ML20237L051
| ML20237L051 | |
| Person / Time | |
|---|---|
| Site: | Comanche Peak  |
| Issue date: | 06/01/1984 |
| From: | BROWN & ROOT, INC. (SUBS. OF HALLIBURTON CO.) |
| To: | |
| Shared Package | |
| ML20237J194 | List:
|
| References | |
| FOIA-87-87, FOIA-87-A-14 35-1195-CCP-10, NUDOCS 8708270396 | |
| Download: ML20237L051 (134) | |
Text
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I JOB 35-1195 COMANCHE PEAK STEAM ELECTRIC STATION i
Construction Procedure i
DOCUMENT CHANGE NOTICE NUMBER 1
Notice applicable to Construction Procedure No. 35-1195-CCP-10 Rev.
S This change will be incorporated in the next revision of the procedure.
Change the procedure as follows:
Picase replace / add the following pages with the attached:
Page 19 of 20 20 of 20 Add 20a of 20 i
Reviewed by:
u d L L-3C AAY 8d Wcf ?$kY PffY i
Origin'ator Date Brown & Root Qtrelity Assurance Date frYL UU U
l~SY Approved by:
TUGC0 (fuality Assurance Date 0
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/-/-9/
06/01/84 4
Construction Project Manager Date Effective Date i
8708270396 870819 PDR FOIA BAUMAN87-A-14 PDR L_____-__-_-__
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A.. D R A C.
INDEXED.
JOB 35-1195 COMANCHE PEAK STEAM ELECTRIC STATION png:
INTERIM CHANGE NOTICE NUMBER 1 This notice applles to: Construction Procedure #35-1195-CCP-10, Revision 5
The intent of this change will (X)) / will not ( ) be incorporated in the next revision to the procedure or instruction.
This Change applies:
Until Further Notice ( )
Until the next Revision is issued (X)$
Only as follows:
CHANGE THE PROCEDURE / INSTRUCTION AS FOLLOWS:
j On Attachment 2, Part D, add to the bottom of the list as follows:
M.
Mechanical Type.2 openings, q
E.
Electrical Type 2 openings.
V.
Ventilation Type 2 openings.
I.
Instrumentation Type 2 openings.
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NOTE I
l HIJ portions of the pour numbers should coincide j
with the last three characters of the Gibbs & Hill block-out designation.
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d Reason for change:
To develop pour numbers for Typ 4-pour-blocks.
This change pprove by:
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/ 71 # > & f ' /2Akr klho
- lM'N Department Head
'Da te al y AEurance 7 Da te Reviewed By:
a fkhenh 4;U% I2-lls(,8
$c.e, M, WW Procedures & Reports q7 /2-/5 6 Date-p..
43
1 ir. :y n ISSUE'p' ' ' ' ' "
PROCEDURE BROWN & ROOT, INC.
NUMBER REVISION
_vait
"--PAGE------
m CPSES l
35-1195-CCP-10 5
12/4/78 1 of 20
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JOB 35-1195 M. m[~/ L/
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TITLE:
ORIGINATOR:
REVIEWED BY:
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" CONCRETE BATCH
/0A/0C 2
Date PLANT OPERATIONS"
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-seu=1 APPROVED BY: I///M vS./
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/A CONSTRUCTION. PROJECT MANAGER DATE c<v=I
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WU Wl s.B~Ayl CONTENTS
1.0 REFERENCES
2.0 GENERAL 2.1 PURPOSE 2.2 SCOPE 2.3 DEFINITIONS 2.4 SPECIAL ITEMS AND OPERATIONS 2.5 F. UNCTIONS AND RESPONSIBILITIES 3.0 PROCEDURE 3.1 CEMENT 3.2 AGGREGATE 3.S AGGREGATE GRADATION FAILURE 3.4
' RESCREENING AGGREGATE 3.5 ADMIXTURE 3.6 WATER 3.7 CLASSES OF CONCRETE 3.8 BATCHING 1
N /h,g 3.9 CENTRAL MIXING i
3.10 TRUCK MIXING
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3.11 DELIVERY OF CONCRETE IN TRUCK MIXER TO POINT OF PLACEMENT 3.12 TICKETING SYSTEM 3.13 MAINTENANCE OF EQUIPMENT i
NOTE This document has been completely retyped for convenience in issuing Revision 5.
Vertical lines (change bars) appear-ing in the margins indicate what information was actuallv changed, added or deleted by Revision 5.
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BROWN & ROOT, 1NC.
PROCEDURE I
ZSSUE CPSES NUMBER I
REVISION DATE PAGE JOB 35-1195 j
- 35-1195-CCP-10 e
5 12/4/78 l 2 of 20 t
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1.0 REFERENCES
1.
B&R Engineering Instruction 35-1195-CEI-13, "High Density Concrete" 2.
ASTM C-150, Specification f,or Portland Cement.
3.
B&R Construction Procedure 35-1195-ACP-3, " Material Receiving, Handling, and Storage".
4 ASTM C-33, Specification for Concrete Aggregates.
5.
U.S. Army Corps o'f Engineers Specification CRD-C119, Method of Test for Flat and Elongated Particles in Coarse Aggregate.
6.
ASTM C-494, Specification for Chemical Admixtures for Concrete 7.
ASTM C-260, Specification for Air-Entraining Admix-tures for Concrete.
i 8.
ASTM C-94, Specification for Ready-Mixed Concrete.
9.
ACI 301-72, Specification for Structural Concrete for Buildings 10.
B&R Construction Procedure 35-1195-CCP-11
" Concrete Placement" 4
- 11. ACI 305-72, Recommended Practice for Hot Weather i
Concreting.
- 12. ACI 614-59, Recommended Practice for Measuring, I
Mixing, Transporting, and Placing Concrete.
13.
Brown & Root Quality Control Construction Procedure No. CP-QCP-2.2.
1 2"4
i BROWN & ROOT, ENC.
PROCEDURE l
XSSUE CPSES NUMBER I
REV!S10ii DATE PAGE i
JOB 35-1195 l
! 35-1195-CCP-10 5
12/4/78 I
3 of 20 2.0 GENEPAL 2.1 PURPOSE 2.1.1 The purpose of this document is to. set forth khe methods and pro-cedures that will be employed in the. receiving, handling and stor-ing of concrete materials and the batching, mixing and delivery of concrete.
2.2 SCOPE 2.2.1 The scope of this pro.cedure covers the methods and procedures that apply to receiving, handling and storing of concrete materials and the batching, mixing and delivery of concrete including grout.
2.3 DEFINITIONS 2.3.1 ACI American Concrete Institute ASTM American Society for Testing & Materials TUSI Texas Utilities Services, Inc.
2.4 SPECIAL ITEMS AND OPERATIONS 2.4.1 High density concrete and its assdciated materials and properties which are distinct from the other classes of concrete are discussed in Reference 1.
2.5 FUNCTIONS AND RESPONSIBILITIES j!
2.5.1 Project Civil Enaineer - Maintains over-all technical assistance I
for concrete baten plants, concrete materials, trucks and.
J associated equipment.
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PROCEDURE
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ISSUE CPSES NUMBER REVISION DATE I
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2.5.2 Concrete Superintendent a.
With the technical assistance and engineering information of the Project Civil Engineer, maintains over-all responsibilities for concrete batch plants, concrete materials, trucks and associated equipment.
i b.
Supervise all phases of the concrete batching, mixing and truck delivery operations.
Supervise all phases of concrete material receiving, handling i
c.
and storing.
3 d.
Assures that activities are performed in accordance with this procedure, Assures that activities are performed in accordance with appli-e.
cable manufacturers equipment operating procedures.and mainten-ance procedures.
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Maintains daily production records and report!! applicable to his responsibilities.
t 3.0 PROC 50VRE I
3.1 CEMENT 3.1.1 Portland Cement shall comply with ASTM C-150, Standard Spec-ification for Portland Cement, and shall be Type II and low alkali (0.60% maximum) in accordance with the requirements of Table 1 A therein.
3.1.2 Except as otherwise approved by TUSI, all cement shall be of the same brand and manufactured at the same mill.
3.1. 3 A manufacturer's certified material test report attesting to the conformance of the cement to ASTM C-150 shall be furnished for each shipment.
3.1.4 Cement will be received in bulk truck transports and will be pneumatically loaded into clean, uncontaminated, water-tight storage silos or storage tanks at either the main batch plant or back-up batch plant where it shall remain until concrete is batched.
3.1.5 Warehousing shall receive cement trucks per Reference 3, and inspect certified material test report and inspect seal on truck hatches to insure that it is intact. Certified material test report will be retained by warehousing and distributed to QA per Reference 3.
i PROCEDURE ISSUE BROWN & ROOT, 1NC.
NUMBER REVfSXON DATE PAGE i
CPSES JOB 35-1195 35-1195-CCP-10 5
12/4/78 5 of 20 3.2 AGGREGATE 3.2.1 Fine aggregate (sand) shall be graded according to the require-ments of ASTM C-33.
3.2.2 Nominal size 3/8 inch coarse aggregate shall conform to size number 8 of Table 2 in ASTM C-33.
1 3.2.3 Nominal size 1/2 inch coarse ag'grega'te shall conform to the requirements of Section 202, Aggregate, of ACI 506, Recommended Practice for Shotcreting.
1/2. inch coarse aggregate shall be uncrushed gravel, graded from No. 4 to 1/2 inch size.
i 3.2.4 Nominal size 3/4 inch coarse aggregate shall conform to size number 67 of Table 2 in ASTM C-33.
3.2.5 Nominal size 1 1/2 inch coarse aggregate shall conform to size l
number 467 of Table 2 in ASTM C-33.
3.2.6 The following are descriptions of aggregate properties (except for 1/2 inch coarse aggregate which is fully described in Section 3.2.3).
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l 3.2.6.1 Aggregate shall consist of natural or manufactured sand, crushed l
stone, or gravel.
The particles shall be clean, hard, tough, dur-lj able, of uniform quality and shall be free from sof t thin, elongated, disintegrated stone, dirt and organic or other injurious materials I
occurring either free or as a coating. The aggregate when'incorpor-I ated in concrete, shall satisfactorily resist chemical or physical l-l changes such as cracking, swelling, sof tening, leaching or chemical l]l l
alteration, and shall not contain contaminating substances which I
might contribute to deterioration or unsightly appearance of the concrete.
1 3.2.6.2 The coarse aggregate shall be well graded and shall consist of gravel, crushed gravel, crushed rock, or crushed stone fragments which are clean, rough, hard and uniform.
No blast furnace slag, schist, shale or slate shall be permitted.
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3.2.6.3 The potential reactivity of the aggregate shall be established by the methods described in the Appendix to ASTM C-33.
3.2.6.4 Aggregate shapes shall be rounded or cubical and shall contain less than 15 percent (by weight) flat and elongated particles as deter-mined by the U. S. Army Corps of Engineers Spec. CRD-C119, Method of test for Flat and Elongated Particles in Coarse Aggregate. A l
flat particle is defined as one having a ratio of width to thickness greater than three: an elongated particle is defined as one having a ratio of length to width greater than three.
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12/4/78 6 of 20 3.2.7 Fine and coarse aggregates will be off-loaded from truck trans-ports into hoppers for conveyor transfer to aggregate stockpile bins which shall be arranged and operated te, prevent contamination 1
by different gradations or types of aggregates and to assure that j
there is pratical minimum segregation.
3.2.8 As an exception to Paragraph 3.2.7, fine and coarse aggregates may be off-loaded and stored in outside uncovered aggregate stock-pile bins.
These aggregates shall be stored and main-tained in a manner that will avoid the inclusion of any foreign materials in the concrete. No muddy or oil leaking j
traction equipment shall be allowed to operate on storage piles.
The placing of the material in storage and its removal shall be done,in such a manner as to maintain the uniformity 1
of the gradation.
The aggregate stockpiles in the outside uncovered bins shall be on concrete slabs, and shall have suit-1 able drainage.
The aggregate storage piles shall be built and maintained to prevent segregation and excessive breakage.
If.
I required, suitable bulkheads between specific size groups or I
aggregate shall be provided to. preclude intermixing of the different size groups.
y 3.2.9 Warehousing shall receive aggregates per Reference 3, and inspect loads to insure conformance to aggregate quality per this construction procedure.
3.2.10 Aggregate hoppers and conveying equipment shall be cleaned, as necessary, to prevent contamination by different gradations
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or types of aggregates and to assure that there is practical minimum segregation.
3.2.11 Access for inspection shall be provided in stockpiles at all times.
3.2.12 Each lot of aggregate shall be identified by signs which show size, gradation, source and controlling specification.
3.2.13 In event of equipment failure, temporary measures shall be initiated and approved by the Concrete Superintendent to insure quality is maintained. All efforts shall be made to expedite repair of original equipment for operation.
3.3 AGGREGATE GRADATION FAILURE 3.3.1 In the event aggregate fails to meet the specification grada-tion requirements, the material represented by the failing test results shall be remixed, reblended or scrapped at the discretion of the Brown & Root Concrete Superintendent or his designee.
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PROCEDURE ISSUE CPSES l
NUMBER REVISION DATE l
PAGE JOB 35-1195 l
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12/4/78 I 7 of 20 3.3.2 Remix shall be accomplished by discharging material. from one or more of the aggregate storage bins into the backup charging conveyor belt, into clean dump trucks,'and unloading this mate-rial into the aggregate receivi.ng hopper back into the respec-tive storage bins via the bin (s) receiving conveyor belt and rock ladder (s).
This procedure shall be repeated until, in the judgement of the Brown & Root Concrete Superintendent or his designee, the material has been thoroughly remixed. At this j
time, retest (s) may be requested by the Concrete Superinten-dent or his designee to check if material is within specifica-tion gradation.
3.3.3 In the case of failing gradation re-test results, it may be requested by the Concrete Superintendent or his designee to elect to scrap or re-blend the material.
If, after review of the test results, it is determined that re-blending is practical and would result in an acceptable graded material, it shall be performed by the procedure described above with the exception that another tested and approved size (s) aggre-gate shall be injected at the time the material is recycled into the storage bin (s) receiving hopper in quantities pre-scribed by the Concrete Superintendent or his designee.
Note that only gravel-to-gravel and stone-to-stone additions shall be made.
3.3.4 To ensure material is within specification limits before use, re-sampling and re-testing shall be performed af ter re-blending.
3.3.5 In order to prevent the use of disapproved aggregate, the QC Batch Plant Inspector shall notify the Concrete Superinten-i dent or his designee, in writing before each day's batching operation, as to which aggregate storage bin (s) are approved for use.
3.4 RESCREENING AGGREGATE 3.4.1 Approved concrete aggregate may be rescreened to meet another ASTM Grading size only if tested and accepted aggregate is used.
3.4.2 The aggregate shall be removed from the batch plant aggregate k
storage bins, loaded into dump trucks and hauled to the on-site l
screening plant. The aggregate handling equipment shall be clean and maintained in a manner that will avoid contamination i
of the aggregate.
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PROCEDURE l
ZSSUE CPSES NUMBER REVlSZON DATE PAGE f
JOB 35-1195 35-1195-CCP-10 5
12/4/78 8 of 20 I
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3.4.3 The screening plant shall be equipped with the proper size screens to produce the aggregate gradation desired.
The screening plant aggregate hoppers and conveyor,s shall be l
cleaned of foreign material to prevent contamination of the i
aggregate being produced. Screens shall be in good condition I
and free of any rips, tears, etc.
3.4.4 The aggregate shall then be delivered to, and stored in one of the approved aggregate storage bins at the batch plant.
Different size aggregates shall not be intermixed within a bin.
Each lot or bin of aggregate shall be indentified by signs which show size, gradation, source and controlling specification.
3.4.5 A monitor gradation sample may be taken from the belt at the screening plant or from the stockpile at the batch plant and tested to ensure aggregate is within the ASTM specification grading size required.
However, the aggregate shall be sampled, tested and accepted prior to hauling'to the storage bin (s).
3.4.6 Aggregate meeting grading requirements of ASTM No. 7 (1s inch) may be used in concrete or shotcrete providing a mix design has been previously approved by the Engineer.
Only aggregate from an approved storage bin shall be used.
3.4.7 If material finer than No. 200 sieve exceeds maximum limits of 1.0% the aggregate may be washed to remove dust or finer mat-erial. The aggregate shall then be resampled and tested as necessary for acceptance.
3.5 ADMIXTURE i
3.5.1 Type A, water-reducing admixture, shall comply with ASTM C-494.
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3.5.2 Accelerating admixture for shotcrete shall be a liquid per ASTM C.-494 or a solid per Challenge-Cook patented formulation named "Challog".
3.5.3 Type D, water-reducing and retarding admixture, shall comply with ASTM C-494.
3.5.4 Air entraining admixture shall comply with ASTM C-260.
3.5.5 Manufacturers certificates as to analysis and composition of the admixture shall be furnished.
3.5.6 Admixture shall be in accordance with the recommendations of the cement manufacturer.
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-l 3.5.7 Type A, Type 0 and air entraining admixtures shall be unloaded, by pump, from bulk truck transport or drums into uncontaminated storage tanks which shall be clearly marked as to their contents, storage requirements and controlling specification.
1 3.5.8 Warehousing shall receive admixtures per Reference 3, and inspect manufacturers certificate and/or spectrographic analysis and dis-tribute to QA per 35-1195-ACP-3.
3.5.9 Accelerating admixture for shotcrete shall be stored per manufac-turer'.s recommendations.
3.5.10 All admixtures shall be protected from moisture and temperatures i
that could adversely effect their performance as per manufacturers'
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recommendations.
3.6 WATER 3.6.1 Water for mixing. concrete and sprinkling aggregates, if required, shall be clean, fresh and free from deleterious amounts of acids, alkalis or organic materials.
3.6.2 Mixing water shall comply with tests required by Engineer specifi-cations.
3.6.3 Water shall be pumped from a deep well(s) and transferred to an uncontaminated storage tank (s).
3.6.3 Water for ice shall be pumped from the storage tank into an ice plant where ice shall be manufactured and stored as to prevent contamination.
3.7 CLASSES OF CONCRETE 3.7.1 Concrete is designated by classes according to the required com-pressive strength at 28 days. The class to be used in each part
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of the work will be shown on drawings, or will be designated by the Engineer.
The method of' determining the 28-day strength shall te in accordance with pertinent ASTM standards.
The site test lab will furnish mix designs for the following standard classes:
a.
Class 1 Concrete Compressive Strength, 4000 psi 3/4, 1/2 or 3/8 inch maximum aggregate j
i b.
Class 2 Concrete l
Compressive Strength, 4000 psi j
1-1/2 inch maximum aggregate c.
Class 3 Concrete Compressive Strength, 2500 psi 4
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PROCEDURE ISSUE-i CPSES NUMBER REVISION DATE i
PAGE JOB 35-1195 35-1195-CCP-10 5
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10 of 20 s
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Class 4 Concrete (miscellaneous)-
e.
Class 5 Concrete
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Compressive Strength, 3000 psi.
3/4 or 1/2 inch maximum aggregate f.
Class 6. Concrete Compressive Strength, 3000 psi 1-1/2 inch' maximum aggregate g.
Class 7 Concrete Compressive Strength,1500 psi 1 1/2. inch maximum aggregate h.
Shotcrete, Class 8 Compressive Strength, 3000 psi 1/2 inch maximum aggregate i.
Grout, Class 9
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3.7.2
" Mass concrete" is concrete which is greater than 2 feet-6 inches in the least dimension. Maximum temperature for " mass concrete" 0
is 70 F at placement, j
3.7.3 Concrete Slump l
3.7.3.1 The maximum allowable slump for concrete at the point of' place.
j ment shall be as follows:
C l a s s A, B', a nd ' C................... 4 i nc he's f
Cl a s s D............................. 3 in i nc hes Cla s s E and F.......................
5 inc hes 3.8 BATCHING 3.8.1 The fine and coarse aggregate will be weighed in a single batcher d
using cumulative weights to within a plus-or-minus one percent tolerance by weight.
3.8.1.1 Adjustments of Aggregate Weights The acceptable range for fineness modules (F.M.) of sand'is '2.3 to 3.1.
However, in order to meet the intent of Section 3.5 of ASTM C33, the following steps are incorporated into the. batching procedure. These steps describe the aggregate weight adjustments that are required because of the different values of sand F.M.
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PROCEDURE ISSUE CPSES NUMBER REVISION DATE i
PAGE JOB 35-1195 35-1195-CCP-10 5
12/4/78 11 of 20 within the acceptable range of 2.3 to 3.1.
a.
The sand F.M. value for a day's production will be the average of the test lab reports given,to the batch plant prior to batching.
b.
Design weights of sand and ' coarse aggregate shall be
.used when the sand F.M. is between 2.5 and 2.9.
c.
When the sand F.M. is less than 2.5, the weight of coarse aggregate shall be increased by 52 lbs. per cubic yard of concrete, and the weight of sand shall be decreased by the same amount.
d.
When the sand F.M. is greater than 2.9, the weight of coarse aggregate shall be decreased by 52 lbs, per cubic yard of concrete, and the weight of sand shall be increased by the same amount.
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3.8.2 Cement will be weighed in a batcher to within 1 percent tolerance by weight.
3.8.3 Water and ice will be weighed in separate batchers to within a 1 percent tolerance by weight.
3.8.4 Air entraining admixture, Type A admixture, and Type D admixture will each be measured by volume, in separate containers to within a tolerance of 3 percent.
3.8.5 Tolerance interlocks are provided to prevent a discharge device from being actuated until the material has been batched within applicable tolerances.
3.8.6 The batchers are equipped with platforms so that an overweight or sample can be removed.
3.8.7 All scales used in weighing concrete mix materials and volumetric measuring devices for admixtures will be calibrated in intervals not exceeding 90 days.
3.8.8 In the event the automatic ticket printer breaks down, the plant operator will fill out the ticket manually, using pen with black ink, to record the actual weights read from the scales.
3.9 CENTRAL MIXING 3.9.1 Mixing equipment will produce uniformity of consistency, cement and water content, and aggregate grading, from beginning to end of each batch.
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'5 12/4/78 i 12 of 20 3.9.2 The mixer operating time will be~ regulated to thel required mixing i
performance in the minimum amount of time as determined by perfor-f -
F mance tests or minimum time per ASTM C-94.
Testresultsshall'beK l
retained by the Concrete Superintendent.
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r 3.9.3 Batch size will not exceed 10 c'.'y., ' Controls shall be provided to insure that the batch cannot be discharged until the required mix '
n iapsea,
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Mixer blades. shall be replaced when they have lost 10 percent o i
their original height. Concrete Superintendent'or his repre-(
sentative shall perform a quarterly check to insure conformanc 3.9.5 Accumulated hardened concrete shall be removed, as necessary, to maintain peak mixer performance and efficiency. Concrete Super-intendent shall insure conformity.-
3.9.6 Admixtures shall be mixed into batch in accordance with Section 7.3 of ACI 301-72.
3.9.7 Tempering and control of mixing water shall be in accordance with Section 7.5 of ACI 301-72.
3 3.9.8 Cold weather mixing and temperature of delivered concrete shall be in accordance with Reference 10.
3.9.9 Hot weather mixing shall be.in accordance with Section 7,6.2 of ACI 301-72, except that for " mass concrete", the maximum tempera '
i ture of concrete as placed shall be 700F instead of the 900F i
maximum permitted by ACI-305.
3.9.10 Central mixing controls provide for monitoring slump by means of e '
slump meter. Also, the slump will be checked periodically by visual inspection of the truck mix.
3.10 TRUCK MIXING 3.10.1 While Loading, the mixer drum will be rotating at a. speed designated by the manufacturer as mixing speed.
3.10.2 Each batch of concrete shall be mixed not less than 70 or more than 100 revolutions of the drum at mixing speed. Any additional drum revolutions shall be done at the rate of rotation designated by the manufacturer of the equipmen,t as agitating speed.
3.10.3 The slump will be checked periodically by visual inspection of the j"
truck mix.
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3.11 L
DELIVERY OF CONCRETE IN TRUCK MIXER TO POINT OF PLACEMENT 3.11.1 When a truck mixer contains concrete that has been completely mixed in the stationary mixer at the Main Batch Plant or concrete
' that has been completely truck mixed, any turning of the drum t
dwing transportation shall be at agitating speed.
3.11.2 When the ambient temperature is 850F or below, the time after the a(dition of water to the dry materials until placement shall not exceed 90 minutes. When the ambient temperature is 0
accve 85 F, the time shall not exceed 45 minutes except when J
permitted by the Engineer on a case-by-case basis.
3.11.3 The number of drum revolutions shall not exceed 300 after mix water is added to the dry materials.
3.11.4 Each mixer truck will be equipped with an accurate revolution counter.
1 3.11.5 Add Water 3.11.5.1
" Add water" may be dispensed into the truck mixer at point of place-ment in order to increase slump to meet specification or to increase j
workability of mix.
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3.11.5.2 Sampling Mix a.
If for reasons stated in 3.11.5.1 it is determined that add water will be dispensed into truck mixer, then a sample from the mix, after add water and after truck mixer has revolved 30 times at mixing speed, must be slump tested before dis-
- charge, b.
Preceding procedure may be repeated as necessary before mix discharge until desired slump or workability is attained.
3.11.5.3 Maximum slump shal'1 not be exceeded as a result of the addition of add water to the mix, j
3.11.5.4 Quantity of add water shall not exceed quantity recorded for " add water" on the batch ticket.
3.11.5.5 Add water will be measured by the sight glass or calibrated container to the nearest whole gallon and quantity shall be so noted on batch ticket in " ADD WATER" block.
3.11.5.6 Responsible contractor representative and testing lab representative will each sign within the block, before water is added, to verify that the add water about to be added does not result in the total add water quantity exceeding the quantity recorded for " add water" on the batch ticket.
For shotcrete, a B&R QA/QC representative may sign in place of the gab representative.
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PROCEDURE ISSUE CPSES NUMBER REVISION DATE PAGE JOB 35-1195
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12/4/78 l 14 of 20 3.11.5.7 CALCULATION OF ALLOWABLE " ADD WATER" The cards will be punched to show the total " design water" or less, such as 230 lb/cy for Mix I.D. No. 202. The batch plant operator will deduct water as outlined below.using the slump control meter.
This deduction will be sufficient to provide required slump for the mix classification, i.e., 4" for Class A, B, and C Concrete.
For Aggregate Moisture compensation, the batch plant control system automatically subtracts the free moisture contained by the fine aggregate from the total " design water" (230 lbs, for Mix I.D. No. 202)..The free moisture in the coarse aggregate is calculated by the B&R batch plant personnel using the latest Hunt report on the C.A. moisture. The quantity obtained by sub-tracting the F. A. free moisture + C.A. free moisture from the total " design water" is the " maximum amount" of water which is allowed to be dispensed into the mix.
If the " maximum amount" of water is not dispensed at the batch plant, then " add water",.
may be added into the truck mixer later at the point of dis-c harge.
The allowable " add water" is calculated by subtracting the " water dispensed at batch plant" from the " maximum amount" and is written by B&R batch plant personnel in the Add Water block on the batch ticket.
Add Water = Design Water - (F.A. free moisture)'
- (C.A. free moisture) - (water dispensed at batch plant) 3.11.6 Same as Section 3.9.4 3.11.7 Same as Section 3.9.5.
3.12 TICKETING SYSTEM 3.12.1 Ticket Description
{
The purpose ~ of the batch ticket (Figure 1) is to record informa-tio'n concerning each batch of concrete.
Following is an explana-tion of the information blocks on the ticket:
1.
Mix ID: explained on Mix Identification sheet (Attach-
)
ment No. 1) 2.
Batch Size: Volume of batch (1/100 CY) 3.
Batch No.:
number of consecutive batches produced by the plant.
o
[~
j.
4 -
j-f l-
- t.
y a.
l
^
BROWN A ROOT, INC.
'! PROCEDURE TSSUE l
/ f NUMBER REVISION
.DATE l
PAGE JOB 35-1195 1:
,a.
35-1195-CCP-10' 5
12/4/78 15 of 20 x-T Oi 4.
M. C. Setting: compensates for moisture content in the.
fine aggregate (1/10 percent)
)c 5.
Plunt:
1 - fack-Up Plant
[
d 2 - Main Plant I
4 Agg.1,Agh)p;f, Agg. 3:
cumulafive coarse ag 6.
weights (1bs/htch)gregate' t
y o
L[
7.
3and: cumulative coarse aggregate' weights plus fine jggregateweight(1bs/ Batch)
)
8.
Cemeqt: cemer.c, weight (Ibt/Eatch) n 7
9.
Admix 1: MasterSuildersMB-VRairentraininpfAdmixtu're, c
meetr ASTf1 C-260 requirements (1/2 fl. oz/ Batch)
- 10. Admix 2: Master Builders Pozzolith 300-R w3ter-reducing and set-retarding' admixture, meets ASTM C-494 for Tyng0 requirements (1/2 fl. oz/ Batch)
- 11. Admix 3: Master Builders Pozzolith 300-N water-reducing admixture, meets ASTN C-494'for Type A require-i ments (1/2 fl. oz/ Batch) 1
).
12.
Ice:
ice weight (lbs/ Batch) t 13.,' Water: cumulative ice and water weight' (1bs/ Batch)
)4 14.* Area Pour Section:
explained on' Pour Number sheet (Attachment.No.-2) 1.5.
Sand Moist: moisture in fine aggregate (1/10 percent) 16.
Truck No.
i e
o y
[
- 17. Agg. Tare: ' aggregate batcher tare weight
]
- 18. Cem. Tare: cement batcher tare weight r
- 19. Nater Tare:
ice and water batchers weight.
s
'a:
)
- 20. Time 21.
Add Water; allowab'.e add water (1/10 gsis./CY)
- 22. Ticket No.-
- 23. Date g
L
I j
J h
BROWN & ROOT, INC.
PROCEDURE ISSUE CPSES NUMBER REVISION DATE PAGE j
JOB 35-1195 j
j 35-1195-CCP-10 5
12/4/78 i 16 of 20
]
)
3.16.4 Ticket Rout,ing and Sign-Off:
Il 1.
After batching is complete, batch plant representative signs i
ticket which verifies that infor'mation on ticket is correct i
~
and retains blue copy of ti'cket for batch plant records, i
2.
The truck driver delivers white original and remaining two copies of ticket to point of concrete placement.
'i 3.
If add water is dispensed into batch, General Contractor l
Representative and Test Lab Representative both sign in 1
their respective spaces in the add water block on the right ride of ticket per paragraph 3.ll.5,. '! Add Water".
For shotcrete, a B&R QA/QC representative may sign in place of the test lab representative.
1 4.
If no " required in-process test" are being performed on the
. concrete batch, the General Contractor Rep. signs in space 7 at bottom of ticket.after he is satisfied that information on ticket is correct and that the concrete batch is accept-a bl e.
5.
White original and two copies of ticket are then returned by I
truck driver to batch plant where they are given to Concrete Superintendent or his representative.
6.
Concrete Superintendent distributes daily the following:
)
a.
white original to Test Lab b.
pink copy to Engineer (if Engineer so requests) c.
yellow ' copy to B&R Cost Engr. Dept.
3.13 MAINTENANCE OF EQUIPMENT 3.13.1 Maintenance records of equipment shall be kept by the Concrete Superintendent.
l 3.13.2 Manufacturers' operating instructions for major equipment shall J
i 1
be available at the batch plant..
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BROWN & ROOT, INC.
PROCEDURE ISSUE CPSES NUMBER REVISION' DATE l
pAGE JOB 35-1195 35-1195-CCP-10 5
12/4/78 18 of 20 ATTACHMENT l-MIX IDENTIFICATION ABC I.
flix ID Number A.
Class Number 1.
Class 1 C.oncrete Compressive Strength, 4000 psi 3/4 or 1/2 or 3/8 inch maximum aggregate 2.
Class 2 Concrete Compressive Strength, 4000 psi 1-1/2 inch maximum aggregate 3.
Class 3 Concrete Compressive Strength, 2500 psi 4.
Class 4. Concrete (Miscellaneous) 5.
Class 5 Concrete Compressive Strength, 3000 psi 3/4 or 1/2 inch maximum aggregate l
6.
Class 6 Concrete Compressive Strength, 3000 psi 1-1/2 inch maximum aggregate j
3 7.
Class 7 Concrete Compressive Strength,1500 psi l-1/2 inch maximum aggregate 8.
Shotcrete, Class 8 Compressive Strength, 3000 psi 1/2 inch maximum aggregate 9.
Grout, Class 9
]
BC. Mix Number i
Numbers 00 thru 99 will define different mixes of a particular l
class.
For example a need may exist for Class 1 concrete to i
have two mixes with different cement contents.
Therefore, different mix numbers will be assigned to distinguish between the mixes.
?
II. All approved mix designs, mix design variations and mix identi-fication numbers shall be issued on an up-to-date list by the B&R Construction Engineering DeserDnent.
. 16F i
- l
[
BROWN & ROOT, INC.
PROCEDURE EFFECTIVE-CPSES NUMBER REVISION.
DATE-PAGE JOB 35-1195 C CP-10 5
'12/04/78 19 o f 20
- ATTACHMENT 2 POUR NUMBER AB C-DEFG-HIJ -
~
A.
Unit Designation 0 - Common Building 1 - Unit 1 2 '- Unit 2 B C.
Work Area as follows:
01-21 BUILDINGS 01 Co nta inme nt 02 Auxiliary 03 Fuel Randling Building 04 Turbine Generator Building
~
05 Sa feguards Building 06 Maintenance Building 07 Administration Building 08 Electrical Duct Ba nks 09 Sanitary Sewer Manholes 10 Storm Sewer Catch Basins 11 Pipe Tunnel 12 Misc. Yard Valve Pits 13 Transformer Area Foundations 14 Main Transformer Foundations 15 Auxiliary Transformer Foundations 16 Misc. Ta nk Foundations 17 Misc. Yard Structures 18 Refueling Water Storage Tank 19 Condensate Storage Tank 20 Reactor Make-Up Water Storage Tank 21 Electrical Manholes 22 011 Spill Containment Dams & Footings at Switchyard 23 Class I Electrical Ductbanks Train A 24 Class I Electrical Ductbanks Train B 25 Class I Electrical Manholes Train A 26 Class I Electrical Manholes Train B 27 Relay House 28 Waste Management System 29 OPEN 30-39 CIRCULATING WATER & ESSENTIAL COOLING WATER FACILITIES 30 Circulating Water Intake Structure 31 Circulating Water Intake Tunnels CCP-10 Rev. 5 DCN #1 06/01/84 Sheet 2 of 4 1
BROWN & ROOT, INC.
PROCEDURE EFFECTIVE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 CCP-10 5
12/04/78 20 of 20 ATTACHMEVI 2 (CONT'D)-
32 Circulating Water Discharge Structure 33 Circulating Water Discharge Tunnels
/
34 OPEN 35 Service Water Intake Structure -
36 Service Water Discharge Structure 37 Squaw Creek Service spillway 38 Squaw Creek Outlet Facilitie s 39 Pump Station 40-41 MAJOR EQUIPMENT FOUNDATIONS 40 Turbine Pedestal 41 Steam Generator Feed Pump Pedestal 42-49 OPEN 50 Po table Wa te r Ta nk Foundatio n 51-59 OPEN 60-99 MISCELLANEOUS D.
TYPE OF STRUCTURES AS FOLLOWS:
0.
Floor Topping 1.
Fill Slabs or Seal Stabs 2.
Foo ting s & Ma t s 3.
Floor Slabs on Earth 4.
Wal ls-Inte rio r 5.
Walls-Exterior 6.
Columns 7.
Elevated Stabs or Beams 8.
Roof Slabs or Dome 9.
Other Structures M.
Mechanical Type 2 openings E.
Electrical Type 2 openings V.
Ventilation Type 2 openings I.
Instrumentation Type 2 openings NOTE:
HIJ portions of the pour numbers should coincide with the last three characters of the Gibb s & Hill block-out designation.
CCP-10 Rev. 5 DCN #1 06/01/84 Sheet 3 of 4 c
m
1 1
BROWN & ROOT, INC.
PROCEDURE ETFICTIVE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 CCP-10 5
12/04/84 20a. of 20 ATTACHME!C 2 (CONT'D)
EFC.
ELEVATION Use top of concrete elevation for all' slabs, foo ting s,. mat s,
{
beams, and dome.
Use bottom of wall. or' column section elevation j
for all walls and columns.
On ductbanks, the G&H ductbank
{
number will be used instead of the elevation.
On manholes, the j
G&H manhole number will be used instead of the elevation.
i H.
OP '.N
'i IJ.
'. 0UR NUMBER CCP-10 Rev. 5 DCN #1 06/01/84 Sheet 4 of 4 w
j I
J Reacto'r Coolant Pressura Boundary Piping - Review of. Quality i
Assurance Implementing Procedures Procedure No.:
490518 Issue-Date:
03-31-75 SECTION III INSPECTION GUIDANCE General Guidance See Section III of Procedure No. 351008 i
Applicable portions of the SAR should be reviewed t'o deter -
i mine licensee connitments relative to ~ construction and insp'ectjon requirements prior. to inspection,in.this area.
l The.. inspector should make.this detbrminatiion during in-spection preparation.
The purpose of the inspection requirements in Section II is to verify that the licensee-contractor (s) have met the QA program requirements for receipt inspection,. storage, handli.ng,
).
. erection, installation, inspection. and. testing of.the reactor
. coolant pressure ~ boundary. piping.
Thecintent of this' pro.
cedure is to-include'all~ pertinent piping activitie.s at the~
site'except welding.
Piping'. incl.uded in this category is i
defined.in 10 CFR 50.2(v).
j Each of the items identified 'in Section II that is applicable to a particular ' facility must be inspected.
The inspection items should be completed for each onsite organization which has responsibility for this piping, i
Completion of inspection requirements of this procedure and of Procedure No. 490618 (Other Safety Related Piping) may be accomplished simultaneously.
The organization (s) involved and work scheduling will partly determine whether the in-spections (490518 and 490618) may be done at the same time.
l The inspector should use judgment in this area.
The " procedures" involved will vary from site to site, and may take many forms such as fonnal procedures, instructions, check--
lists, drawings, etc.
Review the inspection procedures / lists and compare with the requirements in the principal codes-(ASME B&PV Section III) and construction specifications that are applicable.
Evaluation should result in a sound indication III-1
Reactor Coolant. Pressurs Boundary Piping - Revicw of.-Quality Assurance Implementing Procedures Procedure No.:
490518 l
Issue Date: 4/1/77 i
that all quality related inspections will be performed and will be based on appropriate criteria and further, that the i
results of inspections will be transmitted to responsible quality assurance personnel.
Provisions to assure the following merit special attention:
Determination of the status of protective mechanisms at the time of site receipt and initial storage Adequacy of dunnage for piping and piping system components during storage Continued adequacy. of such things as end caps for piping and protective coverings for Weld prep areas Weather protection in the form of ~ anvas. or plastic-c c'overing.
(In most deficient cases, the~ original protective covering was adequate, but inattention to damage and normal " wear and tear" lead to sub-standard or unacceptable protective provisions.)
(
Sites near salt water should receive special at-tention to assure that protec'tive storage measures are considerate of salt water damage.-
Storage areas located on sandy soil, or near sandy' beaches, require special attention to avoid the entry of wind-driven sand particles into piping components.
)
i Improper location of storage.
In many instances, j
storage locations are selected without consideration for construction traffic patterns, or possible falling i
objects and/or missiles.
(See also 10 CFR 50, Ap-1 pendix B, Criterion XIII, and RG 1.38.)
{
Inadequate or illegible material identification.
l (Damage by handling and/or environment.)
l t
Adequacy of snubber installation, testing and inspec-tion procedures, especially relative to alignment and testing. (Completion of Procedure 500908 satisfies
~
these requirements).
III-2 l
i Piping - Review of Quality.
i Assuranco Implementing Proceduris' Procedure No.:
_490518
)
Issuo Date:
03-31-75 I
t r
References SAR, Chaptars 1, 3. -5, 6 and 17, including pertinent codes i
and standac, references in these chapters Regulatory Guide 1.26, Quality Group Classifications and Standards Regulatory Guide 1.29, Seismic Design Classification Regulatory Guide 1.28, Quality' Assurance Program Requirements j
(Desigh and Construction)-
j Regulatory Guide l.38, Quality Assurance Requirements for Packaging., Shipping, Receiving Storage.and Handling of 3
Items for Water-Cooled Nuclear Power Plants j
Regulatory Guide 1.39, Housekeeping Requirements for Water-Cooled Nuclear Power Plants Regulatory Guide '1.58, Qualification of Nuclear Power Plant
}
Inspection, Examination ~,'and Testing. Personnel v
l 1
l d
i l
1 1
III-3 l
Rbactor Coolant PressuriBeundary
. Piping I ~- Observation of Work-and Work Activitics Procedure No.:. 490538
-}
Issue Date: 4/1/7/
~
SECTION II INSPECTION REQUIREMENTS 1.
In two systems listed in Section. III of.this procedure,-
observe five different piping activities such as:
handling; protection; installation of pipe spools, fittings,. bellows, nondestructive examinations; and quali.ty related inspections.
2.
Ascertain whether the following activities and/or.re-quirements, for the activities selected above, meet applicable. requirements and established. procedures:
a.
Inspection (QC) and/or work performance' procedures. -
including specified frequency of inspectio.ns b,
Record. keeping requiremen.tsf E
- c. 'C'onstiuctiori/.iitsta11ation specific'at'ionjequire-.
ment's d.
Issuance and use of specified materials-
- e.. Utilization of qualified inspection personnel-3.
If'NDE activities are performing on piping and related components in the two systems selected above, ascertain whether the following requirements are met:,
a.
performar.ce of prescribed NDE activities b.
Calibrationanduseofpropermeasuringand,testi.
equipment c.
Qualifications of NDE' personnel 4.
For two locations or " runs" between major components within the reactor coolant pressure boundary, where piping in-sta11ation has been completed c essentially completed, ascertain whether the runs are installed as specified.
)
')
II-1 t
l
Rsacter Ccolant Pressuro B:undarf i
- Piping I - Obscrvaticn cf Work
.' and Werk Activities'
- Proccduro No.: 490538 Issue Datei 03-31-75 SECTION III-3;i-va rec INSPECTION GUIDANCE T- ]
~
v General Guidance l
l Prior to obskrving ~the activities selected in-Sectios IT,e ' '
review the pertinent SAR chapters as well as related spec-1 ifications, drawings, and procedures.
For example / perordto6i inspecting ma,terials and components in storage, determine
.the requirements for such things as storage conditions,'l ' -
r protection from. damage, special preservation requirements, material and component identification, segregation of non-conforming items and ' required records.:
r M" ' H
'J
"?'
The inspector may not be able to observe 'alb. facets of att;3 4 Yel'ested 'in'Sectionpr' ogress relative to piping activities work activities in II of this pro'c'edu're'. Ho#even,wtheidiredt
. observation of portions of activities 'should be made.
In.
.. some ' cases it w'i1,l' be..ine' essary' tg obserye tne ' comp 1.eted-c work rather'than.we' k-in' progress.. Noreover, it pay,be mo.re r
a appFopria te Fdbs e rW !s'ome pipingFaTttirMiris tall a'ti6n ra th'es -
, than during installation. ' The. intent is td determine 'whether activities and/or"end products meet. requirements. The inspector should us'e' fudgment' ' fit rigard.'to this mat'tfr19I W m'a vf s2 The reactor coolant pressure bounda'r'y forlaLBNR '.inbluder:3099 all systemi which tie directly into the reactor pressure t
vessel ouf'tiol andif6clu~dihg the second isolation valve.
The reactor coolant pressure boundary for a PWR includes the primary coolant system piping and those, branch connec-tions out to and including the second1solatfori valver'! @"
r (Reference 10 CFR 50.2(v))
a-u, w. :
8 3g s
6 s
III-1
)
I l
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5
Se c
- :..-e,..c..,
,KReactor' Coolant Pressure Boundary
." b :.s i.?. 'c.'...m.. Piping I - Observation of Work and Work Activities Procedure No.: 490538-Issue Date: 03-3T-T!T----
(
Piping systems in the reactor coolant pressure boundary include but are not necessarily limited: to:.
1 i
Recirculation System Primary Coolant System 1
Core Spray System Chemical and Volume Control
'l wr.t_')vD icmne*:
.. H i gh.P res s ure..Sa fe ty.; Ird ec ti on Contr.ot Rod :Ortive.i t.<,., rt:
- M m. 71 y 1.' es.
- t. e t.
- e. v..d :. nec set..w: HT Feedwatern System z.a w-
. ;.m '
dm,7;;. i., nb,:not3i.::i -
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~,. Low Pres.sur.e,S.af,eknl: on..yggiject4on {
v c:ct, arm;
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- .. c : 2 :..:. -
Main Steam. System.j;.nc-n gr
- s. ~ ' ep. c a r:ww
. eprest c:~k u
n c.* v.* c v wc r,h, y
'. :.":.:7e,;
- .12
.. a c. : e... :
r Standby Liquid Control System...
Accumulators (.Saf.ety..Irijection) i Reactor Water. Cleanup.Syst.em
, t.- 9.c :,2. ri :
o, iu r: W 31. pu t c t 6 c.:
ss.'...
.:.wc t n.e-wt.~~t :in c:r:
- Reactot, Core Isolationd'o.ol;.ing
- Res1du.a1. Hea.ty.,Remov,a);
- Syst,em r
. ' c r.. ; -:..? e vikmv-:s: ce d
, s's. W t ' uM ei;
- ,7 faf,etyjnd' Ap1;idf,. a)yes;p r c.H : c m.1 ogsv wnio en b. ' n sct: vet: n. F.w..
. i :c...... 1:. : +.,nce~
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' Residual -He'at iRefnoyal Jy@ stem <.
Reacton AQ.l nt gent,end..Orai.n-
)
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,. h e. n. e
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.a M.n:>
... > n-c. e
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,rv, u t: r. -
..r Jg, g p Safety and Relief Vabe;.e
...P,re.ssurizer.; Surge,O ne,..-
s.
Reactor. Coolant Vent.and. Drain;
~ a 1.n
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. M. 4
- n. :i.!ct-
. Jnstrument $.
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HighPressureCoolant.Injehtfon.
lp 7
Instrument Piping Where selections are involved during inspection activities, do not establish a " pattern" so that the licensee / contractor can expect only certain activities or components to be in-spected. Selection of activities should provide for di-versift' cation of piping systems.
(
111-2
R5 actor Coolant Pressuro Bsundary
~
Piping I - Observation of Work j
and Work Activitics J
Procedure No.: 49053B
}
' Issue Date:
03-31-75 l
k Due to the'importance and extent of reactor coolant pressure boundary piping, two inspection procedures are utilized to 1
observe work activities in this area. The intent of this procedure is to accomplish the inspection requirements of
)
Section II when piping activities in this area are about one-third complete.
This. procedure pc.-tains to all reactor coolant pressure boundary piping activities at the. site except welding; i.e., receipt, receipt inspection, identification, storage, handling, protection, installation, testing, inspection and documentation.
1 The inspection requirements in Section II of this procedure are, in general, of an auditing nature. However, detailed observations are required to determine whether. components /
activities confonn to applicable requirements.
Specific Guidance 2.a. - The intent is to deterr$1ine whether piping is installed and inspected in accordance with applicable speci-
{
fications, drawin'gs and procedures.
.)
.2.e.
Inspection personnel should be qualif'ied.for the work ithey,are ' doi'ng. and they s.hould be perfo~rming.their assigned duties.
~
~
3.a. - NCE may be specified if field repairs are allcwed and accomplished.
~
References,s SAR, Chapters 1, 3, 5, 7 and 17, including pertinent codes-and standards referenecd in these chapters Regulatory Guide 1.38, Quality Assurance Requirements for packaging, Shipping, Receiving Storage and Handling of Items for Water-Cooled Nuclear Power piants Regulatory Guide 1.26, Quality Group Classification American Society of Mechanical Engineers, Soiler and Pressure vessel Ccde,Section III
/
III-3 O
Reactor. Coolant Prassure Boundary Piping. II - Observation of Work and Work Activities Procedure No.:
49054B Issue Date:
4/1/80
)
l, SECTION II INSPECTION REQUIREMENTS I
1.
Observe five different piping activities in two systems listed I
in Section III of Procedure No. 490538, such as:
- handling, protection, installation of pipe spools, fittings, bellows, I
nondestructive examinations; and quality related-inspections.
Ascertain whether the following requirements, as applicable, are met:
a.
Inspection (QC) and/or work performance procedures, l
including specified frequency of inspections b.
Record keeping requirements c.
Construction / installation testing specification requirements d.
Issuance and use of specified materials Ut.ilizatiori'of'qualif'ied. inspection personnel..
e.
- 2. 'For two l'o' cations or 'irurts" b'etween major components w' thin the i
'rea'ctor coolant piessure boundary, determine whether piping runs.
j
. - are installed as required by appli' able specifications..
1 c
3.
If NOE activities are performed on piping and related components in the two. systems selected above, ascertain whether the i
following requirements are met:
a.
Performance of prescribed NDE activities b.
Calibration and use of proper measuring and test equipment c.
Qualifications of NDE personnel.
4.
Select three to five as' built / final design reactor coolant loop piping drawings and compare with the actual installation.
Discrepancies observed may be due to in-process changes such as those initiated by the design organization or those initiated in the field.
If in-process changes are involved, determine whether the licensee has
.these changes on a currer) properly controlled and documented t basis (Qr engineering re approval and subsequent incorporation into final asviewbuiltdrawings.
i 11-1 I
l.
a Reactor-Coolant Pr, essure Boundary Piping II - Observation of Work-and Work Activities Procedure No.:
490548-
' Issue Date:
03-31-75 l
1 SECTION III INSPECTION GUIDANCE General Guidance 1
Prior t'o observing the activities selected in Section II, re-
)
view the pertinent SAR chapters as well as related specifications,
)
drawings and procedures. -For example, prior to inspecting materials and components in storage,.detennine the requirements for such things as storage conditions, protection from damage, j
specific preservation requirements, material and component i
identification.'se'gregation of nonconforming items and re-
)
quired records.
See Section III of Procedure No. 49053B.
Where selectio.ns are involved during inspection act$ivities, dp not establish a " pattern"'so that the' licensee / contractor can.
expect only certain activities or i:omponents to be,insp.ected,.
l
'Due to, the importance and ~ extent of reactor coola'nt pressure boundary piping, two inspection procedures are utilized to observe work activities in this area.
The. intent of this
't i
procedure is to observe activities when the work is about
{
two-third.s complete.
l This procedure pertains to all piping activities at the site except welding; i.e., receipt, receipt inspection, identi-fication, storage, handling, protection, installation, testing, inspection and generation of pertinent quality records..
Specific Guidance 1.
- The inspection requirements in Section II'of this pro-
)
cedure are, in general, of an auditing nature.. However, i
detailed observations are required to determine adequate-1 conformation to applicable requirements.
Selection 1
of activities to be observed should provide for diversi-ficatien of piping systems and pipe fabrications. The piping systems should be different from those selected in Procedure No. 490538.
~i III-1 l
l j
l 1
i
,t J
Reactor Coolant Pressure Boundary Piping II - Observation of Work and Work Activities Procedure No.:. 490548
/
Issue Date:
4/1/80
\\
2
- Due to variations in piping layouts, special plant features, 2-etc., it is not possible to specify_ a -particular piping' in location.. The intent is to select one location or run, each of two different piping. systems for i'nspection, such as between an accumulator and the reactor vessel-or between the reactor vessel and a steam generator (PWR).
3.a. - NDE may be specified and required if field repairs are allowed and accomplished.
4_._ - The intent is to determine whether reactor; coolant loop -
piping is being installed according to properly approved drawings - either the original design drawings or properly approved revisions; and, if revisions are in process, that these changes are properly handled in accordance'with i
l established procedures.
Appropriate standards can be used as a guide in. this area.
.For example, ANSI N45.2.11 requires that where changes to previously verified designs have been made, design 4
verification 'shall be required ;for, the changes, eincluding
'evalua_ tion of the effects of those changes o.n'the overall I
design.
Further, N4Sg2 states that records.which correctly
' identify the "es-bui.1t" conditions of items-in'the nuclear facility s' hall be maintained arid stored for the life of the.
particulaY ite'm 7 iile it is installed in the nuclear facility.
Additionally,.10 CFR 50, Appendix B, Criterion III, states in part that design and field changes shall be subject to the same design control procedures as the originto design.
l 1
Numerous changes may be made to the reactor coolant piping during construction that are different from'tha original.
(SAR) design. Such changes will result in the accumulation j
of various types of design change. documents and/or marked-up-l drawings. Since these changes reflect as-built conditions, they should be adequately controlled so they will be readily available for use with affected original design documents during future evaluations on the effect'ct'her design changes have on the overall design. Additionally, the as-built process should result in proper and timely updating of the-original / master drawings and specifications. to incorporate such changes.
t f,
(
III-2 j:
?
jr 1.-
Reactor Coolant Prtssura Boundary Piping.II - Observation of Work and Work Activities Procedure No.:
49054B i
j Issue Date:
4/1/80 References I
i k
SAR Chapters 1, 3, 5, 7 and 17, including pertinent codes and standards referenced in these chapters g
j Regulatory Guide 1.38, Quality Assurance Requirements for Pagkaging, Shipping, Receiving, Storage and. Handling of Items for Water-Cooled
)
Nuclear Power Plants Regulatory Guide 1.64, Quality Assurance Requirements for the Design of Nuclear Power Plants Regulatory Guide 1.26, Quality Group Classification Regulatory Guide 1.28, Quality Assurance Program Requirements (Design and Construction)
American Society of Mechanical Engineers, Boiler and Pressure Vessel Code,Section III l
)
-~
\\
III-3
' Reactor Coolant Pressure Boundary i
Piping I - Review of Qual *:ty Records Procedure No.:
49055B Issue Date:
03-31-75
(
The generic terms CTR and MTR should not be confused with the term " Certification".
A " Certification" is a document in lieu of actual quality documentation records stating that.the quality requirements, contained in specifications and purchase orders, have been met.
1
" Quality Release Form" and " Certificate of Equipment" are ex-j amples of generic designations for forms which are used by NSSS manufacturers to serve as certifications of quality (in lieu of original quality documentation) for components and 3
equipment manufactured by, or for, the NSSS manufacturer.
Due t.o the importance and extent of reactor coolant pressure boundary piping,. two inspection procedures are utilizied to-review records in'this area.
The' intent of this pro.cedure is F
to rev.iew pertinent records during the early stage,of piping work.
This procedure pertains to records of all reactor coolant pressure boundary piping activities at ths site except welding, i.e., records of receipt, receipt inspection, identification, protection, testing and. inspection.
(
Specific Guidance 1.a. - C'ompare the material test report / certification values 1
with.the specified requirements of ASME-B&PV Sec. tion III and applicaole ASTM specifications.
__1.b. - Review all pertinent records in detail to ascertain j
whether conformance to designated fabrication, thru construction and quality requirements, including ~
1.d.
related procedures, has been achieved.
References SAR, Chapters 1, 3, 5, 7 and 17, including pertinent codes and standards referenced in these chapters Regulatory Guide 1.26, Quality Group Classification Regulatory Guide 1.28, Quality Assurance Program Requirements (Design and Construction)
Regulatory Guide 1.38, Quality Assurance Requirements for Pack-aging Shipping, Receiving, Storage and Handling of Items of Water-Cooled Nuclear Power Plants l
III-2
1
~
Reactor Coolant Pressure. Boundary Piping II - Review'of Quality Records Procedure No.:
49056B Issue Date:
03-31 _
(
References SAR, Chapters 1, 3, 5, 7 and 17, including pertinent codes and standards referenced in these chapters W
Regulatory Guide 1.26, Quality Group Classification Regulatory Guide. l.28, Quality Assurance Program Requirements I
(Design and Construction)
.i 1
Regulatory Guide 1.38,' Quality Assurance Requirements for Packaging, Shipping, Receiving, Storage and Handling,of Items for Water-Cooled Nuclear Power Plants l
. (
f s
4 9
e MD -
III-2
(
i 4
4 9
Reactor' Coolant Pressure Boundary :
Pip,ing'II
' Review:of. Quality Records Procedure No.:
490568
(-
Issue Date:
03-31-75 f.
Storage Inspection -Records
'(1)
Inspections made at required frequency-(2)
Records confirm that storage requirements were met g.
Installation Records (1)
Installation checklists (2) Alignment 4
/*
(3)
Cleanliness
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II-2
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85-e 7 FS-os j
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l os an v, uua i
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ler 2C'y c h sw 21v + wpk 2 b
- Spl gue 9 a -grv<# a a v a~u re m aac w o/ w w ar a 9w un
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12 Following Regional managements review of the initial version and based on discussions with the inspector, the issue was changed to an unresolved item in the second version of the report (Attachment 4).
It remained unchanged in the final issued inspection report.
3.
Safety Significance of the Issue This issue was found to have no safety significance.
The Region IV management position was that an audit of the reactor vessel installation was not specifically required.
10 CFR 50 Appendix B, Criterion XVIII, " Audits," requires audits of activities, such as mechanical installation, but doe _sjot prescribe which specific activities must be auditeo.
In reviewing the Traveler ME-79-248-5500 (Attachment 1) for installation h,
of the reactor vessel, Regional management also found that the TUGCo QA LUN ~ manager had witnessed and signed step 11 of the traveler.
It should also be noted that the previous NRC senior resident inspector had witnessed the reactor vessel installation.
Nearly every step of Traveler HE-79-248-5500 required QC td verify, witness or write an inspection h4 [
_ report.
As a result of NRR Technical Review Team activities as described in SSER 11, and the findings of the NRC Region IV in Inspection Report 50-445/50-84-32, it was already determined that TUGCo audits h '^3
--_ _ _ u
i 22 1
l 4.
Region IV Management Handling of Issue The removal of this issue as an unresolved item from the first version of l
the inspection report was proper based on a correct interpretation of the Code.
V fj)h 7 nk hmd quer% ?
4 1
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l 1
j I
-)
+
v Inspection Report 50-445/85-07; 50-446/85-05
{ m d<b w) eowd (*
-fpd 4
f 4
t o +1 " ' T cW ad*N Item 6 C'"Y U,Ja4 l*( bY Ao 1.
_0IA Statement of the Issue (See Attachment MM)
Issue Resolution of Final Report l
6.
No objective evidence (records)
. Violation maintained but no that mixing blades had been requirement for_ utility to inspected quarterly since trucks respond to this violation.
were placed in service in 1977.
1 l
Expanded Description of the Issue and Related Background Information 2.
The basic issue as understood by Region IV management is as follows:
1 The NRC inspector (H. S. Phillips) believed that a response to the failure to document quarterly inspection of mixer blades, a Level V violation, should have been required. The inspector believed that, based on this l
particular finding, the licensee should be required to review all other inspection activities to assure that they are properly documented.
This issue was initially identified in the first version of Inspection Report 50-445/85-07; 50-446/85-05, as Item 4 in the Notice of Violation j
and in paragraph 8 of the report.
It appears as the same in the second
24.
t version.
It appeared as the:same in the issued report except that the the NRC, Region IV letter was revised.to. require no reply to the NOV and the inspector.was requested by Regional management.to. provide referened'in
.the body 'of the report to the FSAR commjemant and ?=r4can-Concr-ete
. Institute'.(ACI) that. required blade maintenance.
He was also requested to. drop a reference to the " national recognized checklist" for which there was no reference to a licensee commitment which adopted the use of this checklist.
g is.
l 3.
Safety Significance of the Issue This issue was found to have no safety significance.
t No hardware problems have resulted, as evidenced by consistent concrete strength and uniformity tests.
Inspections of th'e mixer blades were conducted but not recorded.
B&R Procedure 35-1195-CCP-10 was? revised to Ao#
require documentation of the inspection of truck mixer blades.
There was a
no indication that other inspections were not being documented, as the f
inspector four.d no.other instances.
This did not preclude continued NRC inspection emphasis on documentation for the other required inspections.
Regional management had discussions with the inspector relative \\ c this t
violation. The inspector had found that paragraph 3.10 to the'B&R Procedure 35-1195-CCP-10 P.evision 5, dated December 4 '1978 (Attachment.
1 1
y
a q
25 l
- 19) " Truck Mixing" was silent on blade wear but he inferred that j
I doction 3.11 would indicate that blades should be checked for. central and j
jruckmixers.
l i
1 The B&R procedure required quarterly blade checks but did not require
{
/
dqcumentatiortnf the Mspec+6n.
Regional management determined that the inspector was inferring the requirements.of the BsR procedure. The I
l inspector was asked by Regional management to determine whether the i
inspection of blades was an ACI requirement comitted to'in the FSAR.
The inspector took exception to the request and indicated that he'saw no need to go beyond the utility's own procedure.
The. inspector subsequently added to the final inspection report "In'the FSAR, Volume V, l
Section 3.8.1.2.1, the applicant comits to A In ACI 304, the maintenance of mixer blades is reonired 'l The inspector informed Regional 1
J n.anagement that the inspection requirement was annual.
The inspector had provided no reference to the FSAR for the " national recognized checklist" he had used in the course of the inspection.
Since the checklist was not a utility comitment, the inspector was requested to discuss the attributes I
he inspected and to delete reference to the checklist.
1 Regional management viewed this as a weak violation, in that the J
inspector had interpreted the utility's procedure to imply that the truck'
' blades should also have been checked.
In addition, following the OIA 1
investigation,tRegional management has, in reviewing ACI 304-73, Section
)
4.2, found that it states only the following, with regard to mixer blades:
t
26 Stationary mixers should be equipped with suitable timing interlocks
]
to prevent under or over-mixing of the batch.
Batch size should not exceed the manufacturer's rated capacity as marked on the mixer name plate. Mixers should be properly maintained to prevent mortar,or
~
dry materials leakage and inner mixer surfaces should be kept clean i
and worn blades replaced. Mixers not meeting performance standards outlined in Section 4.4 should be taken out of service until I
necessary maintenance and repair results in correction of their I
deficient performance, d
This section specifies no annual inspection requirement but rather that I
maintenance and repair be performed when the mixer does not meet the l
I l
performance standards of Section 4.4.
The section this is'taken from is Chapter 4. " Mixing," which applies to central batch mixing.
It would apply to a truck mixer used as a mixer at the site.
Section 4.4 states the following:
4.4 -- Mixer performance The performance of mixers is usually determined by a series of uniformity tests made on samples taken form two to three locations within the concrete batch being mixed for a given time period.
Mixer performance requiremer.ts are based on allowable differences in test results between any two locations or in differences between individual locations and the average of all locations.
s
'l
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4
)7
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'i 27 h
,i t s
1 Among the many tests used to, check mixer performance, the following are the most ccmcn: air content, slump, unit weight of air-free mortar, compressive strength, water dentent of mortar, cement 1
i content of dried mortar, and coarse aggregate content.
Another important aspectj of ' mixer performance is batch-to-batch unifonnity of the concrete which is also largely.affected bygthe uniformity of nateriels ir.d their measurement as well as by the efficiency of the mixer. ' Visual observation of the concrete during mixing and discharge from the miser is an important aid in maintaining a uniform mix, particularly uniform consistency.
Some recording consistency meters, such as those operating form the amperage draw on the electric motor drives for revolving' drum mixers, i
1 have also occasionally proved to be useful.
However, the most i
positive control method for maintaining batch-to-batch uniformity is a regularly scheduled program of tests of the fresh concrete including unit weight, air content, slump, and temperature.
Strength tests are not for this purpos,e.
I In Section 4.4, there is no inspection of tlades' required, but rather l
1 uniformity tests.
l 4.
Region IV_ Management Handling of_ the Issue i
l..
It has been an accepted practice to indicate in inspection reports that a -
I written reply to a Notice of Violation is not required when all corrective-i
-- - ~ <
J',
QqJ, hO
28 1
action had been completed before the report was issued.
Regional i
management did not agree with the inspector that for this Severity I
Level V violation, a programmatic review of all inspection procedures by the utility was necessary.
There was little or no safety significance to the issue and therefore the appropriate corrective actions that the NRC required were limited to the problem at hand.
Footnote Attachment MM states that based on Mr. Haughney's opinion, Regional management changed the Notice of Violation to require no reply.
Regional management recalls tnat Mr. Haughney, NRR's consultant, and Mr. C.
Trammell recommended removal of the violation.
Regional management did not remove the violation because it appeared to be properly written at the time; however, Regional management found that all corrective action had been completed and that further reply was not considered necessary.
Witti iespect-tc Mr. Scarbm9 s comment witn regard to concern 5 to~
h Inspection Report 50-445/85-07; 50-446/85-05 (Attachment HH) that "If an applicant mistake is of such significance as to be written as a violation, then it should not be negated by the cover letter to the inspection report." The requirement for a licensee to respond to a Notice of Violation is to assure that appropriate corrective action has been taken.
When all required actions are promptly completed and known to the NRC before the report is issued, a written response becomes moot.
Indicating that a written response is not required does not negate the violation.
The item is entered into the utility's enforcement history and such violations would be taken into account when evaluating licensee performance.
L Y
5 pc 9 e
29-1 i
Inspection Report 50-445/85-07; 50-446/85-05 l
l
- i
\\
Item 7 1.
OIA Statement of the issue (See Attachment MM) i None 1
1 2.
Expanded Description of the Issue and Related Background Information The basic issue as understood by Region IV management is as follows:
The NRC inspector (D. Norman) found that the NPP-1 form certified that the cold leg subassembly met requirements of ASME,Section III, 1974' Edition through Wpter of 1975, and the FSAR, Table 5.2-1 specified ASME, L
@p Section III, 1974 Edition through Summer 1974.
He considered this eg discrepancy as an unresolved item.
This issue was initially identified in the first version.of Inspection Report 50-445/85-07;50-446/85-05(Attachment 3),asanunresolveditemin
- i reportparagraph14.c.(2).
It appears the same in the second version report (Attachment 4) as report paragraph 14.c.11. After receiving connents from NRR and OGC and based on additional review by Regional.
management, the item was removed form the final inspection report.
b i
30 l
3.
Safety Significance of the Issue This issue was found to have no safety significance.
The second version of the inspection report, which was sent to NRR and OGC, resulted in a comment from G. Mizuno, OGC, requesting the Region to determine if the reactor coolant cold leg pipe was in conformance with 10 CFR 50.55a, " Codes and Standards." Regional management, in followup to OGC's comment, found that Section 3.2 of the FSAR " Classification of Structures, Components and System" states in Note 1, with regard to Table 3.2-1 (Reactor Coolant System) "Later Code revisions may be used optionally in accordance with 10 CFR 50.55a." The NRC letter of July 3,1985, from V. S. Noonan to M. D. Spence (Attachment 20) was reviewed by Regional management.
It states that as of July 3,1965, "The most recent version of 10 CFR 50.55a, dated March 30, 1984, approved the editions of Section III of the ASME Boiler and Pressure Vessel Code, through the 1980 Edition and Addenda through the Summer 1982, and is only applicable to Code Class 1, 2, and 3 components.
The reactor coolant cold leg pipe is a Code Class 1 system.
Regional management discussed the Codes and Standards Rule, the FSAR connitments, and the NRR July 3, 1985, letter with OGC.
It was concluded by Regional management that there was no violation of 10 CFR 50.55a: however, there was a conflict in,the
,c FSAR.
ndment 5 to the FSAR has been submitted, which revised the v
FSAR(Table 5.2-1).
From the review of Mr. Phillips OIA testimony, pages 133 and 134 it appears as stated by Mr. Phillips that he and l
Mr had earlier called Mr. R. Bosnak, Chief of the Mechanical n
INDEXED
~!
l l
CONSTRUCTION OPERATION TRAVELER 35 1195 g
@ME-79-248-5500
@ EQUIPMENT NO.
hNIT NO. QUANTITY (51PAGElOg[#9 TRAVELER NO.
TCX-RCPCRV-01 2
1 Mu As ACTIVITY DESCRIPTION REFERENCE DRAWINGS eactor Vessel installation som noinw g SPEC./ PROC./ENG. INSTR.
gLOCATION g SYSTEM MCP-1 FN M Containment #2 n.c.
l PREPARED SY Mk DATEMDM DEPT. M * - EUG-REVIEWED BY O
DATE
~/O " O QA/QC ENG ANI gl SteVLE.M.' f M/Ar l#200 4 -10
- 79 ANI REVIEW NA 6
DATE QA43C OP. NO.
DEPT.
OPERATION,, -
ENG ANI 1
General Notes:
(1)
All support nuts and bolts shall be tightened to " snug tight" condition.
Snuc tight shall be defined as the condition which insure that parts of the joint are brought into good contact with each other.
This can be attained by a few impacts of an impact wrench or the full effort of a man using an ordinary spud wrench.
Reference the appropriate.
Traveler for rigging and lifting require-1 ments of the reactor vessel.
(2)
Clean al$ R.V.
Support Shim with acetone prior to installation.
(3)
Reference Drawings:
8
- c W 1210E59--- R.V.
Support Hardware QA RECORD W 1457F27--- Reactor Vessel Supports
, 4 C-E 10773-171-004----R.P.V. General 7,y
- DLES NOTED Arrangement j7 g
u UAEl B ASliURA NC C-E 10773-171-005----R.?.V. Gene h
1 M/W Install the R.P.V.
Supports and Shoes per W Drawings 1210E59 and.1457F27.
The min.
't
~
engagement for the guide pins is 23 ". Therefore s
j the following gaps between the Support Shoe and pin top surfaces are as follows:
5 4
l A
CONSTRUCTION OPERATION TRAVELER CONTINUATION TRAVELER NO.
ACTIVITY DESCRIPTION PAGd OF[f ME-79-248-5500 Reactor Vessel Installation PREPARED BY h--
DATE 0} %
REVIEWED BY v&
DATE ANI REVIEW Nb OATE
/
QA/QC OP. NO.
DEPT.
OPERATION ENG ANI g
Hot Leg--Shoe to pin = -2 3/8" to -7/8" Cold Leg--Shoe to pin = -3/8" to +1 1/8" D
A G.G e Y u#
G
": chine the eiJc :'.ine ic 1 3/4" mn.
Pull M 77 The side inLed restraints to the side shim and support colums prior to concrete' pour.
0" clearance must be met after the pour.
0" clearance shall be less than.001"? The' side shims are to also be modified per C"C-4260'; &f Weld the side shims to the R.P.V. Oupport per b BRM-1457F27. QC to inspect Welds and attach applica-ble NDE Reports.
The optimum elevation to set the R.P.V.
I Support shoes is as follows (based on R.P.V.
j d
As-Builts):
{
6 67 -----824'-5.754" 0
158 ----824'-7.784" 0
247 ----824'-5.755" 338 ----824'-7.777" The shoe bearing surface should be as level as possible, not be exceed + 1 must be within 1/8" vertIca/8".
The supports ll'y, \\" radially,
" tangentially.
Record final readings on i
Attachment i 1.
Obtain appropriate signatures.
w The Leveling screwt shall be set as close as l
rl-feasibly possible to the following elevations:
l 67 ------824'-7.004" E0R INEg' i i M $U T
1580-----824'-9.034" 247 -----824'-7.005" 3380-----824'-96.027"
' phelevelingscrewsmustproject1" min.--l"
. max. above the shoe bearing surface.
e b
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. ski N r.f-A Q. 3w.w g th.
e.w a w.s e Ic en ~
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N'w 4% 9
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me. m PMB A Pkw % g, n
94 1%
~n ma..
CONSTRUCTION OPERATION TRAVELER CONTINUATION TRAVELER NO.
ACTIVITY DESCRIPTION ME-79-248-5500_ m Reactor Vessel I3 tallation PAG E,,3#
~#*
REVIEWED BY DATE ANI REVIEW OATE
/
QA/QC OP. NO.
D E PT.
OPERATION ENG ANI 1
i 2
M/W Lower the R.P.V.
The vessel should be level i
to + h" while suspended from the crane.
The QCW vessel must be orientated such that the inner and out monitor tubes straddle the 2700 azimuth.
Lower the vessel to the point of contact with the leveling screws, taking care that the vessel weight is fully imposed on all screws.
Raise any screws not in contact with the under-side of the vessel support pads.
3 M/W Level the vessel to within.0005" per foot
(.007" overall) on the internals seating flange thru the access covers in the shipping fixture.
Raise the vessel and adjust the leveling screws as necessary.
Top of the seating flange should be set at elevation 832'-10.058".
Maintain vessel orientation using W_ supplied instruments in the four keyways.
Align the vessel to + 1/64" of containment axis.
A worksheet 'for leveling readin s b J
$;taclwdM idh Ob-1 for field use.
4 F.E.
After obtaining proper elevation, level and orientation, recheck the calibration of all instruments to be sure no errors have be introduced. o y j-A N ec # w ds-T h. 7 7 9 5
M/W Take height measurements between the under-QCW side of the vessel support pads and the support shoe bearing surface at four points 7p and record on Attachment i 2 _.
These results must be no less than 1. 90".
Also record the I
reactor cavity temperature. QC to initial and l
date Attachment 2.
fg'g,.g g 900 g.
6 M/W Machine the permanent bottom shims to QCW dimensions of Operation No.J. Tolerance to be
CONSTRUCTION OPERATION TRAVELER CONTINUATION i
TRAVELER NL, ACTIVITY DESCRIPTION g
E-79-248-5500 Reactor Vessel Installation PAGlag m
PREPARED BY L
DATE D EDI%
^
b #~
REVIEWED BY 1
DATE ant REVIEW
^M DATE i
OA/OC OP. NO.
DEPT.
OPERATION ENG ANI 1
001" -
0",
temp. 1 5 F.
%g 7
INSVI, While bottom shims are being machined, apply R.P.V.
insulation per manufacturers supplied QCM drawings and instructions. QC to write inspection report as required.
8 M/W Raise the R.P.V.
and lower the leveling scred QCV until they are.375" +.010" above the bearing surface of the support shoes.
Install the hold 7--fyf I
down nuts.
9 M/W Insert the bottom shim plates.
Do not allow QCV the bottom shim plates to be held off the bearing surface of the support shoe by the leveling screws.
EUR INEONAilBil GHu 10 M/W coat the top surface of the vessel pads with prussian blue.
Lower the vessel monitoring the vessel axis to the containment axis.
11 M/W Lift the vessel and check for surface contact I'I QCW between the top of the shim plates and bottom sf/
Agf(7 IO of the support pads.
75% surface contcet is required.
Mmdddsisessphtw$1gggpsed r3 pest'9Podass M-
~4ce.ft to ebtairreegihd stmthet:1rtwqn neestepppary.
,//
/
3.zagr CT,2 Oy 12 M/W After required contact area has been met, p
fp4 QCV remove prussian blue from the contact surfaces 7.gg F* * "
and coat the top surface of the shim plates with "molykote type Z" dry film lubricant.
rg.[3 Buff to improve finish.
13 M/W Lower the vessel onto the shim plates.
Check the leveliness and axis orientation.
e
CONSTRUCTION OPERATION TRAVELER CONTINUATION TRAVELER NO.
ACTIVITY DESCRIPTION 9
ME-79-248-5500_
Reactor Vessel Installation PAG Q g @,
M10)%
PREPARED BY h
DATE
~ /O ~ 7 REVIEWED BY 1
DATE ANI REVIEW N
DATE OA/OC OP. NO.
D E PT.
OPERATION ENG ANI 14 M/W Take gauge readings of the spaces on either T[
QCW side of the vessel support pads and record on A'ttachment # 3 Also recorded cavity
'3 0~M.
temperature.
gC[
15 M/W Machine the side shims to the thickness D.
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'3 *N cold clearance.
Tolerance is + 0, -.001" 0
temperature + 5 F.
gg og 16 M/W Coat the surfaces of the side shims which wilI%)
QCV be in contact with the vessel support pads with "molykote type Z" dry film lubricant.
g#g Buff to improve) finish.
17 M/W Install the side shim in the support shoes.
Raise the vessel to a height necessary for top installation of the shims.
Bolt the shim keepers onto the support shoes.-
E08JNE0ilMitil0H 0W u 18 M/W Lower the vessel and check levelness and vessel axis for orientation with containment axis.
Record and obtain approvals on Attachment fl.
~
19 M/W Verify cold clearance of.020" to 0"
.005" QCV for each side shim.
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NUCLEAR REGULA70RY C3MMISS10N j
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- o, PARKWAY CUNTRA1. PLAZA SutLDING v-In Reply Refer To:
Dockets:
50-445/85-07 50-446/85-05 d
i
-i Texas Utilities Electric Company ATTN:
M. D. Spence, President, TUGC0 Skyway Tower 400 North Olive Street k
Lock Box 81 Dallas, Texas 75201 Gentlemen:
This refers to the inspection conducted under the Resident Inspection Progran by Mr. H. S. Phillips and others during the period April.1, 1985, through June 21, 1985, of activities authorized by NC Construction Permits CPPR-125 and CPPR-126 of the Comanche Peak facility, Units 1 and 2, and to the discussion of our findings with Mr. J. T. Merritt, and other members of your staff at the,
{
conclusion of the inspection.
a-Areas examined during the intpection. included plant status, action on previous NRC inspection findings, action on applicant identified design construction q
deficiencies (10 CFR Part 50.55(e) reports) and plant tours.
Within these areas, the inspection consisted of selective examination of procedures and representative records, interviews with personnel, and observations by the inspectors.
These findings are' documented in the enclosed inspection report.
i k
During this inspection, it was found that certain of your activities were in
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violation of NRC requirements.
Consequently, you are required to respond to this violation, in writing, in accordance with the provision of Section 2.201
]
of the NRC's " Rules of Practice," Part 2, Title 10, Code of Federal l
Regulations.
Your response should be based on the specifics contained in the Notice of Violation enclosed with this letter.
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Should you have any questions concerning this inspection, we will be pleased to discuss them with you.
Sincerely, 1
1 Dorwin.R. Hunter,Ch[ef s
Reactor Project Branch 2 l
t l
Enclosures:
1 1.
Appendix A - Notice ~of Violation 2.
Appendix B - NRC Inspection Report 50-445/85-07 50-446/85-05' l
cc w/ enclosure:
Texas Utilities Electric C'ompany Skyway Tswer 1
400 North Olive Street Lock Box 81 Dallas, Texas 75201 Texas Utilities Electric Company ATTN:
J. W. Beck, Vice President Skyway Tower 400 North Olive street i
Lock Box 81 Dallas, Texas 75201 a
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i APPENDIX A l
NOTICE OF' VIOLATION I
Texas Utilities Electric Company Docket: 50-445/85-07 Comanche Peak Steam Electric Station 50-446/85-05 Units 1 and 2 Permit: CPPR-126 CPPR-127 l
During an NRC inspection conducted on April 1 through June 21, 1985, violations of NRC requirements were identified.
The violations' involved a failure to correct RTE Delta hardware problems; failure to use class "E" concrete (grout) as specified; failure to document unsatisfactory conditions I
during receipt inspection of the Hydrogen recombiners; failure to inspect concrete mixer blades quarterly; failure to document cement scales which were l
l out of calibration; failure to translate design criteria for reactor vessel i
installation into specifications, procedures, and drawings; failure to maintain i
stated tolerances and to report the failure on a nonconformance report; failure to audit RPV specifications / procedures, installation, and as-built records; failure to properly identify a charging system spool piece; and failure to' furnish or maintain records for reactor coolant systems materials.
In accor-dance with the " General Statement of Policy and Procedures for NRC Enforcement Actions "10 CFR Part 2, Appendix C (1985), the violations are listed below:
1.
Failure to Promptly Correct an Identified Problem with RTE - Delta Potential Transformer Tiltout Subassemblies 10 CFR 50, Appendix B, Criterion XVI as implemented by the Texas Utilities Generating Company (TUGCO) Quality Assurance Plan, Section_
i Revision
, requires that measures shall be established to assure that l
conditions adverse to quality, such as failures, malfunctions, deficien-cies deviations, defective material and equipment, and nonconformances are promptly identified and corrected.
Contrary to the above, a potential problem with RTE _ - Delta potential transformer tiltout subassemblies, which are used in the en.ergency diesel generator control panels, was identified to the applicant via a letter, dated June 15, 1983, from Transamerica Delaval Inc.
This letter also provided instructions for correcting the potential problem.
However, the applicant did not perform the corrective action.
The NRC initially reported this item as unresolved in NRC Inspection Report 445/84-40.
This is a Severity Level V Violation.
(Supplement II.E) (445/8507-01 446/8505-01).
2.
Commercial Grout Used in Lieu of Class "E" Concrete 10 CFR Part 50, Appendix B, Criterion V, n implemented by the TUGC0 QA Plan, Section 5.0, Revision
, requires that activities affecting quality
j shall be prescribed by documented instructions, procedures, or drawings,.
of a type appropriate to the circumstances and shall be accomplished in accordance with these instructions, procedures, or drawings.
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Contrary to the ahove, commercial non-shrink grout was used to. grout the Unit 1 reactor coolant pump and steam generator supports in lieu of Class i
"E" concrete ss specified in Section 6-6 of drawing 2323-51-0550,
-l Revision 4.
The NRC initially reported this item as unresolved in NRC l
IR 445/84-16.
This is a Severity Level IV Violation.
(Supplement II.E) (445/8507-02).
3.
Hydregen Recombiners - Out of Speciff. cation Voltage Recorded on I
Westinghouse Quality Release Document 10 CFR Part 50, Appendix B, CriLerion V, as. implemented by the TUGC0 QA Plan, Section 5.0., Revision 2, requires that activities affecting quality shall be prescribed by docuiNoted instructions, procedures or drawings, of a type appropriate to the circumstances and shall be accomplished in l
accordance with these instructions, procedures 3 or drawings.
j i
Brown and Root Procedure QI-QAP-7.2-8, " Receiving of Westinghouse Safety l
Related Equipment", Section 3.1.11, required a QC inspector to verify l
l that the Westinghouse Quality Release (QR) docNeent checklist items be
-l l
ffiled out completely and accurately.
l Contrary to the above, the voltage recorded on Westinghouse QR 41424 checklist, attachment 1l step 4.1, was outside the specified tolerance, but the QR was accepted as satisfactory by quality control receipt inspection:
The NRC initially reported this item as unresolved in NRC IR No. 50-415/84-16.
l This is a Severity Level V Violation Supplement II.E (445/8505-03).
I 4.
Failure to Provide Objective Evidence (Records) to Show that Concrete Central and Truck Mixer Blades were Inspected 10 CFR Part 50, Apper.dir 8, Criterion V. as implemented by the TUGC0 l
QA Plan, Section 5.0, Revision 2, dated Nay 21, 1981, requires that l
activities affecting quality shall be prescribed by documented instruc-tiens, procedures, or drawings, of a type appropriate to the circumstances I
and shall be accomplished in accordance with these instructions, proce-dures, or drawings."
Brown & Root Procedur4CEL 135-CCPDjevision 5, dated December 4, I
1978, requires t hat cent vahf ruck muer blindes be chackesi nuartpely to assure that mixer blade wear does not exceed a loss of 10% of original blade height.
Contrary to the above, on May 31, 1985, the NRC inspector determined that there was no objectivq evidence (records) that the mixing blades had been inspected quarterly since the trucks were placed in service in 1977.
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1 This is a Severity Level V Violation.
(Supplement II.E) (445/8507-04; 446/8505-02).
f 5.
Failure to Issue a Deficiency Report on Cement Scales That Were Out of Calibration 10 CFR Part 50, Appendix B, Criterion V, as implemented by the TUGC0 QA i
Plan, Section 5.0, Revision 2, dated May 21, 1981, and Section 15.0, Revision 4, dated July 31, 1984, requires that activities affecting quality shall be prescribed by documented instructions, procedures, or drawings, of a type appropriate to the circumstances and shall be accomplished in accordance with these instructions, procedures, or drawings.
Brown & Root Procedure CP-QAP-15.1, " Field Control of Nonconforming Item, " states that nonconforming conditions shall be documented in a Deficiency and Disposition Report (DDR).
Procedure CP-QCP-1.3, " Tool Equipment Calibration and Control," dated July 14, 1975, states that out of-calibration equipment shall be identified on a DDR.
l Contrary to the above, on May 31, 1985, the NRC inspector reviewed the calibration file for scale (MTE 779) used for weighing cement and found that difficulty was encountered with the water and cement scales during a j
1975 calibration of the backup plant scales; however, no DDR was issued l
to identify this condition and require disposition of the scale and concrete (if any) produced.
This is a Severity Level IV Violation. (Supplement II.E) (445/8507-06; 446/8505-04).
6.
Failure to Translate Design Criteria Into Installation Specifications, Procedures, and Drawings; and Failure to Control Deviations from These Standards 10 CFR 50, Appendix 8, Criterion III, as implemented by TUGC0 QA Plan, Section 3, Revision 3, dated July 31, 1984, require that measures shall be established to assure that applicable regulatory requirements and the design basis, are correctly translated into specifications, drawings, procedures, and instructions.
These measures shall include provisions to assure that appropriate quality standards are specified and included in design documents and that deviations from such standards are controlled.
Contrary to the above, (a) Unit 2 reactor pressure vessel installation design criteria recommended by the NSSS vendor, such as centering tolerances, levelness tolerances, and shoe to bracket clearances, were not included in installation specification, procedures, and drawings; and (b) the criteria were specified in Construction Operation Traveler ME-79-248-5500, but were not treated as design engineering criteria as evidenced by an undocumented change of shoe to bracket clearances.
This is a Severity Level IV Violation (Supplement II.E) (446/8505-06).
7.
Failure to Maintain Tolerances Stated and Failure to Report These Results on a Nonconformance Report 10 CFR 50, Appendix B, Criterion XV as implemented by the TUGC0 QA Plan, i
Section V, Revision 2 dated May 21, 1981, requires that measures shall be established to control materials, parts or components which do not confurm I
to requirements; and nonconforming items shall be reviewed and accepted, rejected, repaired; or reworked in accordance with documented procedures.
Brown end Root Quality Assurance Manual, Section 16, dated March 27, 1985, requires that unsatisfactory conditions identified on process control documents shall be identified on an Nonconforming Report.
Contraiy to the above, clearances between the reactor vessel support brackets and support shoes were not within the tolerance stated in 3
Construction Operation Traveler ME-79-248-55 and the condition was not j
reported on a Nonconformance Report.
This is a Severity Level IV Violation.
(Supp4 ment II.E) (446-8505-07)
)
8.
Failure to Audit RPV Specifications / Procedures, Installation and As-built Records 10 CFR 50, Appendix B, Criterion XVIII as implemented by the TUGC0 QA Plan, Section 18.0, Revision 2, dated July 31, 1984, requires that a -
Acebensive system of,f L planned and periodic audits be carried out ta verify compliance with all ty aspects of the quality assurance program.
d 4
\\ Contrary to the above, there was no evidence that TUGC0 had audited i
O fk' 3 either Unit 2 reactor vessel installation specifications, placement procedures, actual hardware placement, or as-built records.
This is a Severity Level IV Violation.
(Supplement II.E) (446/8505-08).
9.
Failure to Properly Identify a Spool Piece l
10 CFR 50, Appendix B, Criterion VIII, as implemented by the TUGC0 QA Plan, Section 8.0, Revision 0, dated July 1, 1978, requires that measures be established for the identification and control of materials, parts, and components, including partially fabricated assemblies.
These measures shall assure that identification of the item is maintained by heat number, part number or other appropriate means.
Article NA3766.6 of ASME,Section III, 1974 Edition, requires that the identification of material consist of marking the material with the applicable material specification and grade of material, heat number or heat code of the material, and any additional marking required by this
)
section to facilitate traceability of the reports of the results of all tests and examinations performed on the material.
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- - 1
/
Contrary to the above,. spool piece. 3Q1 (DWG No. BRP-CS-2-RB-76) had '
'neither been marked with the material' specification and. grade, heat' i
number or heat code of the material.
.This is a. Severity Level IV Violation (Supplement II.E) (446/8505-09) 10.
Failure to Furnish or Maintain Records for Material
)
i 10 CFR 50, Appendix B, Criterion XVII, as implemented by the TIGC0, requ
'QA Plan, Section-
, Revision be maintained to furnish evidence of activities affecting quality. -The records'shall. include at least.the'following:, operating logs, and_the results of reviews, inspections, tests, audits, monitoring of work i
performance, and materials analyses.
Articles NS-2130 and NA3767.4'of ASME Section III,.1974 Edition requires
)
a-Certified Material Test Report for all pressure retaining material over 3/4 inch nominal size.
j Contrary to the above, Certified Material Test Reports were not available for the 22 degree elbow, 10 inch 45 degree nozzle, and three thermowell i
bosses, which were a part of the loop 3 cold leg piping subassembly.
This is a Severity Level IV Violation (Supplement II.E)'(446/8505-10)
Pursuant to the provisions of 10 CFR 2.201, Texas Utilities' Electric Company i
l-is hereby required to submit to.this office, within 30 days of the date'of I
this Notice, a written statement or explanation in reply, including:
(1) the corrective steps which have been'taken and the results achieved; (2) corrective steps which will be taken to avoid further violations; and 1
(3) the date when full compliance will be achieved.
Consideration may be given to extending your response time for good cause shown.
Dated:
1 I
4 j
q a
l In Reply Refer'To:
Dockets:
50-445/85-07 50-446/85-05 Texas Utilities Electric Company ATTN:
M..D. Spence, President, TUGC0 Skyway Tower 400 North Olive Street
/
l Lock Box 81 Dallas, Texas 75201 Gentlemen:
This refers to the inspection conducted under the Resident Inspection Program by Mr. H. S. Phillips and others during the period April 1, 1985, through June 21, 1985, of activities authorized by NRC Construction Permits CPPR-125 and CPPR-126 of the Comanche Peak facility, Units 1 and 2, and to the discussion
)
1 of our findings with Mr. J. T. Merritt, and other members of your staff at the conclusion of the inspection.
Areas examined during the inspection included plant status, action on previous NRC inspection findings, action on applicant identified design construction deficiencies (10 CFR Part 50.55(e) reports) and plant, tours.
Within these areas, the inspection consisted of selective examination of procedures and representative records, interviews with personnel, and observations by the inspectors.
These findings are documented in the enclosed inspection report.
During this inspection, it was found that certain of your activities were in violation of NRC requirements.
Consequently, you are required to respond to this violation, in writing, in accordance with the provision of Section 2.201 of the MRC's " Rules of Practice," Part 2, Title 10, Code of Federal Regulations.
Your response should be based on the specifics contained in the Notice of Violation enclosed with this letter.
RPB2/B C/RPB2B C/RPB2 NRR HSPhillips/dc DHunnicutt DHunter VNoonan
/ /85
/ /85
/ /85
/ /85
l
' Texas Utilities Electric Company 2
]
l Should you have any questions concerning this inspection, we will.be pleased to discuss them with you.
Sincerely, DorwinR. Hunter,ChiIf l
Reactor. Project Branch 2 1
Enclosures:
1.
Appendix A - Notice of Violation 2.
Appendix B - NRC Inspection Report 50-445/85-07 50-446/85-05 cc w/ enclosure:
Texas Utilities Electric Company Skyway Tower 400 North Olive Street Lock Box 81 Dallas, Texas 75201 Texas Utilities Electric Company ATTN:
J. W. Beck, Vice President Skyway Tower 400 North Olive street Lock Box 81 l
Dallas, Texas 75201 I
bec distrib by RIV:
TEXAS STATE DEPARTMENT OF HEALTH l
bec: to DMB(IE01) bec distrib by RIV:
- RPB1
- Resident Inspector OPS
- RPB2
- Resident Inspector CONS R. Martin, RA
- D. Hunnicutt, Chief, RPB2/B R. Denise, D/0RSS V. Noonan, NRR C. Wisner, PA0 S. Treby, ELD MIS SYSTEM RIV File Juanita Ellis Renea Hicks
- D. Weiss, LFMB (AR2015)
- w/766
_..m__
___..___._._.______-_____m
1 APPENDIX B I
i U. S. NUCLEAR REGULATORY COMMISSION I
REGION IV
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1 NRC Inspection Report:
50-445/85-07 Permit: CPPR-126 l
50-446/85-05 CPPR-127 l
1 Docket:
50-445; 50-446 I
1 Applicant:
Texas Utilities Electric Company (TUEC) f Skyway Tower J
400 North Olive Street i
Lock Box 81 j
Dallas, Texas 75201 j
I l
Facility Name:
Comanche Peak Steam Electric Station (CPSES)
Units 1 and 2
]
Inspection At:
Glen Rose, Texas Inspection Conducted:
April 1,1985, through June 21, 1985
~
1 J
Inspectors:
H. S. Phillips, Senior Resident Date Reactor Inspector Construction (pars. 1, 2, 3, 8, 9, 10, 11, 15, 16, 17, 18, and 19) l l
J. E. Cummins, Senior Resident Reactor Date Inspector Construction (April 1 - May 10,1985)
(pars. 1, 3, and 19) l l
O. E. Norman, Reactor Inspector Date (pars. 1, 12, 13, 14, and 19) 1
- 0. M. Hunnicutt, Section Chief Date
]
Reactor Projects Branch 2
[ (pars. 1, 4, 5, 6, 7, and 19)
Approved:
p D. M. Hunnicutt, Section Chief, Date
)
y Reactor Project Section B I
I 1
-2 ~
Inspection Summary Inspection Conducted April 1, 1985, through June 21, 1985(Report 50-445/85-07)
Areas Inspected:
Routine, announced and unannounced inspections of Unit 1 which included plant tours and review of plant status, action on previous NRC.
inspection findings (violations / unresolved items), review of documentation for site dams, and.'eview of 10 CFR Part 21 and 10 CFR Part 50.55(e) construction deficiency status, The inspection involved 77 inspector-hours onsite by four NRC inspectors.
Results:
Within the areas' inspected, three violations were identified (failure to promptly. correct an identified problem with RTE - Delta; Potential Transformer Tiltout Subassemblies, paragraph 3.a.; and commercial non-shrink grout was used to grout the Unit i reactor coolant pump and steam generator supports in lieu of Class "E" concrete, paragraph 3.b. ; hydrogen recombiners out-of-specification voltage recorded on quality release document, paragraph -
3.c).
Inspection Summary Inspection Conducted April 1, 1985, through June 21, 1985 (Report 446/85-05).
Areas Inspected:
Routine, announced ~and unannounced inspections of Unit 2 which included plant tours and review of plant status, action on previous NRC inspection findings (violations / unresolved items), review of documentation for-site dams, review of documentation for voids behind the stainless steel cavity liner of reactor building, observation of NDE on liner plates, inspection of concrete batch plant, review of calibration laboratory records'for batch plant, review of concrete laboratory testing, inspection of level C and D storage, review of reactor pressure vessel (RPV) and piping records / completed work, and review of 10 CFR Part 21 and 10 CFR Part 50.55(e) construction deficiency status, and review of violation and unres'olved items status.
The inspection involved 355 inspector-hours onsite by four NRC-inspectors.-
Results: Within the sixteen areas inspected seven violations were identified (failure to provide objective evider.ce to show that concrete central and truck mixer blades were inspected, paragraph 8; failure to issue a deficiency report on cement scales that were out-of-calibration, paragraph 9c; failure to translate design criteria.into specifications, procedures, and drawings, paragraph 12a.; failure to maintain RPV installation tolerances / document nonconformance, paragraph 12b.; failure to audit RPV specifications, procedures, installation, and as-built records, paragraph 12d. ;- failure to identify a spool piece, paragraph 14b. ; and failure to maintain material records, paragraph 14c.
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DETAILS 1.
Persons Contacted I
Applicant Personnel M. McBay, Unit 2 Reactor Building Manager B. Ward, Gen. Supt., Civil D. Chandler, QA/QC Civil Inspector W. Crcseans, QA/QC, TUGC0 Laboratory / Civil Supervisor i
- J. Merritt, Assistant Project General Manager
- P. Halstead, Construction Site QA Manager l
- C. Welch, QA Supervisor TUGC0 (Construction)
J. Walters, TUGC0 Mechanical Engineer j
K. Norman, TUGC0 Mechanical Engineer J. Hite, B&R Materials Engineer G. Purdy, B&R CPSES QA Manager 1
I
- Denotes those present at May 10, 1985 exit interview.
- Denotes those present at June 10, 1985 exit interview.
The NRC inspectors also interviewed other applicant employees during this inspection period.
2.
Plant Status Unit 1-l At the time of this inspection, construction of Unit 1 was 99 percent complete.
The fuel loading date for Unit 1 is pending the results of ongoing NRC reviews.
Unit 2 At the time of this inspection, construction of Unit 2 was approximately 74 percent complete.
Fuel loading is scheduled for approximately 18 months after Unit 1 fuel loading.
3.
Applicant. Action on Previous NRC Inspection Findings, a.
(Closed) Unresolved Item 445/8440-02:
Potential Problem with Potential Transformer Tiltout Subassemblies.
By letter dated June 15, 1983, Transamerica Delaval notified the applicant of an RTE - Delta 10 CFR Part 21 report to'the NRC reporting a potential problem with the primary disconnect clips of the potential transformer tiltout assembly used in the emergency diesel generator control panels at CPSES.
The Transamerica Delaval letter also provided instructions for correcting the problem.
However, the NRC inspector could not determine if the problem had a
4 I
j i
been corrected at CPSES and made this an unresolved item. 'The
)
applicant determined that the problem had not been corrected and i
subsequently performed the recommended corrective action.
The I
Unit 1 corrective action work activities were documented on startup l
work permits Z-2912 (train A) and Z-2914 (train B).
The Unit 2 work l
activities are being tracked as master data base (MDB) item 3003-31.
1 The failure to promptly correct this identified p'roblem is an apparent k
violation (445/8507-01; 446/8505-01).
1 i
b.
(Closed) Unresolved Item 445/8416-O'3: Commercial Grout Used in Lieu l
of Class "E" Concrete The applicant determined that the use of non-shrink commercial grout in lieu of the Class "E" concrete specified on drawing 2323-S1-0550 was acceptable.
Design Change Authorization 21179 was issued to drawing 2323-51-0550 accepting the use of the commercial non-shrink grout.
However, the failure to grout with Class "E" concrete as j
specified on the drawing at the time the work was accomplished is an apparent violation (445/8507-02).
j c.
(Closed) Unresolved Item 445/8416-04:
Hydrogen Recombiners -
1 Out-of-Specification Voltage Recorded on Westinghouse Quality Release Document Quality Release N-41424 was. revised changing the specified voltage from 10+-2V to 12+-2V which put the questionable voltage within l
specification limits.
However, the failure of receipt inspection to l
verify that the QRN-41424 was filled out accurately as required by Procedure QI-QAP7.2-8 is an apparent violation (445/8505-03).
d.
(0 pen) Unresolved Item 445/8432-06; 446/8411-06; Lobbin Report Described Site Surveillance Program Weaknesses During this reporting period the NRC inspector reviewed the status l
of this open item several times and interviewed TUEC management and site surveillance personnel.
The Lobbin report stated that the l
scope and objectives of the site surveillance program were unclear, lacking both purpose and direction.
There is no specific regulatory requirement to have a surveillance program; however, TUEC committed to have a surveillance program and-has established procedures to implement such a program as a part of the 10 CFR Part 50, Appendix B, QA program.
This extra effort is a strength; however, the NRC inspector also observed, as did the Lobbin Report, that the surveillance program lacks both purpose and direction to be effective and complimentary to the audit and inspection programs.
Since the TUEC audit group is not located on site, the TUEC surveil-lance program on site takes on added significance.
This item was discussed with the TUEC site QC manager who described a reorganized site surveillance function and changes that have occurred.
New procedures which describe this organization's duties l
and responsibilities are forthcoming.
1
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f TUEC has elected to defer responding to the violations pertaining to
]
the audit function in NRC Inspection Report 445/84-32; 446/84-11, but rather to have the Comanche Peak Response Team (CPRT) respond to i
this report and other QA matters.
The surveillance issue is closely tied to the audit deficiencies in NRC Inspection Report No. 445/84-32; j
50-446 84-11.
This item will remain open pending the review and
)
implementation of the CPRT action plan.
A special point of interest
]
f will be how audits and surveillance work together to evaluate the control of all safety-related activities.on site to essure quality especially the overview of quality control effectiveness.
4.
Document Inspection of Site Dams The NRC inspector reviewed documents describing the inspection activities performed on the Squaw Creek Dam (SCD) and the safe shutdown impoundment (SSI) for impounding cooling water for the two units at CPSES.
The j
purpose of the 5C0 is to impound a cooling lake for CPSES.
A secondary reservoir (SSI) is formed by a channel connecting the SCD impoundment to j
the SSI.
Three documented inspections have been performed since 1980.
The inspections were:
a.
Relevant data for SCD is contained in Phase I Inspection, National
-l Dam Safety Program, Squaw Creek Dam, Somervell County, Texas, Brazos River Basin, inspection by Texas Department of Water Resources.
Date of Inspection:
June 10, 1980.
b.
Inspection on August 25, 1982, by registered professional engineers from Mason-Johnston & Associates, Inc., and Freese & Nichols, Inc.
c.
Ini; Olion oc Geptember 19, 1984, by a registered professional engineer from Mason-Johnston & Associates, Inc.
The inspection activities consisted of visual inspections by inspection teams that included accompanying Texas Utilities Service, Inc. (TUSI),
and Texas Utilities Generating Company (TUGCO) representatives.
Photographs were taken as a part of the documentation.
The data for the piezometer observations and the data for the surface reference monuments were reviewed by applicant per:sonnel and Mason-Johnston engineers.
No items of significance were observed or reported by these inspection teams.
Slight erosion areas were observed and reported.
A cracked area on the service spillway upstream right bridge seat was observed by the inspection teams and continued monitoring of this area was recommended by Mason-Johnston and Associates.
No signs of cracks, settlements, or horizontal movement at any location within the SCD or the SSI were reported.
The NRC inspector reviewed the' applicant's records and the Mason-Johnston inspection reports.
These documents indicated that the SCD and SSI were structurally stable and that the applicant was performing inspection activities to maintain the structural integrity of these dams.
The state of Texas requires periodic inspections of these dams (principally the SCD) due to inhabited dwellings downstream.
The applicant has met these inspection requirements.
No violations.or deviations were identified.
5.
Voids-Behind the Stainless Steel Cavity Liner'in Unit 2 Reactor' Building The NRC inspector reviewed applicant records, including NCR C-82-02202; NCR C-1784, Rev. 1; NCR C-1784, Rev. 2; NCR C-1766, Rev. 1; NCR-C 1791, Rev. 1; NCR C-1824, Rev. 1; NCR C-1824, Rev. 2; Significant Deficiency Analysis Report (SDAR) - 26, dated December 12, 1979; DCA-20856; and Gibbs and Hill Specification 2323-SS-18.
The review of these records and documentation and discussions with various applicant personnel indicated the following:
Structural concrete was placed in Unit 2 reactor building at elevation 819 feet 6-3/4 inches to 846 feet 6 inches on June 21, -
1979.
This concrete was placed adjacent to the stainless steel liner walls. The concrete ' forms for this pour were not removed until October 1979 due to subsequent concrete placements for the walls to elevation 860 feet 0 inches.
When the forms were removed, honeycombs and voids were observed by applicant personnel.
The applicant's review of the extent of unconsolidated concrete resulted in the issuance of SDAR-26 on December 12, 1979.
Investigations were begun and Meunow and Associates (M&A) of Charlotte,- North Carolina, were contracted to perform nondestructive testyng on in place concrete.
M&A performed these tests on a two foot grid pattern on the compartment and liner sides of all four steam generator (SG) compartment walls.
The selected test locations did not include the locations where the voids were later found toobe located; therefore, the voids were not detected during the M&A testing.
In August 1982, preparations were made to pour the concrete annulus-around the reactor vessel.
When the expanded metal'forework was-removed from the reactor side of the compartment walls, voids were observed _and NCR C-82-01202 was prepared.
DCA 20856 was prepared as a procedure to repair the void area.
DCA 20856' indicated that the voids were not extensive (a surface area of about 28 square feet by 8 inches maximum depth) and that the repair procedure assured that.
the total extent of voids had been-identified.
One half (0.5) of a cubic yard of concrete was used to complete the repairs as indicated on grout pour card 261.
The applicant's review'and evaluation of the gird pattern and a comparison of SG compartments 2 and 3 to 1 and 4 indicated that voids did not exist in SG compartments:2 and 3.
The review of test girds extended down to elevation 834 feet, which is the floor elevation of the liner.
The liner walls of SG compartments 1 and 4 1
-____._____.----_-------------.e-_
were not tested at elevation 834 feet, but at elevation 836 feet which is above the area of the identified voids.
No testing was done on the liner side of the area of the voids beeow elevation 836 feet.
The program also included removal of 2 inch x 2 inch plugs from ine stainless stcel liner at locations where test indications raised questions concerning the concrete.
The inspections of the concrete by appifcant personnel after the plugs were removed confirmed that there were no additional unconsolidated concrete areas (voids).
The applicant removed stainless steel liner plates from three areas (one area about 1 foot by 1 1/2 feet and two areas about 3 feet by 1 foot, excavated or chipped to sound concrete, and cleaned the concrete surface area.
One and one quarter inch (11/4) diameter probe holes and grout access holes were drilled in the liner plates to determine the extent of and to assure full definition of the void I
area.
Air access holes were drilled in the stainless steel-liner plates to assure that grouting would be accomplished in accordance with the procedure.
l The procedure (DCA-20856) specifed that the grout was to be cured for 28 days or until the grout reached a compressive strength of 4000 psi.
Repairs to the liner plates were specified in DCA-20856 and G&H Procedure 2323-SS-18.
DCA-20856 required that under no circumstances was cutting of the j
liner across weld seams, across embedded weld plates, or into leak chase seal welds or drilling through the liner at leak chase channels, embeds, or weld seams permitted.
Documentation review indicated that DCA-20856 was adhered to and that no cutting or drilling occurred in prohibited locations.
No violations or deviations were identified, 6.
Nondestructive Testing Observations of Ling Plates in Fuel Transfer Canal The NRC inspector observed portions of non-Q liquid penetrant examinations (PT) being performed on liner plate welds following re-installation of the liner plates in the areas of the fuel transfer canal removed for inspection and repair of the concrete.
The inspector performed the PT on the welds as requirea by the repair package and the procedure (QI-QP-11.18-1,
" Liquid Penetrant Examination").
Scattered weld porosity was identified by the inspection.
The porosity was ground out and a repeat PT was performed.
The final inspection is scheduled to be performed by QC inspection personnel.
The liner plate areas to be inspected by PT were identified in DCA 20856.
No violations or deviations were identified.
- - - f 7.
Rebar Placement and Cadweld Splice Observations and Records The NRC inpector reviewed the rebar placement and Cadwell Splice activities associated with the Unit 2 containment (reactor building)
- closure, a.
Calibration of Tensile Tester The NRC inspector observed the calibration of the Tinus-Olson-Universal Testing Machine (Model Number 600-12 Identification Number M&TE-784) on April 2 and May 7, 1985.
The machine was calibrated just prior to performing tensile testing of cadweld splices and subsequent to completion of tensile testing each day that tensile testing was performed.
The machine calibration date for April 2, 1985, prior to start of tensile testing was observed by the NRC inspector and recorded as follows:
l
\\
Nominal load Calibration Reading Error Error Remarks (1bs)
(1bs)
(1bs) 0 0
0 0
0 machine on 4/2/85 100,000 99,750
+250
+0.25 200,000 199,600
+400
+0.2 1
300,00 299,450
+550
+0.18 350,000 350,300
-300
-0.08 400,000 401,200
-1200
-0.03 500,000 501,350
-1350
-0.27 600,000 602,450
-2450
-0.40 The NRC inspector reviewed calibration data for March 4, March 8, April 2, April 3, April 30, and May 7,1985.
All calibration data met within the +/- 1% accuracy requirement specified by Calibration Procedure 35-1195-IEI-37, Revision 3, dated March 11, 1982.
The reference standards were identified as follows:
ID No.
Manufacturer Calibration Due Date RS-75 BLH Electronics January 27, 1987 RS-75.3 BLH Electronics January 27, 1987 b.
Observation of Cadweld Splice Tensile Testing (1) Qualification Tensile Testing On April 2, 1985, the NRC inspector observed the following tensile testing of cadweld splices for cadwelder qualification:
E80 Q8, GBH Q1, GBH Q2, GBV Q1, BFD Q4, BFD Q3, BFH Q4, GAH Q1, GAV Q1, and GBV Q2.
Each of the above qualification cadweld splices was tensile tested to 400,000 pounds (100,000 psi) and met the requirements stated in the procedure.
j
< I (2) Production Tensile Testina The NRC inspector observed the tensile tester calibrations and-the following production cadweld splices tensile testing on May 7, 1985: FXD 3P, FYD 4P, FYD 8P, FR0 87P,;and.FUD 6P.
Each of the above production cadweld splices )vas tested to 400,000 pounds (100,000 psi)and met the requirements stated in
-)
the procedure.
1 (3) Insta11ation~of Productibn Cadweld Splices-The NRC inspector observed. installation of rebar and.cadweld j
splices at frequent intervals:(five.or.more observations per week during the weeks 'of_ April 8 and 15; May 6,13, 20, and 27;-
a and June 3, 1985).
The rebar installation for the Unit 2 l
closure was performed in the area identified as elevation 805
~~
feet to elevation 875' feet and azimuth 300 degrees to 335 degrees.
The installation activities observed included rebar~
spacing, location of cadwelds, observation of selection and removal for testing of cadweld splices for testing, and determination of. location of rebars and cadwelds for the
'l as-built drawings.
l (4) Documentation Reviewed The NRC inspector reviewed the following documentation for the rebar placement and cadwelding for.the Unit 2 containment l
(reactor building) closure area:
g q
Drawings DCAs NCRS j
l 2323-S-0785, Rev.7 22616, Rev. l' C85-200294 1
2323-S-0786, Rev.9 22728 C85-200339, Rev.1
]
2323-S1-500, Rev.5 22737 C85-200355, Rev.1 1
2323-51-506, Rev.5 22836
)
2323-52-505, Rev.5 22878 (Sheets 1-7) 2323-52-508, Rev.2 22772 2323-S2-506, Rev.3 No violations or deviations were identified.
-]
8.
Concrete Batch Plant Inspection The NRC inspector used a nationally recognized checklist _to_ inspect the concrete production facilities. This list included the specific characteristics for the ~ folicwing areas:
(1) material storage.and handling of cement, aggregate, water and admixture, (2) batching equipment scales, weighing systems,' admixture dispenser, and recorders, (3) central mixer (not applicable because it had been dismanteled), (4)-
ticketing system, and (5) delivery system.
. The current batching is a manual operation since almost all concrete has been placed.
The central mixer was dismanteled and removed from site two or three years ago when concrete placement was virtually completed.
Presently, the backup batch plant (which was a backup system for the
~
central mixer) is in operation to complete the remaining concrete placements. -This batch plant is in good condition and complied with_the subject checklist except for one area.
~
5 The NRC inspector inspected the inside of one of three trucks used for mixing concrete (that is, the batch plant dispenses the correct weight of 4
materials as required by-the specific design mix numbers and the truck then mixes the batch to be placed.).The blades inside the truck are, subject to wear and should be' checked at a reasonable frequency.
The i
Brown & Rost (B&R) representative responsible for checking the blades in i
accordance with B&R Procedure 35-1195-CCP-10, Revision 5, dated j
December 4, 1978,..was asked for evidence.that the blades had been checked i
for wear on a quarterly. basis and it was found that there was no record of such checks dating back to 1977 when they were initially checked.
Procedure CCP-10, paragraph 3.10 " Truck Mixing", is silent on blade wear but Section 3.11 infers that the blades should be checked for both central and truck mixing.
The inspection of both central and truck mixing blades was not documented, although the B&R representative stated that the mixing blades were periodically inspected and laboratory testing would have probably indicated if'there was a problem with the mixing blades.
Strength and uniformity tests have consistently been within the~ acceptable range indicating that concrete production'was acceptable even though mixing blade inspection was not documented.
Otherwise, the condition of the inside of the truck was satisfactory as the drum and charging / discharging were clean.
The water gage and drum counter were in good condition.
This failure to follow procedures is a violation of 10 CFR'50, Appendix B, Criterion V.
Subsequent to the identification of this violation, the blades were checked for wear and blade wear was presently.within allowable limits (445/8507-04; 446/8505-02).
4
~
I No other violations or. deviations were identified.
)
9.
Calibration Laboratory for Batch Plant i
The-NRC inspector obtained batch plant scale numbers from tags which indicated that the scales.had been calibrated and were within the calibration frequency.
Cement (MTE.779), Water (MTE 766), admixture scale (MTE 764), and aggregate (MTE 780) were reviewed.
The scales had-been periodically calibrated since the batch plant was activated.
The records were adequate except as follows:
a.
Scales MTE 766 records do not clearly differentiate between the required accuracy of the scale and the digital readout.
b..
Scales MTE 779 and 780 records show various accuracy ranges _for the same scale; i'e., MTE 779 (SN749687) records the following:
report '
dated January 1976 gives 1%; report dated July 1976 gives 1% 'while report October 1976 gives-+/-'O.2%.
The above items'are unresolved pending further review of the licensee actions regarding-these records.during a subsequent inspection (445/8507-05;-
j 446/8505-03).
The calibration appeared to be proper.
I c.
Records for scales MTE'779 records conta'ined B&R meno IM-1108 dated July 16, 1975, which described a nonconforming condition.
This condition affected the water and cement scales' causing a.24-48' pound deviation during the calibration test.
The memo stated that the i
condition was corrected and-the scales were then' calibrated; i
however, no deficiency report wasl written as required by B&R f
Procedure CP-QCP-1.3, " Tool and Equipment Calibration and Tool Control" dated July 14, 1975,- and CP-QAP-15.1, " Field Control of i
Nonconforming Items,'.' dated July 14, 1975. As a result there is no l
evidence that' corrective action included an evaluation to' determine if concrete production was adversely affected.
This failure to assure that a nonconforming condition was evaluated is a violation of Criterion ~XV of 10 CFR Part 50, Appendix B.
(445/8507-06; 446/8505-04).
10.
Concrete Laboratory Testing TUGC0 procedure QI-QP-11.1-1, Revision 6, was compared with ASME i
Section III, Division 2, Subsections 5222, 5223 and 5224 to assure.that.
each ASTM testing requirement was. incorporated into the procedure.
The NRC inspector inspected the testing laboratory equipment and found the test area was in good condition and each piece of equipment was tagged with a calibration sticker which showed it to be within the required calibration frequency.
Test personnel were knowledgeable of test requirements and equipment.
The NRC inspector witnessed field tests performed by laboratory personne1' as follows:
i Date Truck No. Mix No. Ticket No.
AirContent(%)SlumpTegperature (in.)
F-1 6/3/85 RT-41 925 64013 Req 8.2-10.3 NA 70 max Mea 8.7-9.1 NA 57 6/3/85 RT-35 128 64014 Req 5.0-7.0 5 max 70 max Mea 6.6
-6.25*
-57
- Truck was rejected by quality control but was later accepted when second.
slump reading came into required range.
i The following laboratory equipment was checked and found to be within calibration:
Forney Compression Tester, MTE 3031; Temperature Recorder 1
MTE 3013 and 3014; Unit Volume Scale, MTE 1053; Pressure Meters MTE-30008, 3002 and 3004; Steves MTE 1286,'1239,?l272, 1274, 1136A, 1156,.
1094, 1093, 1095, 1178, 1179,-1300 and 1180; Aggregate scales, MET 1058 and 1067; and 2" grout mold MTE 1111.
Thefollowingtestrecord'sforplacementnumber201-58d5-034were reviewed: (1) concrete placement inspection,.(2) concrete placement summary and, (3) unit weight of fresh concrete.
No violations or deviations were identified.
11.
Inspection of Level C and 0 Storage The NRC inspector inspected all laydown areas where. piping', electrical
.j conduit, cable, and structural reinforcing steel were stored.
These j
materials were neatly stored outside on cribbing in~well drained areas' which allowe'd air circulation and avoided trapping water.
This met the j
Level "0" storage requirements of ANSI N45.2.2.
The electrical warehouse contained miscellaneous electrical hardware.
.This building was required.to be fire and tear resistant, weathertight', and well ventilated in order to meet' Level "C" storage requirements.
This warehouse was well kept and met all requirements except for a lock storage area located upstairs at the rear of this building (electrical termination tool room).
Two minor problems were identified and the warehouse personnel initiated action to correct them.
The first problem noted was that.a box of nuclear grade cement was marked
" shelf life out of date" but it had no hold' tag.
The box-was i
subsequently tagged with Nonconformance Report (NCR) E85-200453 after
'l being identified by the NRC.
During discussions with the warehouseman, the NRC determined that engineering told the warehouseman to. mark the material and lock it up, but did not tell him to apply an NCR or hold tag.
TUEC should determine if engineering is aware of. nonconforming material controls and provide training if this is other than an isolated' instance.
Also, the NRC inspector noted a very small leak in the roof above the electrical termination tool room.
This leak'was in an area that did not expose hardware to moisture.
The roof is currently being repaired.
d The millwright warehouse storage area was inspected; however, only a small number of items or materials were stored in this area.
The overall.
i storage conditions in this area met or exceeded Level "C" storage i
requirements, poNil'T
)
No violations or deviations were identified.
pW E gf y - oW 12.
Reactor Pressure Vessel.and Internals Installation -' Unit 2 p\\M b
,30 hw<'
This-inspection was performed by an NRC inspector to verify final'-
_ T ' p.
placement of the reactor pressure vessel (RPV) and internals by examining 0
the completed installation and inspection records.
-Mg
_._______________m.
i q a.-
Requirements for Placement of RPV Requirements.for placement of the RPV to ensure proper fit-up of all' other major NSSS equipment are'in Westinghouse Nuclear Services.
Division (WNSD) " Procedure for Setting of Major NSSS Components"~,
Revision 2, dated February 13, 1979, and " General Reactor Vessel-Setting Procedure" Revision.2, dated August 30, 1974.
The NRC inspector reviewtd the.following drawings,.which were referenced in
.]
the RPV operation traveler, to verify implementation of WNSD l
recommendatforu:
J o
WNSD drawing 1210E59 " Standard - Loop Plant RV' Support Hardware Details and Assembly" j
o WNSD drawing 1457F27." Comanche Peak SES RCS Equipment Supports-
- Reactor Vessel' Supports" o
CE drawing 10773-171-004 " General Arrangement Elevation"'
o CE drawing 10773-171-005 " General Arrangement Plan" Neither site prepared installation drawings nor specifications (which implemented the WNSD recommended procedures) were available'-
and the drawings examined did not show certain saaeHic-iart:11ation criterion such as centerina toierances. levelness tolerances and g
cliiirance between surret Ereckat< mnd suooort shoes.
Ins lack of engineering documentation did not provide full control of the q
action and would allow changes to installation criteria important to safety to be made without complying with established change procedures.
This is considered a violation of 10 CFR 50, Appendix B, Criterion III (446/8505-06).
b.
Document Review j
The NRC inspector reviewed B&R Construction and Operation Traveler No. ME79-248-5500 which described the field instructions for installation of the Unit 2 RPV.
Requirements recommended by WNSD procedures were implemented in the traveler.
Worksheets attached to the traveler showed the RPV to be centered and leveled within the established tolerances, Traveler operation 19 required verification I
of a 0.020 to 0.005 inch clearance between the support bracket and support shoe, after applying.the shim plates. Change 5 subsequently I
changed the clearance to a 0.015 to.025 inch clearance. -The installation data reflected in attachment 38 of the traveler indicated an as-built clearance of 0.012 to 0.026 inch which exceeds:
both the original and revised tolerances.
This condition was accepted on the travelar based on Westinghouse concurren_ce, and:there were neither nonconformance reports nor documented engineering evaluations-to determine if the condition was acceptable. 'This failure to document nonconforming conditions and engineering deviations is a violation of 10 CFR 50, Appendix B, Criterion XV (446/8505-07)
The NRC inspector reviewed the following receiving records for RPV.
hardware and found them to be in order:
o Report No. 14322 for 54 each closure studs, closure nuts,'and closure washers o
Report No. 09507 for vessel S/N 11713, Closure Head 11713 and 26 0-Rings o
Deviation notices and corrective action statements The NRC inspector reviewed the following completed travelers.for internals installation and found them to be satisfactory:
o ME-84-4641-5500, " Assemble Upper Internals" o
ME-84-.4503-4000, " Install and Adjust Roto Locks d
ME-81-2145-5500, "Reiorque UI Column Extension" o
o RI-80-385-5500, " Transport and Install Lower Internals" o
ME-84-4617-5500, " Repair Lower Internals" o
ME-84-4640-5500, " Assemble Lower Internals" c.
Visual Inspection i
At this time, visual inspection of the internals by the NRC. inspector was i
not possible, and inspection was limited on the vessel placement to a l
walk-around beneath the vessel to inspect the azimuth markings and for construction debris between the vessel and cavity.
No problems were identified in this area.
d.
llecords of QA Audits or Surveillance The NRC inspector requested TUGC0 QA audits or surveillance performed by TUGC0 of the Unit 2 RPV installation. 'TUGC0 did not make available any audit or surveillance reports of. specifications for placement criteria. placement procedures, hardware placement, or as-built records. Nn 1're to parW re auaits or surve111aor3s of RPV, l
specifications, procedures and. installation is a violation of 1
10 CFR 50, Appendix B,. Criterion XVIII.(446/8505-08).
]
No deviations were identified; however,'three violations were identified and are described in the above paragraphs.
13.
Reactor Vessel Disorientation 1
On February 20, 1979, the applicant reported to the NRC Resident J
Inspector that a design error had'resulted in the reactor support structures being placed in the wrong position on the reactor-support i
pedestal such that the reactor would be out of position by 45 degrees.
Initially, Unit 2 was to be a mirror image of Unit 1, however, a design change was initiated to permit identical components for both units.
The~
{
J design change was implemented for the reactor vessel,-but not for the i
pedestal support locations.
The problem was not considered by the applicant to be reportable under provisions of 10 CFR Part 50.55(e) since the error could not have gone undetected.
l
)
Th'e problem was reported to the NRC Office of Inspection and. Enforcement on February 22, 1979, and during a March 27, 1979, meeting in Bethesda, j
Maryland, the applicant presented the proposed redesign and rework procedures for relocating the pedestal supports.
No unresolved safety j
concerns with the repair were identified at the meeting.
During this inspection the NRC inspector. reviewed various documentation relative to the disorientation problem, including design changes and the
- 1 construction traveler which implemented the repair.
j The following documents were reviewed:
o NRC Inspection Report 50-446/79-03 o
NRC Inspection Report 50-446/79-07 o
NRC Inspection Report 50-446/79-13 1
o TUSI Conference Me:o, dated March 1, 1979, H. C. Schmidt to S. Burwell (NRC Lh: 1 sing PM) o TUGC0 letter TXX-2980, dated April 30, 1979, to W. C. Seidle o
NRC letter to TUGC0 dated May 29, 1979 i
o DCA 3872, Revision 1, dated February 28, 1979,
Subject:
Rework of Structure for Placement of the RPV Support Shoes o
DCA 4122, dated March 22, 1979,
Subject:
Replacement'of Rebar for RPV Supports o
Construction Traveler CE79-018-5505, dated March 14, 1979,
Subject:
Rework of Reactor No. 2 Cavity - New RPV Support Locations -
o Grout Replacement Cards lio. 007,008, 009, 010, 014'and 015, various dates,
Subject:
Replacement of Grout around Rebar for Repair of RPV Support Shoes Various Inspection Reports for Grout Properties and Application for o
RPV Support Shoes No violations or deviations were identified.
14.
Reactor Coolant Pressure Boundary (RCPB) Systems t
The inspection was performed to verify:
the applicants system for preparing, reviewing, and maintaining records for the RCPB piping and components; that selected records reflected compliance with NRC requirements and SAR commitments for manufacture, test and installation
. i of items; and.that as-built hardware was adequately marked and traceable to records.
The following items were randomly selected and. inspected:
a.
Pressurizer Safety Valve - This item was inspected to the commitment stated in FSAR, Table 5.2-1 which includes ASME Section'III, 1971 edition through winter.1972 addenda. Valve S/N N56964-00-007, which' is installed in the B position was inspected.
Th.e following records were reviewed:
~
o QA Receiving Inspection Report No. 21211 o
Code Data Report Form NV-1 o
Valve Body CMTR The valve was.in place, however, installation had not been completed; therefore, the hardware installation inspection consisted q
of verifying that the item was traceable to'the records.
j b.
CVCS Spool Piece 301 - Requirements for this item are statedcin ASME,Section III, 1974 edition through summer 1974 addenda, which is the commitment from the FSAR, Table 5.2-1. 'The item was field -
fabricated from bulk material'and installed in the CVCS with field I
welds number 1 and 3 (ref. BRP-CS-2-RB-076). 'The following records J
were reviewed:
o B&R Code Data Report
.)
o Field Weld Data Card o
NDE Reports o
QA Receiving Reports (for bulk order) o Certified Material Test Report (CMTR)
The installed spool piece was inspected for weld quality-and to verify that marking and traceability requirements had been met.
The item had been marked with the spool piece number (3Q1) and the B&R drawing number, however, marking of the material specification number and type, heat code,'or other means of traceability could not be found.
In respect to material requiring a CMTR,'(nominal pipe size greater than 3/4 inch) NA-3766 requires marking with the applicable-specification and grade of material and heat number or heat code.
When material is divided, the identification' marking is required to be transferred to.all pieces.
This failure to identify i
material marking is a violation 10 CFR 50, Appendix B, Criterion VIII (446/8505-09).
c.
Loop 3 RC Cold Lea - Requirements for.this item are stated in'ASME,Section III, 1974 edition through summer 1974 addenda, which'is the commitment from'the FSAR, Table 5.2-1.
This piping. subassembly.
consists of a 27.5 inch cast pipe with a 22 degree elbow on the reactor end, a 10 inch 45 degree nozzle, a 3 inch nozzle, and three 2 1/2 inch thermowell installation bosses.
The following records were reviewed for the subassembly:
o QA Receiving Inspection Report No. 12389 o
Westinghouse Quality Release (QRN 47523) dW Code Data Report Form NPP,
o 27 1/2 inch line CMTR o
3 inch nozzle CMTR o
Field Weld Data Cards o
NDE Reports
^ (1) The NRC inspector determined that CMTR's were required by the code but were not available for the following items:
22 degree elbow 10 inch 45 degree' nozzle v
2 1/2 inch thermowell bosses This failure to maintain retrievable records is a violation of 10 CFR 50, Appendix B, Criterion XVII (446/8505-10).
(2) Sandusky Foundary and Machine Company test report for the cold leg pipe certifies that material meets requirements of ASME Section II, 1974 editions through winter 1975.- Southwest Fabrication and Welding Company code data report NPP-1 Form certified that the cold leg subassembly met requirements of ASME Section III,1974 edition through winter 1975.
The FSAR commitment is ASME Section III, 1974 edition through summer 1974.
This discrepancy is unresolved pending the applicant's evaluation to determine if material nonconformances exist (446/8505-11).
(3) The cold leg NPP-1 Form stated that no hydrostatic (Hydro) test-had been performed.
In discussions with Westinghouse.and B&R personnel, the statement was made that it is normal practice to 0C defer the partial hydro test until the whole system is hydro i
1 tested.
B&R Procedures CP-QAP-12.1 and CP-QAP-12.2 describe-4 (6 M
/
requirements for the test.
i ASME,.Section III, (NB-06114(a)) states in respect to the time of testing piping subassemblies, that the component test, when conducted in accordance with the requirements of NS-6221(a) shall be acceptable as a test for piping subassemblies.
NS-6221(:) st+tn inai. uv-pieted Oe panents shall be subjected to. m hydrostatic -tes4.mrior te f acta 11atina 4a +ha svsten.-
]
I i
Paragraph (b) of NB-6221 requires pressure testing of all pressure retaining components that,are within the boundary protected by overpressure protection devices and paragraph (c) permits substitution of the system test for component test.
It is not evident that the system test substitution was permitted for pipe subassembly since NA-1200 makes a distinction in the definition between components and piping subassemblies.
N8-6115 states that pressure testing of components shall_be performed i
prior to initial operation of a system and that the Data Report Form shall not be completed nor signed by the code inspector and.
the component shall not be stamped until the component manufac-turer has conducted the hydrostatic pressure test.
Additionally, 4
NA-8231 prohibits the application of a Code stamp prior to.
hydrostatic test regardless of whether the test was performed-1 prior to or after installation of the item.
The NPP-1 Form for the cold leg had been completed and signed by the manufacturer and Authorized Nuclear Inspector (ANI).
An ASME Code Stamp had also been applied to the item. The NRC inspector observed that a hydrostatic test had not been performed and was noted on the NPP-1 form.
btb' The above items are unresolved pending clarification of code p
requirements by NRC headquarters (446/8505)-12).
(4) SI~ncethecoldlegpipesubassemblyhadnotbeenpressure tested prior to installation, the NRC inspector reviewed the procedures and hydro test data applicable to Unit 1, since Unit 2 hydro had not been completed.
Requirements for the tests were presented in Procedures CP-QAP-12.2, " Inspection Procedure and Acceptance Criteria for ASME Pressure Testing" and CP-QAP-12.1, "ASME Section III Installation,, Verification, and N-5 Certifi-cation." Procedure CP-QAP-12.1 requires that a data package to be used in the test, be prepared with the test b.oundary and the additional following data shown:
o Base metal defects in which filler material has been added, and the depth of the base metal defect exceeds 3/8 inch or 10% of the actual thickness, whichever is less.
i o
Untested vendor performed piping circumferential welds.
o Approximate location and material identification and description for permanent pressure boundary attachment with applicable support number referenced.
o Weld history, which shall reflect weld removal and/or weld repair.
I
__ =
1 The completed hydro data package (PT-5501) for Unit 1, loop 3 cold leg was reviewed for compliance with the above requirements.
Drawing No. BRP-RC-1-520-001 had been used to j
annotate the test boundary.
A handwritten statement on the j
drawing indicated:
"No major base metal repairs could be located" and "No hangers with weld attachments could be j
located." Welds performed by the pipe subassembly vendor, including the 22 dcgree circumferential weld'and the penetration fittings had not been f.dentified.
The following
]
items were unresolved regarding the adequacy of the hydro test:
j o
Was the determination of no major base metal repairs based on a visual inspection or on a review of vendor and site inspection and repair records?
.y o
Was the shop circumferential weld attaching the 22 degree elbow to the pipe assembly inspected during the test?
If so, where is the inspection identified?
o Procedure CP-QAP-12.1 does not require identification of welds.for penetrations into the pipe assembly and they were not identified on the drawing.
Were those welds inspected?
If so, where is the inspection documented?
The above issues will remain unresolved pending further evaluation by the applicant (445/8507-07; 446/8505-13).
d.
Personnel Qualifications - Personnel who had performed selected tasks
)
were identified during inspection of installation records.
Training and experience records for the personnel were revfewed to verify 1
that employee qualifications and maintenance of records were current
{
and met requirements.
Names or codes for five welders and two NDE examiners, who had performed tasks during installation of the items being inspected, were identified and their qualification records reviewed.
There were no questions in this area of the inspection.
15.
Special Plant Tours (Unit 1 and Unit 2)
On May 23, 1985, the NRC' inspector conducted a tour of selected areas of Unit 1 and Unit 2.
The group consisted of one NRC inspector, two NRC Technical Review Team (TRT) representatives, two allegers, and several TUEC representatives.
The TUEC representatives tagged each area where a deficiency was alleged.
With the alleger's consent, a tape recorder was also used to note locations and describe any alleged deficiencies.
The allegers indicated that they had identified all deficiencies during the tour and all other deficiencies that they had knowledge The NRC TRT is analyzing this information and will decide what action, if,any, should be taken.
During this tour the NRC inspector independently identified a questionable practice in that the top of the the pipe chase at the north end of room 88 in Unit 1, safeguards building had two large stickers which l
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stated that areas on the' wall were reservedifor pipe hangers GHH-SI-1-SB-038-006 and R1(?)1-087-X11.- These. stickers were dated 1980.
j
-It was ??? evident whether hangers' missing lor.none were needed in these H
locations and the reserve tags were not removed.
TUEC representatives were unable to answer the question immediately.
This' item is unresolved i
pending further' review during a subsequent inspection.
(445/8507-07;.
446/8505-05).
b' R
No violations or deviations were identified.'
f, 16.
Routine Plant Tours (Units 1 and 2)
At various times during the inspection perjod NRC inspectors. conducted general tours of the reactor building, fuel building, safeguards building, electrical and control building,.and the-turbine bu11' ding.
During the tours, the NRC inspector observed housekeeping practices, preventive maintenance on installed equipment, ongoing construction work,.
~
and discussed various' subjects with personnel engaged in work activities.
No violations or deviations were identified.
17.
Review of Part 21 and 10 CFR 50.55(e) Construction Reports Status, i
The NRC inspector reviewed all reports issued to date to assure that NRC and TUEC status logs were complete and up to date.
A total of 183 reports have been submitted to date.
This inspecticn period one Part 21 report on Diesel Generator Oil Plugs and two 10 CFR 50.55(e) reports on the Equipment Hatch Cover and SA106 Piping (light wall) were submitted.
No violations or deviations were identified.
18.
Review of Violation and Unresolved Item S'tatu's
?-
The NRC inspector reviewed all violations and unresolved items' reported' to date to assure that NRC and TUEC status logs were complete and up to date.
Two hundred nineteen items were reviewed.
In addition, a trend-analysis of NRC findings was performed to generally determine how many findings could be broadly classified under each criterion'of 10.CFR, Part 50, Appendix B. _The frequency of findings,showed broad and general trends under the following criteria:.II.-QA Program; III. Design Control; V. Instructions, Procedures and Drawings; VII. Control of! Purchased Material,-Equipment and Services; IX.
Control of Special Processes; X.
Inspection; XI. Test control; XIII. Handling Storage and Shipping; XVII.
QA Records; and XVIII Audits.' The most significant_ trends'were-Criterion III, V, VII, IX, X, and XVIII.
Also, a number of violations occurred with respect to 10 CFR 50.55(e) items.
These findings mainly pertained to Unit 1 and related closely to trends identified by the NRC Technical Review Team TRT.
These trends will be j
considered during followup on TRT findings..Also, Unit 2 inspection i
emphasis will consider these trends during future inspections.
1 i
No violations or deviations were. identified.
j 3
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- T-
.19.
Exit Interviews The>NRC. inspectors met with members of the TUEC staff (denoted in-paragraph 1) on May 10 and June 10, 1985.
The scope and findings.of the inspection were discussed. ' The- @,-'; cant acknowledged'the findings.
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Texas Utilities Electric Company 2
Should you have any questions concerning this inspection, we will be pleased to discuss thee with you.
Sincerely, R.P.Denise,Direc$or Division of Reactor Safety and Projects
Enclosures:
1.
Appendix A - Notice of Violation 2.
Appendix B - NRC Inspection Report
~
50 445/85-07 50-446/85-05 cc w/ enclosure:
Texas Utilities Electric Company Skyway Tour 400 North Olive Street Lock Box 81 Dallas, Tsxas 75201 Texas Utilities Electric Company ATTN:
J. W. Beck..Vice President Skyway Tower 400 North Olive street Lock Box 81 Dallas, Texas 75201 bec distrib. by RIV:
TEXAS STATE DEPARTMENT OF HEALTH bec: to DMB(IE01) bec distrib by RIV:
- RPB1
- Resident Inspector OPS
- RPB2
- Resident Inspector CONS R. Martin, RA
- D. Hunnicutt, Chief, RPB2/B R. Denise, D/DRSS V. Noonan, NRR C. Wisner, PA0 S. Treby, ELD MIS SYSTEM RIV File Juanita Ellis Renea Hicks
- D. Weiss, LFNB (AR2015)
- w/766
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APPENDIX A NOTICE OF VIOLATICN 1
Texas Utilities Electric Company Docket: 50-445/85-07 Comanche Peak Steam Electric Statida 50-446/85-05 Units 1 and 2 Permit: CPPR-126 CPPR-127 9
During an NRC inspection conducted on April 1 thrctg:h June 21, 1985, violations of MRC requirements were identified. The violations involved a failure to correct RTE Delta hardware problems, failure to use class "E" concrete (grout) as specified; failure to docuent unsatisfactory conditions during receipt inspection of the Hydrogen recombiners; failure to inspect corcrete mixer blades quarterly; failure to document cesant sesles which were l
out of calibration; failure to translate design criteria for reactor vessel installation into specifications, procedurds, and drawings; and failure to maintain stated tolerances and to report the failure on a nonconformance report.
In accordance with the " General Statement of Policy and Procedures for NRC Enforcemen,
Actions "10 CFR Part 2 Appendix C (1985), the violations are listed below:_
1.
Failure to Promptly Correct an I,dentified Problem with RTE - Delta l
Potential Transformer Tiltout Suoasset3e_s,s j
t 10 CR 50, Appendix B, Criterion XVI as implemented by Texas Utilities Generating Company (TUGCO) Quality' hssurance Plan (QAP), Section 16.0, Revision 0, requires that measures shall he estab1Mhed to assure that conditions adverse to quality, such as. failures, malfunctions, deficier.
S k promptly identified and corrteted.cies deviations, defective material and ej Contrary to the above, a potenti&F problem with RTE - Delta potential ti transformer tiltout subassemblies, which are used in the emergency diesel j\\
( generator control panels, was identified to the applicant via a letter, dated June 15, 1983, from Transmerica Delaval Inc. This letter also l
provided instru:tions for correcting the potential problem. However, the applicant did not take the corrective action, The NRC initially reported this ites as unrtsolved in NRC Inspection Report 445/84-40.
i This is a Severity Level V Yiolation.
(Supplement II.E) (445/8507-01 l
446/8505-01).
2.
Commerytal Gro# Used in Lieu of Class "E" Concrete l
10 CFR Part 50, Appendix B, Ct itarion Y, as implemented by the TLE0 QAP,
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Section 5.0, Revision 2 requires that activities affecting quality shall be' prescribed by documented instructions, procedures, or drawings, of a tJPe appropriate to the circumstat:ces and shall be accom iance with these instructions, procedures, or Pawings., plished in accor-i j
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Contrary to the above, coamercial non-shrink grout was used to grout the k Unit i reactor coolant pump and steam generator supports in lieu "E" concrete as specified in Section 6-6 of drawing 2323-S1-0550, Revision 4.
Mi This is a Severity Level IV Violation.
(Supplement II.E) (445/8507-02).
3.
Hydrogen Recombiners - Out of Specification Voltage Iscorded on westinghouse Quality Release Document 10 CFR Part 50, Appendix B, Criterion V, as implemented by the TUGC0 QAP, Section 5.0., Revision 2, requires that activities affecting quality shall be prescribed by documented instructions, procedures or drawings, of a type appropriate to the circumstances and shall be accomplished in-accordance with these instructions, procedures, or drawings.
BrownandRootProcedureQI-QAP-7.2-8,"ReceivinkofWestingho Related Equipment", Section 3.1.d.1, required a
. inspector to verify that the Westinghouse Quality Release (QR) document checklist items be j
filled out completely and accurately.
Contrary to the above, the voltage recorded on Westinghouse QR-41424 checklist, attachment 1, step 4.1, was outside the specified tolerance, I
but the QC receipt inspector accepted QR as satisfactory.
This. is a Severity Level V Violation (Supplement II.E) (445/8507-03).
4.
Failure to Provide Objective Evidence (Records) to Show that Concrete central and Truck Mixer Blades were Inspected 3
10 CFR Part 50, Appendix B, Criterion V, as implemented by the TUGC0 QAP, Section 5.0, Revision 2, dated May 21, 1981, requires that activities affecting quality shall be prescribed by documented instructions, procedures, or drawings, of a type appropriate to the circumstances and shall be accomplished in accordance with these instructions, procedures, d
or drawings.
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1 1978 Brown & Root Procedure 35-1195-CCP-10, Revision 5, dated December 4,
, requires that central and truck mixer blades be checked quarterly g
to assure that mixer blade wear does not exceed a loss of 105 of original blade height.
Contrary to the above, on May 31, 1985, the NRC inspector detemined that there was no objective evidence (records) that the mixing blades had been inspected quarterly since the trucks were placed in service in 1977.
This is a Severity Ievel _V Violation.
446/8505-02).
(Supplement II.E) (445/8507-04;
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Failure to Issue a ()eficiency Report on Cement Scales That Were Out of Calibration 10 CFR Part 50, Appendix B, Criterion V, as implemented by the TUGC0 QAP,
)
Section 5.0, Revision 2, dated May 21, 1981, and Section 15.0, Revision 4, dated July 31, 1984, requires that activities affecting quality shall be d
prescribed by documented instructions, procedures, or. drawings, of a type appropriate to the circumstances and shall be accomplished in accordance
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with these instructions, procedures, or drawings.
/
Brown & Root Procedure CP-QAP-15.1, " Field Control of Nonconforming i
Item.
- states that nonconforming conditions shall be documented in a I
Deficiency and Disposition Report (DDR). Procedure CP-QCP-1 3, " Tool Equipment Calibration and Control " dated July 14, 1975, states that out-of-calibration equipment shall be identified on a DDR.
1
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Contrary to the above, on May 31, 1985, the NRC inspector reviewed the calibration file for scale (MTE 779) used for weighing cement and fou that a 24-48 pound deviation from the required accuracy was encountered with the water and cement scales during a 1975 calibration of the backup s
g plant scales, however, no DDk was issued to identify this condition and require disposition of the scale and concrete (df any) produced.
This is a Severity Level IV Violation. (Supplement' II.E) (445/8507-06; 446/8505-04).
6.
Failure to Translate Design Criteria Into Installation Specifications, Procedures, and Drawings; and Failure to Control Deviations from These standards 10 CFR 50, Appendix B, Criterion III, as implemented by TUGC0 QAP, Section 3, Revision 3, dated July 31, 1984, requires that measures shall be established to-assure that applicable regulatory requirements and the design basis, are correctly translated into specifications, drawings, procedures, and instructions. These measures shall include provisions to assure that appropriate quality standards are specified and included in design documents and that deviations from such stancards are controlled.
Contrary to the chove, Unit 2 reactor pressure vessel installation criteria such as centerin tol clearances were:g(a) erances, levelness tolernaces, and shoe to bracket specified on Construction Operation Traveler ME-79-248-5500 based on NSSS vendor recommended criteria which had not been translated into CPSES specifications, drawings, procedures, or instructions; and (b) changed on the traveler without appropriately documenting such engineering changes.
This is a Severity Level IV Violation (Supplement II.E). (446/8505-05).
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Failure to Maintain Tolerances Required and Failure to Report Tolerance Deviations on a Nonconformance Report 10 CFR 50, Appendix 8. Criterion XV as insiemented by the TUGC0 QAP, Section 15.0, Revision 2 dated May 21, 1931, requires that measures shall be established to control materials, parts or components which do not conform i
to requirements; and nonconforming items shall be r.eviewed/and accepted, rejected, repaired; or reworked in accordance with documented procedures.
Brown and Root Quality Assurance Manual, Section 16. dated March 27, 4
1985, requires that unsatisfactory conditions identified on process centrol documents shall be identified on a nonconforming report.
Contrary to the above, clearances between the reactor vessel support brackets and support shoes were not within the original or revised permissible tolerance stated in Construction Operatica Traveler ME-79-248-55 and the deviation was not reported on a nonconformance report.
This is a Severity Level IV Violation.
(Supplement II.E) (446-8505-06)
Pursuant to the provisions of 10 CFR 2.201, Texas Utilities Electric Company ~
is hereby required to submit to this office, within 30 days of the date cf this Notice, a written statement or explanation in reply, includin (1) the corrective steps which have been taken and the results achieved; (g: corrective 2) steps which will be taken to avoid further violations; and (3) the date when full compliance will be achieved. Consideration may be given to extending your response time for good cause shown.
Dated:
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J Westinghouse Water Reactr r r!
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[f wenionemers o..on Electric Corporation Divisions
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- A w d..I.[]ft Pmskrgh Perrepaua 15n0 0anuary 10, 1986 S.O.,No: TXUJ-2004(Q)
Mr. J. T. Merritt, Jr.
Ref:
- 1) Comanche Peak Assistant Project General Manager Field Traveler #ME '
Texas Utilities Generating Company 248-5500 (Unit 2)
P.O. Box 1002
- 2) CPPA-48113 Glen Rose, Texas 76043 TEXAS UTILITIES GENERATING COMPANY COMANCHE PEAX STEAM ELECTRIC STATION I
Consideration for Acceptance of the Comanche Peak Unit #2
Dear Mr. Merritt:
As requested in customer letter CPPA-48113, Westinghouse offers the following_
i considerations that form the basis for acceptance of the Unit 2 Reactor Vessel Support Shoe Side Gaps:
l 1.
The reactor vessel support shoe grows (thermally) slightly less than the RV nozzle pad.
Therefore, the required 0.020" (cold) side gap closes slightly to provide a small hot clearance, i
l 2.
The remaining hot gap is necessary to account for shim undulations (i.e.,
l warping, etc.) due to machining, thus ensuring binding will not occur.
3.
Once shims are installed, an average of the (4) corner gaps is determined i
and is considered representative of the installation. 'Past experience indicetes that shim warping during machining and shim alignment on the shoe can cause gap measurement inaccuracies.
4.
Cold gaps which are slightly in excess of the 0.020" (cb1d) requirement have no effect on the design / analysis of the reactor vessel support / reactor coolant loop system.
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..__-___._____-_m_____
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- WPT_8148 J. T. Merritt, Jr.
Based upon the above, and a review of the data presented by Reference #1, the Unij 2 reactor vessel show side shim installations are found to be acceptable.
If there are any further questions or comments, please advise.
Very truly yours, y
WESTINGHOUSE ELECTRIC CORPORATION fse' 4: h R. S. Howard, Manager WRD Comanche Peak Projects M.Torcaso/jj s/8682d:1 cc:
J. T. Merritt 1L R. D. Cal der 1L J. W. Beck 1L C. B. Hartong 1L J. C. Kuykendall 1L ARMS ll
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1 installation?
How for do we carry audits?
Should 2
we audit all steam generators, all four of them?
3 Should we audit the pressurizer?
Do we audit 4
every concrete placement?
5 I think you have to decide'what did they 6
or did they not comply with in not auditing the 7
reactor vessel installation.
8 Now, we're also talking about in~the 9
earlier time frame, I believe.
I don't recall
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10 whether the vessel was set.
It must have been '81 11 or
'82.
There was an ISAP, again, that deals with 12 TRT findings that goes right along with 8432,
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13 which required the utility to go back in a third i
14 party and look at their audit program to see why 15 there had been problems with whatever problems 16 with their audit program.
17 This violation was nothing but I_ don't 18 want to characterize.it.
This issue was related 19 back to what has already been identified under TRT I
20 which there was an ISAP 0412i and, so, in our 21 discussion, I indicated that I wanted to make that 22 an unresolved item pending whatever the utility 23 does as a result of the ISAP.
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24 Q.
(By Mr Goldberg)
Question ist In the
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25 audit plan, was there specific equipment listed or I
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JOB 35-1195 Q
COMANCHE PEAK STEAM ELECTRIC STATION INDEXED
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INTERIM CHANGE NOTICE NUMBER 2 g.
This notice applies to: Construction procedure CP-CPM-6.3 Revision 5.
The intent of this change will (X) / will not ( ).be incorporated in the next revision to the procedure or instruction.
/
This Change applies:
Until Further Notice ( )
Until the next Revision is issued (X)
Only as follows:
CHANGE THE PROCEDURE / INSTRUCTION AS FOLLOWS:
(1) Delete Reference 1.5.
(2) Change Paragraph 3.1.3 to read as follows:
3.1. 3 After the Traveler is prepared, it shall be submitted to QC for review. QA/QC will not be required to review each cable tray hanger traveler as each operational document will be identical ex-cept for the Traveler number. Review requirements for ASME related travelers are delineated in Reference 1.4.
V (3) Change Par,agraph 3.1.4 to read as follows:
3.1.4 QC shall return the Traveler to the originator for distribution.
I All signoffs will be on the " original" making it the valid working document. Component support traveler packages shall be controlled in accordance with Reference 1.4.
(4) Change Paragraph 3.6.2 to read as follows:
3.6.2 When design changes are received that affect issued and approved travelers, construction engineering shall notify the superinten-dent immediately. The applicable changes will be made to the trav-eler and it will then be reviewed in the same manner as the original issue. At the superintendent's discretion, work may continue on the traveler operations not affected by the design change. Changes to component support traveler packages will be routed in accordance with Reference 1.4.
Reason for change: Additional requirements.
I This change approved by:
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4- -7 Department flead MR.JNg
' Data ty Assurance Date ReviewedBy.:knD Q
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Procedures & Reports, Data w
JOB 35-1195 AE y
COMANCHE PEAX STEAM ELECTRIC STATION ggg i
1 INTERIM CHANGE NOTICE NUMBER 1 mm This notice applies to: Construction Procedure CP-CPM-6.3
, Revision 5 i
The intent of this change will (X) / will not ( ) be incorporated in the next revision to the procedure or instruction.
/
J This Change applies:
Until Further Notice ( )
Until the next Revision is issued (X)
Only as follows:
CHANGE THE PROCEDURE / INSTRUCTION AS FOLLOWS:
1.
Add the following sentence to Paragraph 3.6.2:
" Changes to component support traveler packages will be routed in I
accordance with Reference 1.5" 2.
Add reference 1.5 as follows:
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-l 1.5 CP-CPM-6.9 b
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Clarification This change approved by:
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8 6-4 19 Departa nt Mac
'Dste Quality Assofance Date Mar M CW Q
Reviewed By:
$h b**$~ W Procedtres & Reports
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1 to me'if -- I certainly would go out to look at k
2 all that detail on everything.
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(By Mr. Goldberg)
You didn't suggest to 4
the inspector to go dig up the audit plan?
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A.
No.
4 He drew his conclusion based on wha 6
he thought the utility ought.to d$.
7 Q.
In this area, you'didn't suggest the 8
inspector do any additional work to susta ti n
ate 9
this issue?
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10 A.
I indicated he should look to see if 11 there were not audits, maybe, in the mechanical 12 installation area.
Maybe there was something
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13 there.
Okay.
I mean, we related to the same kind 14 of things as the installation of the reactor 15 vessel.
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There may tue a basis for citation It 17 was left unresolved based on that
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comment plus the 18 fact that there's an issues specific action 19 Q.
There may be a more basic issue than thi i
20 s
audit of the vessel.
There may be an inadequate 21 plan behind all this.
Maybe the audit plan is in 22 question.
23 A.
That's why there's a specific astion 24 plan.
The TRT reached the conclusion that the 25 utility was asked to go look at their audit i
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documenting and qualifying the procedures and material. The marking shall include the heat or lot welders or welding operators.
number as applicable, a control marking code which identifies the materials with the Certified Material NA 3766.5 Handling, Storage, Shipping, and Pres-ervation. Measures shall be established to provide eM 8 er mf nna n Suc 85 5Peo instructions for handling, storage, shipping, and sfication, grade and classification number, supplier's preservation of material to prevent damage or name, and trade designadon.
deterioration.
NA 3767 Framinattana. Tests, and Reports
' NA 3766.6 Identification and Marking of Material NA 3767.1 FaenMahmaet of Framanneiama and Produced. Measures 'shall be established for con-g g g;g g
trolling the identification of material throughout the shall be established to assure conformance with the manufacturing processes and shipment.
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(a) MaterialIdentafication J
(/) The identification of materialshallconsist of
. NA-3767.2 Records of 5'v==a-a aa== and Tests. All marking the material with the applicable specification characteristics required to be reported by the material and grade of material, heat number or heat code of.
specifications and by this Section shall be verified and the material, and any additional marking required by the results recorded. Records shall be traceable to this Section to facilitate traceability of the reports of procedure and revision to which an cuammation or -
the results of all tests and examinations performed on test is to be performed, with space provided for the material; except that, for those materials for which recording results of examinations and tests. During the Material Manufacturer's Certificates of Com-manufacture, measures shall be established to in-pliance are allowed, heat number identification need dicate by the use of markings such as stamps, tags, not be indicated either on the material or the labels, routing cards, or other suitable 'means, the Cenificates. Alternatively, a marking symbolor code status of examinations and tests performed upon may be used which identifies the material with the individual heats or lots of material. These measures material certification and such symbol or code shall shall provide for the identification of those materials -
be explained in the certificate.
which conform to the examination and test re.
(2) Method of Marking. Materials shall be mark-quirements.
j ed by any method acceptable to the purchaser which will not result m any harmfulcontamination or sharp NA 3767.3 Naacantor ning Material. In order to discontinuities and will identify the material m prevent the inadvertent use of material which does not accordance with the material specification. Stamping.
c nf rm, adequate control measures. hall be.
s es-when used, shall be done with blunt nosed continuous tablished to preclude nonconformance with the or blunt nosed interrupted dot die stamps.
requirements of this Section. These measures shall (3) Transfer of Morking When Material is Di.
include procedures for identification, documentation, vided The identification marking shall be transferred segregati n, and disposition. These procedures shall a
to all pieces when materialis divided.
Provide for a review and acceptance, rejection, or (4) Marking Requirements for Small Products.
repair of the nonconfonning material. Disposition of Except as required by the material specification, bolts nonconf nningmaterialshaH bedocumented, and nuts 1 in. nominal diameter and smaller, and NA-3767.4 Certificadon of Maserial other products where the largest space available for (a) Certiped Material Test Aspart. He Certified marking is less than 1 in. in any direction need not be Material Test Report shallinclude the actual results individually marked provided they are packed in of all required chemical analyses, tests, avammations packages or containers which shall be clearly (including radiograpluc film when radiography is identified by legible marking to ensure positive required), weld. repairs, and ~ heat treatments identification of the material, ne markmgs on the (including times and temperatures), performed on containers shall identify the material with the Ma-matenal. Notanzation of the Certified Material Test terial Manufacturer's Certificate of Compliance or Reportja not roquired.
Certified Material Test Report, as applicable.
(b) Certsfearson by #arerief Mansferswer. De
.t (b) Welding and Brazing Materials identification.
Material Manufacturer, including the manatacturer Welding and brazing materials shall be clearly of welding and branng materials, shau provide a identified by legible marking on the package or Certified Material Test Report. he Material Mass container to ensure positive identification of the ufacturer shall certify that the contents of'the' report 9
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ARTICLE NB-4000 FABRICATION AND INSTALLATION REQUIREMENTS NB-4100 GENERAL REQUIREMENTS impact properties below the required values, the tensile and impact tests shall be repeated by the NB 4110 INTRODUCTION Manufacturer or installer on test specimens taken l.
from test coupons which have been taken and treated 1
Components shall be fabricated and installed in in accordance with the requirements of NB-2000, i!
accordance with the requirements of this Article and I
shall be manufactured from materials which meet the g.
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requirements of NB 2000. The term component shall
. t 73;JL be understood to include parts and appurtenances.
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NB-4120 CERTIFICATION OF MATERIALS
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AND FABRICATION BY COMPONENT MANUFACTURER P##*.
OR INSTALLER material during subsequent fabricati6n or m.
stallation. In either case, an as-built sketch' or a NB 4121 Means of Certification tabulatson of materials shall be made identifying each The Manufacturer or installer of a component shall piece of material with the Certified Material Test certify, by application of the appropriate Code Report and the coded marking.Forstuds bolts. nuts, symbol and completion of the appropriate Data and heat exchanger tubes it is permissible to identify Report in accordance with NA-8000, that the ma-the Certified Material Test Reports for material in terials used comply with the requirements of NB 2000 each component in lieu of identifying each piece of and that the fabrication or installation comply with material with the Certified Material Test Report and the requirements of NB 4000.
the coded marking. Welding and brazmg materials shall be identified and controlled so that they can be NB-4121.1 Certification of Treatments, Tests, and traced to each componenf' r instahakaa of a piping o
Examinations. If the Manufacturer or Installer or system, or else a contr@ '
subcontractor performs treatments, tests, repairs, or which ensures thht dC
" 8'"u c t esung "can m aa% -
g.,
examinations reoitired by other Articles of this Subsection, he sh'll certify that he has fulfilled that Materials a
requirement. Reports of all required treatments and All welding and brazing materials shall meet the I
q of the results of all required tests, repairs, and requirements of NB-2400.
l examinations performed shall be available to the Inspector.
NB-4130 ELIMINATION AND REPAIR OF f
DEFECTS I
NB-4121.2 Repetition of Tensile or Impact Tests. If y 3,433g.
g during the fabncation or installation of the com-t ponent the mat:rialis subjected to heat treatment that f
has not been covered by treatment of the test coupons DefectsM on i
(NB-2200) and that may reduce either tensile or delivery orM promss of j
fabrication or installation may ~be ehmmated or 159 repatred by. welding, provided the defects are re-m nv,A renaired and ewaminmA in arenrAnnew with
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NB-6000-TESTING N BG312-N B.6323 i
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(c) For the vessel hydrostatic test before in-system. The system design pressure shall be es-l stallation, it is recommended that the test be mad: at a tablished in accordance with the rules of NB-7411.
temperature not lower than RTsor + 60 F (see NB-(b) All pressure retaining components of the 233i).
completed system that are within the boundary protected by the overpressure protection devices I
NB-6213 Check of Test Equipment Before which satisfy the requirements of NB-7000 shall be Applying Pressure subjected to a system hydrostatic test at a pressure not The test equipment shall be examined before less than 1.25 times the system design pressure. The pressure is applied to ensure that it is tight and that all system design pressure for the protected boundary
" hall be established m accordance with the rules of low pressure filling lines and other appurtenances that N
should not be subjected to the test pressures have been disconnected or isolated by valves or other suitable means.
gr g.
NB4215 Examination for I enkage After a result f the system hydrostatic test,in Application of Pressure accordance with the rules of NB 2500:
Followmg the application of the hydrostatic test (2) The w prar.t' repair can be postweld heat pressure for a minimum of 10 min. (NB-6224),
treated, if reqmrod and nondestructively examined in exuaination for leakage shall be made of alljoints, accordance with rules of NB-2500, and NB-5100 as connections. and of all regions of high stress such as applicable, subsequent to the system hydrostatic test:
regions around openings and thickness transition (3) The component is subjected to minimum
]
sections. Except in the case of pumps and valves, required system hydrostatic test following the com-which shall be examined while at test pressure, this pletion of repair and exammation.
examination shall be made at a pressure equal to the j
greater of the design pressure or % of the test i
pressure, and it shall be witnessed by the Inspector.
NB-6222 Maximum Permissible Hydrostatic Leakage of temporary gaskets and seals, installed for 7
the purpose of conducting the hydrostatic test and i
which will be replaced later, may be permitted unless (a) The stress limits specified in NB-3226 shall be l
the leakage exceeds the capacity to maintain system used in determining the permissible hydrostatic test test pressure for the required amount of time. Other pressure. In multichamber components. pressure may leaks, such as from permanent seals, seats. and be simultaneously applied to the appropriate adjacent gasketed joints in components, may be permitted chamber to meet these stress limits. The number of 1
when specifically allowed by the Design Spec-test sequences for which the above provisions may be ifications. Leakage from temporary seals or leakage considered applicable shall not exceed ten.
permitted by the Design Specification shall be (b) When hydrostatically testing a system, the test directed away from the surface of the component to pressure shall not exceed the maximum test pressure avoid masking leaks from otherjoints.
of any component in the system.
NB4220 HYDROSTATIC TEST PRESSURE NB-6223 Hydrostatic Test Pressure for Pumps REQUIREMENTS and Valves, and for Cc, ----ots and Appurtenances Containing Brazed NS-6221 Minimum Required Hydrostatic Test Joints Prior to installation, pumps and valves and other (a) Except as may be otherwise required by components and appurtenances containing brazed material specifications (NB-6114), compictadiconh joints shall be hydrostatically tested at a pressure 1.5 ponces and appurtenances except those contangggj** times the system design pressure as determined by the brazed joints, pumps, and valves shs11Feiub}Nff8T5 rule of NB-6221(b). except that in the case of valves a hydrostatic test at a pressure notless than 125 times designed in accordance with NB-3531, the rules of the system design pressure prior to installation in the N B-3531.2 shall apply.
207
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I N A.l l40-N A.12 20 SECTION 111. DIVISION I - SUBSECTION NA NA ll40 EFFECTIVE DATES OF CODE the nuclear power plant to be constructed in ac.
EDITIONS. ADDENDA. AND cordance with this Section.
CASES I
NA-1200 GENERAL REQUIREMENTS l
tal Code Editions become mandatory on July I of FOR AND DEFINITIONS OF
{
the publication year printed on the cover. Addenda ITEMS AND INSTALLATION may be used on and af ter the date of issue and become mandatory sa months af ter the date of issue.
NA 1210 COMPONENTS fbj Code Cases may be used beginning with the
,...u a _,,,
{
date of approval by the ASME Council and, being ycpapos,tendl_el a;mp$lggp piant iadsde l
permissive, do not become mandatory. Only Code items such as. vesselysyneenysumps, valves.
Cases that are specifically identified as being ap-and storage tanks. EaGi component shall bear the plicable to Section til may be used for construction in required Code N-type Symbo!4 and Manufacturer's
{
accordance with this Section.
Data Reports shall be prepared for them (NA 3370 (c) The Code Edition. including Addenda,which is and NA-8400). The installer of such components or mandatory on the contract date for a comnnnent shall any associated appurtenances shall complete Data determine iTimandatory rules for.the manufacture Report Form N 5 which serves to indicate that each j
aiid installation,of that component. including its component or appurtenance assemb'ed into the l
materials. parts. and appurtenances. Earlier editions nuclear power plant and the installation meet the shall not be used escept to meet the requirements of requirementsof thisSection.
Section XI for alteration, modification, renewal.
replacement. or spare components, parts, or ap-J purtenances.
N A.1220 MATERIALS l
the mandatory rules for manufacture and installation of core support structures and component supports Materials are manufactured to an SA, SB. or SFA ine'uding their materials. Earber editions shall not be Specification 5 or any other material specification used.
permitted by this Section. Such material shall be (ej The contract date for an entire nuclear power manufactured and certified in accordance with the system does not govern the Code Edition. Addenda, requirements of this Section. Materials produced 1
and Cases applicable to the components. core support under an ASTM designation may be accepted as
{
structures, and component supports.
complying with the corresponding ASME spec-l
/// Code Editions. Addenda,and Cases which have ification provided the ASME specification is des-not become mandatory on the contract date for a ignated as being identical with the ASTM spec-component may be used by mutual consent of the ification for the grade, class, or type produced and l
Owner 8 or his agent and Manufacturer 2 or Installed provided that the material is confirmed as complying on or after the dates permitted by (a) through td) with the ASTM specification bya Certified Materials above. It is permitted to use specific provisions within Test Report or Certification from the Material an Edition or Addenda provided that all related Manufacturer. Welding material produced under an requirements are met.
AWS designation may be accepted as complying with (g) Caution is advised when using Addenda or the corresponding ASME specification provided the l
Cases that are less restrictive than former re-latter specification is indicated to be identical with the
]
quirements without having assurance that they are AWS specification and provided the welding material acceptable to the enforcement authonties having is confirmed as complying with the AWS specification junsdiction at the nuclear plant site.
by a Certified Material Test Report or Certification fh) The Owner or his agent shall obtain a Cer-from the Matenals Manufacturer, tificate of Authonzation (NA 3230 and NA 8240) prior to the field installation (N A-1250)of any item of
- The term N.ippe symbol means any one of the symbols shown in Figure NA 8220-1.
'See N A-3210 for definiuon of Owner.
SSA or SB Specificauons listed under the heading Bars, Rods, Shapes, forgmgs may be used as matenal for any of these product
- See N A.3310 for dehniuon of Manufacturer.
forms even though not all product forms are listed in the SA or SB asce NA.3410 for definiuon of Installer.
Specificauon.
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NB-6100 GENERAL REQUIREMENTS (2) When components, appurtenances, or sys-NB-6110 TESTING OF COMPONENTS, tems, which are not readily dried, are to be used in APPURTENANCES,AND services where traces of the testing medium cannot be SYSTEMS t lerated and, whenever possible, the parts of the components, appurtenances, or systems have been NB-6111 Components and Appurtenances Previously hydrostatically tested to the pressure required in NB-6220.
NB-6111.1 Hydrostatic Testing (b) A pneumatic test at a pressure not to exceed 25 fa) All components and appurtenances con-psi may be applied, preliminary to either a hydrostatic structed under the rules of this Subsection shall be hydrostatically tested, in the presence of the In-or a pneumatic test, as a means of locating major leaks. If used, the preliminary pneumatic test shall be spector. Nuts, bolts, studs, and gaskets are exempt carried out in accordance with the requirements of from hydrostatic testing.
N B-6300.
(b) The hydrostatic test of each line valve and pump with irilet connections over 4 in nominal pipe NB-6112.1 Precautions to be Employed in Pneu-size shall be witnessed by the inspector and a data matic Testing. Compressed gas is hazardons when report completed for each(NA 8400).
h b hh m fc) A hydrostatic test of each line valve and pump commended that special precautions for protection of with inlet piping connections of 4 in. nominal pipe size and smaller shall be performed by the Manufacturer as test medium' and so noted on the data report form (NA-8400);
however, this hydrostatic test need nre be witnessed NB 6113 Testing of Systems I
by the inspector. The inspector's review of the NB-6113.1 Hydrostatic Testing. Prior to initial Manufacturer's test records will be his authonty to operation, the installed nuclear energy system shall be i
sign the report and takes precedence over N A 5280.
hydrostatically tested except as permitted in NB.
NB 6111.2 Pneumatic Testing. When a hydrostatic 6113.2 in the presence of the Inspector. The test shall test is not practical (NB.6112) a pneumatic test, in be conducted in accordance with the requirements of N B-6200.
accordance with NB-6300, may be substituted.
l NB 6113.2 Pneumatic Testing. When a hydrostatic NB-6112 When Pneumatic Testing may be test (NB 6112) is not practical, a pneumatic test, in Used accordance with NB-6300, may be substituted.
(a) Pneumatic tests may be used in lieu of the NB 6114 Time of Hydrostatic Tests of Parts, hydrostatic test required by NB 6111.1 and NB-6113 Piping Sa====% and Materials except as permitted in (b) belom only when the following conditions exist:
7,j test
(/) When components, appurtenances or sys-P tems are so designed or supported that they cannot be k:tNPC*
safely filled with water:8 (b) The component or appurtenance hydrostatic inese tests may be made with the item bems tested pamauy taled test when conducted in accordance with the re-with water. if desired.
quirements of NB-6221 may be used in lieu of any 1
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cach component support or group orTowpnwrn g jg g]
supports for each component shall be furrmhed by the t-j ~ ~ ~ ~ -
Manuf acturer. Data Reports and Stamping shall be as required in N A-0000.
NA 1231 Parts Parts have work performed on them requiring the N A 1260 APPURTENANCES AND PENETRATION ASSEMBLIES
(
presence of or verification by an Inspectori and are furnished to a component Manufacturer by other Manufacturers, or by the same component Man-N A 1261 Appurtenances l
under a different Certificate of Au-An appurtenance is an item similar to a part (NA-ufacturer theorization (N A 8113) thaa that applying to the 1230) which is attached to a completed and stamped component. By definition, a part is attached to or component. The design conditions for appurtenances becomes a part of a component before completion shall be included in either the component Design and stamping of the component. The Design Spec-Specification (NA 3250) or,in a separate Design ifications (N A 3250) and Stress Report (N A 3350) for Specification. A Stress Report (NA 3352) for each components shall apply to the parts of such com.
appurtenance or group of identical appurtenances for ponents. Data reports and stamping shall be as each component shall be furnished by the ap-included in the required in N A-8000.
portenance Manufacturer if not component Stress Report. The Owner, directly or a8cnl 5 aH e rc5Po@c Me merau NA 1232 Pi subassemblies as sections of a c trelation of the component and appurtenance Piping subassembhes are de i piping system consisting of fittings and pipes or tubes Stress Reports {N A 3260). Data reports and stampmg
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which are fabricated as subassemblies in a shop or in
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the field before they are installed m a nuclear power system. The Design Specifications (N A 3250) andN A 1262 Penetration Assemblies Stress Report (NA-3350) for the piping system shall Penetration assemblies are defined as electrica apply to the piping subassemblies of that system. Data mechanical parts or appurtenances required to permit reports and stamping shall be as required in N A-8000.
piping, mechanical devices or electrical connections.
pass through the pressure retaining boundary of_a t
CORE SUPPORT STRUCTURES component.
N A 1240 Core Support Structures are those structures or MISCELLANEOUS ITEMS parts of structures which are designed to provideN A 1270 direct supportor restraintof thecore(fuelassembbes)
Control Rod Drhe Housings within the reactor vessel. Core Support Structures NA 1271 require Design Specifications (N A 3250) and Stress Control rod drive housings attached to a reactor Report (N A 3350). Data Reports and Stamping shall vessel shall be considered in the Design Specifications be as required in N A 8000.
as a vessel part or appurtenance or as a separate vessel. The rules of Subsection NB shall apply to those NA.1299 CQMPONFMr userwre -.
portions of the housings formm, g a pressure retammg
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boundary.
iW 3"Prem ase h smessi suoports whdhare deciphed to"trumesent leeds ihna the
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as ws r f w tne N A 1272 Hester Elements pra loa 44arrysag Italieng structure. He doenga con-That portion of heater elements forming a pressure ditions for component supports shall be included in retaining boundary of a nuclear power system shall be either the component Design Specifications (NA.
considered in the Design Specification either as a part 3250) or in a separate Design Specification. A Stressor an appurtenance.
Report or Load Capacity Data Sheet (NA 3352) for each component support or group of component N A 1273 Fluid Conditioner Devices supports f or each cotaponent shall be f urnished by the That portion of a fluid conditioner device such as a Manufacturer of the component or the component filter, demineralized, trap, or strainer which forms the support. Data Reports and stamping shall be as requiredin N A 8000.
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(61 Year built.
st25 Authorized Inspectors and Inspection (b) The N-type symbol and the above required Agencies data may be stamped. etched. or impressed thereon.
The selected method shall not result in any harmful j
inspectors and Inspection Agencicopermitted to contamination or sharp discontinuities. The data shall perform inspections required by this Section are be in characters not less than b in. high. Stampmg.
defined in N A 5111 and NA-5112.
when used, shall be done with blunt nosed continuous or blunt nosed interrupted dot die stamps. Na-NA 8130 OBTAINING OF STAMPS meplates shall not be used on Core Suprort Struc-tures.
All stamps for applymg the Code symbol shall be obtained from the Society.
(a) SYMBOL FOR VESSE!J5.STORAGli N
NA 8140 REGULATIONS SUBJECF TO TANKS, PUMPS, AND LINE VALVES CHANGE The Society may at any time make such regulations M y E BL F
PARTS OR concerning the issuance and use of such Certificates APPURTENANCES OF A COM-N PT and stamps as it deems appropnate and all such PONENT. FOR COMPONENT regulations shall become binding upon the holders of SUPPORTS.OR FOR CORE any valid Certificates of Authorization.
SUPPORT STRUCTURES (c) SYMBOL FOR SAFET) VALVES NA 8200 REQUIRED NAMEPLATES AND STAMPING (d) SYMBOL FOR INSTALLATION NA-8210 DIAGRAM OF RELATED CERTIFICATIONS, STAMPING, NOTE: ne class of construction (1,2,3. CS, or MC) shall be AND DATA REPORTS indicated by the nurneral 1,2, or 3 or the letters CS or MC stamped below and outside of the official Code symbol.
Figure N A 8210-1 is to provide assistance in FIG NA4220-1 OFFICIAL SYMBOLS establishing the certifications. N type symbol. and Data Reports required by this Section. The complete detailed requirements are contained in the following paragraphs of this Article.(Table NA-3120-1)
NA 8230 REQUIREMENTS FOR STAMPS AND STAMPING NA 8220 REQUIREMENTS NA-8231 Application of Stamp (a) Each item and m, stallation to which an N type (a) The Manufacturer who completes the fa-symboli s applied shall be marked with the following:
brication of an item, or who fabricates parts of such i
(1) The applicable official N type symbol, as tems, or who joins such items by welding or the shown in Figure N A 8220-1.
- Installer who installs such items shall have a valid Certificate of Authorization for th e
ine term N.spre symbol means any one of the symbols shown in appropriate Code symbol Ther Fig. N A-82241.
applied by lMe,
/[
53 tw?m plased.Md mtulfleeh foemed by thelaspesest(NA 5200).Such application of the Code symbol together with final certification in accordance with the rules that all applicable reg th (NA-3370 and N.
M8 have been m A
%,ed, ;;>8'PPort
<,o.tatie.
struc I
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Nm00 Cl.RI I(CATLS OF AUTilORIZATION N A.8231 -N A 42 33.5 NOTES TO FIGURE N A,82101 1 Applicable only when Manufactu-er's author ration inn includes extension to fielci operations for compietion or rep cons %cted in his own shop or field loc 8 tion (Table N A.31201, Note (2) and items 1,2,3,4,5, and 81. In this case form applicabie to the items may be used in 04ce of Form N 5 (Appendix VL
- 2. The class cf construction (1, 2,3, CS, or MC) shall Je indicated by the numeral 1,2, or 3 or the letters CS or M outside the of f scia: Code symbol.
- 3. Field installation of items requires Authonration and appiscation of N A symbol stamp.
Man-NA 82201(b), may insneed be identdied by unaMag (b) In those cases where the %xent ufacturer elects to substitute the system hydrostatic in any manner acceptabis to the'inspectorwhishvill i
test [NB-6221(c)] for the component hydrostatic tat, serve to identify them with the Manufacturer's Data l
Report. The permanence and visibility of this mark-l a Code symbol shall not be applied to the cost peinent iag t, hall be consistent with the nced for identification until the hydcostnic test and all required ex-aminations, tests,' and inspectic,ns have been sat-during construction, installation, and power plant isfactorily completed. The system hydrostatic test operation. This marking requirement does not apply shall be conducted under the responsibility of the to accessories such as handhole covers, bolts, and holder of a Code N type Certificateof Authorization
- gaskets, for that field site: however, a representative of the (c) Those parts requiring mspection undtr this y
Section which are furnished by other than the component Manufacturer shall be present, to witness Manufacturer responsible for the completed com-and accept responsibility for the component hyd-ponent or component support shall have the Code rostatic test and to sign the data rrport. The sy,bol shown in Fig. NA-82201(b) applied to them, completed stop fabrication portion of the data report
. Parts f urnished by a component Manufacturer for the forms, together with his c*n inspections, shallbe the
.same component Manufacturer under a different authority for the field Inspector to autawtze and Certificate of Authorization may be furmshed with- -
witness the stamping of the completed component by out the Code Symbol Stamp being applied to the part Manufacturer. For the purpose of the component witnessing the system hydrostatic test and applying provided:
(1) The Manufacturer's Quality Assurance Man-his stamp in the field, the Manufacturer need not have ual includes a requiremer.t for a procedure that will j
his Certificate of Authorization extended to that field provide traceability of each part.The procedure shall site.
pionues toue symooi requirements as be accepted by the Authorized Inspection Agency wim.
related to item type and classification. The class of W ei sd construction (1, 2, 3. CS, or MC) shall be indicated by (2) Such procedures shallincorporate the use of:
the numeral 1. 2 or 3, or letters CS or MC stamped (a) Manufacturer's transmittal forms for each below and outside of the officialCode symbol.
shipment listing all parts and their specific NA 8232.1 Required Sur eys. Manufacturers and identification and provide for a description of shop Installers of Classes 1,2.3.CS,and MCitems require fabrication performed. These transmittal documents a survey d sheir facilities and Quality Assurance shall be signed by the Manuf acturer and the Inspector Programin accordance with N A 8120.
at the plant or field site of the component Man-j ufacturer; or (b) Form N 2 or NF-2 with supplemental NA-8233 Code Symbol Stamps sheets as provided for by this Sect.on, if required, NA-8233.1 Starnp for Vessels and Storage Tanks.
listing all parts for which the data report applies and The Code symbol shown in Fig. NA 8220-l(a) shall the specific identification of each part; or be applied to completed vessels of Classes 1,2,3, and (e) Form N 1 or NF-1, which provides for MC and to Class 2 and 3 storage tanks.
shop f abrication and field assembly; or (d) A combination of Forms N 1 and N 2 or NA-8233.2 Stammy for Parts and W f rms NF l and NF 2.
(a) Appurter,ances shallbe stamped as required for shown in Fig. NA-82201(b) shall be applied to Class parts:
1, 2, and 3 piping subassemblies that are fabricated in (b) Parts and appurtenances which, because of a shop or in the field, except in the case where the their size and other considerations, do not lend Fabricator and installer are the same. When the themselves to being stamped with the symbol of Fig.
Fobricator and installer are the same, piping sub-uacturer ror tne same component manuianuici under a different Certificate of Authorization may be assemblies may be furnished under the provisions of 55
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- ,'4 ISSUE'p'"-"'"1 irGy; q PROCEDURE BROWN & ROOT, INC.
NUMBER REVISION m. ufu e
- ---PAGE-- - -
CPSES JOB 35-1195 35-1195-CU-10 '
5 12/4/78 1 of 20
/r --
TITLE:
ORIGINATOR:
YI d / L/
L y 1 >lit W #' e ff /24-7R REVIEWED BY:
a
/Z 78
" CONCRETE BATCH
/0Al~0C Date
^
^
7,
=i APPROVED BY:
Y/
M /h /
/278I CONSTRUCTION. PROJECT MANAGER DATE c< u ai
/
TM] #1 fin"/
CONTENTS
1.0 REFERENCES
2.0 GENERAL 2.1 PURPOSE 2.2 SCOPE g
2.3 DEFINITIONS 2.4 SPECIAL ITEMS AND OPERATIONS
~
2.5 F. UNCTIONS AND RESPONSIBILITIES 3.0 PROCEDURE 3.1 CEMENT 3.2 AGGREGATE 3.3 AGGREGATE GRADATION FAILURE 3.4
' RESCREENING AGGREGATE 3.5 ADMIXTURE 3.6 WATER 3.7 CLASSES OF CONCRETE 3.8 BATCHING N lb,4
.. 9 CENTRAL MIXING 3.10 TRUCK MIXING 3.11 DELIVERY OF CONCRETE IN TRUCK MIXER TO POINT OF PLACEMENT 3.12 TICKETING SYSTEM 3.13 MAINTENANCE OF EQUIPMENT NOTE This document has been completely retyped for convenience in issuing Revision 5.
Vertical lines (change bars) appear-ing in the margins indicate what information was actually changed, added or deleted by Revision 5.
ww
9 4
l JOB 35-1195 COMANCHE PEAK STEAM ELECTRIC STATION Construction Procedure DOCUMENT CHANGE NOTICE NUMBER 1
l i
Notice applicable to Construction Procedure No. 35-1195-CCP-10 Rev
,5 This change will be incorporated in the next revision of the procedure.
Change the procedure as follows:
Please replace / add the following pages with the attached:
Page 19 of 20 20 of 20 Add 20a of 20 I
Reviewed by:
AD 3C AAV 8d f/f f$ 0Y Jh$dW Origidator Date Brown & Root Qtrality Assurance Date ffL (L/O USl~ N Approved by:
TUGC0 (fuality Assurance Date O ' Me -
/- / -W 06/01/84 Construction Project Manager Date Effective Date
7-A D RA C
\\
l INDEXED JOB 35-1195 COMANCHE PEAK STEAM ELECTRIC STATION DATE INTERIM CHANGE NOTICE NUMBER 1 This notice applies to: Construction Procedure #35-1195-CCP-10, Revision 5
1 The intent of this change will (X)) / will not ( ) be incorporated in the next revision to the procedure or instruction.
This Change applies:
Until Further Notice ( )
Until the next Revision is issued (X4 Only as follows:
CHANGE THE PROCEDURE / INSTRUCTION AS FOLLOWS:
On Attachment 2, Part D, add to the bottom of the list as follows:
4 M.
Mechanical Type 2 open.ings.
E.
Electrical Type 2 openings.
V.
Ventilation Type 2 openings.
l I.
Instrumentation Type 2 openings.
NOTE
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HIJ portions of the pour numbers should coincide with the last three characters of the Gibbs & Hill block-out designation.
l l
i Reason for change:
To develop pour numbers for Type 2-pour-blocks.
(
This change pprove by:
fAWhl
/2/kr hlk) lW'N Department Head
'Date al y Assurance 7 Date Reviewed By:
N he d I z-lrs h 8 ha, /I, WW Procedures & Reports W jg.fy.
Date
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PROCEDURE ISSUE i
CPSES NUMBER I
REVISION DATE I
PAGE JOB 35 '1195 i
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1.0 REFERENCES
1.
B&R Engineering Instruction 35-1195-CEI-12, i
"High Density Concrete" 2.
ASTM C-150, Specification for Portland Cement.
3.
B&R Construction Procedure 35-1195-ACP-3, " Material Receiving, Handling, and Storage".
4.
ASTM C-33, Specification for Concrete Aggregates.
5.
U.S. Army Corps o'f Engineers Specification CRD-C119, Method of Test for Flat and Elongated Particles in Coarse Aggregate.
6.
ASTM C-494, Specification for Chemical Admixtures for Concrete 7.
ASTM C-260, Specification for Air-Entraining Admix-tures for Concrete.
8.
ASTM C-94, Specification for Ready-Mixed Concrete.
9.
ACI 301-72, Specification for Stru tu 1
onprete for Buildings g/
10.
B&R Construction Procedure 35-1195-CCP-11
" Concrete Placement" lf
'1 h i
- 11. ACI 305-72, Recommended Practice for Hot Weather f{
Concreting.
sc M
- 12. ACI 614-59, Recommended Practice for Measuring, Y
Mixing, Transporting, and Placing Concrete.
13.
Brown & Root Quality Control ruction Procedure x>
gcf No. CP-QCP-2.2.
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BROWN & ROOT, INC.
PROCEDURE TSSUE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 l
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12/4/78 I
3 of 20 2.0 GENERAL l
2.1 PURPOSE 2.1.1 The purpose of this doc" ment is to.. set forth the methods and pro-cedures that will be en. ployed in the receiving, handling and stor-ing of concrete materials and the batching, mixing and delivery of concrete.
2.2 SCOPE 2.2.1 The scope of this procedure covers the methods and procedures that apply to receiving, handling and storing of concrete materials and the batching, mixing and delivery of concrete including grout.
2.3 DEFINITIONS 2.3.1 ACI American Concrete Institute ASTM American Society for Testing & Materials TUSI Texas Utilities Services, Inc.
2.4 SPECIAL ITEMS AND OPERATIONS 2.4.1 High density concrete and its ass 6ciated materials and properties which are distinct from the other classes of concrete are discussed
{
in Reference 1.
j 2.5 FUNCTIONS AND RESPONSIBILITIES l'
2.5.1 Project Civil Enoineer - Maintains over-all technical assistance
'1 Tor concrete batch plants, concrete materials, trucks and l
associated equipment.
(CONTINUED ON NEXT PAGE) i l
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i ISSUE BROWN & ROOT, INC.
PROCEDURE CPSES NUMBER REVISION DATE I
PAGE JOB 35-1195 I
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12/4/78 I
4 of 20 1
2.5.2 Concrete Superintendent
)
a.
With the technical assistance and engineering information of the Project Civil Engineer, maintains oveF-all responsibilities for concrete batch plants, concrete materials, trucks and associated equipment.
b.
Supervise all phases of the concrete batching, mixing and truck delivery operations.
I Supervise all phases of concrete material receiving, handling j
c.
and storing.
d.
Assures that activities are performed in accordance with this proc edure, Assures that activities are performed in accordance with appli-e.
cable manufacturers equipment operating procedures and mainten-ance procedures.
f.
Maintains daily production records and reports applicable to his responsibilities.
3.0 PROC $ DURE 3.1 CEMENT 3.1.1 Portland Cement shall comply with ASTM C-150, Standard Spec-ification for Portland Cement, and shall be Type II and low alkali (0.60". maximum) in accordance with the requirements of Table 1A therein.
3.1.2 Except as otherwise approved by TUSI, all cement shall be of the same brand and manufactured at the same mill.
3.1. 3 A manufacturer's certified material test report attesting to the conformance of the cement to ASTM C-150 shall be furnished for each shipment.
3.1.4 Cement will be received in bulk truck transports and will be
~
pneumatically loaded into clean, uncontaminated, water-tight storage silos or storage tanks at either the main batch plant or back-up batch plant where it shall remain until concrete is ba tched.
3.1.5 Warehousing shall receive cement trucks per Reference 3, and inspect certified material test report and inspect seal on truck hatches to insure thet it is intact. Certified material test report will 'be retained by warehousing and distributed to QA per Reference 3.
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NUMBER REV!STON DATE PAGE i
CPSES l
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i 3.2 AGGREGATE 3.2.1 Fine aggregate (sand) shall be graded according to the require-I ments of ASTM C-33.
3.2.2 Nominal size 3/8 inch coarse aggregate shall conform to size number 8 of Table 2 in ASTM C-33.
l 3.2.3 Nominal size 1/2 inch coarse ag'grega'te shall conform to the requirements of Section 202, Aggregate, of ACI 506, Recommended l
Practice for Shotcreting.
1/2 inch coarse aggregate shall be i
uncrushed gravel, graded from No. 4 to 1/2 inch size.
3.2.4 Nominal size 3/4 inch coarse aggregate shall conform to size number 67 of Table 2 in ASTM C-33, 3.2.5 Nominal size 1 1/2 inch coarse aggregate shall conform to size number 467 of Table 2 in ASTM C-33.
3.2.6 The following are descriptions of aggregate properties (except for l
1/2 inch coarse aggregate which is fully described in Section 3.2.3).
3.2.6.1 Aggregate shall consist of natural or manufactured sand, crushed stone, or gravel. The particles shall be clean, hard, tough, dur-able, of uniform quality and shall be free from soft thin, elongated, l
disintegrated stone, dirt and organic or other injurious materir.s I
occurring either free or as a coating. The aggregate when incorpor-I ated in concrete, shall satisfactorily resist chemical or physical changes such as cracking, swelling, softening, leaching or chemical i
alteration, and shall not contain contaminating substances which might contribute to deterioration or unsightly appearance of the concrete.
3.2.6.2 The coarse aggregtte shall be well graded and shall consist of gravel, crushed gravel, crushed rock, or crushed stone fragments f
which are clean, rough, hard and uniform.
No blast furnace slag, schist, shale or slate shall be permitted.
3.2.6.3 The potential reactivity of the aggregate shall be established by the methods described in the Appendix to ASTM C-33.
3.2.6.4 Aggregate shapes shall be rounded or cubical and shall contain less than 15 percent (by weight) flat and elongated particles as deter-mined by the U. S. Army Corps of Engineers Spec. CRD-Cll9, Method of test for Flat and Elongated Particles in Coarse Aggregate. ' A flat particle is defined as one having a ratio of width to thickness greater than three: an-elongated particle is defined as one having a ratio of length to width greater than three.
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PROCEDURE ISSUE CPSES NUMBER REVISION DATE PAGE JOB 35-1195
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12/4/78 6 of 20 3.2.7 Fine and coarse aggregates will be off-loaded from truck trans-ports into hoppers for conveyor transfer to aggregate stockpile bins which shall be arranged and operated to, prevent contamination by different gradations or types of aggregates and to assure that there is pratical minimum segregation.
3.2.8 As an exception to Paragraph 3.2.7, fine and coarse aggregates may be off-loaded and stored in outside uncovered aggregate stock-pile bins.
These aggregates shall be stored and main-tained in a manner that will avoid the inclusion of any foreign materials in the concrete.
No muddy or oil leaking traction equipment shall be allowed to operate on storage piles.
The placing of the material in storage and its removal shall be done in such a manner as to maintain the uniformity of the gradation.
The aggregate stockpiles in the outside uncovered bins shall be on concrete slabs, and shall have suit-able drainage.
The aggregate storage piles shall be built and maintained to prevent segregation and excessive breakage.
If.
required, suitable bulkheads between specific size groups or aggregate shall be provided to preclude intermixing of the different size groups.
3.2.9 Warehousing shall receive aggregates per Reference 3, and inspect loads to insure conformance to aggregate quality per this construction procedure.
3.2.10 Aggregate hoppers and conveying equipment shall be cleaned, as necessary, to prevent contamination by different gradations or tyoes of aggregates and to assure that there is practical minimum segregation.
3.2.11 Access for inspection shall be provided in stockpiles at all times.
3.2.12 Each lot of aggregate shall be identified by signs which show size, gradation, source and controlling specification.
3.2.13 In event of equipment failure, temporary measures shall be initiated and approved by the Concrete Superintendent to insure quality is maintained. All efforts shall be made to expedite repair of original equipment for operation.
3.3 AGGREGATE GRADATION FAILURE 3.3.1 In the event aggregate fails to meet the specification grada-tion requirements, the material represented by the failing test results shall be remixed, reblended or scrapped at the discretion of the Brown & Root Concrete Superinterdat or his designee.
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PROCEDURE ISSUE I
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12/4/78 I 7 of 20 3.3.2 Remix shall be accomplished by discharging material. from one or more of the aggregate storage bins into the backup charging j
conveyor belt, into clean dump trucks, and unloading this mate-rial into the aggregate receivi.ng hopper back into the respec-i tive storage bins via the bin (s) receiving conveyor belt and l
rock ladder (s).
This procedure shall be repeated until, in the judgement of the Brown & Root Concrete Superintendent or his i
designee, the material has been thoroughly remixed. At this time, retest (s) may be requested by the Concrete Superinten-dent or his designee to check if material is within specifica-tion gradation..
3.3.3 In the case of failing gradation re-test results, it may be requested by the Concrete Superintendent or his designee to elect to scrap or re-blend the material.
If, after review of the test results, it is determined that re-blending is practical and would result in an acceptable graded ma;erial, it shall be performed by the procedure described abcve with the exception that another tested and approved si;e(s) aggre-gate shall be injected at the time the material is recycled into the storage bin (s) receiving hopper in quantities pre-scribed by the Concrete Superintendent or his designee.
1 Note that only gravel-to-gravel and stone-to-stone additions l
shall be made.
3.3.4 To ensure material is within specification limits before use, I
re-sampling and re-testing shall be performed af ter re-blending.
I 3.3.5 In order to prevent the use of disapproved aggregate, the QC Batch Plant Inspector shall notify the Concrete Superinten-j dent or his designee, in writing before each da operation, as to which aggregate storage bin (s)y's batching.
i are approved for use.
I 3.4 RESCREENING AGGREGATE i
3.4.1 Approved concrete aggregate may be rescreened to meet another ASTM Grading size only if tested and accepted aggregate is und.
3.4.2 The aggregate shall be removed from the batch plant aggregate storage bins, loaded into dump trucks and hauled to the on-site screening plant.
The aggregate handling equipment shall be l
clean and maintained in a manner that will avoid contamination i
l of the aggregate.
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3.4.3 The screening plant shall be equipped with the proper size screens to produce the aggregate gradation desired.
The screening plant aggregate hoppers and conveyors shall be cleaned of foreign material to prevent contami, nation of the aggregate being produced.
Screens shall be in good condition and free of any rips, tears, etc.
3.4.4 The aggregate shall then be delivered to, and stored in one of the approved aggregate storage bins at the batch plant.
Different size aggregates shall not be intermixed within a bin.
Each lot or bin of aggregate shall be indentified by signs which show size', gradation, source and controlling s pecifica tion.
3.4.5 A monitor gradation sample may be taken from the belt at the screening plant or from the stockpile at the batch plant and tested to ensure aggregate is within the ASTM specification grading size required.
However, the aggregate shall be sampled, tested and accepted prior to hauling to the storage bin (s).
3.4.6 Aggregate meeting grading requirements of ASTM No. 7 (h inch) may be used in concrete or shoterete providing a mix design has been previously approved by the Engineer.
Only aggregate from an approved storage bin shall be used.
3.4.7 If material finer than No. 200 sieve exceeds maximum limits of 1.0% the aggregate may be washed to remove dust or finer mat-erial.
The aggregate shall then be resampled and tested as necessary for acceptance.
3.5 ADMIXTURE 3.5.1 Type A, water-reducing admixture, shall comply with ASTM C-494.
3.5.2 Accelerating admixture for shoterete shall be a liquid per ASTM C.-494 or a solid per Challenge-Cook patented formulation named "C hal l o g ".
3.5.3 Type D, water-reducing and retarding admixture, shall comply with ASTM C-494.
3.5.4 Air er, training admixture shall comply with ASTM C-260.
3.5.5 Manufacturers certificates as to analysis and composition of the admixture shall be furnished.
3.5.6 Admixture shall be in accordance with the recommendations of the cement manufacturer.
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5 9 of 20 3.5.7 Type A, Type 0 and air entraining admixtures shall be unloaded, by pump, from bulk truck transport or drums into uncontaminated storage tanks which shall be clearly marked as to their _ contents, j
storage requirements and controlling specification.
3.5.8 Warehousing shall receive admixtures per Reference 3, and inspect j
manufacturers certificate and/or spectrographic analysis and dis-L tribute to QA per 35-1195-ACP-3.
3.5.9 Accelerating admixture for shotcrete shall be stored per manufac-l turer'.s recommendations.
'j 3.5.10 All admixtures shall be protected from moisture and temperatures j
that could adversely effect their performance as per manufacturers' t
recommendations.
I 3.6 WATER 3.6.1 Water for mixing concrete and sprinkling aggregates, if required, shall be clean, fresh and free from deleterious amounts of acids, alkalis or organic materials.
3.6.2 Mixing water shall comply with tests required by Engineer specifi-l cations.
i 3.6.3 Water shall be pumped from a deep well(s) and transferred to an uncontaminated storage tank (s).
3.6.3 Water for ice shall be pumped from the storage tank into an ice-plant where ice shall be manufactured and stored as to prevent contamination.
3.7 CLASSES OF CONCRETE 3.7.1 Concrete is designated by classes according to the required com-pressive strength at 28 days. The class to be used in each part i
of the work will be shown on drawings, or will be designated by
[
the Engineer.
The method of' determining the 28-day strength shall be in accordance with pertinent ASTM standards.
The site test lab j
will furnish mix designs for the following standard classes:
J a.
Class 1 Concrete
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Compressive Strength, 4000 psi 3/4,1/2 or 3/8 inch maximum aggregate b.
Class 2 Concrete Compressive Strength, 4000 psi 1-1/2 inch maximum aggregate c.
Class 3 Concrete Compressi,ve Strength, 2500 psi f
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Class 4 Concrete (miscellaneous) i e.
Class 5 Concrete
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Compressive Strength, 3000 pst.
3/4 or 1/2 inch maximum aggregate I
i f.
Class 6 Concrete enmpressive Strength, 3000 psi 1/2 inch maximum aggregate 9
Class 7 Concrete Compressive Strength,1500 psi 1 1/2 inch maximum aggregate l
h.
Shotcrete, Class 8 Compressive Strength, 3000 psi i
l 1/2 inch maximum aggregate i.
Grout, Class 9
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3.7.2
" 5ss concrete" is concrete which is greater than 2 feet-6 inches in the least dimension.
Maximum temperature for " mass concrete" is 704 at placement.
3.7.3 Concrete Slump 3.7.3.1 The maximt m allowable slump for concrete at the point of place-ment shall be as follows:
Cl a s s A, B', a nd C................... 4 i nches Class D............................
Cla ss E and F.......................
3 h inc he s 5 inches 3.8 BATCHING l
3.8.1 The fine and coarse aggregate will be weighed in a single batcher using cumulative weights to within a plus-or-minus one percent tolerance by weight.
3.8.1.1 Adjustments of Aggregate Weights 6
The acceptable range for fineness modules (F.M. ) of sand is 2.3 to 3.1.
however, in order to meet the intent of Section 3.5 of ASTM C33, the following steps are incorporated into the batching procedure.
These steps describe the aggregate weight adjustments that are required because of the different values of sand F.M.
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PROCEDURE ISSUE
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CPSES NUMBER REVISION DATE PAGE JOB 35-1195 35-1195-CCP-10 5
12/4/78 11 of 20 within the acceptable range of 2.3 to 3.1.
i a.
The sand F.M. value for a day's production will be the average of the test lab reports given to the i
batch plant prior to batching.
b.
Design weights of sand and' coarse aggregate shall be i
used when the sand F.M. is between 2.5 and 2.9.
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c.
When the sand F.M. is less than 2.5, the weight of coarse aggregate shall be increased by 52 lbs. per cubic yard of concrete, and the weight of sand shall be decreased by the same amount.
d.
When the sand F.M. is greater than 2.9, the weight of coarse aggregate shall be decreased by 52 lbs.
per cubic yard of concrete, and the weight of sand shall be increased by the same amount.
3.8.2 Cement will be weighed in a batcher to within 1 percent tolerance
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by weight.
i 3.8.3 Water and ice will be weighed in separate batchers to within a 1 percent tolerance by weight.
3.8.4 Air entraining admixture, Type A admixture, and Type D admixture will each be measured by. volume, in separate containers to within a tolerance of 3 percent.
3.8.5 Tolerance interlocks are provided to prevent a discharge device from being actuated until the material has been batched within applicable tolerances.
3.8.6 The batchers are equipped with platforms so that an overweight or sample can be removed.
3.8.7 All scales used in weighing concrete mix materials and volumetric measuring devices for admixtures will be calibrated in intervals not exceeding 90 days.
3.8.8 In the event the automatic ticket printer breaks down, the plant operator will fill out the ticket manually, using pen with black ink, to record the actual weights read from the scales.
3.9 CFNTRAL MIXING 3.9.1 Mixing equipment will produce uniformity of consistency, cement and water content, and aggregate grading, from beginning to end of each batch.
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3.9.2 The mixer operating time will be regulated to the required mixing performance in the minimum amount of time as determined by perfor-mance tests or minimum time per ASTM C-94.
Test results shall be retained by the Concrete Superintendent.
l 3.9.3 Batch size will not exceed 10 c.y. ' Controls shall be provided to insure that the batch cannot be discharged until the required mix-ing time has elapsed.
3.9.4 Mixer blades shall be replaced when they have lost 10 percent of their original height. Concrete Superintendent or his repre-sentative shall perform a quarterly enecs i;o insure conformance.
3.9.5 Accumulated hardened concrete shall be removed, as necessary, to maintain peak mixer performance and efficiency. Concrete Super-intendent shall insure conformity.
3.9.6 Admixtures shall be mixed into batch in accordance with Section 7.3 l
of ACI 301-72.
3.9.7 Tempering and control of mixing water shall be in accordance with Section 7.5 of ACI 301-72.
3.9.8 Cold weather mixing and temperature of delivered concrete shall be in accordance with Reference 10.
3.9.9 Hot weather mixing shall be in accordance with Section 7.6.2 of ACI 301-72, except that for " mass concrete", the maximum tempera-~
ture of concrete as placed shall be 700F instead of the 900F maximum permitted by ACI-305.
3.9.10 Central mixing controls provide for monitoring slump by means of a slump meter. Also, the slump will be checked periodically by visual inspection of the truck mix.
3.10 TRUCK MIXING 3.10.1 While Loading, the mixer drum will be rotating at a speed designated by the manufacturer as mixing speed.
3.10.2 Each batch of concrete shall be mixed not less than 70 or more than 100 revolutions of the drum at mixing speed. Any additional drum revolutions shall be done at the rate of. rotation designated by the manufacturer of the equipment as agitating speed.
3.10.3 The slump will be checked periodically by visual inspectt' af the truck mix.
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PROCEDURE ISSUE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 35-1195-CCP-10 5
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13 of 20 3.11 DELIVERY OF CONCRETE IN TRUCK MIXER TO POINT OF PLACEMENT 3.11.1 When a truck mixer contains concrete that has been completely mixed in the stationary mixer at the Main Batch Plant or concrete I
that has been completely truck mixed, any turn'ing of the drum during transportation shall be at agitating speed.
3.11.2 When the ambient temperature is 850F or below, the time after the addition of water to the dry materials until placement shall not exceed 90 minutes.
When the ambient temperature is 0
above 85 F, the time shall not exceed 45 minutes except when permitted by the Engineer on a cese-by-case basis.
3.11.3 The number of drum revolutions shall not exceed 300 after mix water is added to the dry materials.
3.11.4 Each mixer truck will be equipped with an accurate revolution counter.
3.11.5 Add Water 3.11.5.1
" Add water" may be dispensed into the truck mixer at point of place-ment in order to increase slump to meet specification or to increase workability of mix.
3.11,5.2 Sampling Mix a.
If for reasons stated in 3.11.5.1 it is determined that add water will be dispensed into truck mixer, then a sample from the mix, after add water and after truck mixer has revolved 30 times at mixing speed, must be slump tested before dis-
- charge, b.
Preceding procedure may be repeated as necessary before mix discharge until desired slump or workability is attained.
3.11.5.3 Maximum slump shal'1 not be exceeded as a result of the addition of add water to the mix.
3.11.5.4 Quantity of add water shall not exceed quantity recorded for " add water" on the batch ticket.
3.11.5.5 Add water will be measured by the sight glass or calibrated container to the nearest whole gallon and quantity shall be so noted on batch ticket in " ADD WATER" block.
3.11.5.6 Responsible cottractor representative and testing lab representative will each sign within the block, before water is added, to verify that the add water about to be added does not result in the total add water quantity exceeding the quantity recorded for " add water" on the batch ticket.
For shotcrete, a B&R QA/QC representative may sign in place of the tgab representative.
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PROCEDURE ISSUE CPSES NUMBER REVISION DATE PAGE i
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12/4/78 i 14 of 20 3.11.5.7 CALCULATION OF ALLOWABLE " ADD WATER" The cards will be punched to show the total " design water" or less, such as 2301b/cy for Mix I.D. No. 202.
The batch plant operator will deduct water as outlined below,using the s' ump control meter.
This deduction will be sufficient to provide required slump for the mix classification, i.e., 4" for Class A, B, and C Concrete.
For Aggregate Moisture compensation, the batch plant control system automatically subtracts the free moisture contained by the fine aggregate from the total " design water" (230 lbs. for Mix I.O. No. 202).
The free moisture in the coarse aggregate l
is calculated by the B&R batch plant personnel using the latest l
Hunt report on the C.A. moisture. The quantity obtained by sub-tracting the F. A. free moisture + C.A. free moisture from the total " design water" is the " maximum amount" of water which is allowed to be dispensed into the mix.
If the " maximum amount" of water is not dispensed at the batch plant, then " add water".
may be added into the truck mixer later at the point of dis-c harge.
The allowable " add water" is calculated by subtracting the " water dispensed at batch plant" from the " maximum amount" and is written by B&R batch plant personnel in the Add Water block on the batch ticket.
Add Water = Design Water - (F.A. free moisture)
- (C.A. free moisture) - (water dispensed at batch plant) 3.11.6 Same as Section 3.9.4.
3.11.7 Same as Section 3.9.5.
l 3.12 TICKETING SYSTEM l
3.12.1 Ticket Description The purpose' of the batch ticket (Figure 1) is to record informa-tio~n concerning each batch of concrete.
Following is an explana-tion of the information blocks on the ticket:
1.
Mix ID:
explained on Mix Identification sheet (Attach-ment No 1) 2.
Batch Size: Volume of batch (1/100 CY) 3.
Batch No.:
number of consecutive batches produced by the plant, e
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CPSES hUMBER REVISION DATE I
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M. C. Setting: compensates for moisture content in the fine aggregate (1/10 percent) 5.
Plant:
1 - Back-Up Plant 2 - Main Plant 6.
Agg.1, Agg. 2, Agg. 3:
cumulative coarse ag weigh'ts (lbs/ Batch) gregate i
7.
Sand:
cumulative coarse aggregate weights plus fine-aggregate weight (lbs/ Batch) 8.
Cement: cement weight (lbs/ Batch) 9.
Admix 1: Master Builders MB-VR air entraining admixture, meets ASTM C-260 requirements (1/2 fl. oz/ Batch)
- 10. Admix 2: Master Builders Pozzolith 300-R water-reducing and set-retarding admixture, meets ASTM C-494 for Type D requirements (1/2 fl. oz/ Batch)
- 11. Admix 3: Master Builders Pozzolith 300-N water-reducing admixture, meets ASTM C-494 for Type A require-ments (1/2 fl. oz/ Batch) 12.
Ice:
ice weight (lbs/ Batch) 13.
Water: cumulative ice and water weight (ibc/ Batch)
- 14. Area Pour Section:
explained on Pour Number sheet (Attachment No. 2) 15.
Sand Moist: moisture in fine aggregate (1/10 percent) 16.
Truck No.
- 17. Agg. Tare: aggregate batcher tare weight
- 18. Cem. Tare: cement batcher tare weight 19.
Water Tare:
ice and water batchers weight 20.
Time
- 21. Add Water: allowable add water (1/10 gals./CY)
- 22. Ticket No.
23.
Date
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3.12.2 Ticket Rout,i,ng and Sign-Off:
1.
After betching is complete, b1ch plant r$ preventative signs i
ticket which verifies that inror'mation on ticket is correct and retains blue copy of ticket'for batch plant records.
?
The truck driver delivers white original and remaining two 1
2.
copies of ticket to point of concrete placement.
l 3.
If add water is dis;'ensed into batch, General Contractor Representative and Test Lab Representative both sign in their respective spaces in the add water block on the right side of ticket per paragraph 3.11.5, " Add Water".
For
's shotcrete, a B&R QA/QC representative may sign in place of the test lab representative.
t 4
If no " required in-process test" are being performed on the f
concrete batch, the General Contractor Rep. signs in space ~
j at bottom of ticket.after he is satisfied that information on ticket is correct and that the concrete batch is accept-i a bl e.
- 5. ' White original and two copies of ticket are then returned by
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truck driver to batch plant where they are given to Concrete l
i Superintendent or his representative.
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6.
Concrete Superintendent distributes daily the following-a.
white original to Test Lab l
l b,
pink copy to Engineer (if Engineer se requests) yellow copy to B&R Cost Engr. Dept.
c.
3.13 MAINTENANCE OF EQUIPMENT 3.13.1 Maintenance records of equipment shall be kept by the Concrete Superintendent.
I 3.13.2 Manufacturers' operating instructions for major equipment shall be available at the batch plant.
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BROWN & ROOT, INC.
PROCEDURE ISSUF CPSES NUMBER REVISION DATE l.
PAGE JOB 35-1195 q
l 35-1195-CCP-10 5
12/4/78 18 of 20 j
)
ATTACHMENT 1 MIX IDENTIFICATION ABC I.
Ilix ID Number j
- h. Class Number 1.
Class 1 Concrete f
Compressive Strength, 4000 ps1 3/4 or 1/2 or 3/8 inch maximum aggregate 1
2.
Class 2 Concrete Compressive Strength, 4000 psi 1-1/2 inch maximum aggregate 3.
Class 3 Concrete Compressive Strength, 2500 psi l
4.
Class 4 Concrete (Miscellaneous) 5.
Class 5 Concrete Compressive Strength, 2000 psi 3/4 or 1/2 inch maximum aggregate 1
6.
Class 6 Concrete Compressive Strength, 3000 psi 1-1/2 inch maximum aggregate 7.
Class 7 Concrete l
Compressive Strength,1500 psi 1-1/2 inch maximum aggregate 8.
Shotcrete, Class 8 Compressive Strength, 3000 psi 1/2 inch maximum aggregate 9.
Grout, Class 9 BC. Mix Number Numbers 00 thru 99 will define different mixes of a particular class. For example a need may exist for Class 1 concrete to have two mixes with different cement contents.- Therefore, different mix numbers will be assigned to distinguish between the mixes.
II. All approved mix designs,' mix design variations and mix identi-fication numbers shall be issued on an up-to-date list by the B&R Const.'Jetion Engineering Depe@nent.
N
I
=-
BROWN & ROOT, INC.
PROCEDURE EFFECTIVE l
CPSES NUMBER REVISION DATE PAGE 1
i JOB 35-1195 C CP-10 5
'12/04/78 19 o f 20 ATTACHMENT 2 POUR NUMBER AB C-PEFG-HIJ -
4.
Unit De signa t ion 0 - Common Building 1 - Unit i 2 - Unit 2 B C.
Work Area as follows:
01-21 BUILDINGS 01 Co nta inme nt 02 Auxiliary
]
03 Fuel Randling Building l
04 Turbine Gener ator Building 05 Sa feguards Building 06 Mainte nance Building 07 Administration Building 08 Electrical Duct Ba nks 09 Sat.itary Sewer Manboles 10 Storm Sewer Catch Basins l
11 Pipe Tunnel 12 Misc. Yard Valve Pits 1
13 Transformer Area Foundations 14 Main Transformer Foundations 15 Auxiliary Trans former Foundations 16 Misc. Ta nk Founda tions 17 Misc. Yard Structures l
18 Re fueling Water Storage Tank i
19 Condensate Storage Tank l
20 Reactor Make-Up Water Storage Tank i
21 Electrical Manholes l
22 011 Spill Containment Dams & Footings at Switchyard 23 Class 1 Electrical Ductbanks Train A 24 Class I Electrical Ductbanks Train B 25 Class I Electrical Manholes Train A l
26 Class I Electrical Manholes Train B l
27.
Relay House l
28 Waste Management System 29 OPEN 30-39 CIRCULATING WATER & ESSENTIAL COOLING WATER FACILITIES 30 Circulating Water Intake Structure l
31 Circulating Water Intake Tunnels CCP-10 Rev. 5 DCN #1 06/01/84 Sheet.2 of 4
1 1
BROWN & ROOT, INC.
PROCEDURE EFFECTIVE CPSES NUMBER REVISION DATE PAGE 1
JOB 35-1195 CCP 5 12/04/78 20 of 20 ATTACHMENT 2 (CONT'D) 32 Circulating Water Discharge Structure 33 Circulating Water Discharge Tunnels
./
34 OPEN 35 Service Water Intake Structure -
l 36 Service Water Discharge Structure
)
37 Squaw Creek Service Spillway 38 Squaw Creek Outlet Facilities 39 Pump Station 40-41 MAJOR EQUIPMENT FOUNDATIONS 40 Turbine Pedestal s
41 Steam Generator Feed Pump Pedestal 42-49 OPEN 50 Po tab le Wa te r Ta nk Founda t ion 51-59 OPEN 60-99 MISCELLANEOUS D.
TYPE OF STRUCTURES AS FOLLOWS:
0.
Floor Topping 1.
Fill Slabs or Seal Slabs 2.
Footing s & Ma t s 3.
Floor Slabs on Earth 4
W lls-Interior a
5.
Walls-Exterior 6.
Columns 7.
Elevated Slabs or Beams 8.
Roof Slabs or Dome 9.
Other Structures M.
Mechanical Type 2 openings E.
Electrical Type 2 openings V.
Ventilation Type 2 openings I.
Instrumentation Type 2 openings NOTE:
HIJ portions of the pour numbers should coincide with the last three characters of the Gibbs & Hill block-out de signa t ion.
CCP-10 Rev. 5 DCN #1 06/01/84' Sheet 3 of 4 w.
~
.o e
BROWN & ROOT,.INC.
PROCEDURE EFFECTIVE CP5ES NUMBER REVISION DATE PAGE l
JOB 35-1195 CCP-10 5
12/04/84 20a of 20 ATTACHMENT 2 (CONT'D)
EFC.
%2VATION Use top of concrete elevation for all slabs, foo tings, mats, beams, and dome. Use bottom of wall. or' colu:nn section elevation for all walls and columns.
On ductbanks, the G6H ductbank number will be used instead of the elevation.
On manholes, the G&H manhole number will be used instead of the elevation.
H.
OPEN IJ.
POUR NUMBER I
'I CCP-10 Rev. 5 DCN #1 06/01/84 Sheet 4 of 4 f
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ISSUED Nol
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'09/17/81' Ssc. 9.0 IDENTIFICATION AND REvi!ED PAGE CONTROL OF ITEMS 00T 91 sooa i of a U W bF --
1
,a SCOPE 3
4
'I 5
This section establishes the controls for assuring that.
]
6 items and materials, including partially fabricated 7
I e
subassemblies, retain their identification and required s
traceability from time of receipt through installation.
10 11 12 9.2 METHOD OF IDENTIFICATION 13 14 is Materials and items shall be identified by. markings which will not result in harmful contamination-or sharp 17 discontinuities.
Identification may be by stenciled, etched l
19 or indented markings, strip. markings,- imprinrad tape, color 1
20 coding or tags.
Stamping, when used, shall be done.with low stress stamps.
2, j
23
.I 4
24 i
Such identification shall be legible and shall be located 2$
l 26 in areas that will not interfere with the function or f
27 quality aspects of the item.
l 28 29 30 31 32 l
33 i
34 35 EXHIBIT 36 37 36 i
39
+ -............
l -'
i
- DO NoT REPRooUCE OA432 0 (11-81) ',
PbSPdo()(
vrv tw
____..___..___2
isdfitsl?/81 NO. Sac. 9.0 i
IDENTIFICATION AND I
%k%
CONTROL OF ITEMS ebvisf'oC, 311984 PAGE cf 4 i
1 2
3 9.3 IDENTIFICATION DURING RECEIVING 5
l 7
During receiving inspection, the Receiving Inspection Group 8
(RIG) shall verify that the materials and items have identification markings to as required by the purchase order 11 and/or appropriate receiving inspection instructions.
12 13 1d 9.4 MATERIAL ISSUANCE 15 16 17 All items and materials, except welding materials (See
\\
Sec. 10), shall be issued from storage by means of a I
)
Material Requisition form (MR; Exhibit 9.1) prepared by the
,o 21 craft superintendent.
The MR shall contain, as a minimum, e
22 the following information:
23 24 a.
Item description; 8'
b.
Quantity requested; and I
26 E
c.
Intended use to to Item identification (e.g. heat number or code, tag number, 30 or serial number); is entered on MR by warehouse personnel.
Di 32 33 RIG shall verify that material is as specified on the 3,
25 MR and acceptable for release to construction and shall 3e document the verification by dated initials /s3.gnature on 37 3a the MR.
l 39 40
?
DO NOT REPR00UCE
....., +
ISSUEo No.
09/17/81 Ste. 9.0 d
IDENTIFICATION AND CONTROL OF ITEMS r.Db7 311984 PAGE 3 of 4 1
2 9.5 MARKING TRANSFER 3
4 s
Material shall carry identification markings which will 6
remain distinguishable until the item is assembled or 7
installed.
Identification of assembled or installed items,.
8 requiring heat number / heat code traceability, shall be I
so documented by the QC Group on fabrication and/or inspection is records.
13 f
1
'k If the original identification markings will be cut 33 off or 16 the e.aterial is divided, the markings shall be transferred
{
l 57 by construction prior to division.
The QC Group shall
)
18 s
so verify prior to the division of material that the markings have been properly transferred.
This verification shall be 21 documented by the QC Group's dated signature on the 23 Manufacturing Record Sheet (MRS; Exhibit 10.13) or the 2
i 24 Material Identification Log (MIL; Exhibit 9.2), for piping 25 and component supports, respectively.
2e 27 28 29 1
30 31 32 34 35 36 1
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37 36
.30..._.......
40 oo Not REPAoDUCE CA 022 0412-81 I
'85d6717/81
"' Sac. 910 IDENTIFICATION AND CONTROL OF ITEMS N 817984 N of'4 1
2 9.6 NAME PLATES FOR N-STAMPED COMPONENTS 3
4 At the time of fitup or mechanical installation inspection, e
the QC Group.shall verify that N-stamped items have a Code 1
l name plate attached, and enter the serial number of the Code i
i a
name plate on the Weld Data Card or the Operational Traveler.
If the Code name. plate is missing the item shall be handled n
in accordance with Section 16.0.
13 14 l
9.7 LOSS OF IDENTIFICATION 15 16 t
Materials or items for which the identification cannot be
{
16 established on the material, or documentation traceable to 19 l
ro the material, shall be considered nonconforming and shall be l
handled in accordance with Section 16.0.
f 22 1
23 1
2d 25 26 27 28 29 30 31 32
)
i 34 33 36
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37 38
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.m 40
,./
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Do NoT REPRoDUCT__..
./
oA 032 0 tit.t1 4
- _.. _.._