IR 05000302/1971005
| ML19317G159 | |
| Person / Time | |
|---|---|
| Site: | Crystal River  |
| Issue date: | 01/31/1972 |
| From: | Faulkner H, Moseley N, Warnick R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II), US ATOMIC ENERGY COMMISSION (AEC) |
| To: | |
| Shared Package | |
| ML19317G152 | List: |
| References | |
| 50-302-71-05, 50-302-71-5, NUDOCS 8002280747 | |
| Download: ML19317G159 (12) | |
Text
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" UNITED STATES 't ATOMIC ENERGY COMMISSION ,,
le l DIVISION OF COMPLIANCE: l REGION li - SUITE 018 v 22 P EACHTREE STREET. NoRT HWEST 7,Lc,w,,,, (4,,,,,,,,,,, AT LANT A, GEORGI A 30303 ., CONSTRUCTION INSPECTION REPORT CO Report No. 50-302/71-5 FLORIDA POWER CORPORATION.. Crystal River Unit 3 Docket No. 50-302, Licensee No. CPPR-51, Category A2 Crystal River, Florida.
Type of Licensee: B&W, PWR,.855 Mwe-Type of Inspection: Routine, Announced _ Dates of Inspection: December 7-10, 1971 Dates of Previous Inspection: October 6-8, 1971 Principal Inspector: [[ aA yygk_ /.7/-72 y \\ R. F. Warnick, Reactor Inspector.
Date (Testing.and.Startup) Accompanying Inspector: /[5 /
N. C. Moseley, Senior Re or Inspector 'Date' (Testing.and.Startup) Other Accompanying Personnel: H. L. Faullner, DRL $ A. Schwencer DRL N 6M 3/ 7L Reviewed by:
- .N. C. Moseley, Shnior Reactor Kspector Date' (Testing and Startup) Proprietary Information: None ~ O soo2 280 7yp . - .
. . .. . .. _ n m
e ' ( CO Report No. 50-302/71-5-2- , . SECTION I Enforcement Action ..s A.
Noncompliance Items 1.
Material and fabrication. certifications for the. decay. heat pumps and the. reactor. building spray pumps.
(See Section II,
Paragraph 6.)
, < 2.
The inspectors were unable.to find ~ evidence.of. investigation, documentation and. correction.of void and aggregate separation in exterior surface of the containment building concrete.
(See.Section II,. Paragraph.7.)
B.
Nonconformance Items None C.
Safety Items .None c Licensee Action on PreviouslyIdentified Enforcement Matters None Unresolved Items 1.
Stainless steel pipe. and. valve storage and cleaning.
(See Section II, Paragraph 8.)
2.
Change in main steam line seismic classification.
(See Section II, Paragraph 9.)
Status of Previously Reported. Unresolved Items.
. FPC's plans for ultrasonic. examination of the reactor coolant pump flywheels are consistent with AEC Safety Guide 14.
(See Section II, .- Paragraph 10.)
Design Changes None Unusual Occurrences None .
_ . m . . . . ,, ( C0' Report No. 50-302/71-5-3- ' " .. Persons Contacted Florida Power Corporation (FPC) ^
- J.
Alberii - Nuclear Plant Superintendnet
- H. L. Bennett - Director, Generation Construction
, P. G. Davis - Manager, Power Testing.
- E. E. Froats - Quality Engineer J. C. JIobbs -Superintendnet,. Electrical and Mechanical Systems
- C. E. Jackson.- Contruction. Superintendent
- R. B. Johnson - Engineer
- M. H. Kleinman - Manager, Quality Programs and Standards P. F. Mckee.- Nuclear. Operations.. Engineer
- D. W. Pedrick - Engineer.
F. E. Williams - Power. Test. Supervisor..
Pittsburgh Testing Laboratory ' (PTL). G. B. Brown Chief Inspector. - i Babcock and Wilcox Company (B&W)_.
R. R. Beach - Managar, Field Engineering ~ s,, D. A. Giluck - Test Working. Group Representative Management Interview
1 1.
The inspector stated that. contrary _to the requirements.of Appendix B,10 CFR 50.and. the FSAR, the dscay heat. pumps. and.the reacter
building spray pumps.could not.be. identified by: serial number from the information contained.in.the. material.and fabrication. certifications, and that each QA data package.for the four pumps contained.one or more certifications pertaining _to another. pump..
Kleinman said the quality program _ files would be returned to B&W
i for correction and that FPC would conduct an audit of other data i packages supplied by the.same vendor.
(See Section II, Paragraph 6.)
l 2.
The inspector stated that he was. unable.to. find evidence.of identi-fication, investigation,.and documentation.which.would lead to the l correction of..the.apparact defects. observed in the containment building concrete.
Kleinman stressed that.once a problem is , identified, FPC has a system to "close the loop." Jackson agreed
' , j -* These individuals also attended the Management Interview , ! -
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_ _ - _ t ^ S . . . CO Report No. 50-302/71-5-4-d - that the present identification system did not specifically pick up concrete deficiencies. Bennett indicated that the present system would be'modifieduto-require recording concrete deficiencies on the concrete curing.and. form. removal report.
Kleinman.said that
the concrete defect would.be corrected..(See Section II, Paragraph 7.)
3.
The inspector commented.ou the stainless. steel valves stored'out-of-doors without protective covers and the stainless steel' piping stored _in contact.with the ground.
Bennett reminded the inspectors that FPC was in the process of moving.the valves to indoor storage.
, Kleinman stated that originally all. pipe.had been covered with plastic but that this had proven to be impr'actical to m.aintain.
He also stated that the matter would be corrected.
On December 21, 1971, Jackson informed the inspector.that FPC.had a procedure in the draft stage.to determine.the contamination on stainless eteel surfaces. He stated FPC also plans.to write pro-cedures describing how both internal and external surfaces will be cleaned.
(See Section II, Paragraph 8.)
4.
The inspector questioned the change.of seismic classification of the main steam lines from Class I to Class III, after the lines leave the containment building but.before they reach the turbine " main steam stop valve, since the Class III piping and valves are not included in the scope of.FPC's quality prearam.
The inspector stated that this matter would.be referred t.
it for review,' evaluations and possible action.. Kleinman. indicated ther '7/C had discussed this with DRL in Washington.but.that FPC had no minutes of the meeting. Faulkner of DRL indicated he was not aware of the problem nor of any previous discussions of the subject at DRL.
(See Section II, Paragraph 9.)
5.
The inspector informed.FPC that their proposed in-place 100% volumetric ultrasonic. examination.of each. finished. flywheel had.
been discussed with DRL, and Compliance has no further questions or comments.
(See Section II, Paragraph 10.)
6.
Compliance faspectors requested..FPC to furnish Region.II.with one copy of each of the approved.preoperational tests, startup ' tests, operating. procedures,.and a. copy of the procedure index.
FPC was requested to send one copy of any revisions to the approved.
procedures.- Davis agreed.to do this.
(See Section II, Paragraph 11.)- ~ . 7.
The inspectors requested FPC to supply Region II with one copy of each of the following QA/QC manuals; . i s i . - - .. . -- . -. .- -
-..
- a
- __ . -- - - .. _ _.
_ _ _ _. --.- - n -. .- .. CD Report No. 50-302/71-5-5- ' a , a.
Florida Power Corporation Quality Program Manual, Volume 1.
. b.
Florida Power Corporation Quality Program Manual, Volume II.
c.
Field Specifications for NSS Components-B&W Erection Department.
d.
B&W Construction Company. Quality Control Manual for Nuclear Construction.
Kleinman indicated FPC woald supply. Region.I.I with copies of their manuals but that they would have to talk to B&W before making any commitment concerning B&W manuals.
(See Section II, Paragraph 12.)
c
- w O
. -. . . - a A . e* g - . - m C0 Report No. 50-302/71-5-6- .- Section II . ADDITIONAL SUBJECTS INSPECTED., NOT. IDENTIFIED.IN SECTION I, WHERE NO DEFICIENCIES OR.. UNRESOLVED ITEMS WERE FOUND - 1.
General Jackson reported that construction.was 41%. complete.. The construction work was reduced from_two. shifts..to single-shift _ operation on November 19, 1971...This will. continue through the winter months.
The reactor vessel.was-placed on its suppert. plate on November 13, 1971.
Steam generator.No. 2 was. set.on its support. plate on November. 19, 1971, and steam generator No. 1 was set on its support plate on November 22, 1971.
FPC has established.a.new. position in their. quality control organization.
J. F. Rashinsky, formerly the Chief Recieving Inspector,.has been set up as the. Site-Quality. Control _ Supervisor.- He.is. employed..by J. A. Jones but will be reporting to Jackson of FPC. He will be responsible.for. coordinating all site quality control activities.
2.
Reactor Vessel a.
Implementation of quality assurance program.
- b.
Review of quality control. system.
(1) Crane testing and. vessel. lifting.
c.
Follow 2p record revfew.
(1) Installation inspection.. d.
Followup observations.of work.. (1) Installation. techniques.
(2) Protection of installed _ vessel.
3.
Other Class I Components.- Letdown. Coolers,.MU-CIA &.MU-CIB ' a.
Implementation of quality assurance program.
b.
Review of quality control system.
.(1) Receipt inspection and handling.. ' (2) Special handling.and. storage-precautions.
- ' (3) Quarantina of nonconforming components.
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j '
['~N CO Report No. 50-302/71-5-7- _
_ (4) Installation specifications and procedures.
(5) Installation. inspections.- c.
Followup record. review.
-4 41). Material.and. fabrication certifications, , d.
Followup observations of. work.. (1) Protection..of. components.in storage.
4.
Other Class I Components . Steam Generators , a.
Followup observations.of work.
(1) Installation. techniques.
(2) Protection..of.. installed. components. i 5.
Other Class.I Components - Pressurizer , a.
Followup observations of work.
e (1) Installation. techniques.. DETAILS OF SUBJECTS DISCUSSED IN SECTION I.
6.
Material and. Fabrication Certifications for Other. Class I Components , FPC maintains a QA document file for each purchase made under their quality program...The QA document file for any specific purchase contains an.index, purchasesorder, changes to the purchase order, purchase specifications, design data, inspection.-reports,. drawings, and.an. individual 4 A.. data package.for each individual piece of equipment procured under..the one.. purchase. order...Each--QA data package is supplied by the vendor and should contain the material and fabrication. certifications for.one.particular piece of equipment.
The inspector reviewed.the.QA. document file.for. purchase order
81551 LW for two. decay heat pumps.and.two.. reactor. building. spray pumps. _From.the information.. contained.in.the. file,.the inspector determined the decay. heat _ pumps.had. serial. numbers 1624920.and.
1624921 and-.the. reactor. building _ spray. pumps.had_ serial uumbers.
l 1624922 and 1624923;..however, it.was.not possible for the inspector or Froats to identify a. specific-pump.such as DH-PIA with a specific.
serial number.
In addition, the inspector.found identification g-discrepancies in each of the four data packages.
In particular, l ks l
_ _ _ _
- . b , Cd Report No. 50-302/71-5-8- , a.
The certifications labeled.DH-PIA, contained the following pages j which, although labeled DH-PIA were traceable to other pumps: t ...One pump curve identified by serial number 1624921 (which is
., DH-PIB).
...One hydrostatic test certification identified by serial numbers 1624922.and.3.(reactor building spray pumps).
...One materials cartification for pumps with serial numbers 1624922 and 3 (reactor building spray. pumps).
f ...Two psges of chemical analysis and physical test reports marked " Reactor Building Spray Pumps".
b.
The certification labeled.DH-PIB contained the following pages which, although labeled DH-PIB,.were traceable to other pumps.
...Two pump curves identified by serial number 162490 (which is DH-PIA).
...One hydrostatic. test. certification identified.by serial. numbers
1624922 and 3-(reactor. building spray pumps).
, ...A materials certification for pumps with serial numbers 1624922 and 3.(reactor building. spray. pumps).
i ...Two pages of chemical analysis and physical. test reports marked " Reactor Building Spray Pumps."
, c.
The QA data package for.each. reactor building spray pump. contained.
three pump curves. Two. pump curves were. identified by serial ' number 1624923 and one. pump. curve.was. identified.by. serial number 1624922.
In the material and fabrication.. certifications for RB-PIA, all three. pump curves.v A e labeled RB-PIA.
In.the material and fabrication certifications for RB-PIB, all three pump curves were. labeled.RB--PIB.
This fa11ure to provide. properly. identified. material.and. fabrication J certifications which are traceable.to a specific piece of equipment ' appeara to be in noncompliance.with Criteria VII and VIII of Appendix B, 10 CFR 50 and Paragraph 1.7.6.4.5 of FPC's FSAR.
Criterion VIII, Appendix _B,.10 CFR_50, states.in part, 'h asures shall 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, serial number, or other appropriate means either on the item or on records traceable to the item...." .. - - . . -.. . . - -... - -_- --
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,.M , l
' . ) , CO' Report No. 50-302/71-5-9-Criterion VII, Appendix..B,.10 CFR 50, states.in part, " Measures shall be established. to_. assure. that purchased _ material,. equipment, and services;... conform.co.the procurement. documents.
These measures shall. include... objective evidence of quality furnished . by the contractor.or subcontractor,.. inspection.at.the. contractor or subcontractor source,.and examination.of.. products.upon_. delivery.
Documentary evidence.that~ material..and. equipment. conform.to the procurement requirements.shall.be.available.at.the nuclear. power plant site prior.to installation or use of such material or equipment...." Paragraph 1.7.6.4.5.of_the FSAR.. states, "During. manufacture the vendor maintains all-required-quality documents. including material identification....At the completion of the manufacturing the documents are distrubuted and stored as specified by the , Owner...." This problem was discussed.with.Kleinman.and.Froats who stated the file would be returned _to.B&W for correction. This.was discussed in the management interview and in addition to stating that the data packages.would be corrected, Kleinman said.that.FPC would conduct an audit of other data packages supplied by the same vendor.
, 7.
Containment Building Concrete-. During the inspection, a tour of the construction site was made to observe construction activities and the physical conditions of the work in progress.- In.the containment building concrete, the inspectors observed an area with small. voids.and. aggregate.. separation..in pour 263RB between.. buttresses 6 and.1.at elevation.103 to 110. The inspectors asked to see the records documenting the identification of this - ' defect for follouup investigation and. corrective action..Neither Froats of FPC nor Brown of PTL was aware of any documentation of the defect.
Both men expressed their belief that the defect would + be investigated and corrected; however, they were unable to show evidence that a system. existed.co. assure.this.
! The lack of a system for control of concrete defects appears.to.be _ in noncompliance with.Critorion.XVI of Appendix B,.10 CFR 50, which.
states in part, '?eas: res shall be established to assure that conditions adverse ; quality, such as failures, malfunctions, deficiencies, deviations, defective material and. equipment, and nonconformances are promptly identified and corrected."
. a m--.,,. . yr - , --
.-.. - . _- __ _ _ - _ _ - _. - - - _ _ _ _ - _ _ _ _ _. - _ O .n~ .. _ <-n . . r; \\ - , , - ~y ' Cd Report No. 50-302/71-5- -10- , , . Later.during the' inspection.and..again.during_the exit interivew, Kleinman, Froats,'and Jackson. stressed.that once a problem.is identified, a system _ exists.to "close.the loop." However, they , agreed that the. identification _ system.did.not.specifically-pick.up - concrete deficiencies.. Bennett stated.that the present system would be modified to require, recording.. concrete. deficiencies on the concrete. curing.and form removal _ report. This record would i then provide the formal identification to initiate followup by the loop.clocing. system...-. 8.
Stainless Steel Pipe and Valve Storage and. Cleaning The inspectors observed.st=f alaas steel piping _and valves stored ' out-of-doors without.any_ protective. covering...In. addition to the { , valves and piping being.continuouly exposed to the salt water l ' atmosphere, some pipa.enda. ware. observed to be in.. contact.with the ground. At the time of the inspection, FPC was in the process of moving all valves.co. indoor. storage.. The inspector questioned FPC!s program _for. assuring.the cleanliness < of the pipes and.. valves...On. December _.21.,.1971,. Jackson described.
FPC's cleanliness. program and.. stated that.as.the procedures.are.
completed they will.be.made available for the inspector's review, s A draft copy of their_ detailed '! Procedure. for Determining Contamination on Stainless Steel. Surfaces" has been prepared and is in St. Petersburg - for review. -Jackson. indicated _FPC.will. prepare.a procedure.for cleaning the external piping. surfaces.and.also. flushing procedures for cleaning the. interior _ surfaces of piping systems.
In addition, - cleaning procedures will be prepared for specific components such i as individual tanks.
i Valve and piping. storage was discussed.in the exit interview.
Kleinman stated that originally all pipes had been covered with plastic but that.this had. proved.to.be. Impractical _.to. maintain.
Bennett remindad the inspectors that.the. valves were in the process of being moved to indoor storage. Jackson indicated that the piping would be stored so_it was_not.in contact.with.the ground.
9.
Main Steam Line. Seismic Classi fi cation _.
- I The seismic classification of the main. steam lines changes from Class I to Class III.inside.the turbine building.but upstream of the turbine. main-steam.stop. valve..-(See Figure.10-3, Drawing No.
302-011, in the.FSAR.).The. Class.III piping and. valves.are not-included within.the. scope..of..FPC's-quality program.. (See Paragraph.
1.7.4 of the FSAR.) The' inspectors. questioned the appropriateness of this and indicated the matter would be referred to DRL for review, evaluation, and possible action.
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_ _ - -. . . .- . - _ - w , , - ' CO Report No. 50-302/71-5-11- ,
This was discussed in the exit interview,and Kleinman.. indicated that FPC had discussed this matter with DRL at Washington but FPC has no. minutes of the. meeting.. Faulkner (DRL) indicated he was not aware of the problem.nor of any previous discussions of-s the subject at DRL.
10.
Ultrasonic Testing of Reactor. Coolant _ Pump.FlywheelN As reported previously, the pump flywheels were ultrasonically tested prior to machining the flywheels from the blanks.,ltrasonic FPC plans to subject each finished flywheel to a.,100%. volumetric u examination in place. This proposal meets.the. requirement of. Safety Guide 14 and was discussed with.. Faulkner of DRL. At the exit interview, FPC was told that. Compliance had no further questions or comments.on this subject.
This matter is considered resolved.
11. _Preoperational Testing Program The inspectors met with Kleinman, Froats, Alberdi, Davis, and W'.11ams of FPC, and Giluck and Beach of B&W to discuss FPC's preoperational testing. program. and the Co..:pliance's inspection.
program.
The inspectors highlighted the. requirements.of 10 CFR 50 and the AEC's "Guidesl' for both-preoperational.. testing and. initial.
c startup programs._. Davis. explained how FPC intended.to implement the requirements of Appendix.B, 10 CFR 50, and gave the inspectors a revised copy of FPC's Test Program Guide for Review in the Regional Office.
Compliance inspectors requested.FPC.to. furnish Region.II with one copy of each of the approved-preoperational... tests, startup tests, operating procedures, and a. copy of the procedure index. FPC was also asked to send one. copy of any revisions to the approved procedures. Davis agreed.to.do.this.
Warnick reviewed the first draft of FPC's Test Program. Guide, their Test Procedure Format, and_ Operating _ Procedure _1102.02, " Plant , Startup," and discussed nis comments with Alberdi and McKee.
The ! inspector's.. comments can be summarized as follows: ~ The stepwise how-to-do-the-job part of the procedure needs a.
more detail in each. step.
b.
The balance of the procedurc should encompass the points discussed in the Guides, More emphasis should be.given to seeing that Criteria XI, XII, ~ c.
XIV, XVI, XVII and XVIII of Appendix B to 10 CFR 50 are implemented.
-i/ CO Report No. 50-302/71-3, Section II, Paragraph 4, and CO Report , No. 50-302/71-4, Section II, Paragraph n ~ ) , , ,
. ~ N CO Report No.50-302/71-5-12-
12. ' QA/QC Manuals The inspectors requested FPC to Supply Region.II with one copy of each of the following QA/QC manuals.
^ a.
Florida Power Corporation Qual.ity Program. Manual, Volume.I.
- b.
Florida Power Corporation Quality Program Manual, Volume II.
c.
Field Specifications for NSSS Components - B&W Erection Department.
d.
B&W Construction Company Quality Control Manual for Nuclear Construction.
l Kleinman indicated.FPC would. supply Region II with copies of their , manuals but that they would have to talk to B&W before making ' any commitment concerning B&W manuals.
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