35
,e l!.e ... (1· ( TEXAS UTILITIES GENERATING CO, INSTRUCT I 00 REVIS JOO ISSUE PAGE NL"1BER CPSES DATE QI-QP-11.0-1 2 3-7-79 1 of 21 .. CADWELD INSPECTION PREPARED BY: s-7r/q DATE ACTIVIIIES 1.0 1-A 1-B 2.0 2.1 2.2 3.0 3.1 3.1.1 APPROVED BY: a{?/7'J DATE' REFERENCES FOR ltffORMATION ONLY Reinforc::!;; Steel." ' .•. . Specification 2323-SS-ll, "Cadweld Connectors for '•, \\ To describe the QC inspection and testing methods for mechanical splicing of reinforcing bars using the Cadweld Rebar Splice Method • SCOPE To conn-ol methods for qualification, requalification, identification.of splicer and cadwelds, production records, cadweld inspection, and sampling and testing. INSTRUCTION lf:u"J.9--SS"'--ry' OF CADWELU SPLICERS L e-( 31>'11 a. Proposed splicer shall attend a documented slide .film presentation on Cadweld Splice Preparation given by the B&R Training Coordinator/Designee. b.. A QC Inspector shall attend the film presentation with the proposed splicer(s) and doc\Jment by submitting a list containing the name, date,badge number and social security number of those attending· to the Civil Inspection Supervisor/Designee. c. The propr.oed splicer(s) shall then receive training from a qualified instructor on the presentation of splices for each ·position that he is bdng quaHHed 9512020258 851106 PDR FOIA GARDEB:5-:59 PDR - TUGCO QA

Rev 2 to Procedure QI-QP-11.0-1, 'Cadweld Insp Activities ...The QC Inspector shall Vt?rify tl1at sleeve ident .t:y markings are legible prior to acceptance, b. The QC Inspector shall

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Page 1: Rev 2 to Procedure QI-QP-11.0-1, 'Cadweld Insp Activities ...The QC Inspector shall Vt?rify tl1at sleeve ident .t:y markings are legible prior to acceptance, b. The QC Inspector shall

~

,e •

l!.e ...

(1· (

TEXAS UTILITIES GENERATING CO, INSTRUCT I 00 REVIS JOO ISSUE PAGE NL"1BER CPSES

DATE

QI-QP-11.0-1 2 3-7-79 1 of 21 ..

CADWELD INSPECTION PREPARED BY: d~ s-7r/q DATE

ACTIVIIIES i!J~ 1.0

1-A

1-B

2.0

2.1

2.2

3.0

3.1

3.1.1

APPROVED BY: a{?/7'J DATE'

REFERENCES FOR ltffORMATION ONLY

Reinforc::!;; Steel." ' .•. . Specification 2323-SS-ll, "Cadweld Connectors for ~· '•,

iSlOR\C~C'Rtt ~\ \\ To describe the QC inspection and testing methods for mechanical splicing of reinforcing bars using the Cadweld Rebar Splice Method •

SCOPE

To conn-ol methods for qualification, requalification, identification.of splicer and cadwelds, production records, cadweld inspection, and sampling and testing.

INSTRUCTION • lf:u"J.9--SS"'--ry' :~.:::ATION OF CADWELU SPLICERS L e-( 31>'11 ~

a. Proposed splicer shall attend a documented slide .film presentation on Cadweld Splice Preparation given by the B&R Training Coordinator/Designee.

b.. A QC Inspector shall attend the film presentation with the proposed splicer(s) and doc\Jment by submitting a list containing the name, date,badge number and social security number of those attending· to the Civil Inspection Supervisor/Designee.

c. The propr.oed splicer(s) shall then receive training from a qualified instructor on the presentation of splices for each ·position that he is bdng quaHHed

9512020258 851106 PDR FOIA GARDEB:5-:59 PDR

- TUGCO QA --------------~

Page 2: Rev 2 to Procedure QI-QP-11.0-1, 'Cadweld Insp Activities ...The QC Inspector shall Vt?rify tl1at sleeve ident .t:y markings are legible prior to acceptance, b. The QC Inspector shall

• ... -----0 ' ....

nsrnutrroN ISSUE r~(.\S L'!I!..l7ES G2:='_'t.\TmG CO. Nl!.·IBER

REVIS IO~ PAGE ·C?S:::S

3.1.2

3.2

. - · .. '.·

Ql-QP-11.0-1 2 3-7-79 2 of 21

for at that time. Qualification for all positions is not mandatory at the same training session,

d, The proposed splicer~s training acssion'vill be witnessed and documented by the QC Inspector.

Qualification

a_, After the training eession. the proposed splicer. shall prepare two splices for each position that he is qualifying for:

Note:Bar size Cl8 Test Splices qualify for all bar sizes.

b. The QC Inspector shall inspect the completed splices in accordance with paragraph 3.4 of this Instruction.

c:.

c!.

If the splices nre found satisfactory, they shall be tensile tested in accordance with ~eference 1-A and the results documented on the Cadweld"Splicer Qualification Form (Figure 1),

Upon receipt of satisfactory tensile test results, the qualified splicer shall be issued a unique I.D. symbol to be used as part of the identification for all of his future splices. An example of a typical splice sleeve identification is "ABH2P" w~ere:

AB

H

2

p

·le the splicer's I.D. symbol

Denotes that splice vas shot in the horizontal position CV-Vertical or D-Diagonal)

Denotes the second splice for the splices in the horizontal position for this particular bar size.

Denotes a Production Test Splice (S-Sister Test Splice or Q-Qualifica­t~on Teat Splice.

e. The aplicer'a I.D. symbol, name and badge number 1hali · be entered in the Cadweld Splicer'Qualification

Statue Report (Figure 2) by Civil.QC Personnel 'to reflect the splicer's current qualification status.

REQUALIFICATION

.· .. :.,: .

Page 3: Rev 2 to Procedure QI-QP-11.0-1, 'Cadweld Insp Activities ...The QC Inspector shall Vt?rify tl1at sleeve ident .t:y markings are legible prior to acceptance, b. The QC Inspector shall

•••

ISSUE TEXAS llfILITIES GENERA.TrnG CO.

Il~STRUCTION NUMBER REVISIOO PAGE

CPSES

3.2.l

3.2.2

3.3

3 • 3 .1

3.3.2

nl-OP-11. 0-1 2 3-1...-79 . 3 of 21

Conditions for Requalification

a. The position (Horizontal, Vertical, Diagonal) has not been used for three months or more, or

b. If completed splices fail to pass visual inspection. It is not necessary to requalify a splicer on the basis of a single v~sual reject, but consistent visual rejects ·· by t~e QC Inspector shall be cause for requalification, or

c. If completed splices fail to pass the tensile tests (rate exceeds one of 15 test failures), or

d. If there is another reason for the QC Inspector to question the splicer's ability.

Me~hod of Regualification

The =ethod of requalification shall be identical to the original qualification procedure for all positions utilized.

INSPECTION REQUIREMENTS FOR SPLICE SET-UPS

Frequency

a. The QC Inspector shall visually watch the preparation and set-up of Cadweld Splices on a random basis.

b. It will be to the QC Inspector's advantage to watch as many splice set-Upf during a shift as possible,

Cleaning

a. On those splice set-ups observed, the QC Inspector shall verify that bar ends are properly cleaned by heating and vire brushing to remove all loose mill scale, rust, etc.

b. If hand wire brushing is used, the bar shall be heated and brushed twice, then wiped with a clean dry cloth to remove dust.

c. ·The bar ends shall be cleaned a distance equal to ~ the sleeve length+ 2 inches •

Page 4: Rev 2 to Procedure QI-QP-11.0-1, 'Cadweld Insp Activities ...The QC Inspector shall Vt?rify tl1at sleeve ident .t:y markings are legible prior to acceptance, b. The QC Inspector shall

• c

<1-----------1'-· ,; ·---------------' ··~_-·;.·

T~S UT1LITJES GENERATING CO,

CPS ES

INSTRUCT JOO Nll-1BER REVISION ISSUE

DATE PAGE

3.3.3

3.3.4

Ql-QP-11.0-1 2 3-7-79 4 of 21

Reference Marks

a. On those splice set-ups observed• the QC Inspector shall verify that relerence marks are placed on each piece of rebar a distance of 12", + "" from the bar end. .•. • . -

b. The marks shall be inscribed in the rebar rib with a draw file. preferably prior to putting the sleeve on the bars.

c. If the bars must be marked after the sleeve is centered. the QC Inspector shall visually check the bar end locations through the tap hole before the marks are added.

d. If for some reason the marks cannot be located at 12" + ~" from the bar ends, the splicer shall notify the QC Inspector before igniting the powdeT so that"he can verify sleeve centering by looking through the tap hole. The QC Inspector shall document the location of the marks (if other than at 12" + Ii;") for future. reference on the Cadweld Sleeve Inspection Record (Figure 3). ·

e. If the 12" reference marks are on the bar end and it ie necessary to change the marks (prior to 1gn~ting the splice), the QC Inspector shall verify the new mark location from the bar end. He will then require the splicer to pe~n out the original mark with a hammer.

f. Removal of the reference marks by peening also applies when it is necessary to trim the bar ends after marks have been placed on the bars.

Positioning of Sleeve

When inspecting the position of the sleev~ for centering, the QC Inspector should be able . to see ... the. gap be.tween

·rebar ends through. the tap bole. On VertiCal·.set-Ups the gap should be 1/8" - 3/16" (using a spacer) and a maximum of 3/8" on horizontal or diagonal set-ups.

-------------- TUCCO QA---------------

·- ...... ·-·--· . ··-·' .. . . . .

Page 5: Rev 2 to Procedure QI-QP-11.0-1, 'Cadweld Insp Activities ...The QC Inspector shall Vt?rify tl1at sleeve ident .t:y markings are legible prior to acceptance, b. The QC Inspector shall

(

., ·:··'· .·.

. · · · · · ·· - r. INSliWGl'lllN ·11~ lTITLlTIES GENERA~ co NlNllER .

CPSES 1------~~~t--~-----...~-------+----------1

3.3.5

3.4

3.4.l

3.4.2

QI-QP~ll. 0-1 2 3-7-79 5 of 21

Docwnentation of Splice Set Up Inspection

The QC Inspector shall document inspection of splice set-up or preparation on the Cadweld Sleeve Inspection Record (Figure 3).

INSPECTION OF CO~ll'LETED SPLICES

Each completed splice shall be inspected by the QC Inspector.by:

Reference Marks

a. The QC Inspector will inspect each splice for prope= sleeve centering by using reference file marksjlrovided on the rib of each piece of rebar.

b. The reference file m~rks are placed on the rebar by the splicer during the set-up operation,

c. Tha QC Inspector shall measure from mark to mark, locate the center of that measurement, and check to see if the center of the tap hole is located withi:l .:!: ~" of that center.

d. MaximUill allowable distance between marks is 24 7/8". Minimum allowable distance between marks is 23 11/16". ThEse tolerances are based on the.ref~rence marks being 12", ±. ~" from the bar ends.

Tap Hole Inspection

a. The QC Inspector shall inspect the tap hole of each completed splice for the presence of good filler metal, slag, or porous metal.

b. The inspector can determine that the material in the tap hole is good filler metal if it shines after being hit with a hammer.

c. Slag is a hard, brittle, ceramic type material; a flat chalky gray color, and will shatter vhen hit with a hamer. , ·

""--------------·TUGCO QA

Page 6: Rev 2 to Procedure QI-QP-11.0-1, 'Cadweld Insp Activities ...The QC Inspector shall Vt?rify tl1at sleeve ident .t:y markings are legible prior to acceptance, b. The QC Inspector shall

3.4.3

n~srnucr:ro:~ Nlr-1BER

Ql-QP-11.0-1 · 2

ISSUE·

3-7-79

.-•··---....,

PAGE

6 of 21

d. Porous metal will have a physical appearance similar to sponge. A single shrinkage bubble in the tap hole should not be confused with porous metal and is not cause for rejection. •

e. .If the QC Inspector determines. that slag is in the tap hole, the slag will be removed. If it extends past the thickness of the sleeve, the inspector shall reject the slice.

f. If the slag is removed from the tap hole and good fillet metal is discovered before passing through the·thickness of the sleeve,·the splice will not be rejected for slag in the tap hole.

g. All slag must be removed from the tap hole before accepting the splice. ·

InsDection of Sleeve End~

a. Each accessible end of each completed splice shall b_e inspected by the QC Inspector for excessive voids, low fill and porous metal.

b. Excessive voids may be determined by using ·a piece of small tie wire to measure the depth and a standard steel tape to measure the .width.

c. The width will be measured at the bar and the depth will be determined by the deepest point of the void. Th~ void will be considered rectangular in ahape.

d. Excessive low fill will be calculated by the same. method used for voids.

e. If a splice has both low fill and voids, the area shall be added for a cumulative total of void area.

f. The QC Inspector can use the chart (Figure 4) as an . aid for. calculating the void or low fill area.

g. The QC ~napector shall use theCadweld Manufacturer's criteria (Figure 5) for acceptance or rejection of

·a void or low fill area. · ·

'b, Porous metal in t.he sleeve end1 having the same physical appearance as a sponge, is cauae for

·.rejection •.. · · -

. : .

Page 7: Rev 2 to Procedure QI-QP-11.0-1, 'Cadweld Insp Activities ...The QC Inspector shall Vt?rify tl1at sleeve ident .t:y markings are legible prior to acceptance, b. The QC Inspector shall

~ .. .. '·"1

4 -~ ...

, •. . '

. · .. .. (;.: . . UiSTRUCTION ... · . {i· · -~.\S l.'!I!..ITIES ~~ING CO. NUMBER f{f;VI u~: 'ISSUE

-. .,_ ... ·~.·-. .. ".--.:..· .. CPS::S

3.4.4

3.4.5

3.4.6

3.4.7

. · .. 11"1." .

. : . . . ['·

"'··-----· Ql-QP-11.0-1 2 3 .... 7-79 . 7 O!f!:.l

i. Sound ·splices often have pin.holes, shrinkage fi·9'aes and cold joints visible at the ends of completed splices which are not cause.for rejection.

Inspection of "B" Series Splices

The inspector shall use the Inspection Report '(Figure f>):· for the :i.napection and documentation of "B" Series Sp 1.ices ....

Cach.leld Acceptance

..,. . The QC Inspector shall Vt?rify tl1at sleeve ident .t:y markings are legible prior to acceptance,

b. The QC Inspector shall apply a white acceptance atrir~e to each splice inspectea and found to be satisfact:ory,.

c. The Cadweld Sleeve Inspection Record (Figure 3) shal~. be used to document inspection of satisfactory splicE~~

Cadweld Rejection

a. Th~ QC Inspector shall ~pply a yellow rejection stri:pe to each splice inspected and found to be unsatisfact,~ry.

b. A rejected splice shall be cut out, removed from the area and shall not be used for tensile testing purpos;es.

c. The Cadweld Sleeve Inspection Record (Figure 3) shall. be used to document the inspection of a rejected apli.ce, and shall indicate\l:he reason for i~'s rejection.

· Sa:npling and Testing

a. The QC Inspector shall select the location of produc~ior and sister splices for testing to maintain the fre­quency requirements. (Ref. 1-A Para. 7, 7 ~ l & 7. 7 .•. 2)

b •. Sister Test samples shall be Substituted for Productton samples for "B" series splices weided to embedmenta .. and "B

11

ee.ries anchorage splices where· the configuration doesn't allow Production samples. ·

. ~ .. : ! ~ •.

Page 8: Rev 2 to Procedure QI-QP-11.0-1, 'Cadweld Insp Activities ...The QC Inspector shall Vt?rify tl1at sleeve ident .t:y markings are legible prior to acceptance, b. The QC Inspector shall

·· .. i.·

l.

I

I I l

·IT!~~- L~ILIT~s ~2~~6 a» .. n!srnucrro:~ · Nl.£·IBER

ISST.JE PAGE

3.4.8

· ... :··

C?S:::S ,--~~~~~~~~~~~-;-~~~~~t---~~~--1

Ql-QP-11. 0-1 2 3-7-79 8 of 21

c. On tightly curved bars (as deterinined by the TUGCO Civil QC Supervisor/Designee) Sister samples shall·be made in lieu of Production pamples and the sample fre~uency shall be as noted in Ref. 1-A Para. 7.7.2.

d. All other test samples shall be Production splices removed per the frequency noted in Ref, 1-A Para. 7.7.1 • .

e. The QC Inspector may use the Daily Test ·Status Report (Figure 7) ·as an aid to dete_rmine the next applicable test for each splicer, position and bar size.

f. If a ~est is required, check the appropriate blank on the Cildweld Consecutive Splice Record _(Figure 8) under "Test" (P-Production, $-Sister).

g. The QC Inspector shall notify the splicer of a Pro­duction Test after the splice is completed.

b.

1.

If the requirement is for a Sister splice, the QC Inspector shall notify the splicer that a ·sample will be required immediately after the one that the splicer is currently setting up.

Test samples shall be identified by the QC Inspector with a red stripe and documented on the Cadweld Sleeve Inspection Record (Figure J)i "P" for Production and "S" for Sister.

j. The test splice shall be removed by B&R Const~uction and subsequently delivered to the Site Testing Lab by QC personnel for tensile testing •

.. Report ins

a •. QC personnel shall complete items 1 1 2 and 3 on Cadweld Splice Testing Report (Figure 9) for each splice tested and submit to Site Test Lab, which will perform each te... . and return completed report to Civil Inspec-tion Supervisor/Designee~ · ·

b. ·QC personnel shall complete the Cadweld Sleeve Tensile Test Average Repor.t: (~igure 10) for each -15 Production

. or Sister tensile testa an4 aubmit t~ the Civil · Documentation Supervisor.

. '

Page 9: Rev 2 to Procedure QI-QP-11.0-1, 'Cadweld Insp Activities ...The QC Inspector shall Vt?rify tl1at sleeve ident .t:y markings are legible prior to acceptance, b. The QC Inspector shall

·48 I·

l

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T::·:!.S L'T!!.I"rITS 0±?iJJING CO. N!J..IBER

~~~ r----~r~---J~---f---------1 PAGE.

ISSUE

1~~~~~~~~~--~~~uQuI=-~QP~-~1~1~.o~-~1--~----...:.2~~--~·3_-_7_~_7 ___ 9 __ ..._.9--.:.o~f~2~1----~

3.5

c. QC personnel shall perform the Cadweld 90 Day Review (Figure 11) and submit to the Civil Docume~tation Supervisor.

MAPPING SPLICE TEST LOCATIONS

All splice locations on the Containment wall iµid "dome sl:iall be located, by QC persoQnel, on a record drawing prior to ~oncrete placement. Information shall include

·test splice locations and numbers on the record'drawing.

a

Page 10: Rev 2 to Procedure QI-QP-11.0-1, 'Cadweld Insp Activities ...The QC Inspector shall Vt?rify tl1at sleeve ident .t:y markings are legible prior to acceptance, b. The QC Inspector shall

(·.· (·

TEXAS UTILITIES GENERATING CO, INSTRUCTION REVISION ISSUE PAGE NlMRFR · nrm~

CPSES QI-QP-11. 0-1 2 3-7-79 10 of 21

Figure 1

CADWELD SPLICER QUALIFICATION

. PROJECT: COMANCHE PEAIC J08N0.1 UNIT: PADE OF

1. Spliar't Nenw Becl91 No.

2. B&Rs,.i- t.D • ..,.

l. Po1Nclc-· llooiacw1tiol. ·VwrtiQI,; Dl19onal ICird. Onol

.c. Ouali!ica1;,,.. i:::-

VrK..&J

llTS...e- U"1m.111 No"', Y.·Sect. T1ntilt f1ilun A:wa1 h./l l.Jia:i !Ibo) ""' 11,,21• S1re11111h Type~ Rej~IXI lp.1J.Jb ,~ ...... s.1;.1

- 4.0 ---- 4.0 ---

5 ;. .. ,...,.'-~oq..,,;, p.1.I.

ti. T•n11tt':'~ by Diie:

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"I. 0..olif•c.r..i• "-ulir. Satotlactory; Unwtlst.aory ICtrcl1 Ono!

, Ou.i::."' CanlTot Doto:

COMMENTS:

'

NOTCi .. IJI qYlllliuo:ion tam ,.rformid Olt •ti nbor, II. Mini- p.JJ. for ndl tnr It 75,oilo p.1J. c. F.U-T.,,...: Cl'l "'4lo.11; Ill 1111•• F 1ilul'9; CBFI ._F1M11r1

.. ..... -. -. .

TUCCO· Q A

.. ( . .... . . ~-----··-···:·-------- .. -:-•· .......

Page 11: Rev 2 to Procedure QI-QP-11.0-1, 'Cadweld Insp Activities ...The QC Inspector shall Vt?rify tl1at sleeve ident .t:y markings are legible prior to acceptance, b. The QC Inspector shall

• c

·• c

.... i.. ~

... (· ... . - INSTRlJCTION ISSUE ~S UTILITIES GENERATING CO, NIJ.mER REVISION T'l.\TE PAGE

CPSES QI-QP-1l.0-1 2 3-7-79 11 of 21

Figure 2 ,,

CAOWELD SPLICER QUALIFICATION STATUS REPORT PROJECI': COMANCHE PEAK JOB NO.: lJNIT PAGE_O,_ •

SPLICER'S OUAllfli;ATION STATUli

SPLICER'S SPLICE" HDRllDNTAL v ATICAL CIA iOllAL l.D.ND. -NAME llADGE NO. QC . QC QC.

DATE INITIALS DATE . INITIALS DATE INITIALS

I I I I

l I I I

I I !

I i

I i I

'

.

. ~

NOTES:

-- ... - ·-- .

.. - .. ....

TUCCO QA

Page 12: Rev 2 to Procedure QI-QP-11.0-1, 'Cadweld Insp Activities ...The QC Inspector shall Vt?rify tl1at sleeve ident .t:y markings are legible prior to acceptance, b. The QC Inspector shall

CADWELD SLHVE INSPECTION RE co no ·PROJECT: COM.\NCHI PIAI( JODNO.: UNIT ·-·- PAGE ___ OF

DATE SPllCES "'ADE: CADWELO ntcono OWG.NO.: --------------------~---- -l'RlPAnf\.!!!!!!J..NJf! _C!!._OI~- ____ .:. ___ 1,:~_Mr_l):.!I.Q~!.!_ICf VISUllL fNSfECTION.

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Page 13: Rev 2 to Procedure QI-QP-11.0-1, 'Cadweld Insp Activities ...The QC Inspector shall Vt?rify tl1at sleeve ident .t:y markings are legible prior to acceptance, b. The QC Inspector shall

• ·' 1

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INSTRUCTION · NlMRER

Q 1-QP·d l • 0-.1

REVISION

2

Figure 4 - -WIDTH

1·3/C · 1-11a .2 2-1/8 2·1/4

1.42 1.52 1,63 1.73 1.83

1.64 1.76 L88 1.99 2;11

1.86 1 .99 2.12 2.25. 2,39

2.08 2.23 2.38 2.53 2.68

2.29 2.46 2.62 2.78 2.95

Z.52 2.70 2.88

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·ISSUE nll.TE

3-:-7-79•

2-1/2 2-5/B

2.0l 2.13

2.35 2.46

2.65 2.1e

2.98

PAGE

13 of 21

.. . -· 2-J/4 M/8 3

2.Zl 2.~ 2.u

2.58 2.7~ 2.81

2.92

2.7J 2.93 ----Z.96

-•w~~ --------~- LOii FILL AREA

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1/~ .UJ .375 .313 .250 .188 .125 ! ,063 I

5/16 .686 .75 .626 .soo .376 .25 I .125

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7/16 1.77 1.50 1. 25 I .752 .5 .ZS

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9/16 2.66 2.Z5 1.88 1.5 1. 13 .75 .375

S/& 3.11 2.63 2.19 1.75 l;U .875 ,438

' flOlt: Add answers fl'O!ll both charts as needed.

• ·3/15 for picking has already been figured. fn both cherts

.__ ____ ....._·· ;..· ---------.· TUGCO <QA. - ------------------

1..-------------------------------------- --

Page 14: Rev 2 to Procedure QI-QP-11.0-1, 'Cadweld Insp Activities ...The QC Inspector shall Vt?rify tl1at sleeve ident .t:y markings are legible prior to acceptance, b. The QC Inspector shall

• (' .

TEXAS UTILITIES GENERATING CO, CPSES

(:.

REVISION ISSUE PAGE

Ql-QP-11. 0-1 2 3-.7-79 14 of 21

·. !?~ ,..,_-; :--~ .. ~ :-: . r.-;i R .. ..U. SPLliCJsi.D

Figure 5

--------, Splicn shall Ii. ICCIP&abl• 1111 .. wlcl '* end d<>H nol •1tHd the .. u lllled bel-.

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Page 15: Rev 2 to Procedure QI-QP-11.0-1, 'Cadweld Insp Activities ...The QC Inspector shall Vt?rify tl1at sleeve ident .t:y markings are legible prior to acceptance, b. The QC Inspector shall

.,,,· ( ···· -·t· .

TEXAS UTILITIES GENERATING CO. REVISION ISSUE PAGE

~·.· ' .

CPSES 15 of 21 3-7~79 2 Ql-QP-11.0-1

Figure 6

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Page 16: Rev 2 to Procedure QI-QP-11.0-1, 'Cadweld Insp Activities ...The QC Inspector shall Vt?rify tl1at sleeve ident .t:y markings are legible prior to acceptance, b. The QC Inspector shall

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T-EXAS UTILITIES GENERATING CO, INSTRUCTION REVISION ISSUE .·PAGE. Nl.MBER DATE

CPS ES Ql-QP-11. 0:-1 2 3-7-79 16 of 21

Figure 6 (Sheet 2)

-,~ INSPECTION REPORT -(SUPPl..EMENi:.LI rNO. •

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Page 17: Rev 2 to Procedure QI-QP-11.0-1, 'Cadweld Insp Activities ...The QC Inspector shall Vt?rify tl1at sleeve ident .t:y markings are legible prior to acceptance, b. The QC Inspector shall

·• ~ ~;.;...,

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INSTRUCTIQ\J JSSUE TEXAS L1r 1 LI TI Es GmERA TI NG co. REVJSJON PAGE Nll'1BER DATE CPS ES

Ql-QP-11.0-1 2 3-7-79 17 of 21

Figure. 7

Daily Test Status Report

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Page 18: Rev 2 to Procedure QI-QP-11.0-1, 'Cadweld Insp Activities ...The QC Inspector shall Vt?rify tl1at sleeve ident .t:y markings are legible prior to acceptance, b. The QC Inspector shall

TEXAS- LITILITIES GENEP.A£~G CO. INSTRUCTION · . REVIS 1J·:. ISSUE PAGE NIMR~D. nATF '•

CPSES ,.

• QI-QP-11. 0-1 2 3-7-79 18 of 21

Figure B

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CAOW:lLO S?LICEA CO;"o;SECUTIV~ .';?LI':.!; f!EC:OAO

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Page 19: Rev 2 to Procedure QI-QP-11.0-1, 'Cadweld Insp Activities ...The QC Inspector shall Vt?rify tl1at sleeve ident .t:y markings are legible prior to acceptance, b. The QC Inspector shall

c. TEXA~ LJTILITIES GENERATING CO, INSTRUCTION ·REVISION ISSUE PAGE

i..-~Nw.:..IM'R~~~~-~--<~~~~~~~n~A,.u....n:·~-+-~~~~---t CPSES

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QI~QP-11.0-1 2 3-7-79 19 of 21

Figure 9

CADWELD SPLICE TESTlNG REPORT

MOJECT~ COMANCHE PEAK JOB NO.: UNIT: ______ PAGE_._oF_

1. Test~ Tyi>s: IP) Pl'Oductioft; IS) Smor .•.••.•••••• , •••••

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COMME.N'l"S:

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Page 20: Rev 2 to Procedure QI-QP-11.0-1, 'Cadweld Insp Activities ...The QC Inspector shall Vt?rify tl1at sleeve ident .t:y markings are legible prior to acceptance, b. The QC Inspector shall

. ,. .. . c~., . .. .

TEXAS UTILITIES GENERATING CO, INSTRUCTION REVISION ISSUE PAGE NLMBER nATF CPSES

QI-QP"." 11. 0-1 2 3-7-79 20 of 21

Figure 10

CADWELD SLEEVE TENSILE TEST AVERAGE REPORT

PROJECT: JOB NO.: UNl.T PAGE __ oF_

TEST SPLICE TYPE INDLVIDUAL ..

8 & A SPLI~ BAR TENSILE I l.C. NO. SIZE PROO. IP) SISTER ISi STRENGTH lp.&JJ

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TUGCO QA

. '. . . . .. . . . . - . . ,. . -··-- ·-. ······~·---.-···-

Page 21: Rev 2 to Procedure QI-QP-11.0-1, 'Cadweld Insp Activities ...The QC Inspector shall Vt?rify tl1at sleeve ident .t:y markings are legible prior to acceptance, b. The QC Inspector shall

TEXAS UTILITIES GENERATING r.o, CPS ES

PAOJECJ: CPSES

C~ ~t Ci' R~~!£::

INSTRUCT!~ NLMBER

Ql-QP-11. 0-1

Figure 11

REVISION

2

CAD'.lELD 90 DAY ~<.'i Im

ISSUE DATE

3-7-79

Uf:IT ___ PAGl-- OP_

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PAGE

21 of 21

.

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Page 22: Rev 2 to Procedure QI-QP-11.0-1, 'Cadweld Insp Activities ...The QC Inspector shall Vt?rify tl1at sleeve ident .t:y markings are legible prior to acceptance, b. The QC Inspector shall

.....

CONCRETE TESTING DATA MANAGEMENT

CP244

REVISION A

RUN DATEa 03-15-79

PROJECT I COMANCHE PEAK

JOB NUt\BER 1 35-1195

CONCRETE ?\IX 1 C-302

~8 DAY TESTS TOI 02-23-78

0 OAl TESTS TOz

BROWN ' ROOT, INC •.

POWER ENGINEERING DIVISION r,- ' '-,·' ' ;i ,, HOUSTON, TEXAS m{t-~-;-q

c/3ofo J L - ..

··.· :, ... · ..

Page 23: Rev 2 to Procedure QI-QP-11.0-1, 'Cadweld Insp Activities ...The QC Inspector shall Vt?rify tl1at sleeve ident .t:y markings are legible prior to acceptance, b. The QC Inspector shall

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( C0"1RNCHE -PERK lcoNCRETE HIX• C-302 -1 RUN DATE• 03-16-19 'PLOT 6 .. I CP-244

------------- DESIGN STRENGTH -------

6 0 6 0 s 0 TEST NUMBER

INDIVIDUAL TEST DATA- 28 DAY COMPRESSIVE STRENGTH CPSIJ

Page 24: Rev 2 to Procedure QI-QP-11.0-1, 'Cadweld Insp Activities ...The QC Inspector shall Vt?rify tl1at sleeve ident .t:y markings are legible prior to acceptance, b. The QC Inspector shall

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DESIGN STRENOTH -- -- - -- - - - - - ._._ - - -.- - -()~ O ~

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-ING-AVERAGE OF PREVIOUS THREE 28 DAY STRENGTHS CPS I J

Page 25: Rev 2 to Procedure QI-QP-11.0-1, 'Cadweld Insp Activities ...The QC Inspector shall Vt?rify tl1at sleeve ident .t:y markings are legible prior to acceptance, b. The QC Inspector shall

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0 15 0 5 0 s 0 5 TEST NUMBER

NOV ING AVERAGE OF PREY IOUS TEN. 28 DRY RANGE~ CPS I J

Page 26: Rev 2 to Procedure QI-QP-11.0-1, 'Cadweld Insp Activities ...The QC Inspector shall Vt?rify tl1at sleeve ident .t:y markings are legible prior to acceptance, b. The QC Inspector shall

I I . :~ .

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g f cortANCHE PE~K •

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~ ~.s- J 0 16 0 6 0 5 40 45 \ . ~~ c..:> TEST. NUMBER ,\ t-~ =lfl HIN TEST COEFFICIENT OF VARIATION. 28 ORY Ci.1 \_

Page 27: Rev 2 to Procedure QI-QP-11.0-1, 'Cadweld Insp Activities ...The QC Inspector shall Vt?rify tl1at sleeve ident .t:y markings are legible prior to acceptance, b. The QC Inspector shall

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_:·· -·~- ~--OVf RALL COE FF I CI ENT OF VAR I AT I ON. 28 DAY Ci. J

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0 s

Page 28: Rev 2 to Procedure QI-QP-11.0-1, 'Cadweld Insp Activities ...The QC Inspector shall Vt?rify tl1at sleeve ident .t:y markings are legible prior to acceptance, b. The QC Inspector shall

.- ---- - -~ -

.. •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• • CLIEIH NAME -TEXAS UTILITIES SERVICt:s ll~C. •

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couc~EfE TEST. DATA MGT. CP-244 NEVJSION A um J70-15S.fl68 J/15179

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------------------CALCUl.AflON NJM~E~

REVISION HUM'l~A

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Page 29: Rev 2 to Procedure QI-QP-11.0-1, 'Cadweld Insp Activities ...The QC Inspector shall Vt?rify tl1at sleeve ident .t:y markings are legible prior to acceptance, b. The QC Inspector shall

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Page 31: Rev 2 to Procedure QI-QP-11.0-1, 'Cadweld Insp Activities ...The QC Inspector shall Vt?rify tl1at sleeve ident .t:y markings are legible prior to acceptance, b. The QC Inspector shall

. . . . .

.·I

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L .•.

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------~----~----------------------------------~-------------------------------------------------------------·-----~----qEQUJREO OVERUESIGN STPENGTH=

1.;(I C11/IY'.•l '.'l1,•1 ">TliL~rr,111 15 Cl\LCULl\TLU lf" THE.FiE 1.IH t l -~i: I( 11 •r.q :11) '.'.>I"[ •• r, o~ 1r5 rs f"UM I HF: S[CONO A~E. l1f TL!>IJ•u, lf,tl Jltt-fl !>U.r ... l.l.~,., ... l •• ~.cn

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Page 32: Rev 2 to Procedure QI-QP-11.0-1, 'Cadweld Insp Activities ...The QC Inspector shall Vt?rify tl1at sleeve ident .t:y markings are legible prior to acceptance, b. The QC Inspector shall

·(· ' .

/

' I \ ..

... -...... •·.

"U·. ;..,._ -~ f,.r.41; '~1-\.::lf • ....., .,,,,,,.;J ..:......_ ....,_ • • '··•"• •..; •• ~ ...

------ ~WJW JOG i·~O. 35A1.~9ti

~ECEIVEi. ~ !NGINEERS CESIGNERI> CONSTRUCTO•H;

~I .J MAR 2 9 1979 1.1 ~ 0'"~' .,., '~""""" ~ n H m:11 TllO· 4 4 so ~ECEIVEf.U

March 23, !·979"? !:CC CiST. -:- -------. 1 · I l '~·=--:-~~----.J·i.......-f : .-··--.. ·::r ~=-::a I GTt~-:-35206

Texas Utilities Generating Company Post Of!ice ~ox 1002

! r::.· .. ;.;:.- .-,.. . '- .::·~.::.:~ r.r .,Tf. J ~ ( .. ' ,. ~.. I i

Glen ?.cse, ~exas 76043 " ·.·.·.. 1-i ... 1 ·~~~~~!-]~::r. Er::i:t . i

Attention:

Gentlemen:

Mr. J. T. Merritt Manager of Construction &

. • : c:;-:1:: ,,_\ I I Engineering: -.. ·. . 1 ·

I ·IJ·!, •• ,_ •• - .. ~~·I ''"fl l • ·.: t ·~· ... ~ •:". ~ V'91t. 1•1,l.h - r. " .... ,~ 1· I . i ...... -~ · -~L :

TEXJ\S UTILITIES GENERATING Cm-1PA?;Y ?.d17 6° C .// ... k_ ·- P.:~ COMA.."JCHE PEA.'!\ STEJ...!·l ELZCTRIC STAT!CN l "

1981-83 - 2300 Hi\7 I~~5T1-.L~1\TIO~~ .. j ;

G&H PROJECT WJ. 2323 l ?:.-j ·: OS209 cm~CRETE _ (2{ rv ~ •·:! REF: TGH-10722 .~~~

Enclosed are six (6) copies of Specification 2323-SS-9, Revision 5 dated February 16, 1979, entitled "Concrete".

The followin~ c'loc:urnents have·been incorporated in this revision as requested ·in TGH-10722.

DC/DD FICR FPA."q CDR DC/DDA

158, 229, 236, 241, 275, 280, 286, 310, 311, 357 3 I 179 . 547 S46, SSl, SSS,· SS6 590, 1269, ~732Rl, 1800R2, 1961

Other docu.'1lents . listed ir. TGH-10722 do· not involve specification deviations and have not been incorpdrated in thi~ revision. !n most cia~e~ ·the above documents have been-included verbatim. In a few cases onlv the intent has been -~~coted. . . .

'

·~0\)-;_.~

.. ri··1 ~.~~·'' . V ~u . . . ·. . .

Page 33: Rev 2 to Procedure QI-QP-11.0-1, 'Cadweld Insp Activities ...The QC Inspector shall Vt?rify tl1at sleeve ident .t:y markings are legible prior to acceptance, b. The QC Inspector shall

•.

(

': .. •':

GTN-35206 -2- March 23, 1979

Texas Utilities. Generating Company

In addition to the above1 other revisions, as noted, have been embodied in the specification.

Should you have any questions, please do not hesitate to con­tact this office.

Very truly you+s,

GIBBS & HILL, Inc.

~.1-.~. Harvey R. Rock ' f Project Manager

cir 'u~~ HRP..-ELB-MLB:lc 1 Letter + 6A CC: ARNS (B&R Site) OL + lA

H. c. Schmict (~USI Dallas) 2L 2A. J. C. Kuykendall (TUGCo Sitef lL lA R. E. Holloway (G&H Site) 2L 2A

Page 34: Rev 2 to Procedure QI-QP-11.0-1, 'Cadweld Insp Activities ...The QC Inspector shall Vt?rify tl1at sleeve ident .t:y markings are legible prior to acceptance, b. The QC Inspector shall

FORM NRM66·S. OCTOBER 1977 IMC 05351

• DOCKET NUMBEP.

UNITED 11ATH NUCLUll REGU~ATDlllV CDMllllUIDN

INSPECTION & ENFORCEMENT-STATISTICAL DATA SUPPLEMENT

.....--GENERAL INSTRUCTIONS: . BLOCK A MUST BE CHECKED TO SHOW TYPE OF INFORMATION

CONTAINED ON THE FOAM. ONE FOAM IS TO BE COMPLETED FOR EACH IA! ITEM OF NONCOMPLIANCE .CITED. 18) ITEM OF NONCOMPLIANCE NOT CITEO. ANO, ICI DEVIATiON CITED IN ENFORCEMENT CORRESPONDENCE

SQ-445 OR LICENSE t.IUMBER REPORT NUMBER 79-1 l A-TYPE OF FINDINGS

!CHECK ONE BOX ONLY) 8-SPECIFIC NfC CODE

OR pEVIATION l'UNCTIDNAL

CAUSE 3 7

PllOC'EDIJllE 9

IEVfllllTV AllEA 10 11 12

A ~ NONCOMPLIANCE

2 · a 0 LICENSEE IDENT1F1Eo ITEMS

c D DEVIATION

IE le EI I I r!J Cf] [I] DJ

D-HOW ITEM IDENTIFIED ICHECK ONE BOX ONL YI

L D LICENSEE

20 I fXI INSPECTOR

0 0 OTHER

F -EXEMPT INFORMATION

22 s D CHECK BOX IF EY lllPT INFORMATION

C-MOPULE NUMBER '

E-CONSEOUENCES !CHECK ONE BOX ONL YI

A >{i) CAUSE OR CONSTITUTED ACTUAL OCCURRENCE

21 p D HAD f'OTENTIAL TO RESULT IN ACTUAL OCCURRENCE

N D DID NOT HAVE POTENTIAL TO PIESULT IN ACTUAL OCCURRENCE

G-ADDITIONAL UNITS IENTER "WM IN FIRST BOX FOLLOWED BY OTHER _2l ___ :z_& UNIT NUMBERS! ._I ...... I ...... _._I _I

IS INCLUDED r· .c;.XT BELOW. PER ~------------'-----------t 1DCFR 2.7110 H-NONCOMPLIANCE REPETITIVE QCCURRENCE

llF FIRST OCCURRENCE ENTER "I" I

I.:. TEXT IENTER UP TO 2400 CHARACTERS FOR EACH ITEM. IF THE TEXT OF ntE NONCOMPLIANCE OR DEVlloTION EXCEEDS THIS NUMBER, IT WILL. H NECESSARY TO PARAPHRASE)

Failure to Implement the Quality Assurance Program For Civil construct; on .

10 CFR 50, Appendix B, Criterion II requires that a quality assurance program be established and implemented for the construction of the structures important to safety of the nuclear plant. 'The Texas Utilities Generating Company Comanche Peak Steam Electric Station Quality Assurance Plan affinns the intention to fulfill this require­ment •. The CPSES 11 C1vil Inspection Manual" provides a body of inspection and testing procedures required to implement the Quality Assurance Plan.

Contrary to the above:

On January 18, 1979, personnel of the civ11 construction labor force placed an undetennined amount of concrete of an unknown quality on the dome of the Unit 1 containment without the knowledge of your Quality Assurance orga.iization and without benefit of required inspections and testing of the concrete.

• E N D •. NOTE: DATA,ENT•IY CLE"K:.THE LAST LINE ENTE~EO MusT c0'4TAIN . THIS INFORMATION.

I

:· ···:··_ .................. · .... .

IOVl!AI

llO 111

121

131

41

151

71

181

" 1101

1111

, .. ,

Page 35: Rev 2 to Procedure QI-QP-11.0-1, 'Cadweld Insp Activities ...The QC Inspector shall Vt?rify tl1at sleeve ident .t:y markings are legible prior to acceptance, b. The QC Inspector shall

. ..

• rnVESTIGATION PLAN

IE Investigation Report No. 50-445/79-11; 50-446/79-11

Licensee: Texas Utilities Generating Company

Location: Glen Rose, Texas

Facility: Comanche Peak, Units 1 & 2

Type of Licensee: M_, PWR, 1150 t4le

Type of Investigation: Allegation

Dates of Investigation: April 2-3 and April 13-23, 1979

Dates of Previous Investigation: April 6-

I nves ti gators: R. G. Taylor, D. P. Tomlinson, and A. B. Beach

SCOPE OF INVESTIGATION

0990148 - investigate four allegations by fonner Brown & Root rigger .

Date Appr~· · bate

•••