ML19308D608

Insp Rept 50-302/70-01 on 700108-09.No Noncompliance Noted. Major Areas Inspected:Const Status,Chemical Grouting, Consolidation Grouting,Testing Lab,Primary Pipe,Electrical/ Instrumentation Quality Program & Personnel Qualifications

ML19308D608
Person / Time
Site:	Crystal River
Issue date:	02/09/1970
From:	Fred Bower, Bryant J, Seidle W US ATOMIC ENERGY COMMISSION (AEC)
To:
Shared Package
ML19308D602	List: ML19308D601 ML19308D604 ML19308D608
References
50-302-70-01, 50-302-70-1, NUDOCS 8003041008
Download: ML19308D608 (8)

Text

{{#Wiki_filter:- o. O U. S. ATCIIIC ENERG'l C01211SSION RECION II DIVISION OF COMPLIANCE Report of Inspection CO Report No. 50-302/70-1 Licensee: Florida Power Cornoration Crystal River Unit 3 License No. CPPR-51 Category A Date of Inspection: January 8-9, 1970 Date of Previous Inspection: Septeraber 24-25, 1969 Inspected Dy: P s7.!b fB C.' Bryant Cifcactor Inspector Date In arge) ?d F. U. B wer, Reartor Inspector (Construction) Date Reviewed By: N!7!E0 W. C. Seidle, fenior Reactor Inspector Date Proprietary Inferraation: None SCOPE A routine, announced inspection was made of Crystal River Unit 3, an 055 ike pressurized water reactor under construction near Crystal River, Florida. l UM'ARY Safety Items - None Nonconforr.ance Items - None Status of Previously Renorted Prol, lams - Nonc (n) Other Significant Probicms - Conc V 80030 F cf

k' '/ CO Ret. No. 50-302/70-1 - Management Interview - The interview was held with Bennett and Froats. The construction status and schedule were discussed. (See Section B.) The lateness of FPC and their consultants in the develoement of the electrical / instrumentation QA/QC plans, manuals and detailed procedures described in the PSAR was described by the inspector as problems requiring prompt attention. Bennett said that he was well aware that they were behind in procedure preparation. He added that the nrimary effort had been to get Unit 2 on line, and that now that this unit is operating, they would be concentrating their efforts on Unit 3. (See Section G.) Failure to anneal the two pieces of primary oipe that have been received was discussed. The inspector said that if FPC decides to use the pine as is, he will be ine.erested in seeing the engineering evaluation. (See Section F.) L DETAILS m f 't A. Persons Contacted e v H. L. Bennett, FFC, Manager, Power Construe. tion E. E. Froats, FFC, Quality Eng_neer W. R. Zimmerman, FPC, Assistant Construction Manager J. C. Hobbs, FPC, Electrical Construction Supervisor W. Hurst, Pittsburgh Testing Laboratory, Resident QO Chief Inspector B. Construction Status Construction backfill with lean concrete is almost complete except for the residual heat pit, which will not be backfilled immediately, and two areas which are receiving chemical grout. Crystal River Unit 2, a coal fired unit, is now in operation, and construction of Unit 3 is expected to proceed mcre rapidly. Construction personnel are beginning a 60-hour week immediately; and when actual construction work can begin after consolidation grouting, it is anticipated that a two-shift schedule will be employed. Current predictions, cccording to Zianerman, are that work will begin on consolidation grouting in 15 working days. Af ter 30 days of grouting, work will begin on the tendon galleries. This is anticipated to begin on March 1,1970. A total of 68 working days is calculated to be needed for consolidation grouting. The cre-dicted fuel loading date is September 1972 with commerical operations in December 1972. V) ( 1

a 7(G i CO Rpt. No. 50-302/70-1 - C. Chemical Grouting IJ-CO Report No. 50-302/69-5, Section E, describes two cracks that the Y inspector observed in tendon gallery walls.and in the limerock p foundation material. He discussed these cracks with the Gilbert g 3 (A Associates geologist at that time. The neolocist theimke ek,e che cracks were caused by nearby nile drivino onerations. The geologist assured the insnecene thnt he would continue his examination or tne _ b cracks. It was since found that in these two areas, either large vo'Tds or areas filled with fine ungroutable material lay beneath the surface. Efforts to use cement grout were unsuccessful in that the material washed away, apparently due to horizcatal water flow, before k the concrete could set. It was decided to use chemical grout to fill V these areas or at least to fill them to the extent that cement grout could be used. The chemical grouting operation was discussed with Bennett and Zim=erman, who expressed com91ete confidence in the ultimate success of this operation. The larger of the two areas is apnroximately 4,200 square feet in g area, and there is evidence that some of it extends from about the d 70-foot to the 30-foot level. Quality control orocedures were develoned for use of the chemical grout and certifications an chemicals were cresented to the inspector for examination. Tests of materials, instrument calibration, and daily reports are furnished by Pittsburgh Testing Laboratory (PTL). In the larger area described above, a oroof-test area,16 x 16 feet, was used to develon the technique. Froats had computer nrintouts showing the take and results in each grout hole. Woodward, Clyde, Girrard, consultants to the arch!tect-engineer, have furnished an engineer who is directing the chemical grouting operations. This man personally directs every move made in the operation. In addition, FrC has obtained the services of Dr. H. Q. Golder of H. Q. Golder and Associates as the owner's con-sultant in this o9eration. When_the work is com,leted, a formal _ j recort will be issued by Golder. D. Consolidation Grouting i on the orevious inspection report, the inspector noted that no QC procedure had been written stating the required strength of grout 4 material as delivered necessary to furnish the correct strength in place. This nrocedure was available on the current inspection and designated as QC Procedure No. PTL-3, "QC Procedure for Furni. Sing, Delivery, Mixing, and Testing of Ready. Mixed Grout." This procedure described PTL coverage of all facets of the grouting operation. It px stated that two sets of three grout cylinders would be made during ) delivery of each 150 yards of grout. It orescribes a 7-day strenEth Ed of 200 nsi and a 28-day strength of 500 psi. Strength in place was

\\ LJ CO Rpt. No. 50-302/70-1 ~ l not snecified. As stated in nrevious resorts, all sareles of grout ~ excavated have shown higher strength in place than as taken from the truck. Froats stated that there is no plan for samnling grout in niace, but that any grout thich is later excavated will be tested for l strength. The residual heat nit will not be backfilled until consolidation grouting is comniete in other areas. A filter blanket is being installed in the heat nit to recove water disniaccd by grouting. When grouting is comniete in other areas, the nit will be backfilled and the foundation mat placed with grout pipe installed penetrating the backfill and mat. The nit area will then be greuted. E. Testing Laboratory As nreviously reported, a tcsting laboratory has be:n built at the site in which all concrete tests and tests on aggregates are made. The machine has now been installed for reinforcing steel tensile strength tests and Cadweld tests. Hurst demonstrated a machine which {h measures density and surface moisture of aggregates by use of a ,) radioactive source. y F. Primary Pine CO Reaort No. 50-302/69-5, Section F, descrites two sections of Class I piaing that have been received at the site. 3 veral questions con-cerning the pipe ware left open after the last inspection. Froats nresented complete documentation on fabricaticn of the pipe, including documentation from supnliers of the pine to the f abricator. In addition, there uas a very complete reacrt from Gilbert Associates, Inc., (GAI) on vendor inspections of the nine, which was f abricated by Power Piping Comnany of Pittsburgh. The CAI renort stated that convolutions on the inner side of the pine met code requirements. To the question of grinding into base metal, the renort gave minimum wall thicknesses to show that they were within code requirements for the nine. The renort said that discoloration at the bend was not. m er4-H y - l/ ' it was_due_ta,_f f socaking, corrosion _but a,rotective cuation. and that the nine not being annealea atter cending. The nurchase order did not require anneating. cr d snecitications require annealing, but this was ommitted from the nurchase order on this narticular pipe. The GAI report said that the oipe was bent under Power Pining Comnany bending nrocedures. Froats said a copy of this nrocedure was in /'~'N St. Petersburg, but he did not have one at the site. Temperatures (v) 6 were taken during bending with an optical ayrocater. A graph shows

g ( l v C0 Ret. No. 50-302/70-1 that the nipe was removed frem the furnace at 22000F and that it was 16750F when bending was comoleted. The GAI report states that the nine was then cooled us ranidly as possible with a full stream of water to less than 6000F. The report nor the chart showed the time required for this cooling. In answer to a question Froats had askcJ, the GAI re-cre re-n~-onded that the nipe not be annenied 2nd -9ELtd, since this is exnensive and the pipe service would not require it. The,ine, to be embeddad in the base mat, is ASTM A358, type 304L, and is the suction line for residual heat removal pumps. Froats said that he did not know what the FPC position would be on the nine. The omission of annealing from ourchase specifications has been corrected. The insocetors said that since annealing is a part of FPC soecification, he would want to see the FPC engineering evaluation if the nine is to be used as is, and that he would like to know the time elansed in the quenching onoration. It was noticed that the oipe still bears Froatst "Reiect" ein. ,.-m ( Note: The ASME Code for Nuclear Power Pining, USAS B31.7, paragraph N-1-729.3.2.b, states, "Austenitic stainless steel pipe that has been heated for bending or other forming onerations may be used in the 'as-bent' conditions unless the design specifications require a post-bending heat treatment." C. Electrical /Instrur entation Ouality Frogram Discussions with Hobbs revealed that the only electrical work nerformed on the Crystal River Unit 3 project to date is installation of the construction rower service. None of the nroject cermanent installation has been made. Further discussior. with Hobbs revealed that only one anproved electrical construction drawing bad been issued which was for a ground grid connection to the containment liner clate. Qcne of those documents referenced in the PSAR, such as the OA "'n"M md_ " - ' mmernl QC ero- ~ cedures, were availuvie rur review. The resnonse to further inquiries r6garding the status of these narticular de:c=ents, as well as others, indicated to the insnector that the current status was unkncwn to Hobbs. Due to the annarent lateness of the licensee's action in the formaliza-tion of their QA nrograc, the Region II insocction activity was revised f ~ 'x from an anticipated audit of nians and procedures to one best described ( ) as "econle engineering." This erocess was intended to nrecondition \\~ the resnonsible site renresentatives in a manner that would allow them

~ p CO Rpt. No. 50-302/70-1 early and timely recognition of many of those problems encountered at other projects. With this certain knowledge available, action could be taken by them to avoid rather than correct the deficiency. This process was based on inquiry into the planning action of the site staff members in many specific areas and an open, adversary-type discussion of their resoonse. It was quite obvious that many new considerations were revealed to them that will permit more efficient olanning action on their part. The need for increased speed of 7roduction of QA and QC procedures was stressed at all levels. As mentioned in previous reports, FPC has assured the inspector that QC procedures would be on hand for every job before work is begun. It was pointed out that time is pressing in the generation of these, particularly in receiving inspection areas. Bennett said that he was aware that they were late, and that since Unit 2 is now on line, Hobbs and his other engineers would be free to concentrate on olans for Unit 3. He added that the site would now be cressing the St. Petersburg of fice, where most of the procedures are generated. b) g Although Hobbs is the electrical construction supervisor, in many ways \\~ / responsible for the construction schedule and the costs of the electrical installation, he is also responsible for the QC activity of the electrical contractor. He has not yet formalized his expected action in this effort, nor has the contractor developed his quality control orogram as described in the PSAR. The discussion regarding their plans for meeting these commitmenta indicated that FFC has the ontion to develop the QC program with their in-house forces or by one of their consultants. The main imnact of the discussion, as discerned by the inspector, was that this effort has not yet commenced. The quality assurance function (planned and systematic audits) is performed by the GAI onsite QA manager's organization to monitor and evaluate the function of the contractor's QC activity. This is the second level quality system activity. A third level quality surveillance function (random audits) is super- ~ imoosed, both on the contractor's QC activity and the GAI consultar.t's QA activity. This activity is performed by the FPC site qualiti engineer's staff. These second and third level quality activities are planned to be performed in accordance with detailed procedures with documented results; however, no documents other than the PSAR were available at the site, nor was Hobbs familiar with the status of the documents. ~x v 9

) G \\.) CO Rot. No. 30-302/70-1 ~ H. Personnel Qualifications The only,erson at the site with imminent quality responsibilities for the electrical / instrumentation installation is the Electrical Construction Supervisor, Hobbs. Note: The FPC Quality Engineer, Froats, and the GAI QA manager will have attendant resnonsibility; however, their intentions are to assign the specific responsibility to one of their staff who will be acquired when job progress dictates the need. Hobbs has been in his present position through construction of the fossil fueled power plant, Crystal River Unit 2, and has been with FFC since 1964. Subsequent to graduation from the University of Florida with an electrical engineering degree in 1963, he worked at General Nuclear Corporation and Combustion' Engineering as a design engineer on nuclear projects. During 1968, he returned to the University of Florida and received a degree in nuclear engineering. (N) pro fessional engineer. In addition to the above accomplishments, he is a Florida registered The discussion with Hobbs revealed an intelligent and cooperative individual anxious to fulfill his obligations. He was quick to nerceive the intent of our conversation and readily acknowledged the potential lat eness of the required documents. Hobbs indicated that he would promotly initiate any action falling within his purview to alleviate the notential problem areas discussed.

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