IR 05000312/1970003
| ML19309A308 | |
| Person / Time | |
|---|---|
| Site: | Rancho Seco |
| Issue date: | 04/22/1970 |
| From: | Dodds R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V), US ATOMIC ENERGY COMMISSION (AEC) |
| To: | |
| Shared Package | |
| ML19309A301 | List: |
| References | |
| 50-312-70-03, 50-312-70-3, NUDOCS 8003270735 | |
| Download: ML19309A308 (14) | |
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s U. S. ATOMIC ENERGY Cole (ISSION
REGION V
DIVISION OF COMPLIANCE Report of Inspection L
CO Report No. 50-312/70-3 Licensee:
Sacramento ihmicipal Utility District License No. CPPR-56 Category A Date of Inspection:
March 18-20, 1970 Date of Previous Inspection:
February 12, 1970 to bv A.,h Y/2 L h*
Inspected by:
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R. T. Dodds (
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Reactor Inspector s
Reviewed by:
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' G. S. S pencer Senior Reactor Inspector Proprietary Information:
Yes _S)sD audit of B&W (Section D.)
SC0FE Tvoe of Facility:
Pressurized Water Reactor Power Level:
2452 Itte Location:
Sacramento County, California Type of Inspection:
Construction Inspection (Containment)
Acconnanvina Personnel:
None 7d 8 0 0 3 270 7 38~
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SUNIMLY
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Construction Deficiencies No construction deficiencies were identified
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that appeared to be significant enough to warrant the sending of a CDN
to the licensee.
Status of Previousiv Renorted Problems 1.
Satisfactory corrective action has been taken on all of the construction deficiencies that were identified during the October, 1969 inspection.
These were related to activities associated with the manufacture and testing of concrete for Rancho Seco.
(Section E.)
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Satisfactory remedial action on all of the discrepancies that were identified during the January,1970 initial quality assurance inspection of SHUD and Bechtel (Vernon Office) has been implemented in accordance with the statements previously made by SNUD officials during the
" Management Meeting" in February, 1970 (Section C.)
l Other Significant It?ms
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1.
Overall project construction was estimated to be 7% complete as of February 28, 1970. The containment building base slab has been poured.
Construction has been started on the containment liner; the floor and about three 10-foot tiers had been completed at the time of the visit.
(Sectio 1 B.)
2.
SHUD's audit of the B&W Lynchburg facilities disclosed essentially the same discrepancies as have been observed during CO's inspections, Early resolution of these findings has been requested.
(Section E.)
i 3.
Samples for compression strength tests are est u at the batch plaat ! N rather than the point of placement. No react: se piping, such as edbC'
aluminum pipe, has been or will be used. Also, the average time of
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p?.acement from mixing runs about 15 minutes.
(Section F.1.c.)
4.
Exc(pt for the concrete sampling location, the policies followed for the menufacture of concrete were consistent with the appropriate CO PI's.
(Section F.)
5.
CB&I is constructing the reactor building containment liner. All of the records pertaining to material traceability will not be available at the site until the liner has been complete. However, the existence of appropriate material certifications and material acceptability is being verified by a Bechtel source inspector prior to shipment of the material to the site.
(Section G.)
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6.
The welding procedures employed in the construction of the containment liner were consistent with the appropriate CO PI's.
(Section H.)
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7.
Some weld electrodes were observed to be "left out" overnight. Bechtel plans to do some after-hour inspection to assure compliance with
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electrode control procedures.
(Section I.4.)
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The results of the visit were discussed with Manamement Interview
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Messrs. Mattimoe, Raasch, Stinchfield, Jackson, Vander Knyff and McMahon.
The inspector acknowledged the corrective action taken on the deficiencies that were observed during the October,1969 construction inspection and the January. 1970 initial quality assurance inspection. Specific statements regarding some of the items discussed were as follows:
1.
Mr. Stinchfield stated that additional inspection would be performed after hours to assure that CB&I followed the required weld electrode material control procedures.
A log has been established for daily recordings of the temperature in the concrete sample curing room.
3.
It was not deemed appropriate or necessary to change the method of concrete sampling unless extensive or complicated pumping of concrete
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was required.
DETAILS A.
Personnel Contacted The following persor.nel were contacted during the inspection:
S.NE.
Assiatant Chief Engineer J. Mattimoe
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D. Raasch Project Engineer
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J. Jackson Quality Assurance Director
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J. Hiltz Civil Engineer
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j-4-Bechtel Corporation W. Stinchfi21d Rancho Seco Construction Manager
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V. McMahon Quality Assurance Engineer
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R. Cutler Manager, Civil Construction
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C. Marquess Materials Supervisor
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B. Boyd Senior Engineer (Welding)
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J. Maries Field Engineer
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A. Cappelletti Welding Inspector
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Leave 11-Dravo
W. Steen Project Manager
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Chicaeo Bridee and Iron R. Childres Job Foreman
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R. J&mison Welding Inspector (Supervisor)
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B.
Status of Construction l
Site construction was estimated to be essentially on schedule with 7%
completion as of February 28, 1970 The containment building base est has been poured and the floor plus about three tiers of the containment liner have been welded in place. The containment building was estimated to be 12%
complete. Foundations for major structures, including the cooling towers, turbine p(destal, auxiliary building and containment building, were estimated to be 807, complete.
C.
Initial Quality Assurance Insoection Licensee action in response to the initial QA inspection by CO:V was reviewed with Mr. Jackson. The material reviewed, which included the revised QA manual and QA records, showed that SMID had taken promised correction action on all items pursuant to the consnitments that were made during the management meeting on February 12, 1970 following the initial QA inspection (CD Report No. 50-312/70-2).
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SMUD Audits of BW
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Hr. Jackson has conducted several QA audits of BE design and manufacture of components for Rancho Seco. The Barberton facilities were audited in October,1969 and found to be pretty much in compliance with the AEC's 18 point QA criteria. The Lynchburg facilities were audited in November, 1969 and in
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more detail on January 20-21, 1970 The results of the January audit show
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essentially the same deficiencies as have been identified by CO's audits of
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Lynchburg. The results of the Lynchburg audit were as follows*:
"1.
Ormanisation (Reference AEC Criteria No. 1)
(a) ThereisnoclearstatementofresponsibilityoftheQuality; Assurance Manager as he relates to other plants of B W,
such as:
Audit responsibilities at Barberton/Mt. Vernon
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QA Manual approvals for all plants
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Quality Assurance coordination with customers j
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(b) Since the internal operating procedure (ICIS) is under the cognizance of the Standards and Coordination Section, it is not clear as to the degree of control the Quality Assurance organization exercises on the formation of company policy
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with regard to the AEC 18 point criteria.
"2 Quality Assurance Pronram (Reference AEC Criteria'No. II)
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l (a) QA procedures showing the detailed implementation of the AEC 18 point criteria do not as yet exists. Certain elements of the quality program are gathered in varying parts of the ICIS manual, however, the need exists for a Quality Assurance Manual. An inconsistency was noted between the definition for Quality Assurance classes as set forth in the ICIS manual and recent correspondence from BE.
(b) Throughout the audit, reference was made to methods of operation whereby QA reviews such documents as purchase orders, specifi-cations, drawings, etc.
Procedures are lacking which assure
QA participation as evidenced by approval signatures.
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- NOTE: This information (audit findings) is proprietary.
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"3.
Desien Control (Reference AEC Criteria No. III)
Calculation supporting the design review effort on the NSS were i
reviewed. Not all calculations show evidence of independent review.
The ICIS manual formalized a system of documenting an independent review with a formalized certification statement. An estimated 20 to
30 percent of the components are lacking any form of objective evidence of an independent review.
"4 Procurement Document Control (Reference AEC Criteria No. IV)
(a) No procedure for QA purchase order review.
(b) Supplier evaluations are performed by NPCD and Barberton.
However, Barberton worksheets are not available at NPCD.
It is therefore impossible to verify the extent of a supplier's conformance to the criteria.
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(c) Procurement documents show no evidence of imposing the AEC criteria on suppliers.
"5.
Control of Purchased Meterial Equionent and Services, (Reference AEC Criteria No. VII)
(a) No procedures exist for covering source inspection or
receiving inspection.
(b) The BW Quality Assurance Manag e indicated that B W source inspection activity would be confined mainly to surveillance audit with little or no inspection. There were no plans for receiving inspection beyond an examination for shipping damage.
"6.
Nonconformina Meterial Control (Reference AEC Criteria No. XV)
(a) No evidence exists of BW imposing approval of supplier's nonconformances.
(b) The procedures for nonconforming material control at NPCD,-
as described in the ICIS manual, are in insufficient detail to describe the method of implementation.
(c) A review of a nonconforming report written on fuel pellets (another customer's contract) indicated a lack of knowledge of administration of sample plans. The quality engineers are i
not represented on the nonconforming material. review board
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and have no formal approval (or disapproval) authority on nonconforming asterial."
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-7-Mr. Mattimoe, SMUD Assistant Chief Engineer, formally requested cooperation on a timely b a sis from B6M in resolving the deficiencies identified during the January, 1970 audit.
E.
Previousiv Reoorted Deficiencies (Concrete Manufacture)
The validity of SMUD's answers to CO:V's CDN regarding the manufacture of concrete was verified during the inspection. Specifically, plant records and a tour of the plant provided the following information*:
1.
The combined tricalcium silicate and tricalcium aluminate content of the cement supplied to Rancho Seco has been tested by both the cement manufacturer and SMUD's consulting laboratory (Lowery Associates) and found to be 53-58%.. This is within the limita specified in ASTM Designation C150. Regardless, the combined limit of 58% for C S plus C A is not limiting because low heat of
3 hydration is not a requirement at Rancho Seco according to Mr. Hiltz, SMUD Civil Engineer. However, thermocouples were inserted during the placement of the containment building base j
slab. The peak temperature was 120 F.
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Tests of the cement in use at Rancho Seco have demonstrated the false set relative penetration to be between 83-94%, well above the minimum limit of 50%.
3.
Backup data has been obtained from the cement supplier, Pacific Cement and Aggregate (PCA) that shows a concrete compressive strength curve for various water-to-cement ratios for the same type of cement being used at Rancho Seco. This data adequately supports the concrete design mixes that have been used at Rancho Seco.
A review of aggregate test results for the period of November 1969-February 1970 showed that each size aggregate was being sampled from the stack to batch plant conveyer belt each day the concrete batch plant was in operation. No discrepant material was accepted for usage during this period.
- C0 Report No. 50-317/69-3.
CDN dated 12/17/69.
SMUD reply dated 1/2/70 O
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A cheet metal shield has been installed under the stacker conveyer belt to catch and keep sand fines _from settling on the aggregate storage piles. During a tour of the concrete manufacturing facilities, the aggregate piles were observed to be clean and free of any significant quantity of fines.
General User tests are being made of cement time-of-set, compressive j
strength and false set for a cement silo prior to the time the j
cement is supplied to Rancho Seco. The supplier's chemical analysis of cement has been verified and no further user analyses are planned. However, the supplier's mill test reports for each new silo will be examined. The trucker also provides the plant with a certificate of compliance for each delivery that shows the source of cement.
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F.
Containment-Concrete 1.
Completion of Review of OC System *
a.
Sluso Tests
Slump tests are performed periodically at the point of place-ment to assure that there is no substantial difference between concrete properties at the time of mixing and time of place-rent. Tests at the batch plant are made for at least every 100 cubic yards of mixed concrete. During the pour of the second lift of che containment building base met (2898 C1)
28 slump tests were made at the batch plant and 18 were unde t
at the point of placement. The average of these slump tests taken at the batch plant and point of placement (containment building) were 2.43 and 2.50 inches respectively. None of the tests showed slumps that exceeded the maximum average
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limit of 3.0 inches.
b.
Air Entrainment Air entrainment tests are run for each 100 CY of mixed concrete. Tests are not performed at the point of placement I
- See CO Report No. 50-312/69-3
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since it is difficult to contrcl the samples according to
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Mr. Cutler. Also the slump tests show a close correlation between the batch plant and point of placement. The norms 1
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time between batch plant and concrete placement is usually less than 15 minutes. The msximum allowable time is 45 minutes. The air entratasent test results for the two j
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containment building base slab lifts averaged 4.34%
(desired - 4.5%).
c.
Comoression Strenath Tests The samples for compression strength tests are taken at the batch plant rather than the point of placement. Messrs.
l Cutler and Erickson defended the sampling system for the following reasons:
(1) the slump tests have ei.own consistent
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results between batch plant and point of placement; (2) the
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average time-of placement is usually about 15 minutes i
(specifications allow no more than a 45-minute placement time); (3) the concrete trucks only have paddle-type i
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agitators and do not six the concrete; and (4) no reactive i
piping, such as aluminum pipe, has been or will be used.
d.
General The inspector's review of the quality assurance and quality control system in use for the manufacts re of concrete disclosed that the licensee's quality control procedures,
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work performance procedures and record keeping requirements i
have been established and are consistent with (CO's) PI 4605.03 and.04, with the possible exception that samples for compression tests are taken at the batch plant and not the point of placement.
Followuo Record Review A review of the records for (1) concrete and splice strength
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tests, (2) slump tests, (3) adherence to mix designs and (4)
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placement control disclosed that the licensee's program and test results were consistent with CO's PI 4605.05 a.1., a.2., L.2. and b.7. and with sections 5.1.3.1, 5.1.3.2, 5.4.3.2 and Addendum SC
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l of the PSAR. The following records were included in the review:
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Concrete Test Results (mix nowber, slump, % air, unit weight, concrete temperatura, ambient temperature, and compressive strength - 7 day and 28 day).
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Concrete Quality Control Chart.
c.
Concrete Batch P1e-! Reports d.
Concrete Placement Reports.
e.
Preparation for Concrete Reports (checkout data sheets),
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Concrete Aggregate Tests, g.
Concrete Mixes.
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Trucker Concrete Delivery Tickets (mix number, strength and cubic yards received and delivered).
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Batch Plant Tape Printouts (printout of weights of the various materials in each batch of concrete delivered).
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User Tests of Reinforcing Bars, k.
Operator Qualifications for Cadweld Splicing.
1.
Cadweld Splice Tests (tensile tests of production and sister splices).
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Nknufacturer's Certifications of Reinforcing Bars.
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Nonconfornirg Material Reports, o.
Source Inspection Logs - Reinforcement.
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Receiving Inspection Logs - Reinforcement.
G.
Containment Liner - General CB&I, a Leave 11-Dravo subcontractor, is responsible for obtaining the materials and construction of the reactor building containment liner. In accordance with CB&I policy, the complete package of material certifications and other records relating to the fabrication of the liner will not be turned over to SMJD until completion of the job. However, no material can be shipped to the site until a Bechtel source inspector has released it and so notified the site by telegram. The source inspector is responsible for verifying
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QA-QC program which requires a record of the results of all inspections, etc. These records are kept in CB&I's files at Rancho Seco; however, copies are supplied to the Bechtel QA group for review.
One of the inspection data eports for the containment liner plate was reviewed. It was observed to contain the following information:
1.
Source inspection acceptance reports.
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Shipping damage reports.
3.
General surface condition.
Handling and storage information.
Record piece identification numbers.
H.
Containment Liner - Weldina The inspector's review of the implementation of the QA program and the QC system in use for the welding of the reactor building containment liner disclosed that the licensee's QC procedures, work performance procedures and record keeping requirements are consistent with CO's PI 1305.03 and.04 and sections 5.1.3.4, 5.4.3.5 and 5.5.1.1 of the PSAR. Information was obtained from discussions with Nhssrs. Boyd, Marices, McMahon, Jackson, Jamison and Childress and from a review that included the following records:
1.
Weld Procedure Qualifications.
2.
Welder Qualification Tests.
Construction Inspection Data Reports.
NDT Inspector Certifications and Qualifications.
5.
Welding Drawings * (Liner Plate Blue Prints)
Welding khterial Control Procedures
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Information on coupleted weld drawings includes (1) welder identification symbols, (2) welder performing the work, (3)
i Bechtel and CB&I inspectors who witnessed NDT tests, and I-(4) welding procedures to be followed.
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Drawing Control Procedures 8.
Procedure Control
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Field Examination Check Lists
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Non-Conforming Meterial Reports (a report required for each defect detected by inspection).
11... NDT Inspection Requirements and Procedures (vacuum box, dye penetrant, radiography and magnetic particle).
System for correlation of records to weld.
13.
Shipping and Receiving Inspection Reports of Filler Materials
I.
Tours of the Construction Site, i
Ses Tal tours were made around the construction site for the purpose of observing the following items:
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1.
Concrete Placement Placement of concrete in the turbine pedestal was observed to be consistent with the prescrited practices. A Bechtel inspector was prasent during placement.
2.
Storane of Materials for Corerete No deviations from accepted practices for the storage of materials were observed.
3.
Concrete Laboratory The vibrators for concrete samples were tested and found to exceed the minimum acceptable value of 7000 cym.
The temperature of the sample curing room (1001 relative humidity because of continuous spray) was being checked twice a day and
maintained at 73.4 + 30F in accordance with ASTM C-39; however,.
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the curing room temperature was not being recorded. Since the
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curing temperature is an essential code requirement, Mr. Cutler
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I immediately had the Laboratory Supervisor establish a temperature
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log.
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Weld Electrode Control A tour was made after normal working hours to observe liner construction and to check on weld filler metal control. Two deviations from material control procedures were observed.
a.
About half of a box of E6010 electrodes was observed to be lying under a welder's helmet.
(Should have been stored in a dry box.)
b.
About a third of a box of E7018 (low hydresen) electrodes was still in a welder's bucket. Also, several E7018 electrodes were lying on top of an oven.
(All of these j
electrodes should have been stored in an oven.)
Nk. Boyd stated that he would discuss these material control
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procedure violations with CB&I and, in addition, Bechtel would have their inspectors work overtime several nights a week just to check on electrode control.
5.
Radiography (Containment Liner)
Several radiographs were reviewed that showed defects and
' subsequent repair of seam welds in the liner. The radiographs appeared to be of acceptable quality and showed the required penetrameters. The film also showed the contract number, seam location, film number and welder's identification symbol, l
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DIVISION OF COMPLIANCE MONTHLY REPORT, APRIL 1970 g ;, 3lk Sacramento Municipal Utility District.(Rancho Seco)'- An inspection was conducted on March 10-20. Satisfactor/ action has been taken on the construction deficiencies identified during the October inspec-tion (November Monthly Report) and on the discrepancies identified during the January initial quality assurance inspection (January Monthly Report).
Overall project construction was estimated to be 7% complete as of February 28. The contairment building base slab has been poured.
Construction has been started on the containment liner. 'Ihree 10-foot tiers had been ccrnpleted.
SMUD's audit of the B&W Ignchburg facilities disclosed essentially
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the same discrepancies observed during CO's inspections of B&W
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(December Monthly Report
'Ihree Mile Island). SMUD pas requested early resolution of these findirgs.
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