ML19319D051
| ML19319D051 | |
| Person / Time | |
|---|---|
| Site: | Crystal River  |
| Issue date: | 11/30/1970 |
| From: | Bryant J, Kelley W, Long F US ATOMIC ENERGY COMMISSION (AEC) |
| To: | |
| Shared Package | |
| ML19319D046 | List: |
| References | |
| 50-302-70-03, 50-302-70-3, NUDOCS 8003040967 | |
| Download: ML19319D051 (15) | |
Text
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-s gG U. S. Atomic Energy Commission Region II Division of Cmpliance Report of Inspection CO Report No. 50-302/70-3 Licensee:
Florida Power Corporation Crystal River Unit 3 License No. CPPR-51 Category A Date of Inspection:
October 14-16, 1970 Date of Previous Inspection:
June 3-4, 1970 Inspected By:
// 8 jd C B eactor Inspector Date O
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W. D. Kelley, Reactor /Espector (Construction) Date '
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/ //l 717I F. J. Iong, Sdnior Reactor Inspector Dhte '
Proprietary Infomation:
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.
The inspection included areas of PI 3800/2, Attachments C, F, G, J, K, and L.
Bryant was not present at the site on October 16 due to illness.
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SUMMARY
Safety Items,None Nonconfomance Items - None l
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Status of Previously Reoorted Problems - None
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Other Sinnificant Itans - None Management Interview - A fonnal exit interview was not held at the close of the inspection since Bennett and Rodgers were not to be at the site on Friday.
A discussion was held with them by Bryant on October 15, and th? items were discussed with Froats at another meeting.
1.
Construction Status Bennett said that the overall schedule had slipped approximately three months (see Section B), and added that reporting of Chicago Bridge and Iron Company (CB&I) to the site had been postponed to avoid a boiler-maker picket line.
(See Section C.2.)
2.
Tendon Wire The inspector asked if a decision had been made on what company would supply the tendon wire, since Amendment 10 to the PSAR, autaitted on i
O August 28, 1970, had discussed two types. Rodgers said he was fairly j
certain they would use the Japaneca wire.
He said that, as the amend-ment stated, this e had proven to be sups ior in the tests. He added that he an GAI had visited the Shinko Wire Company, Ltd., in Amagasaki, Japan, and that they had been very favorably impresse1 with the plsnt and the quality cont *ol system.
3 Mill Certificates The inspector asked what would be done to speed delivery of equipnent certifications to the site.
Froats said that he did not know just what would be done, but that the delays would be eliminated.
(See Section G.)
4.
Receiving and Storage The inspector mentioned that, though the receiving and storage procedures specified that some equipnent would be stored under controlled tempera-ture and humidity, there were, as yet, no provisions for this. Bennett said that buildings and equipment would be available when needed.
(See Section G.)
5 Procedures /Other Areas Inspected The inspectors discussed other areas inspected and said they had no
J CO Report No. 50-302/70-3 specific ccanplaints. Although all work procedures were not complete, progress u==
=dann=+= nnd plana fb pv~'adnvesJ o_be wr_it.ji.en seemed t'o h- =d-an=+=.
Other areas of inspection discussed were:
a.
Concrete placement in the base mat.
(See Section C.)
b.
Babcock and Wilcox Company (B&W) supplied components for the nuclear steam supply system.
(See Section D.)
c.
Primary coolant loop welding and NDT.
(See Section E.)
d.
Other Class I piping.
(See Section F.)
DETAIIS A.
Persons Contacted J. T. Rodgers, Florida Power Corporation (FPC), Nuclear Project Manager H. L. Bennett, FPC, Manager, Power Construction E. E. Fronts, FPC, Quality Engineer D. W. Pedrick, FPC, Assistant Quality Engineer C. E. Jackson, FPC, Supervisor, Mechanical Construetion J. C. Hobbs, FPC, Supervisor, Electrical Construction E. P. Shows, J. A. Jones Construction Company (J. A. Jones),
Construction Manager S. R. Buckingham, Gilbert Associates, Incorporated (GAI), Recident QA Engineer W. Hurse, Pittsburg Testing Laboratories (PTL), Resident Chief Inspvctor B.
Construction Status Base mat construction was a.1most complete, with one large placement remaining which was scheduled for the following week. Auxiliary building wall forms were in place and the walls had been poured.
The predicted fuel loading and comnercial operation date has slipped approximately three months to December 1972 and March 1973, respectively.
C.
Containment (PI 3800/2 Attachment C) 1.
Concrete (PI 4600. 4605.05 al-2. b2-3-7. 4605.06. a-3-5-6-8. b5-8)
Records of concrete placements in the base mat were examined. Of O
sixteen 28-dcy cylinders broken for this 5,000 psig mix, compres-
\\j sion strength ran6ed from 4,960 psi to 6,000 psi, with an average
,-m CO Report No. 50-302/70-3 4-of approximately 5,600 psi. Records of 95 Cadweld breaks (74 production and 21 pilot splices) were available.
Of these 95 splices, none broke below the tensile strength of the rebar, 70,000 psi. Most of the breaks were in the rebar rather than in the splice. Froats stated that many of the breaks were made on splices which had not passed visual examination.
Records of each placement were quite complete,. indicating the mix specified, verification that the proper mix was delivered, signoff frcut each group that adequate personnel were available, j
and proper signoff on the pour slip by all required personnel.
l Slump tests were taken on each truck and four compression test cylinders taken on each 50 yards. Air entrainment tests were taken twice on the first 50 yards and on each 50 yards thereafter.
The slump ranged frcza 1-1/2 inches to 3 inches throughout the l
placements. Individual batch records were checked against the specified design mix and were found_ to c9Af9? +^ it.
Batch
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plant calibrations were checked ard found to be up to date.
Curing verifications were signed off by required personnel QC inspections of preplacement, placement, and curing were signed off by GAI and by PTL.
An 850-yard placens as made in the base mat during the inspection. The forms were inspected prior to the placement and
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were found to be clean and well made.
%e condition of reinforcing steel was satisfactory and Cadwelds bore proper identification.
Several Cadwelds were inspected and no deficiencies were noted. The pour slip and preplacement QC inspections were in order. It was noted that the water added was approximately 90% ice in order to bring the mixture tanperature to 65* or less. Slump tests were made on each truck and cylinder and entrainment tests were made as required. The trucks in use were clean and were observed being i
vashed after each load. Delivery times and rotation counts were in order and temperatures were verified to be as required.
In this 170-square-yard area, concrete was being delivered by two pumps through steel pipe and by bucket into 14 hoppers with
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l chutes reaching close to the surface of the concrete. Eight l
vibrators were in use and there was no indication of transporting of the concrete by the vibrators.
PTL had ten men in attendance, with four at the batch plant and six at the placement site. These men were involved in making the specified tests and, in general, looking to verify that the placement was made correctly.1 In addition, J. A. Jones QC personnel were on hand and Buckingham and Froats or Pedrick were on hand i
most of the time.
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A steam generator anchor assembly was being embedded, and QC records of aligrament and proper signoff were available.
Tendon sheaths were installed and were already embedded in the ceiling of the tendon gallery. The gallery could not be inspected at this time since there was no access.
The sheaths were sealed on top, and Froats stated that r ter each placement a wooden pig e
4 was run through the sheaths to ify that there was no blockage by concrete.
2.
Contaiment Liner The reactor containment liner will be erected by C MI on FPC Contract 68-3871U in accordance with Specification No. SP-5566.
CMI had been scheduled to report onsite on October 26, 1970; however, FPC has asked that CB&I delay reporting because of expiration of the CBkI Boilemaker Union contract and an antici-pated strike. The delay was requested by FPC to prevent possible work stoppage at Crystal River by a boilemaker picket line.
CB&I has a quality assurance program for construction of nuclear vessels and components which is contained in its three-volume QA manual. These manuals were audited by Kelley in an inspection at Florida Power and Light Company's Hutchinson Island facility.
This audit is contained in CO Reper' No. 50-335/70-3 The manuals were reviewed at Crystal River to verify that they were the same. Welding procedures, nondestructive testing procedures, and heat treatment procedures were audited and are as reported in the above reference. A vacuum box leak test procedure, VQPlL, will be used for leak testing of tha contaiment liner and a spot radiographic procedure, RTP-5L, is also contained in the manual.
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D.
B&W Sucolied Canoontnts for the Nuclear Steam Sucoly Systen Reactor Coolant Pressure Boundrv Picina - Attachment F Reactor Vessel - Attachment J Reactor Internals - Attachment K Other Class I Comoor.ents - Attachment L 1.
Contractura) Arrangements i
Al' material for the nuclear steam supply system (NSSS) is being sur.glied to FPC by B&W of Barberton, Ohio. Some of the B&W supplied g
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components are onsite and have been received by J. A. Jones in accordance with the MW erection department field specification for NSSS components. It is anticipated that in the near future, MW Construction Company forces, who will do the receiving, erection, and testing of the reactor, steam generator, pressurizer, and main coolant loop piping, will arrive onsite and will receive M W components in accordance with the erection department specifi-cations. The M W Construction Company is a separate company from MW and has offices in Atlanta, Georgia.
A contract with MW gives the accpe of supply as follows:
Reactor vessel; steam generators; pressurizer; complete primary pumps; primary piping; control rod equipnent; makeup and purification system, including tanks, pumps, heat exchangers, filters, and valves; chemical addition sampling system, including tanks, pumps, samplers, and coolers; soluti,n pumps, solution tanks, and valves; component coolinc water systen, including valves; emergency reactor ailding cooling system, including anergency cooler fans and drives; the decay heat removal a
system, including pumps, coolers, and valves; reactor building spray system, including spray pumps and valves; spent fuel cooling system, including pumps, coolers, demineralizers, and filters; turbine bypass system modulating valves; core flooding system, including flooding tanks, valves, nuclear instrumentation and protection system; 4
reactor nonnuclear instrumentation.
Other auxiliary system nonnuclear instrumentation is also furnished, as well as special tools and fueling equipment.
In the contract for field erection of the NSSS, MW subnitted a critica.L path of erection sequence. A detailed drawing showing the location of the guy derrick for handling and erection of heavy components gives its capacity as 600 tons with the 110.-foot boom 40 feet out from the 120-foot mast.
-l 2.
Receipt Inspection. Handling. and Storare of Material and Components In the MW QA manual, Specification No. FS-I-l states that the manual provides, in the fom of specifications, the minimum requirements for the receipt, inspection, unloading, storage, and the installation of each major piece of equipnent supplied by MW or its vendors. Each such specification consists of the criteria from all applicable sources such as engineering codes, acceptance standards, design or manufacturing specifications, design
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or manufacturing drawings, construction drawings, and equipnent 11struction books. Prior to the inclusion in this manual, each' specification is subject to detailed review by the MW engineering, manufacturing, and erection departments. MW will update and revise the contents of this manual periodically and reserves the right to modify any of the infonnation contained as required.
3pecification No. FS-II-l requires that prior to receipt of equi p ment,, the erection contractor will submit to the MW site representa-tive, for review, his intended storage plan.
MW Con'struction Company will receise, unload, transport, erect, and weld the reactor vessel, steam generators, pumps, and main coolant piping. The reactor internals will also be received, stored, transported, and installed by MW Construction Company in ccordance with MW erection department specifications, l
The MW fielci specifications for NSSS ccaponents receipt, inspection, handling, storage, and installation are as follows:
a.
The reactor vessel and head specification - FS-III-1A and B.
y b.
Control rod valve service structures, control rod valves and reactor vessel internals in accordance with specifications -
FS-III-10, D, and E.
c.
Stera generator and accessories specifications - PS-III-2A and B.
d.
Reactor coolant piping, including pump casings - FS-III-3 i
e.
Reactor coolant pump internals and motors - FS-III-4A and B.
f.
Pressurizer and accessories - }S-III-5A and B.
g.
Core flood tank - FS-III-6.
Specifications are also available for the auxiliary equipnent, 1
domineralizer, heat exchanger, auxiliary tank, valves, filters,
- I auxiliary system motors, instrument and controls, reflective type insulation, fuel handling system, in-core instrumentatic and piping.
Included in the field specifications for NSSS components are:
inspection reporting, FS-IV-1; deviation reporting, FS-IV-2; weld control record, FS-IV-3; weld inspection record, FS-IV-4; coupling aligranent record, FS-IV-5; and stud / nut installation record, O
FS-IV-6.
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The NSSS emponents are received and their condition reported on NSSS component inspection report form No. PDS-31581. The fom indicates what type of inspection is to be reported, whether receiving, installation, or final. Space is available for the identification of the equipnent, the applicable field procedures, carrier bill of lading, date received, and a place for the descrip-tion of the type of inspection perfomed.
Installation and Inspection Specification No. FS-I-2 states that MW requires all aspects of work perfomed on equipnent supplied by it or its vendors be per-fomed in accordance with procedures written by the erection contractor. Prior to erection of the equipnent, MW Construction Company will review the contents of the specification and will subnit to the MW site representative drawings, plans, and procedures necessary to assure that the requirements are met.
Specification No. FS-I-3 states that during the course of construc-tion, MW Construction Canpany will provide the MW site representa-Os tive with copies of all inspections perfomed on MW supplied equipnent. The MW site representative will inspect. jointly with the erection contractor, all MW supplied equipnent upon receipt at the jobsite. The M W site representative provides documents of such inspections to MW Construction Company. The MW site representative reserves the right to make, personally, any inspections that he deems necessary.
Any discrepancies discovered during +.he inspection perfomed by MW Construction Company or by the site representative will be documented by the latter for resolution by MW as required.
16SS component deviation report fom No. PDS-31582 is for documen-tation by the erection contractors of deviations from contract specifications or drawings which occur and are reported after the inspection report is issued on an item.
Specification No. FS-II-7 describes the use of NSSS component tags. A green tag releases the component for the next step of installatir with no restrictions. A yellow tag is a conditional release with restraints as described on the tag. A red tag indi-cates that all work must be suspended on the equipnent.
Welding and Nondestructive Testinr Specification No. FS-II-5 is for welding, nondestructive testing, b
preheat, postweld heat treatment, and storage of electrodes for
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field welding on the NSSS.
Prior to perfoming any welding, B&W Construction Company is required to submit to the B&W site representative, for review, the procedures established and results of tests conducted to satisfy the requirements of AS(E Boiler and Pressure Vessel Code,Section III and II; USAS Code for Pressure Piping, B31.1.1; USAS B31.7; and the applicable B&W weld data sheet. However, B&W Construction Company will use the specification provided by B&W erection department.
E.
Primary Coolant Looo Pine Welding and NDT A separate document has been furnished by B&W, Barberton, Ohio, which establishes the field weld criteria for the main coolant-loop piping.
It is divided into six sections: Section I - Field Weld List;Section II - Weld Data Sheet;Section III - Applicable NDT Specifi-cations;Section IV - Applicable General Welding Specification;Section V - Field Erection Drawing Release; and Section VI - Weld Procedure Qualification. This document contains a separate weld procedure for each individual weld to be made on the main coolant p\\
loop piping. The list gives the weld number, the drawing number,
>b zone location identification, description, and the quantity to be welded.
The applicable general welding specifications are Nos. W 50, W 56, W 60, and WS 151. The specifications were written by the B&W boiler division and are qualified in accordance with AS(E,Section II. The procedure qualifications show that the reduced section tensile test and bend test were acceptable. The procedures are signed by Paul E. Campbell of B&W. Procedure qualification tests j
were available on weld procedures W 1, W 2, W 20, W 22, W 29, W 50, W 51, and W 56.
i A weld control record is kept which indicates the weld or seam number, contract - number, the quality control specification number, the weld data sheet that is to be used, the weld process, polarity, inspection ticket number, and repair number if required. The data that must be recorded during the welding is the time, the date, shift, weldor's personal number, amount of weld perfomed, amps, voltage, wire size, welding electrode, heat or lot number, flux lot number, automatic travel, preheat, postheat temperature, and~interpass temperature.
This data must be signed with supervisor's initial and time of signoff.
A weld inspection report fom No. PDS-31028 is for recording the dye fg penetrant test, magnetic particle test, ultrasonic test, and radio-(
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graphic tests. It is required that the specification number, the
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l date, and the inspector's name be recorded. The form is to be signed by the MW inspector, the custmer's inspector, and others such as code or insurance inspectors.
l Main coolant loop pipe welding will be done by pipetitter weldors who have been qualified in accordance with Section II of the ASME Code. A data sheet has been made for each individual weld and the sheet is to be filled out giving tce applicable information such as govermental specification, travel speed, amps, voltage, type of weld surface, type of quality control inspection required, postweld heat tieatment.
Specifications are available for the radiographic method acceptance standard Specification S-102A which acets the requirements of Section III of the ASME Code. It was noted that the penetrameter selection for penetrameters on film side was not in accordance with the Summer 1970 Addendtan to the code. The procedure outlines the type of film to be used with the different types and thicknesses of material. Also, given are the shooting schedules for different configurations of weld geometries that will be encountered in the field.
The magnetic particle inspection is to be done in accordance with si B&W Specification S-102B which states that it is to be in accordance with the AS(E Boiler and Pressure Vessel Code. Ultrasonic inspection is to be in accordance with B&W Specification S-102C which is ultra-sonic inspection of weld metal overlay or cladding. Postweld heat treatment is to be done in accordance with B&W Specification No. HQ-19, postheat treatment of nuclear weldments. The weld data sheets specify the =vi== temperature to be used and the length of time for the postweld heat treatment as a further check on Specification No. HQ-19.
Sectinn III of the applicable NDT specificationa diinat g_ont_ain a
_ dye penetrant examinati_on.
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The specification for the storage and handlh g of electrodes, FS-II-6, was not in the manual.
F.
Other Class I Piping - Attachment G Main Steam Piping Baernency In.iection i
Reactor Building Sorr.y System l
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Material Receipt. Storare, and Protection All piping except the main coolant loop will be installed by a subsidiary of J. A. Jones (The Livsey Company, Inc.
(Livsey)
Industrial Mechanical Contractors, Decatur, Georgia),. All i
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material is being purchased by FPC purchasing department with the exception of NSSS equipnent purchased by B&W. Vendor inspection and vendor qualification for FPC purchased items are perfomed by GAI and by FPC design and engineering personnel.
Material is received, stored or warehoused, and issued by a J. A. Jones warehouseman. He issues an inspection report upon receipt and tags the material with either a hold, release, or reject tag. Material that is released can be withdrawn.
Material that has a hold or rejected tag is quarantined until the hold is removed or the rejection clarified. Material can only be drawn frca the warehouse on a warehouse withdrawal order which is signed by authorized personnel.
2.
Weldine FPC is providing weld procedures written by Jackson who is qualifying the procedures onsite using J. A. Jones weldors, and in accordance with the ASME Boiler and Pressure Vessel Code,Section II. A total.of eight welding procedures have O
been written, five of which have been qualified in accordance 6
with the requirements of Section II of the ASME Code. Each welding procedure is complete without requiring a general welding specification for its use. The physical tests for the welding procedure qualifications were perfomed and reported by PTL. The procedure qualification data reports on the five procedures showed that the reduced section tensile test and the guided bend test are acceptable. The procedures contain a paragraph describing the reoval of defects, their repair, and the nondestructive testing for verification of defect removal. The welding procedures will be used by Livsey in the erection of all piping systems.
l In the folder for each welding procedure is a list of weldors qualified in accordance with'that procedure. The weldors are presently uployed by J. A. Jones and will be transferred to
'j the Livsey payroll as 'needed. The code does not pemiMualM-cation of weldors to be,tr_an.sfe_rred from_one c I
however, in this instance, the work is beingy_empartto_another; ndu,,ctfd by FPC and the contract. ors _are acting.aslits,. agents. Therefore, it is considered _t_o__bp_irtancpi,anc_,e witAthe code _by_the Re6.o_n II d
1 inspector.
At present, FPC does not have a repair procedure for weld repair of major defects, but a procedure will be written.
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3 Nondestructive Testing Nondestructive tisting will be perfomed by PTL and these NDT I
procedures were written at PTL headquarters. The four procedures that have been written and approved to date are: NDT liquid penetrant inspection procedure, PTbQ5; NDT magnetic particle inspection procedure, PTL-Q6; NDT radiographic inspection, PTb Q7; and LDT ultrasonic inspection procedure, PTL-Q8. These procedures were approved by Bennett for FPC. The procedures require that the nondestructive testing personnel be qualified in accordance with SNT-TC-1A. Appendix A to each of these procedures states how the qualifications and certifications of the personnel are to be performed.
The RT procedure specifies penetrameter thicknesces in accordance with the code prior to the Summer 1970 Addendum. Appendix A of this procedure specifies that a Ievel II radiographer shall have a minimam of three months experience in industrial radiography and shall have demonstrated his preficiency_in radiography technique, and satisfactorily completed the NDP training course
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which PTL conducts.
Work at the site will be inspected and tested by PTL. GAI will perfom a 100% audit of PTL work. PTL reports are to be trans-mitted to Froats, who reports to Rodgers. Onsite, PTL reports to Bennett, who also reports to Rodgers.
G.
Receint. Warehousing. and Record Control FPC has generated a comprehensive procedure for receiving, inspection, storage, and release of equipnent. The procedure divides equipnent for storage into four categories:
inside storage under controlled humidity and temperature; inside storage; outside protected storage, i.e., wrappid and weather protected; and outside storage on dunnage but with no particular protection fnm weather. The procedure is in the process of final approval.
The warehouse was inspected and found to be sound and dry. Several Class I components had been received, including charging pumps. The pumps were well mounted for shipping and wrapped with h avy plastic.
Froats was asked for receiving inspection reports and pedigrees on.
the pumps.
Descriptions of the pumps adequate for receiving inspection and i
storage requirements were available in the B&W manual. A receiving O
inspection report properly prepared was also on hand. Certific_ations, had not_been received.
Froats said that GAI still had the paperwork
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i and that this was a general problem that he was working,on. Cu2xantly, it sometimes reonives +m manm row him_go receive certifications Cxxa GAI. This is not acceptable to him and he said that it would be remedied, but ho did not know yet just how it would be done. The 4
pumps will bear hold tags until the certifications are received.
All receiving inspections are presently being made by J. Rashinsky who is employed by J. A. Jones but is working under Freats. Rashinsky is a graduate electrical engineer and was fomerly a senior design engineer at Cape Kennedy, Previously, he had worked for Minneapolis Honeywell. When asked how a man of these qualifications happened to be =Mng receiving inspections, Froats said that he had been caught by the reduction in space activities. He added that it was planned for Rashinky's duties to expand until he was in charge of all J. A. Jones QC at the site.
H.
Steam Generator Anchors The steam generator anchor assemblies were fabricated by Kline Iron and Steel Company of Columbia, South Carolina. They arrived at the site with the anchor bolts welded into two anchor c
rings. One of the rings is at the bottom of the embedment, the other at the top. The material is ASM A449 steel.
It was found by GAI vendor inspectors that the sulphur content was too high for ASM A449. Metallurgical Engineering Company of Atlanta, Georgia, was hired to perform destructive and nondestruc-tive tests on the material and assemblies. Investigations were also conducted by GAI. The metallurgical Engineering Company report stated that, although the material did not meet A449 chemistry, testa demonstrated that it would be adequate for the intended use.
GAI wrote a letter reccannending the use of the anchor assemblies as they are.
I.
Miscellaneous Items Frem CO Retort No. 50-302/70-2 1.
Section D of the referenced report describes trouble experienced
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with the Forney testing machine when making tensile tests on 18S rebar. Alignment has been Laproved on the machine and heavier bolts installed. At present, it is perfoming adequately and further action has been postponed pending further test experience.
l 2.
Section E states that a new source of fine aggregate was being cought.
Fine aggregate is now being provided by the same company
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but from a diffsrent pit. Design mixes using this aggregate are satisfactory.
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The same section stated that chloride analysis would be added to canent mill certifications. This has been done, and the analyses reported as less than 0.25.
3 Section I and previous reports stated that the licensee had hired H. Q. Golder and Associates to evaluate the chemical grouting operation. Golder report has been reco'ved and was examined. Though some relatively soft spots
' ce reported, Golder found the foundation satisfactory.
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DIVISION OF COMPLIAUCE MONTHLY REFORT OCTOBER 1970 50,30k.
FloridarPower Corporation-(Crystal River 3)
An inspecti_on was conducted on October 14-16.
The containment built 11ng base mat is nearing complefi~on a~nd i's scheduled to be finished by Oct. 20.
Some delay has been experienced-due to labor problems.
Additional delays are expected when liner erection begins because of an anticipated strike by Chicago Bridge and Iron-Company employees.
Records of concrete test cylinders and Cadweld testing were ex-amined and found to be satisfactory.
Warehousing-facilities were inspected and found adequate, although some construction remains to be completed.
Receiving inspection and quality con-trol procedures were examined and found to be adequate.
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