ML19319C680
| ML19319C680 | |
| Person / Time | |
|---|---|
| Site: | Rancho Seco |
| Issue date: | 08/19/1971 |
| From: | Dodds R, Spencer G US ATOMIC ENERGY COMMISSION (AEC) |
| To: | |
| Shared Package | |
| ML19319C679 | List: |
| References | |
| 50-312-71-04, 50-312-71-4, NUDOCS 8002210541 | |
| Download: ML19319C680 (7) | |
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-U.'S ATOMIC ENERGY C0!OiISSION DIVISION OF COMPLIANCE REGION V INSPECTION REPORT CO Report No.71-004 Subject
' Sacramento Municipal Utility Dist.
Docket No. (s) 050-0312 Rancho Seco Unit $1 License No.(s)
CPPR-56 Location Clav Station Priority ~
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_ Sacramento County, California Category A
Dates of Inspection-July 21-23, 1971 Dates of Previous Inspection May 17-19, 1971 Type of Licensee 963 Mwe'(2772 Mut) PUR, B&W e
Type of Inspection-Construction, Routine Announced Principal Inspector.
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$ L R. T. Dodds, Reactor Inspector Date Accompanying Inspectors None Date Date Other Accompanying Personneli G. S. Spencer (July 23, 1971)
Reviewed By-W WU '
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-G. S. Spender, Senior Reactor Inspector Date Proprietary Informati>n: None O,
8002 210 EI /
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s SECTION I Enforcement' Action None Licensee Action on Previousiv Identified Enforcement Nhtters Kone required Unresolved Items A.
. The instructions'to welders do not include all ' essential variables suchlas the rate of shielding gas flow.
(Paragraph 6)
Status of Previousiv Reported Unresolved Items A.
The procedure for the records of weld filler metal now requires the use of each form only once. A new form will be used to re-issue filler metal. Previously, the records did not show the return and/or reissue of the filler metal.
B.
The sheathing covers that had been dislodged from the-ends of the A
containment vessel tendon sheaths were replaced and none were observed
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-to be out of place at the time of the current inspection.
C.
The records show that Rancho Seco operations personnel are now auditing
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the meteorological tower data collecting equipment for operation twice a week.
l D.
SNUD has obtained from Trapelo West copies of the procedures for handling and testing the environmental samples. The procedures have been reviewed and judged by SMUD to be satisfactory.-
Persons Contacted The following personnel were contacted during the inspection:
S}g[D,,
J. Mattimoe Assistant General Manager.
D. Raasch Project Engineer W. MbHhhon Quality Assurance Director W. Friedrich Quality Assurance Engineer L.:Kielman.
Nkchanical Engineer 5
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Bechtel' Corporation - (Enginet eing and Construction Mananement)
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W. Stinchfield Project Manager Chief Quality Assurance Engineer L iStromberg R~ Hunter;
~ Quality' Assurance Engineer (Source Inspection)
-W..Chapla
-- Quality Assurance Engineer (Piping and Welding)
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Bechtel Corporation - (Construction)
Project Superintendent
- J.-Vander Knyff
'. Welding Supervisor-
.B Boyd:
' Department Superintendent;(Piping)
'C. Berk.
Senior Engineer, Quality Control HM..Rosen'
. Manaaement Interview
- The ~results of. the inspection were discussed with the following individuals
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- at the conclusion of the inspection.
SE Assistant General Manager, Chief Engineer
..J. Mattimoe O'
-D..Raasch-Project Engineer Quality. Assurance Director V.~McMahon
.L. Kielman
. Mechanical Engineer Bechtel l
Project Nhnager W. Stinchfield S tartup. and' Quality Assurance Nhnager
-I..Ibsen Chief, Quality Assurance Services L.-Stromberg Senior Engineer, Quality Control M. Rosen-Pertinent comments were as follows:
A.
- Verification 'of Nuclear Volvr1 to Desian Specifications The documentation will be checked and a' program developed and implemented to. assure _that major primary system valves conform to design-specifications.
i-B.
Instructions'to Welders-
. The. instruction to welders will be modified to include essential variables
.suchias the rate of shielding gas flow.
(Paragraph 6)
- C'. -
Identification 'and Control' of Class I Carbon Steel-Pine. AfTM A'-53,
-Type S. Grade B-
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'The inspector ackhawledged SMUD's quarantine of carbon steel pipe' for
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Class I!non-nucicar r -tems untti certification consistent with the AEC
~QA criteria can be obtained;.(Paragraph 7)'
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- D. ' ' Steam Generator Material Specification Change l
B&W's proposal to change a material specification for the No. 2 steam
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generator to permit the use of'one ring of hot rolled steel instead of i
hot rolla 1 normalized steel in the shell will be evaluated and approved (if satisfactory) in accordance with the contract variation (nonconformance) procedure in the Project Quality Assurance Manual.
(Paragraph 8)
SECTION II A.
Additional Subiects Inspected. Not Identified in Section I, Where No Deficiencies or Unresolved Items Were Found 1.
Status of construction Project construction was estimated to be 467. completed as of July 23, 1971. The construction progress was slightly behind schedule but Bechtel plans to use two-shift operation to make up for the time' lost due to delays in the delivery of pipe and valves. The reactor building is 907 complete. The interior concrete in the d
reactor building is now complete except for that which must be placed after the NSS system has_been erected. _ Scheduled completion dates for major buildings were as follows:
' Containment Liner August 1971 Turbine Building November 1971 Auxiliary Building December 1971 Fuel Storage Building December 1971 Reactor Building.
June 1972 2.
Procedures and Records a.
Weekly Progress Reports b.
- Constrt.. tion Status Reports c.
Construction Schedule Summary
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Startup Schedule e.-
Schedule delivery records for. Class I equipment f.
Corrective action memorandums (3) resulting from the previous AEC inspection
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g.
Bechtel and SNUD organization changes
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h.
~ Project Quality Program Manual i.
Nonconformance Reports
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Biweekly Log of Meteorological Tower Data k.
Bechtel Inspection. Guide, Nuclear Job 8812 for Field Welding
~and Piping Engineers 3.
Review of Records for Other Class I Piping (Decay Heat Removal System) a.
Nhterial certifications as follows:
'(1) Mechanical Testing Reports (2) Inspection Reports 1
(3) Hydrostatic Test Reports (4) Heat Treatment Charts
- (5) Chemical Analyses (6) As-Built Prints (7)- Form NP-1 Data Reports (8) Production Planner (Shop Travel Card Inspection Checklist)
(9) Radiographs of Seam Welds (10) Radiographic Inspection Reports b.
Receiving Inspection Records as follows:
(1) Inspection Data Report (2) Shipping Reports (3)~ Trucking Receipts (4) Telegrams from Vendor Irspectors c.
- Design Specifications 4.
-Administration Discussed changes in the Bechtel and SNUD organizations.
5.-
Weld Filler Metal Tracability Discussm: documentation required for-the traceability of weld filler
. metal.
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- B.
Details of' Subiects Discussed' in Section I 6.-
Instructions to Welders
-The instructions to welders-have not yet been modified to include the essential variables,-such as shield gas flow rates, for the several. weld procedures. While some effort has been expended in this area, it' had not' yet been completed. -- Since the installation of Class I' piping was just getting underway,- Messrs. McMahon and Rosen stated that the instructions would be modified as soon as possible.-
7.
Identification and Control of Class I Carbon Steel Pipe Durir.g an audit cf-PIPEFAB, Santa Fe Springs, California, the Bechtel QA Enginser discovered-that the mill heat numbers were not on the carbon steel pipe (ASTM A-53 Type "S" Grade '?B") that will be-used for Class I non-nuclear systems'. This is low pressure-low temperature pipe that will be used to carry pond water, treated water.and diesel oil to heat exchangers, pumps and diesel generators.
As allowed by. ASTM A-53, the mi11' certifications that were available
-were by " lots *" and not by heat numbers. However, at the time of the QA finding,'the pipe in the fabricator's stock pipe was not even identified by lots.. A quarantire has been placed upon the use of this material until traceability can be established.
QA has requested the following documentation to be obtained before
.use of the pipe.
a.
Chemical analysis fer each' mill heat.
b.
Heat numbers in each lot.
(Currently available.)
c.- -Mill certifications for each lot.
(Currently available.)
j rd.
Identification of each pipe spool or piece of pipe by its lot number.
I The only difficulty expected, according to McMahon, will be in identifying the pipe by lot number since it was "placed in stock piles for the SNUD job" by PIPEFAB. = However, he-believes that it l
will be possible to identify most of the pipe because of;the uniqueness of_the lots.
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1* A " lot" is defined-se-500 lengths, or fraction thereof and may. consist of several heats..
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Saram Generator Material Specification Chenne
-A discrepancy in the manufacture of the No. 2 steam generator for
' Rancho Seco was identified by-BER during an internal QA audit in late Fhy 1971 The specifications required that the shell of the steam generator be made of hot rolled normalized SA-516 Grade 70 steel.. However, the ring just below the thickened center ring was not normalized.
The ring is 4-7/16-inches thick and approximately 10 feet wide.
It was manufactured by Lukens Steel and is identified as Part No.
4-212-55-1, Heat No. C-5932. The purchase order to Lukens specified SA-516 Type III steel which is hot rolled only and not normalized rather than Type I or II which are normalized. Therefore, the BGR receiving inspector (Mt. Vernon) did not find the discrepancy since the material' met the requirements of the purchase order. At Mt.
Vernon the steel is cold rolled into a barrel, seam welded and ends trimmed. It is then shipped'to Barberton for assembly.
The code permits the usage of normalized or non-normalized hot rolled steel in the steam generator. However, the test samples
' jr" for the-mill certifications had been normalized. Therefore, a g
piece was cut out of the vessel and tested. The yield strengtb was low (36,750 psi vs 38,000 for Grade 70) and the NDT was high j
0 (70 F vs 400F at 20'ft-1bs).
The ring is thicker than specified (4-7/16 inches vs 4-3/16 inches) and will probably be found to be acceptable pursuant to a specifi-cation change authorization. This will necessitate the hydrostatic pressure test _ being run at 1300F rather than 1000F but is not expected to present an operational problem.
The request for a material specification change authorization with
- chnical justification was to be transmitted 'from B&R to SNUD on July 26, 1971. This change does not alter any of the commitments made in the FSAR.
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