ML19317F821
| ML19317F821 | |
| Person / Time | |
|---|---|
| Site: | Rancho Seco |
| Issue date: | 04/20/1971 |
| From: | Dodds R, Andrea Johnson, Spencer G US ATOMIC ENERGY COMMISSION (AEC) |
| To: | |
| Shared Package | |
| ML19317F811 | List: |
| References | |
| 50-312-71-02, 50-312-71-2, NUDOCS 8002210574 | |
| Download: ML19317F821 (13) | |
Text
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s F. S. ATOMIC ENERGY COMMISSION O
DIVISION OF COMPLIANCE REGION V Report of Inspection CO Report No. 50-312/71-2 Licensee:
Sacramento Municipal Utility District License No. CPPR-56 Category A Date of Inspection:
March 22-25,1971 Date of Previous Inspection:
January 26-28, 1971 Inspected by:
R. T. Dodids (Principal)
Date Reactor Inspector s
i tr.-/W G l A. D. Y nson Ifate Reacto Inspector Reviewed by:
.~G. S. Spencer Date Senior Reactor Inspector Proprietary Information:
None SCOPE
. Type of Facilitv:
Pressurized Water Reacter Power Level:
2452 Mut Location:
Sacramento County, California Tvre of Inspection:
Construction Inspection q
Acc6mpanvinR Personnel:
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Construction Deficiencies - No significant deficiencies were identified during the inspection.
Status of Previously Reported Problems No significant problems were listed as being outstanding following the last inspection.
Other Sinnificant' Items -
1 Overall project construction status was estimated.to be on schedule
'with 33% completion as of NWrch 24, 1971. Class I pipe construction has been delayed because of lack of pipe from the fabricator. All of the concrete far the vertical wall of the containment building has been placed. The two 90. ton support girders for the polar crane have been set in place on the crane rails. The field fabrication laydown work for the dome liner plate was essentially complete.
1 All of. the concrete for the second natural draf t cooling tower has been placed.
(Section B.)
y 2
A detailed review of Nonconforming Reports disclosed that nonconfor-mances were being reviewed and dispositioned in accordance with h
the QA-manual. However, a number of reports did not contain the i
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basis for disposition or cause of the nonconformance.
(Section'C.)
)
3.
An unannounced inspection the evening.of March 27, 1971 disclosed that weld electrodes were properly stored.
(Section D.)
4.
Records of welding operations were being modified to show compliance with essential variable requirements at the start of operation.
Additional checks will be made by the welding inspector but'not necessarily as a requirement for each weld..(Section E.)
5.
Construction inspection planning for the installation of electrical 1
cable and wire, reactor protection' circuits and safeguards actustion circuits has been modified to require mandatory comparison of' computer output with applicable drawings prior to the installation of' cabling.' (Section F.)
6.
No deficiencies were. identified during'the review of the QC system for Class I components.
(Section H.)
i Manaaement Interview - The results of the inspection were_ discussed with Messrs. Connelly, naasch, Jackson, Hiltz, Stinchfield, Vander Knyff and Steen.
The following items.were included-in the discussion:
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While the Plant Review Committee has been activated and has started to function in accordance with the proposed technical specifications, the Management Safety Review Committee had not formed its charter t
. and had not yet met as a group.
Mr. Connelly agreed with the inspectors'that it would be prudent to have the Management Safety
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Review Committee review the technical specifications to be submitted with the FSAR, particulary, since all changes to the technical specifications must be approved by this Committee.
2.
The inspectcrs observed that discussion with QA personnel disclosed that SMUD policy permits " rework on the spot" if it can be accomplished in a timely manner without dispositioning the rework on a " Nonconforming Report". This practice is not consistent with the Project quality Program Fknual.
Mr. Jackson stated that the manual will be corrected to provide guidelines for rework consistent with construction practices.
3.
Nr. McMahon concurred with the inspector's findings regarding the
' lack of sufficient information on some of the Nonconforming Reports concerning the technical justification for acceptance or cause of
[)N nonconformance. He indicated that the deficient reports will be
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corrected. It was noted that SMUD had made a similiar finding during a recent audit and that the quality of reports has since been improved.
4 The licensee was apprised of the inspector's concern that some of the stainless steel piping to be supplied to Rar.:ho Seco may be
- sensitized because of SWEPCO's fractice of air quenching the pipe during heat treatment.
Mr. Jackaon stated that additional information would be obtained and submitted to the inspector for review.
DETAILS A.
Persons Contacted The;following persons were contacted during the inspection.
SMUD
.R. Connelly
' Manager Engineering Department D.-Raasch Project Engineer fJ. Jackson
- -Quality Assurance Director 4
W. Friedrich Quality Assurance Engineer J. Hiltz Resident Engineer R.-Oubre' Assistant. Superintendent, Nuclear Plant Operations R. Colombo Technical Assistant b
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/- ~x (Q)' Bechtel Corporation - (Engineerine and Construction Management)
W. Stinchfield Project Manager-V. McMahon Chief Quality Assurance. Engineer R. Hunter Quality Assurance Engineer (Source Inspection)
W. Taylor Quality Assurance Engineer (Mechanical)
W. Chapla Quality Assurance Engineer (Piping '& Welding)
C. Marquess Materials Supervisor Bechtel Corporation - (Construction)
J. Vander Knyff Project Superintendent B. Boyd Welding Supervisor Leave 11 - Dravo W. Steen Project Manager B.
Status of Construction
(N Overall project construction status was estimated to be on schedule with
(
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33% completion as of FWrch 24, 1971. Class I pipe construction has been delaved because of lack of pipe from the fabricator. All of the concrete for the veritical wall of the containment building has been placed. Concrete placement inside the containment building is essentially complete to (+) 20'.
The two 90 ton support girders for the polar crane have been set in place on the cr ne rails. The field fabrication laydown work for the-dome liner place was essentially complete. All of the concrete for the second natural draft cooling tower has been placed.
C.
Nonconforming Reports A detailed review was made of the nonconforming reports that had not been previously reviewed by the inspectors (reports nos. 150-525). It was observed that the dispositioned items had been reviewed, accepted, rejected, repaired or reworked in accordance with QA Procedure Number 17.
The completion and acceptability of repair and/or rework dispositions were verified by Inspectors / Engineers. The Engineering Review Board members and other cognizant engineers passed judgement on all accept / repair dispositions.
.A number of reports in the 300-400 series did not appear to provide sufficient technical justification for the disposition of the item nor did they adequately' state the cause of nonconformance.- The more recent reports appeared to contain sufficient information and provided the basis for disposition of the items. When questioned. Fr. McMahon G
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i U stated that SMUD had also made these same observations in a recent audit and that corrective action had been initiated as evidenced by the completeness of :he more recent repcres.
?.
Weld Metal Control-An unannounced inspection was made che evening of March 22, 1971 to check for af ter hour storage of weld metal.
Mr. Jackson accompanied the inspectors on the tour of the construction site. The CB&I laydown work area for the liner plate, turbine building and reactor containment vessel were included in the inspection tour. No instances of improper weld electrode control (improperly stored metal) were. observed. Work areas were clean and as a general rule, the stubs from used electrodes had been.placed in waste buckets that were being used specifically for that purpose. Full length electrodes in vaste buckets were noted to have been bent to preclude future use.
E.
Class I Piping (Record of Essential Vcriables During Welding Operations)
A discussien was held with the Messrs. Boyd, McMahon and Jackson regarding
('^g records to show compliance with essential variables during welding
%j operations of Class I piping. The Quality Control Instructions are be'ng revised to require the welding inspector to periodically visually check gas flow rate at the rotometer and to periodically check the amperage with a clamp-on ammeter. This will not be a requirement for each weld but rather will be a check of work in progress. According to Mr. Boyd, the gas flow rate will be specified under veld requirements on the
" Field Welding Check List" that is used for each weld. Amperage will not be.specified since it is not an essential variable for manual are welding of P-8 materials.
Mr. McMahon stated that the inspector's check of essential variables and/or amperage may.he discontinued if experience shows the checks to be of little or no value.
F.
Instrument and Electrical Cable Trav Loading According to Mr. McMahon, the construction inspection plan for " Installation of Electrical Cable and Wire" has been modified to require mandatory comparison of Cable Pulled Card Numbers with applicable drawings prior to pulling cables. Computer outputs will be checked periodically during all printouts. Raceways will be visually ins]ected for proper cable and trayfloading during the installation of electrical cables in the raceways.
Any raceway having visual indications approaching or exceeding a maximum loading of 40% will be physically checked by counting the number of' cables, measuring' cable diameters and calculating the actual loading.
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v Special construction inspection planning will be prepared for the installation of reactor protection circuits and safeguards actuation circuits after revised drawings have been received and reviewed.
Inspection planning will be oriented toward ensuring that the required isolation and separation of circuits, color coding, marking, etc., of circuics has been accomplished and maintained.
G.
Other Class I Structures (Site Fabricated Vessels)
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The contract for. site fabricated vessels has recently been let to
. CONSECO, San Leandro, California. No site activity.is expected until July, 1971. CONSECO's QA program for manufacturing has been reviewed and found to be acceptable according to Mr. McMahon. The procurement document was reviewed by the inspector and found to contain provisions requiring the constructor to have a QA program consistent with applicable AEC criteria.
H.
Stainless Steel pipe It was learned during the review of the Nonconforming Reports that a O
Bechtel Source Inspector had noted that the stainless steel pipe to be supplied by the SWEPCO TUBE CORPORATION, Clifton, New Jersey war air cooled after heat treatment rather than water quenched. The Bechtel inspector observed that this may be in violation of ASTM-A358 paragraph 4.3.1 which states, "The heat treatment procedure shall consist of heating the material to a minimum temperature of 19000F and quenching in water or rapidly cooling by other means." SWEPCO subsequently j
furnished Bechtel with a heat treat chart and a Mechanical Test Report to verify material properties. SWEPCO stated that it is their preference to minimize thermal stress and avoid water quench whenever possible.
Consequently standards have been established whereby certain diameters and certain wall thicknesses are satisfactorily cooled by air through the sensitizing temperature range as evidenced by studies of photo-micrographs. Thicknesses below -inch are cooled in stagnant ati while thickness -inch and above are rapidly cooled using compressed air.
The pipe must be " black" within a maximum period of three minutes.
SWEPCO concluded from the photomicrograph observations and material
. properties tests that the pipe in question has been satisfactorily heat treated and properly cooled.
During the management interview, the inspector indicated a desire to obtain additional.information as well as an opportunity to view a photo-micrograph because of the potential for sensitizing stainless steel if it is not " rapidly quenched". This material was subsequently forwarded to CO:V.
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- The material included a photomicrograph of T304 annealed pipe 18" 0.D. x'3/8" W x 24' L.
Information relating to the photomicrograph
. stated it to have a magnification of 100X and the etchant was 10 ml HNO3, 30 m1_ hcl and 30 ml glycerol. A copy of the photomicrograph has been appended to the report.
The inspector. informed Mr. Jackson by phone on April 14, 1971 that it is not apparent that the photomicrograph demonstrates anything more chan general structure arrangement of grains and that CO may wish to pursue i
the matter further.
I.
Other Class I Components (PI 3800/2 Attachment L) 1.
Review of OC System Bechtel Corporation has the contractual obligations for receiving, storing and installing the mechanical components in the Rancho Seco plant, including the nuclear steam supply system supplied by the Br.bcock and Wilcox Corporation (B&W). Pursuant to Attechment L of PI 3800/2, the procedures for assuring proper receiving, handling, storing, quarantining, installing and inspecting of components were reviewed ~and discussed with Messrs. Jackson and McMahon. The s
SMUD Quality Program Manual, the Bechtel Quality Control Instructions and the B&W Erection Quality Assurance Manual, Procedures and Nuclear Standards were specifically reviewed by the inspector. In addition, the inspector confirmed that the on-site files contained purchase orders, applicable specifications and technical data related to the eight other Class I components selected for review pursuant to the PI inspection requirements.
The selected components were:
a.
Main reactor coolant pumps, b.
Decay heat removal coolers, c.
High pressure safety injection system pumps, d.
Pressurizer relief valves, e.
Control rod drives.
f.
Pressurizer g.
Isolation valves for decay heat removal coolers.
h.
Recctor building upper dome emergency air circulators.
None of the above components have as yet been received onsite.
Therefore,.neither the specific receiving inspection procedures nor installation procedures relating to the specific items had been formulated..However, the B&W procedures manual provides,
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. L in the form of specifications, the minimum requirements for receipt, inspection, loading, storing, and installation on each major piece
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- of~ equipment supplied by B&W. The specifications were stated to
' consist of. criteria from applicable sources, such as engineering codes, accepted. standards, design or manufacturing specifications,
. design or manufacturing drawings, construction drawings and equipment instruction books.
Prior to inclusion.in the procedures, each specification was indicated to have been subjected to a detailed review by B&W's' Engineering.. Manufacturing, and Erection Departments.
The procedures and provisions were stated to be binding on Bechtel (the contractor) via'the contract provisions. The procedure manual provided that prior to handling any of B&W's equipment, the erecting contractor is' required to review the content of the manual and to make available to the B&W site representatives, for review, all i
written procedures, plans, drawings, etc., indicating how the requirements of the manual will be met.
The Eechtel procedures for receiving inspection and storage required
- that a specific procedure be formulated fer each Class I item. The need for formulating a particular procedure is triggered when the source inspector informs the sLte that the shipment is being prepared and that the source inspectior. group has confirmed that the item has been satisfactorily inspected for conformance with the pertinent requirements. At that time, the inspection planning group at the site is required to assure raat the receiving inspection and storage procedure is formulated ans given to the material inspectors for implementation.
During 's tour of the site area, the inspector confirmed that adequate facilities had been constructed to provide appropriate storage of other Class I components. : Warehouse ~ capacity with. temperature control consisted of two concrete buildings. Concrete slabs were available for outside storage of material such as cable. Tanks and other components stored outside,-but not on concrete slabs, were observed to be' elevated from the ground by use of wooden cradles and supports.
A material quarantine area had been established and was observed.
to;be appropriately identified. ~ Materials in the area were noted-to be identified as. unacceptable for use in accordance with the QA tag procedure.
- Fk. Marqueas, Material Inspector, explained to the inspector how the receiving inspection group functioned. He reviewed a recent receipt of materials by' showing the inspector the receiving inspection and. storage procedure supplied by.the inspect 4on planning group and o
how the receiving inspectors. implemented the procedure and' documented their findings ~and' action. 'From the review, it appeared that the' particular material had been received. inspected and stored in
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accordance with the SNUD and Bechtel QA-QC procedures.
.B&W.is required to provide technical assistance and the necessary
-expertise to assist and assure appropriate installation of the Class I components associated with the nuclear steam supply system.
As discussed above, Bechtel' is to prepare procedures consistent with a
the B&W QA requirements for installation of the components. The procedures are required to be reviewed by the B&W technical representatives prior to proceeding with any particular installation g
activity.
J.
Miscellaneous Construction Items -
1.
Post Tensioninn Nhterials for-Containment Structure Other than the bearing plates and trumpets which have already been installed, none of the post tensioning materials were at the site.
These components were expected to start arriving in June, 1971.
The tendons have been scheduled for fabrication at the site begfaning in August or September,1971, with installation schedule 3 to start in January, 1972.
j f-2.
' Source Insnection Plans for Electrical Moters 1
During.the previous inspection, it was observed that the source j
l inspection plan for the boric acid injection pump motors did not include a specific requirement for the source inspector to review or verify manufacture performance test results. The general Source-Inspection Plan has been revised to be more specific for Class-I motor requirements.
In addition, all Class I motor recuirements of Source Planning have been reviewed ~and found to be satisfactory..
4 3.-
SMUD Proiect Ennineerinn ~ Corrective Action Lons y
LMr. Jackson stated that an Engineering Order has been issued by
'SNUD's Project Engineer for Rancho Seco that establishes a uniform logging system of items requested for consideration by the SMUD i
^ design review engineers.; fDais was an item of discussion at the Management Interview in January,1971.
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Safety Review Committees L
-Activities of the Management and Plant Sa'fety Review Committees were-
' discussed.with Messrs.-. Oubre' and Colombo. - The EbnagementLCommittee has-not;yet met nor has its charter been prepared. The Plant-Committee-
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has been: formed and met on two occasions for the purpose of: reviewing
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, preliminary and, final functional test procedures,~ maintenance procedures and to discuss ~the preparation of the emergency plan and-the Committee
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charter._ Hr. Colombo felt chat the charter, which was being prepared by Mr. Rodriguez, Plant' Superintendent, would be formulated in the i
near future. In the interim, the Conunittee plans to function in j
accordance with the proposed technical specifications.
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i DIVISION OF COMPLIANCE MONTHLY REPORT FOR APRIL 1971 r
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t i-4 Sacramento Municipal -Utility District (Rancho Seco) - CO inspection was conducted on-March.22-25-to observe site con-i struction activities and to review the quality control pro-gram associated with installation of the polar crane, field fabrication of the containment dome liner plate, and place-j ment of concrete.
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