ML19317F807
| ML19317F807 | |
| Person / Time | |
|---|---|
| Site: | Rancho Seco |
| Issue date: | 06/16/1971 |
| From: | Dodds R, Fish R, Spencer G US ATOMIC ENERGY COMMISSION (AEC) |
| To: | |
| Shared Package | |
| ML19317F802 | List: |
| References | |
| 50-312-71-03, 50-312-71-3, NUDOCS 8002210566 | |
| Download: ML19317F807 (15) | |
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i; Os U. S. ATOMIC ENERGY COMMISSION DIVISION OF COMPLIANCE REGION V Report of Inspection CO Report No. 50-312/71-3 Licensee:
Sacramento k nicipal Utility District License No. CPPR-56 Category A Date of Inspection:
May 17-19, 1971 Date of Previous Inspection:
March 22-25, 1971 Inspected by:
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R. T. Dodds tatt Reactor Inspector n
R. F. Fish da te' Radiation Specialist Reviewed by:
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G. S.
encer /
Date Senio Reactor Inspector 4
Proprietary Information:
None i
SCOPE Type of Facility:
Pressurized Water Reactor Power Level:
2452 Nt Location:
Sacramento County, California
-Type of Inspection:
Construction Inspection, Announced Accompanyinst Personnel:
None O
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SUMMARY
Conscruction Deficiencies - No significant deficiencies were identified o
during the inspection.
Status of Previousiv Reported Problems - No significant problems were listed as being outstanding following the last inspection.
Other Sinnificant Items 1.
.The project construction status was estimated to be essentially on schedule with 38% completion as of May 17, 1971. CB&I has completed 39% of the dome liner and expects to finish by September. Concrete for the dome will probably be placed about November 1971.
(Section B.)
2 The SMUD Quality Assurance Director is terminating on May 21, 1971 to accept employment with Kaiser Engineers.
(Section C.l.)
3.
The Management Safety Review Consnittee has been activated.
(S ection C.2.)
4 A review of construction log book practices disclosed only one log
.which identified deficiencies and/or problem areas. The log did not always describe the disposition of items.
(Section E.)
5.
The issue records of weld filler metal only showed the initial issue of-filler metal to a welder for a specific wald or series of welds.
The records did not show the return and/or reissue of the filler metal.
(Section G.5.)
6.
Several covers for the containment vessel tendon sheaths were noted to be nissing.
(Section J.)
7.
The licensee initiated an environmental monitoring program in October 1970. The program was found to be as described in Section 2.8 of the FSAR. The samples are being anslyzed by Trapelo/ West, Division of LFE Corporation, Richmond, California. The results of the first quarter samples have ~been submitted to SMUD.
Initial fish and human edible vegetation samples are expected to be obtained during the summer of 1971.
(Section K.)
8.
The p2rmanent 200 foot meteorological tower has been erected. Data is being collected at the 6, 50 and 200 foot levels in accordance with the description contained Appendix 2B of the FSAR.
(S ection -
L.)
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Construction problems experienced at other facilities were discussed with the licensee.
(Section M.)
Management Interview The results of the inspection were discussed with Messrs.
Mattimoe, Raasch, Hiltt, Columbo, Rodriguez, Stinchfield, McMahon, Ibsen, Vander Knyff and Metzger. Pertinent comments were as follows:
1.
The filler metal withdrawal authorization form will be revised to show all aspects of issue control including the reissue of filler metal.
2.
An instruction sheet was being prepared for the welders that will show the range of essential and nonessential variables for each welding procedure as appropriate.
3.
CONSECO will be advised of the contract requirement that all design and drawing changes must be submitted to Bechtel for review and approval.
4 The desirability of having construction logs document the disposition of problems or deficiencies described in the logs was discussed in depth.
Mr. McMahon stated that this item would be discussed with the groups responsible for the preparation of logs and reports to
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promote complete records. He further stated to those present that v
any deficiency significant enough to be logged by an inspector should be properly documented in a Nonconformance Report.
5.
Rancho Seco Operations will audit the meteorological tower data collecting equipment for operation following the weekly servicing of equipment by SMUD Engineering.
6 The Operation's Chemics 1 and Radiation Protection group will familiarize themselves with Trapelo/ West's procedures for sample processing and analyses to assure continuity of the environmental pro' gram should SMUD elect to make other provisions for this type of service.
4 DETAILS A.
Persons Contacted The following persons were contacted during the inspection and management
. interview.
SMUD
'J. Mattimoe Assistant Chief Engineer D. Raasch Project Engineer Resident Engineer ps J. Hiltz
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R. Rodriguez Plant Superintendent MI R. P. O'ubre-Assistant Superintendent, Nuclear " lent Operations
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.. R. Colombo Technical Assistant J. McColligan Assistant Superintendent, Technical Support R. Miller Chemical and Radiation Protection Engineer D. Martin Plant Health Physicist Bechtel Corporation Engineering and Construction Management W. Stinchfield Project Manager V. McMahon Chief Quality Assurance Engineer R. Hunter W. Taylor
~ QA Engineer (Source Inspection)
QA Engineer (Civil & Mechanical)
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W. Chapla QA Engineer (Piping & Welding)
D. Nkrtz-QA Engineer (Electrical & Instrumentation) j
'Bechtel-Corporation - Construction t
J. Vander Knyff Project Superintendent
'B. Ayers Project Field Engineer R. McConkey Welding Inspector F. Pangburm Welding Engineer R. Blobner File Clerk M. Rosen Field Engineer Leave 11~- Dravo J. Nktzger QA Engineer B.
Status of Construction The project construction status was estimated to be essentially on schedule with 38% completion as of May 17, 1971. CB&I has completed 39% of the dome liner and expects to finish by_ September 1971. Concrete for the dome will probably be placed during November 1971. The turbine generator gantry crane and the reactor building polar crane have been erected but are not yet available'for use.
C.
SMUD Administration and Organization 1.
Quality Assurance Mr. Jackson, Quality Assurance Director was to terminate his employment with SMUD on May 21, 1971 to accept a job with Kaiser Engineers at the Zimmer project near Columbus, Ohio. His replace-ment had not yet been selected.
2.
Manaaement Safety Review Conunittee The Management Safety Review Committee has adopted a charter and held its first meeting. Minutes of that meeting verified that the
[N Committee had reviewed and approved the proposed set of technical
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specifications that was submitted with the FSAR in May 1970.
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QA Program (Rework)
The Project Quality Program Manual has now F en revised to permit " rework" without dispositioning the rework on a "Nonconformance Report" in accordance with the following procedure:
"If a non~conformance is to be reworked within a short period of time, such that accounting and special instructions are not necessary, a nonconforming report is not required."
E.
Construction Lon Boo'ks The use of construction log books and the logs were reviewed and discussed with Mr. McMahon. Historically, QA has insisted that all nonconformance and deficiencies be identified on Nonconforming Reports and therefore there is no need for log books. Nevertheless the following legs or rer rts are being used by Bechtel Management or Construction.
1.g Bechtel Field Inspector Reports (Management)
These are daily reports to Bechtel field management by the chief civil, mechanical and electrical inspectors listing work in progress.
The reports do not describe deficiencies.
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2.
Week 1v Progress Reports (Management) d These are weekly reports by Bechtel management listing all work accomplished during the report period. The reports do not contain information relating to construction deficiencies or problem areas.
They may however reference the deferral of jobs while awaiting the repair of equipment previously identified in Nonconformance Reports.
3.
0A Engineer Lors (Mananement)
Each of the QA Engineers for Bechtel management prepares a chronolo-gical diary of items reviewed. The logs are transmitted to Mr. Ibsen, Manager of Startup and Quality Assurance, Vernon Office. Only the Welding Engineers' logs identifies problem areas. The others list itema reviewed but do not describe problem areas.
Mr. McMahon stated that the logs are a chronology of items reviewed and should not describe problem areas since they are only utilized as an adminis-trative tool for manpower utilization. According to Nk. McMahon, the Welding Engineer will be cautioned against the practice of including problem areas in his log.
4.
Construction Inspector Reports (Construction)
The construction inspectors prepare daily reports listing (1) item reviewed (2) work performance and (3) deficiencies and problem areas.
The reports reviewed did not, in all cases, indicate the disposition of the identified deficiencies.
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S.
Field Inspection Check Lists (Construction) i:
These check lists with' attached drawings are utilized by the Civil Inspectors to check location and coordinate the installation of
' equipment. The check list packet.shows the final disposition of
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equipment location and orientation.
6.
Final Aliennent Record of Rotatina Nhchinery (Construction)
This.is the engineers inspection record of final alignment of rotating equipment and contains no information relating to equipment deficiencies.
7.-
Construction Progress Reports (Construction) l These are weekly status reports from Bechtel Construction to the Vernon office.- The report provides information relating to (1) con-struction progress, (2) schedule of work for the following two
. week period, (3) " hot material list" (items needed to meet construc-tion schedule), and (4) schedule meeting notes. The " Schedule Meeting Notes" include (1) project areas where schedule. delays are anticipated and reason for delays and (2) construction deficiencies and proposed corrective action.- Presumably all identified deficiencies have j _
already been documented in nonconformance reports.
F.
Stainless Steel Pine As a result of an inquiry by the inspector-relating to the heat treating technique (air cooled) used for' stainless-steel pipe, SWEPCO TUBE CORP. engaged an independent laboratory to perform additional photomicrographic tests on the pipe.
Samples from a section of 3/8-inch pipe from a SHUD ' order were electroly-tically etched.with oxalic acid in accordance with ASTM A262-55T. The 500X magnification photomicrographs showed evidence of the structure "being free of susceptability to. any rapid intergranular attack".
When questioned, Nk. Chapla checked with SWEPCO who stated that the test E
results qualified pipe sizes up to %-inch thick (largest size. pipe supplied by SWEPCO to SMUD).- SWEPCO plans to change their own QC procedures to require s2_the oxalic acid ditching test for sensitization rather than the previous ~ etching test which wsi"priSarily used to verify grain structure. A magnification of
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i only.400K will be used :since this is the upper limit of SWEPCO's test equipment.
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LSHDD considers this matter to be satisfactorily resolved. ' Neverth'eless, i-Mr. McMahon stated that SMUD may wish to have a sample of -inch pipe checked lby their own consultant laboratory'.
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Class I Pinine (Followun Record Review)
Shop fabrication is the only work performed thus far on Class I piping.
The code radiographs have not yet been reviewed for acceptance by Bechtel.
Nevertheless the records accumulated to date were reviewed for content in accordance with CO instructions.
1.-
Visual Inspection Records were being maintained of the welding inspectors visual inspection of. (1) joint preparation, (2) environmental control, (3) root gap, (4) axial and angular alignment, and (5) completed weld. An inspection of the root gap weld is not required for all welds, particularly for the smaller thickness of pipe.
It was also noted that records were not being maintained of gas flow rates.
2 Heat Treatment Records Records were being maintained for preheat and interpass temperatures to certify that temperature limits were not exceeded. None of the records for welds reviewed required controlled cooling or stress i
relief.
3.
Nondestructive Testina Records were being amintained of liquid penetrant examinations.
While radiographs of completed welds had been made, they had not 1
yet-been reviewed and accepted by Bechtel. No other type of' nondestructive tests have as yet been performed.
Isometric diagrams of each section of piping are used for the purpose of correlating records to the welds, l
4 Renair Records
)
No repair of welds have as yet been required on Class I piping.
S.
Material Control The review of records for the control of weld filler metal disclosed only-one item of concern. A record was not being maintained to show the return and reissue of filler metal for a specific weld or series of welds being performed by a single welder. The material transfer l
records only showed the date of initial issue. For example, filler metal'for weld "P" on Isometric No. 21006 was originally issued on i
April.20, 1971 and the weld was made 'on April'22,1971. The " Filler l
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H..
Class I Vessels (Site Fabrication)
The inspector's review of CONSECO's QA program manual for Class I vessels disclosed one item of concern. The manual did not reference the SNUD contract requirement that all drawing changes must be reviewed and approved by Bechtel QA and Engineering. This provision of the contract will be emphasized to CONSECO according to McMahon.
I.
Instrument and Electrical Cable _Trav Loads The existence of the inspection plans for the special QA programs for electrical and instrument cable installation was verified. The special 4
programs have been designed to provide independent assurance that cable installations conform to the design criteria for cable separation, cable tray loading, etc.
J.
' Tour of Construction Site During the tour of the construction site, several sheathing covers (used j
to keep debris out of sheathing) were observed to have been knocked off of the ends of the containment vessel vertical tendon sheaths. No other itema of concern were identified during the tour.
K.
Environmental Program 1.
General Inforistion Section 2.8 of the licensee's FSAR contains a description of tha intended environmental monitoring program for the Rancho Seco site.
' Mr. McColligan said the program had been developed with the assistance of personnel from Trapelo/ West, Division of LFE' Corporation, Richmond, California. Also,,Trapelo/ West has been given a one year contract to conduct radioanalyses on the environmental samples. The first environmental' samples were collected in October 1970. Trapelo/ West has submitted to th'e licensee a report of the results of the radioanalyses of the first quarter (October to December 1970) samples.
2.-
Air Samples i
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The five air samplers shown 'in Table 2.8-1, Section 2.8 of the FSAR, have been placed in operation. Samples are collected using a Gelman. Nuclear Airo Sampler, Catalog No. 26003,~ with a Metricel
~ filter whose mean flow pore size is 0.45 microns. Each week a 2's n
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hour sample is collected by an assigned individual at the air sampler site.- This individual changes the filter and mails the sample directly to Trapelo/ West. The air samples are analyzed in accordance with-the description in 2.8.2.1 of the FSAR.
3..
Water Samnles Three types of water samples are being collected. Surface water
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is collected monthly from Folsom Lake, Comunendie Reservoir and the reservoir on the reactor site. Well water is collected once a quarter from the well on the reactor site and a well at a private residence in the Clay area. When available, water from the runoff of the reactor facilities area, the site runoff and a location below the junction of-these two runoffs is collected monthly and j
composited for a quarterly analysis. All water samples are collected
- by SNUD personnel and sent to Trapelo/ West. The samples are analyzed in accordance with the descriptions in 2.8.2.2, 2.8.2.3 and 2.8.2.4 of the FSAR.
4 Soil. Nbd and Silt i
-Initial soil samples from 5 locations at the perimeter of the reactor site have been collected. Additional samples will be collected semi-annually. Mud and silt samples have been collected at the three locations where runoff waters from the reactor facilities and the site plus a junction below where these runoffs join were sampled. Additional mud and silt samples will be' collected at these locations on a quarterly frequency. The soil, mud and silt samples are analyzed in accordance with the descriptions in 2.8.2.5 and j
2.8.2.7 of the FSAR. These samples are being collected by SMUD personnel.
5.
Venetation Vegetation used for cow feed has been sampled at the 3 dairy locations shown in Table 2.8-1 of the PSAR.
.This t pe of sample is collected 3
by SMUD_ personnel on a quarterly frequency.
Mr. Miller said that the cows are on this type of feed for about 10 months of the year.
To date no human edible vegetation samples have been collected.
According to Mr. NK11er, they intend to obtain samples of human edible vegetation when they become available in produce stands established:st the farms in the area. The cow feed ~ samples have been analyzed in accordance with the description contained in 2.8.2.6 of the FSAR.
~ 6.
Milk l
Milk samples are being collected from the three dairies shown in
-Table 2.8-1 of the FSAR.-
The samples are collected hgr personnel at each dairy. Once a month a sample of milk is collected and put.
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7.
Fish l
To date no fish samples have been collected.
hk. Miller said such samples will be obtained starting in the summer of 1971.
Mr.
Colombo stated that the reservoir on the site had been stocked with fingerlings about two months ago.
8.
Rabbits 1
hKiler said that only one rabbit had been obtained to date. The i
licensee still expects to obtain rabbits on a quarterly frequency.
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The rabbits will be analyzed in accordance with the description contained in 2.8.2.10 of the FSAR.
9.
Background Radiation Dose l
l The licensee is using film badges and TLD devices to measure the background radiation dose at 10 off-site and seven on-site locations.
The off-site locations were found to be those described in Table 2.8-1 of the FSAR. Five of the on-site locations are at the perimeter s,
of the site. A film badge and two TLD devices have been placed at each location. SNED personnel change the films and TLD devices on 3
a quarterly frequency. The films and TLD devices are sent to Tracerlab, Division of International Chemical and Nuclear Corporation, for interpretation. The results are sent to Trapelo/ West for inclusion in the quarterly reports.
L.
Meteorology A permanent 200-foot meteorological tower has been erected on the site.
Data are being collected at three levels on the tower. Temperature is measured at the 6, 50 and 200 foot levels; however, wet and dry bulb measurements are made at the 6 foot level only. Wind speed and direction, including horizontal and vertical direction,' are measured at the 50 foot level. Wind speed and horizontal direction are measured at the 200 foot level. The instrumentation was 'found to be as described in Appendix 2B of the FSAR. All data are collected on a magnetic tape which is changed on a weekly frequency. SHUD Engineering is re rnnsible for the meteorological program at the site. hkteorology Research, Inc., Altadena, California processes all of the meteorological data.
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, e At the time of the inspection, the magnetic tape recorder was found to be in a " test" condition and was not recording data. According to Nk. Raasch, their investigation into this matter disclosed that the recorder had been in the " test" condition for about one week. Also, Mr. Raasch discovered that the instrument technician normally places the recorder in the " test" condition, i
following replacement of the magnetic tape, for a short period of time (i.e.,
coffee break) before returning it to operational status. The condition discovered during the inspection, according to Mr. Raasch, resulted from the
- technician being directed to other activities during the period the recorder was in the " test" condition and not returning to place the recorder in an
. i operate condition.
l M.
Miscellaneous 1
The inspector discussed with Bechtel and SMUD construction problems that have been observed at other sites. Pertinent comments were as follows-l 1.
Microfissures have been observed during weld end preparation of cast pipe fittings manufactured by U. S. Pipe & Foundry for use by SWEPCO.
This item will be reviewed, but Mr. McMahon did not think it to be of concern since they were only receiving straight pipe from SWEPCO.
The fittings for Rancho Seco are being manufactured by Taylor Forge.
2.
The procedures for electrical motors will be checked to assure that they contain provisions to preclude phase reversal during installa-tion and maintenance operations.
2 3.
The need for a requirement for dimensional measurements of wall thickness for primary system valves will be reviewed. It was observed that none of the primary system valves will be supplied by Crane-Chapman or Darling Valve Companies.
4 Informed the licensee that clad cracking problems were being experienced with the 6 wire strip cladding process currently being used on some reactor pressure vessels. McMahon stated that this would be reviewed for applicability to the vessel for Rancho Seco.
5.
The need to evaluate the dynamic effects of water in pipe designs, including measurements of pipe novement during'the preoperational and-power ascension test programs, was discussed.
Mr. Hiltz stated that EDS '(Energy Data Systems) of Palo Alto, California had been hired to do a complete dynamic analysis of Class I piping systems as required by B31.7.
The effects of water hammer and water in
- 1 steen lines will be considered.
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6 Mr. McMahon inquired about low ferrite in the welds at Surry and stated that he intended to obtain additional information about the problem.
7..
The actuating mechanism that closes the boric acid injection valves will be reviewed to assure that redundant systems cannot be deacti-vated by a single failure such as the failure of a comanon power supply.
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DIVISICII 0F' COMPLIANCE M0mLY EEPORr g
_MAY 1971
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h Sacramento Municipal Utility District (Rancho Seco)'- A CO inspection was-conducted.on May 17-19, 1971..
Items reviewed included <the preoperational environmental-survey program, QA-QC: program.for site-erected Class I. vessels and record review-of Class.I piping.
No deficiencies.were. identified.
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