ML19308D889
| ML19308D889 | |
| Person / Time | |
|---|---|
| Site: | Crystal River  |
| Issue date: | 01/31/1972 |
| From: | Moseley N, Warnick R US ATOMIC ENERGY COMMISSION (AEC) |
| To: | |
| Shared Package | |
| ML19308D888 | List: |
| References | |
| 50-302-71-05, 50-302-71-5, NUDOCS 8003191110 | |
| Download: ML19308D889 (12) | |
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' "*e UNITED STATES a
't ATOMIC ENERGY COMMISSION l.i Xe D. I olvissoN OF COMPWANCE j,
Q REGION ll - SutT E 818 p
M PE ACHT R EE STREET. NoAT H4EST T e tt emone r (404) 526-45:3 AT LA NT A. GEoRot A 30 M3 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 Tyce 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: [ [ [/ Argpg,/y_ _ _
Date
/-7/-72 R. F. Warnick, Reactor Inspector (Testing and Startup)
Accompanying Inspector:
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/1 N. C. Moseley, Senior Re or Ins 90ctor Date (Testing and Startup)
Other Acconpanying Personnel:
H. L. Faulkner, DRL A. Schwencer,DRL Revieued by:
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N. C. Moseley, Senior Reactor [spector Date' (Testing and Startup)
Proprietary Information: None 80031911/ O
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t CO Report No'. 50-302/71-5 SECTION I Enforcement Action
'A.
Noncompliance Items l'. !!aterial and fabrication certifications for the decay. heat pumps and the. reactor building spray pumps.
(See Section II,
. Paragraph o.).
2.
The inspectors w., 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 Licensee Action on PreviousivIdentified Enforcement "atters 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.
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CO Report No. 50-302/71-5, Persons Contacted Florida Power Corporation (FPC)
- J. Alberdi - Nuclear Plant Superintendnet
- H. L. Bennett - Director, Generation Construction P. G. Davis - Manager, Power Testing
- E.
E. Froats - Quality Engineer J.-C..Hobbs'-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 Testine Laboratory (PTL)
G. B. Brown - Chief Inspector.
Babcock and Wilcox Company (B&W)
R. R. Beach - Manager, Field Engineering D. A. G11uck - Test Working Group Representative Manacement Interview 1.
The inspector stated that.centrary to the requirements of Appendix 3, 10 CFR 50 and the FSAR, the decay heat pumps and the reactor building spray pumps could.not.be. identified by serial number from the information contained.in the material and fabricatien. certifications, and that each QA data package.for the four pamps contained cae or more certifications pertaining..to another. pump.
Kleinman said the quality program files would be returned to B&W for correction and that FPC would conduct an audit of other data packages supplied by the same vendor.
(See Section II, Paragraph 6.)
2.
The inspector stated that he was unable.co. find evidence of identi-fication, investigation,.and documentation which would lead to the correction of the apparent defects observed in the containment building.cencrete. Kleinman stressed that once a problem is identified, FPC has a system to "close the loop." Jackson agreed
- Thesa individua1r also attended the Management Interview
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C0 Report No.:50-302/71-5 that the present identification system did not specifically pick
- up concrete deficiencies.
Bennett indicated that the present system would be modified to 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.on 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 impractical to maintain.
He also stated that the matter would be corrected.
Cn December 21, 1971, Jackson informed the inspector that FPC had a procedure in the draft stage.to determine the contamination on stainless steel 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 progran.
The inspector stated that this matter would be referred to DT1 for review, evaluations and possible action.
Kleinman indicated that_FPC had discussed this with DRL in Washington but that FPC had no cinutes of the
=ceting.. Faulkner of DRL indicaced 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 co cments.
(See Section II, Paragraph 10.)
6 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 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;
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.CO Report No. 50-302/71-5 a..
Florida Power Corporation Quality Program Manual, Volu=e 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 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.
(See Section II, Paragraph 12.)
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CO Report No. 50-302/71-5 'Section II' I
-ADDITIONAL SUBJECTS INSPECTED, NOT. IDENTIFIED IN SECTION I, WHERE NO
- DEFICIENCIES OR UNRESOLVED ITEMS WERE FOUND 1.
General Jackson reported that construction was 417. complete.
The construction j
work was reduced from. two shif ts to single-shif t_ operation on November 19, 1671. This will. continue through the winter conths.
The reactor vessel.was placed on its support 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.
I FPC has established a acw position in their quality centrol organization.
l J. F. Rashinsky, fcreerly the Chief Recieving Inspecter, has been l
set up as the Site _ Quality. Control Supervisor.
He.is employed by l.
J. A. Jones but will be reporting to Jackson of FPC.
He will be l
responsible.for coordinating all site quality centrol activities.
2.
Reactor Vessel a.
Implementation of quality. assurance program.
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b.
Review of quality control system.
(1)
Crane testing and vessel lifting.
c.
Followup record review, i
(1)
Insta11stien inspect 2n.
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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.
Imple=entation.of quality assurance program.
b.
Review of quality control system.
(1) Receipt inspection and handling.
(2).Special handling.and storage-precauticas.
-(3)
Quarantine of nonconforming components.
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CO Report No.-50-302/71-5,
(4)
Installation specifications and procedures.
(5)
Installation inspections, c.
Followup record review.
- 41) thterial 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.cozponents.
5.
Other class I components - Pressuri cr a.
Followup observations of work.
(1) Insta11atica techniques.
DETAILS OF SUBJECTS DISCUSSED IN.SECTION I 6.
Material and Fabrication Certifications for Other Class I Components
'PC maintains a QA document file for each purchase nade under their quality progran...The QA document file for any specific purchase contains an index, purchase order, changes to the purchase order, purchase specifications,. design data, inspection reports, drawings, and an individual.QA~ 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-cne 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 7 pumps. From the inforzation contained.in.the. file, the inspect **
determined the decay, heat. pumps had serial numbers.1624920 and 1624921 and the reactor. building. spray. pumps.had. serial numbers 1624922 and 1624923;.however,.it.was.not possible for the inspector or-Froats'to identify a~ specific-pu=p.such as DH-PIA with a specific serial number.
In addition, the inspector.found identification discrepancies in.each of the four data packages.
In particular, f
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CO Report No. 50-302/71-5 a.
The certifications labeled DH-PIA, ccntained the following pages which, although labeled DH-PIA were traceable to other pumps:
...One pump curve identified by serial number 1624921 (which is DH-PIB).
...One hydrostatic test certification identified by serial r2=hers 1624922 and.3 (reactor building spray pumps).
...One materials certification for pumps with serial numbers 1624922 and 3 (reactor building spray pumps).
...Two pages 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 pu=p 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).
...Two pages of chemical analysis and physical test repcrts marked " Reactor Building Spray Pumps."
The QA data package for.each reactor building spray. pump. contained c.
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. ware labeled RB-PIA.
In the material and fabrication certifications for RB-PIB, all three 4
pump curves were labeled.RB-PIB.
This failure to provide-properly. identified. material.and. fabrication ~
certifications which are.traceabic.to a specific piece of equipment appears 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, " Measures 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 haat number, part number, serial number, or other appropriate means either on the item or on records traceable to theLitem...."
e' CO Report No. 50-302/71-5 Criterion' VII, Appendix.B,.10 CFR 50, statas in part, " Measures shall be established to-assure that purchased material, equipment, and services-... conform to the procurement documents. These measures shall include... objective. evidence of qualit'; furnished by the-contractor.or subcontractor,. inspection at the contractor or subcontractor source,7and examination of products upon. delivery.
Documentary evidence that caterial-and. equipment conform to the procure =ent requirements _shall be available at the nuclear pcwer plant site. prior to installation or use of such material or equiptant...."
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 store] as specified by the Owner...."
This problem was discussed.with Klein=an and Froats who stated the file would be returned'co B&W for correction.
This was discussed in the management interview and in addition to stating that the data packages wculd be corrected, Kleinman said that FPC would conduct an audit ei other data packages supplied by the same vendor.
- 7.. Containment Building Concrete.
During the inspection, a tour of the construction site uas made to obse.ve construction activities and the physical conditicas of the work in progress.
In the containment building cen rete, the inspectors observed an area with small voids and aggregate. separation in pour 263R3 between buttresses 6 and 1 at elevatien 103 to 110.
The inspectors asked to see the records documenting the identification of this defect for followup investigation and corrective action. Neither Froats of FFC 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.to. assure this.
The lack of a system for control of. concrete defects appears. to.be
~in noncompliance with Criterion _XVI of Appendix B, 10 CFR 50, which states in part, " Measures shall be established to assure that conditions adverse to quality, such as failures, malfunctions, deficiencies, deviations, defective material and equipment, and nonconformances are promptly identified and corrected."
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,1 CO-Report No.- 50-302/71-5 Later during the inspection and again during.the exit interivew, Klein=an,-Froats,'and_ Jackson stressed that once a problem is identified, a system exists to'"close the 1 cop."
However, they agreed that the identification system did not.specifically pick up concrete deficiencies. Bennett stated that the present system would be modified co require recording concrete deficiencies on the concrete curing.and form removal. report.
This record would then provide the formal identification to initiate followup by the loop, closing. system..
8.
Stainless Steel Pipe and Valve Storage and Cleaning The inspectors observed stainless steel piping and valves stored out-of-doors.without.any protective covering.
In addition to the valves and piping being continuou1y exposed to the salt water atmosphere, some pipe ends were observed to be in contact with the ground. At the time of the inspection, FPC was in the process of moving all valves to 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 ara completed they will be made available for the inspector's review.
A draf t : copy of their. detailed. !? Procedure for Determining Contamination on Stainless Steel Surfaces" has been prapared and is in St. Petersburg for. review. Jackson indicated FPC will prepare a procedure for cleaning the external piping surfaces 2nd also flushing procedures for cleaning _the interior surfaces of piping systens.
In addition, cleaning procedures will be prepared for specific components such as individual. tanks.
. 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.co maintain.
Bennett reminded the inspectors.that the. valves were in the process of being moved to indoor storage. Jackson indicated that the piping
-vould be-stored.so.it was.not.in. contact with the ground.
9.
} kin Steam Line. Seismic. Classification.
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 staam.stop valve..(See Figure 10-3, Drawing No.
302-011, in the FSAR.) TheJClass III piping and valves are not included within the scopeLof EPC'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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. '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 the subject at DRL.
10.
Ultrasonic Testing of Reactor _ Coolant. Pump. Flywheel 1/
As. reported previously, the pump flywheels were ultrasonically
- tested prior to machining the flywheels from the blanks. FPC plans to subject each finished flywheel _to a 100% volumetric ultrasonic 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. -Preoterational Testine Program-
-The inspectors met with Kleinman, Froats, Alberdi, Davis, and Williams of FPC, and Giluck and Beach of B&W to discuss FPC's preoperational testing program and the Compliance's inspection program. The inspectors highlighted the requirecents of 10 CFR 50 nnd.the AEC's!" Guides'.' for both preoperational testing and initial.
startup programs.. Davis explained how FPC intended.to implement the requirements of Appendix B, 10 CFR 50, and gave the inspectors a revised cepy cf 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
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Test Procedure Format, and Operating. Procedure. 1102.02, " Plant
'Startup," and discussed his comments with'Alberdi and McKee. The.
~ inspector's: comments can be summarized as follows:
.a.
The stepwise' how-to-do-the-job part of the procedure needs more detail in each step.
b.
The balance:of the procedure should encompass the points discussed
. in.the Guides.
c.
More emphasis should be.given to. seejng that Criteria XI, XII, XIV, XVI, XVII and:XVIII of Appendix B to 10 CFR 50 are implemented.
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-CO' Report No.50-302/71-5 12.: QA/QC Manuals The inspectors requested FPC to Supply Region II with cne copy of each.of the following QA/QC manuals, a.
Florida Power Corporation Quality Program. !!anual, 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.
Kleinman indicated FPC would supply Regicn 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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