ML19319D059
| ML19319D059 | |
| Person / Time | |
|---|---|
| Site: | Crystal River  |
| Issue date: | 02/05/1971 |
| From: | Kelley W, Long F US ATOMIC ENERGY COMMISSION (AEC) |
| To: | |
| Shared Package | |
| ML19319D056 | List: |
| References | |
| 50-302-70-04, 50-302-70-4, NUDOCS 8003040974 | |
| Download: ML19319D059 (16) | |
Text
{{#Wiki_filter:- _ _. - _ _ _ - _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ - _ _ _ _ _ ~ /'t s V ~ U. S. ATOMIC ENERGY COTilSSION REGION II DIVISION OF COMPLIANCE Report of Construction Inspection C0 Report No. 50-302/70-4 Licensee: Florida Power Corporation Crystal River Unit 3 License No. CPPR-51 Category A Date of Inspections: December 14-18, 1970 Date of Previous Inspection: October 14-16, 1970 Inspected By: N / 2-2 -7/ 2, W. D. Kelley,' Reactor pspector (Construction) Date Reviewed By: hY7/ ^'" d ong, Senipactor Inspector (Dat'e Proprietary Information: None SCOPE A routine announced inspection was made by W. D. Kelley on December 14-18, 1970, of the Crystal River Unit 3 located ten miles northwest of Crystal River, Florida, on the Gulf of Mexico. The plant is a Babcock and Wilcox Company (B&W) boiling water reactor designed for a maxitum power level of 2560 Mwt (885 Mwe). The inspection p. q,se was to audit the records of the containment liner in accordance with Attachment C of PI 3800/2 and continue the audit of Attachments F, G, and L of PI 3800/2. SUE 4ARY Safety Items - None Nonconformance Items - None Unusual Occurrences - None v 8008040f
\\ 1-C0 Rpt.~No. 50-302/70-4 -- 1 Status of Previously Reported Problems - Ncne Other Significant Items - 1. FPC stated that-it was considering contacting all utility companies in the southeast for an expression of interest in setting a periodical - meeting to discuss construction problems and their resolution. 2. Welding machines which have-high frequency starters are being pur-chased and the new machines will be used for TIG welding. A program has been developed for the periodic inspection of all welding equip- - ment on the site by the electricians to confirm that their settings for amperage and voltages are correct. Any machine that is'out of range will be immediately removed from service and reworked. 3. A channel head.on the decay heat service heat exchanger supplied by Struthers Wells Corporation.(SW) was not stress relieved at-the foundry. The head has been removed and returned to the foundry. (See Section F.) 4. FPC has developed a procedure to stop work when the workmanship or N material is in noncompliance with applicable codes, specifications .j or drawings or the safety of personnel or equipment is endangered. (See Section E.) Management-Interview - A management interview was held on December 18, 1970, at 9:30 a.m. in.the Florida Power Corporation (FPC) construction office.at the Crystal River Nuclear Plant Unit 3 site. The meeting was attended by the following persons: Florida Power Corporation (FPC) H. L. Bennett. Manager, Power Construction E. E..Froats Quality. Engineer. D. W. Pedrick - Engineer, Quality Program Chicago Bridge and Iron Company (CB&I) 'i i l . J. R. Herman - QA Engineer (part time) The following items were discussed: i 1. Containment Liner The FPC management was informed by the Region II inspector that he had observed lack of fusion of the' bottom line plate weld not marked by I the Gilbert Associates, Inc. (GA) inspector. although he was present. CB&I was observed. welding over the transverse weld bead that had overrun
R i ,~ fS ? C0 Rpt. No. 50-302/70-4._ s-l the weld groove onto the adjacent bottom plant without back gouging; and again the GA' inspector was present without marking the area. CB&I was observed welding the leak chase. channel over the bottom welds without cleaning excessive amounts of rust. Spot radiographs ) had been reviewed and they contained slag but were within ASME-Code limitations. It was observed that CB&I was following its welding procedures.mui they were qualified.in accordance with Section IX of the ASME Code.but the amount of. slag was common to the welding pro-cedure being followed. CB&I was.using.a four-inch,.100 psi gage for i pressurizing the. leak chase _ systems.co.5 psi of. freon for the halide leak testing which would be difficult to read at this low pressure. FPC stated that it was reviewing the qualification of the GA inspec-tor and would have the Livesey Company (LC) welding supervisor review the CB&I welding and welding procedure to determine if the amount of slag in the welds could be reduced. 2. Decay Heat Service Heat Exchanger FPC was informed that.the Region II inspector had audited the GA f)g quality assuranca checkoff. sheets for.the SW decay heat service \\s,, heat exchanger but desired to verify that it had been inspected by e both GA and the code inspector. FPC stated that the documentation of the defective channel head would be at the corporate office in St. Petersburg. This will remain as an open item. 3. Reactor Coolant Bleed Tanks FPC was informed that the Region II inspector had observed are strikes on the Pittsburgh-Des Moines Steel Company (PDM) tabricated reactor bleed tanks and that the. "N" stamp for the ASME Code, Section III, Class C vessel had not been stamped on the nameplate. The inspector will audit the records on the next inspection. FPC stated the records were in St. Pe tersburg. This will remain as an open item. 4. Other Plants Construction FPC statad two 550 Mwe oil-fired plants were to be installed at FPC's Anclote, Florida, plant with operational dates of April 1974 and April 1975. I addition, eight 50 Mwe crude oil peaking units were [ ') to be installeo at Bartow, Florida, with operational dates for the \\,_,/- first four units of February 1972 and tbn other four units of February 1973. A budgetary study.is currently being made for another nuclear unit but the location has not been determined.
A nr \\ 'C0 Rpt. No.-50-302/70-4 1 DETAILS .y A. Persons Contacted FPC E. E..Froats Quality Engineer - D. W. Pedrick - Engineer. Quality Program C. E. Jackson.. Mechanical Construction Superintendent H. L. Bennett - Manager Power Construction E M. C. Brown - Welding Supervisor - CB&I W. Batchelor - bdlermaker Foreman.
- 0. Copeland - Welding and QA Supervisor J. R. Herman - QA Engineer R. Miss11 dine - NDT Technician B.
Construction Status Crystal River Unit 3 is estimated.by Bennett. to be 20% complete. This percent complete includes design, purchasing and overhead. The i percent complete for the unit including only site labor and material is 15%. The bottom and conical section of the containment liner for the reactor building has been erected for CB&I. Placement.of reinforcing steel and. concrete continues on the auxiliary building.. A pipe fabrication. shop.to.f abricate onsite piping two inches in diameter and less is being erected. C. Administration and Organizational Changes s The following CB&I supervision reported onsite November 23, 1970, to start the erection of the containment ifner for the reactor building:
- 0. Copeland - Welding and QA Supervisor J. R. Herman - QA Engineer F
R. Missildine - NDT Technician W. Batchelor - Boilermaker Foreman -.--e e e - v
W ) ~ -~ f LCO Rpt. No.L50-302/70 ' I f-Two resident. inspectors. (C. R. Hoffman and M.- J.- Damase) were Lassigned to the Crystal. River site.by GA and report.to S.~ R. Buckingham, Site. QA Coordination Engineer. - Hof fman. who has.30. years : welding,. pipe fabrication, pressure vessel, and structural. steel experience reported onsite November 11, 1970. Damaso who.has.20. years concrete experience . including testing-laboratory experience on nuclear and fossil generating plants reported onsite December 7,1970. Brown, Welding Supervisor for LC, reported.onsite October 19, 1970, l and will be responsible for training and qualifying boilermaker, pipefitter, and mill wright weldors.- E. FPC Procea.ce for Work Stoppage, Tagging Control, and Deficient Reports FPC has written Procedure. No. FPC-Qll, Revision 1, dated November 9, 1970, for work stoppage,. tagging control, and deficiency reports. The purpose of the procedure is to assure documentation of actions taken. The reasons for stopping. construction work will be noncompliance with applicable. code standards, specifications,.or drawings or endanger of - l the safety of personnel or equipment. The -persons that can authorize - -9 i work stoppage for FPC ie the manager of power construction, construction -I supervisor, and the quality control engineer. ~ A deficiency report-must. outline the deficiency of the item, and include the account number and purchase order number and the recommended action. A hold / rejected tag must be placed on the equipment or work'and no work can be continued until corrective action has been taken. A work stoppage report must be signed by the supervisor and a deficiency report must be signed by the quality engineer. - The deficiency report is then routed back to the inspector who initiated the original work stoppage for the issue of a release and permitting work to continue. I F. Decay Heat Service Heat Exchangers a The decay heat service heat exchangers were purchased by FPC on Pur-chase Order PR3-1105. During the. hydrostatic test of Unit No. 2, leaks were discovered in the channel. head casting. SW rejected ths casting and required the vendor to. case a new channel head. The channel head.was machined,. installed,.mui the. unit hydrostatically tested at 300 psig on shell side and.150.psig on tube side, and accepted by both.GA inspector and the Hartford Steam Boiler Inspec-tion and insurance Company inspector during the week of July 6-11, 1970. The decay heat service heat exchanger was shipped to Crystal - O~ River, received by J.- A. Jones Company. (JAJ) and site inspected by a JAJ inspector. The GA. quality assurance inspection report of vendor fabricated items is a. checkoff sheet of items that are insoected by. l a a ,e , - + h, a r- ,--_-w-- ,. -. ~ um6 -,,.w. .-,-r -r,m-_.-,, m, -1.---,--., m I
) v CO Rpt. No. 50-302/70-4. -- ~ the GA inspectors. Copies of this. document are sent to the FPC engineering office at St.. Petersburg and to the. Crystal River site. A copy of thie. report may be. attached.to.the shipping ticket along with a certificate of-inspection from GA quality assurance department. During a review of the documentation, by SW. Quality Control Chief Inspector, L. Cornell, discovered that.the stress relieving charts for the channel. head were inaccurate and. requested the foundry to supply the correct. stress relieving chart. The. foundry admitted that it had not. stress relieved.the. head. Cornell' was onsite on December 14, and supervised.the. removal.of the channel head and its loading for shipment to SW for stress relieving. FPC was informed-an audit will be made of the quality assurance program for vendor inspected items at the next inspection. G. Other Class I. Piping.- Attachment F - Main Steam Piping, Emergency o Injection, Reactor Building Spray System 1. Electrode Control (4805.04.g.1-6) \\- A building approximately 20 x 40. feet has been designated as the weld material. storage and withdrawal area. A man has been assigned the. duty of keeping welding material in order and issuing the welding electrodes on a quality engineering welding rod withdrawal order..This man's classification is toolroom clerk, a salaried position and nonunion. Should labor problems become involved in the issuing of welding rods, wire and flux, this man will supervise the crafts. that will issue the welding ) material. Fifteen Phoenix electrode holding ovens and one large Phoenix electrode baking oven with.an upper limit of a 1000*F are in the building. The storage of the electrodes in a holding oven is liL' ed to one electrode size and heat with the electrode's heat number posted under.the electrode. oven. Presently, the craft veldors are iseued Hobart " Dry Rod" electric electrode hold bcxes in the morning with.their. electrodes in.it and it must be checked in at the end of the shif t. This will become a problem as the number af weldors increase because it takes approximately two minutes to check each weldor in or out. Electrodes and wire are issued on the welding rod withdrawal order which requires that the weld. number, sys tem, and location be recorded and signed by.the authorized person. The toolroom clerk must record the heat and lot. number, date, and name of i['"'g weldor receiving the material. Electrodes that are returned are also recorded, with the.date.and. time. FPC has issued a procedure (FPC-W21) which is a detailed procedure for withdrawing
+ k , M 4. + l 4 I ~ CO.Rpt.'No.' 50-302/70-4 ~ i 4 and handling welding rods.and. electrodes.fo'r.use on Crystal'. 4 River Unit;No.'.3. The procedure states ' the scope, responsibility,- the reports that.must be _ filled'out, and detailed instructions L-for' the rod withdrawal.. - Electrodes have been purchased _in lots that' are considered adequate t for the site needs. It has been specified that it is desired.one size electrodes be from.one heat = and-lot number but in no case shall' 4 i a heat and'. lot. number contain less.than;1000 pounds of electrodes. Electrodes from three. heats were returned to the-supplier because : they did not meet this requirement. Typical certifications are not. acceptable.and all certifications must be from a weld. metal i sample. f rom _the. heat. shipped. ' The. certifications are checked j against the shipping notices and electrode boxes before they are stored in the electrode building. FieldWeldData(48h5.04.b.2-b.6,c.1-c.6-d.1-d.4,e.1,e.2ande.6) 2. } FPC has written a field welding, data sheet procedure (FPC-30-14) for piping at Crystal River Un;.t No. 3. The procedure outlines g the responsibility of construction supervisor, the craf t. foreman,- 1 and the testing laboratory. ;The purpose of the field weld data-sheet is - to provide essential information.and instructions to the j-workmen needed to. produce acceptable _ records of field welding and i nondestructive testing. The scope of the document is to cover i only.B31.7 Classes N1, 2 and 3 piping; however, it is anticipated ( that this will be used for.B31.1.0 piph.g is essential services. j: FPC Mechanical Construction Supervisor,.!cckson, or his - delegated representative will initiate the form which will indicate the systems,.the pipe size, and the base metal. The instruction por-tion is to include such information.as weld procedure ~, electrode, gas purge, preheat, postweld.or interpass temperature. The craft foreman will use the data sheet to. instruct his weldors prior to [ and during.the. welding sequence. The.weldor's name and stamp number i and the heat number of the. filler material he uses must be recorded. j. The weldor will. turn in the. data -sheet along with all welding sup-j- plies withdrawal. orders to his foreman af ter completion of the -weld and postweld heat treatment to permit scheduling the required J nondestructive ~ test. The approval.of the-weld joint.fitup (root opening and alignment) l' root pass and ' rework.will be performed by Pittsburgh. Testing i Laboratory (PTL). The ' dye penetrant, magnetic particle and radio-l graphic examination willibe performed by PTL in accordance with its nondestructive testing procedures and by PTL personnel who 4 i ) have been qualified in accordance with SNT-TC-1A. The radiograph l will b~e.the basis of. final acceptance of the weld ~ and they will be' evaluated by PTL!and audited'by GA.- ~
.m . O) -fU CO Rpt. No. 50-302/70-4. 3. Pipe Fabrication - (5005.03) ' FPC has issued Purchase Order No..PR3-1219.to M. W. Kellogg Company -(MWK).for the. furnishing, fabrication, testing and delivery.ofiall fabricated pipe 2.1/2. inches..in size and over for Crystal River Plant. Unit.No. 3. _ Excluded from this pur-chase order are the main. coolant. loops and nuclear steam supply system. items furnished.and. erected.by. Babcock and Wilcox Company. Fabricated. pipe is.to.be supplied in_accordance with GA Specifi-cation No..RO-2891, Revision 4. Pipe.will.be fabricated in accordance.with.both.B31.1.0 and.B31. 7...The GA specification required. the. contractor.to. submit.for. the. engineer 's app roval, six copies of his. shop procedures.which he. intends.co use for, the contract. including. bending,. welding,. heat treating and nondes tructive. test. It.was required that all. preheating be in accordanca..with B31.7.or B31.1.0..Codea.. Waldar. qualifications and procedure -qualifications. ara to.be.in.accordance with Section IX.of _ tha. ASMF.. Code.and. welding pu.icadures must be submitted for the engineer's approval...The. welding _procadure..must include all partd lent data.for the. essential.and.. nonessential. variables. WK n is required.to furnish a. procedure.for documentation.of filler v metal, backing.. rings.,_ consumable.. inserts,.and.shi p1ded gas as part.of. MWK's. documentation in its..qnn1i ry control manuals for its. shop _practi caa. Ihesa_ procedures..have._been audited and are considered. part.of..the. vendor.. inspection program.of. Compliance as noted;in 011er's inspection report on MWK (MWK. 69/1). hectio$ 4.bof GN spec 4I4 cation.11sts th$ requirements of test reports..and_ nondestructive testing. reports..that.must be submitted for. the. different classea of_ pipe and codes.._-.Tha. documentation furnished. to FPC..must.be_in. accordance.with_ requirements of applicable codes for each system as specified in GA specifications. Class h.. piping. less. han_2-1/2.. inches..wi1Lba. f abricated onsite_.by LC. personnel.. GA has.not.. written a specification for. this. piping _ A. fabrication shop. is under. construetion for .the. f abricating of. both. the B31 L and. B31 7. piping. Material recaipts,. storage and issuing will be as reported. in C0 Report No. 50-302/70-3... Reactor Coolant Bleed. Tanks - Attachment 'E - (480h.04.a, b, e, H. f,.and..g.and 4805.05,a.3-a.5) I ^ The.. three reactor. coolant bleed. tanks e d the. miscell nnaeus _was te . storage... tank were purchased _by_ FPC on. Purchase.. Order No.. P.R3-1065 f rom _ PDM.. The. reactor. coolant.. bleed. tanks are 20...fect. Inside diameter '(f by 39_ feet 8 inches. high and were.. fabricated.in_accordance.with GA . Specification No SP.-.5532..enti e1 ed,. '.' Specification. Reactor Coolant Bleed _ Tanks and Miscellaneous. Equipment," and Addendum A. The p_ m. ~ w
/ -,a + ~ \\ h 'CO - Rp t. No. 50-302/70-4' - 4 specification requires. that.. the threa. tanks..be.. Class. C vessels in accordance with.Section III.of the. ASME Code., ~ Class C vessels require the ' stamping.of the' vessel.with the Section VIII "U" stamp j - with I he letter. N" beneath it..The. tanka.were inspected at the'- t site' by. the Region II inspector.and.it was, noted that the "N" did not appear on the nameplate. It was-noted there are are strikes on the tank and discoloration of the.outside surface from welding on_ the inside of the. tank.. Rusting.has. occurred on the outside of l the ~ tank due to contact in the shop. with carbon steel-material.. The manufacturer's data. reports were' available ' for the three tanks-under' the manufacture's. Serial.No. 8130 and. National Board Nos. 730, 731, and.732.. The.. certificate..of. shop inspection was signed for. the Mutual. Boiler and Machinery Inspection. Company on September 21, 1970, by D. L. Best, National Board.No..NB6028. The data report certifies that. the vessel has _ been designed, constructed and the workmanahip of the. vessel conforms to the ASME Code for Nuclear Vessels;.however, it does not signify that.it is a Class C vessel. 4 The certificate of design states that. the design information is 'on - file :at GA, Reading, Pennsylvania, and the stress analysis report is on file at PDM Pittsburgh, Pennsylvania. The data reports have been stamped by.the.GA quality assurance representative, Stamp LNo. 8N.. The. certification states that the - vessel's shall and head were. built of _ SA240, Type 304 material, the nozzles conform to.SA312,. Type 304 and thermocouple wells and i couplings are from forged SA182, Type 304 material. The.FPC purchase. specification _ requires that all mill certifications, 3 NDT reports, radiographic film, weldor. qualifications, mill certifi-l cations for welding material, manufacturer.'s data report, nameplate rubbing, seismic -graphic. calculations, hydrostatic test report, rollout drawing.to identify. the. radiograph. readers ' report, material heat and.other symbol, and documentation.of. major repairs to be suppliad to FPC. The Region II. inspector.was informed these docu-ments are in the FPC engineering office at St. Petersburg, Florida. ~ 1. ~ t The tanks were inspected by GA acting as agents for FPC. On file j is GA's transmittal of the final. vendor. inspection report dated t-November 2,1970. The. vendor. inspection. report states that the j inspection of the. tanks was -performed.in..accordance with the established.. vendor inspection point. program and GA/QA procedure No. 25.3. The report stated. that. at the time the tanks were com-pleted and loaded on the barge, the documentation was not considered acceptable. However, during the time PDM. quality assurance was i correcting the documentation deficiencies, the barge broke loose .from.its mooring and damaged the miscellaneous waste storage tank. t n ~.. - . _, _ _. - - ~ -..
^ ) !p}. CO Rpt. No. 50-302/70-4 _ When the GA inspector was. finally notified that. the documentation was ready for approval, the. miscellaneous waste storage tank had been repaired, hydrostatically tested, and loaded on the barge at the PDM plant. Documentation of repair.of. the damage included NDT reports were available and approved.by.GA on the basis that PDM followed the loading procedure.and the visual. inspection by the inspector at the time of loading.the.three reactor. coolant tanks on a previous-visit...GA field records.of.the. final inspection report 2 states that all. certifications,. radiography, qualification of the welding. procedure, weldor qualification, and.NDT personnel qualifi-cation.are. acceptable.and.the PDM records are. complete for the pro-cedures, material,. receipt,. storage _and issue.of weld material, dimension, surface finish, material, NDT, and.fitup. It was roted by the Region. II inspector.that. certain items. required by the specifications.had.not been. performed..It.was.noted on the quality. assurance department. certificate.of inspection four items where. PDM had not conformed..to the. specifications. One item was the use of ASME SA36 material.for support. girths and lif ting lugs rather than.SA240 as required in. Addendum A to the specification. \\s_-}- [ Ultrasonic inspection _of the. plates..as. required.by the specification s was not performed. Attached to.the final, report was a letter dated September.28,1970, from PDM listing GA comments and PDM replies for seven items pertaining to the workmanship. Presently, the tanks are in quarantine with a hold tag on them until arrival of all documentation onsite. J. Reactor Building Containment Lining (Attachment C) 1. Material (4805.05.a.5) The reactor building containment. liner is being. erected by CB&I in accordance with GA Specification.SP-5566, " Reactor Building Liner and Penetration and Personnel Access Lock, Criterion III," and Addendum C. " Scope of the work" of the specification states that the contractor shall design,. furnish, f abricate, deliver, unload, store as necessary and erect the steel liner including penetration sleeves and installation of penetration inserts. The erected liner must have a. leak rate of less than 0.25% by weight of containment. air in 24 hours at 55 psig. Containment liner and penetrations are to. conform in all respects to the applicable sections of USA. Standard _ Institute N-6.2,1965, "Saf ety Standard for Design, Fabrication _and Maintenance of Steel Contain-ment Structures for. Stationary Nuclear Power Reactors." The speci-fication. states except as noted materials, design, fabrication and i-k- workmanship.are to conform.to the. requirements of the ASME Code, Section.III, Nuclear. Vessels, for. Class.B vessels. The portions of the. equipment. access. extending.beyond.the reinforcing concrete are to conform in all respects.to the requirements of the ASME Code, Section III, Nuclear Vessel, for Class B vessels.
_,I \\. 1-v) \\ CO Rpt. No. 50-302/70-4 - Section 4.06,' " Materials,".of the.GA specification requires that the steel plate, for the. main shell. including...the. dome'symetrical walls.and. base plate. conform.to. the. ASTM. A283-67, Grade C,' and - roll.section.shall meet ASTM. A36--67...This.is in. agreement with ~ the.PSAR,. Appendix.5E, Liner. Elate. Specification, Section 3, "Caterial.".It is noted.in the. specification that the steel plate material.per. ASTM A283-67.does.not. meat.the requirements for Class B. nuclear. vessels.. FEC-.was. advised the use of this material.will.be. investigated by. Region _II.. JL special-note in this paragraph requires. that the shell. excluding the base mat 4 plate, the knuckle plate.and. thickened. portion of the symetrical wall plate.in the area of.the crane.have a. minimum copper content of 0.2%. Material for the thickened. portion of the symetrical walls in the area.of _ the. crane.gf rder. bracket. is to be ASTM A516, Grade 60. All. material.for Unit.No. 3_ containment is being sup-plied by the CB&I Birmingham. shop except 'for the personnel airlock which will be fabricated in.the Greenvilla shop. All mill certi-fications.willibe retained.at.these _ shops.and will be forwarded to Memphis upon completion of the. fabrication for microfilming and eventually the. certification.for the material will be sent to FPC St. Petersburg office for filing. ~ v 2. Quality Assurance Manual and Procedures (4805.04.b.5, e.2, e.4, e.5, e.6, f.2, f.6) CB&I was required to submit its quality assurance manual for review and comment. The document was to contain the following items : Cleaning procedures for NDI inspection technique. a. b. Material control procedure, c. Welding electrode control procedure. d. Marking and material identification procedure. e. Control of construction conditions by dimensional check procedure. f. Qualification requirements for NDT personnel and weldors. g. Documents and drawing control procedures. h. Nonconforming procedure. \\' i. Control of inspection and test records.
.(-) kJ '^ C0 Rpt.. No. 50-302/70-4 _j. Control of purchased parts. k. Criteria for approval and' rejection of work. 1. Examination of checklist. m. Corrective action procedure. n. Traceability code. o. Proof test procedure. CB&I submitted its nuclear quality control manual that has been previously reviewed by Region II at Hutchinson Island plant. (See 00_ Report No. 50-335/70-5.) The procedures submitted by CB&I that have been approved by GA for FPC are as follows: ) a. Construction Control and Storage of Inspection Record Pro-- ,) cedure, CFR-lL. b. Construction Dimension Control, DC-lL. c. Halogen Leak Test Procedure, HLP-lL. I d. Construction Nonconformance Procedure, NCP-lL. t e. Liquid Penetrant Examination Procedure,.PPP-5L. f. Spot Radiographic Examinacion Procedure, RIP-SL. g. Ultrasonic Examination for Full Penetration Welds, UTP-lL. h. Vacuum Box Tes t Procedure, VPP-lL.
- i. Welding Procedure Specification, WPS-1L.
J. Construction Weld Rod Control Procedure, WRC-lL. 3. Welding (4805.04.b.3, 4805.05.n.4 and 4806.06.a.1) 4 Welding is being performed in accordance with welding procedures-y that have been qualified in accordance with Section IX of the .} ASME B&PV Code as modified by paragraph N541 of Section III of - \\s_,/ the code. _ Repairs of defective welds will be repaired in accord-ance with paragraph N528 of Section III. Three' welding procedures
1 ,s bv] 00 Rp t. No. 50-302/70 - are being used for all welding of the containment liner. These are CB&I Welding Specifications No. 315 for manual metal are using E7018. electrodes, No. 24 for. horizontal (3 o' clock) sub-merged arc welding using Linde 29W wire and GR. 50 flux, and L341-B for flat submerged arc welding using Lincoln L61 wire and 860 flux. The Region II inspector verified that the sub-merged arc welding was.being performed in accordance with Pro-cedure No. L341-B and conformed.with the stated values for amps, volts, and speed. The joint geometry was originally designed for welding with manual metal arc; however, the welding process. was changed to submerged are and two-pass welding. The submerged arc welding procedure was qualified for single pass; however, this is not an essential variabla and does not violate the requirements of the procedure. 4. Weldor Qualifications (4805.05.a.1 and 2) Ten weldors and weldor operators are qualified in accordanr.e with Section IX of the ASME Code. The qualification of weldor Satchelor e~N g was audited and his initials are used as his identification stamp required by the code. He was the only.weldor operator qualified ~ at Crystal River in accordance.with Welding Specification No. L341-B; however, the weldor qualification.was in error in apecifying that Linde products were used when..it was actually Lincoln. How-ever, the Lincoln identification. numbers were correct. The weldor qualifications for the other nine weldors are up to date and were brought to the site witn them from other sites being erected by CB&I ~ 5. Electrcle, Flux and Wire Sto. age and Control (4805.05.q. 3, 5) The electrodea. flux, and wi w are. stored in a trailer. The E7018 electrodes are stcrad da ner toticolly-sealed containers until needed. It is required er t'te.C3&I Construction Weld Rod Control Procedure No. WRC-lL that af.er a. container of electrodes has been opened, the. remaining electrodes.are. stored in the holding oven at 250*F. Weldors are instructed to remove only enough electrodes from the storage oven that will be used during one shif t. No electrodes are to be used.that have been. wet or lef t out for an extended period of time. At the end of.the shif t, the electrodes are returned to the electrode oven and held at 250'F. The sub-merged arc welding flux is delivered in. water repellant bags and s tored in the trailer. Only one bag is removed from storage to the site and s tored in a.55 gallon.. drum. The excess flux from fs the welding operation is. reclaimed by vacuum flux reclaimer and (' ) stored in a reclaimer watertight. drum. The project welding an'd QA supervisor is required by the specification to check welding
i ~ i ,/ s } C0 Rpt. No. 50-302/70-4 _ l, material containers and certification of analysis upon arrival at the' site to insure that the welding material conforms with the _l requirements of the job. He instructs the weldors in the use of electrodes and. audits weldors at work _at least twice a day to see that they.are using correct welding. materials. Only typical certificate of analysis of welding material is required. ] 6. Quality Control and Nondestructive Test (5805.04.b.1, b.2, b.6, 4805.05.a.5) GA Specification SP-55-6 states that. certificate of mill test reports of the steel plata material used.for the liner and rein-forced in plates.to the penetration sleeves are to be submitted to the owner for approval. Certificate of compliance of typical analysis of the veld electrode or weld filler metal for liner welds are acceptable and they are to be submitted to the owner for approval. Penetration welds.and penetration assembly material for the containment. that must be.f abricated and erected in accord-ance with Section III of the code for Class B vessels must have traceability. All material received at the site contains a piece-mark or arrives as.a fabricated. unit; therefore, the traceability being maintained at the site is on a rollout drawing by piecemark. It is required that the longitudinal.and.circumferential weld joints in the main.shell and the welded joints connecting the dome to the. cylinder side walls be inspected by the liquid pene-trant.me thod.and. spot radiography. The spot radiography is to be performed-in accordance.with.Section NIII,. paragraph UW-52 i. and 2% of all welds and.2% of.eadi weldor'.s welds shall be radio-graphed. All penetrations including.dae. equipment access door must be examined in accordance with the requirements of ASME 4 Code, Section III,.for Class B vessels. All. shop fabricated components including the reinforcing about openings shall be radiogrcphed fully. The radiography is.to be done in accordance with Section III, paragraph N-1350, which requires the procedure and acceptance criteria. conform.with Section NIII, paragraph UW-51. The spot radiography.is.periormed in.accordance with CB&I Procedure.RTP-5L, " Spot Radiographic Examination Procedure." Spot radiographs of.the knuckle section joining the bottom to the conical section were audited by the. Region II inspector and they met code and specification requirements. Liquid penetrant examina- . tion will be performed.in accordance with CB&I Procedure PTP-5L, i " Liquid Penetrant Procedure." l It is required that the steel channel. leak. chase system be instslied [s ) over all butt welds and. angles.be. ins talled over penetrant sleeves j - (,/ to liner plate welds that will be inexcessible when all construction i is completed. The leak chase system is required ' to be segmented to l l e
7-f-. ..r - C0 Rpt. No. 50-302/ 70-4 insure that any length of weld covered by any one channel will not extend to the greatest. dimension of..one plate. Each. channel segment is to be provided with a. fitting.diat extends to ' a sump - which. terminates at elevation 95. feet...The leak chase system will be examined for. leak with.a soap. test at 63.3 psi then a strength. test at.72.5 psi and.a. final. halogen leak test with a mixture of air and. freon and.the results. recorded on CB&I leak test record.. These test.must be signed off by an NDT technician. All exposed seams must be. tested.with.a halogen leak detector and 100% of the detectable. leaks. corrected. - The. test shall be conducted in accordance with the. proposed standard fortleak rate tes ting of. containment. structures.for nuclear reactors, ANS7.60,. Appendix.A..The leak test will be performed in accordance with CB&I Procedure HLP-lL,," Halogen Leak. Test Procedure." The CB&I procedure requires 5.psig of freon to be. introduced into the . channel and the channel. pressurized.to.63.3 psig with air. - A halogen leak standard.and.a halogen.. leak detector manufactured by the. General Electric. Company, Type LS-20, has been sent to the site; however.the. accuracy.of.the. leak. detector is only 10-4 cubic centimeters per second.and the specification requires C,, that the accuracy of the halogen leak detector be 10-5 cubic o centimeters per second. The halogen. leak detector will be i replaced with a more accurate detector. All weld seams not covered by the, test channel are vacuum box tested. The pressure differential.is.not.less than 4 psig and the race of inspection does not exceed two feet of weld per minute. The box is lapped a maximum.of six inches over the previous tested section, and.all detectable leaks must be corrected. The test is performed.in accordance with.CB&I Procedure VPP-lL, " Vacuum. Box Test Procedure.." The procedure-requires that a manu-factured soap. solution be.used and mixed and applied in accordance with the manufacturer's direction. The records for the liquid penetrant is kept on a'CB&I liquid penetrant inspection report which must be signed by the foreman and.QA supervisor. The vacuun box. test.results.are. recorded cn.CB&I vacuum box report which requires a. description of the. area, the test result, the description of. repairs, the.name of the person performing the test and test approval by the. welding QA supervisor. Leak test is kept on a CB&I form called " Leak Test Record." l A record of the weldor identification is kept on a rollout of the asbuilt of the bottom plan and this drawing will also be used to keep a color-coded record of soap testing, halogen leak tested, vacuum box. testing.. FPC.will request that the working copy of this record be turned over to FPC as part of its permanem records. j E ~ s" s ws x .m-- -w s~ -v w w -r~ N
i-CO Rpt.'No. 50-302/70-4 - The qualifications of the NDT.tachnicians. performing the non-- ^ I . destructive. testing.were avaminad..hy..the.ltagion.II inspector and were qualified in.accordanca.with. CB&l's nondestructive . testing. personnel qualification. practices. which meet the re ~ j quirements of SNT-TC-1A...Two men. ara.quali fiad..to. Level II for liquid. penetrant,.two men.to Level IL.for magnetic particle, one to. Level II for radiography and One to Level I for radiography. f i t d 1 l 9 1 1 I 4 e 4 --e. - - -w ,-,v v, +-,,- -,,,. --., ws-. -.w, e,-----+,..,,-.w..' y 3 -,w+ gy --er +<m,--.v-< =-.wav+s}}