ML20209B066
| ML20209B066 | |
| Person / Time | |
|---|---|
| Site: | South Texas  |
| Issue date: | 05/29/1981 |
| From: | Gallagher E NRC OFFICE OF INSPECTION & ENFORCEMENT (IE) |
| To: | Wilber H NRC OFFICE OF INSPECTION & ENFORCEMENT (IE) |
| Shared Package | |
| ML20150F241 | List:
|
| References | |
| FOIA-85-378 NUDOCS 8106190079 | |
| Download: ML20209B066 (182) | |
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M M t s 1gg3 , MEMORANDUM FOR: H. A. Wilber, Reactor Projects Section, DRRRI, IE FROM: E. J. Gallagher, Mechanical structural & Metallurgical Section, REB, DRR, IE
SUBJECT:
SUMMARY
OF APRIL 26-27, 980 EETING ON STRUCTURAL BACKFILL AT SOUTH TEXAS PROJECT, UNI (DOCKET No. 50-498; 50-499 On April 26-27, 1980 meeting was held at the IE office in Bethesda, Maryland to discuss the re ution and review of the South Texas Project (STP) investi ' gation findings concerning the structural backfill. Those in attendance were: IE Headquarters STP Investigation Team Members R. E. Shewmaker D. W. Hayes (Region III) E. J. Gallagher R. B. Landsman (Region III) Recional Staff NRR (LPM) , R. E. Hall (Region IV) D. E. Sells J. 1. Tapia (Region IV) . S. K. Chaudhary (Region I) A list of references used for the discussion and review are included as Attachment A. The meeting discussion focused on the following main issues: o Technical adequacy of the structural backfill to meet desige. require-ments. o QA/QC aspects of backfill construction. o Resolution of investigation findings identified in report 79-19.
/
o Review of Houston Lighting and Power (HL&P) responses to Show Cause Order Item 2 Category I structural Backfill.
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MAY 2 91981 Pg. 2 ef 1
%- ' 296
, 1. Technical adecuacy of the structural backfill to meet desion reautrements ,
I A consensus was reached that the structural backfill meets project design requirements. This conclusion was based on the results of the field investigation borings which are presented in 1eferences .4 and 5; coupled with the in place density test results performed during construction. Fifteen borings demonstrate the backfill material to be compacted to a 1 .
. density above specification. The extent of the four local areas found l as a result of the show cause order with den.sities below 80% relative
- density were identified by thirty-four additional borings. An analysis was performed for the potential of liquefaction based on the standard penetration test values. The results indicate a factor of safety greater than 1.5 (with the exception of one test at 1.35) as presented in
, reference 15, section 4.3, Figures 18 & 19).
It was agreed that the liquefaction analysis and results of these four areas as well as the material beneath the foundation mat would be subject to review by NRR geotechnical engineering branch. A task interface agree-ment has been issued with the end of August as a completion date. In addition to the field borings, the in process field density tests - exhibit relative densities in excess of specification requiremerits. NRC inspectors who observed the field and laboratory tests agreed that the test results are reliable. The results of these tests are presented in reference 15, appendix C.
- 2. QA/QC Aspects of backfill construction l .
i Investigation report 79-19 identified certain QA/QC deficiencies with j respect to backfill construction activities which included: i o Backfill compaction was not performed in accordance with a s ( qualified procedure (finding 79-19-18). t o Corrective action had not been taken to c~orrect nonconforming laboratory test equipment (finding 79-19-22). o Procedures for a syst'ematic sampling (i.e. , location and depth of soil tests) had not been established (finding 79-19-21).- o Quality control inspections did not document specific controls (i.e., soil layer thickness or number of roller coverages) identified as contruction requirements (finding 79-19-24). o soil penetration tests were performed using nonconforming equip-ment (i.e., hammer weight and split spoon size)(findings 79-19-27 and 79-19-28). HLtP submitted reference 3 on May 23, 1980 affirming the above findings and identified corrective actions taken. It was agreed that the actions taken by HLAP were acceptable. Notwithstanding the above findings, the conclusion reached on the technical adequacy of the backfill to meet design requirements remains valid.
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EAY 2 91981 Pg. 3 of 5 3
- 3. Resolution of Investication Findings ,
l The summary of the NRC investigation findings contained in report 79-19 (reference 1), HL&P's response to the investigation report to show cause ' order item 2 (references 3 and 7) and the status of Region IV inspection followup (references 6, 9,11,12,13,14, and 16) are presented in ! Attachment 8.
' The resolutions to each of the investigation findings (items of noncompliance !
and unresolved items) were discussed. With*the exception of five items, all present agreed that the findings have been satisfactorily resolved. The five items include: o Findings 79-19-18 and 79-19-58 pertain to the compaction method used and the basis for the specification limit of 8 roller passes and a maximum 18 inches layer thickness. , The differences in approach to resolving these items are academic since the field borings demonstrate the in place material was compacted to above specification requirements with varying methods used during compaction.
~
o Findings 79-19-19, 79-19-26 and 79-19-30 pertain to the values used in the liquefaction analysis presented in the SAR and the liquefaction potential of material actually used. It was agreed that the resolution of these items are further subject to NRR geotechnical engineering branch review.
- 4. Review of HL&P Responses to Show Cause Item 2. Category I Structural Backfill On July 28, 1980, an HL&P submittal (reference 7) addressed show cause
! order item 2(a) through (e). The submittal indicated an independent review committee was retained to assess the engineering acceptibility of the , . Category I structural backfill. On February 27, 1981 HL&P submitted the ! " Final Report Concerning Show Cause Order Item 2, Structural Backfill l
Investigation" (reference 15). - A review of the HL&P final report was made resulting in the following comments: o The overall conclusion (Pg 56) that the condition of the fill meets the project requirement is supported. This was based on the results of the field borings and in place density tests as previously described. o The statement "that the vibratory rollers are capable of compacting the specified lift thickness to the required densities" (Pg 56) is accurate, however, it does not qualify under what conditions 18 inches lift thickness can be compacted to achieve the required results (i.e., moisture content, no. of passes, equipment speed). 2 The text,of the report (Pg 30) does state that, "It is to be noted that 16 to 20 or more passes are presently needed to consistently l meet the specifications." This is illustrated in reference 15, l figure 16. The specification required only a minimum of 8 roller
! passes, however, it included a performance criteria of 803: relative i
l _ _ _ _ _ _ . _ . _ _ . _ _ _ _ _ , , _ _ _ . _ , _ _ _ _ . _ _ _ _ _ __ . _ . ~ _ . _ _ _ _ _ _ _ _ _ _ _ _ _ _ . . _ _
MAY 2 9 381 Pg. 4 of 5 298
- density. Specifying a sinimum method that does not consistently ,
achieve the desired "and results" is not an effectiv's manner to assure a uniformly compacted material. 1 o The final report concludes (Pg 56),,that, "eight roller passes is a satisfactory minimum compaction to obtain engineering integrity and safety, and a proper startina point for acceptance testing"
~
During the meeting it was determined that a high degree of original Q.C. tests did not achieve specification requirement and necessitated rework of the area until a retest was taken to accept the material (i.e. , Unit 1: total of 2571 tests with 619 retests (24%); Unit 2: total of 3127 test with 854 retest (27%)). This may indicate that 8 roller passes was not an effective starting point for testing and assuring a uniformly compacted fill. The in process. tests are intended to be representative of saterial previously placed to that point during construction. o The final report concludes (Pg 55), "that with the type of compaction equipment used, the number of passes actually accomplished and the thickness of the layer placed, a dense,
- homogene'ous, compacted structural backfill resulted which is adequate for the intended use and is generally in accordance with specification requirements."
W5at was "actually" accomplished is not documented, however, it is agreed that in order to achieve the in-process test results (reference 7, Appendix C) it must have been in excess of the, . minimum required. It was agreed that the fill is in accordance
- with specification requirements except for local areas as identified by the borings.
- 5. Summary Cenclusions '
o Structural Backfill meets project design. requirements based on results of in place density tests and field investigation borings required as a result of the show cause order. o QA/QC deficiencies were identified in report 79-19 and HL&P has taken corrective action, o Investigation findings have been satisfactory resolved with the exception of those subject to NRR geotechnical engineering branch review concerning liquefaction potential. l l -
. 1
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~ ~
NAY 2 91981 Pg. 5 cf 5 299 o HL&P conclusion in final report response to the show cause order that the fill meets project requirements is supported. Eugene J. Gallagher
=
Mechanical, Structural
& Metallurgical Section Reactor ' Engineering Branch, RRRI, IE
Enclosures:
Attachments A & 8 cc: J. H. Sniezek, IE E. L. Jordan, IE R. W. Woodruff, IE R. E. Shewmaker IE H. Wong, IE R. E. Hall, RIV J. I Tapia, RIV S. K. Chaudhary, RI - [D.W. Hayes,RIIIRIII
. W. Landsman, D. E. Sells, LPM, NRR D. Gupta, NRR e
e D l l l l l
Attas.hment A
^
300 LIST OF REFERENCES .
- 1. April 28, 1980: IE Investigation Report 79-19. ,
- 2. April 30, 1980: Show Cause Order.
! 8.. May 23, 1980: HL&P's Response to Investigation Report 79-19.
- 4. May 28, 1980: Woodward-Clyde Report 6000-11-1, Relative Density of Structural Backfill, STP.
i
- 5. May 28, 1980: Woodward-Clyde Report 6000-09-1, Relative Density of Structural Backfill, STP.
- 6. July 16, 1980: IE Inspection Report 80-17.
- 7. July 28,1980: HL&P's Reponse to Show Cause Order.
i
- 8. August 6, 1980: Woodward-Clyde Report, Analysis of Soil Test Boring Split-l Barrel Shoe Confirguration. ,
- 9. August 6, 1980: IE Inspection Report 80-19.
- 10. September 30, 2980: Woodward-Clyde Report, Standard Penetration Test Evaluation and Validity Report.
- 11. November 6, 1980
- IE Inspection Report 80-24. -
- 12. De:e'nber 3, 1980: IE Inspection Report 80-30.
i 13. January 30, 1981: IE Inspection Report 80-38. , l 14. February 11, 1981: IE Inspection Report 81-03. ,
- 15. February 27, 1981: HL&P's Final Report Concerning Show Cause Item 2, Structural _ Backfill Investigation.
- 16. May 7, 1981: IE Inspection Report 81-10 .
l 4 9 f
i ATTACittENT B , StNetARY OF SOILS INVESTIGATION FINDINGS, . P HL&P RESPONSES AND INSPECTION FOLLOWUP NRC INVESTIGATION HL&P RESPONSE OF HL&P RESPONSE OF REGION IV REPORT S/23/no TO 7/2n/n0 TO Sit 0W INSPECTION l FINDINGS 79-19-( ) DESCRIPTION INVESTIGATION FINDINGS CAUSE ORDER FOLLOWUP STATUS I
- 18 Backfill material Item A-2 80-17, Pg 3 Closed (noncompliance) was not compacted Page 10-12 Item 2(a), Pg 2-8 to 80-24, Pg 17 l Show Cause Order in accordance with 2-12. Item 2(e), Pg 80-30, Pg 3 1
Item 2(a) & 2(e) a qualified proce- 2-31 to 2-32. I dure based on results i of a test fill. I I l 19 Concern that the No response Item 2(d), Pg 2-28 80-24, Pg 10 Closed l (unresolved) upper portion of the required to 2-31 Show Cause Order last lift of backfill
- j Item 2(d) underlying building 1 mat foundations was l
not compacted to require density. l 20 Observation of exces- No response No response 80-24, Pg 11' Closed (unresolved) sive number of roller required required loverage during test fill program. l 21 (noncompliance) Systematic sampling No response Item A-4, 80-17 Pg 5 Closed for soll testing Pg 15-16 required - program had not been established. . e e O l CO CD l Fa
Attachment B paIge 2 cf 7 . j 22 Item A-3 No response 80-17. Pg 4. Closed - i (noncompliance) Corrective action Pg 13-14 required I i was not taken to correct nonconforming i soll testing equip-l ment. l I 23 Quality records did No response Item 2(c). Pg 2-17 81-10. Pg 2 Closed { (unresolved) not document 11f t required to 2-27 Show Cause Order elevation corre-j Item 2(c) sponding to soll , test. i 24 Inspection verift- Item A-5 No response 80-19, Pg 2 Closed
- (noncompliance) cation of soll Pg 17-18 required placement 11ft I thickness and number
- l ef roller coverage
~
- was not documented. -
25 Laboratory density No response No response 81-03, Pg 3 Closed (unresolved) tests were not per- required required . formed wet & dry as prescribed by ASTM . 1 procedure. , i i 26 Observation that No response Item 2(b), 80-24. Pg 11' Closed l (unresel-ed minimum & maximum required Pg 2-12 to 2-17 l Show Catse Order densities deter- - Item 2(t) mined in the field l differed from those - , l values used for ! liquefaction analysis ! & results presented ' j in the SAR. . l CD to l
Attcchment B Page 3 cf 3- . I ! 27 Nonconforming hammer Item A-16 No response 80-17, Pg 5. Closed - I (noncompilance) weight was used required l during standard 80-19, Pg 5, L penetration test borings. 28 Monconfoming equip- Item A-17 No response 80-17, Pg 6 Closed (noncompilance) ment (split spoon required size) used during test borings. 29 Comparison of No response No response 80-24, Pg 11 Closed (unresol est) Standard Pene- - required required tration Test borings using nonconfoming - equipment (i.e., , hammer & split spoon). 30 Loose material No response Item 2(d), 80-24 Pg 12 Closed (unresolved) identified during required Pg 2-28 to 2-31 . Show Cause Order boring f204, near Item 2(d) base of unit 2 foundation mat. 58 Basis for specif1- No reponse Item 2(e), 80-30, Pg 5 Closed (unresolved) cation requirement required Pg 2-31 to 2-32 80-24, Pg 19 Show Cause Order for backfill com-Item 2(e) p' action with 18 inches lift thickness. 80-17-01 Procedure for No' response No response 80-24, Pg 5 Closed - (unresolved) sampilng top required required . J 1ayer of backfil). " O CO
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6e' 71-l9~lII 321 In addition, the FSAR in Section 2.5.4.5.6.1 states that the maximum lift thickness for structural backfill would be 18 inches where
'there was unrestricted placement . B&R' Specification 3Y069YS029,
' Rev. F, also indicates the 18 inch maximum lift thickness. The inspector reviewed the document purported to represent the results of the test fill program (See section E.3.b herein). This indicated that the test fill program resulted in the determination that for 18 inch saximum lift thickness, it would be necessary to make 12 passes with the compaction equipment. The inspector reviewed the associated construction procedure, STP-QCP A040KPCCP-2, Rev. 2, Structural Backfill, and determined it required only 8 passes.with the compac-tion equipment for the maximum lift thickness of 18 inches. ,
The failure to complete backfill compaction, a special process, in accordance with a procedure that reflected the qualificatfon proce-dures used for an activity affecting quality.fs a noncompliance and
' is contrary to the requirements of 10 CFR Part 50, Appendix 8, .
Criterton IX as dis. cussed in Appendix A of the report transmittal letter (498/79-19-18 and 499/79-19-18). I Sr-17 (open) Infraction 50-498/79-19-18; 50-499'79-19-18: Failure to Coeplete Backfill Coepaction in Accordance with a Qualified Procedure. During this inspection, Brown & Root (BAR) Technical Reference Document (TRD) No. 3A700GP002-A, " Test Program for Co=paction of Category I Structural Backfill " dated June 2, 1980, was reviewed. The purpose of this test program was to provide assurance that the construction methods defined in BAR Coestruction Specification A040KPCCP-2 were sufficient te produce a backft11 which satisfied PSAR cormittaents of 80% Relative Density throughout the layer, including that backfill in the top of previously 3 99* .****M < y ** * * " " y - -
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322 _ , m .. placed layers. ,. . . - Preliminary test data were reviewed from the test fill
- program performed for 2, 4, 6. 8 and 12 passes of the compaction These data verified increased compaction of the interlayer bou ent.
Ior the entiredid bevever, not produce underlyi.n,g leyer. consistent retults above 80% relativ The test is continuing,-and ,results will be incorporated into the response to Show Cause Order Ice 1 Portions of the compaction of the test fill area were this inspection; acasurement of the vibration frequency ofcompactor the observed observed being performed in the test fill.and three subsequ e were observed during this inspection. No discrepancies with the TRD differences coepaction verebetween noted: ~ the test fill and normal backfill placement and
- s. ,
The water application methods observed for the test f.ill were ' different in that water was applied insediately on the ro!!er and im=ediately' ahead'of the roller during the test fill. For corr.a1 backfill, wetting .of the area is more generally applied.. b.
) Surface protection and preparation for rolling of the test fill were more carefully controlled relative to normal backfill. . '
The potential for these differences affecting test results will require evaluation in the test fill final report. Results of the original test fill program procedure verification program (1977) were(also reviewed.1976) and the c These data
' ofreg'uTemen,t to cocpact the newly placed lifts wit the cocpactor before relative density testing.
e These tests though not well documented, were apparently used as the basis for change e,arly construction froe 12 to 8 passes before testing. Since the test fill program is not yet cocplete, and since the soil boring and test program is still being evaluated to support a respons to Show Cause Order Ites Number 2, this ites will remain open . f I
.r *. -
323
$0 00 . (C1csed) Infraction (50-498n9-19-18; 50-50-499n9-19-18): Failure to
[ Completa Backfill Compaction In Accordance With a Qualified Procedure.
- Brown & Root Technical Reference Document (TRD) No. 3A700GP002, Revision 8, " Test Program for Compaction of Category I Structural 8ackfill," dated September 29, 1980, was reviewed durina thfe insnectiaa- This TRD revision documents the compiefed test fill program and includes a synopsis of pre-
- vicus test fills and of the unrestricted lift qualification program.
The latter program was required by the backfill specification to demon-strate, in the first twenty in place density tests, that satisfactory densities could be achieved prior to proceeding with full scale backfill placement in Category I areas. The specification requirement was used as the basis for documenting the adequacy of the construction procedure. The complete TRD report has also been reviewed by the Independent Review Committee anc the conclusions ha,* been incorporated in the licensee's respense to tne Shew Cause Order. The response to Show Caysa Order Items V. A.(2)(a) and V. A.(2)(a) wara reviewee during Inspecticn No. 50-493/80-24; 50-499/80-24, and specifically address the test fill prcgram which established the in place density testing criteria and the use of 18 inch 1cese 11fts. Based on the review of these Show Cause Orcer responses and of the T,RD, this item of nonc:mpliance is closed. 3 Co-1.V
.3 (Closed) Show Cause Order. Ites V.A.'(2)(a): Provide Information to
-- Address the Test Fill Program Wich Established the Seil Cooditions,-
17
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824 Ltft Thackness, Compactive Effort, and Equipment Characteristles Necessary to Develop the Necessary In-Place Densities. A test f all program was performed by the licensee for the purpose of providing nev fara to
- s_upport the field Dlarement criteria previously established. This test fill program was addressed during .%'RC anspection .No. 30-498f80-12; 50-499/80-12. During this inspection, the,IE inspector reviewed the procedure used to perform the test fill program. Technical Reference Document No. 3A700GP002-A, " Test Program for Compsetion of Category I Structural Backfill," and the results of the program as documented go/ % in the licensee's response. In addition, Menorandus No. SC-00993-JDC.
,/ $g/ t dated June 16, 1976, documenting the test Ell originally used to -
establish the construction methods and equipraent to be used in the
/ placement of Category I structural backfill, was reviewed. This
( sesorandum shows that the density of the jewer 18" lift _is incre.ised f significantly by cocpaction of the lift above it. The results of 12m . I{W this test fill were used to establish the minimum nucher of passes feltiated in the lower lift. Thiscriterish g'". f;. . required before test'ng If was established'as sa
~
f consideration to' limit coassencement
)-
of the in place density tests until it was felt that specification ph* density had been achieved. The criteria chosen was a minimum of 8
, passes on an 18" lift before testing commenced. If density was,not reached, additional passes were then added.
construction procedure was verified by the so_The__ nt recent adequacy.af test fill this prosHm. The Expert Coemittee of Independent Engineers (Dr. 5. Bolton Seed, Professor of Civil Engiceerns, University of California; Dr. A. J. Rendron, Jr., Professor of Civil Engineering, University of p 111inois; Stanley D. Wilson, F.E., consulting Ecgineer) have reviewed G'sA,( e the test fill progras results and have documented their findings ia the " Int 1ria Report to Brown & Root on Adeguacy of Category I Structural f'@ Ra ckfill ." This report show cause response. is independent attached, as ~ Exhibit 9, to the licensee'.s _TLas concluded that I
' The cossaittee s g a.8-- testing of the uner portion of the underlying lift produces conservative y I geJ t h results used were when also a sintrum judged by theot,s_independentpassescommittee,isThe used. construction procedures
" correct to determine d.N p- the point of starting in-place density testing." Based on the reviews performed during this inspection, the licensee has satisfied the Show b Cause Order to provide information to address the test fill progras
>l used to establish in-place density. testing criteria. .
h g [ This ites is closed. g 1 go-2+- (Closed) Show Cause Order, Ites V.A.(2)(e): Frovide Information to Address the Rationale Behind the Use of 18 Inch Loose Lifts Compacted by 8 Passes of the Equipment to Achieve' the Required Densities. During this inspection, the 11 inspector reviewed the licensee's response to this show cause ites. The 8 passes referred to is the minimus required cospective effort prior to in-place density testing. The .
. ~
ase of this suaber is based on the gest fill program conductedin May 1976 acd on recamnendations from the vibratory roIIer sanufacturer. ' % F '+C5. 751ti construction criteria has beert verified by the test rail program 3-conducted in June 1980. (a) for more detail. See the closure of Show Cause Order Ites Y.A.(2 Based on the re~iev :erformed by the IE inspector (g during this inspection, the ites is considered resolved.
.. 5 ,- . s .:s . .. . .
This item is closed. '
~
. ?HN1 Because of observations in the field, Woodward-Lundgren's special
. study, discussions with the S&R sofis' engineer and ht&P field personnel and a literature review, it is evident that the upper part of the
= last lift of the backfill material used at STP "cannot" be compacted using the current methods. Ctven this fact, at least six to nine inches of material beneath Category I buildings probably does not ,
iteria. B&R's cognizant engineer, when questioned I seet aboutcompaction the loose fi cr,ll, indicated that they have literature that l fndicates loose material under the structures is satisfactory. This item remains unresolved pending review of the B&R literature (498/79-19-19 and 499/79-19-19). , fra # (Closed) Unresolved Ites (50-498/79-19-19; 50-499/79-19-19): Coepaction i of Upper Part of Last I.ift. This ites was addressed in Inspection Report No. 50-498/80-17; 50-499/80-17 as a part of infraction Ifo. 50-498/ 79-19-21; 50-419]J4:19-21. The licensee response to the NRC Show Cause Orde r, de cTIoit Ill{dl addresses the performance of the top layer of backfill insediateTfTelow mat foundations during postulated earthquake loadins ' conditions. Dr. E. Bolton Seed, a ser.ber of the South Texas Project - Independent Review Committee, analytically determined the factor of ~ safety against liquefaction for a four inch layer of backfill at for1Y-five percent of relative density and a layer four to ten 10ches deep at a 7 elative density of sigv i sercent. The minimum factor of safety against liquefaction was determined to be 1.85. The fact that the top layer of Lackfill placement is subject to additional roller passes according to the construction procedure indicates that the relative density of the top lift is higher than that assumed in the aerlysis. This fact is also based on the statistical results which . show mean relative densities of the layer from four to ten inches ', l-deep for Units 1 and 2 of ninety-eight, and sinety-four_ percent. respectively. In addition, th'e top four in'i:hes of backfill is subject [ })! to the cementatious effect of the mortar in the six inch aud slab _ b, '., which is applied directly on the upper backfill lift. The high confining stress resulting from the building load will also serve against .. c the buildup of excessive pore pressures. These factors resolve this - i t e,e . . This ites is closed. . .. 10
^
qq,Jo C 320 Subsequently, on February. 6,1980, as a result of the NRC findings, the licensee conducted a site test fill to demonstrate that 18 inch
- lifts could.indeed be compacted with only eight one-way passes of
. the equipment in use. The results of this test fill had not been
*
- fully evaluated as of February 21, 1,980 and had not been provided to the NRC. During the conduct of the retest of fill placement the NRC inspector and the licensee's representative observed that the compac-tion equipment roller was overlapping a full half drum width. Thus, the center section of the test fill would have received 16 passes instead of the specified eight of the field procedure. The licensee, fc11owing questioning by the NRC, stopped the improper rolling of the test fill. The matter remains unresolved pending review of the test fill resu'lts (498/79-19-20 and 499/79-19-20).
y.p - . a . . ~ - n , w w : w w . . y ..--. ~ ..-. - - .w. z F
/ .
iClase.1) Unresolved Ite:n (50-498,'79-19-20; 50-499,19-20): Excesstve Nu=ber of Roller Passes. The NRC observations of excesstve overlap were b.ased on the test f all program attempted in February. This test was ' performed without a procedure addreistng saxtmum peratssible roller
, overlap. Revtsions to Construction Procedure No. CCP-2 in August. 1980 spectfy saximum roller overlap crateria. The test fill progrJe was subsequently perfor=ed in adherence to the requirements during the period of June through July 1980. Observations by IE inspectors, during the July test fill develope.ent, confirmed the proper use of the compaction equipment. This retesting resolves the matter.
This item is closed. l l 1 l l l l l l 1
i er #
-7.~$.N.i((U'
~
fne a6ove documents were reviewed for basic scope, completeness, censistency with referenced codes, standards and MRC regulatory 7'O.- : : c 'd .. : utdes and for reference during inspection of field activities and i --l- fnthereviewofqualityrecords. The following procedural deft-
'~
-W ciency was discussed with the licensee:, PTL's QA Procedure No.
.- 25-511-D-1556-64 requires that the in-place density seasurements are to be performed according to ASTM D-1556. However, there are no instructions in the PTL procedures as to what depth below the back .
fill lift surface the test should be performed. A review of FTL's density records and discussions with soll inspectors indicated that PTL inspection personnel have been performing density tests at various test depths. This failure to establish procedures for a systematic sampling technique as part of a testing program to verify that the required densities are being obtained throughout the placement lifts is contrary to the requirements of 10 CFR Part 50, Appendix g, Criterion V, as discussed in Appendix A of the report transmittal letter (498/79-19-21 and 499/79-19-21). BH7 ' (Clesed) Infraction 50-498/79-19-21; 50-499/79-19-21: Failure to Establish Frocedures for Systesstic Saepling as Part of Soil Testing Program. The 11 inspector reviewed the changes in procedures effected by Document Change Notices 3YO69YS029-F/DCN/2 14-80, and 2Y06055033-C/DCN/2-14-80 and ' 6-5-80. These doeueents and FTL Tield Change No. 042, dated February 19, 1980, to the QC Procedure QC ST, Revision 4 were reviewed for content, and applicability of the proposed changes to the items of noncocpliances. Based on tSe review of the above indicated documents and discussion with M licensee and consultant personnel, the It inspector determined that the gchanges effected in the procedures by the above documents adequately resolve the noncompliances regarding depth and location of in place testing of granular backfill in all layers except the very top layer. p[ These procedural changes are consistent with the RIAP answer to this pg 4 ites of noncoepliance; however, the licensee indicated that the re-solution of the in-place density test depth and location in the top layer is still under engineering svaluation. This resolution will be based on experience obtained with the new procedure and analysis of the test fill program. Procedures relating to the sampling of the top back-fill layer will be revised to incorporate the requirearnts at a later date; i but before the work on the top layer begins. A DCN to Specification 3Yo69YS029-T (DCN 4-25-80) has been issued to prevent placement of top lifts of Category I structural backfill until sampling provisions can be defined and incorporated into the specification. < This infraction is closed; however, during a subsequent inspection, the anticipated changes to the specification and resultant procedures changes will be reviewed. This is considered an unresolved ites. (Unresolved Ites 50-498/80-17-1; 50-499/80-17-1. , , __ _ _ i
. .fe 323 p.M This ites is closed. ,'
(Closed) 1Toresolved Ites (50-498/80-17; 50-499/80-17): Procedure for '
'* Sampling Top !.ayer of Backfill. The It inspector reviewed the change to the structural backfill specification effected by Docu.ent Change I
No. 3Yoo9YS029-T/bCN/?-23-80., Thi,e change provides crtteria for testing "of backfill top lif ts immediately below foundations. Pittsburg Testing !aboratory (PTL) Tield Change Request and Approval No. PT-fCA. 049 was also reviewed. This revision to the PTL procedure for backfill testing, incorporates the..B&R specification critstta. These criterta are based on detailed studies 7erformed by the Independent Review Cocnittee and conservatively satisfy the unresolved ites. See closure of Unresolved Ites 50-498/79-19-19; 50-499/79-19-19 in this ' report for detatls of the anal) performed by the coccittee. t e l l E
6 - -- - 774142 Ot . 329
~
- c. Soll'Samplino Program A comprehensive soil sampling (testing) program must be implemented at the beginning of backfill operations to verify the consistency of the backfill placement procedures and to insure that the specified .
densities were obtained. The FSAR in section 2.5.4.5.6.2.4 and B&R's Specification No. 3YO69YS029, Revision F, paragraph 9.e. and B&R's Procedure No. A040KPCCP-2, paragraph 3.3.3.5 require that at least one relative density test be performed for every fourth field sand cone density test. A review of PTL's relative density laboratory data on December 18, 1979, indicated that a relative density test had not been performed since Mcvember 17, 1979, although plant backfill material continued to be placed during that period. Furthermore the i testing laboratory personnel failed to document and correct this nonconforming condition. Discussions with the PTL cognizant indi-vidual indicated that the relative density test apparatus had been out of service since November 17, 1979 and had been breaking down .
. periodically during the previous month. The test equipinent was replaced and relative density testing was resumed on January 7, 1980, nearly two months later. Plant backlift continued to be
. placed during the entire period of the equipment breakdown. Subse-quent tests on the retained samples indicated that the required relative densities had been set.
The failure to take prompt corrective action once the defective equipment was identified and the failure to preclude repeated cases of tests not being performed is in noncompliance with Criterion XVI of 10 CFR 50, Appendix B as discussed in Appendix A of the report ' transmittal letter (498/79-19-22 and 499/79-19-22). - so -i7 - (closed) Infraction 50-498/79-19-22; 50-499/79-19-22: Tailure to Take Proept Corrective Action When Test Apparatus Failed, Halting Testing. Daring this inspection, it was verified that a backup vibratory head and a spare sold for measuring relative density had been procured and both were available on site. R&R Instruction Letter SQA-3329, dated February 1, 1980, was reviewed relative to clarifying subcontractor responsibilities concerning identification and reporting of nonconforming conditions. It was verified through review of Pittsburgh Testing Labortory (PTL) Docu=ent Dissemination signature sheet that each FTL employee on site had reviewed SQA-3329. This ites is closed. 1 o 4 1
.o 330 7 M -23 B&R Specification No. 3YO69YS029, in paragraph 7.1.e. requires that the backfill saterial be placed in unifore layers not exceeding 18 inches of loose thickness. Paragraph'3.3.3.2 of B&R Procedure No. CCP-2 requires that the minimum number of passes of compaction equipment will be eight one-way passes. A review of the test records and procedure indicated that neither the procedure or the test record Form SF-6, "In-Place Density Test by Sand Cone Method,"
required this important information to be documented. It was determined from discussions with PTL's personnel that the lift number on the test record has no relationship to lift elevation in a specific area. The NRC inspecto,r and HL&P. personnel attempted to obtain elevation data on consecutive lif ts in a specjfled area f'f ~ g from other QA records to establish that the fill had been',placed
- systematically and uniformly in 18 inch layers and compacted accordingly. However, due to the method of lift numbering and system of filing, this could not be accomplished during the inspec-tion. The 11censee is continuing their efforts to assembTe this data. Further review is planned for future inspections o6 this .
unresolved item (498/79-19-23 and 499/79-19-23). 8He f w-
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331 [l-fd CET Af t. .
- 1. Persons Cor.tected
' Principal Lic ensee Ercin:.ee. .
R. A. Frazar. Manager, Laa'. i ty Assur anct
. *R. A. Carve' . Project 01 5.rt rvisor - I". :1 L. D. Wilscn, Project Qt Supervisor - he1Jit.g R. J. Viers. Senior OA !se:iclist B. R. Schulte, Civil GA Spe::alist T. H. McGriff, Civil GA Specialist G. W. Steinr. ann, Lead Site Engineer - Civil Other Personnel
- 5. C. Pettersson, Lead Geotechnical Engineer, Erown ar.d Root (E>.R)
R. Rorier, Area Civil Er ginee r - RCB-1. ESR G. Cook, Field Engineer. E&R C. Younger, Project Site En ineer - Civil / Structural . Esc. P. Steger, Lead Site Engineer - Civil /Structu-a', B!' C. M. Singleton, Civil 0C Superintendent, B&R The NRC inspector also centacted other licensee and contractee r<rscret' including merters of the OA/DC and engineering staffs. t
'Denotas attendence at ttc esit interview. ,
- 2. Licensee Action on Previtas Inspectien Findir.rs During this inspection. licensee action taker. to Fest: sc the ' l'.0 win; unresolved item identified in 'nvestication c i - - . '. - ~'-49c/'t 'o.
50-499/79-19 was reviewec: , (Closed) Unresolved Ite? (SC ace /79-19 '3: ci 49 ~4-19 3: F.c c :*d . of Fill Lifts Versus Lccatio, it. Sect r t; -ecenstr,ct F il t'acement Procedure Lacking. The sub ect unresolvec item nos bee . ir.:errerate: in the licensee's response to Show Cause Creer item Va(2;.c). Flan . views and profiles to shnw the >* cue-ce r:
- ni fill r ioce-e : h a . .-
been developed. Tht clesure o' t>c Show t c. c c e se - Ite- 1, o.~a-cere-a:c: ty t r. ' s graph 4 of this re:i rt re t al .es t*=c isan i :r.t!1 un re sol ved i ter.
- 3. Concrete Placement
+,-
Ey letter, dated Jar.uarv R.19R1. the li er.see t re uested a '- .r,.c res 3 -
.-. s: 7. ,
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The sesenth place ent ma . otterve.; t> tr.e NFC r *.: e .to, carir: l l
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L 5'. 332,+].9 .. 1 (g,6 w Thit piece ent (he. CS-W18) r.c -isted c t~ :- - te- .;- f% 69! Ur.it 1 Reactor Containment Builc ng. Tr e 0:. ',e v' r Di '. .+ ~ ni _ .c consolidation tec.tnic;ues were .fo nd to be in acrerdar. ' witt eua'ity;
~
pi Control Construction t rocedure Nr. A040r.FCCP-25 and e.ntistent with M standard industry practices fr- tne succersful o' ace . cf c . cretr . c e, A review wa) condacte: of t.he c.ality centrei ro.cro: 'cr t . 'r-
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six ccriplex concette riacererts. Frm tr.- revie- a n.: t r:: - .- f, cussions with cogr.icar t peronrei, it was deter ; red t' n ne - t:r'- ". :- for air content cf Grout Mis Ide' tificatien No. *-C-7.15 ti..e: ::c: Ie-F pe rformed. Brown e .c Root Interc f fice he.cranda- ho. ' v-4u 7.
" Approved Concrete Vises. recuit es that tr.e air ccnte-
- fe" re.*
I:lu- . Mix Identification No. A-0-3-15 r at encee.1 10 oercent. T h i . rv - .rr*- K4 dum is an attachment to approved field Chance Ee".se t *,. ,- 5. W-to Brown and Root Specification he. 2A010f_5001-G The Field Char.ge Feasest served to coeurient the currer.* approvec con-Cor.. rete so;.r.. . p g2, crete and groat r ixes. The faticre to te t for e r cc. ent cf e at wa in order to assure co pliance with tne de,ign camirt.cfr. -7ur.t 4'i:: +: 1- - I ,;. represents a failure to meet the recairervrts o' Critt- On *
** FE E 't Appendit B to 10 CFF P rt 50 and is there'ere a cola *. n. y.y p.
Licinsee Resscnsa to Show Cause C-der--
- (,..
r-p The NRC inspector resiewed the it :er we's retoe .n tr - . .- . Order transmitted to FL&P by S 0 tetit . .eted 4 r 1 l following items were addressed: [-, ! I * (Ckosed) Shcw Ca.cse Order it. ?>r -1: e . . t c< n t- ' Address the Sequ+ nce of Censin,ction ef L ..t rig - i
. h. .. ,
3
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the 1.oose Lif t T*.ickness and NW er of Passes rf *- ! . . E Independe-t Empe rt Revie., Cte-rittee's riru ter: .r- r. r - er ' dated Jinuary 11, 14 ' . e s - '- .re Cause Order Ite- ?.* ' bH inspection. Section a.8 cf :nt C ntte a- ~r- c- -
.t e review of the Et /HLAP 5pect il Teoe r r,c . . .cf .
Show Cause Order Ite . I t m is the f.o : t ts a : d. ~ i:
- - ** c a:
t.ackfill rlaceer*.ts can oe r.>cc s:rarte f er.- tho -
-te~ (d
; Gr:
records. The Ta k Force c'ft,rt 1: r uc . r .. a in '. r -'e. Cucament No. 3A730GP001-L. ":sts - l ;:e . .c a i ..,- ac. *7 and Quality Control Data.- This dncrent w- - w -1. r- :e.r- Ip'3 l - . , -
.: t -
I caring this int N tion rcrnets et,r.! re--c e
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four fror' each u .it , wht - w ra cree b c r 1 ' - t t " ,s - # - ss l 'nspection r eports , Soil'. in .;a c t r . Ct. M ,t'. a- r . .- Rep.rts. The crr:ss sect:n '. st. * '. "n - - + ev . {['e: , (cwrpacted I f f t t'.ickness c ' ' - -- <'.- - -i - I *nspection Checklist notatic ., tr. : '+ *' * : *. - - .
. i wr t i 'k* ;i .
l or less. The li't nuicr'nc U : Pr r e e'.t : 1 .* M 3ar 4:n ebcr - [] area also ctver, tne part1(.sio l '.
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- or . *h rn:-t t rtr- f.P. )
*tates t"at the *-tal nu-icr r-
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, 333 3 density testing. The developrnent of the cre" sectier.s frur tr . ri N1 quality control records is used as a basis to deronstrate tnat tv backfill was placed in a determinate sequence. Based on the revir h9 of this docurantation perforfed during this ins 9ection, the NRC inspector concluded that the Itcensee has satisfied the ShN Cause $
a
" Crder to proode information to address the sewence of corstructm of existing backfill inclucing the loose lift thicknes: anc nu.ne- h of passes of the equiprent. 3. r, This iter is closed. .;
g (Closed) Shc>< Cause Order item VA(2)(d): Provide Ir:f:r-ration to Ad:fre:s the Ade:uacy of E~aisting Eackfill Fateria! Inc!udir.: The' [ Under Structures Founded or Backfill. The Independent Expert q Review Cocrittee's " Final Report Concerning Show Cause Orde-Item 2' also addresses the engineering adecuacy of the in-clace ' J density of tne Category I structural backfill. Their evaluatien L is based on considerations of the backfill r.aterial properties, ' j'. the construction techniques, the in-place density test results, f and the boring program. The Cocrittee has concluded that "a dense, is. homogeneous, co pacted structural backfill resulted which is adequate for the intended use and is generally in acco-dance with f. specification requirerents." Four small, isolated zones detected G by the boring program, which indicated a relative dc.ndity 'e.ss tr e- - M construction quality control criteria, were anlayzed e d foand tc. bf have a factcr of safety against lic Jefaction of creater than 1.5 rc for three zones and a minitram factor of safety of 1.2i for tne 'c ru.. .
?
The Comittee further conc 19ded tha:, since the bor g loc.i'iens n e Selected in an unbiased F.ar9er, their nuter is adent'e to prov ce [*. .f a representative sarnple of fill conditions. The actua field certal M procedures for placement of the fill aro for deterrinin relative :; i density were fcand to yield a statistically deten-ired +e reia .<. R density of 95 percent with a stan::ard deviatier of E 5 '
- ne 0.
statistical an.elysis furtrer shcras , with a 9's r.+ -ce - c' t. ' - de .ce, that less than 4.0 percent c' the bad.fi;! vc1 - .ts e te v 'u ke: censity less then 80 percent, anc t at 0.0E re-cent is h s: t .a- y c. 70 pers.ent. Based on these results. the C m i: %e re t* th<t . r b[g' i if portions of the structural back fill nave relative ce'sities a- L u: indicated by the statistical analysis results, we stili co', lace "r*. M there is no risk of licuefa. tion.- A sir.ilar can:1usi r. was rea.r4c for the analy1.is of thin la sers tercdiatal e del
- a? '" m tion J' g*
4 relative density of 45 pe cent. ',e fact: a* ufe e a aint: l liquefaction for this analy.ts was fount t , > N e s m. - c' .d. n-" wed for this analysis resuite.1 fr~ ina re . s t r -t* M e 19F . : fill prograr in which it was shown tnat tbm is unifor9ity cf cc r 3 - r) l tion throuc%ut the backfil' place! in li: incn lts . e n cept for -r. l upDer pc
- tion of the top li't.
*he tes t f i ' ! ort.crar' e i s o s m.r * :" '
the density te .t'ng depth b(low the :aceft; su' #3cc i'. not ! rr -- g, ;, ' ry
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334 to canynence acceptance testing, Based on the reviews p.:rieme.'
. during this inspection of the Independent Expert Revies. Co nittes; s
" Final Report Concerning Show Cause Order Item 2 and of the Tea
' Force's Technical Reference nocrent, the licensee has cer:1ude '
.. that the entsting backfill material satisfies the desic.- r. tent.
1
; The atsv[noted Ir. dependent Expert Review Corrittee's "iral Re::cet i Conce ning Show Cause Orffer Item 2' was also reviewed daring t*.:s inspection to confirir. that items previously closed by t"c GC inspector, based on the Covittee's interirt and status re:sr:s, were consistent with the final report. Thert wem no e f ferencet noted betwen the interim and status and final re:crts vtich affect previous item closares. At the reauest of I[ HeaQQuarte.rs, the
,t final report will also.be reviewed by the Geotechnical !. ranch of the NRC's Office of Nuclear Reactor Regulation (NRR). ;. sarticu-lar, the Comittee's conclusicns relative to .'he calculetions
- supporting the 114.refaction potential, the adequacy of the methods -
previously utilized for t,ackf fll placerent and cc7actic e, and the significance of n::ed 161fts in nr.animur. and -inter.r dentit:es fr-values reported in the FSAR will be evaluated by Nc.R. This item is closed. , 5. Show Cause Order Conr.it ents ' The NRC inspector revie*.ed the irrpierentation of the cc.--itn
- de:c- tf .:
in the attaen. rent to HL!.P lettc r ST-HL-M-533, dated Sc-te-te ; o. , HU The following corritrents, utilizing the identifia::c. nurt. . in tne . attachrent to the LH&P 'etter, were reviewed: (Closed) Item A20. A21. A25 A27, A28. A20. I'.. ;- 31, " 4 *" . Mll . M13, and H16: The listed iteru rei.4:e 1.' an: serve - tre basis for the closure of the Shs. Cause 0-c. * *r - I t s:- n paragraph 4 of this report. 1.n additior...
- e .e 111:< - . c r. : 1 -
ments were individcally reviewed ar. frwr.: 1. t . e re- - aa: were therefore clo ed.
- 6. Exit Interview The NRC inspector et w'th the I tce'isee reme.e-i.e vr : .m . . .- ,
paragraph 1 on April 9, 19M ,
- tie r . . ., ,- .r . :. -
Scope and the findines e f tw - r< t G.
k M Discussions with B&R excavation personnel indicated that no instructions as to minimum number of passes to make with the compac-tion equipment are given to the compactor operators. The operators are told to roll an area until told to stop. This information was obtained through an interpreter since the compactor opera {or did not speak Engitsh and his foreman didn't speak Spanish. B&R's excavation
. superintendent also indicated that "there are no project requirements on number of passes of equipment since each compactor has different characteristics, and to specify number of passes would be meaningless."
PTL's soil inspectors indicated that they have no idea on how many
- passes of the compactor the fill area received before they test it, only that the B&R supervisor calls them over to perform a. test.
Failure to document the lift thickness and the number of hasses of the compaction equipment, which are needed to assure that the back-fill material is being systematically placed and compactes, is . contrary to the requirements of 10 CFR 50, Appendix B, Criterion XVII as discussed in Appendix A of the report transmittal letter (498/79-19-24 and 499/79-19-24). , 80 -l 2 (open) Infraction 50-498/79-19-24; 50-499/79-19-24: Tailure to Document soil Lift Thickness and Nur.ber of Passes of Equipment as Part of QA Records. This ites will ressin open since the revision of PTL procedures had not been cocpleted as indicated in the RL&P response to this ites. N
/(Closed) Infracticn (50-498/79-19-24; 50-499/79-19-24): Failure to Decrent Soil Lift inick . css and Mu-ter of Passcs of Equipwnt as Part of QA Records.
[ ft.a IE tr.:, :ctor reviewed the changes in procedures effected by Revision 4 to Brown & Root (B&R) Quality Construction Procedure A040KPCCP-2, " Structural
~.. .
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/
Backfill," and by Pittsburg Testing Laboratory (PTL) Field Change No. PT-FCR-046 to PTL Procedure QC-ST. Revision 7. "Sofis Inspections and Tests - Field." These document changes were reviewed for content, and , applicability of the proposed changes to the items of noncompliance. ' The changes now require documentation of loose lift thicknesse number of roller passes. de fined. Based on this revier, the IE f aspector de.temined that the changes effected in the procedures by the above documents resolve tne item of noncompliance. .
. l This item is closed. J - = !
jgt,7 . 336 A review of the Woodward-Lundgren drilling procedure tndiEated that they were to conduct the soil penetration tests according*to ASTM
'9-1586, Penetration "
Test and Split-Barrel Samp1 tog of Soils." The resident NRC. inspector determined on January 30,1980 af ter several tests were run, that the required ASTM 140 pound hammer on
. the test rig did not have a weight certification. Upon f rther examination it was determined that the hammer had been we ghed on January 28, 1980 and was found to be in nonconformance wi,th ,the requirements of ASTM D-1586. This ponconformance was documented on a Woodward-Lundgren "Nonconformance and Corrective Action Report" dated January 28, 1980. Although disposition of this nonconformance was not completed until February. 4,1980, site soil penetration testing activities were allowed to continue during the period
. .7 f January 28 to February 4,1980, using thi: hammer which had been ,
identified as nonconforming. . This is contrary to the requirements of 10 CFh 50, Appendix B, Criterion XV as discussed in Appendix A of the report transmittal letter (498/79-19-27 and 499/79-19-27). s0-0 (Open) Infraction 50-498/79-19-27; 50-499/79-19-27: Tailure to Control the Use of a Noncomforming Raem;r for Fenetration. Woodward-Clyde Consultants' letter to Brown and Root, " Evaluation of Nonconforzacce Reports (NCR)," dated February 20, 1980, was reviewed. This letter ~ i docu ented the fact that the inicially reported weight of the ha=-r (148.9 lb.) included the weigst.of the hoisting chain. Actual ha=er weight as found to be 138.9 lbs. Another hic:aer used by Younger Drilling Coepany weighed 142 lbs. Since ASTM D-1586 does not prescribe acceptance tolerances, both hanser weights were considered acceptable by koodward-Clyde Consultants. The initial ha=sser was within 11 of the weight specified by ASTM D-1586, and the Younger Company hacer, though slightly heavier than the ASTM D-1586 requireeent, would result in conservative test results since a slightly lowered blow count would be obtained because of the asall excess weight. The consultant stated to the IE inspectors that any variability introduced by these ininor weight variations would be mashed by .other uncontrollable variables of the test such as hammer fall d tance, friction of the hac=ner, friction of the boring tool, etc.
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.__._. _ -~ _ _ _ _ . . _ _
o 337
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,- ,'Woodwald-Clyde was commttted to revise site work.
pf,NCRs prior to resumption of their work activities. procedures for handling At the time of this inspection, these by July 2, 1980). These procedures will be reviewed during a subsequent revised procedures were eat yet available (due inspection. IE re few of the revised procedures relative to NCR resolution will be required prior to closure of this ites. This infraction remains open. IO 'I? (Closed) Infraction (50-498/79-19-27; 50-499/79-19-27): Failure to Control the Use of a Nenconforming Hancer for Penetration. The IE inspector reviewed' the revised Woodward-Clyde procedures which now , define _ the handitan of nenconformances. Revision 2 to the Woodward-CTyde STP Quality Assurance Manual also' establishes the position of Quality Assurance Monitor (s) for the purpose of reviewing, monitoring. and reporting on the quality assurance of work items assigned. A Nonconformance and Corrective Action Report form generated for the , purpose of reporting and processing nonconformances was also reviewed.
' ~
Previous corrective actions to this infraction have already been reviewed by the IE inspector (see Inspection Report No. 50-498/80-17; 50-499/80-17). This completes inspection of the committed corrective action. , This item is closed.
'I.
1 7 M 1-24 - asa
. ~
On February' 5,1980 the NRC inspector measured the inside diameter of the split-spoon cutting edge to be 1.50 inches. ASTM D-1586 requires the spoon inside diameter of the cutting edge to be 1.375 ) inches. Also, the required 0.75 inch taper on the end was 0.50 inches and the cutting edge was very rough. From discussions with the Woodward-Lundgren engineer responsible for logging in the borings, it was determined that he was not aware that the spilt spoon should ; be 1.375 inches. This failure to identify a deviation from the spei:ified ASTM test procedures is in noncompilance with Criterion XI of 10 CFR 50, Appendix B as discussed in Appendix A of the report transmittal letter (498/79-19-28 and 499/79-19-28). I e 8H7 (closed) Infraction 50-49.8/79-19-28; 50-499/79-19-28: Tailure to control [ the Dimensions of the Split Spoon in Soils Test Control. Woodward-Clyde -
~
Consultants' letter to Brown and Reof, "Ivaluation of Nonconformace Reports (NCE) " dated Tebruary 27, 1980, dispositioned the dimensional differences { between the Terzaghi spoon used and the spoon specified by ASTM D-1586 as having no effect on the standard penetration test results. Their disposition indicates that the thinner annular wall of the shoe would, b s if anything, reduce driving resistance producing conservative blev count results. d The length of the bevelled tip (1/2" es oppos.ed to 3/4") was s judged to have little or no influence on blow count results. - The It inspector requested the calculations supporting the conclusions ? described above; however, since they were not av'allable on site, they l' will be reviewed during a subsequent inspection. Unresolved Ites { 50-498/79-19-29; 50-499/79-19-29 incorporates the requested analysis. y g 3 on the basis that the licensee's consultant has concluded that the i dimensional variations had little, if any, impact on test results, and y since the Terzaghi shoe was replaced with an ASTM D-1586 shoe early in r the test program, this infraction is considered closed; however, Unresolved Ites 50-498/79-19-29; 50-499/79-19-29 will remain open pending review i
?
et the technical basis for blow count shear resistance calculations or ;-: disregardshoe. Terzaghi. of standard Fenetration Test Data from tests performed with the
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714 f -29 339 The recorded blow counts with these two deviations (i.e., hammer weight and split spoon size) cannot be compared to " Standard Penetra-tion Test-Relative Density Curves" since they are not " standard"
' blow counts. This item is currently under review by Woodward-Lundgren to determine if the recorded blow counts can be transformed into
" standard" blow counts. This item is considered unresolved pending review of the resi.its of this study (498/79-19-29 and 499/79-19-29).
$d'Y iClosed) Unresolved Ites (50-498/79-19-29; 50-499/79-19-29):
Correlate Standard Penetration Values to Those From Oversized 31untAttempt to Spoon and Nonconforming Namer. During NRC inspection No. 50-498/$0-17; 50 -91/80-17, infractions No. 50-498/79-19-27; 50-499/79-19-27 and 50-498/79-19-28; 50-499/79-19-28 were addressed by the It inspector. ' These infractions involved, respectively, the apparent use of a hamer E 4 setsht and a spist barrel spoon not in strtet compitance with ASTM D-1580, " Penetration Test and Spitt-Barrel Samp1tna of Soils." Both inf ractions have been closed out (also see Inspection Report No. 50-498/ l 80-19; 50-499/80-19). The hanraer weight an question was found to be l . two rounds heavier than the ASTM specifted weight of 140 pounds. Yhts .
' setsht was considered a sinor vartation which would Tesult in a conserva-ttve test result, if an fact, any effect were noticed. The dimensional l dtfference between the Terraghi spoon used and the spoon specified by ASTM D-1586 was determined as having no effect on the penetration test results. The calculations supporting the determination are the subject of this unresolve'd' item'(50-498/79-19-29; 50-499/79-19-29) and were made .- '
available to the IE inspector during this inspection. The oathematical h% I analysis was of the The reviewed. forceresults required of the to drive analysis the show different thatspoon configurations the small difference' / in spoon configuration is not a significant fac or in the blow count determinations of the borings made in the STP structural backfill. , ( l . This ites is closed.
- l l
l
_._..-..-m--__ . __ . . .a 7NP30
- K Ouring the subsequent inspection it was also learned that Soring 204, near containment building No. 2 encountered loose material near l the base of t.he foundation mat. The extent and thickness of the l
. , area of loose material had not been determined as of February 21, !
- 1980 but B&R Indicated that this matter was being evaluated. 8&R engineering indicated that there had been a slope washout at that l location durin2 August 1977 before any backfill material was placed. 1 However, a review of PTL's inspection reports for backfill material !
placed in the same ar'ea met density requirements. The NRC is currently waiting for the Woodward-Lundgren subgrade verification report for that area. Pending receipt and review of this report i this item is considered to be unresolved (498/79-19-30 and 1 499/79-19-30). , _,
$0 N ~
(Closed) Unresolved Ites (50-498/79-19-30; 50-499/79-19-30): Boring 204 Loose Material Near Base of Unit 2 Toundation Mat. Woodward-Clyde ' Consultants have completed a coeprehensive study of the density of back-fill in Units 1 and 2. The IE inspector reviewed the report submitted to Brown & Root by Woodward-Clyde. The area of Boring 204 was extensively addressed. Twenty additional borings were taken in the adjacent area. j, The report submitted to Brown & Root will subsequently be reistu r by Houston Iighting & Power Cocyany .in response to Section1X'(2)(d f *s 1 the Show Cause Order. This response will provide information te I G ,e, , address the adequacy of all entsting backfill saterial. The subject of Boring 204 will be specifically addressed in the response. This ites is closed. , I l l l l I
. b
.1", .
D , 341 TheNRCinspectorfalsodeterminedfromconversationswiththecogn thickness that 12 inch lifts had originally been specified. The lift thickness was changed to 18 inches as a result of a suggestion by the soils consultant, Woodward-Lundgren, during the review of the 8&R specification. Woodward-Lundgren in making that recommendation also suggested that a test fill section should be completed to demonstrate that 18 inch lifts could be consistently compacted to
.the required density. This item remai.ns unresolved pending.further review (498/79-19-58 and 499/79-19-58)'.
10 M (Closed) Unresolved Ites (50-498/79-19-58; 50-499/79-19-58): Basis. for 5;:ecification Require. ment for Backfill Lift Thickness of 18 Inches. The subject of this unresolved item is an integral part of Infraction No. 50-4S8/79-19-18; 50-499/79-19-18, " Failure to Complete Backfill Compaction In Accordance With A Qualified Procedure." The actions taken by the' ' licensee in response to the infraction serve to address the issue originally generated. These actions have resulted in closure of the infraction and therefore resolve this ites. . This item is c1csed. as Y-
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. ' y 342
- a. ,
- e. Field. Activities PTL's testing activities were observed both in the soils kaboratory and in the field. PTL personnel were interviewed as to rbspon-sibilities and procedural requirements and acceptance crl)eria.
A laboratory relative density test was obs'erved and was performed in accordance with the procedure. However, a review of PTL't laboratory data on relative density determinaticns indicated that PTl. had run only dry maximum density determinations in the laboratory. ASTM 0-2049-69, the reference testing standard states in Note 2 that, "While the dry method is preferred from the standpoint of securing resu1%.s in a shorter period of time, the highest maximum density is obtained for some soils in a saturated state. At the beginning of a 1*aboratory testing program, or when a radical change of materials octurs, the maximum density test should be performed on both wet and dry soil to determine which method results in the higher maximum density. If' the wet method produces higher maximum densities, (in " excess of. one per cent) it shall be followed in succeeding tests." Therefore, the inspector requested that a maximum density test be rqn wet and
, a Modified Proctor test be run to determine if the maximum density that PTL is using to control the backfill placement is iddeed the maximJa density. Theresultsofthesetestsindicatedthatthe
. I- '; -
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j.~ . . - d ,,,ce,ent is indeed the maximum density. The results of these tests fedicated that the relative wet maximum density was less than the
.- - relative dry density. In fact, the material in the relative density i h sold became looser under vibration with the addition of water. This matter was discussed with B&R and HL&P perscnnel to determine what C
f effect this might have on the plant backfill material under earth-
,. quake conditions in view of the normal plant high water t&ble. HL&r
~
and B&R representatives indicated that the would look into it. The t probles of possible liquefaction is considered unresolved pending completion of their review. (498/17-19-25 and 499/79-15-15) t
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._ , - _ __ _ _ . . _ _ - _ _ . _ _ . _ _ _ _ _ _ - _ . . _ _ _ _ _ _ _ _ _ _ _ _ , _ _ _ _ _ ~ ...___________ _.._ _ _ _ __ _ _ ,__ _._._.__- . . _ . _ .
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343
. 7/ ~o 3 LETi1LS ,
- 1. Persons Csntacted
#rincipal Lice asee Er: e.. es'
'R. A. Frazar, nanage , 0.ality Assurance "R. A. Carvel,, Project QA 3upe rvisor - Civil
*L. D. Wilson, Project QA Supervisor - welding ,
R. J. Viens, Senior GA 5;ecialist G. W. Steinas.nn, Lead Site Engineer - Civil
*T. J. Jorcan, Supervisor, Quality Systems Ot% r Persennel _
"W. J. Friedrich, Project QA Manager, Management Analysis Ore. , ro:
L. M. Campbell, Senior Project Engineer', woc:> arc-C1;,:e C: .si tris
*R. L. Hand, Froject QA General Supeevisor, MAC
- 8. C. Pettersson, Lead Geotechnical Engineer, Brm.n & Roct (B!.O J. L. Ruud, Supervisor, Civil QA Engineering, NAC '
G. Y. Yefstey, Civil QA Engineer, MAC
'F. G. Miller, Project We' ding Engineer, 84R
- 0. Eller, Piping General Foreman, B&R
*0. J. Harris, Manager of Quality Engineering, E&R L. A. Weigel, Level III Inspector, US Testing s "G. L. Hall, Quality EngineeriniCoordinater, B&R The IE inspectors also contactea other licensee ano e ma:t: < . ;: .eet including memsers of the QA/QC, and ent,ineering sta":
l
- Denotes those attending the exit interview. ,
- 2. Licensee Action on Shew cause Orde- Cownitments During this inspection, the following unresolved item icentif:e: n .E Investigation Report No. 50-498/79-19; 50-439/79-19 -as revie 1 (Closed) Unresolved Item (50-498/79-19-25; 50-499/79- F-CE):
Decrease in relative density of coepacted material in =et state cce-vibration. Maximum density tests were consuctec by M- C. K. C...- c-the University of California, using both 16e et anc c y met".e s 'e' results are presented in the Independent Review Coevni. tee's "Inte- w . l Report to Brown & Root, Inc. on Adequacy of Category 1 Structurs' Baa-fill," dated July 12, 198]. The maximum censity dete-sined o> in -at i l method was shown to be less than that of tne dry metnod. The w cer- ! dent Review Coceittee's " Status Report on acequacy cf Ca*egory .:- ' tural Backfill," dated October 24, 1980, furtr.er accresses th . .$ .: 1. : l ' l \
' \
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.i s . ., .:
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. ::enee+ a:tio, : _re Ca_5e _ . - .:e : _.
x a ine IE irs:.e:ter revie-e_ :le cr.:nt.e- -
.- s censee's rec ense to tr dre. Ca.re 0-:.- t .
.- P t icensee anc contr:cter r*:resentativas v : :. . . . e.-
cescribed in tne attachme t to HL&D lett.n 5:- . ci ..; - Se;tember 18, 1980. The 'o11owing commit ents, ot . :: nt, :me [ fication nam:ers in tne attacht.ent to tra m &? . :-t:* e, -e-- rc .. .
' d (Close:) Iter. A 5 i e Ta'k Force h6. : ;:etc. 3 :...:at -- - -
I' cersity test with ce th i. 'he backf411 :Ta.ev. .ts t-- fi '. ..-.- ficaticn of lift in: Aness in accer,'tle 3 ..- . : - tien, t'.e IE inspect r ciscessec the fie': .e- e>- .n t -
- I on site w ~th the ' woc -ar:-Clyce Cons.ita-t :. .: :;t.: : ; .e-The tabulation of ce sity test with ceots sa- a rc en ec i . p.-
observation of the t;:Afill mapptr.; cein; :e .re: .rce- ., direction of the W C Project Eng"ncer. - [b ' (Close:) Iter A32: r.e :ncemene a: "e,9- -
.;e. a- --
all pertinent aspect of the str. tural ta. - 2es e . st:.:- - specification criter a, cons.ruc;ien seoce v 4: = r.c .s;e-- c. s* . testing coeur.entation. The Comm ttee ha: r.: -tec -a f: .- ; two reperts, which accress the listed tA . - tes : - 2:: - sati; factory design: 5 j
" Interim Report to Bro.n & oct. In: -
M Category I Stru tural' Back,f.111." ca., r.
" Status Report to Brown & Rc:t. In: ...__.: -
Category I Stru tural Eac.f . . ca ... ..:... .t. The final response t: the Show Ciuse 0.-c
- t .m . .
both reports in a fo-pat which will accr... ..
. s.:e,t .-
backfill adecuacy. l (Closec) Itee As1: nresol.ec c . 2 - - ! in the nc-sal course of the -*. . . :" in .. -- . tion. The " Status Report" by the !ase Fercs o- Jorc-cte .r-l cation, catec August 15, .1980, =as revie-ec s t..e IE ins; e:- i Page 11 of the repor. cocuments the Cemrittee*i "Re.'ew e* Adcitional Concerns. This reste. in.-l.1r, NT WLp r Kt H
?
i. 1 9
,m 5
w. l - t
q q-Iq -z b . 345 The Modified Proctor test showed a maxieum dry density of 127.5 pounds per cubic foot which agreed with the values documented in the SAR. The minimum-maximum relative density values referenced by the FSAR (93.5 and 128.1 pcf) represent those values noted orginally in
. the PSAR. These were different from those being used in the field (105.3 and 123.6 pcf). In Ifght of discussions with PTL personnel who indicated that the material properties haven't changed during the . course of the work, the inspector questioned what backfill material was tested to obtain the SAR's values. .Since the values documented in the SAR's were used for liquefaction studies, further review of this matter is needed. This item remains unresolved pending this further review (498/79-19-26 and 499/79-19-26). - .
su 4 4" LClosed) L'aresolved Item (50-498/79-19-26; 50-499/79-19-26): Discrepancies tn Mtatmum and Maxtzum Denstties of Backfill Used Versus Those Reported in the SAR for Liquefaction Analysis. The licensee response to the NRC Show Cause Order, Section (2)(b) addresses .the compliance of the backfill material placed with the design basis material characteristics, described in Section 2.5.4.8.3 of the STP TSAR. The backfill sateria'l placed originates from the same geolagic formation and has the same
- j. gradation and particle shape characteristics as the saterial used in the determination of the cyclic leading characteristics. The backfill material listed in the STP TSAR had a sinimum dry density of_914 '
pounds per cubic foot (pcf) and a maximum dry density of J128.pcf. l The values observed during NRC Investigation No. 50-499/79-19; 50-499/ 79-19 were 105.3 ocf for minimum dry density and Q3bei for saximum dry density. Cocputation of 80% relative density for both sets of minimum and saximum dry density values res21ts in values of 119.27 pcf and ' 119.45 pef, respectively. This shows that the dry density weights at 40% relative density are approximately identical. This value is the weight to which dynamic test specimens were cospacted in the design phase liquefaction analysis. For the dry density weight at 80% relative density
. used, the liquefaction analysis showed a factor of safety greater than 2.5 against initial liguefaction, and greater than 3.5 for liguefaction at + 10% strain. The variation, in minimum and saximum dry densities noted'in NRC investigation No. 50-498/79-19; 50-499/79-19, can be attributed to subtle changes in the gradation and coefficient of uniformity which
( 'have occurred over the four years of structural backfill placement. i[ Sance this chaAge.has been shown to not significantly affect the saterial's engineering properties with respect to liguefaction, the 11guefaction analysis performed for the design and presented in the TSAR is considered valid and applicable to the backfill material placed... s . . .
' ~
This ites is closed. g- 6
~
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. s :- . ..
(Closed) Show Cause Order, Ites Y.A.(2)(b): Provide information to Address the Coeparison of Materials Tested and Described in Section
. 2.5.4.8.3 of the TSAR Addressing Liguefaction with Those Used in the Tield. The licensee's response was reviewed and found to resolve -
the apparent discrepancy in densities of saterial used in the design with those placed. Thya pa rent _ discrepancy was c_aused by_a_,_fa,11u.te to compute the 80 percent rela _tive dennityValues for purposes of c n. . ~, 's '
. "12 '.' - "
. . ..' . . :......~__...-
c.~ . .; 2 * % .L- 8 . . - ..
. m. c . .; ._.. L .'
. gg -- .? . .-
_ . . - - - - . - .- ._ . _ . . . _. a.. . ,. m y __ __ \
/
Computation of this value, which was used an the liquefaction analysts results in a 0.18 pot.nd dif ference between the design 80 percent relative dry density and the field 80 percent relative dry density. This tssue is further addressed in this report in the closure of Unresolved Ites No. 50-498/79-19-26; 50-499/79-19-26. Based on the IE ins;ector's
, review, the liquefacti'on analysis perfor=ed for the design and presented l
in the TSAR is considered valid and applicable to the backfill material placed. This ites is closed. u. k I l
'n
,,' j dh 347 U. 5. NUCLEAR REGULATORY COO'.15SION RECICDi Ill TRANSMISSION SERVICE R2DUEST . .-
, CITTGOING -
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/. Mar 3. 1994 ST.45-TS egges File me.: 416.4 ,
r, Mr. L. E leurst i ' Project CA Manager , Sechtel trergy Carperstfee , P.O. Sea il . Say City. Tesas F7414 q SUL1tCT: 50nmi TtIAS Pe0JtCT CLECTRIC GDERATING STATIOR PROJECT AUDIT REPORT 505-401 ll Omar Mr. Iturst: l Attsched is tJue Project Audit Report for Category I Sackfill Activities l
- Including EC'i Assett ihamber 505 401, conducted on March 26 through April 3 IM4 The results are saammarized as follows:
TUTAL j(( ,g,j, E
*fnamber of Itams Auviesed: 696 -
*Puster of Dettciencies: $3 22 15 16
*%suber of Cascarus
. 8 2 4 I i
*'hamber of CARS: 16 10 4 2 ,
* % mber of l Msg F I 1 4 L
' master of stas: 1 0 1 0 b All deficiencies and concerns identified that reestred a ressense essee issued to Sechtel en April 10. 1964 Carres. Ihamber ST-le5 70-00761. ,
Sechtel theality Assurance is recuested to distribete the appropriate sections of this entit report to Desce and Pittsburgh Testing Lakerstery. Stacersty. t T. J. Jerese
** Project CA Me
*Q Souta Temas ect ,
- -~'
TJJ/J 1r Attachment y -. - ....-. . 4
= - -w ~ -
0 F 0
,e'M CO3194h5JJ_'
\ 370 r__-
__ _L _L ;,5'% ? T ~ '-_ . _ _ _ k s ,, 3
/ ..'.' . ,
~ l
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j ,
)
l
! j It. L. E Muest ST-46.TINEMOS Pese 2
[ 1 ett 4. E Opree. Jr. r J. E. Seiger p
- 3. S. Sorter e l
-- R. J. Merent l' C4. T T '" - 5. M. Dow J. W. W111 fans -' / '
R. L. Ulroy E. A. Turner A. R. Beavers je l J. S. Dowcase
- J. M. Gol eerg 1 L. 8. Morrigan R. P. Itsrphy .
l T. M. McGriff I' O. T. Krisha (BPC) S. L. Lee (BEC) ' R. V. Miller (BEC) ) E. R. Detterer (BEC)
- 5. R. McCullowth (SEC) { , -
C. L. Mawn (Est) w/o attacament : J. Crnich ([51) w/o attachment i ! L. B. Triplett (PTL) w/o attacsumet Audtt File 505-401 l STP aMS (2) w/o attachment - 5tte Lttrary s l-i I n i P
., 7, r
l
- x. J_ ochu$paGf an
~
1.~ TOY'((' -- -^ -
. ,v.
.. A g- ..
i r s SouTII TDAS PRlblECT AteiT EPOET t Pope 1 Aue!T: as. 305 401 Amerf an1ES:
; Category I sectft11 se,o 25-April 3.1984
/ Activities incluetag EQf g' .
/ '
AtelTED ORGANIZAT10ms: Atelf Ttet: h techtel Energy Carperstlen T. N. Interiff ' Team Lander)
/ P.O. Sea Il '
i
/ tay City. Teses 77414 C. L. Grover i Auditor)
T. E. Legaa LAuditor) R. B. Jonalags i; Tech. Spec.) thosce Servicie. Inc. 8. 4. Lang LTech. Spec.) P.O. Sea 1647 Say City, Texas 77414 ., Pittsburgh Testing Laboratories P.O. een 15 Say City. Temas J7414 Ym $ hl* Leed meditor #w
'Y SLueSo/$$$
ante - WO Austt sneervisor 4~. T ante N i PER$0 leg CONTACfD: Pre- During Post Audit l' Emme 71t1e Audtt Audtt 3Ite noustes > T"T. Leder Ceed QA Engineer a a T ( L. B. Triplett PTL finneger I I I l s. v. stergen etc 04 tagineer I I R. 4. Sefieleen BEC Lead Site togineer I I I (Civil) J. ft. Little ett Site Oneu ty I I tagineer
, J. R. Sethardt BtC Geotechnical Engineer I I r
J. W. Williams ESP Site stanager I L. fee 8(C Sells Grene I I Superviser t
.. Talaege IfC Geetech Caerdinator I I J. L. Berter R &P Site Eng1 w e I f E. W. Smith BEC Asservetr C3erdfaster I ,
T. Itttoman M C Lead Centracts I I I
- 4. C. Gunhal Caerdinator N C OC Engineer I I
[ C. J. Staffel( SEC OC 1 Peer I I W. J. Futrell . NC Site ett Engineer I (Civil / Structural) I 4 I
-}' "[ g ['
r *
- . - - ~ , , - -n_,,-- .- --
-e , ,- ,- , , . _ _ - , -,,
- '7 m c. -
u_ .m N ' Ase t Resort SOS-del Pope 2
. htR50MEL CINITACTED: (CWflaES)
Pre- betag #est Audit
. Rttler 0A Eastaser
($tte) P. W. Joyce IEC 04 Eastasse I I
- R. E. Pact ESI th Site Superviser I I J. L assas NC tapety manager I t, Ce n treetten r
. A. E. Priest NC Pegjert meeger I l Ce n treetten .
J. E. Geiger EAP manger, p I S. 8. James NC Assistant Project I
- Ihmager (Onelity l L R. Detterer Services)
NC Project GA Eagtaser f
/ (Neusten Oestga Office)
I p a. M. E. Pirell E&P Lead Eagtaser I
- R. R. Permandet EAP Supervistag Project I , !,4
- mese '; R. L. Rogers . NC oct Engineering I senneser ' J. L. Itseley NC Project Esgteser I ;.
- 8. W. Malligen BEC Vice Freeldent. I Progresamanger J. N. Geleerg ESP Tice President. I muclear Eastasertag and Cemetraction .
D. S. Berter ESP Project Ignaeger I
- 1. M. Osw EAP tagtasering naaeger I T. J. Jorden E AP Project GA Manager I J. A. Stevens ESI Land OC ($stis I E. 3. $sith ESI theitty Catre I J. E. Peel ESI Guelity Castrel I W. M. Sean MC Lead OC Engineer I (Recolet )
J. E. Berlev NC Ittartal Supervisor 1 I [ W. P. Priest, Jr. N C Recotelag Superviser I J. C. Ford BEC teersheese $mperviser I ': O. O. htose N C Preceremmet Supplier I , tieltty $sgervleer ! R. M. Christian ESI Land Civil Eagteser. I i , Y i A. J. Bleesterg NC Ctvil Superlatendset I W. E. atfeng NC Samplier Ibellty I tupresentative . M. U. Boston EST Ascard Specieltst I S. A. Dona ESI Lead Civil DC Eastaser I I I S. R. Raettog EAP Prgject S Genere3 I Superv1ser B. F seeierczyk EAP Project GA Superviser. I Civil / Structural e L eA-_i_._
- 7 r .
b
+ee
j sTl@ L C031% . 373
, . *Oo. Nad I?
b dit Ammert M Ptge 3 sux= w = mem
, i To serify proper trans16 tion of FSAR technical and coality rogstrumsmes ihr Category I and EQi Bactft11 sporettens late design disclosere documents and feelementing proce6ces. Addittenelly, laplementatten of these
- restruments assectated with meterial receipt constructies acttrities.
- taspection, and testing is tecluded. Also, the audit tecluded a retter of Bechtel Centract letters to FTL to assess ensign change impact. g I'
8 AISIT W O M f I
/ Sochtel Energy Careeraties .
I i Sochtel's performence uns judged enecceptable based on the large nunter of ~
- .* efittencies identified. Tuo areas of enjer tapertence mere identifted: .
- 1) The translatten of FSAA technical and goality regstruents to doelps .'
;f ,
disclosure documents and taplementing procedures is deemed enec. . . captable based on the large volue of FSAR violatteesesnopproved exceptions discoverve. ?. I
- 2) Eschtel t>sality Centrol is not taplementtag procedures to essere the guality of daily backft11 activities. Receiving Inspection of Catage=
ry 1 Backf t11 meterial as well as Effectiveness Inspectisms and 4 A Ouelity Control Surveillances of daily hectft11 activities, more all found 14 he inadeguate la verifying implementation of regrirements.
.)I I It is recommended that Bechtel assess the 1spect en engeing uert as well es !, i evaluate the tapact of the deficiencies en past vert. Asettienelly,it is d recommended that Bechtel review the evaluetten anthods used untch emeure technical and quality comitments are adequately translated and tracted t!
e' throu9h design documents to tuplementing proceeures one subsequently 1ste 8 actual nort practices. thesce Services. lee4 thesco's performance uns judged satisfactory except for the noted deft. ciencies which included tuo tapertent items ahtch were identtfled prior to . this audit. (See ESI defittency numbers 3 and 4). Greater attentiae to spectf tcation requirements and translattee of these requirements to Wie. i r meeting procedures is recommended. ; pittsburgh Testine Lahoretary FTL's performance was judged satisfactory escent for the noted deft. ciencies. Greater attentten to eetailed reeutrements contained la FTL procchrM and ASTM testing procedures is r=*e. 7
- l
* = . . .. ..
F .
@O3 !&%! -
E __ ._ _. G -E D W M a-M 9 -- - - - a 3 ." ' l Ander nosert so6401 page 4 BartClocits: . Sechtel Enerer Careerettes
- 1) Spectftcatten 2T06075044 favokes AmS! 245.2.5-19T3 enly and does est include Regulatory Guide 1.54 (Rev. O. CS/73) as modtfied by posittens '
.C.S. C.E. C.7. C.8. and C.10 of Revisten 1. (qpP0 part A rogstrament).
g i IG.&P CAA S-4031soned.
'3
- 2) Specificatten 37069750043 %es not require et least one relative [
/ density sasele per shift to be ehtstrad free the compacted backftll. l This is a F5AR requirement. . ,, G CAR S-404 issued. !
- 3) Spectficatt6n 37069750043 requires tests to be performed a mistnum of g ence per an eight hour work day. The F5AR reqpstres this frequen g of -e .
test be per work shift. * : 6 M CAA S-404 lssued. J:
- 4) Spect f tcatten 37069750043 does not contale the F544 requirement to '
obtain a stalmus of Orwe in-place doestty tests withis each tested g subgrade area. , , M CAR S-404 tsamed. l i .
- 5) PTL has been allased to take exceptten to the hydrometer porttee of !
ASTM 0422-43 for Category I Structural Backftll, but the F54R and i 5pectf tcattens 2Y060Y1044 and 3Y069750043 do not unte this escepttee. ! ( p CAR S-406 issued. . ,
- 8) The F5AR requires tuo bulk density deterstaattene for each new beg of r ,
sand used for sand cone tests. The Spectftcattens and PTL taylement-tag precedures do not tac.rporate tAls requiraammt. I
& CAR S-406 issued. l
- 7) The F5AR reeutres bulk density sand to have 1005 passtag the me.10 steve and none passing the 20. 200 s1 eve. This is an adet11enal requirement to ASTM 01556-64 which is not tacorporated late the .
Spectf tcattens or PTL toplementing precedures.
& CAA S.40E issued.
- 3) Re objective evidence was previded to show what changes were made to spectf tcattens and procedures to satisfy cong11ance with On-Getag Shos I Cause item VA(2)MB.
O CAR S-406 issued. P . . .
. m_
7 r . s - . , . _ _ _ _ - . . . _ _ .
l co31% 44! - 375
.. . v. r .. - -
L I
.w Aedit neeert 105-401 Pege $
W itttNCitS: (CWfflIREB) *
- 9) he objective evidence was provided to shes what docuentatten has been '
generated by E31 and PTL te emeere esmoltance te On-Geing Shoe Cause item VA(2)Mt.
- ESP CAR 5 408 issued.
- 10) Specificatten 37069750043 does not catain the FSAR cammitment to 4 entain one sample for Relative Density testing ( ASTN 02049-49)for i
' the Category I backf tl1 stockptie for esca 20.t20 cubic yards delivered. j
- , i b
ESP CAR 6-407 1ssued. i:
._ _-r...- l
- 11) The Receiving Inspecttee precedure, trP/tlCI-4.0 Auststen 5 does not j..
describe the process, methodelegy. specific docuent requirements, and - the approval / release process employed when Category I backft11 j , material is ' received on-stte as Class 9 and subsequently upgraded te
/ Class 3. ,
KAP CAR G-409 tssued.
- 12) Personnel ot$er than these assigned by the Receiving Supervtser are *
- I perforatng receiving functions for in-coming Category I beckftll y-material (Constrwetion personnel are perforwing this function). 3, i
ESP CAR G-411 issued. .j
- 13) ' Meld for Receivinq Inspection' tags are not apelled to in-contag Category I backf tll stockpiles op to the point of QC acceptance. ;
K AP CAR G-411 tssued. i '
- 14) Receiving QC personr.e1 have been stamping the " Accept" colum of the .
Receiving Inspection Report (Rit) for Task me.1.2. which requires e ; visual inspection for cleanliness of in-coming Category I beckftli 5 esterial. even though these persennel have not performed the required
- visual inspection. g R &P CAR G-411 tssued.
- 15) The cognizant Supplier hality nepresamtative of Field Procurement, is , (
not signing and dating IWE's for fa-caming Category I beckftli esterial as required. R &P CAR G-411 tssued.
- 16) Cuality Control has ret performed as Effectiveness Inspectten of -
Category I backf tl1 activities sface October,1982, a perted of , approminately 16 montas. KAP CMt G-410 issued.
=- . -
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- 3 '
. ... .g Audit Report 55-40I Pege 6 8 *tlEFICIENCIES: (CIET!IWEB)
- 17) One11ty Centrol has met perfereed a survettlance of Catsgery I tectf tll activities stace the original issue of that precedere to Octaher.1983, a period of appresiastely I seeths.
- ILAP CAR S-419 tsamed.
4 1s) The Centracts lennoger issued a revisten to specification reestruments regeretng the fregency of steckette sampitag by correspondence rather 3 than by an approved design change documest. a
/ ,
l II.8P CAR S-417 isamed. [ t c ig) Re abjective eviduece mes preided to show approval by the a Constructten Manager of compaction control criterte to be ettlized as i' required by,5pecification 2706075044 It&P CAR G-418 isomed.
- 20) Re evidance uns provided to show that campacties com' trol criteria uns I submitted prior to use as twoutrod by Fore S-321.E. lactuded as se 6 attachment to Specificatten 2T0607$044. j IL&P CAR M IS isamed.
- 21) Inseettien Report (RIR) Itsted the wrong testerial Receiv-ja AtagReceiving Report (ISR) ammeer. .
Id.8P 135164 famed. f J
- 22) Testing frecuencies are not directed by both the Constrweter and the !
Constrwction Manager as requiree by $pstificaties 2T06075044. IL&P 15 188 issued. g Ebasco Services. loc. I l
- 1) The t>sality Centrol Sells Inspection proceerre does not provide criteria en density variation with depth to enable Oc te determine the correct location for testing as roeutrod by Specificatten , l i
3T069750043 and the F5AR. Therefore the field test elevattaa I' selection process does not give represestative density informatten for
- all depth totervals within the 1trt. f i
it.AP CAR S-415 tesmed. l
- 2) The Sells Inspectten proceeure does not rentre test doeths to be recerees and thus me evleence. in genere1. can be provided te .
desenstrate bactft11 installed by ESI has been tested at the required depths. Specifically. no evidence exists to demonstrate tests below the .4 f act diameter EClf pipes are taken at a depth of 7. Inches beles L i the invert. Additionally test depth infomaties is not provided to PTL. . IL&P CIA s-415 tsamed. r
@ o 31 % J 5]5R _ 377
__ - _ _ _ . ___:.. M M NLX M ~ ^ "-^ r s . . . s Amitt assert 305-401 page F i
*KFICitNCID: (CBlf!!aEB) .
- 3) The everage statam/meaimme values obtained ertag the Anistlee Sonstty deterwtatten more met app 1tes to accordance with femetftce.
tfem 3706gf50043. *
- Presteesty identiffed by MC CAA F-3E.
- 4) enctft11 If fts em est tested prior to piectag noe enterial (f.e.. the amatlift).
i Previently tesetttted en D1 IFR.1 of Audit EOM30.
=
/
/ 5) lity Centrol has not ettsted the SEC Foundatten 9erification ineer's signature en backftl1 faspection reports to provide evi-dence that SEC has performed geologic mapping and accepted natural svDgrade when enc 3untered during the constrwction of safety-related 4 duct banks and menholes.
, s e
.( & CAA G 414.
I i-
; i
- 8) Cemesction for local escavations for densit testing wittle the fill )
mes not performed as it uns for the origina placammet. It&p CAA S-412 issued. Additionally. NCA AC-00051 mes issued to r; teentify a harthere deficiency, y , 1
- 7) t>nality Control was not settfted by constrwetten persennel that 1 ecol e ; '
escavations for density tests eithin the fill had been hectf111ed, capacted, and were ready for tospection. I y
& CAA G-412 tssued. Addittenelly. NCA AC-00051 mes issued to I l Identify a harthrare esffctemey. $
- 4) The Set 1s Inspection prece6re does not reestre verification /inspectice to insure the gradation and distributies of I materials in the compacted areas is such that the backf111 er fill ts , t met segm gated.
g g
& CAA 8-413 issued. It.
g) The Sells Inspection precetro does not rugstre I , verification /1nspect1on to 1asure ff11 surfaces are censtructed se i meter will readily drata off at all times. ' p CAA 6 413 isssed.
- 10) The Set 1s Inspection proce6re does met require verification /taspecttee to tasure compaction is not altamed withis 20 feet of as area where in-sttu density tests are being performed.
- ISAP CAA 6-413 issood.
- 11) The Setts Inspection proce hre does met require vertftcation/taspectica to insure if concrete mets and basement malls have been materproofed. and that backftlling is perfereed se that the
*4 9e
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.7 , -
T_ T , 3 f ; 7 , , - 1 _ _ _ ,
' Asett ammort M Pepe 8 s IEFICIDCIES: (GNT1mEB) protective unterprooftng anterial is est enmeyed. i IEAP CAR 6-413 isoned.
. 12) The Setis Inspection processre does not reestre
- sortftcatten/taspectten to tsuure hectft11 edjacent to structores er over porttens of foundattens is placed and campacted symmetrically and j eniformly la e menner to prevent ocesstric leading er unbalanced f pressure upon er against the structores.
~
IL&P CAR 5-413 issued.
- 13) Verifications perforund dortag the almaltffcatten progres for Meche !
vibratory plate compacters are not year m eally required to be rutard- l ed on the referenced " Attachment L*. . t
. it.1P DE 1M tssued. .
I 14) Verificattens perfereed ehering the Test Fill for cualtftcatten of l Verteus Mand Operated Compacters are met proceesrally regstred to be recorted on the referenced "Attachuset F. IL&P IW 1 M issued.
- 15) no letter of approval from DEC Engineertag for the results of the
- fill program for hand propelled vihretary plate compacters mes com- ,
tatnee in the e t pectose. Corrected thering the audit. Pittsburgh Testine Latereteer ,
- 1) Category I backft11 samples are not propered for testing as described 4 l to ASTR D421-58. l It&P CAR 6-4181 semed. j
- 3) The length of'aechanical steving time and the thereughness of steving, as required by ASTM 0422-63, has met team deterwined er doc uented. ,
It&P CAR 6-416 issued.
- 3) Category I beckft11 samples passtag the us.10 sieve are not unshed
- over a ns. 200 steve as required by ASTR 9422-43.
- k It&P CAR 6-416 1sesed.
- 4) The hardiess of Category I beckft11 asterial is met recorded as required by ASTM 0422 43.
IE.8P CAR 6-416 issued.
-~ ~~'
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.- i s
b ett esmert 906-401 Page 9 , GEFICIDCID: (GETIIRED) S) Butt density deterstaattens for density sand ett112ed to sand-esmo tests are not performed to strict compliance utth the precedure described in A5 TIE 319M-64. , ,
- It&P CAR 6-416 teamed.
- 6) The vehme of the sold stiltred to the Relettve Omnetty I detereinstion is not calibrated in strict comp 11ance with the ' '
proceeste described to ASTM MO49-49. { l st&P CAA M16 tsamed. l i
- 7) Initial dtal gage readings attained dertag the maatsus porttee of the g Relative Density test are not obtained as described la A$fM 02049-49.
'~
HL&P CAR 6-416 issued. ) ,
- 3) *Mstch Marts
- are met attilged when dlal gage maaserments are made during the asaiem esosity portien of the Aslative Cons 1ty tests as
. required by ASTM 0 549-40.
NOTE: "Metch Marts' are to be uttitzed se the meeserements ces '- he made in the same relative positten for each eastam density detersleetten. EAP CAR 6-416 tsemed. ,
- 9) Sample asterial is est pieced to the sold for helative Osastty determinations in strict camp 11ance with the reestruments of ASTN 02049-49. ,
P it&P CAR 6-416 tsamed.
- 10) no written proceerre er teatractions (by PTL) entst for samp1 tag -
backflil material from the stectaties It&P CAR 6-415 1 semed. ;
- 11) The procedure used for deterstatag the bult density of sand uttitzed i in send cone tests does met adeouately describe how the sand from different bags is theremyhty blended to ensure genes of dtiferent kult density de not resent within the contateer. -
It&P DE 1691 semed. , , I ' 12) The mothed used (sesse er femel) for detervining the sistaus doestty porttee e' the Relative Constty tests is met recorded, i MITE: FCR 103 mes goeersted by PTL en 01/26/84 roguesting Bechtel's approval to incorporate this requiremet. Re such approval has been received to este. It&P 0s-167 isssed. 6 b 1 l l
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. Audtt assert W 5-401 Page 3B' 6EFICItuCIES: (CIsrTIIEAED)
- 13) Retests reference the crisinal test mater but not the origine1 report mater and the retests are not filed with the artginal report as required by PTL Proceeste OC-DC.I. novistem 11.
. - IEJP 05-146 teseed. .
- 14) PTL proceeure 15-51b 5049-49 references a superceded prese kre fte relative density table cattbretten rather than the curvest precedere e le use. .
l. ItaP 156-165 issued. i
. - . . t
- 15) Samples were being tamoorectly retained iifilliirisrepPfiWttetma i tedicater tags. j Corrected hrtog the audit. No fure er actie's regelred.
- 14) .A Belative Bensity table ca11bretten uns h ated on a --
) form.
! Carrected bring the audit. As further action required.
, 1 .
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- 1) he methodelegy(has been devised to date to correct errenosusi.e.. legs, inspection reports test repo s documentatten ,
cross-reference the acturate recalculattens unich were sedressed ty BEC CAR F-302. A ressense from Eb4sce is rogsIred. ,
- 2) It is vaclear hou ESI QC determines which Category I backfill
- t ,
meterial source type is encountered (f.e.. TH2. TII. Porter Bros.. I s etc.) at the required subgraae elevatten during escavatten te onette i OC to accept the material as subgreen prior te susseguent backftlling o er concreting operettoms. A response from g,a3 si rege1 red. L {*
- 3) The centrol criteria (f.e.. Relative Bensity Mas / Min) is not consis.
test for all test fill programs. The sampling reevirements and data oppitcatten for Relative Density deteretnetiens is prescribed differ. ently in ESI QC Procedure OCP-10.10 for "The Correlatten Test Fl11* (no requirements). *the Wacker vibratory plate compacter quellficatten* program" (one R.D. taken en the top Itft after applicatten of eight eme-esy passes), and the
- Test Fill for Qualificatten of earteus hand operator cespectors' (rvnning average of the last five esatam/mistase nelative Densttles). 18 tere *the average of the last five les/ Mis Relative Densities" is mentioned it is unclear if this refers to preesction averages. er te what source asterial. Additionally. It is unclear uhy no requirements have been included in the 'Correlattes ,
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20eCDW5: (CONTIIRE3) Test Fil1* proceers for control criteria. LB. sasyllag, or appites. tien of R.D. Itss/Mie resulta. l A response from h is regatred.
- 4) Bechtel Soecification 3Y00gT50043. Revisten S. peregraph 7.3.12 statas ,
, te part. *. . .For the final lift of a teckft11 sporettee, donetty tests shall he performed within tuo taches of the serface elevottee . l F5AR peregraph 2.5.4.5.6.2.3 states to part % top lifts to be !
located tamediately below foundettens are tasted at depths hetuose l' ! and 12*. regardless of Ilft thtchmess." ; elle it appears the corrent specificatten escoeds F54R regatruments for surface density tests. the spectittatten conflicts with the description in the FSAR. . A response free techtel is required. . l,
- 5) Inspection /verificattens indicated in ESI QC precedere OCP-10.10 Sections 5.2 and 5.3 are recerced on the Ostly sectft11 Imepecties )'
Report under
- generic" checkpotats (i.e.. Excavetten. Causpectice.
e tc. ) . Each " generic" checkpotat includes only one acceptance for several spectfit attributes. From the Beckfl11 Inspection asport. It carnet be determined that each specific attribute costatand to the procedures has in. fact been vertfted. A response free thesce is required. y
- 6) There is ne traceability of acceptance tests to shipments of Category I backf t11 material other than the date of the test and the $1em (en er gun). As a result. it is not pesstkle te deterstes if PTL 1s l
. meeting the mintsam test frecuency (each 500 yards) prwacrthed le ;
i spectficatten 3Y069750043. . Addittenelly, this same concern applies to the helt domstty .l deteretnatten perdermed on density send for sand cane (te place l F density) tests. It is not possible to deterwise if all hogs of Ottme , sand received in a shipment have been tested. A response from Pittsburgh Testine is rewired.
- 7) Reviou and appreval of PTL generated FCDs (te PTL procedores) by MC appears to take en excessive amount of Stas unich coeld impact ,
on-gotog activities. FCRs containing changes uhtch are staar to nature and de not require estensive study or restes have not been responded to by BCC for ever one month. The fellering are asesples: PTL FCR No. 097 (sutoitted to BEC 01/26/84). PTL FCR an. 098 (submit-ted to DEC 01/31/84), PTL FCR No. 103 (setaitted te OEC 02/16/04). and PTL FCR me. 099 (subettted to SEC 01/31/84). PTL FCR an. 099 , adds requirements to test for weight of reher, a test regnested to be perforsed as directed by SEC. As of Aertl 2.1934. these FCas have ge y : ( A M - h I e l l
co31% .E fiF . 382
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*CsuCDus: (CONTluutD) not been approved by BEC. Perthovuore, as of May 2.1994. only one of the four PTL Futs has tese appromed.
A response from tochtet is engsfred.
= .
- 3) PTL Proceeste OC-AS-1. "thselity Asserence Program Addomen", is met [
t referenced e addressed te other PTL implementi proceesres. This j proceesre *sedif tes requirusmits la P1L Osality trol Precedores.* ;
- l One of five PTL personnel spiestlemed, as to the purpose and scope of AD-1. know this procedure ses an addene s to other PTL proceesres I, ut1113ed for STP. It is noted that PTL Mensels revisued at the site g testing laboratory contatand head urittee cAseges to the affected e-Sectlens. .
A response from Pittsburgh Testtee is reestred.
/ ,
ECtWemATituts: , f; la addittoa to the initial recommndettens sede prevleusly in the summary , of this audit reeert, the fellertag are effered for censiderettom:
- 1) The Bechtel (>sality Centrol Department should be evaluated to deter.
eine the rest causes of their lach of involvement to centrolltag the cuality of Category I backf111 activities, i .
- 2) Quality secords generated as a result of inspections and tests most provide accurate informatten and rellahtitty as to the quality of installed items. Erroneous dm==ntatten should be corrected per proceduralized requirements. (Concern me. 1)
- 3) Stace different source types of beckft11 unterial may be encountered, i l s a preceduralized anthed for deterwining tetch source type material is g being inspected / tested should be devised to provide confidence the material is in fact the type documented by ESI QC and PTL. (Concors l
- m. 2) I b
d) Since test fill and qualtftcatten programs are established to apprest. . ante actual field practices and demonstrate acceptable constrecttem 8 methodelegy and egutoment performance in obtaining the desired accep. l tance of material, the control criteria (i.e. Relative Density deter. 3 etnetten) apelled should be caseststent for all test fill and geall. fication programs performed. (Concers he. 3)
- 5) Since the specificatten for testtag the surface Itft for conosction appears more conservative thee the F548. the F5AR sectica should be considered for possible rettstem. (Concera me. 4) t
- 8) The tackft11 Inspectlen Report should be reetsed te include sfersace to the specific paragraph containing the attrthutes which are tospect.
ed/verifted under each ' generic
- checkpotnt. This could be provided
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%Cova* Tim 3: (CMTTREB) adjacent to er to the tieck estch identified each ' generic
- tospectten r checkpotet. (Concere be. 5) .
- 7) Acceptance tests for incoming beckft11 meterials shoold reference the .
t
. lead ttchet numeers and date en the load ttchets to prgelde traceabil-ity to specific shipments. (Concere As. 6) 8)
Tests tesorefor helt density traceshility. (send should Concere as. 6) reference speelfic shipmeste to
- 9) Bechtel sheeld evaleets the contracter FtR system and determine hoe i the system could be enhanced to redece approval times sad subsequent
/ mettitcatten to the centracter for implementation. (Concern 28. 7) i
- 10) PTL Precedwre OC-AD-1 should be referenced te such that personnel a uttitzing PTL procedures are aware that modtf tcations to reeutrements contained in those procedures are included in (;C-AO-1. (Concere As. '
j -
- 8) !
ATTA090tT: . I le.1P CAR: G-4c3. W. G-405. G-406. 5-407. G-40s. E-409. G-410. S-411 4 6-412. G-412. G-414. G-415. G-416. G-417. G-418; all Asvistes 6 j. , it&P Dn: 164.166.1M.167.168.169 and 170 44.&P NCA: AC-OtEE1 .l, l' d a t
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- Project Specifications". Rev. 4 l
{ SLOCE (7) OCSCRIPTION OF CON 0!TIOlt ADVER$t 70 SIALTTT (CDrff)
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Paragraph 2.3 of EDP-4.49 states in part. ' Personnel preparing spectfications . 5 shall review the reeutrements to ensure apolfcable regelrepents are addressed. { g 1 h. Aan19enhie enees. standards. and reculetery reeutruseats.
! i
- f. Preiset nuality Precres escuireawnts.' '
i 0APO. Rev. 5. Part A. Table 1 (Also POAP. Rev. 3. Table 2.2) stata in eart that t*e e.sa11ffestions of inseettion. fraafastfee and Testien eersormel - L confnes to ANST rias,r.g.1973 ,nd P.C.1.53 (Dev. 6. t/F31 as coff ff ed tv " netitf ens E 9. f 8. C.T. C *. and C.10 of Rev.1. s
% . vee. to the conte we. SEC Socetffestion 3ffE0?'O.*t. *Fleid and 13boraterv t tf-e af r met %r* Paatteectinn* f also Pit fem L e 8M".f0 21 en1, f er nLes Amt -se M.1ets and A e an* cor-it reafemnre tn R.C.1.!! fr ev. O. 3173) as mdf flad >v msittans C.S. C.6. C.7. C.8. and C.10 of Pev.1.
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; e) Type of esserience i b) Recuirino documented ehjective evidence (f.e.. scoceenres and '
record of written test) f a the event capahtlf ty demonstration ' r l f t the criteria for secteusei certification. j .
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- 1) F$AR caraersch P.$.a.$.$.f.4 states in oart. ".9enover fill er bactff11 isas placed durino a tert shift, at least one field test us cerducta4 during the shift and a sasete for laboratorv relative dewstte testfew ii test obtained, provided that the eersaction was caustetad to sose arme.
i, Contrary to the above. SEC Specification 37069Y10Cs3. te,. 4. vanvires; i . I e a) One test per eieht hour nort day and. l l /b1 tees not retire saroline for laboraterm relative geweity testirn k l 71 FSAR oareceanh 7.5.4.5.6.7.5 states in eart. 'Fer staterade creaarations. a sinimum of three additional in.elace tests had to be cerforced within each tested area. [ Contrary to the abeve. StC eartMet seeetff estinas dn eat toetsin the above ouoted rennf rauents for suberede ne,aarptf aa. j FCTT! Ett rosnense eerst addr-ss the imet af the .3t'eva cleficie cf as en the fill /bactffit stared to dara sad 9at*4 =ce ef t) arre-'*1rniv. t 0
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_St0 Cit (7) Ot3CRf PTim 0F Colfff!ON ADYtitSt TO QUALITT (CO'fr) ' l F5A4 Paraorech 2.5.4:5.6.2.5 states in part. "All testfro ws done in eeneral accordance with ASTM 'Standar6s. treestions or clariffeations to AST't are seted hereunder for each fest type. j* . t
'/1) 3. Ffeld density ustne the Sand-Cone l'etsd-ASTN 01556-44 (I MS).
/
MOTE:VTie butt density tests were run as a etnirw for each new ! * ( h'., e*.'** bio. Additieral tests rust te run if results deviated more
;,el*
- t* n cae cercent. Stardard sand had 100 cereent cassine the V':o 10 steve and none passine the Ms. 200 sieve.
font-3rv to the above. the tw ouoted cemitreats (strineent requirerents) are t not incer orated into PTt Proce+sres/f astructions, r l F) d. ASTM 03??.61. Crafn sfre-steve and hydrerTter.
/ Contrarv to the above. PTt stoceeare OC-LT 1. Rev. 35 takes eteeotion to ASTM CMf in that, the hvort-eter me* fen of the tnst ts not reeuf red to be nerfor-ed 'ee faterv i ste:cturs1 backf tll.
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litt SaGanafung pA;g gai3 gFfECTivsSATE l I 413a CA4JSE OF CossoaTe r I l
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jf* ' . p l se :Es. - t-tgh* ca enantcmq actiese ermopy commusuatwng its can suo. O NS a mv-- / 4 K0CK (7) M 5 0!PTIGE Of COMO!TIGE ADVERSE TO 0U4 117 (CENT) On.noing show Cause Comitment VA(2) M states in part. that for bedding
- and backf tlling of ECW System pipino. CEC specifications. ESI QC Procedure.
j ; and PTL phres arg revised tu incorporate the fellowing requirement: l
'tocations and sequence of various placesents and correspondence (e. place -
' density test results will be documented together with smuories of the h report construction metteds and conditions.'
l i
! Contr.iry to the above. during the audit. no objective evidence tes ,
orovided as ter a e / a) idhat changes were made to the specifications and the procedures to satisfy comitance to the above evoted requirement. , l g / b) tarat doewentation was generated by Est and PTL to ensere corpliance to the snow cause coe=1:eents. - r
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me # K 0Cr (7) IKSO!PfitEl Or Core!TIOt AlWE115E TO OCALITT (CtNT) 1 F5AA peraeraph 2.5.4.5.6.2.5 states in part. *A sufficient stectalle nas 4 . 1 eaintained at all times at the site to perrit saeoling and verificatfee of ' I I the estarf at procertfes before it was placed. . . One smote mes attaland a
- for each 20.000 yards as the wort proceeded. These sarsles were tested as I .
t roottf red in the above paragraph.' Above peregraphs If st testfag as per , b 0 ASTF1 0F049. 0422 and 02438. f Contrary to the above. se specifle evidence cou1J be prod.ted to substantiate l that relative density (ASTH D2C49) is also determined frtur the sarples fasm l stoctoiles. II0ts need to be inttf ated if the ateve stated condition has i 4 fanact es prevfously placed baciftll/ fill. ' __ i i _ a.m = _,,,..x..==. - - - - - r
- E_ cos,9 5D3 aos s .
s e 6 f. i- - Ar//r' M.M SOUTM TEaAS Pm0 JECT ELECTatC G44snATm4 STATION Todl3 II e ** * =*G. M O N8 guatryy aggypApoct N [,. gd f I
., C "3 Cd37'y* g CORRECTWE ACT3084 REPORT a mevenus # I as e-eu.o= l m t. g i., ou g m m aarv=Arno g ,,,3 , esv ,. w t. l=T*.am = '",a
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ir, _ 1,o o , - ~ rio aov.a u ro un . 1 M
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<ss susta visosu ttao auoiroy y,,,,, .c .f,,,,... j,,;,,, oAra .af.y jgg. ,
g una samoeatactiose
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I i 2 t e S. oo ..c.uruns para paa peacTiva oars o4. w .,eosca.o. m L i i g g nas coma.crivs AcTim to rnavaur ascunasucs v t N I 9 nsa asvearsaeca,*novao
- cars pies 6**ECTivs pars a'-"a'-"'a vp.,:lig r",8 8:tyl: c:r .::; t ;;-a'a= ~'da ""
,,, a s cu=anco.ws.u.cs s - ca RilPQtsSE alm poter asetT& Aron I g af,e j se,PtnvamosbLsAo.assaiOA oAIE ia, v.a....ar.on so mrao g;:;, g.u.s a. so.usAn auonoa oars ,
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- 2. eses:*:-% f.*.? ttates t- es*; t* t 7!c t s res :=eir*e f .N*se'.--t-s
/ and f. sle seti-t treceteres arf f est=:ett.-res fe* cc-!==! ef e221!tv cels?cJ nctivities.
s
! Contrary to the ateve. no written erecchre er testrsettens (Pv PTL) esist for sa mitee t'actf t11 rate *f al frn t*.e ste:1.stics .
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a.i. ~. ,t /1 SOUTN TEMAS PRCWECT ELECTRIC G49etRAfugE STAT 10pt I y'pa ; ig.). t assustcu Laonerves a powes i
. ..:1 -_m Qtss e a)./Q4 f y
.; oua urv assura es encan s # +'e r i t
CORRECThrt 4CTIO8e REPORT gg ngygggse / f IJa ^*' "'^Tsous ,y y lpgefjecugo, lssi,s,i y sWEoATE i., m eirv o u rso l m,,,,, jas v. , r= , , ,
'#3 MN@dfW6W4MYWEr?. 9 .(tfC). . . tad eN contractors perforwins j activities affectine esas11tv are reeutred to accerelf th and i:EsM these activities ,
in acceedance trith writtan erecedures.
- Centrary to the ahese. WF/DCI-4.0. Rev. S. does not descritie the e.w-s. s. i:2 1eev. '
l and teeciffe doctaneet rueisf rusents utilfred when Cateenry I backfill it received on-titi [ Class 9 and suteseevewtiv usereded to C1ast 3 ories" to tree. (20*'T) 156 6h6 T4 ATOA y ,y g ,e ,g DAIR u , p g y, 696 suri Avis 0R4LLAG AuOsTOR yp.g q /,.f p e g ,, j , . DATE % g pp j
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. f 046 GGAREGTfVE ACTaGrt TO PWEWEffT RECURREpsQ L
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ts.W yrr'", " * 'a'""a in.Tlt!J c:T:t.f.3 "*""* '*** *""a d^ Ausproso s wane m >ee--a - t AESPopfte t ag. nLJ.r s.wa r Argst g a gswitnvisca,LgAD AuOeTQat naATE i a .. .. o re.c - rso g ,g, g av u a uAaAuo.ron oAis 4 ai. a...w.c:. cw4 TAna 1 i m -tu cA aow. . m. ,m i
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t f en ar e a i ROCI (7) ECRfPfl0N OF CIBCIT13 ADVEItSt TO CUAlf77 (CC':7)
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Additionally, the rethod of eco* eval / release for use is not saecified. . ti
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-IhpIi aou'rca o*** m=** *.... !
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. s (3) gGAm@Taan y g gaguhango_ gmj ous can
'" #7","'MIR*M^."* i"'* m Fit'^va (7) etKJiaFTIQ88 OF -Tipse Asynnus TO EM4A4JTY j f A1 OCT.t.4. Rev. S. seregreen 5.1.3 states to port. % methly plan shall provie (
f coversee of safety related construction activities and he flexible enough to
/ adfust to constructfon schedules or areas of concern. Pretien areas shall have follow.ve Effectiveaess Inspections at increased freeuencies entti confidence
, it re-estabitshed and t>e deficiencies have been corrected.' (CIBlf)
'*> # #U" *>**s,o we /d ($4"$*.)J /* DAH A 0 1 * 'b *
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cars pf p f p , iiO4 A&MtosAt ACT40ss e
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o ll I b 2 . , j me sec:. arums paTa pia anscriva oars - L us i.auw oe ca u isua k i k ( l ' s i r, (144 GGARECTeVE ACTEDfe FQ Palv5MT RECune:M w
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manoso P '8""*"**'.ca :ean l asspor:ss ..t., unimod cara iia. g gs,.y lw e a v e uAo auoiroa
.a v.....u re.cc. ru ras g g, g-..wau o u.s.:o ura e 4 .ai. vaaa.c.u a.. a u r w :4 a
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f can as m i I 1 g SLOCK (7) Ot3CRIPfl0ft 0F GeITI0tt ADvttst 70 OuALITT (CC!T) I
- t Contrary to (A). 8tc OCE has set perforced an Effectiveness fassection certalatae .
4 to STP Cateoorv I Sackft11 actief tfes since Cetober 1942, a seriod of ae-rev. teately 15 senths.
< p (S) 0C12.9. Rev.1. paraeroph 4'.1 s'tatesi "Surve111ances are en netm revtm
'! of the contractor's/constrveter's cuality practices' for confor aace to the ,
!! anolicable cedes and stuutards for safety related censtmtfen activtries at
)
i the south T...s prefect.- L sl !
-l M Contrary to (B). SEC Oct has not perforred a survet11ance of $T7 Catewry I '
.1 ,-
8 hackff11 activities since the orieinal issue of CCI.2.9 (*ev. O) en
.I octoi, c 21. i,es. . riod of re><r.ateir five (si centh . I Il.
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- y. pg gim eATu tea DOCUMENT VN3 LATED wee wt 2 n
- 17) DE3GarTaose OF CnmoeTiose Acytasa To euAuTV lag w* a f% 31ad (71 1 fA1 Parneranh 4.1 statet. *All receivine shall be ordnes=ed by certennel etsiened l j
hv the Et* IRecievine tuaarvisarl. g y Contrary to ( A). sersonnel are recetrine Cateery I backft11 meterial and they have ; not been assioned by the R.S. (Construction eersonnel arn perforwino this fwietten). l isi .riAron %, y f;.,,pgff o^<* a_ r it i , wi suPanvisonsLIAo AvoiTon 4,,.. a e,ir* A,. , / OATE W 8 79 I.
, 1806 MLA44.04AL ACTaose t
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"la UGa^rund ,Mit pi2i teseCitva nars I usa s.Auu oo cmossoon i 4
( t 6 L s 1944 LonmEGT4WE ACTION ToPnEvtNT n&GunsitroC5 I l , 4lle MEvaI. vase 0 A N nQvAb .uArt ple6 47 FECT4WE DATE
.........s 6e,u :.Arun w. o. ,...av, .w.u. wunwa ennu (tMN9e pie, et st e, e . m- d Aussoso use manswoncencs an ll t nasporass us.
w wiesaAron g .w.,.
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/ . l / KOCR (7) DESCRIPT!Gt 0F CotSITTOR ADVERSE TO QUALITY (CII!T) i g!(8) Paragraph 7.2.1 states. 'Shloments that are received eastside of a controlled ,
receivine ares shall be tagred with a
- Hold for Receivine issmection" tae. ,
f l Contrary to (8). SEC Receiving does not apoly status indicators to lesentsug {
' ' I Cateeory I backfill stactoiles.' 8 l
[(C) Cahibit VPP/0Cf.4.01A. Tast Im.1.2 recuires Receiving CC ta perform a i* visual insoection for cleanliness of Category I backft11 material.
- s I
Contrary to this. SEC 9eceivine CC is starping this attritrute "Actsyt* srf thest perforstng the required visual inspection. (D) Paragraph 4.7 states "For echtel procured non-safety related. ...anterial.
! the coentrant sucolf er Cuality Representative of Field Precuruset. . .shall review soo11 cable documentation and if found accestable. shall sten and date the petR. . .* l h, l
' Contrarr to (D). the SCR is not signing the $*R for Category I backfill meterfal. ,
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' ----- SOUTM TSEA8 PROJECT ELECTRIC GENEAATueS STAfices acus 7a" cama mman i p3J 3 i h+
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, T* , ,,, _c.- _ :; ouAun assue cz in m = -
i w w4 e s) #C&& 4y CDRREN ACTDOst REPORT gm @ $ 0" ' " f3f renttruction fd.'eE Ew he. see gGCuaanNT vsOLATED f 3 gg gg.g gy,y f Elect (7) (7) psaEnWTagm QF eveT8Q.4 AQVBREE TU ERAA4JTT See Continuation Eheet. J n // 8 , (se thaT6ATQp g y y .CMTE gg/g , its suetAva5sAsLs2O AfDATOA y, , g {gN_gf ,OAlt gp(,M g i1 03 AEas406AL ACT4CN e. l 2 i i k h hh k Ih h i us, Ca or conossoc., o 04a CORRECT 6wE ACT60m TO PRLvEsef AlcuAAENCE so
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4 usa dev.aa..uaremova6 ;oaTa pie a**acraws oaTa .. WTf@rsk r"' "*'""* 80*/l: c::'M' AutnesoI"* """** * *" " " - Responsa jua. nw uuriarca gzy c g swas Aviso.t 6 ado Awa6Toa oAis
- m. .a .+ ;AT.u:.uuTao g g, ls s.vwa uAo A4 . nom uAi.
( .,216 .4 AaFICAT4 Wee ACT4Cl4 TAmbe i e-GA aW CA CLbsuAs up e.A.i k . -. .. - - - - . . G
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t l 1 l me ca conesemw armas meetwv etymusuATwpe til CAA8EIL j m m- / ) eLOCK(7) etsCR! Primi er conomen Acvtitst to quaLITT (cc:rt)
/ , 9 Attactrent 4.01 of C5P.1. Rev. 3 states le part as fellers: ,
I 5eovence rio 3.3 *If backft11 saterial ees net have proper snisture centent, it shall to conditioned by sprinkitsg. . .*
' secuence tio 3.9.*Cohesteeless backft11 meterials any be spreed to itfts per I
+
spectflcation 37069750043." i Secuence fd 3.13.*Reewst comaction tests fres (hality Control fa: sector fer each Itft in accordance wlth paragraph 9.03 ef this i s proceshrre." (OC Mold Point). , I t Contrary to the atevebocal excavations for density testine within the fill area are backfilled without CC inspection ankomaction is set perforced as I
- f t was for the oriefnal stacament.
' for exarole. in en eserestrate 4 foot by 2 foot escavation for density test.
' flo. EL.U2 21C7. and an amorostrate 2 fcot by 2 foot excavation for test i
I T3o. E1.?J2 21L*$. tactf t11tre taas acetyreltthed with a lift that exceeded 2 feet in its decest certien. Aldittenally, the rater 131 mes placed la h 1 aeora+steiv 3 inches of standing mater, and was cassacted ettwat_ the { i add 1***n of tret*e. (ffff; These Mlr$ Were etcavated keverst testing deeth te $ , l centmi = te, see m e). , f m- ~-v- ' ~ w w-e,- , f
_ . o. . - _ - * - . B(Dg 405 CO3194 8
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" ShffM T13AS PItOJECT E LECT 1tsC SEleG AAT1848 STATecus a === c-#'J -
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. (7) DE5GJteFTIO8e 07 GG.NDITaQas ADanam TU (RAA&ATT See C9ntlRhf4110m sheets.
./ Ak (Se GNaTIATQA , DATE g g m suraaviscww Avogoa % ,, , y. f;; c ,,,, ,. oar. ,f.p ,, ,
1890 ASAft0tAL ACT40fe
- g' i
i-i 2 , e i . - I p1B EfFSCTIVEDATE lill S8G*ATUAG PAT 4 , tid GAusd OFG4enastaua ' i I f f
'I tide CORA&CTowE ACTION TO PAEvtNT AECndAAEfeCE 3 i, r
]
l I ns msv am Asoc arraovAa, pars pia ausCrrwaOArs Eh64a
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ggg GATE N 613e Mb4P EelI4AIGN Q , as g54,rtevanges,L&AG A6mf70H GATE GBs winees MT@e n'Eart& TIO g g, g56vtaviMet LEAD Aup40st 620s W6 AspsCAt SON ACT*s5 T A&Le
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- 4I/I en me e BLOCK (7) DE30t!Pfl0ft 0F CDielTIOut ADVERSE TO QUAL 117 (CIITT)
./
(17 MCAM4. Section 01-11!-11 earaorsch 3.1 states in eart. *fnseection documents g thA11 he Ore 0ered based 400n the egality re0UlrWETnts Contaired in pur9:hase erders, ' e s
/' seccifications . *". .
1 Centrarv to the above. EST OCP-10.10. *$cils Insoecties." Rev. I', does not ' f centaia the fe11ewiae recuire eats of SEC Specification 370697$0tM3 ' Structural s
' t f reesvatten and 'act*111.* Pev. 8?
I /11 The e*Pdetien and distributie* ef enterials in the c=rnacted areas shall be , I tte t9t bee 6f t11 er fill is aet seareasted. (Paragrooh F.8.1) a l
,fl Fitt turf aces that) t*e censtmeted to that water will readily drain off
* ! at all times. (Parsersch 7.8.51 ,
11 femmetien will act ta 4116s a d withia *00 feet of an area where in-situ
' *11tv Msts are belea *erfiered in neanular caterials. (Parseraem 4.1.#1
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ts e.d He-t . alls hwe haaa etNfad, th* hackfillian _ ,i
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! th.111 te aeefe*=ed ta that the erntective wateramfinsi aterial is ret
- 1. 1 I' d.- ed. fe=e cesch 7.9.11 n
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0031 % 5 JUG . 407
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SLOCK (7) DESCRIPTIG10F CER1DIT113 AI7ttR$t TO Ct!ALITY (Ct317) S) Backft11 adjacent to structures or over cortions of foundations shall be [ olaced and cascacted syr:ratrically ard unifomly by the Constructor in a e manner to pre'ent eccentric loadtm or unbalanced pressure seen or against the structures. (Paraerash 7.9.7) p F i . . The condition is not Ifsited to above cieted recuiremts and EST needs te O P, review tPe seeciff eation and precedure to e9sure tPat all specification I reuf mnts are either directiv incomrated into the crecedure or included
' by e v61ee reference to the spectfiestien.
e, t In the event oreviously olaced backfill / fill is frMeted due to non-conD11ance to tSe stove eueted reeteirwwnts, ft?.fs) read to be initiated. } I i . l. I 1 . 4 i
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.Th9 . _ _ .!COi auA6m assu.A e in su == /2 ""'
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pr9.in in B.= 1 ameanenn.i bA i i f hi t*1 ten "nAnore PA MP9I #Hb.PS89 $t ------ - ^ _ - -' thm 9mehtet "- ' a t4 na Veri f f ra *1Pe Fse.4=ae,19t*11 t ruti r?*. hit meesats.ee in the res.rts tection of Attathurnt 98* f fack fill IntDettinn 8*et*Pt).
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I I e 4644 6CARICTiwE ACTaQte TO PREVENT RECuMREhcE c t .: ; ills MEvit. van 3 MPRQvAs guaTE psae EHECTavE gult s l ge e.. .. s ..g p i, . .w u s.,. g ,....
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, Stocit (7) DC3CRIPTION OF ttmott!!>s AOYt1t$f TO CUALITT (03:7)
Centrary to the above, no objective evidence could be provided that the SEC Foundation vertftcation taetneer has maeood or accepted natural suberade
, ielch is encountered during constnaction of safety-related eset hemks and ,
t i senholes. ,
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' ' t t taar:1es: Manhole 53.C ,
Ducttant 134 (south of manhole 155)
- Manhole 57 4
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= =="*"' "'^" s si = = m i"'% si.es m T'" s stoca m (7) stauserTepet GP GQM0lTtDh aOwlP5E TU EBaa&JTT sGG CORtiMbeet109 theet.
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i 2 : I ( i I inn s cs.aruna p ra piza unctive omia ( i o - os ca .o.m i i , I L , Lies GQARECTivt AC160;e 10 PA4WEh! Alcua AENCE S I l I , L 1 r l I i l I pn asescrivs oars . os. .isvia,v aho arwaova6 pais l **na l t;;p,:;u yau "s"""~w vem::: o=~y=1 ~ = " ~* ~~ ~~* " cQnamo.sQ...cs:.w ua j l , , , , o o4is nesponsa o v. w ..nuG.i g= gusAn a.uuAa.wairoA e4is . ca. , .. ar u.6cus.ario g g, sweana,6.ao Aw ru 4 .an v an.s.wus actic:.s ras..
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geup ca emteTwt actwpe mescore tzymspavirue m ennna O- #f e .^.i. _- A GLOG (7) DESCRIPTION (F Gre! TION Atritit$t 70131ALITT (tINff) l FSAlt Section 2. 5.4. 5. 6. 2.5 2nd parserach states la part. 'The inspectors f considered possible variations in density wit.4 doeth la determining t.Se test locations. The tists are selected such that a series of consecutive tests , will eive reeresentative density infor=ation for all doeth intervals witMn I the Itfts.' Seeeification 3Y0697!0083. Rev. 8. earanceoh 4.1.2.2 states in part. . .
*The Constructor shall contiter variations in density with doeth decending en If ft thickness, slacement and coreaction cetteds. and shall distribute I the test deeths to obtain the true condition of the hockft11.' "
O I, ,. i $pecification 3Y06975c043. Rev. 8 (Tectica 4.1.3.1. *30. Inch (Cf Pices').
- I paraaraoh 4.1.3.1.3 states in eart. *. . .The test shall he located ;
f f tr*13telv adf acent to the etce at an elevation of 7 inches below the invert. . .*
-l
' _ PCf.1tt.10. Rev.1. PCR 7. esraer. inh S.3.1.1 s tates. *Frecuency of testing shall ta as eser1Pe4 f a 'echtet teaciftestie.n !TC$172MM3.* OCP.10.10. Rev.1. PCR F. I f . eerserseh 9.3.1.? sutM. "terstien ef test sh311 he as described in techtel l I S eeIffc:tf on 3TPA97!OC43.*
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e I g 3 i estas na emeneevive amose meerme crustegntwwe tst CAn na, M#8 f , m u._ # jl - . . . _ . K 0CK (7) DESCRIPTION Of'bt!'Tict 40 VERSE TO CUALITT (C0r!T)
,! Contrary to the above itsted roeutrements: /
11 OCP.10.10. Rev.1. does not provide criteria om density variattee with
.+ ,
' doeth to enatie OC to determine the correct location for testing.
- 2) There is no objective evidence that bactft11 installed by DI has team '
T teste<t at tre required deeths. in geceral. In particular. there is so ob*ective evidence that tests tetow 30 tnch 3 EC:t otros are takaa at a deeth of 7.tnehas below the invert. OCP.10.10. Sev.1. does not require k, test deeths to be recorded.
! rat: a) The fieid test eievation seiection orocess does act eive reocesentative density infor .ation for all depth intervals I wm nt,eitn.
I g) PTt Pmeedure CC-371 provt:::s for recordin*J test depth, but l l
! tti et is not trovidina test desth inferration to F*t for l sukseeuent refertian on the PTL test fore. ,
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Ut.3EmIFT3088 Or u. TION ADVERAE TU MTY i"" w swaen
/ nt one. dure oc-tv-1. n. vision n. section it.r. states. *asennein contatas a 3 11stin. of standard writtea test u.thods editch shall h. employed in conducting sn. is. citied tests.-
a .ther tn.es, a asin i nr.mne.s asm east.e (.e unien o an is l f l inteeral eart) seed 2049 69. (CONTP4l(D)
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t sette on comercTtve acTwn espoort evmunewn m can eso. 8-4//6 m h+-r-i K 0Cr f71 DEstatPT1GI 0F CoactTYes Ac?tt!E TO Ct'ALITT (CC*ft1 PTt emee6 r. ne.tT.1. nevtsion 7M. fection 11.1 ststes f a cart. "The fo11ertne
.fl1 AST't test rethod standards d.all be osed to aerform the tests treef ffed.
.0-1516-44.(631. .'.
I al AST4 D472-61 reestres e.curatica of tk tes't tapete for rischaatcal ana1Flis ner AST.4 6 821. A31*4 reoutres air drvine of sasele received free field 8 b t' etiem *.19. t5 evarterine (f eat m 3.11. tha seatretim en e 'E 19 h Sf a a f **ettaa 4.11. tPea ashiaa the rete *f at retataed ca t>e m.10 sim fr of 411 flee esteeist aW devine (Tection 4.21. t**a stevina en the tie. 4 sfeve f?Miten 4.71. ,
,l t al atm om.as. sectie. a.1 -,te-s =. .sievice , tit ee mee t*aa a .ess I
1-neeeeat et the e-tf A e aa a sim *19ses that sfeve #8urten erg p4Me of
,$.,fna. m .a r.e m entesi eleviae is used. test the teerenahaess nf s!. vias er , ,,tf ae *>e h pA cett ed of simir9. .".
l ige.( sagnica ef -1; trial esssine the fle.10 4 c) 45T** P279 A3. Tecta., in,) r ( $ eensb $%fmegqh 8 "19 . N 9iaWS. o e pt me-, et?*.s1. e.ette,r ?? 1.3.2 reant ers raaerting tka h3ms of the r I -se.e4 1 *.e*ed een.ame e e n. ese E i I I
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s l St0Cr (7) OtStRIPT10lt & Cc+'D1710M ADvitst 10 GJALITY (CtrtT1
/
el Am cists-es. Teetten 1 reentres deter =ination of t*e wtwie of t>e f ar ' and attattrent for determination of butt density. Note 4 allows deter.
- mination of *. . butt deatity in other containers of taew vetur, that
/. i diceationally &ee.esimete tPe f arcest test hele (Ast will te due. . .If i tMs n,eceA. ; in fellow 4. it shall be deterwined that the resultine igulk e
- deastev souais that eiven bv the f ar deterwination.
fi st*8 n*nie 8s. 'eette= a .1 con aires detereinstion of the m1Ve of the
**14 hv diraet reaie r xat. and Chettine by filling with mater, el AST"' 07C49-49. Section a.1,3 reevireg ettaining an init141 dial reading.
Men = rill reasin consteat f:r a oarticular wessur, and sure%aras tase I, elite combination.1Pv elecinn the calibration bar acrets the diameter of I the reld eccess the eutet bracket amis, il 1,1 hi es*a OW9 49. Tett1*in 1.1.3 reevires catch rarts to used to the ceasure. ease *n tha M9 af the hi se elste c39 t, rede in tPe $3re relative Cetitlen fne eer> n =1=re doest *4 h*e***instina. I 89 SM f*ete 49. Teet1*n 4.1.? st3tes, for r1ter131 SlJted with a funnel. L 4 * ., =r e s. .. . nit to,.1,,1** t*e tas b ett t re e a centinue is res.eeneetaw r rats trith the,Stael 4trateh**+=e.' Y g.
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II A K0CK (7) OtSCRIPTION OF CO*0fff tPt ADft1t$f TO fRIAtfTY ftt"r1 Cent **cv te al above.PT1 enarteet. then even def pt the van 1=_ shnet et Vfth smearste en a Me.10 tieve. and deet not math the rateefit ro ule*4-i recard to b) above. PTt uses a mechanical efevino device. Altheue> fabo N story oersonnel are fast 1 tar with the tength of tfre for sferine this tfee has not been does nted, and 'thek is se c'tiective evideve tshat smoles are steved for the same leaeth of tire. Further. the thermNs of sievine is , not C,,ded. Contrary to c) above, PTL detemines the aseunt of meterial finer than a fio. i 200 steve bv dry stevine ente. I i Contrarv to di above. PTt for-s *eceert of Particle $f re AA11rsis". Form fio.
- ST.3. and "Recort of Steve Analysis'. Fem rm. St.A. have no erweislea for recordf ao this infometten.
l l
! Contrary to el above. PTL detemines bulk densities in a 0.1 cubic foot ente.
his not #tt+mia*4 the N1t daatity usien tha AF orescrited athed. and has l mt e. cad t*= casu1*t af ***f e -atMt nf detWa.*tian ta ensure that it eauals tPe 8er rethnd.
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K0CK(7) DESCRIPT!CR OF C0fetTIOlt ADVtit1E 19 338.117 (C3ff)
~
s Contrary to f) above. m instruction sheet IS-OL.22. Rev. O. 03/03/82 . reoutres determination of sold valuee by the wtar filltag method only. l- .
/ l::
- Contrary to g) ateve. m seres the gage on the base plate for each of ,
the sin reasuremnts, then ratsas'the' gage ' stas by hand, and slides the end of the calibration bar in along the periphery of the eeld. steeding - the bar by hand as the reading is taken.
+
l " [ Contrary to h) above. m uses no match maris. se the base plate measurerents are made in different locatiens each time the masteue density is deternimed. r
, Contrary to il above. m adds matarial by hand to the surface of the I set 1. filled rold. after screedf ag. >
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.~***-" SOWTM eusmiwas TEJ.EAS PnOJSCT i
a smaELECTmaC 483.gAAragg gfATidNS , '
'.~dg...ya,, * [c1l .ht l' ou.ury AssueA ca sacaa m * * " J coansCws crupinsmar . # {
ww .y l#i aug=gg,, l=.,. t r ou= = = i
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5".ny'N '*'^*w.Tsun m i tar nousorw movanas To smaAuTT g* The !____- reference statet (a Bart. % visions te SpeCifiCat10ng shall h 6 W J revision. FCR/FC3. 501 er Addendua. . .* Centrary to the above. the SEC Contracts flanager instructured PTL. la serressenaence
#57.Y5 00 00182 dated 2/2/83. *to change the frequency of tests reevested to the
! mference correspondence" (5T.75 00-000173. dated 01/25/83).
o^n :. . p . ee d' " ** M.. m e titr% a oars 2, 9, g is, surt A visoneLLAD AwonTog _,, , ,, ,, ,, , , ,. 41 0. ALadio.AL ACT.ON i . 2 __ tilt N Narwat ;oAta paa suscT wsaars . oa c was os co.woor.cM i I t l Ild GORRECTavt ACT60.4 To rREv5MT RECnJR AENCE
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Nt Ap OA Co#RfCTWE ACT43sf Wet COffTnfu4Tirug 310 CAAE80. DY m R. _ SLOCK (F) DESCRIPTIOR (F @!TIOR ADVERSE TO tR:ALITT (03:7)
/ .
I
- 1) Specification 2T06075044. Rev. 3. paragraph 4.CA.2.6 states in part.
'Conoaction control critaria shall be controlled by t2e soll tne and
,e referenced specification and developed in accordance with ASTH 1558.
/ ! A5fT10598. AITH D1557. ASTM 02049 or SCR E-25-43. as apolicable, and i
approved by the Construction Manager.' 21 Forn G-321-[. *tegineerteg Docurent peowtrerents". reemtr-s suscittal of ccenaction control criteria prior to use. * ( I Contrary to the above. no objective evideste could be provided for s casoltance to the above quoted requirements. i l P c i i
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WPP/OCf.4.C $ s eE re n es
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The aheve states. 'fator Material Receivtag Report aster. i Contrary to tais AIP F2015 IIstad N1 ft.2015 feeteel of the proper it #5-44M.
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\. alAutiAsm.asars eesao N 5 OEFIC3ENCY %T88:1 1 e.... ;.r.o.
s . . s . ..a..e n pe.sa Y eer. M-DC u4
. ow =4.r v.o OC.LT-1 se . . . . e :. g se WW e ee.s..e res= or essec.a.c, 5 f 12.3 t 1 >
I 1he eteve reference states in part. "isien stande=d arttten test metlede de not ~, ' entst for the test activities. . .FTL shall prepare arttten teatruction sheets. ' which shall be identified fn Appendla I and attached ta tats precedure. . .' 15 510 5049 49 paragraph II.) states. ' Vibratory table shall be calltrated in' accordance with IS-515A.VTC.*
! re
. Ce,n,.t.rar.y to..the
, . . , x. De .lative n. dens.ity w t.a,b.,le,,,.calibrettons r e...i n s.w have been performed
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. GAsuff Ass;naascs se,, je 6 l OsFnalitcy r:v3?.C3 0 ,
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.er; ...r..e64eae sv.m.tst I sr.#-spf -
- . . =.sa. a e eaaa.
. EC.DC.1 11 lF.10.2&F.18.3 e sen. r.c. os se e.c a.c.
y peregraph F.10.2 states la part. "The retest report shall referene the erfeinal report to revide traceablitty. . .*. Paragraph F.10.3 states in part. "All rotest reports saa 1 Indicate the date of the retest (s) and shall be filed vita the original report.' i 8Ja'i*n t - Osetrary to the ateve. tettle retetts are clearly tematiffed. and rehressee the original test by test number, they de not reference the original test reports, nor are they filed arith the original reports. ,
. A e en.a y aage
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+ /9/e r' asia eara C1) h t.'as lL L %.;** es* fond" / .W8. *.,o i d. Gn. M*L*0$
u nanas o.46 as!.e.. l . t S . 3 P t b
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5T.4E5-19 00P53 I . Pile Re.s (15.8 It". L. E Ihrst Project GA Menager Buchtal Energy Carperettee P. S. Sea 15 Bay City. Texas 77414 .
SUBJECT:
50UTit TEIAS PROJECT ELECTRIC SEMERATING STATICE
- DEFIC!thCT DOCE(NTS (CAAs. DRs AND rnaarranc)
IDENTIFIED IN TIE 98.17 $UPPLDIEATAL ALN!!T W SACKFILL QPERATIons Beer It". Nurst: Attached are the CARS. Deffcfency liet1ces and Cancerns from the U inspelemental Audit en Sackf t11 sperattens. These deficteacten were discussed with responsible personnel during the site exit asettag held April 2. 1984 and with sensgesent personnel to Houstaa en April 3. 3 28 . es felleest personnel at site emit en 4 7 04 personnel at Newsten sett em 4 5-88 N. W. Miller 5LG QA rgAL K. R. Dotterer etf. rget >
- 6. C. frankel BEC QCE 5. B. Jones BEC Arts E J. Fotrell SEC SE0 0. E Halligae BEC V.P.. Prop us Her.
T. E Itttetimen BEC Centracts R. L. Rogers BEC Prei. Empr. W. rg , L. Tee SEC Geotech J. L. Itsrley BEC Proj. Esgr. R. 6. Peck E5I QA L. Tae OEC Eastsch L. B. Triplett FTL R. Talange BEC Esotsch I I The reselts free that audit fadicate several wannesses to the current j ' methods: ; I*
- 1. Inadequate dfsetpline by Sechtel in ensuring that P5AR cammit. I monts are totally and accurately translated to destge decoments. I proceh res and wert practices. .
' l
- 2. Inadequate Bechtel 04/0C sonttering coverage. '
- 3. Inadeguate construction /f aspei:tten prece&re properaties by S' -
Ebesco,and (
- 4. Lastty en the part of Pittsburgh Testing Laborator" s le performing thete actiettles le strict compliance with the teetieg '
standards.
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semmann1Juhung & pmwar Cm*ipany ID. L. W. Ilaret-5745 14. W ER Page 2 i . Rechtet has been previously roguested to ser seeting of April 3. Ige 4 8 tot
- 1. Immediately evaluate the fopect en oogsteg uort.
- 2. Imediately evaluate the lepact of the esftcisactee se past mort. I
/ and
- 3. Emediately assess the evaluattes methods used to emeure s technical / quality comiteents are adequately tracted and .
translated through destge documents to precedures and late acteel . wert practices. Bechtel's response to the documents attached is reentred by 04 24-84 and should address the generic issues Itsted la this letter, as mall as the specific esftciencies cited. Please sutett 04-24-84, and tressett a copy of the response (s)toyour response Mr. J. W. titella(s) setothe mesame by este. stacerely. T. J Aliens Project GA seeth Teses s TJJ:1b
~" '
At W hmmeg cc: J. E. Geiger D. S. Berter R. J. Iternet S. It. b J. W. W1111ses
!. P. Itervios
- 0. R. Emettag J. W. Estelle ,
B. F. Beenerczyt P. W. Rotter T. II. IIcArtff *
- 8. S. Berris B. T. trisha (SPC)
- 8. L. Les (IEC)
- a. W. mller (stC)
L R. Setterer (stC) 8.s.necallough(stc) STP 845 (2) , Site Litrary i g. .y l C e a .uN e . 7 e g
g, 9 0o31 % tioR .
"XTfh .- - - - . ,
e 4 'e . s Humans tJe umag & Pe=av Cm.mymer fir. L. W. Ihrst ST-se5-19. m761 Pege 3 I g.. A ATTADOWr m IL&P CARS W. W. 6-405, 6-408, 6-407. c1-408. W. HIS. 6-411. 6-412. 5-413. G-414, 6-415. M18, 6-417. Mla. '
/ all artiste M .
DEFICIDCT 11071,2 1: IM.145. IM.187. IM.1H and 170 ' ConCDAS: 1.2.3.4.5.4.F&8
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- b. Anetteable codes. standards. and eteelstery reevirements.
- f. Prefect Qua11tv Proerum tsautrements.'
GAPO. Rev. S. Part A. Table 1 (Also PGAP. Rev. 3, Table 2.2) state le port , i that the eunlifications of Inspection. Examinalien aW Testine eersespel l l A a,=fte Afr51345.t.61973 and R.S.1.58 (hew. c. a/13) es end.ifted by ; I l mattttens f.3. f.s. c.7. c.R. and C.10 of Rev.1. ~ \ Mauever to tJe centrarv. SEC Soecification 3706075044. ' Field and Laborstory > l l Atine of far+Jasert Construction * (also PTL Procedure OC 80 2) enir tavetes I must ast _y s.1e71 and Ng mt cesett cavfonunce ta R.C.1.58 (Rev. O. S/731 es endified by sositions C.S. C.G. C.7. C.B. and C.10 of Rev.1. l b son-ene stwee e r- T .
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I il P5AR sersersch P.S.4.5.6.r.4 states in sort. *tsierever f t11 er ha-6ft11 uns eleced durine e nort shift. at least ene field test was conducted thertne the shift' and a sesele for laboratory relative density tastfm tes ettained, provided that the coseectfen eos cessisted in - ama. Centrary to the above. SEC Seecification 37089Y5tD43. Rev. E. reautres? - al this test ser eieht hour wert d6r end. b) Does not reevice saseline for laboratory relettve density testina.
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I Contrary to the above. ICC eart%et seecificatione e not contain the above eJoted reeutreseats for suberede arenaration. l I IWff! MC response enest address the iseact of the stove deffeiencies en I the f111/backffl1 elaced to date and initiate WERf t1 acenedinate. t
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herousmier for each test type. 11 3. Field density vsine the Sand-Cone Methd-ASTN 01556-44 (1954). a0ft: he hult density tests more run as a sinfam fee each suu , hee. Additional tests must he run if results deviated sure tien one percent. Standard sand had 100 percent sessine the me.10 steve and wie massine the me. 3W sieve. , Centrary to the above, the tw quoted causituents (stringent requirements) are not incormorated into PTL Procedures / Instructions. 21 d. ESTN 04??-43. Grain stre steve and tydronster. Contrary to the above. 77L procehre QC-LT-1. Rev. 35 takes exception to MTR 3422 to that, t9e hydremster portion of the test ts not required to be morferimd sur tweenry I structural hockft11. a e. vv
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On-going Show Cause Comeltment VA(2) IS states in part. that for hadding . and backft11tng of ECW System pipfng. Stc specifications. DT OC Procoesm. [ end PTL precedures are revised to tacorporate the fellering requirement:
'tocations and seguence of various placements and terrespondence 1e place density test results will be documented together with sammaries of the ,
report construction metteds and comettiens." Centrary to the above. during the aestit as objective evidence es I provided as to:
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F a) t#wt changes more made to the specifications and the proceehrtes to .g satisfy comp 1f ance to the above ansted retuirement. - b) lAmt documentation uns generated by DI and PTL te ersure comptf ance to the show cause coeuritments. . b mO sea-me tim I
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for each 20.tMe yards as the mort proceeded. These samples wee tested as s i reeutred in the above peregraph.' Above peregraphs list testing as per ASTM 02049. 0422 and Mem. , Contrary to the aheve. ne specific evidence could be produced ta sadstantiste that relative density (A5114 DE049) fs else determined from the samples frun steckpiles. IICRs need to be inttf ated if the above stated condities has M I [ fasect on previously placed hacift11/ft11. l 1 mman l \
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- 2. paraq'raph 5.2.2 states is part that '8EC is responsible for develootne j-and implementing Mres asd f antructions for control of meltty related activities.
Contrary to the above. as writtaa procedure or instructfens (by PTL) esist . for sampling backft11 uterial frem the stockpiles.
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,Gintrary to the ahese. WP/0CI-4.0. Rev. 5. does not describe the erecess. methnenlame.
and taaef fic hmt reauf rauents utilfred me Cateenry I backff t1 11 received eMite
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=- an rc%.i m vs - or - ..u ~ .. s re mnurr j (A) Oct t.4. Rev. 5. screeroph 5.1.3 states in part. *The sonthly plan shall provide enversee of <e rei.ted .e n. cue., mu me. . .e n me e .
/' adfust to cesstruction schedules ce areas of- -. .:-- . probl e eress shall have follow.m Effectiveness Inspections at increased frequencies until conffdence 1 is re-established and the deffctencies have twn corrected." (CONT) g m mmATon y,_ y (At *$:p.p. DAIE 4) f a f4 ivi liyt.ivisosuuAn Avodoa rte, .. h. 4:#' A. u " ^ " */ W
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In w.-_ _ # l I steer (7) erscarrTras a co e spies asftast To cuattTT (couT) Contrary to (A) SEC QCE that ret performed an Effectiveness Inspection pertainiae - to STP Category I Sackfl11 activities since October 1982, a period of appros-testely 16 months. (t) Oct-2.9 hev.1. peregraph 4.1 states. 'survet11ances are en seine reviews of the contractor's/ constructor's quality practices for confermance as to . apolteable codes and standards for safety related construction activities at the South Texas Project.' I contrsry te (3). WC IEE has met performed a surveillance of STP Category I M backfill activities since the original 1sse of QCI-2.9 (Rev. 0) en , k tober 21, 1983, a parted of approximately five ($) masths. I u P l l l i M ll M
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" Jr?#,'"H'*'" i"'v- i l'aanu , ,,3 pl w.-.sw.= or - a muss Apvasum is manuTT j fA1 Shemarmah 4.1 States. 'All receivina shall be enf=ferend by Earlannal ARAM hw tem as* f anciavina -- ." mar 1.
1 Centrary to ( A). sersonnel are receivine Category I backffll esterial and they have not been assigned by the R.S. (Construction personnel are performing this functfen). cas wTsAma 4,,, e y rp gg,,jf aan ,, f, gp tel BArERv6sOR/WAo AuD4TOA y , 'y q,ey f oATE gpp. lie AEASEDeAL ACTIQse l 2 lHI sag 8aANAS pArg paa gFrGCTfwEmaTE I (1 34 GAME Or CDeeOsviose t L
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- tag.
Contrary to (8), SEC Receiving does not apply status indicators to f act:M ap Category I backfill stocketles. (C) Eshibit WPF/0CI-a.0-1A. Task no.1.2 reevirus escaf tf ag CC to perfere a visual inspection for cleanliness of Category I bacift11 material. b M J
'T contrary to this. SEC asceiving OC is stamping this attribute " Accept
- without performing the reefred visual inspecties. E e
4 i i i e (D) Paragraph 4.7 states "For Bechtel pr9 cum sea-safety reisg. . .seterial. the cognizant supp1ter Ouality Representative of Field Procuruent. . .shall review applicable decw station and if found acceptable, shall sige and date the MIR. . .* . r
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O'atrary to (D), the SOR is not signing the petR for Category I backfill saterf a1. s 4 MMM 9 4
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Rom (7) MSGIPTION (F CDetT13 AMERSE 10 tRIALITY (CINif) f Attachment 4.01 of C$p.1. Rev. 3 states in part as follows: .
- Sequence no 3.3.*If backft11 material does not have preser meisture content. it s$all be conditiened by sprink1 tag. . .*
r Sequence Re 3.9.*Cohestantess hectft11 aterials my be spread in lifts see specification 3T59Tm3." Seeuence h 3.13.*Reevest conectfen tests fres Quality Centrol Inspector-F for each Ilft la accordance with peregraph 9.03 of this , procedure.' (OC Itald point). p i Centrary to the eheve local escovettens for doesity testing within the fill ; aree are hockft11ed without CC tasasetten and cosoection is not performed as , it tes for the oriefnel plasmoset. For enample, te mi apprestoste 4 feet by 2 feet escavetten for density test. me. EL.AFr.f.1987. and an apprestante I feet by 2 foot escavatten for test me. E1.A72 3 1535. beckfilling ins aceneplished with a lift that escoeded I feet in its deepest portten. Addittenelly the material mes placed in apprestaately 3 taches of standing noter, and m.s comeected without the additten of eter. (ICTtt These bles tore escavated beyond testing depth to control seter seepage).
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ESI NOAPM. Section 0A-11T-11. pareeresh 3.1 states in part. ' Inspection decwents ' , shall be ;..enrod based woon t5e quality Perstruments contained in purchase orders,
..# l / saecifications. .". r / t cetrary to the above. EST OCP-10.10. "Sof1s Inspection.* Rev.1. does met .
eentain the followine ewertrements of SEE Suecification 3YO69Y50041. "Structurel l r cavatten and a-6ft11.* Rev. 3; s 11 The eradation and distributiren of meterials in the compacted areas shall he > 9 much that backft11 er fiti is est eeweestad (Perseraph 7.3.1) e 21 Fill surfaces shall be constrected to that wter will readily drein off P at all times. (Pereeraoh 7.8.5) . r i il Gensetton will not be allowed wittete EB fleet of an area where in-site density tests are toine serformed to yemmler enterials. (Paregresh 4.1.4) ~ l al te c ate eats and basesent wits home teen wterocoofed. the backfilline tha11 he performed so that the protective wtseprooffne material is est
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K 0CE (7) Ot5CRIPTim IF CaetTION Acytit5E TO EWLITT (terr) S) Backf t11 adjacent to structures or over portions of fou:edations shall be
- placed and compacted symmetrically and untformly by the Constructor f a a
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(- ~ manner to prevent ecrestric leading er unbalanced pressure upon or against the st % '.vces. (Persproph 7.9.7)
- The condition fs not limited to above quoted requirements and (31 needs to -
review the specificatten and procedure to ensure that all specificaties 1 reouf recents are either directly incorporated into the procedure er included , by mattne reference to the specification. ,4 '
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~3 In the event provfously placed bactf111/ff11 ts fseacted due to nen-come11ance ;
to the above quoted reeutrements. IO(s) need to be inttfated. f t t M { N 4 {
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I pay I d 3 i faM GA cannecmt actiene assoet czsefumaasses ' m CAmsetL - #d" m new A Keat p) erset:Pflos or tesemos meetSt to cuum (corr) J' FSAR Section 2.5.4.5.6.2.5, 2nd pareeraph states in part. "The f aspectors . considered possible warf ations la density with depth ta determining the test locations. The tests are selected such that a series of consecutive tests WII five representative density 1sfocustion for all depth intervals withf e the 11fts.* r i 1secification 37069750043, hev. 8. pereeraph 4.1.2.2 states to part. . . r
*The Constrweter shall consider variations in density with depth depending on lift thickness. placement and compaction motham. and shall if stribute ,
the test dueths ta obtain the true candition of the hacift11.* *
$cecificattom 37069750043. Av. 8 (Sectica 4.1.3.1. "30.f ach ECW Pipes *).
_ peregraph 4.1.3.1.3 states in port. *. . .The test shall be located , facediately adjacent to the pipe at an elevation of 7.f aches below the tavert. .
- OcP.10.10. Rev.1. Pat 7 paragraph 5.3.1.1 states.
- Frequency of testing shall
. I he as described in techtel Speciffcaties' 31069730043." OCP.10.10. Rev.1. PCR 7 eerseraet 5.3.1.2 states. *tocation of test shall be as described in tochte)
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- 1) OCP-10.10 Rev.1. does met provide criteria se density vertation irtth i
depth to enable CC to determine the correct location for testing.
- 2) There is no objective evidence that backfill installed by E31 has been .
tested at the required depths, in general. In particular. there is no i objective evidence that tests below 30-inch 9 eof pipes are taken at a death of 7 taches below the invert. OtP-10.10. Rev.1. does met require t test depths to be recorded. ICTT A) The field test elevation selection process does not give ; representative density informatten for all depth 1etervals within the 1tft. I I
- B) PTL precedure OC.!T.1 provides for recording test empth but EST OC is not providing test depth inforsetton to PTL fbr subs;; m t resorting on the PTL test flere.
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W ether methods, Appensis I references 257310422 43 (of which O 421 ts as integral part) apdv0 2049-49. (CIbtflIREB) tan vanAlcagg V/fM m sunnvao.canysuo ron rt.-.uo tior4., i s- "" * / m+ he asasaciatactson
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0-1554-44-(681. .'. [ a) ASTM 0422-41 reautms arenaration of the test tapete for enchanical analysts , mer ASTM 0 421. ASTN reevires air dryine of samste received free ffeld . fSection 3.11. thee amarterine (Section 3.11. tien senerettne en a ns.10 tieve itsetion 4.11. t.hme tashine the sateeial retained on the me.10 sieve free of all fine unterial and devine (Section 4.21. then stevine en the he. 4 i steve (section 4.21. o l h1 ASTM 0422-43.1st*.ien 1.1 feeut res *. .tievine until not more than one eats [ waest af the restese en a sfeve casses that Steve durine one etnute of r etavt a. h mechanical stevina is used. test the thereuehness of stevine l av o.s eh. u.4 me.w of nievins. . .a. ! el AsTW 0422 43. Smetion 10.1 reevices washtne of asterial passtne the me.10 stava 1 - " a m. Son nieum. r d) AETM 0422-41. Section 17.1.1.2 reevires resortine the hardness of the ,
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- (7) DE5CRIPTION OF CGIDITION AOvtit5E TO OuALTTY (CWIT) al ASTM 01558-64. Section 3 reonires determination of the vetume of the jer ,
and attacteeat for detereination of bult density. IIste 4 allous detee-
' etnation of *. . bulk density in other containers of kneun welm that disensionally amorosimete the loroest test hele that will be due. . .lf i this oracedure is fellound. it shall be determined that the resultism bulb t
dentity neuals that eiven by the far detersimtion.
- t f) MTN f!f0a9 49. Section 4.1 reovires detereinstion of the volume of the unto hv direct measurement. and checkins by ft1114 with wter, y I s el ASTM O20a949. Section 4.1.3 reeutres obtaintne en f aitial dial reeffes.
dich will remain eenstant for e certicular measure end surcharge base l L etate combination. by stacine the call'bration har across the diameter of j the mold acrets the guide brecket 4315. h1 ASTM 020a9-49. Section 4.1.3 reeutres sistch earts be used so the messare- 1 meet to the too of the base plate can be made in the same relattve panttiem , Gap ameh manisam sientity detergr(natien, O ASTM Broa949. Section 6.1.2 states, for estert 1 placed with a hassel. . I
- er e af th .e.st tatt tevet with the tee by eatine eve coatinuses nom.me = -
sets with the steel straightedee.'
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, <esarate on a ns. To sf eve. and dame net math the materf at retained. Vfth regard to b) above. 'm uses e anchantcal sterfes device. Althoveh labor-story personnel are fest1ter with the teneth of time fler stevine. this ties has not been doewented. and there is no objectfw evidence that semeles are sieved fee the sene Teneth of time. Further. the L _ ;s of Stevine to ^
not chected, l i a Contrary to c) above. m determines the amount of asterial finer then e Ilp. . s 200 sieve by dry stevine enir. . 5 ' i , _ Contrary to d) above m focus " Report of Particle Stae Analysts'. Foru its. i 17 3. and ' Report of Steve Ane1rsts". Fere Ito. St-8, hose as previsfon for . t recordine this infometion. Contrary to e) eteve, m determines bulk densities to a 6.1 cubic feet as14. ,, has not determined the bulk density vsine the A5198 prescribed method, and has met enemered the results of their method of detafebmetime to ensure that f t neuels the 1er entled. O m esmo 0 P @
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A .iL K0CK(7) IESCRIPTION W Ctpe! TIM M 70 tilAL117 (CDif) o Contrary to f) above. PTL instructlen sheet IS-CAL-22. Rev. O. 03/03/82. requires determination of acid velas by the water filling method only.
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i Contrary to g) above. PTL aeros the gage on the base plate for each of the sta sensurements. then raises the gage stan by hand. and sildes the end of the calibratica bar in along the periphery of tan mold, stoeting r l the bar by hand as the reading is tehms. Contrary to h) above. PTL uses no match sorts. se the base plate
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! measurements are made in different locations each time the unzissa density is determined.
t Contrary to t) above. PTL adds antertal by hand to the surface of the I l soil-filled sold, after screeding. i l l l
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- 1) Specification 2Y06075044. Rev. 3. paragraph 4.04.2.h states in part.
/ *
*Cospection control criteria shall be controlled by the sell type and referenced spectftcation and devolesed la accordance with ASTM OSM.
ASTM DEN. ASTM 01557. ASTM 02049 or 35 E-25-43 as applicante, and I approved by the Construction Manager *
. 1 t 2) Form S-321.E.
- Engineering Document Augwirements", requires submittal
'i of cososction control criteria prior to use.
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- Contrary to thfs t!P N615 If sted 881 N-2015 testeel of the proper al' t N-4472. '
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M T-1 5 12.3 e sessairTeen os easic.amcw . t The eksve reference states in part. " Wen standerd written test methods de set erist for the test activities. . .ML shall prepare written lastructies sheets 7* '- telch shall se ideettfled in Appendia I and attached to this proceshre. . .* ' 15-510-5049-49, paragraph II.1 states. *Tibratory table shall he calltrated le occardance trita 15-5-15A VTC.* .
.e' Centrary the l rm .d 9.a.tivendensity . airm table calfbrations have been performed
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Peregraph F.10.2 states to part, 'The retest resort shall refernace the original report to provide tracombility. . .*. Paragraph F.10.3 states to port. "All retast reports shall tedicate sfue data of the retest (s) and shall he filed with the original report." Osatrary to the eheve. .dille rotests are clearly identified, and reference the
" original test try test imamber they de set reference the ortgleal test reports, nor are they filed with the original re.mrts. ,
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, relative density of cohestantes setts. Peregraph 9.1.1 of ASTMIE049-49 requires *e reporting of the " method used, fW deterwistag stalmas density (scoop or funnel). . .*
Centrary to the eteve. PTL me. ST-4. Rev. 4. 9/30/s2 has ao provisten for reporting
# the setned used for deterstatsg statmas dumstty. (Ilotes PTL FCA fl03. 1/26/04 .
addresses this). . . s w> .
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Soecificatten 27000T5044 3 4.3 e sascaseries se espessans, 1 Peregraph 4.5 states. 'The frequency of testing shall be as directed by the seestructor and the Constructies Itanager." Centrary to the aheve. no ehjective evidence could be provfded te sdetantiate that the testing frequencies are directed by both the constructor and the Construction Stenager.
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- senme Texas peosec7 st.scranc essesnatues STA?sess euaufv aamsmasses sam ma /4 I DEFIC 8EpsCY peOTICE 4 em6am.4at e 'a mars muumass agate st#5 .
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,- ' The abova reference states to part. "Flace 300 posseds or less of sumd to a suitable l
. container. ' genne ela thoroughly. . . thtete a representative sample.a The
' does not edegnately descrthe how the send free differest begs is thoroughly lended n- <- to ensure that the sample taken for testing is representative of helt emnetty
.,
- the container, and that senes of meterial of different bulk domstty de not result ( tch isould introdece an errer in density calculations). Conversatione trith FTL personnel Indicated te.tre mes not untform agreement as to how the sand ins actasally being blended. .
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SaAMTV - - gasa l'F# OEPtCIWICY apris s: , s esario. A &f* $*fP rm Y* AYoW ' . . , s__ - .vs.navne 2 Secties 14.3 su r 84RP e . .= .__ _. Secties 10.3 reestres that the taneestina proomenree sAs11 prerfde . fW reserving the **
, g results of the lespottles operettee.
i comerary to the atsee, the fasosctlam es.duced Itsted to parograph TheseS.1.3 inspections and 5.1.4 et GCP-10.10. *Selts Insgestten'. are not t w trud to to recorded. have been recorded en appropriate forms. but the preceders does not provide requirensets. m , .a ry 5 MTIAN W k $k W /5/3t%g??
. eves = a 1 - _. 6 4
r./1/24' r. (
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;ggg 478 003194 a3n h ,C a.
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519 CAftearf f SACFfLL ACffff71D AISIT 15-a01 M8
- 1) He methodeley has base devised to date to correct erremmene
' desammatettee (l.a.. Legs leapection Asperts, test reports) er te Y
tross-referemse the 'eesmeste recalculattene Wch were addressed by
- a C CAs e- me.
i I
- 2) It is umsleer has O! QC deterstees which Category I hockft11 estarial seerte type is emesmotered (f.e.. TNr. III. Porter gree. etc.) at the reestred subgrede elevottee dering escovettes to emette QC to essert the metectal as subprede prior to satsegseet bettftllleg er esserettag ,
sporettoms. I
- 3) The centre) eriteria (f.o.. Relette Ommetty Man /Wie) is est .
consistent for ett test ft11 programe. The samp1 tag rogstruments and , ( data appiteaties for Relettee Dessity date,wtestions is prescrthed w differently to D1 QC Procedere QCP.10.10 for 'The Correlaties Test Ft11' (se receireemets). 'The Wacker ethretary plate esmpacter goalf. I fication progree" (ow R.B. tekee se the top itft efter appittattee of eight eme=uey passes), and the ' Test Ft11 for gestiftestice of verisse head sporetse omspectors' (renalog everage of the last five seat. ; s' ame/etates Reistive tensittet). tenere 'the everage of the test five f leha/Wie helative tenettice 'is meettened it is easleer if this refers L to p%tten esoroges 3er to what seures seterf al. Antittenelly f t is ensleer ey se requiremmets have been included to the *Carvelatie's
- e. .
h y ' _; L AL p__ F 7 mee e. 1
3
, e 003194 % 8@ gg
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Y. W . , _ , ,, _ _ _ _ , , . . . . . . - e... . pues 2 of_4 Audit 2s 4g1 Test Fill
- precedure for control criteria t.9. sempitag, or applice= ,
*/
ties of R.0. Insa/ttte results. 4-
- 4) Sechtel Spectficatten 37069750043. hovisten 8. peroW F.S.12 states
# to part. *. ,. .For the final lift of a backft11 eserettes damatty
- tests shall be perfereed witata two taches of the surface elevottes FSAR peregraph 2.5.4.5.6.2.3 states la part. *The taf itfts to be I located immedtetely beise fevndettens are tested.at myths heemmes 5" ,
e and 12*, regardless of Ifft tsickness.* Wile it appears the corrent spectftcatten escoeds.F5AA reestrummets l ,d for serface density tests, the specificatten conflicts with the esteriptten in the FSAR. vb q i S) Inspection /vertftcattens fadicated to ESI QC procedere etP.14.14 Sections 5.2 and 5.3 are recorded on the Delly Beckft11 taapacttes ! l ampert ander
- generic
- chettestats (i.e.. Escavatten. Campaction. . >
I **
- l etc.). Each
- generic
- checapoint includes sely one acceptause for several specific attributes. From the bactf t11 lespectten Rupert. it cuanet be determined that sech specific attritate costaland le the r
proceesres has in. fact boes vertfled.
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eo.. . l-AUDIT 105-441 Poes 3 of 4
- 4) There is ne traceehtltty of acceptance tests to shipments of Category I bettft11 meterial other than the date of the test and the time (as er pe). As a ,rgit. It is not possible te determine if PTL is meettag the staten test fregrency (sech SCO yards) prescribed te I
** Spectficatten 3706ff50C43. / ,, .
Additteaally. this same concern app 11es te the bulk density determina. tien perfeh en denst*q sand for sand came (le-place density) tests. d It is met possible ta determine if all begs of Ottame send received is , ! a shipmset have been tested. !, t
- 7) Revies and approval of PfL generated FCRs (to PTL precedures) by MC k espears to tate en excessive amount of time unich could tapact
) en-going activities. FCRs containing champes ietch are staar te nature and de not require estenstre study or revies have met home w ,
responded to by NC for ever one month. The fellertas are esamples: PTL FCR No. 097 (submitted to SEC 01/26/84). PfL ptX Re. Og8 (submit. tad to MC 01/31/M). PfL FCR No.103 (tutettted to NC N/18/94). and PTL FCR he. 099 (subaltted to BEC 01/31/M . This PCR edes reestre. seats to test for motght of retar, a test regsested to be perforged as i '
- directed by N C.
i s a
- 8) PTL Procedure OC-AO-1. *0eality usurance Progres Addenem . Is set referenced er addressed to other PTL taplemmettag procedures. This precedure *mediftes requirements to PTL Osellty Centrol Procedures.*
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6
- 481 00319h @t).
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Pame 4 of d anggt M tee of five PTL perenmal genetieasd, as to the purpees and tempe d dic .is,re.e aus-e tee.erm - . ,. ett11:ed for STP. It is seted that PfL Rosmaals reviesed at the site
"~
test 1 ( le M W e E stead hand eritten changes to the effected
' attsed undertaking sectic.ms. This is as addtttenal. = m tattiated by PTL and therefore. ether semeal holders de not neve' .
k , sletter testructions to denote changes la this asamer. (/; ys ,,,,,r/jOl'h(( t
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