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t "ASE Exhibit 99 - Ps6e @
TXX-667 .ry 4, 1975 Dr. D. F. Knuth Director Nuc1 car Reculatory Co : .ission Of fice of Incpection and Enforececnt -
Washington, D. C. 20555 COMA!4CHE PEAK STE.'w'i ELECTRIC f.T.'.TIO!; .
TIACTOR IiUILDI::G CCAVAT10:; I yILE !;0. 10105
Dear Dr. E..uth:
In accordance with the rc quircuents of 10Cin50.55 (e)(1)(IV) and in the intcrcst of centerv-tim, re ar e r.ubri t t i n- tbs s elle. tire. des cript.% . e .'
a possibic dc*1ciency wh. .. . vu tvec durm . tne umse cat w .. oan for Units 1 and 2 Reactor buildinns.
On January 23, 1975 the structural e:-:cavation, to apprcxir.,tc.ly elevatien 793, fer Unit No. I centsin cit benan. As the cr.svatien and geologic c:rping pre ; rest.ed it bcen- n:parcnt that thcre had been a noticeable amount of overbrent anJ/or fracturin., of the rcch, which was to have rc::sined in place around the c::covation perinctc: .
Followin:; a nectinr. between reprenentativer. of Droen & toot, Inc.,
Mason-Johncton li Associater. and 'ic:<su i t.;11 ties Generatina Cen.p:r.y.
the blastinC techniquec which had baen used on Unit I;o. I contain-ment were nodified. The initial bisst for excavation to elevation 793 on Unit No. 2 was acccuplished on 1/25/75. After the binsted asterial vss removed, visus 1 incpecticii" revealed very littic, if any, dair.sgo to t he perincter vs11s.
L A formal report outlining the construction procedurcs, invectinstdvc j progra:: utilized to determine the c:: tent of the rock dar.sge and analysis of the cafety implications and cc.rrective action required
.. vill be forwarded to you within the ne::t 30 days.
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It vc esy provide additional information during the interim ;criod, picace !
( advice.
l4 Very truly yourc, f<.-{~ k l d C~ S - 4,,,;,:.,, .
),obert W. Csedic
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8905040318 890425 PDR FOIA BAUMAN87-535 PDR
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Figure'2.7-3 REQUEST NO 33
- TEXAS UTILITIES SERVICES, INC.
COMANCHE PEAK STEAM ELECTRIC STATION ,
l FIELD INTERPRETATION / CLARIFICATION REQUEST (
APPLICABLE SPEC /I N E1_=> m v 2323-SS-6 JtEVISION: 1 ISSUED DATE 3-18-75 j X SAFETY RELATED L STATEMENT OF PROBLEM OR QUESTION:
(Attach reference, in7 airy, if available)
Contract.e requests approval to pressure grout fractured rock in the Safeguard Building (Unit 1) as noted on FDCR No. 0189 (attached) .
_ 0, Requested by:BLR FDCR-0189 2-19-76 Organization Date Prepared by c
'v \how Date 2-25-76 j
2.
DEDEERING REPLY: (Attach confirming letters, etc.)
Paragraph 7.0 of subject specification states:
) All excavations for plant structures shall be examined by the Geologist who shall certify to the integrity oI cne material against which concrete is to be placed. For those parts of the excavation that art not acceptable ne sna11 prescrioe Lne corrective action recuired to make them acceptable.
Per Mason-Johnston letter MJF-CH-5 (attached) the geologist has concurred with the proposed grouting procedure.
1
- VE RD%W.DD 'IEAT COTDUCIGR (IS), ODD 2DT) AITDiORI2ID ID PPO:'Em a's noted.
( M MI /
(Desigh- Fapresentative) TrILE_ Resident Engr. DAIr 2-25-76 -
- 3. RECUEST
- #" AFPPMED AS PER INGHEI'RDC RDO:tNDCATIQi Nor APPK7/E0 ,
-L f DhIr SUSI Pesident K'Asger
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b Distsibuticn: 7U$1 (Dallas) (6) B&R (Hou.'stSn)' (1) ,C&H (tN) (4)
- TU3I (Field) (2) BT.R (Fleld) (2)b.:.
, r~\ r CONFIDENTIAL limited amount of original rock for only the Unit I containment foundation,
, and if one further assumes that the dental concrete is essentially the same as the natural rock replaced, one doesn't need to have a geotechnical engineer perform an evaluation -- the conclusion is obvious. In addition, as discussed further in the following, both assumptions were erroneous.
And the TRT finally arrived at the following " Conclusion and Staff.
Positions" (page K-94, item 5):
"The TRT concludes that the overexcavation of a small portion of the Unit 1 Containment Building foundation and the subsequent replacement of the affected area with 2500 psi strength dental concrete and grout did not af fect either the static or dynamic characteristics of the f ound a t i er,. Therefore, the expected seismic response has not been invalidated as alleged. The excavation and repairs have had no safety impact upon foundation integrity. Accordingly, this allegation has neither safety significance nor generic implications."
In addition to the erroneous assumptions made by the TRT, we note that there is no indication that the TRT made any investigation into any possible
" generic replications," although they stated in the SSER that there were none.
One of the basic (and errcneous) assumptions utilized by the TRT was that "the dental concrete's behavior, stif fness, and structural strength were essentially identical to those of the natural rock replaced at the site." However, this assumption is contrary to sworn testimony in the June 1982 hearing that the dental concrete was stronger than the natural rock which it replaced (see CASE's attached Proposed Findings Nos.
47, 48, 49, 51, 69-70, 75, 152, 154, and 297; 298; 304; and 306; see,also Applicants' 18 l
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CONFIDmTLAL 1
2/25/83 Proposed Findings of Fact in the Form of a Partial Initial Decision, a Proposed Fact 122, page 67, where they stated " Structurally the excavation 1s stronger with the dental concrete structure than it would have been had l i
the rock nest teen overbroken (Tr. 827)," emphasis added; s e also NRC Staff's 2/24/83 Provisional Proposed Findings of Fact, Proposed Finding 153, page 57, where they stated "The strength of the dental concrete was .less than the strength of the concrete employed in the CPSES structures, but was greater than the strength of the Glen Rose limestone." (emphasis added)).
It should be noted that the Licensing Board confirmed - not once, but twice
-- its understanding of the testimony to be that the dental concrete was l
stronger than the fractured rock it was used to replace (see e previously- l quoted portions from Board Orders of 7/29/83 and 9/23/83). I The TRT made the statement that ". . . the dental concrete's behavior, stiffness, and structure strength were essentially identical to those of the natural rock replaced at the site as indicated by the foundation report" (emphasis added).
CASE requests that the TRT identify specifically the " foundation report" to which it referred, and provide all information regarding such report which is in the Staff's possession, including the report itself, and all letters, memoranda, handwritten notes, etc., regarding the report.
In addition, if the TRT has information which indicates that the sworn testimony in the hearing is incorrect, the Licensing Board should certainly be informed of this immediately and provided with the specific information (including documents, etc.) which so indicate. If the TRT has such 19 l
. m q CONFIDENTIAL.
information, CAST. believes that the TRT should immediately' provide such information (including all relevant documents) not only to the Licensing Board, but to the the NRC Commissioners as well, as a Board Notification.
A second basic assumption utilized by the TRT in arriving at its erroneous conclusions was that there was a limited amount of original rock which was replaced with dentel concrete, that the area affected by the replacement work was relatively small, and that the overexcavation involved only a small portion of the Unit 1 Containment Building foundation.
However, this too is contrary to sworn testimony in the June 1982 hearing, which clearly indicated that the damage from overexcavation was extensive.
For example:
The damage to Unit I foundation due to overexcavation was extensive (see CASE Proposed Findings, copy attached hereto, Nos. 29, 30, 33, 35, 36, 41, 43, 148, 196-215, and 277).
The damage to Unit 2 foundation due to overexcavation was extensive (see CASE Proposed Findings Nos. 43, 56, 58, 196, 216, and 278);
The damage to the Fuel Building foundation was extensive (see, CASE Proposed Findings Nos. 43, 59-65, 80, 93-95, 134-135, 196, 220-235, and 279), and Applicants' expert witness Mason testified that the damage to the Fuel Building foundation was the most extensive of all (see CASE Proposed Findings Nos. 195, 239, 252, and 279).
In addition, Applicants' witness Mr. Mason described the size of the substantial blocks of rock which were displaced during the 20 l
-m .m 9
CONrlDENTIAL overexcavation of the Tuel Building foundation: 50 feet in width.
. approximately 100 feet in length, and a depth of somewhere between 5 and 10 feet, which was physically moved horizontally a distance that you could put your fist through; it slid horizontally ( g CASE Proposed Finding No. 61). Mr. Mason testified that, with regard to the length of displacement for the rock in the fuel building, "I recall an open crack, meaning that the rock was 1 displaced in an amount that -- and I'm not very big, but I could squeeze my body through, let's say ten inches... Substantial." He also stated that it was very visible and that there was " daylight where it should be rock." (See CASE Proposed Finding No. 94.)
Wile looking at and discussing the slides shown by CASE ( g copies of color pictures made from the slides, with summaries of Mr. Mason's comments taped to back of each picture, attached), Mr.
Mason repeated his testimony that there was a crack in the wall or the foundation of the fuel handling building that was so large that he could get into it Limself, that there was one approaching his body thickness; but that we did n_ot o have a picture of it in i'
the photographs which were shown as slides and admitted into evidence as CASE Exhibits series 17 and 18, photograph copies from the slides (s3 CASE Proposed Finding No. 226).
There was also damage to both Safeguard Building foundations, although it was apparently not as extensive as the damage to the Fuel t Building foundation (seee CASE Proposed Findings 148 and 280), and s
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n CONTIDENTLAL fractures were still being found in the Unit 1 Safeguard Building foundation as late as 5/12/76 (see CASE Exhibit 20, page 8, attached hereto).
There was damage to the control building (lower Auxiliary Building)
(see CASE Proposed Finding 192 and CASE Exhibit 22);
. There was damage to the Emergency Diesel Generator Buildings #1 and #2 (see CASE Exhibits 21, 22 and 35);
CASE Exhibit 5, CASE Exhibits 17A-II and 18A-0 (pictures from slides, copies attached hereto; see CASE Proposed Findings 196-235), and CASE Exhibits 19 through 36 (see Findings 236-241) demonstrate the extent of the overexcavation of foundations for some Class I structures (CASE did not receive on discovery all documents relating to the overexcavation; see also Findings 218-219).
And NRC Staff Witness Robert Stewart (from Region IV) stated that the l
overbreak was ao extensive that there was no need to dir*'nguish between building boundaries, since all building excavations were affected (see,NRC Staff's 2/24/83 Provisional Proposed Findings of I .
Fact, page 59, Proposed Finding 164, citing Transcript paFe 1270).
Thus, the TRT's final conclusion and Staff positions were based on l totally erroneous assumptions. These erroneous assumptions included:
That the amount of original rock which was replaced with dental j' concrete ves relatively small, as indicated in Applicants' FSAR, and that on1v a small portion of the Unit 1 Containment Building foundation was involved; 22 L_________--_____-__.__ )
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r CONilDENTIAL That the dental concrete's behavior, stiffness, and structural strength
, were essentially identical to those of the natural rock replaced at the site; That Applicants' FSAR was correct and reflected the true amount of damage from the overexcavation and the true amount of dental concrete was which used to replace the daseged original rock; That the information utilized in the Staff's evaluation was correct, complete, and sufficient to allow the TRT to evaluate the true effects of the overexcavation and subsequent repair on the static and dynamic characteristics of the foundation (thereby allowinF the TRT to arrive at their erroneous and/or unproven conclusions);
and (Perhaps) that Applicants' representatives and/or NRC Region IV personnel had told the truth, the whole truth, and nothinF but the truth to the TRT.
The Licensing Board's Orders (quoted herein) summarize briefly the i Board's findings from the hearings on the overexcavation. CASE's 2/24/83 I
j Provisional Proposed Findings of Fact (copy attached hereto), goes into considerably more detail and quotes extensively from the sworn testimony in the transcript of the hearing. Those Proposed Findings, coupled with the other exhibits which are also attached, provide information which the TRT should have been aware of and should have considered before they arrived at their conclusions and printed SSER #8. CASE urges that they be examined thoroughly now.
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i CONFIDENTIAL l CASE further believes that SSER $8 should be amended immediately (as soon as the TRT/TRT design issues panel completes its investigation sufficiently) as a Board Notification to the Licensing Board and the NRC I
Commissioners. It is obvious that the TRT's bases for its conclusions were '
I incomplete, inaccurate, and erroneous, and.that only a sophisticated
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analysis such as was suggested by CASE in our 2/24/83 Provisional Proposed Findings of Fact can supply the TRT/TRT desiFn issues panel with the information necessary for them to make a determination reFarding this alleFation (as discussed and expanded to its proper content).
CASE requests, as it. formal discovery, that the NRC Staff identify, and provide (if they are in the Staff's possession), all documents (in the broad sense of the word, including the procedures reviewed by the TRT which were "utilizec to replace fractured rock'with dental concrete and to grout surrounding fissures and the accompanying compressive test results." the
" foundation report" referred to by the TRT on the first line of page K-94 of SSER #8, any and all letters to and from Applicants, any and all informal and/or internal letters, memoranda, handwritten notes, tape recordings, transcripts of meetings or tape recordings, etc.) known to, or in the possession of the TRT or NRC Staff, regarding the overexcavation and the TRT's original or subsequent investigation of this allegation and the attached NEW CONFIDENTIAL ALLEGATION. In addition, we request that the TRT provide answars to all the questions we have included herein. We are ]
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requesting this informally at this time, and expect that the Staff will preserve any and all such documents; we will formalize our request if J
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necessary.
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I CONFIDENTIAL It should also be noted that CASE has in its possession some additional l
documents obtained on discovery from Applicants (but which we did not l
introduce into evidence during the June 1982 hearings) with which we would ,
l like to compare the documents reviewed by the TRT. We are still reviewing
- l. l these documents, as well as reviewing other portions of the FSAR and other information. We would also be happy to have the documents in our possession reviewed by the TRT.
In addition, as mentioned earlier, CASE will put the TRT/ design issues !
panel in touch with other individuals who have additional information of which the TRT should be aware before completing the revision of its f investigation of this allegation.
1 We believe that the most beloft1-and most expeditious way to resolve this allegation would be to have a confidential (without Applicants or NRC Region IV personnel present) face-to-face meeting between the TRT/TRT design i
review team CASE, and the other individuals (at least one of whom wants to remain confidential) who have information regarding this matter. We believe it would also be helpful for CASE to show the TRT/TRT design review team the slides which we have, along with a discussion of them. To arranFe this, please contact:
(Mrs.) Juanita Ellis, President CASE (Citizens Association for Sound Energy) 1426 S. Polk Dallas, Texas 75224 214/940-9446 25 1
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TEXAS UTILITIES SERVICES, INC. g6 @/
C0fiANCHE PEAK STEAfi ELECTRIC STATION Edj. ,
1980-82 2300 MW INSTALLATI0li Q-BROWN & ROOT FIELD DESIGN CHANGE REQUEST SHEET 1 of 4
, (FDCR)
FDCR NO.: 0189 FDCR DATE: 02/19/76 FDCR ORIGINATOR J. M. Johnson j T0. C. H. Gatchell - TUSI SITE REPRESEllTATIVE SPEC./fWE. NO.: 2323-55-6 REVIS10ft: 1 SPEC./11's. TITLE: Excavation for Plant StrMtures SPEC./DWG. NO.: REVIS10ft:
SPEC./DWG. TITLE: j REASON FOR CHANGE: 1) Area is inaccessible because all rebar and embedded piping up to El. 790'-6" is installed.
- 2) Pressure grouting of rock is a generally accepted standard for repairing fractures.
f f
PROPOSED CHAllGE: Reference FDCR No.188 which ' requested approval to delete mudmat requirement in the area , approx.14'x16', shown on attachments. Two i
fracture lines, approximate locatirns shown on attachments, have been detected
! in the rock in that area. Appro'.d'i is requested to pressure grout into the fracture lines after the structural concrete placement to El. 790'-4" is made.
Briefly, the steps are:
. 1) Core hole 4" into rock and seat 2"6 grout pipe (see attached detail) at each of the three approximated locations shown on attachments.
- 2) Structural concrete placement will be made to El. 790'-4", with the three grout pipes extending above top-of-concrete.
- 3) After the curing period, pressure grcuting will be perfonned by a method approved by the Geologist.
- 4) The grout pipes will be cut off level to the top of unfinished concrete El. 790'-4".
The Geologist will designate the exact locations of th.e grout pipes, so that they are positioned over the fracture lines.
1 REF. TUSI REPLY: [6 N I
FDC OVE M TUSI REPLY REVIEWED BY WAL' DATE: 2 2 v- 7Cv BtRPROJECTEkGilJER DATE: M.-/Yd6 1
L____________
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a n .jon ., . . , . c u.t i n., ,n.3 O v.. .
. . jos (10. 351195 ..
' .% ) E C E l y E' MASOt)..lOllNSTOli & ASSOCIATESs INC.
b FEB M 1976
, gggyE ) gCOlCChniCQ$ COnSU$lantS r
entisetting coslugy-soit norr Annics-founde son enginwrong eso,e v. so ><ston. e.c NJA-3700 ***""'"'
e a.,iso.e ee-
,c. maio=. '.* Te~b'rus ry 23, 1976 ;
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I.,'.'f.i?."'.'.i o HJT-CH-5 Mr. D. A. Tellinger ,,
Cibbs & Hill, Inc. .
,, P. O. Box 806 ,
.- 'Clen Rose.1 Texas 76043 ,
Ret Texas Utilities Services Inc.
Comanche Peak Steam Electric Station i 1980 - 1982 Units 1 & 2 l
Dear Mr. Tellinger:
Per a va- request by Brown & Root the following are ey comments on TDCR - Olt,o and 0189. i In reference to TDCR - 0188, I feel the rock in question has not been damaged, either by weathering or construction traf fic, and therefore can be treated as called out in ti.e TDh.
In reference to TDCR - 0189, I htive no objections' to this method of '
repsir as en block of rock in qwstion is solid and exhibits no consequentici weathering. The pressure to be used in the pincement of the grout will be defined at the :ise of grouting. I I
Very truly yours. .
MASON-Jol!NSTON & ASSOCIATES, INC.
TIEl.D OFFICE. CPSES by ~! s/f k &,.As _
- HEKBERT C. CROVDER, Tield'Ceologist . )
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Distributions fQqg Mr. C. H. Catchell, Texat Ut 111 ties Services. Ine.. CPSF.S
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'Mr. R. C. Hanon, Hason-Johimt on & Associates. loc., Dallas. Texas -
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%.' C. E. Bonin, Brown & Root . CPSES ,
Mr. A. D. llenicy. Mason-Johnnten 6 Assorintes. Inc.. Dallas., Texas ,
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J Page 3 from CASE Exhibit Ms 5 W
to go with CASE Exhibits 17 and 18
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I References 1 i
- 1) RecJrJ phntrigi aphs of Containment #1 1
Photo numbers CB 1 thru 28 incl. l-I Mise, photographs of Containment _f.1.
I i Photo numbers U 362187 - 2 thru 21 incl.;
U 362192'- 2 and 5; an.1
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- 0) I t 30:193 - 1, l'., 17, .n.., 20.
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- ) 1.e c o r d ph.'r oc r.iph s o f Cont .i t n::. cot (1 P!.e t o no::.t.e r s C H 1 t h r n 26 in.1. ,
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'l i Pre f pii:.t scranh8 of tra. tor rer .. I l.
Cant iinaient rl photo nur.herw i: 15 t? ?!. - 10, 11. 1, 12.
CJn: air.nent .c phat e r u::.: e r r ): ! i l 7 7 J. - 30 6 *1 1 .
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- 4) Plan vice r.ap of Cate;; cry 1 (Aravations ,i
$) Photographs of f racturcs to be grout ed, H Photo numbers Q 223556 - 24 thru 28 incl. h !;
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- 6) Photographs of fractures in Fuel Building, foundat ton area.
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. Photo numbers K 153772 - 30 thru 36 incl. and [
Photo numbers K 153778 - 1 thru H incl.
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- 7) Currespnndence M.1P-Cli-3, copied to 15.V. Drcy cr ll ll c7
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- 69 :,, C-9 on 3-29-76 Call'/ l.N5?EC710,N ;;Ipoki s ".'",". Safeguards Unit 1 contrac; r,o. 2323 L i
l' con rs::o.- Brom and Root Type c,e wor,, Intnect Seal Slab for Blast Damage ir.s;<stors Activ.:ies On February 18, 1976, I inspected the seal of the Unit 1 Safeguards Building, The purpose of this inspectio 'tds e
th.h h h t0'ti='er to ascertain the extent of damaEe, if any, to the slab as a result of fly rock from adjtcent blasting operations conducted on February 4, 1976.
The results of this inspection were hegative. I observed no indication of cracking,neither hairline or otherwise, which would be expected had the slab been damaged.
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O, BrownffRoot Inc. east arrice eox 1001, cien nose Texas 7eo43 March 24, 1976 h '
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bbR C - 1/ G BRF-2401
( YSI #
Mr. C. H. Gatchell Texas Utilities Services, Inc.
P. O. Box 1002 Glen Rose, Texas 76043 Texas Utilities Services, Inc.
Comanche Peak Steam Electric Station 1980-82 2300 MW Installation Structural Excavation
Dear Mr. Gatchell:
nd xba.1n A substantial quantity of structur All excavation remains to be accomplished within the plant area proper.
will be in rock requiring removal Limitations either by use are of explosives prasently or by imposed onuse of nneumatic or hydraulic tools. blasting in the vicinity of concrete structu specifications and " Blasting Attenuation Curves" transmitted per Mason-The re Johnston letter MJT-167 dated July 23, 1975.
curves were implemented upon re:eipt.
The subject blasting attenuation curves were developed from data i obtained during blasting operations involving the use of ammonium nitrateThe curves and Tovex explosives detonated by use of primacord.
using this particular blasting technique limit blasting within the close -
proximity of concrete structures.
y Tests were conducted recently during the initial development of the Borrow Area C quarry using various combinations o Details of these tests are included with this and electric blasting caps.
transmittal and are listed as follows:
17, 1976 Attachment A - Tests conducted on February 25, 1976 Attachment B - Tests conduTted on February 26, 1976 Attachment C - Tests conducted on February 28, 1976.
Attachment 0 - Tests conducted on February Selected data for certain blasts included as part of the above Indications tabulation are that have been sumarized and are presented on Attachment E.
more favorable particle velocity results for blasting within twenty-five (25) feet of concrete structures can be obtained by use of electric blasting ::ps.
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.BRF-2401 Mb*2O ,
l
-page two f (ogk i
This data is also transmitted to Mason-Johnston and Associates, Inc. !
i for their review and evaluation such that with TUSI and Gib".'s and Hill approval, additional Blasting Attenuation Curves can be gen rated which will allow for blasting in closer proximity to concrete structures. Additional data can be developed upon request if desired.
Drawings indicating areas remaining to be excavated for structures or underground utilities are included for information purposes only.
Your consideration of this request will be greatly appreciated.
~
Very truly yours.
BROWN & ROOT, INC.
H. C. Dod Project Manager HCD/CEB/mfm Attachments .
cc: L. A. Ashley (IL, 1A)
P. L. Bussolini (it) {
R. W. Caudie (6L, 6A) ;
M. M. Fitch/L. D. Pyeatt (ll) * !
C. H. Gatchell (0, IL, 2A,1 set drawings)
Mason-Johnston (1L,1 A, I set drawings) I i ffhhf gs :: , .
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PARTICLE VELOCITY TEST BGRROW AREA C OUARRY 2-28-76 FOR iMXMAil0N ONLY TIfE F I E D PARTICLE VILOC11 F.ST Pcttt::S FN7tAGE P'N1 FT 12:30 .2 1 12 55' 43 TIST # 1 A 1 LB 45' 12:32 B _ ,
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12:59 .04 1/8 LB 35' 01 C 25' 1 00 D 1/3 LD 1:01 02 1/8 Im 20' 07 E 1:02 y 1/8 LB 15' 15 10' 1:03 1/8 LD G
35 55' 1:06 TEST # 5 A 2.08 Ias 1:08 45 2.08 Lns 45' 1.05 B
35' 1:10 C 2.08 LDS 1:12 N/A 2.08 125 25' 1.8 D 20' 1;14 II 2.0S IIS e=
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PARTICLE VELOCITY TEST BORROW AREA C QUARRY % P. y g g g7. } 2-26. 5 g* 5 PROCFDiOIS S11075 A,C,C,D,r ,F ,C O'3 1 SIICK TOC. 700 (2"x16") = 2.03 LDS 1 ELECTRIC Cf.P p g pf SOLID STII:iItc T
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