ML19319C810
| ML19319C810 | |
| Person / Time | |
|---|---|
| Site: | Crystal River  |
| Issue date: | 08/20/1969 |
| From: | Bryant J, Seidle W, Swan W US ATOMIC ENERGY COMMISSION (AEC) |
| To: | |
| Shared Package | |
| ML19319C805 | List: |
| References | |
| 50-302-69-04, 50-302-69-4, NUDOCS 8003040778 | |
| Download: ML19319C810 (6) | |
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AU U. S. ATOMIC ENERGY COMMISSION REGION II DIVISION OF COMPLIANCE Report of Inspection CO Report No. 50-302/69-4 Licensee:
Florida Power Corpor d ion License No. CPPR-51 Category A Date of Inspection:
Ju.ly 29-30,1969 Date of Previous Inspection:
June 3-4, 1969 Mdevh 9 / /.8 Inspected By:
J Bryant, @ nctor Inspector (In charge)
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W. B, Swan, Reactor I spector (Construction)
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.eviewed By:
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_W. 3. Seidle, Senior Reactor Inspector Date Proprietary Infe nation:
None SCOPE A routine, announced inspection was made of Crystal River Unit 3, an 855 Mwe pressurized water reactor under construction near Crystal River, Florida.
SUMMARY
3afety Item _s - None Nonconfor nance Items - None Status of Previously Reported Problems - None Cther Significant Problems - None i
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C' CG Report No. 50-302/69-4 Manamnent Interview - The management interview was held with Bennett and Freats. Since no problem areas were found, the interview was a general discussion of site activities and of the construction schedule.
Though B&W has announced a nine month delay in delivery of the reactor veseel, Bennett did not feel that this would delay the site canpletion schedule more than four months.- (See Section J.)
Bennett fears that there may be an ircn workers strike in the near future.
This will not seriously harm work on Unit 3 unless a picket line is estab-lished.
DETAILS A.
Persons Contacted J. T. Rodgers, Florida Power Corporation (FPC), Nuclear Project Manager H. L. Bennett, FFC, Manager, Power Construction E. E. Froats, FPC, Quality Engineer W. L. Hurst, Pittsburgh Testing Laboratories, Resident QC Chief
,CN Inspector
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W. Santamour, Gilbert Associates, Inc. (GAI), Geologist
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R. M. Esbach, GAI, Resident Engineer D. Johnston, GAI, Supervisor, Contract Grouting B.
Organization E. Fleck, GAI resident QA engineer, has resigned to accept employment elsewhere.
His position has not been filled, but is expected to be filled shortly. At present there is no one at the site from the GAI QA department; however, QA work is being covered, tanporarily, by other GAI personnel.
C.
Construction Status The following work was in progress at the site:
1.
Dewatering of footings enclosed within the curtain wall.
2.
Final excavation fcr footings of the auxiliary building.
3.
Consolidation grouting under~the cite of the turbine building.
4.
Driving of sheet piling for a cofferdam for further excavation of the nuclear services sea water pump sump.
b 5.
Testing and other QC activities pertinent to grouting.
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D.
Dewatering of Construction Site he inspectors estimated the flow of water from the pumps to be approxi-mately 4000 gym.
Froats and the GAI engineers agreed with this general range. These men believe there is some leakage through the grout curtain, but that most of the flow is vertical, up through pipes, risers, and fissures in the fragmented ihnestone foundation.
(See Exhibit A-attached to Region II file copy of report only.)
he area within the curtains wall is approximately lh8,000 sq. ft.
The GAI studies indicate that ccmbined voids ccmprise frem 7% to 15% of the volume between the surface and the upper dolomite, or from 700,000 to 1.700,000 cubic feet. Under the unnaturally hi h flow rates due to d
Laping, the median water velocity would be from 0.05 to 0.10 ft/ minute.
However, Woodward-Clyde Associates, Consultants, decided that due to tidal pressure, movement of water in the captive area could dissolve the binder of the loosely cemented conglomerate, and could possibly ccxnpromise integrity of the footing.
Therefore, the decision was made to grout the entire area, p
Some of the weaker footing material crumbles under loads greater than (d
50 psi. Woodward-Clyde Associates recommended design of the concrete
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pads up to an average of 4 tons per square foot over the base material when it had been consolidated by grouting.
Ihe existence of horizontal passageways in the substructure was demon-strated during the inspection by the flow of grout from an injection hole to a sump pump over 100 feet away.
Delays in excavation have continued due to the necessity of hand exca-vation at the auxiliary building site. Soft material is worked out nonnally until the GAI geologist approves the surface for installation of backfill.
E.
Grouting operations Drilling and grouting were in progress at the turbine building site.
Breaded, four inch, access pipes had been placed in the structural fill concrete on a 10' x 10' grid, and operations were carried on through these.
The grout in use was very fluid.
Froats said that it was tested frequently to verify that the design mix was in use. Manual testing by the inspector verified the watery consistency, but revealed good proportion of finely ground solids.
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The inspectors looked at fresh and brcken samples of grout. Some vore taken directly frem the delivary truck, while others were removed from the site after in-place curing.
Freats furnished extencive, detailed records of test mixes, truck camplos, and cored sanples.
Four basic greut mixes are optional under the FSAR.
Of these, the one usirg a 1:1 cement-fly ash mix gave the highest strength and lowest cost.
FFC has not chosen to use this mix, however, since the low cost is due to FFC furnishing fly ash to the contractor frca their local fossil plant.
They do not have an adequate s'tpply of fly ash to use it exclusively; and if they have to purchase it, the cost picture tmuld change drastically.
The grout in use was designed as 25% canant, 20% fly ash, and 55%
lime rock flour. A one cubic yard mixture was 472 lbs. cement, 378 lbs. fly ash,1C42 lba, limerock clour, and 943 lbs. water.
Samples of this mix from the truck yield a 28-day strength of 6(X) pai and a density of 105 lbs./cu. ft.
Scaples of this grcut cured in place and of indeterminate are ranged in strength from 530 to 1650 pai with an average of 1100 psi. This increase in strength over truck senples was anticipated since the grout is injected under
[' ')T pressure, and it was believed that scme ' ater would be aqueezed out, c
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1he 1:1 eement-fly ash grout cured in place has rs.nged from 31CO to 4800 poi in ecmpressive strength.
Froats stated that a detonnination will be made by CAI as to the required strength at the truck to produce the desired strength in the ground.
This desired strength was ICCO to 1100 pai.
Since the limerock campressive strength generally runs frca 150 to 300 psi, the inspectors feel that the present strength probably is adequate.
Until such determinations ara mnde as to the required strength, no grouting will be done under Class I structures.
F.
Grouting Under Class I Structures Methods to be used in grouting are described in Supplement 2 of the PSAR.
This has been supplenented by a detailed drawing with precise spacing and depth call-outs.
Santamour, Esbach, and Johnston doccribed t're sequence of grouting as follows: In sequence, the prinary, cecondary, tertiary, and quaternnry holes will be drilled and grouted dcun throuch the lean concrete struc-tural fill. 'dith the dcuatoring pumps shut off, all primary holes, by stipulated sequenca and depth staging, will be completed at mean elevation t 10 (approximately EO ft. belcu surface elevation). Hopefully, O
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CO Report No. 50-302/69-4 5-consolidation grouting of this harder dolonite will seal off verti-cally rising water. Secondary, tertiary, and quaternary holes will then be drilled and grouted.
Should excessive take of grout occur, additional holes will be drilled to offect a seal.
Limits of weight of grout to be injected in each hole are set forth by Table III and page 10 of the specifications.
G.
Core Sannles At the inspector's request Santamour displayed records or core dril3ings, and discussed the reasoning leading to the detailed plans for grouting operations.
Core drill findings are detailed in the PSAR, Appendix 2G, pages 31-42.
The inspector selected several core sanple records, and requested to see the core scmples. The samples were stored in compartmented boxes marked to designate the hole, elevation, and intervals fran which the widely divergent materials had been removed.
The cored materials had a wide range of color, texture, conglcmeration, and hardness. Many feet of core were not recovered because twisting of
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to powder which had been flushed away.
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A spot check of the geologists' description versus the preserved samples indicated careful analysis and record keeping.
H.
Concrete CO Report No. 50-302/69-2, Section C, describes how the urong cement was furnished for designing of mixes.
New design mixes have now been received using Type II, moderate heat, cement.
The 1500 psi mix is in general use for structural backfill; however, a 3000 psi mix has been designed for tremie placenent of backfill to assure 1500 psi in place strength.
Average 28-day ecmpressive strength for this mix is approximately 4000 psi.
I.
Quality Control Several QC procedures have been accepted since the previous inspection including receipt, and storage of materials and a procedure for receipt, storage, and use of welding rod.
The inspector told Froats that the receipt and storage portions of the welding rod procedure seemed ndequate, but that the use portion lacked detail.
Froats agreed to re-evaluate
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this procedure.
FPC has ordered a machine for Cadweld and rebar break tests.
This will be inctalled in the Pittsburg Testing Labora-tor /' facility at the site, and tests will be made by FTL.
J.
Construction Schedule Bennett said that Babcock and Wilcox have announced a 9-month delay in shipnent of the reactor vessel which was originally scheduled for Movember 1970.
It is anticipated by FPC that much of this lost time can b3 saved by rearranging the site schedule of work.
Bennett felt that the schedule has been extended about 4 months, and gave the following schedule of events:
Begin grouting of auxiliary and reactor building - September 22, 1969 Frame and form tendon gallery - November 11, 1969 Install rebar in containment mat - December 16, 1969 Fuel loading - May 1972 Canmercial operations - September 1972
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K.
Analysis of Intake Water A sample of inlet water to Unit 1 was taken by the inspector and sent to Savannah River Plant for radioactive analysis.
The results were as follows:
Alpha:
Less than 0.12 pCi/1, the lower limit of sensitivity of counting equipnent.
Beta:
15pCi/1.
Gamma:
Pulse height analysis; no identifiable isotope.
Tritium:
Background.
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