain. The following information and observations resulted.

The G. F. Atkinson Company (Atkinson) has contracted with the Pacific i States Steel Corporation (PSSC) of Union City, California, to supply and install reinforcing steel for the concrete structures of Diablo Canyon

9 (Unit 1) plant. The PSSC has retained the Pittsburgh Testing Laboratory (PTL) in Oakland, California , to provide quality assurance of both the manufacturing and fabrication (installation) activitics of PSSC. The Atkinson Quality Assurance Manual contained procedures relating to the following quality assurance activitics of the PTL.

1. Quality Control Organization The PTL quality assurance personnel will be under the supervision of the PTL District Of fice in Oakland. The District Yanager, Mr. R. F. Mikus, is to report to the Vice President, Mr. J. R.

Doubert, of PSSC in Union City. An organization chart in the QA Manual showed the assignment, under Mr. Mikus, of three PTL inspectors at the PSSC mill and four inspectors at the Diablo Canyon site. A footnote on the chart stated that '*Ihc number of inspectors will be governed by workload requirements".

Biographical data and the qualifications of each PTL inspector are to be provided to Atkinson, according to statements in the QA Manual.

2. Quality Control Procedures - Steel Manufacturing Written procedures described the dutics and responsibilities of FIL inspectors at the PSSC mill to include the following:

a. Determine the sequence of sampling of the steci for ladle and check analyses.

b. Observe laboratory procedures of steci analysis,

c. Review all chemical analysis results. (A PTL inspector is to sign the chemical analysis reports prepared by PSSC.)

d. Determine that proper identification and separation (by heat) is maintained of steel billets af ter stripping and

• rolling.

e. Verify the proper marking and identification of finished l bars. (Each bar is to contain, in addition to that  ;

marking required by ASTM A615-68, the number of the heat from which it was rolled.)

f. Select bars and witness the cutting of samples from those for tensile and bend tests. (The PG&2 contract specifications require bend tests on No. 14 and 18 bar. Such a requirement is not contained in the applicabic ASTM specification, A615-68. )

l

g. Witness tensile and bend costs on each heat and bar size.

(Sizes #3 through #11 are to be tested at the PSSC mill.

Sizes #14 and #18 are to be tested at the PC&E Diablo Canyon Laboratory.) A PTL inspector will sign all physical test reports.

h. Verify that all testing results are in accordance with specifications prior to the shipment of any stoc1 to the s ite .

3. Quality control Procedures - Steel Fabrication and Installation at the Site The QA Manual contained procedurcs relating to the following duties and responsibilities of PTL inspector at the Diablo site:

a. Check all steel shipments received at the site, and determine that they are properly identified and tagged.

(Shipments are to be checked against production and delivery order.) Each shipment is to be inspected for damage in t ra nsit .

b. Check the placement of all steel, and verify (by hect number) the location of bars in accordance with detailing drawings.

c. Inspect all welded and Cadweld splicer. (The location of each splice is to be recorded and compared to the detailing drawings . )

d. Conduct random inspections of the quality of deformations,

e. Verify proper spacing of reinforcing steel.

f.

For each Cadweld splice the PTL inspector is to verify and record: The splico number, loca tion (group, layer and run) , pre-hea t , setup for splice (alignment, centering and gap space), post-splice visual inspection, void area,  ;

splicing crew identification, and whether the splice was <

selected for tensile testing. -

Cadweld splices are to be inspected in accordance with  !

Erico Products, Inc. , procedure dated August 1969. This procedure contains void limits for filler metal at the ends of splice sleeves, e.g. , 2.64 square inches for No.18 bar (splice Cat. No. RBT-1876 H). In response to the

( (

i l

~

inspector's inquiry, Mr. Carr said that void areas would be determined by probing the splico ends with a small diameter wire.

D. Containment Building Steel Liner Fabrication and field crection of the containment building liner has been subcontracted by Atkinson to the Pittsburgh-Des Moines S cci Company (PDM).

The Atkinson QA Manual contained quality control procedures to be implemented by PDM. The procedures covered, in separate sections of the Manual, both shop fabrication and field fabrication and crection.

During the current inspection, principal attention was given to the field quality control procedures. The following information and observations resulted:

1. Quality Control Organization An organization chart in the QA FMnual showed a line of "authority and decision" extending, independent of production, from the PDM QA Chief at the site to tiac PDM corporate level management (Corporate Chief Engineer).

Ncndestructive testing (NDT) personnel qualifications are to be on file for those persons employed in that capacity at the site.

The QA Funual stated that the SNT icvol systea l / of qualification for NDT personnel would be followed for all parts which are to meet the requirements of ASFC,Section III, BLPV Code. The SNT level system is not, however, to be followed for the qualification

. of NDT personnel on other components. The qualifications of NDT personnel will be a subject of particular attention during subsequent CO on-site inspections.

2. Quality Control Procedures - Field Erection The Manual contained detailed procedures relating to NDT technic.ucs and the recording of test results. The NDT methods for which individual procedures were available included radiography, magnetic l particle, liquid penetrant and ultrasonic.

I 1/ Society for Nondestructive Testing, SNT-TC-1A, "Recommended Practico for Nondestructive Testing Personnel Qualification and Certification".

l l

I

^

Typical of the several procedures was that relating to radio-gra phy. This procedure, which was six pages in length, contained the requirements and/or provided guidance in the following areas,

a. Equipment This section covered the use of X-ray machines and radio-active isotopes (cobalt and iridium). The applicabic thickness range and source intensity or voltage range was given for each type of equipment as well as the source to film distance,

b. Materials The following film types were specified. Kodak AA or M, Dupont 506, or Ansco Superay A.

The use of lead intensifying screens and back scatter radiation control was specified.

c. Penetrameters The type, location and identification of penocracators, and shims as required, was specified. It was stated that one penetrameter would be used for films ten inches or icss in length and two penotrameters for films over ten inches in length. An exception to the above is the case where a complete circumferential joint is radiographed in a singic exposure. In this case, four penetraceters, equally spaced, are to be used.

d. Acceptance Standards The definitions of unacceptabic weld defects were observed to be consistent with those contained in ASME, Sections III and VIII, B and PV Code, ,

e. Records and Reports Radiographic interpretations are to be recorded. The ?DM form (No. 17955) specified for this purpose provides for the entry of information relating to: type of equipment used, penetrameter and shims used, type of film, welding process, location and description (including sketch) of defects revealed, and disposition (reject, accept or repair).

The form also provides space for the signatures of the radiographer, QA supervisor, -code inspector (if applicable) and the customer 's representative.

3. Non-Conforming or Variance Control The Atkinson QA Manual contained a procedure relating to the control and disposition of non-conforming materials or workmanship. This procedure discussed in considerabic detail the documentation of such deficiencies. The procedure specified the use of a form entitled "Deficiency or Variation Report" (DVR). The DVR is to contain a description of the co=ponent or part, as well as a description of the deviation. For cach such deviation, provision is rode on the form for indicating (yes or no) its detrimental affect on: performance, life, safety, maintainability and/or reliability.

Final disposition approval for "use-as-is" deviations, according to the procedures, is to bc =ade by PGLE. This was a subject of particular discussion betwcon the inspector and Messrs. Bain, Lindblad and Carr. The discussion centored on the inspector's question 'Vith which individual or individuals within PG&E does such approval authority rest?" The discussion revealed that such authority is not currently well defined. Mr. Carr stated that a procedure or instruction is to be prepared for the purpose of clarifying this area of authority within the PG&E project organiza-tion.

4. Miscellaneous Procedures - Not Revicued in Dcoth The Atkinson QA >bnual was observed to contain procedures relating to the following subjects, which were not reviewed in depth at the time of the current inspection.

a. Drawing Distribution and Control. .

b. Construction Plans and Procedures.

c. Material Identification and Storage,

d. Erect, ion, Fitup and Welding Control

e. Weld Electrode Control.

f. Welding Procedure and Welder Qualification Records.

- .14 g . '- Calibration of Measurement and Testing Equipment.

h. Acceptance and Performance Tests.

i. As-built Records and Final Documentation.

These procedures will be reviewed in greater _ depth during future CO on-site inspections.