ML20011A503
| ML20011A503 | |
| Person / Time | |
|---|---|
| Site: | Callaway  |
| Issue date: | 05/23/1978 |
| From: | NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML20011A456 | List:
|
| References | |
| 50-483-78-03, 50-483-78-3, NUDOCS 8110130491 | |
| Download: ML20011A503 (1) | |
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y Appendix A NOTICE OF VIOLATION Union Electric Company Docket No. 50-483 Inad on the inspection conducted en harch 29, April 18 and 19,1978, it appears that certain of your activities were in noncompliance with NRC requirements, cs noted below. This item is a deficiency.
Contrary to 10 CFR 50, Appendix B, Criteria I, and the Callaway PSAR, Section l'.. 10, the QC inspection for the piecement of the Diesel-Generater Fase mat concrete pour, failed to identify that three reinforcing bars were missing.
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8110130491 011007 PDR ADOCK 05000483 0
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L3Y 2 3 B78 Mion r' st~ n% : vt, In a.cordance with Section 2.790 of the NRC's " Rules of Practice,"
Part 2, Title 10, Code of Federal Regulations, a copy of this letter, the enclosures, and your response to this letter will be placed in the NRC's Public Document Roon, except as follows. If the enclosuras contain information that you or your connactors believe to be proprietary, you must apply in writing to this office, within twenty days of your receipt of this letter, to withhold such inforr.ation from public disclosure.
'Ioc. application must include a full state-ment of the reasons for which the information is considered propri-etary, and should be prepared so that proprietary information l
identified in the application is contained in an enclosure to the application.
We s 'll gladly discuss any questions you have concerning this inspection.
Sincerely,
- 1. F. Eei&un, Chief Reaetor Construetion a:
Engineering Support Branc1.
Enclosures:
1.
Appendix A, Notice of Violation 2.
1E Inspection Report No. 53-483/78-03 ec w/encia:
Central Files vReproduction Unit NRC 20b PDR Local PDE NSIC TIC Regions I & IV Ms. E. Dre;
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Hon. C. J. Trass, Chairman,.
Missouri Public Service l
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NGC Form 318 8 (R *n ) (17.) N 7eCM C240
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0-I U.S. NUCLEAR REGULATORY COMMISSION
- OFFICE OF INSPECTION AND ENFORCEMENT REGION III Report No. 50-483/78-03 Docket No. 50-483 License No. CPPR-139 Licensee: Union Electric Company Post Office Box 149 St. Louis, MO 63166 Tacility Name: Callaway, Unit 1 Inspection At:
Callaway Site, Callaway County, }D Inspection Conducted: March 29, April 18 and 19, 1978 E. 2.
Inspector E. R. Schweibinz 2SYE
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N Approved By:
. W.
e Projects Section
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Inspection Sum =arl Inspection on March 29, April 18 and 19, 1978 (Report No. 50-483/78-33)
Areat Inspected: Allegations relative to construction work on the Diesel-Generator building; licensee action on previous inspection findings; and allegations relative to construction work on structural steel. The inspec-tion involved a total of 20 inspector-hours onsite by one NRC inspector.
Results: Of the three areas inspected, no items of noncompliance or deviations were found in two areas; one apparent item of nonco=pliance was identified in one area (Deficiency - failure to identify a nonconforming condit$ on - Paragraphs 1.b a:,6 1.c).
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I' DETAILS Persons Contacted Union Electric Com;any (UE)
- W. H. Weber, Manager Nuclear Construction J. Baker, Construction Supervisor
- M. I. Doyne, General Superintendent, Callaway Construction
- A. A. Kuenzel, Construction Supervisor
- R. L. Powers, Site Quality Assurance Group Leader
- S. M. Hogan, QA Assistant Engineer
- R.
Veatch, QA Assistant Engineer Daniel International Company (Daniel)
T. Bordeaux, Lead Area Civil Engineer R. Bailey, General Foreman
- J. N. Kaelin, Project Audit Coordinator
- H.
J. Starr, Project Manager
- W. L. Petril, QA Engineer
- W. L. Sykora, DIC
- W. Loburk, Area Engineer The inspector also contacted and interviewed other licensee and con-tractor personnel, including craftsman, QA/QC, techrical and engineering staf f me=bers.
- Denotes those attending the exit interview.
Licensee Action on Previous Inspection Findings (Closed) Unresolved Ite= (50-483/77-09-01): Magnetic Particle examination procedure did not give specific requirements for testing using the ycke method. Procedure No. NDE 7.4A Magnetic Particle Examination of We3dments, ASMI Code, has been revised to include a statement in Paragraph 5.2 and Paragraph 7.2 that the poll spacing for yokes shall be 3-6 inches.
This item is closed.
(Ocen) Unreco1ved Ite= (50-483/78-01-08): The QA/QC system implemented by the licensee does r.ot require that nonconforming items in storage be tagged or otherwise identified relative to their status.
Storage and maintenance procedure (WP-261) vill be revised to include the requirement M
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o for placing an engineering hold tag on equipment found to be in noncom-pliance with the storage requirements red identified with regard to the equipment status. This item remains open pending incorporation of the above revision to procedure WP-261.
(Closed) Unresolved Item (50-483/78-01-12): Crack in concrete wall of the control building between elevation 2047' to elevation 2059'. NCR 2-2081-C-A was written for the crack in question along with other cracks in the control Luilding s lis. This NCR was superceded by NCr. 2-2173-C-A after all the cracks documented in the former NCR had been evaluated.
Ivaluation of the crack in question was to "use as is", as it was an acceptable crack caused by normal concrete shrinkage. This item' is closed.
(Closed) N)nce:pliance (50-483/77-11-01):
Cedweld production procedure No. QCP-118, Section 4.4 did not reflect the requirement that a cadweld be identified with a die stamp. Procedure No. QCP-118 had been revised on March 16, 1978 to reflect the above requirement. This item is closed.
l (Closed) Noncompliance (50-483/77-11-02; and 50-483/77-11-03): Failure to identify nonconforming conditions. The RIII inspector reviewed the directive issued by the Project Mant,ger (PM 323) dated March 9,1978 to the Engineering Manager and the Quality Control Manager which required the= to take actions to ensure that verifiers of work are knowledgeable of the requirements of initiating noncenfer:ance reports. Letter CEN-245, fro = the Quality control Manager and Engineering Manager dated March 9, 1978 to the area engineers and quality control inspectors infor=ing the= of the findings and instructing them to be knowledgeable
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of administrative procedure AP-VII-32, " Control of Nonconformance" and to take actions to prevent reoccurrences of a sitilar nature was also reviewed by the RIII inspector. These ite=s are closed.
(Closed) Unresolved Ite= (50-483/78-01-10): Paper Calmenson drawing approval. The RIII inspector rrrieved a letter from Bechtel Power Corporation (BLSE-5820) dated April 6,1978 in reEard to PACAL drawing approval. This letter states that an approval signature is not required on the PACAL drawings in accordance with theft approved quality assurance manual.
This item is closed.
Functional or Program Areat Inspected 1.
The following allegations were received via telephone conversation with Individual "A" relating to the diesel-generator building base =at concrete pour.
This pour occurred on March dy, 1978.
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Allegation Neat lines used to set the outside wall lines of the diesel-generator building relative to the control building are out of tolerance by 1 5/8.
Finding The west vall of the control building at the southwest corner was found to have 1 1/4" additional rencrete coverage at elevation 2000 feet.
This was documented on NCR 2-2377-C-A, dated March 17, 1978. The forms for the west side of the diesel-generator base sla'o were installed in line with the existing concrete of the control building west vall. All base slab reinforcing for the diesel-generator building vest wall was installed with the saquired clear cover to the existing forms except for the outside face vertical dowels for the west vall at colu=n line "DC" which were Cetalled to provide the required clear cover to the designc$ wall neat line (this sentence was paraphased fro = NCR 2-2377-C-A).
A nonconformance report, NCR No. 2-2539-C-A was written to address the concrete neat line cut-of-tolerance for the Control Building on April 4, 1978.
The RIII inspector observed sc=e data inconsistencies between the two NCR's mentioned above, and requested the licensee to resolve the:.
The resolution occurred by superceding NCR 2-2539-C-A with NCR 2-2632-C-A, dated April 13, 1978, and NCR 2-2377-C-A wac voided. A sa=ple of the new data contained in NCR 2-2632-C-A was checked on April 19, 1978 along with the sarple of the data supplied for the basis of NCR 2-2377-C-A being voided.
The infor=ation obtained in both cases was found to be acceptable.
No ite=s of noncompliance with NRC regulations were identified.
b.
Allegation i
Dowels in the center wall of the diesel-generator building are
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not in the right. location, they are out of tolerance, in the horizontal dimension.
Findings
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The RIII inspector checked all of the dowels in the center vall of the diesel-generator building for both horizontal and vertical position, and found none to be out-of-tolerance.
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The RI!1 inspector did observe that two dowels were missing during this inspection. This is an item of noncompliance with 10 CF2 50, Appendix B, Criteria X.
(483/78-03-01)
The missing bars were immediately installed by the licensee during the pour and no response to this portion of the item of nc co=pliance is required for the immediate corrective action.
It should be noted that there were approximately 176 bars required to be installed as center dowels, during this diesel-Eenerator basemat pour.
c.
Allegation The dowels at the center and south valls are not at the correct vertical elevation.
Findings The center wall devels were inspected as described in Paragraph 1.b above and the south wall dowels were also inspected for both correct vertical elevation and horizontal spacing. All bare were found to be in the correce Aerizontal and vertical position.
One vertical devel was observed to be missing fro the south wall by the RIII inspector. This is an ite= of nonce =pliance with 10 CFR 50, Appendix B, Criteria X.
(483/78-03-02)
The one =issing vertical devel was one of approxi=azely 151 vertical dowels in the south wall of the diesel-generator buildin5 A nonconfor=ance report, NCR No. 2-2503-C-A was written on March 31, 1978 to address this deficiency.
d.
Allegation The ~0ase plate which will be used to support the diesel-generator is required to be one inch below elevation 2000 and it is insta11rd such that instead of having one inch concrete coverage it wt11 have approxi=ately three and one half inches concrete coverage.
This allegation was later modified to the following: "The underlying reinforcing st eel mat of the base slab (or floor) i's three and one half or more inches below the surface, contrary to the specifications which call for it to be one inch below--that is call for a one inch coverage of concrete."
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A e ** o Findings The underlying reinforcing steel mat of the base slab was found to be three inches below elevation 2000, as required by the following drawings. Diesel-Cenerator Bu 3dinf Base Slab Elevation 2000 feet 0 inches Bar Reinforcing Plan Drawing No.
R-0511-007, Revision 0 did indicate both on the drawing and with a note that the top most bars to be one inch clear cover.
A drawing change notice to the " Concrete General Notet Drawing" was issued on March 29, 1978 to include the following change to add note 48 " Top slab reinforcement in sloped floors shall be placed level with clear cover measured from the floor low point unless noted otherwise." This drawing change notice was requested to clarify a situation in another building but is applicable to the ditse3-generator buildic3 The drainage system for the diesel-geur;3 tors building elevation 2000'-0" drawing No. M-OP5111, Revision 1 contains the folioving note "the top of equipment drains in floor elevation 2000'-0" shall be elevation 1999'-10" excipt as noted."
(i.e., in order to have one inch clear cover at the area of the floor drain: the reinforcing steel cat must be at elevation 1999'-9", or three inches below elevation 2000'.
It should be noted that one inch clear cover is a minite= for protection of the reinforcement steel bars and it is acceptable to have greater than one inch coverage.
No ite=s of nonce:pliance with NRC regulations were identified.
One ite= of nontm pliance was identified with 10 CFR 50, Appendix B, Criteria X of which there were two exa=ples identifed in paragraph 1.b and paragrayh 1.c above.
2.
At the request of the licensee the RIII inspector reviceed NCR No.
2-1907-C-A with regard to the clear d? stance between vertical reinforcing bars less than that specified in Bechtel Specification 10466-C112, Revision 9.
This ECR was issues on January 9, 1978.
The item covered in this NCR was the subject of an item of noncom-pliance in report No..50-483/78-01, ite= No. (483/78-01-02). Upon review of the situatiCu it was determined that this ite= was iden-
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tified by the licenses prior to identification by the R1II inspector.
This was verified with the RIII inspector that identified the problem.
Therefore this item of noncompliance identified as 483/78-C'-02 is to be withdrawn.
3.
An additional allegation was given to Region III from Individual "A"
t y way of a ' ember of the press. This allegation was in regard to
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g ks. s.w improper tightening (torquing) of bolts used to hold structural steel members together. And that in areas where the iron workers cannot reach with their wrench, they have been instructed to lay the washere on a steel beam and flatten the specifically fabricated torque-indicator protrusions on the vsshers with a hammer, before installing the washers and bolts by hand.
Individual A was contacted by telephone on April 17, 1978 to request adoitional information in regard to this allegation. individual A refused to comment on the allegation.
During this inspectica on April 18-19, 1978 the RITI inspector reviewed this item. This item was also reviewed as part of the routina inspection effort during inspection No. 50/483-78-02 which was performed on March 21-23, 1978. The RIII inspector witnessed torquing of struc-tural steel bolts by iron workers and their checking with feeler gauges which they used to test the gap between the specially f abricated torque indicating was'.iers and the bolt head to indicate that the washer has been flattened during the torquing operation to insure the proper amount of torque on the bolts.
Structural steel bolts were requr.ited to be removed in the lower portions of the auxiliary building to see if there was any evidence that the torque indicating washers had been improperly flattened. The results of these sa=ples and interviews with iron workers indicate that this is not a~ practice on this job.
No items of noncompliance with NRC regulations were identified.
Exit Meeting The inspector met with site staff representatives (denoted in the Persons Contacted paragraph) at the conclusion of the inspection on March 29, 1978 and April 19, 1978. The inspector susaarized the scope and findings of the inspection including the one apparent item of noncompliance identified in paragrtph 1 of the Details section of this report. The licensee acknowl-
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edged (ne findings.
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