ML19308D487
| ML19308D487 | |
| Person / Time | |
|---|---|
| Site: | Crystal River  |
| Issue date: | 04/04/1972 |
| From: | Moseley N, Swan W, Warnick R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML19308D482 | List: |
| References | |
| 50-302-72-01, 50-302-72-1, NUDOCS 8002280794 | |
| Download: ML19308D487 (11) | |
See also: IR 05000302/1972001
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UNITED STATES
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ATOMIC ENERGY COMMISSION
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DIVISION OF COMPT.IANCE
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REGION ll - SUIT E 818
230 PE ACHT REE ST REET, NORT HWEST
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AT1. ANT A. GEORGI A 30303
CONSTRUCTION INSPECTION REPORT
C0 Report No. 50-302/72-1
Florida Power Corporation
Crystal River Unit 3
Docket No. 50-302
License No. CPPR-51
Category A2
Crystal River, Florida
Type of Licensee: B&W, PWR, 855 Mwe
Type of Inspection: Routine, Unannounced
Dates of Inspection:
February 1-4, 1972
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Dates of Previous Inspection: December 20-21, 1971
Principal Inspector:
N-3 72
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R. F' Warnick, Reactor Inspector
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(Testing and Sta up)
Accompanying Inspector:
YM,
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W. B. Swan, Reactor Inspector
Date
(Construction)
Other Accompanying Personnel: None
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Reviewed By:
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N. (T. Moseley,' Senior Reac;ti6r Inspector
'Dafe'
(Testing and Startup)
Proprietary Information: None
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CO Report No. 50-302/72-1
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SECTION I
Enforcement Action - None
Licensee Action on Previously Identified Enforcement Matters
Florida Power Corporation's system for identifying and documenting
concrete defects and assuring prompt corrective action was reviewed
and the inspector has no further questions.
(See section II,
paragraph 7.)
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Unresolved Items
Review of final reports on heat treatment of equipment hatch.
(See section III, paragraph 7.)
Status of Previously Reported Unresolved Items
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No change in status
Design Changes - None
Unusual Occurrences - None
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Persons Contacted
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Florida Power Corporation (FPC)
- H. L. Bennett - Director, Generation Construction
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- E.
E. Froats - Quality Engineer
- C.
E. Jackson - Construction Superintendent
- R. B. Johnson - Engineer
- M. H. Kleinman - Manager, Quality Programs and Standards
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- D. W. Pedrick - Engineer
J. F. Rashinsky - Quality Control Supervisor
W. H. Recker - Quality Control Receiving Inspector
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C0 Report No. 50-302/72-1
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Gilbert Associates, Inc. (GAI)
S. R. Buckingham - QA Coordination Engineer
J. D. Green - QA Mechanical Inspector
- These individuals also attended the management interview.
Management Interview
A management interview was conducted with Bennett and other FPC
staff members at the conclusion of the inspection. The following
subjects were discussed:
A.
Warnick stated that he reviewed the quality assurance files,
which included the material and fabrication certifications, for the
pressurizer, the steam generators, and the makeup (high pressure
injection) pumps. A discussion of the quality assurance files
followed.
Froats said that FPC had reviewed the steam generator file since
the inspector's last visit. Kleinman informed the inspector that
FPC was auditing the quality assurance files supplied by B&W but
the audit was not yet complete. Bennett indicated that although
the audit was not complete, he was satisfied there were problems
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in the material and fabrication certification documents.
Bennett
and Kleinman agreed that FPC would request B&W to upgrade the QA
data packages.
(See section II, paragraph 8.)
B.
Warnick indicated he had reviewed FPC's procedures for receipt,
handling, storage, and inspection of the control rod drive mechanisms
and the pressurizer safety relief valves.
The inspector also reviewed
inspection records and observed Class I components in storage.
The general prob 1 cms of FPC's storage and inspection program were
discussed.
Specific problems were documented as an item of
noncompliance in October.1/ Bennett said that since that time,
FPC had hired one man specifically to work on the in-storage
inspection program. The inspector discussed the two missing
pressurizer relief valves and stated that this was an indication
FPC had not fully corrected their storage and inspection problems.
(See section II, paragraph 9.)
1/ CO Report No. . 50-302/71-4,Section II, Paragraph 4.
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CO Report No. 50-302/72-1
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C.
Warnick requested FPC to supply a list of all primary construction
records maintained by FPC and its contractors.
Bennett indicated-
a list would be prepared and would be available to the inspector-
on his next trip to the site.
(See section II, paragraph 10.)
D.
Lack of definitica of visual inspection requiremects for weld
joint preparation in erection procedures of conts.nment liner
supplier was discussed by Swan. The licensee sta ed that their
QA representatives provide surveillance on weld preparations.
(See section III, paragraph 4.)
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E.
Swan stated that liner installer's procedures do not define
control procedures for liner repairs. The licensee stated that
repairs other than routine have been handled by change notices,
approved by several agencies.
(See section III, paragraph 5.)
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F.
Deficiencies noted by Swan in vendor data on post-stressing
hardware and in preliminary procedures for installatit u and
acceptance criteria for tendons were discussed. The licensee
promised corrective action prior to tendon fabrication and
installation.
(See section III, paragraph 6.)
G.
Incompleteness of file on heat treatment of containment equipment
hatch was mentioned by Swan. The licensee agreed to complete file
for Compliance review.
(See section III, paragraph 7.)
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C0 Report ho.-50-302/72-1
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SECIION II
ADDITIONAL SUBJECTS INSPECTED, NOT IDENTIFIED IN SECTION I, WHERE NO
DEFICIENCIES OR UNRESOLVED ITEMS WERE FOUND
1.
General
Jackson reported that construction was 45% completed. Work
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is progressing on the reactor building concrete.
Concrete has been
placed about one-third of the way up the liner. Preparations are being
made to install the polar crane. After that is complete, the liner
dome will be erected. The licensee's revised core loading date is
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July 1973.
2.
Other Class I Components-Makeup Pumps (High Pressure Injection Pumps)
a.
Followup record review.
(1) Storage inspections.
(2) Installation inspections.
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(3) Material and fabrication certifications.
b.
Followup observations of work.
(1) Protection of installed components.
(2) Frotection of components in storage.
3.
Other Class I Components-Pressurizer
a.
Followup record review.
(1) Storage inspections.
(2) Material and fabrication certification:2.
b.
Followup observations of work.
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(1) Protection of components in storage.
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CO Report No. 50-302/72-1
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4.
Other Class.1 Components-Steam Generators
a.
Followup record review.
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(1) Material and fabrication certifications.
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b.
Followup observations of work.
(1) Protection of. installed components.
5.
Other Class I components-Control Rod Drives
a.
Review of quality control system.
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(1) Receipt, inspection, and handling.
(2) Special handling and storage precautions,
b.
Followup observations of work.
(1) Protection of components in storage.
6.
0ther Class I Components-Pressurizer Safety Relief Valves
1.
Review of quality control system.
(1)
Receipt, inspection, and handling.
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(2)
Sr.cial handling and storage precautions.
DETAILS OF SUBJECTS DISCUSSED IN SECTION I
7.
Concrete Inspections and Deficiency Reporting
FPC has a new form for reporting concrete surface defects.
It is
form no. 36 and is entitled " Concrete Surface Defect Form " The
following information is recorded at the time the concrete forms
are removed and the concrete is inspected: pour number, building,
date of pour, pour sketch number, date forms stripped, whether or
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not there was exposed coarse aggregate, and whether or not further
action is to be taken. The report is signed by the concrete inspector.
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C0 Report No. 50-302/72-1
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If there are defects which must be repaired, then the follow.'ug
additional signatures are required: (a) Concrete finisher foreman
notified, (b) inspection prior to patching, (c) concrete finisher
foreman notified, and (d) inspection after patching.
There is
also space available for remarks.
Any defect recorded on this new form is also recorded on the
"Nonconformance and Corrective Action Report Form." This is
part of FPC's system to assure that conditions adverse to quality
are promptly identified and corrected.
This new Concrete Su
Defect Form resulted from Compliance's December inspection.d.yface
The item of noncompliance is now considered to be resolved.
8.
Material and Fabrication Certifications
During the December 7-10, 1971, inspection, deficiencies found in
the materials and fabrication certification
were reported as an item of noncompliance.2.y for Class I components
At that time, FPC
indicated they would conduct an audit of other B&W supplied data
packages.
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This inspection Froats indicated that FPC had reviewed the steam
generator quality assurance file.
Kleinman informed the inspector
that the audit of other B&W supplied quality assurance files was
not complete. Bennett said that although the audit was not complete,
he was satisfied there were problems that needed correcting.
Bennett and Kleinman agreed that FPC would request B&W to upgrade
the quality assurance data packages.
9.
Pressurizer Safety Relief Valves
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Two pressurizer safety relief valves, one electromagnetic relief
valve and one isolation gate valve, were purchased from Dresser
Industries, Incorporated.
The inspector reviewed the purchase
order, PO#81395LS, and FS-III-llb, the field specification for
receiving, inspecting, handling, and storing the safety and
pressure relief valves.
1/ C0 Report No. 50-302/71-5,Section II, Paragraph 7.
2,/ C0 Report No. 50-302/71-5,Section II, Paragraph 6.
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C0 Report No. 50-302/72-1
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The inspector reviewed the receiving inspection report dated
July 12, 1971, which documented the receipt of one safety
relief valve, RC-RV1B, and one electromagnetic relief valve RC-RV2.
The inspector commented on the lack of in-storage inspection
reports. Upon checking with B&W, FPC quality surveillance
personnel were informed that these two valves were lost.
This was discussed in the exit interview. The inspector stated
that this van an indication that FPC had not fully corrected the
storage and inspection problems that were documented as an item
of noncompliance in October.1/ Bennett said that they had hired
one man specifically to work on the in-storage inspection program.
10. Review of Primary Construction Records
The inspector requested FPC to supply a list of all prima: e construction
records maintained by FPC and all contractors. The inspector explained
the background for this request and indicated that a sampling of
these records would be examined during subsequent visits. This
was discussed in the exit interview and Bennett indicated a list
would be prepared and would be available to the inspector on his
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next trip to the site.
1,/ C0 Report No. 50-302/71-4,Section II, Paragraph 4.
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CO Report No. 50-302/72-1
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SECTION III
Prepared by:
W. B. Swan, Reactor
Inspector (Construction)
ADDITIONAL SUBJECTS INSPECTED, NOT IDENTIFIED IN SECTION I, WHERE NO
DEFICIENCIES OR UNRESOLVED ITEMS WERE FOUND
1.
Tendon Sheaths and Anchorages
The quality control procedures and records were reviewed.
Installation work was observed for adherence to work procedures
and technical requirements. QC inspection procedures including
pressure testing of the sheaths and sheath joints were observed.
2.
Containment Concrete QC System
a.
Location of Testing
Concrete mix is sampled and tested for slump, temperature and
air content at discharge from trucks.
Slump of pumped concrete
is tested at end of pump pipeline.
Test cylinders are cast, cured, and tested at onsite laboratory
per ASTM Standards C-31 and C-39.
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b.
Pump Line Material
Steel pipe only is used for pumping concrete.
3.
Containment Liner Welding Quality Control
a..
QC System
QC measures taken by liner installation contractor are monitored
and audited by FPC's QA agency.
b.
QC Records
Liner installer is not required to document QC for joint
preparation. QA agency monitors on sampling basis and
documents surveillance and auditing findings on joint
preparation and welding.
FPC audits preocedures and
records of QA agent.
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DETAILS OF SUBJECTS DISCUSSED IN SECTION I
No nonconformance or noncompliance was cited.
Details of subjects discussed.at management interview follow:
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4.
Lack of Definition in Erection Procedures of Containment Liner
Supplier of Requirements for Visual Inspection of Weld Joint
Preparation
The erector's QA engineer visually inspects joint preparations.
When dimensional and cleanliness requirements have been u.et, he
verbally notifies welding foreman that joint is acceptable for
welding. The licensee's QA agency does use a detailed written
procedure for visual inspection and recording of results on 'a
sampling basis.
5.
Liner Installer's Procedures Do Not Define Control Procedure for
Welding Repairs
For routine flaw removal, the governing code does not require a
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detailed procedure. A review of the installation reccrds and
the surveillance records of the QA agent showed that substantial
weld repairs are covered by and have been controlled by change
notices approved by the crector's engineer and by the QA agent and
FPC's engineering. Approval of these repairs is by NDT.
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6.
Deficiencies in Vendor Data on Post-Stressing Hardware and in
Preliminary Procedures for Installation and in Acceptance Criteria
for Tendons
The vendor proposal documents reviewed were not in adequate detail
for component acceptance or for installation and acceptance of
stressed tendons.
Installation of tendons is scheduled to start in December 1972.
Finalized procedures and hardware data were not required at time
of this inspection. Licensee stated that finalized procedures will
be provided and are expected to clear the noted deficiencies.
Compliance will verify adequacy on timely basis.
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CO Report No. 50-302/72-1
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7.
Records Deficiencey for Heat Treatment of Containment Equipment Hatch
A follow-On Compliance review of this record file will be required.
The file contained the containment liner insta11er's hand-printed,
detailed record of *,rperatures recorded and other notations.
The recording instrument tape of readings, by contractual agreement,
will be available later. The installer had engaged a consultant
boiler inspector to verify validity of heat treatment of the hatch.
The boiler inspector's report had not reached the file. His
certification is expected to clear the records deficiency.
The licensee's QA agency made no separate detailed report on their
surveillance of the heat treatment of the hatch, although their
surveillance engineer stated that the process was monitored.
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