IR 05000438/1982015

IE Insp Repts 50-438/82-15 & 50-439/82-15 on 820607-10.No Noncompliance Noted.Major Areas Inspected:Structural Concrete Activities,Licensee Action on Previously Identified Insp Findings & licensee-identified Items

ML20058G145
Person / Time
Site:	Bellefonte
Issue date:	07/02/1982
From:	Conlon T, Harris J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II)
To:
Shared Package
ML20058G135	List: IR 05000438/1982015 ML20058G132
References
50-438-82-15, 50-439-82-15, NUDOCS 8208030216
Download: ML20058G145 (6)

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a d i; UNITED STATES 8 n NUCLEAR REGULATORY COMMISSION

$ $ REGION 11 o I 101 MARIETTA ST., N.W., SUITE 3100 ATLANTA, GEORGIA 30303 k .....

Report Nos. 50-438/82-15 and 50-439/82-15 Licensee: Tennessee Valley Authority 500A Chestnut Street Chattanooga, TN 37401 Facility Name: Bellefonte Docket Nos. 50-438 and 50-439 License Nos. CPPR-122 and CPPR-123 Inspection at Bellefonte site near Scottsboro, Alabama Inspector: AN/ 7/.2/82 J. R. Mrris Gate' Signed Approved by: N 1 (# /'l /

T. E. Conlon, Section Chief 7'Nh Date Signed j Engineering Inspection Branch Division of Engineering and Technical Programs SUMMARY Inspection on June 7-10, 1982 I

Areas Inspected This routine, unannounced inspection involved 26 inspector-hours on site in the areas of structural concrete activities, licensee action on previously identified inspection findings, and licensee identified item Results Of the areas inspected, no violations or deviations were identified.

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8208030216 820702 PDR ADOCK 05000438 G PDR

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REPORT DETAILS Persons Contacted

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Licensee Employees i

• R. Ddhnke, Project Manager i

• F. Gilbert, Construction Manager

• J. H. Olyniec, Supervisor, Civil Engineering Unit

• D. Nixon, Supervisor Soils and Concrete Laboratory

• R. Norris, Assistant Supervisor, Civil Engineering Unit

• C. Norris, Civil Engineer, Civil Engineering Unit

*F. L. Moses, Mechanical Supervisor I

Other licensee employees contacted included three construction craf tsmen, i four technicians and three office personnel.

1 NRC Resident Inspector

• J. D. Wilcox

• Attended exit interview Exit Interview

, The inspection scope and findings were summarized on June 10, 1982, with those persons indicated in paragraph 1 above.

' Licensee Action on Previous Inspection Findings (Open) Unresolved Item (438/82-10-01 and 439/82-10-01, " Evaluation and Documentation of Cutting of Reinforcing Steel". It is not clear that rebar i cut for installation of pipe sleeves and expansion anchors has been adequately reviewed and documented by ENDES. This item remains open pending

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further review by NRC.

j Unresolved Items Unresolved items were not . identified during this inspectio . Independent Inspection The inspector examined the following areas: "

l Concrete batch plant.

't Soils and concrete laboratory and currentness of calibration of 4 laboratory equipment. t

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2 Curing controls and results of work on concrete placement number R1-10-29A, Ring Girder, Secondary Wall . Forming and preparation for Unit 1 Secondary Containment Dom Repairs to reinfor cing steel in the west face of the east fuel canal wal Disposition of NCR 180 Wall modifications for main steam flued head and main steam valve room suppor Controls on repairs to concrete placements A23-1B and C5-5 Within the areas examined, no violations or deviations were identifie . Licensee Identified Items (Open) CDR 438/81-33 and CDR 439/81-36, Dimensionally Nonconforming Anchorage Material. This item was reported to NRC Region II on May 5, 1981. The licensee has submitted interim reports to NRC Region II dated June 5, August 19, and November 12, 1981, and February 2, and April 13, 198 As a result of a shophead/ bushing failure during stressing at - the Braidwood Nuclear plant, the contractor for the Bellefonte post-tensioning system, INRYCO, Inc. checked the dimensions

on unstressed anchorage materials at the project site. This dimension check disclosed that some of the anchorage material was oversized and some undersized. As a result of this problem, INRYC0 performed a

computer analysis which compared the pitch, and major and minor dianeters of all bushings and field anchor heads which had not yet been stressed. This analysis gave the combination of anchor heads and bushing which would result in anchorage components capable of with-standing 110% of the guaranteed ultimate tensile strength (GUTS) of the tenden per code requirement The maximum stress imposed on the anchorage components, which occurs during stressing, is 80*i GUTS. In order to evaluate the design capacity of the anchorage components which had been stressed prior to identification of this problem, INRYC0 used a statistical analysis method (Monte Carlo simulation). The statis-tical analysis indicated that there is a 97% plus probability that these anchorage componets were acceptable. The licensee documented the dimensionally nonconforming anchorage heads on 34 nonconformance reports (NCRs). This item remains open pending final disposition of the NCRs by the licensee and review of the licensee's final repor The next report is due July 30, 198 (0 pen) CDR 438/82-016 and CDR 439/81-023, Lack of Rebar at the Main Steam Flued Head. This item was reported to NRC Region II on February 27, 1981. The licensee has submitted interim reports dated March 31, June 3, August 31, and November 20, 1981, and March 11, 198 While chipping concrete to disposition NRC 1308, the licensee dis-

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covered that some reinforcing steel at the main steam flued head supports was missin The licensee performed a detailed design analysis to correct this deficienc The inspector discussed this problem with responsible engineers and reviewed the following docu-ments:

(1) ENC number 1382 (2) Drawing numbers 4AWO322-XI, 3, 4, and 5 " Concrete Floor Slab, E1686.0 Walls to EL 704.5, Outline" (3) Drawing numbers 4AWO323-XI-1, 2, 3, 6, 7, 8, 9, 14, and 15, Concrete, Floor Slab El 686.0 and Walls to El 704.5, Reinforcement (4) Drawing numbers 4AWO325-X1-1, 2, and 3, Concrete, Roof Slabs - El 706, El 728, and Walls, Outline (5) Drawing nt.mber 4AWO328-X1-1, 2, 3, 4, 5, and 8, Concrete, Roof Slabs - El 706, El 728, and Walls, Reinforcement This item remains open pending completion of repair work and review of the licensees final report. The final report is due August 6,198 c. (0 pen) CDR 438/81-50 and CDR 439/81-52, Main Steam Valve Room A Pipe Anchor Support Loads. This item was reported to NRC Region II on July 23, 198 The licensee submitted interim reports to NRC on August 18, October 6, November 13, 1981, and February 9 and March 11, 1982. Preliminary pipe anchor support loads were used in the design of the R-line wall in the Main Steam Valve Room A. After the actual pipe support loads were determined, the wall was not reevaluated for the increased load. The licensee has reanalyzed the wall using the correct loads. The licensee has not yet determined the cause of this proble This item remains open pending further review by the licensee and NR d. (0 pen) CDR 438/81-44 and CDR 439/81-46, Secondary Containment Modification. This item was reported to NRC on July 10, 1981. The licensee submitted interim reports dated August 7,1981, October 5, 1981, and February 22, 1982. A modification involving elevating the dome of the seconday containment to accommodate inservice inspection of tendons was made by the Bellefonte Design Project Branch without approval of either the Civil or Nuclear Engineering Branches. This was due to confusion in interpretation of EN DES-EP 4.02, " Engineering Change Notices (ECNs) - Handling". This problem was identified by the Quality Assurance Branch. The licensee has established a task force *to review the problem and to clarify the intent of EP 4.02 in regard to coordination of ECNs within EN DES. Also, in the future, QA will review all ECNs to verify that design changes have been coordinated between the various branches. This item remains open pending further review by the licensee and NRC. The next report is due in July 198 . - .-

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4 (0 pen) CDR 438/79-05 and CDR 439/79-05, Water in Rock Anchor Tendon '

This item was reported to NRC on May 23, 1979. The licensee submitted interim reports -dated June 22. and November 23,1979, March 21 and September 24, 1980, August 24, 1981, January 21, 1982 and May 10, 198 Inspection of approximately 20 rock anchor tendon head protective grease cans in Unit 1 indicated ground water is' infiltrating up along the grouted tendons through the grout holes in the shim stack and into the grease cans. Any water entering the grease cans has the potential for causing corrosion problem Pumping of water from the Unit I tendon gallery is continuing. Monitoring in Unit 2 indicates no water is infiltrating the Unit 2 grease can Corrosion testing of rock anchor components is continuin This item remains open pending ccmoletion of testing and review of the final report. The next report is due by November 22, 198 (0 pen) CDR 438/82-021 and 439/82-019, Seismic Analysis of the Auxiliary-Building. This item was reported to NRC Region II on February 26, 1982. The licensee submitted an interim report dated March 26, 198 The seismic analysis of the auxiliary building was performed using outline drawings of the structure by the Civil Engineering Branch (CEB). Subsequent to this changes were made to the structural con-figuration of the building by the Bellefonte Design Project Branch.

lhese changes were not coordinated with the CEB so that the effect of these changes on the seismic analysis could be assessed. The licensee is currently reviewing the seismic analysis. Preliminary indications are that some additional interior walls may be added to the structure to restore its structural configuration to tiot assumed in the original i

seismic analysi The licensee is current'y reviewing the seismic analysis performad for other structures at the Bellefonte project and for structures at other nuclear plants to verify a similar problem does not exist on other structures. The next interim report is due in July l 1982.

' (Closed) Item 50-438/78-13-03 and 50-439/78-13-03, Expansion Anchors Not Passing Qualification Test This item was reported to NRC Region II on July 10, 1978. The licensee submitted interim reports on

August 9,1978, January 26,1979, April 9, June 7, and July 20, 1979, January 7, March 25, and July 8, 1980, January 14, March 18, and May 19, 1981. The final report was submitted on August 14, 1981.

l Self-drilling expansion shell anchors were installed in the plant i

before being qualified as required by TVA specification G-32. Also

! supports for cable trays ard heating and ventilation ducts were

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installed using expansion shell anchors in holes where rebar had been cut. Test results indicated a reduction in tensile values for expan-

sion anchors installed through rebar.

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Review of test reports by the NRC inspector showed that each size self drilling expansion anchor being used on the project has now been

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qualified in accordance with requirements of TVA specification G-32.

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Discussion with responsible engineers and review of test reports by the NRC inspector showed that the load capacity of' supports with expansion anchors installed in cut rebar have been adequately evaluated. Repre-centative installations were analyzed based on actual loads using 45 4 percent of the allowables given in TVA Design Standard C6.1, assuming j rebar cuts'as specified on design drawings. . Using 45 percent of the j allowables of C6.1, the installed anchors are capable of carrying actual applied loads while maintaining a factor of - safety of 4.

j Specification G-32 has been revised to prevent the use of expansion '

l shell type anchors in holes with cut rebar. This item is close I f

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