ML19319A636
| ML19319A636 | |
| Person / Time | |
|---|---|
| Site: | Oconee  |
| Issue date: | 10/15/1968 |
| From: | Fred Bower, Long F, Seidle W US ATOMIC ENERGY COMMISSION (AEC) |
| To: | |
| Shared Package | |
| ML19319A635 | List: |
| References | |
| 50-269-68-04, 50-269-68-4, 50-270-68-04, 50-270-68-4, 50-287-68-04, 50-287-68-4, NUDOCS 7911180074 | |
| Download: ML19319A636 (23) | |
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4 U. S. Al'0:41C E:;ERGY CC;DMSSION RECION II DIVISION OF CO::PLIll;CE Report of Inspection CO Report No. 50-269/G0-4
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50-270/63-4
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50-237/63-4 Duke Power Co.pnuy c
Licensce:
License Nos. CPKl-33, 34 ond 35 Category A r
Dates of Inspection:
S eptc r.h e r 25-27, 1968 Date of Previous Inspection:
June 19-21, 1968 7eEded o
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Inspected By:William C. Seidle, Reactor Insp W nr
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/O//<//c.9 Farris U. Eower, Reactoe Id'spector (Const.)
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An sanounccd incpection was r..ade of the three 2550 :ht Pa t r.ori zed water power reactors under construction near Scacca., South Carolina.
The inspection effort was directed primarily to the field and vendor quality assurance program, containment building strain gauge installation, Cadweld tenstic test records, liner plate welds and tha on-site receipt and storage of reactor hardware.
Safety Itens - None h
Nonconfonnance Items - One itea was noted: Ccnstruction specification No. 03-134-2 (Section 1.5.2) states "... randomly selected splices (test splices) shall be tensile tested in accordance with the following schedule for each.positicn, bar size, and grade of bar:
One out of first 10 splices, three out of next 100 splices, and two out of the next and subsco,ocat units of 100 splices." Section 1.5.3 of this specificat ian states "...two (2) production splices will be cut out and tested for each 100 test splices." Cadweld tensile strength test records revealed that the mininum specified f
test requirements were rot met during the splicing of 198-18S rebar joints during the period June 29, 1968, through July 17, 1968.
(Sce Management Int'rview Section, Item 3.)
Unusual Occurrences - rw e e
Status of Previously Reported Prob 1 cms - During the previcus inspection, two items of nonconformance were noted:
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The construction specification for Cadweld splicing of rebar was revised in May 1968 to include a 3 square inch void criteria. This revision, which changed the filler
. metal void criteria fran that described in the PSAR,
! Supplement No. 4 (Answer No.18.1), was made without prior knowledge of DRL.
Corrective Action - Rogers stated that at the conclusion of the inspector's last visit the revised Cadweld specification vas withdrawn, and they have r' rned to he original specification.
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In witnessing the placement of' con cetc os a containment wall panel during the previous vi i
. inspector noted that a placement inspector was nc. present at the form.
Failure to provide an inspectcr on a continuous basis was in nonconformance with the PSAR.
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Corrective Actiori - Wells advised the inspector that iu,nediately af ter this deficiency was brought.to his attention he notified R. 3. McCrcry, Concrete Supervisor, and advised hira -hat he is to provide a full time pinconent inspector at the form as required by the PSAR.
Other Significant Itemn - Based on can hours spent, the percent of construction completed for Units 1, 2, end 3 combined is 7%; for Unit 1, 15%.
'De'fective shop welds in the Unit I contairacnt butiding liner plate penetration sections have delayed the crection of liner plato and placement of concrete vall panels e. bout 2 nonths. All of the weld defects were detected at the site by Duke quality control personnel (See Section D.I.).
Placement of the Unit 2 tendon inspection gallery walls is complete; the conctete work slab for the contain.nent building mat is presently being placed (See Section C.2.).
The second batch plant has been crected on site and is now in
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operation. The plant is presently batching only 3,000 PSI
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strength concrete for use in non-nucicar related structures (See Section E.4.).
A tenative r.ceting date has bcea sat for Compliance to meet with Duke and 3 & W personnel to dir, cuss the quality assurance program associated with the fabrication of the Unit i reactor pressure vessel (See Section G.1.).
Management Interview - TSc inspectors met vith Wells, Rogers, Dick, Dail, and Owen at the conclusion of the visit. The following items were discussed:
1.
Nonconformance Items from Last Inspection _
The corrective neasures taken by Duke on the nonconformance items noted during the y covious in' pection were reviewed by Rogers.
bCorrective ce ssures c ce discussed in Status of Previously Reported Protic33 section of this report.]
2.
Personnel In response to the inspector's inquiry on when the mechanical and electrical field casincer's positions would be filled, Dick replied that at the present tire they had
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}' 6-k.) t l' ./= 6 would produce qualified men to fill these vacancies. IIe concurred with the inspector that the field engineer play. a key role in the quality assurnnce progrem, and, thetefore, these yo:,itIoas should be filled as soon as possibic. 3. Cadweld Records The inspector inforned Dick that a revicu of the Cadweld splice records for the past three conths revealed the _I following deficiencies: Sister splice tensile tests were not conducted at the a. minimum frequency specified in the PSAR. b. Production splices arc'not being removed and tested at the frequency specified in Section 1.5.3 of specification No. OS-134-2. Errors woro noted in the ntrabering system used to c. ,( idtneify sister splices. d. The records do not indicate when a Cadweld has been rejected. For exemple, it was noted in the remark column that the following entry was made af ter several of the logged Cadwald splices "...not enough filler material." The inspector 1carned when discussing this remark with Wells, earlier in the inspection, that l whencycr an entry of this sort was noted in the remarks column the Cadwald was rejected. Replacement Cadwelds for rejects are not in all cases e. t entered into the record. A spot check revealed that in two cases it was not possible to determine by the record 1 i entrics whether or not t, placement splices had been made for the rejects when, in fact, the replacements had been made. Uc11s stated that the recent departure of H. J. Young, Cadueld Inspector, has contributed to the deficiencies noted in the Cadweld records. He quickly pointed out that this ~is certainly not a valid excuse; Duke intends to naintain } adequate ret 'rds, and corrective measures will be taken to assure that this will be done in the future. In regard to the sister splice test frequency problem,he stated that they had been renics in not checking the records more closely to cake sure that the testing frequency, as v . (.L
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O .~.. J. L..; .s s IIc assured the scheduled in the PSAR, was being followed. inspector that he aculd fo11cw up on this item with Baldwin who is ncw maintaining the Cadweld records. 4. Quality Control Records' In regard to quality control records, L'c11s stated that it was not clear to him exactly what records must be maintained by the vendor shops and by the field and where these records should be filed. The inspector responded with the following cc=nents : Duke is fully responsible for the ccuplete safety and 6-adequacy of the reactors now under construction at the n. t= This responsibility carries with it the j 0:once site. burden of satisfying the Commission that the reactors have been constructed in accordance with approved In that specifications, plans and applicchic codes. the Commission uses the nethod of spot checking records as one means of ascertaining whether or not the reactor ~ has been built to specifications, it would, therefore, seem appropriate that the permit holder maintain appropriate quality control documentation. The inspector stated that it was difficult to provide b. a definitive answer to the question pertaining to which records should be maintained. As a general guide, it would seem appropriate to naintain records on those components associated with class I structures and systems, i.e., those structures and systems which provent uncontrolled release of radioactivity and are l designed to withstand all loadings without loss of j The inspector pointed out that excmples of j fsuction. cisas I structurec and systcms would include the reactor l t l - containment building and its penetrations, the reactor vessel and its internals, reactor coolant systems, engineered safeguard systems, fuci storage f acilities, vaste disposal systcus and the reactor control roem The inspector stated that when he and equipment. obtained mora definitive guides for record keeping he would certainly pass this information on to Duke however, until such guides arc issued, it management; would behoove Duke as the permit holder to maintain vendor and field quality control records on all hardware related to reactor safety, f c. The disposition of vendor cud field records is lef t up to the pensit holder. The inspector did point out, U .8'
{ } ...I t ) y(. .s (. howcVer, that to avoid unnecessary delays during the Conaission's pre-startup revicw it vould behoove the permit holder to have 'a recerd keeping cystem that would en'ble hits to ranke any quality control record readily available. The inspector also urged those present to consider filing quality control records by systen. For cxample, all records associated with the reactor coolit.g system including piping valves, pumps, pressurizer, ot'. would be filed under the appropriate system heading. Past expariences have indicated that considerabic revin time can be caved if such a filing system is adopted. } Ccmments fro:a those in attendance wculd cuggest that Duke is reconciled to the fact that appropriate quality control records sust be maintained and that a system must be octablished wherchy records can be made readily availabic upon request. 5. Shop Ucid Defects in Unit 1 Contairment Building Penetrations .( ( Duke nanancment shared the inspector's concern that eight containment building liner penetration sections supplied by the Southern Boiler Shop were found to contain defective ucids when inspected by the Duke quality control field personnel. All of the penetration wolds had been certified at the Shop by the voador and a third party welding inspector from the Law Engineering Firm. The inspector reminded Rogers that defective welds were previously detected in other containment building steci components supplied by the same shop.1/ The inspector ~ - made the observation that it vould appear that every major j component that has been fabricated by the Southern Boiler Shop has arrived on site with defective wolds. Dick stated i that the inspector's observatica was unfortunataly accurate. He did point out, however, that come steel components fabricated by Southern 3 oiler for other non-nucicar related jobs along with hardware recently received at the site has indicated to Duke that Southern Boiler Shop does have the basic capacity for producing quality work. He attributes ~ the. sub-standard workmanship to shop procedures which are not cicar to the welder and to poor quality control inspection practices. Dick stated that the following action has been taken to correct the welding deficiencies. j 1 1/. Discussed in CO Report No. 50-269/68-2, Section H. 4 y. 4, n ; ,.7,. L_: I
r-I (.J ] -...... . g..a <i. i w( ~7-The Law Engineering Firm has placed two core welding a. inspectors in the Scuthern Doller Shop en a full-time basis. (There are 3 third party inspectors now in the shop ~.) b. Duke assigned Mr. F. R. Jackson, Mechanical Engineer, to the Southern Boiler Shop continuously, for a three-week period, then on a part-time basis only. Jackson was formerly the principal field engineer for Duke and has had many years of experience with welding, according to Dick. Duke nanagement has met with Southern Eoiler management c. to discuss the need and methods for improving the j quality control progra:a on this job. (This area will [ be reviewed during the CO:II inspector's pending shop visit.) d. Southern Boiler plans to initiate a financial incentive [ program to encourage their velders to produce quality { velds. (Rogers believes this progrom has been adopted.) Some containment building penetration sections which nontained defective welds were returned to the shop for repair. The defects were pointed out to the shop quality control inspectors who had inspected and certified the weldments. I Dick stated that the quality of workmanship in steel components recently received from the Southern Loiler Shop would suggest that the steps taken by Duke to correct the weld deficiencies j are paying off. As an example of the improved workmanship noted, he pointed out that a boiler feed penetration section had arrived on site a few days ago which after a thorough field quality control inspection was found to be free of weld defects. Dick cemented that to his knculelge this was the first major f abricated steci component to came frota Southern Boiler that did not require weld repairs. The inspector commented, that as more shop-f abricated hardware arrives on site, it is going to be core difficult, if not impossible, for every ucid to be inspected by the field quality control inspectors. Therefore, it would seem imperative that Duke be abic to place faith 'c.' the vendor and third-party inspector's certifications. i o b L_.
i ( ,j J L.s i. The inspector stated that he plans to visit the Southern Boiler Shop in Memphis sometime in November and that he would make arrangements for the visit thrench Duke mananc-ment. Dick stnted that they would be very happy to cooperate with the inspector in making any arrangements for the pending visit. 6. On-Site Receipt and Storage of Reactor liardware The inspector asked Wells to briefly describe the systcm Duke will use to receive and store reactor components as tacy arrive on site. Wells stated th4t only a few pieces of reactor hardware equipment have arrived on site. listever, anticipating that hardware will be coming in at a faster I rate in the very near future, they are setting up a materials receiving system which will be put into effect shortly.. The inspector asked Wells if the raaterials receiving man would also perform a quality control function in that he would check for demaged cquipment, quality control records accompanying the shipuent, that the equipment received met the specification rcquirements, etc. Wells c stated that this quality centrol function would be performed, but details for impicmenting such a progrca have not been worked out. Wells stated that they recently completed the erectica of a 20,000 sq. ft. warehouse building which will be used for storing reactor equipment. Itc stated also that pipe racks are presently being erected for the storage of stainless steci pipe. The pipe rack area will be fenced and the gate kept locked to control the use of the pipe. The inspector stated that he would review the material receiving syste:a and storage facilities for reactor hardware during his next visit. 7. Inspection of Weldments in Vendor Fabricated Tanks The inspector mentioned that he had made a spot check of web r.ents in several tanks fabricated by the Chattanooga Boiler and Tank Company, Chatt'nooga, Tennessee. (Some of the tanks inspected included a miscellaneous waste evaporator feed tank, the RC feed evaporator feed tank, condensate test tank, boric acid mix tank, caustic mix tank, and a condensate test tank. Some of the tanks were constructed of aluminum, others of stainless steel.) The inspector alerted Rogers to the fact that some weld s ~ ,, y.-), m
i y.$ ..) a ~ \\ 9 s defects such as under cutting, slag inclusion and arc strikes were noted, and, therefore, the welduents should be checked against the epplicshle < den for the teverni tanks to determine if the welds arc acceptable. Welic stated that he was certain that all of the tanks discussed by the inspector would sco only atmospheric pressuto and that the weldments would probably satisfy the code requirc-nonts; however, he would folicw up and have the welds reinspected by the Duke quality control welding inspectors. 8. Liner Plate Weldq h The inspector briefly discussed his cursory inspection of liner plate welding in the Unit 1 Containt.cnt building. 3 He pointed out that a spot check revealed two areas of questionable welding technione involving filler uctal deposition and the 'perainsibic. cmount of undercutting allowed (discucsod in Sectien D.2. of this report). Wolls stated that he would follow up on thecc two items with the senior velding inspector and, if necccsary, initiate appropriate repairs. \\ I 9. Rebar Placement The inspector stated that, when he inspected the picce=ent of the 18-S rc5ar in the biological shield wall within the containment building (also serves as a bearing wall), he noted that none of the several rebars cbserved were shapes in a manner that uould permit proper fit up of the Cadweld sleeve. As a consequence, the rebars were being . sprung, a foot or more in sm.e instances, in order to slip the ends of the rebar into the Cadweld sleeve. It was also { noted that all the Cadwelds that had been made in this wall were being cut out due to the misalignment rejection of the splices. Dail replied that proper alignment of this type of connection could probably-ncver be satisfactorily achieved and that they intended to re-design this and other similar walls using No.11 rebar with a lap and tic joint. DETAILS A. Persons contacted The following Duke Power Company personnel wera -contacted during the inspector's visit: e p
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r< ,---. J R. L. Dick, Project Manager J. R. Uc11s, Principal Field Ent;ir.cer/ Quai.ity Anuu.nce Eny. tr . J. C. Rogers, Project Engineer C. R. Baldwin, Concrete Inspector (Placing and Lab Tech)/ Cadweld Inspector ] J. T. Maore, Chief Welding Inspector L. D. Dail, Principal Civil Enginecr/ Design I W. H. Owen, Principal Mechanical Engineer /Pecign R. Boggs, Field Engineer t L. J. Jones, Assirtant Welding Inspector 3. Administration and Organization _ k 1.- Personnel 4 J The position of Field Engineer - Civil was filled by the prcuotion of Hunnicut who had been temporarily handling this Ec has a Civil Engineering degree from Georgia Tech, . job. Class of 1962, and is a registered engineer in the Secte of Georgia. After graduation he worked for a consulting engineering firm in design and later for the Du Pont Company, Rogers stated the Uunnicut has been the acting Fic1d Engineer - Civil for ccveral nonths, and it was the l consensus of Duke canagecent that he was qualified to permanently fill the position. i . The positions of F c1d Engineer - Mechanical and Field i Engineer - E1cetrical remain vacant. Rogers stated that they have been unabic to find qualified tren to fill these positions. The few applicants reviewed for these jobs were either not qualified or demanded salaries in excess of that paid to the Duke Project Manager. Rogers did state that the higher icvels of Duke management have been alcreed'to this probico, and, hopefully, through a stepped-up~ recruiting effort the vacant billets can soon he filled. H. J. Young, Assistant Welding Inspector /Cadwelding Inspector, terminated his employment at Duke in July and 1 O '{' =
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3.\\ i,.- (\\ e. is presently working for the Gulf Cencral Atonics Corporation, La Jolla, California. Rogers stated that they are planning to train Baldwin for the position vacated by Young. Baldwin b..c L c,y. arc of colh.c (.wa ngiucering) and is presently t working in the concrete lab as a technician. 2. Lnhor Relations In response to the inspector's inquiry on this cubject, Rogers replied that the 13EW through the ef forts of the Greenville guilding and Construction Engineers Trade Council is contitating its ef fort to reprecent the Duke job. Rogers stated that to his knowledge, no vote date had been set. The inspector reiterated a co cnent he nade in a previous inspection in which he stated that his only interest in Duke's labor prchicas was on the ef fect nu.:erous work interruptions night have on quality control at the site. Rogers stated that since the inspector's visit in June, there have been no job walk-of f s or slow-downs. / l 3. Training Wells informed the inspector that four of their field quality control personnel had roccatly cenpleted a four-week course in non-destructive testing which was conducted by B & W at Barberton, Ohio. The following personnel attended the course: J. T. Moore - Chief Welding Inspector s ~ 1 D. M. Ritchic - Assistant Field Engineer - Mechanical i ~ L. J. Burton - Assistant Welding /Cadwelding Inspector C. R. Baldwin - Concrete Inspector (Placing and Lab. Tech.) Wells stated that the course is held twice a year and is presented to Duke personnel by a contractual agreenent. Applications have been subnitted to the A5C to license three of the above cource participants in radiography; Moore is aircady a licensed AEC radicgrapher. C. Construction Progress {. 9 8 ?,- 6,:i. s
( 1 ,,h 1 _ g e \\ 12 1. Defective ucids in 8 containment building liner plate penetration sections have delayed the crection of liner pinte and the pincement of concrete wall penels 35 cut two uonthn. The Iinct plate has Lcen erected through the 7th horizontal ring which is about 70 feet above the base mat. A hold has been placed on the erection of liner pinte as the specification does not permit plate erection to exceed the vall pancis by nore than 5 horizontal rings. The Inst concrete placement in the ccntainment valls uas cade l en July 4,1968. Rogers stated that concrete placeacnt should continue during the week of Septcnber 30. 4 The concrete walls are p10ced through the third lif t except for that area arcend the equip. cent and personnel hatch openings where only one lif t has been placed. 2. Unit '70 2 Placenent of the containment building inspection gallery walls is complete. Placcaont of the work slab for the containment building mat is in progress with about 107. of the concrete in place at the time of the inspector's visit. Installation of temporary shoring for the tendon inspection gallery ceiling is in progress. 3. Unit No. 3 The basic excavation for the containment building is complete; no additional construction effort has been made at this reactor site. D.- Liner Plate - Unit 1 1; Weld Defects in Shop Fabriccted Penetrations + During an inspection visit in March of this year, the inspector was informed by Moore that the Duke on-site welding inspectors' had discovered defective welds in many of the containment building steel cenponents supplied by the Southern Boiler Company, Memphis, Tennessee. The veld defects were in thickened sections of floor liner plate fabricated in the shop. (The weldment defect details and the corrective action take n by Duke to correct the defects arc discussed'in CO Report No. 50-269/68-2.) During this visit,. discussions with Rogers and Wells revealed that the Duke o n-site welding inspectors had {~ T I 4 l' ~ 1
( ,I I .c \\ ' discovered defective welds in eight containa.ent building liner plate sidewall penetrations. (Photographs of the penetraticas are filed with the CO:II copy af this report.) UcIls stated that lack of penetration and slag inclur. ion were the weld defects noted; there were no cracks detected in any of the veldm.cnts. All penetrations were fabricated from ASTM A-516, grade 70 steel. Wells provided the following information on the repair history and the present status of cach defective penetration: SP-30Y (2)' - Each section contains one fuct transfer tube penetration (%e Exhibit A). The wcld defects were first oM erved in these penetratica coctions. Af ter the welds ) were visually rejested in the field by Duke quality control, 1 both sections were returned to the vendor shop for repair. l They ucre then returned to the site, installed, and rein-spected by Duka quality control; defective welds were found. According to Rogers, Southern Boiler attempted to repair the defects without grinding away the old weld; lack of penetration resulted. In situ repair of the welds by Duke welders is now in progress. SP-24_ - Thic section, containing 12 mechanical penetrations, was insta11ad and later radiographed by Duke quality control after the defects were noted in SP-30. Lack of penetration and slag inclusion defects were detected. In situ repairs of the defective welds, are conplete; the wolds have been approved by Duke field quality control. SP This ccction, containing 19 ccchanical penetrations, j was inspected by Duke quality control before it was unloaded t from the flatcar. Bad welds were fcund, and the sectivn was i returned to the Southern Eoiler Shop. for rework. Repairs l were made, and the section uas returned to the site but not installed as ':sd welds were again found by Duke quality control. Field weld repair by Duke welders is in progress. Sp This section, containing 39 electrical pencerations, contains questionable welds and will probchly need to be reworked; it has not been installed. SP This section, containing 5 electrical penetrations, If Southern Boiler Shop control nuchar is used to identify penetration sections; one or core penetraticns are contained in each section. v} e .,',1, f,-
y. f.,. L -. 2. l,e _4.. - ~.... - - ~.. y 1 was on the flatcar with SP-23. Many wcld defects were det'ected, and it uns returned to the Southern toilnr chop for cxtensive'rcwork. The section has been returned to the site, inspected, and is ready to be installed. SP This section, containing 21 cicctrical penetrations, was visually inspccted in the field, and questionabic welds, were detected. Radiographs recently made of the questionabic ucids are presently being evaluated. This section has not bee.n installed. SP-2S_ - This section, containing a conbinaticn of 10 electrical and mechanical penetrations, was inspected in t the field by Duke quality control; defective velds werc l found. The section was returned to the S)uthern 'doiler Shop where the welda are presently being repaired. Wells stated that concreto has not been placed around any of the pcnetraticns discusced above. Welding and quality control inspection deficiencies at the .( Southern Boiler Shop and the steps taken by Duke to correct these deficiencies are discussed in the Manancment Interview Section of this report. '2. Liner Plate Welds The inspector's spot check of the liner plate welding on the Unit 1 containment vcesel rcycaled two areas of questionabic technique: It was noted that the equipment hatch penetration and a. ponctration section SP-271I had been fitted into position in the containment building liner shell and welded for j 807. of the perimeter by using scringer beads 3/16" to 1/4" vide. Four such passes were required to fill the gap. For the remaining 207. of the perimeter, the welder had changed his technique to a singic weave pass to fill the entire gap. A review of the welding specification 2/ revealed that 1/ SP-27 located in building wall directly opposite from equipment hatch; contains 8 nachanical and 6 electrical penetrations. 2/ ' Uciding Specification No. DP-1, dated April 3,1968.
f '. ~. (_ t J ( j-y- / 1 ~15-the weld filler metal could be deposited by either tha stringer or weave method. However, it was pointed out to Dail and Wells tht t.hc ece.Sinstion of the tuo deposit techniques in the same weld is not conridered r,ood practice. Uells agreed to discuss this matter { with the chief welding inspector to determine why two different filler metal deposition techniques were used in a continuous weld. Wells implied that if no valid reason is given, then they wculd pecbably adopt one or the other technique for future application. The circumferential weld joining the two halves of the b. equipx. cat airlock was found to have several sections of undercut varying from 3" to 10" long. In discussing the defects with Joacs, the inspector was advised that the particular welds in question have been inspected and the undercut noted. He staced that repairs were picnned but had not proceeded beyond sone preliminary surface grinding. ' 3. Robar Fit-Up Problem The fit-up and Cadwalding of several ISS rebars in a biological shicid (bearing) wall within the Unit I contain-The ment building was witnessed by t.he inspector. particular rebars being placed were single horizontal rebars that were bent to form the inside and outside curtain of i steel. The two ends were Cadwelded together thus forming a continuous loop. None of the robars observed were shaped in a manner that would permit proper fit-up of the l Cadweld sleeve. As a consequence, the rebars were being sprung, a foot or more in some cases, in order to enabic the ends to slip into the Caduc1d s1covo. All the Cadweld -splices made in the wall so f ar were being removed due l to misalignment rejection at the connection. When the inspector discussed. the situation uith Dail, Rogers, and Wells, 'they agreed that proper aligracnt.under existing conditions could probably never be satisfactorily achieved. Dail stated that they intended to redesign the rebar placement in this and other similar walls using size 11 rebar with a lap and tie joint rather than size ISS rebar spliced with Cadwolds. E. Concrete _ 1. Status of' CuestionaMe Ccncrete 1, Unit 1 Pad '/ \\
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t =, -l ,i During the inspection of March 5-7, 1963, the inspector i noted that test cylinder bre.,'< rest rernite f ndicated that concrete at;!;ocilitt d ai th the l'ni t 1 containxnt building pad, first lift pour 2 and 3, failed to meet the 28 day specified strength requirements.1/ During the inspection' of June 19-21, 1968, P. Hager, Duke Design Engineer, advised the inspector r*st a final engineering report on the concrete prebica vould be prepared by the inspector's next visit. Such a report was prepared, a copy of which is attached as Exhibit 3-1 and S-2. The inspector does not plan any further action on this itea at this time. 2. Concrete Water Anal _ysis Data During the inspecticn of March 5-7, 1968, the inspector reviewed the chemical analysis reports for the water cnd ice cced in the concrete for the Unit 1 pad.2/ The reports did not indicate the cmount of organics, if any, present in the water. The ' inspector requested Wells to provide this data by the next inspection (June 19-21,1968). The data was not availabic for the June 19 visit. Dick assured the '{ inspector the data would be available by the inspector's next visit. On August 28, 1963, the Duke Power Company Water Research Laboratory at Mt. Holly, North Carolina conducted a chemical analysis of the water and ice. The results are ~ tabulated below: s Fe Total (mg/1) Organic Fixed Total Hardness Alkalinity and Chlorides Solids Solids Solids as CACO 3 as CACO M1 (ci) i ! (ng/1) (mg/1) (cc /1). (m q /1)___ (og/1) 3 (mg/1) (mc /1) tl 43 ' Water 3/ 21 64 14 31 4.5 Ice 4/ 6 8 14 0 4.5 1.5 1/ Ref. C0 Report No. 50-269/68-2, Section E. 2/ Ref. CO Report No. 50-269/6S-2, Section E.2.c. 3/ Water supplied frcm Seneca, S. C. Ucter Dept, t { 4/-WaterforicesuppliedbyAnderson,S.C.UaterDept. t +< em. g g me e = ~ ~
c_ _ _. _.. -.. _5 -A. J' : u. r .3 .a. ). The Duke concrete specification for the reactor building (No. OS-160 dated June 12, 1968) nteres that the cher.ical impurities in the w.!ter shrill wnply with the following criteria: r Percent Alkalinity in Terms of CACO 3 0.025 maximum Total Organic Solids 0.025 noximum Total Inorganic Solids 0.05 maximum f Total Chierides 0.025 maximum I 3. Potential Reactivity of Aggregatec Uned in Unit 1 Pad The potential chemical reactivity re.2asurcuents of the coarse and fine aggregates, uhich were requested by the inspector during the March 7, 1963, visit, were provided by Wells ( during this visit. The test results are tabulated below:1/ I SC dC Concentration of SiO2 Reduction .n Alkalinity (Millinoles/L of Filtrate) (Millicoles/L of Filtrate) Fine Aggregate 7.32 114.10 Coarse Aggregates 8.03 112.20 i Base'd on the above test results, the aggregates are considered irnocuous according to the interpretation given i in ASTM C 239-66. 1 4. New Batch Plant A new Rex batch plant having a design output of 150 cubic yards per hour was crected on site and placed in operation in early July. The planc, which is owned by the Greenville 4 Concrete Company, is batching only 3000 psi strength concrete for use in non-nucicar related structures. This new plant hcs alleviated the work load at the Cicmson plant which was providing all the concrete for the Duke projects 1/ Ref. Frochling & Robertson, Inc. test reports No. R-3074-1 dated-January 6,1967, and No. P-4094-9 dated cetober 12, 1966. -l 4 t
w. N ...i k. L.). -.-.. -..:.~..-. t J t J (iA i a. and several other jobs in the area. F. Containment Buildine St rain Gnuce Ins tall.ition Boggs provided the inspector with the following strain gauge information: 1. A total of 230 gauges will be installed in the Unit I containment building; none will be installed in Units 2 1 and 3. 2. 64 gauges have been installed to date; 16 in the pad, 48 cn the vall liner plate through the third horizontal ring. ) 3. During construction, resistnnce readings are taken en all installed cauges immediately after they are cabedded in concrete and then at a frequcncy of once per month. 4. The following types of strain gauges are presently being installed: h 'SGA-1_ - Strain gauge rosette attached to No. 4 reinforcing steel bar and waterprcofed for embedment in wet concrete. _4 and SFT-5_ - Strain gauge resettes to bc =cunted on SGR steel liner plate. SCE-2_ - Strain gauge encapsulated in waterproof brass envelope for installation in surface of wet concrete. SGC-3. - Strain gcune for nencuring crack propogation at outside surface of concrctc. All of the gauges listed above are supplied by Saldwin Lima j and Hamilton. G. Vendor Visits 1. Reactor Pressure Vessel Vendor Visit by AEC_ The inspector requested Dick to set up a meeting whereby 4 W. Reinmuth, CO:Hqs., and the CC:II inspector could meet i uith Duke and 3 & W (Fressure Vessel vendor) to discuss the quality assurance progrra associated with the vessel Dick advised CO:II, by tciccon on October 3, 1 fabrication. that he has scheduled the necting tentatively for a t
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...) \\... - J ( \\ _19 November 8 at the principal offices of Duke in Charlotte, North Carolina. 2. Miscellaneous Vendor Visits by Duke Quality Control Personnel In response to the inspector's inquiry on the participation of field quality control perecnnel in vendor shop inspections, Wells stated that during the past year he has made the following visits: SWEPCO Tebe Corporation - Clifton, New Jersey welded pipe i II. K. Porter Co:.pyy - Fase11e; New Jersey I' rachined stainless steci pipe fittings Flovline Cor paration - New Castle, Pennsylvania all sir.es of stainless steel fittings to 14" t ( Grinnell Company - Warren, Ohio pipe, pipe hardware, some spool pieces B & W - Entberton, Ohio stean generators B & W - Mt. Vernon, Indiana reactor pressure vessel Southern Boiler and Tank Works - I'esshis, Tennessee-containment building liner plate and penetrations Progressive Fabricators - St. Louis, Missouri equipment hatch; energency and equipment air locks _ Spear and Woods - West Mernhf;s, Arkansas all 11'6" dieneter reactor cooling intake and discharge pipe Crane Company - Chicn'qo, Illinois . i.. k .?-
,.a II-1 6 various valves volan cenpany - J'qntrtni,_ Cnep4a various valves 3. Third Party Quality Control Inspectors Nolls stated that to date Duhe has utilized the services of the following third party inspection firms: Grinnell - pipe inspection Sechtel - equipment hatch i e Law Engineering - contain.cnt building liner plate and penetraticas ( t e i .F s 9 .ga s
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