IR 05000302/1973007
| ML19319C946 | |
| Person / Time | |
|---|---|
| Site: | Crystal River  |
| Issue date: | 09/27/1973 |
| From: | Crossman W, Vallish E NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML19319C926 | List: |
| References | |
| 50-302-73-07, 50-302-73-7, NUDOCS 8003040885 | |
| Download: ML19319C946 (16) | |
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UNITED STATES o
g ATOMIC ENERGY COMMISSION
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- I DIRECTORATE OF REGULATORY OPERATIONS
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AT L. A NT A, G EORG O A 30303
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RO Inspection Report No. 50-302/73-7 Licensee: Florida Power Corporation 3201 34th Street South P. O. Box 14042 St. Petersburg, Florida 33733
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Facility Name: Crystal River 3 Docket No.:
50-302 License No.:
CPPR-51 Category:
A2 Location: Crystal River, Florida Type of License: B&W, PWR, 2560 Mwt, 885 Mwe Type of Inspection: Routine, Unannounced, Construction Dates of Inspection:
September 11-14, 1973 Principal Inspector:
E. J. Vallish, Reactor Inspector Facilities Section
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Facilities Construction Branch Accompanying Inspectors:
F. U. Bower, Reactor Inspector Engineering Section Facilities Construction Branch
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A. R. Herdt, Metallurgist
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Engineering Section l
Facilities Construction Branch W. D. Kelley, Reactor Inspector Engineering Section
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Facilities Construction Branch Other Accompanying Personnel: None l
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RO Rpt. No. 50-302/73-7-2-Principal Inspector:
i (L E. J/ Vallish, Reactor Inspector-17-73
Yacilities Section Date Facilities Construction Branch Reviewed By:
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W. A. Crossman, Senior Inspector
_9*2 7* 73 Facilities Section Date Facilities Construction Branch
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RO Rpt. No. 50-302/73-7-3-
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SUMMARY OF FINDINGS
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I.
Enforcement Action A.
Violations
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Safety Item _s None II.
Licensee Action on Previously Identified Enforcement Matters i
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A.
Violations
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73-1/A1 Decay Heat and Makeup and Purification Systems Welding The licensee has fully reviewed the completed field
. weld data sheets, analyzed the radiographic results l
I and re 1 sed the welding procedure This item is closed.
(Details II, paragraph 2)
73-1/A2 Decay Heat and Makeup and Purification Systems Radiography The licensee has identified the deficiencies in radiographic inspection. A corrective action program has,been approved and is starting to be implemented.
Ihis item rh '91ns open.
(Details II, paragraph 3)
B.
_ Safety Items None III.
New Unresolved Items
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None
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RO Rpt. No. 50-302/73-7-4-
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IV.
Status of Previously Reported Unresolved Items
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73-5/2 Safety Valve Piping Assurance is required that safety valve piping design l
criteria did include dynamic force reactions.
The
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licensee is performing an engineering evaluation..This
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73-5/3 Control Rod Drive Motor Tube Extension Discontinuities This item is closed.
(Details IV, paragraph 3)
73-5/4 Limitorque Valve Operator Failures
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This item is closed.
(Details IV, paragraph 4)
73-5/5 Control Rod Drive. (CRD) Undervoltage Trip Assembly Deficiency The generic problem identified with these assemblies is continuing in review.
This item remains open.
(Details I,
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parsgraph 5.a)
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73-5/9 Paddle-Type Flow Switches The licensee has determined that none of these type switches are installed in adverse environments.
This item is closed.
(Details I, paragraph 5.b, and Deca 11s IV, paragraph 5)
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73-5/12 YPC Audit of B&W
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The applicant directed an audit of the NSSS supplier and I
the report will be reviewed later.
This item remains open.
l 73-5/14 Reactor Internals Modification
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Modification to these internals is being accomplished in the vendor shops prior to delivery to the site.
This item remainc open.
(Details IV, paragraph 6)
73-5/15. Quality Assurance Audits
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The licensee has initiated corrective action to assure quality assurance audits receive management attention and are acted upon and closed promptly.
This item is closed.
(Details II, paragraph 5)
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RO Rpt. No. 50-302/73-7-5-
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73-5/16 cable Insts11ation The licensee has made an analysis of the cable spreading area and initiated action to forestall anticipated problems. 1 hic item is closed.
(Details I, paragraph 5.c)
73-3/1 Radiography.of Piping i
j The licensee has reviewed M. W. Kellogg's radiographic
procedure and evaluated their radiographs with regard I
to the primary usage of film side penetrameters.
This item is closed.
(Details II, paragraph 4)
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72-3/5 Procedures for Final Inspection of Piping
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This item is closed.
(Details IV, paragraph 7)
72-5/3 Valve Wall Thickness Requirements In response to the RO:II letters or June 30, 1972, and February 16, 1973, the licensee has developed a valve l
I wall thickness verification program..This item remains open.
(Details III, paragraph 2)
V.
Design Chcnges N ne o
VI.
Unusual Occurrences
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None VII.
Other Significant Findings
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A.. Project Status s
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l Details IV, paragraph 8
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B.
Personnel Changes
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Details IV, paragraph 2 VIII. Management Interview The inspectors met with H. L. Bennett, Director, Generation
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Construction, and others of the staff, and discussed the
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results of the inspection.
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.1 RO Rpt. Ho. 50-302/73-7 I-l DETAILS I Prepared by:
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' U. Bowerv/ Reactor Inspector Date
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agineering Section #
Facilities Construction Branch
.l Dates of Inspectio * Sep tember 11-14, 1973 Reviewed by:
-A f/h///13 J
. Bryant,(senior Inspector Date ineering Section Facilities Construction Branch 1.
Persons Contacted
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Florida Power Corporation (FPC)
a.
R. C. Bonner - Electrical Engineer D. W. Pedrick - Quality Engineer J. C. Hobbs - Mechanical, Electrical Superintendent
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I R. Slater - Electrical Inspector A. Gomez - Electrical Control System Manager G. Walker - Electrical Construction Engineer b.
Centractor Organizations E. C. Ernst Company A. Brewton,- Electrical Supervisor, Cables 2.
E/I Construction Progress Electrical construction is estimated to be 50% complete overall.
Work has progressed farthest in the turbine building and control building. Some work has been performed in the auxiliary building
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and practically none in the reactor building.
Cable pulling is reported to be 33% complete with 1,018,000 feet pulled to date.
This figure consists of 5,448 cables pulled of the nearly 16,000 identified to be pulled. Of this number, only 490 safety related cables have been pulled.
Circuit termination work has continued with 22,000 terminals com-pleted.
The work crew has decreased from the previously reported number of 350 to the present average of 270 electricians.
This drop in work crew size was reported to be elective and characteristic p)g for the summer months. The crew is expected to increase again in the
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ne'.r future.
All E/I work, with minor exceptions, is now accomplished
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on a single shif t basis.
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3.
Startup and Auxiliary Transformers and Primary Systems An examination of construction drawings and installed systems and related discussions with members of the site staff was made to determine if the installation and connection of the subject system followed the operating philosophy and fulfilled the basic criteria
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as established by the application doc'uments. This cursory examina-
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tion provided the required assurance that the applicable criter.ia sere being met.
Apart from one minor problem, associated with the understanding of a construction drawing (EC-206-013), which will be corrected if found in error, no deficiencies were identified.
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4.
Instrument vendor Seismic CerEification It was informally reported by the site QA staff that the seismic
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documentation for all Bailey Meter Company supplied components was available in a topical report previously submitted to Regulatory.
This information, as applicable to the Crystal River project, is being assembled and will be certified and made a part of the appropriate QA/QC record at the site.
O As stated by the site staff respondent, this information should be available for RO:II examination in the near future.
5.
Previously Reported Unresolved Items a.
Control Rod Drive (CRD) Undervoltage Trip Assembly Deficiency (73-5/5)
The NSSS cgntractor is continuing with his analysis of the reported generic defect.
It is the intent, as reported by the licensee, to take appropriate action to correct the deficiency in a timely fashion. This item remains open.
b.
Paddle-Type Flow Switches (73-5/9)
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The licensee reported that FPC has determined that none of i
these type devices are installed in adverse environments.
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This evaluation was reached following an examination of engineering documents pertinent to the question. This item is closed.
c.
Cable Installation (73-5/16)
The licensee has completed the analysis promised at the last O
inspection and is taking the action indicated. This has included assigning approximately 7,500 cables to specific entry slots that were previously unassigned.
In addition, a number of ducts, trays and conduits have been added to provide a means of
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RO Rpt.-No..50-302/73-7 I-3 J
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meeting the. required separation criteria for redundant circuits.
' The physical' effort of cable and hardware revisions is in work.
This. program is expected to continue uni.1 completed.
This item is closed as an unresolved item but will continue.as an inspection item since the area in, question will be a focal point.
for continuing E/I installation effort for the duration of the construction program.
6.
125/250 V Station Batteries, 3A and 3B The procurement, receiving and installation records and the physical instan ation of the subject equipment was examined.
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The batteries and support racks were purchased f*om C&D Company by GAI in accordance with procurement specification R0-3044. Pro-curement documentation was examined and found to be in accordance with the requirements. Receiving inspection records and source
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inspection records, found in the file, attested to this fact.
Instan ation inspections were performed by E. C. Ernst inspectors
and their acceptance of the installed system is documented on check-
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list form Q-036 as signed on February 3,1972.
The installed system was inspected by this inspector for such factors as structural connections, workmanship, cleanliness, equipment protection and the quarantine of deficient components.
No deficiencies were identified.
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Cable Installation Four installed cables in the 125/250 V d.c. control system were chosen for sample examination. These cables serve control power to the four sections of the 5 kv essential buses 3A and 3B.
Identification of the cables selected is MIE-8, MIE-9, DPE-12 and DPE-33. These cables represent redundant feeds to the essential buses and as such are re- -
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quired to meet the single failure requirements set forth in IEEE-279 l
and the licensing documents.
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l Both the QC records and the instaned cables were examined to i
' determine that such factors as procuremer*. and receiving docu-
mentation, installation inspection, separation, protection, hostile environment, workmanship, identification, cleanliness, ampacities, tests and other installation and inspection requirements had been suitably considered.
l The QC records contained documentation for all of the above events,
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indicating that the QC program has been implemented as. required.
Examination of the installed cables did not reveal deficiencies.
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RO Rpt. No. 50-302/73-7 II-1 d
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DETAILS II Prepared by:
A. R. Herdt, Metallurgical
'Date Engineer, Engineering Section Facilities Construction Branch j
Dates of Inspect. ion: September 11-14, 1973 Reviewed by:
be 4 7/ )J J
.Brpay~SeniorInspector Date '
gineering Section, Facilities Construction Branch 1.
Persons Contacted a.
Florida Power Corporation (FPC)
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H. L. Bennett - Director, Generation Construction C. E. Jackson - Construction Superintendent D. W. Pedrick - Quality Engineer j
L. R. Wade - Mechanical Quality Engineer b.
Contractor Organizations
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(1) Pittsburgh Testing Laboratory (PTL)
l J. F. Artuso - Assistant to the President E. L. Andresky - QA Consultant
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j G. W. Martin - NDE General Supervisor G. B. Maksin - NDE Supervisor (2) Gilbert Associates, Inc. (CAI)
S. R. Buckingham - Site QA Coordinator (3) Babcock and Wilcox Construction Company (B&W)
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R. Shope - Site QA Representative J. R. McGill - Quality Control Supervisor 2.
Decay Heat and Makeup and Purification System Welding The inspector reviewed the action taken on this previous violation (73-1/Al). The licensee has revised walding procedure, SS-1-TIG, to permit the. use of either 1/16 or 3/32-inch diameter filler metal.
This change is not an essential variable, thereby not requiring welding procedure requalificatio._
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The licensee has reviewed 730 field weld data sheets for correct rod heat and size.- A total of 267 field welds covering various classes and systems were welded to the above procedure using only
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i 3/32-inch diameter filler metal. Thirty-four welds were ' radio-
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graphed with thirteen welds found unacceptable, twelve of which r
were Class N-2.
All Class N-2 system welds must be radiographically i
inspected. All other welds are inspected to various nondestructive testing requirements in accordance with applicable codes and all welds must meet the required acceptance standard.
The licensee has.
evaluated the radiographed rejects of all welds (40.3%) and compared this to the radiographic rejects that were welded to SS-1-TIG using only 3/32-inch diameter filler metal (38.3%). The licensee states
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that the evaluation shows statistically that the reject rate is consis-tent with Livsey and Company radiographed reject percentage and the use i
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of 3/32 -inch diameter filler metal is. not detrimental to the, welding and no testing above and beyond the applicable code requirements is necessary.
l The inspector has reviewed the data and evaluation. He concurs with the findings since all welds will be tested and meet the applicable and required acceptance standards. The inspector considers this item resolved, f
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Decay Heat and Makeup and Purification Syste'm Radiography The inspector reviewed the action taken on this previous violation (73-1/A2). Based on this violation and the FPC audit performed on May 21, 1973, PTL is reviewing all radiographs for film' quality, weld interpretation (acceptance or rejection) and complete reporting. This review encompasses approximately 650 welds. The results of this review show approximately 200 welds needing weld repair and 230 welds requiring to be reradiographed because of film quality not in accordance with code requirements.
PTL has initiated a corrective action program dated July 13, 1973, to remedy the entire nondestructive examination (NDE) problem. This pro-gram covers: restructuring of PTL's Nondestructive Examination Group,
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onsite; establishment of a system to review all radiographic film taken prior to commencement of this program; and establishing a system of
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i raradiography and repair of unaccepted weld defects. Organization, i
responsibilities, auditing, training of NDE personnel, review of radio-graphic film and corrective action procedures are included in this program.
Furthermore, PTL is requiring two Level II interpretors to review all radiographic film and sign the radiographic report. The licensee has I
required that GAI audit 25% of PTL acceptable radiographs and FPC review 100% of all acceptable radiographs ' from both PTL and B&W.
Also, the licensee has procured two operating densitometers so film density can be
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The corrective action program was reviewed by the inspector with PTL and FPC. The following areas of concern were identified:
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All the required NDE personnel qualification records and documentation shall be onsite and in accordance with the prescribed procedures.
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The radiographic shooting techniques need to be reviewed and deemed acceptable to Code and procedure requirements.
c.
The radiographic procedure, PTL Q-7, shall be clear, accurate and in accordance with onsite work and code requirements.
PTL agreed that these areas need to be examined and has initiated work on these items. The licensee further stated that the field weld data sheets are also being corrected and reviewed for comple-tion and accuracy.
The inspector stated that these items and assurance of satisfactory program implementation, which includes NDE and radiographic review /
q performance, would be examined during subsequent inspections.
This item remains open.
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Radiography of Piping
The licensee conducted an audit of M. W. Kellogg Company (MWK) on
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June 19-21, 1973. The results of the audit indicated that MRK's radiographic procedure had been revised to state that film side penetrameter will be used only when impractical (changed from physically impossible) to use a source side penetrameter.
This wording is in accordance with ANSI B31.7 and Code Case 72.
MRK had not received approval of this change from FPC. The inspector reviewed the audit and documentation from NWK determining the practicality of penetrameter placement and considers this item resolved.
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Quality Assurance Audits The licensee has initiated corrective actions to assure that quality assurance audits receive management attention and open items are
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acted upon and closed promptly. The corrective actions initiated are:
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Monthly review of outstanding audit / corrective action items.
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noting the assignment of cognizant and action parties. This is sent to both FPC and GAI management.
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Approximately 25 of 38 outstanding audit iten have her closed.
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.R0 Rpt. No. 50-302/73-7 II-4 i.
c. ' GAI has responded to all FPC's audit replies.
The inspector has reviewed these corrective actions and had no further
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questions. This item is closed.
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Class I Piping a.
Followup Record Review of Welding There was no welding record review performed on field welds since field weld data sheets from Livsey and Company are being reviewed for accuracy and completeness. The inspector reviewed the weld record documentation on B&W field welds DH-149 and MU-421.
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For the above-listed welds, the licensee produced records and documentation which included weld data sheets, radiographs, radiographic evaluation reports and weld rod material control receipts.
The weld data sheets contain information such as weld procedures, weldor's name and number, and components to be welded.
In addition,
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there are inspector signoffs for fitup, visual, liquid penetrant and
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radiographic test results.
I Radiographs of the above-listed joints were reviewed for jeint identification, date, size of penetrameter; quality of radiograph,
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density and apparent quality of weld.
There were no violations or deficiencies identified during this inspection.
b.
Followup Record Review of Piping
l The inspector reviewed records for spool pieces, manufactured by
MWK of the main steam system, Nos. 4,5,29,41, makeup and purifica-tion system (MU), Nos. 74,88,241, and decay heat system (DH),
Nos. 28,68,84,127. Material certification records for chemical
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composition and mechanical properties were reviewed. The records
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indicated the piping met material specifications. The vendor nondestructive testing records, radiographic film, shop cleaning and hydrostatic test results as well as records of onsite receipt inspection were reviewed. There were no deficiencies or violations identified in this area.
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RD Rp t. No. 50-302/73-7 III-1
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Cl Mw 9,4[7T DETAILS III Prepared by:
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'Date W. D. Kelley, Reactop/ Inspector g, Engineering Section, Facilities Construction Branch Dates of Inspection:. September 11-13, 1973 9#
T Reviewed by:
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" Ddte J.g. B'ryagSenior' Inspector Ergineering Section, Facilities Construction Branch 1.
Persons Contacted Florida Power Corporation (FPC)
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a.
H. L. Bennett - Director, Generation Construction J. Lander - Engineer II, Generation Construction J. E. Banett - Engineer II, Generation Quality & Surveillance b.
Contractor Organizations I
l (1) J. A. Jones Construction Company (JAJ)_
J. R. Amundsun - Site QC Manager i
2.
Valve Wall Thickness Requirements FPC has prepared a quality control procedure for verification of the wall thickness of reactor pressure boundary valves for Crystal River Unit 3.
The inspector reviewed with FPC their quality control procedure and the requirements of RO:II letters of June 30, 1972, and
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February 16, 1973. Minor descrepancies noted were corrected.
The licensee stated that they had measured the wall thickness of all three.
the valves designated as reactor coolant boundary valves except
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The data of wall measurements for nine valves may require an engineering i
evaluation.
The data for these nine valves, with the recommended
'f corrective action, will be forwarded to Gilbert Associates Inc. for engineering approval, if required.
Upon completion of the valve wall thickness verification program, an audit will be performed by FPC.
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RO Rpt. No. 50-302/73-7 IV-1
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7-M-73
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DETAILS IV Prepared by:
E. J. Wallish, Reactor Inspector Date Facilities Section, Facilities Construction Branch Dates of Inspection:, September 12-14, 1973 9*27 73 Reviewed by:
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- C u tu W. A. Crossman, Senior Inspector Date Facilities Section, Facilities Construction Branch 1.
Individuals Contacted Florida Power Corporation (FPC)
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a.
D. W. Pedrick, IV - Quality Engineer
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b.
Contractor Organization Babcock and Wilcox Construction Company (B&W)
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C. Barksdale - Project Manager
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sm J. R. McGill - Quality Control Supervisor 2.
Organizational Changes The new organization $1 chart for the Generation Quality and Standards
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Department that was effective September 3,1973, was reviewed.
There are now three. Managers under the Director, Generation Quality and Standards: Manager, Quality Surveillance Audits; Manager, Site Surveillance Nuc. lear; and Manager, Site Surveillance Fossil. This Director reports to the Assistant Vice President - Generation Engineer-ing.
3.
Control Rod Drive Motor Tube Extensions Discontinuities
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Inspection of B&W field records indicated that their field verification of the shop acceptance inspection criteria showed that 42 of the 70 motor tube extensions have wall thicknesses less than that required by the 650 F design criteria.
The control rod drive mechanisms that will
have these thinner walled tubes have been indexed and their future loca-tion on the reactor vessel head is thus assured. This item is resolved.
4.
Limitorque Valve Operator Failures
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Inspection of file 620-0007-93-45 produced the completed Repair Order No. 371194 and the B&W records of the changes to these valve operators.
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f RO Rpt. No. 50-302/73-7 IV-2 Records indicated valve identification, operator size, vendor order number, operator serial number, switch replaced, completion verifica-tion and date. This item is resolved.
5.
Paddle-Type Flow Switches
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Inspection indicated that paddle-type flow switches are not being used on this plant. This was indicated by a letter from the Director -
Generation Engineering to the Quality Engineer dated September 13, 1973.
There are no further questions.
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6.
Reactor Internals Modification B&W personnel indicated that these modifications will be completed 20 days after the strike ends at the B&W shops.
All internals are scheduled to be onsite in May 1974.
7.
Procedures for Final Inspection of Piping Quality Control Procedure FPC-25, entitled " Piping System - Construction
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Completion Check-out," was reviewed and there are no further questions.
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8.
Construction Progress
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Construction is estimated to be 82% complete.
All the primary loop piping has been fitted and hung in position. Welding will not start until af ter the reactor vessel anchor bolts have been tensioned.
Piping to the pressurizer has not been fitted.
Core flood lines are hung and welded except at the reactor vessel nozzle and spools to the flood tanks.
The primary coolant pump casings are fitted into place without internals or motors. The dome of the containment liner is still open.
Concrete placement layout ring girder is up to the bottom of the trumpet layout elevation.
Ventilation ducting is being installed inside the containment
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building and cleanup and painting underway.
The refueling pool is being prepared for lining.
A major effort is the pulling of electrical cables. The control consoles are installed and wire terminations are being made.
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Ltr to Florida Power Corporation
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. D. Thornburg, RO
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RO:HQ (h)
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