ML19317D314
| ML19317D314 | |
| Person / Time | |
|---|---|
| Site: | Oconee  |
| Issue date: | 06/24/1970 |
| From: | Kelley W, Murphy C, Seidle W US ATOMIC ENERGY COMMISSION (AEC) |
| To: | |
| Shared Package | |
| ML19317D313 | List: |
| References | |
| 50-270-70-05, 50-270-70-5, 50-287-70-05, 50-287-70-5, NUDOCS 7911270485 | |
| Download: ML19317D314 (8) | |
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U. S. ATOMIC ENERGY COMMISSION REGION II DIVISION OF COMPLIANCE i
Report of Inspection C0 Report Nes. 50-270/70-5 50-287/70-5 Licensee:
Duke Power Company Oconee 2 and 3 j
License Nos. CPPR-34 and 35 Category B Date of Inspection:
May 25-28, 1970 Date of Previous Inspection:
April 27-May 1, 1970 Inspected By:
[/j 4///70 C. E. Murphy, geac.
nspector Date (In Char e) bSY@
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~Date' W. D.
Celley', R c
r Inspector (Construction) d[2 f f4 Reviewed By:
s W. C. Seidle, Senior Reactor Inspector Date' NOTE: The sections of this report relating to welding and piping were prepared in the main by 'T.
D. Kelley, Proprietary Informat ion:
None SCOPE A routine, announced inspection was made of the two 2568 Mwt pressurized water reactors under construction near Seneca, South Carolina, known as Oconee Station Nos. 2 and 3.
Purposes of the inspection were :
(1) to determine the construction status and significant changes to schedule dates; (2) to review records and work perf 2nce relating to mechanical equipment and piping systems.
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CO 1pt. Nos. 50-270/70-5 - -i-50-287/70-5
SUMMARY
i Safety Items - None j
Nonconformance Items - None Status of Previously Reported Problems -
l.
The strength of the concrete placed in Units 2 and 3 as indicated by the 28-day tests, showed an increasing trend.
On eight occasions since March 25, 1970, it has failed to meet the requirements stated in the FSAR.
(See Section F.)
i 2.
The defective forged stainless steel pipe fittings have been returned to the manufacturer for repair.
(See Section M.)
I 3.
More defective Cadweld sleeves have been found and placed in quarantine.
(See Section F.)
j 4.
The welding of the Unit 2 equipment hatch to the containment 1/2-inch stif fener plate has been completed.
(See Section F.)
i 5.
Weld Procedure S1 had been previously reported as having been qualified using 1/2-inch-thick material for the bend tests.1/ A second test has been run with specimens milled down to 3/8-inch as required by Seccion i
IX of the ASME Code.
The procedure is now considered to be properly qualified and the inspector plans no further action.
Other Signi ficant Items - The low-pressure injection pumps for Unit 2 have been returned to the manufacturer for repair.
(See Sect ion H.)
j Management Interview - The management interview was held on May 28, 1970, and was attended by Dick, Rogers and Wells.
1.
Dick was advised that although the 28-day tests indicated that there-had been some improvement in the strength of the concrete placed in the reactor building, some breaks were still below the 5000 psi minimum permitted by the FSAR. The inspectors expressed concern that concrete placement operations were continuing even though the cause of the -low-strength concrete had not been determined.
Dick stated that they were continuing to try to determine the cause of the low-strength concrete, i
and that Wells and the manager of the concrete plant were to visit the cement manufacturer's f acility in -Birmingham on May :!9,1970.
It-was the opinion of the QC staf f that the cement was the problem, but they had not as yet been able to establish this as a fact.
Dick noted that 7
the trend of the test results was toward increasing -strengths and 1/00:11 Report No. 50-270/70-4.
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,s CO Rpt. Nos. 50-270/70-5 _ 287/70-5 hopefully they would have no further breaks below the 5000 psi allowable.
He stated analyses were being made of the ef fect o f the low-streotth concrete on the integrity of the structures and that the results of the analyses would be available to the inspectors.
(See Section F.L.)
2.
The inspectors advised the licensee that they lad again noted that some of the electrode ovens were not at temperature. Wells acknowl-edged that this was a cont inuing problem, and that the QC inspectors l
were constantly reminded to check the ovens.
He stated that the matter would again be brought to their attent ion.
DETAILS 1
A.
Persons Contacted
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R. L. Dick - Construction Manager, Duke Power Company J. C. Rogers - Project Engineer J. R. Wells - Principal Field Engineer C. L. Hunnicutt - Field Engineer, Civil l
R. E. Blaisdell - Welding Engineer C. B. Aycock - Field Engineer, Electrical K. E. Cater - Instrumentat 2on Technic ian A. B. McCrary - Supervising Technician, Concrete W. d. Owen - Mechanical Engineer Supervisor B.
Administrat ion and Organization Dick, formerly. Projects Manager, Keowee-Toxaway Projects, has recently been promoted to the position of Construction Manager, Duke Power Com-1 pany.
He advised the inspectors that he would transfer to Charlotte in approximately one month but expected to spend approximately one day per week at the Oconee site.
C.
Quality Assurance i
l 1.
No changes have been made in the licensee's quality. assurance organication or procedures.
12. Quality assurance items are discussed in the individual report sections.
.D.
Construction Progress 1.
Concrete placement in.the Unit 2 reactor building has been com-pleted to the fifteenth ring.
Installation of the polar crane girder is in process.
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(S CO Rpt. Nos. 50-270/70-5 50-287/70-5 2.
The final pour of the Unit 3 reactor building base slab is expected to be completed the first week in June.
Installation j
of the liner plate floor structural members is in process.
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E.
Schedule Dates l
1.
The Unit 2 reactor vessel is scheduled for shipment in March 1971 but r assibly may be shipped ahead of this date. Other shipping i
l date are unchang2d.
2.
The L ait 3 schedule has not changed.
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F.
Containmeit - Attachment G j
1.
Concrate (4600) l The.1spector was advised by Hunnicutt and Wells that the cause of th. low-strength concrete had not been determined.1/ Records reviewed by the inspector indicated that the strength of the con-crete as indicated by the 28-day tests showed an increasing trend.
On eight occas ions, however, since March 25, 1970, it had failed to meet the requirements stated in the FSAR.
The inspector expressed concern at the management interview that the licensee continued to place concrete in critical areas when the cause of the low strength had not been determined and corrected.
The inspector was advised that Wells was inspecting the cedent manu-facturer's facility on May 29, 1970, in an attempt to determine if the cement is the cause of the low breaks. The inspector was j
further advised that the licensee was prepared to show by engineering analyses that the low-strength concrete placed to date had not ccm-i promised the containment integrity.
The inspector will continue to review the concrete operations on future inspections.
2.
Unit 2 Equipment Hatch t
The welding of the equipment hatch to the containment liner plate t
from t e ' o' clock to the 10 o' clock position had been noted i
durir, the previous inspection to be incompletc.1/ These welds should have been ' completed prior ' to placing. concrete in the area.
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The thickness of the existing weld was measured ultrasonically and found~to be 3.482 inch. The. weld was completed by building i
up to the required thickness in accordance with Procedure Si by the same weldor that had made the initial weld. The licensee is reviewing the NDr records to determine if spot radiographs are required.
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j 1/CO:II-Report No. 50-270/70-4.
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'50-287/70-5 3.
Cadweld Sleeves The licensee has continued to find defective Cadweld sleeves
. hat were f urnished by Southern Boiler and Tank Company.
Included are sleeves for Nos.11,14, and 18 reinf orc ing steel. All defective sleeves have been placed in quarantine, The licensee has advised the inspectors that the defective sleeves will not be used unless they are properly repaired.
Since the sleeves had been received as a part of the liner plate embedded material, the inspector asked if it was possible that any cf the sleevc.s had been used, A visual inspection was made of Cadweld sleeves welded at Southern Bciler and at the site for Unit 3, and it was found that some were welded cithout root openings resulting in the lack of complete penetration. A review of the licensee's drawing 0-62F revealed that no root openings were indicated in the weld symbols.
Blaisdell checked the Erico Cadweld catalog which indicated that the Cadweld sleeves fcr welding to plates are normally furnished with a square end for attachment with a fillet weld.
Hunnicutt called the Charlotte Engineering of fice and was advised by the design engineer that engineering was aware that this was not a full penetration weld.
He stated that a "J" groove weld was suf ficient for design strength; hcwever, a fillet weld was added as a part of the design.
Hunnicutt stated that the design stresses for these joints were 30 kips and, the present tensile tests on the splices were between 90 and 108 kips with failure occurring in the reinforcing steel bars.
On Unit 1 some f ailures had occurred at the weld but not below tne allowable strength. TF S item is considered to be satisfactory and the inspector does not plan further action.
G.
Hich-Pressure and Low-Pressure Injection Systems - Attachment G Installation NDT Procedures (5005.04.f.5)
The high-pressure and low-pressure injection systems piping welds are being inspected in accordance with Oconee Nuclear Station Ceneral Procedure for Radiography.
The procedure requires the use of film that meets ASTM E94-62T. The radiography is being accomplished using an iridium 192 source with s ingle film technique.
The change was made f rom the double film technique to the single film technique since the licensee had found by making test "adiographs that the single film technique gave better sensitivity.
The radiography is done in accord-ance with Specification Sheet, Specification No. RT-34 and 25, which require s an acceptance criteria in accordance -with OSAS E31.7, Appendix B, paragraph B.1.140.
Liquid penetrant examination is done in accord-ance with Oconee Nuclear Station procedures, Specification No. PT-1,
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CO Rpt. Nos. 50-270/70-5 6.-
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50-287/70-5 Revision 2.
The proced.e requires that the penetrant examination meet the requirements of l'SAS B31.7, Appendix B.
The requirements of 5005.04.f.5 are considered to have been met.
H.
Low-Pressure In jection Ptmps - Attachment L The inspector was advised that the pumps for the L' nit 2 low-pressure injection system have been returned to the manufacturer.
B&W had found that the shafts were binding after the pumps had been installed on their foundations. The inspector will review this item on the next inspect ion.
I.
Reactor Vessel Support Structure, Units 2 and 3 - Attachment E 1.
General The QC procedures and the records rr '.at ing to the reactor veshel support structures were reviewed ir etail. The reactor vessels rest upon reinforced concrete slab Bolts anchored in the con-crete would restrict movement of the vessels in the event of a9 earthquake or other major incident. Since no structural steel ss involved in the foundations, inspection items relating to structures (5400) and welding (4800) are not applicable.
2.
Concrete (4600)
Initial Review of QC System (4605.03 and.04)
Although the licensee's QC system relative to concrete has been previously reviewed,1/ the inspector audited the procedures to determine if any revisions had been made that could have an adverse effect on quality.
The licensee's Specification No. OS-160,
" Reactor Building Concrete," was reviewed by the inspector.
Section 1.5 of the specification details the requirements for the reinforcing steel and requires that certified test reports be submitted to the Licensee for approval.
The licensee, as a part of 'us Cadweld testing, also tests the reinforcing steel.
The licensee purchases ready-mix concrete from the Greenville Concrete Company but specifies the source of raw materials and designs the mix.
Sections 1.13 and 2.4 of Specification CS-160 details the testing and-mix design requirements of the concrete.
The requirements for tecting Cadweld splices are included in Section 1.6 and concrete placement requirements are included in
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1 CO:11 Report No. 50-269/68-2.
rN CO Rpt. Nos. 50-270/70-5 ' J 50-287/70-5 4
Section 1.8.
The requirements relating to measuring, batching, mixing and delivery of concrete are included in Section 1.11.
The inspector considers the applicable requirements of 4605.03 and.04 to be satisfied.
3.
Followup Record Review (4605.05)
The inspector reviewed the drawings of the reactor foundation reinforcing steel and obtained the mark letters for the steel in the reactor foundation.
The mill test reports for the rein-forcing steel are listed on the bills of material for the steel.
The inspector selected fou-heat numbers at random and reviewed the test reports for these heats.
No discrepancies were noted.
The inspector reviewed the Prepour Site Inspection Reports, Form QC-4, for the reactor base concrete pours. The forms had been properly completed and no discrepancies were noted. A review of the concrete compression test records indicated that the 28-i day breaks were above 5000 pounds and the 90-day breaks ranged from 6614 to 7074 psi.
The Records of Concrete Placed, Form QC-5, for the base slab pours were also reviewed and found in order as were the Concrete Batch Records, Form A0-1.
The Records of Cadweld Splices, Form QC-10, were audited and found to be in order.
The records for the analyses of sand, cement and aggregate were also reviewed, and no discrepancies were noted.
The Reports of Chemical and/or Physical Properties for t he reactor vessel anchor bolts were also audited. The chemical properties were noted to meet sp ec if ica tio ns. The tensile strength was not given but the Brinnell hardness numbers indicated the tensile strength to be in the range of 153,000 to 164,000 which is above the minimum required. The inspector considers that the applicable requirements of 4605.05 to have been completed.
4.
Followup Observations of Work (4605.06)
The placement of concrete has been previously audited and it was observed that the requirement s of 4605.06 were met.
This item is considered to be complete.
M.
Miscellaneous i
Forged Stainless Steel The S. K. Porter representative visited the site to inspect the defective fittings previously reported.1/ As a result, all the 1/CO:II Report No. 50-269/70-5.
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50-287/70-5 fittings f rom six heats that had not been installed were returned to the vendor's plant. These fittings will be dye penetrant tested and any fittings having indications of folds in the metal will be ground and retested to verify defect removal. Any fittings that be ground to less than minimum allowable wall thickness will must be rejected. The S. K. Porter representative recommended that all fittings that have been installed in the system be dye penetrant inspected and defects removed by grinding.
If defect removal results in less than minimum wall thickness, it is to be cut out.
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