ML19322A836
| ML19322A836 | |
| Person / Time | |
|---|---|
| Site: | Oconee  |
| Issue date: | 02/01/1971 |
| From: | Brownlee V, Cochran B, Long F US ATOMIC ENERGY COMMISSION (AEC) |
| To: | |
| Shared Package | |
| ML19322A835 | List: |
| References | |
| 50-270-71-01, 50-270-71-1, 50-287-71-01, 50-287-71-1, NUDOCS 7911270390 | |
| Download: ML19322A836 (12) | |
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U. S. ATOMIC ENERGY COMMISSION REGION II DIVISION OF COMPLIANCE 5-s Report of Cons truction Inspection C0 Report Nos. 50-270/71-1 50-287/71-1 Licensee:
Duke Power Ccapany 4
Ocenee 2 and 3 License Nos. CPPR-34 and 35 Category A J
Date of Inspection:
January 6-7, 1971 i
Date of Previous Inspection Novenber 23-25, 1971 Vb f3Ym,d M
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Inspected By:
V. L. Brownlee, Reactor Inspec tor Date' (In Charg h jiwt
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B. J.gCocE'ran, Reactor Inspector
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Reviewed Q j-
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i. J'. Lon g, S enic
..uuttor Inspector
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Preprietary Informatica:
None S COPE An announced inspectica was parformed at the teo 2,568 Mwt pressurized water reactors under cons tructica near Seneca, South Carolina, known as Oconee Station Nos. 2 and 3.
Inspection ef forts were directed toward a review of progress of construc-tion, follow-en inspection of containment construction, review of the QA program for installation of the reactor vessel, and procurement docenent review of the pressurizer safety valves.
Inspection ras to the scope of PI 3800/2 and by requirements of the provisional ins tructions of Attach-ment C (PI 4800
- ielding), Attachment J (PI 4900 - Mechanical Components),
and Attachment L (PI 4900 - Mechanical Components).
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CO Rpt. Nos. 50-270/71-1 50-287/71-1 SDSiARY Safety Itens - None Nonconformance Items - None Unusual Occurrences - None Status of Previously Reported Problets - Component Storage (See Sunnary, Other Significant Items, Iten 5. C0 Report Nos. 50-270, 287/70-7) Duke did correct the areas of concern and new discrepancies were not noted in regard to compenent storage. l Other Sic,nificant Items - 1. The reactor vessel handling and installation precedures appear to be adequate and, if properly followed, we can expect to see the vessel safely installed according to the design intent. 2. Containment liner erection, welding and NDT practices and record maintenance are considered to be adequate and in conformance to the design intent and QA program requirements. 3. Review of purchase documents and field informatica pertaining to the pressurizer relief valves indicate that the valves will not have a hydrostatic shell test pressure applied as required by the FSAR, purchase order, and purchase specification require ents. (See Section D.) Management Interview - The inspectors cet informally with the licensee's representatives. The inspectors debriefed the licensee's representatives on those areas covered by the inspection and the findings. The inspectors did take exception to housekeeping practices on Unit 3 relating to Class 1 structures and components. The inspectors had removed a soda water can frc= a tendon trumpet and reinforcing s teel from another. The steam generator embedded support fixture was ccvered with debris. 'dunnicut acknowledged the legitimacy of the corrents Duke's position was that cleanup and protective measures will be taken to correct the deficient areas. +w w .m g a FWm-m
CO Rpt. Ncs. 50-270/71-1 50-287/71-1 The inspectors informed the manage =ent persennel that the pressurizer safety valves were not presently programmed to receive the shop shell hydrostatic test as required by the FSAR, purchase order and purchase spe ci fica t i.:n. Cells s tated that the comments vould be forwarded to engineering. DETAILS A. Persons Contacted
- R.
L. Dick - Projects Manager
- J.
R. Wells - Principal Field Engineer
- D.
G. Beam - Assistant Proj ect Engineer
- G.
L. Hunnicutt - Senior Field Engineer T. E. Touchstone - Field Engineer (Civil) D. L. Breeze - Field Engineer (Of fice) ~ R. E. Blaisdell - Assistant Field Engineer (Welding) G. W. Grier - Field Engineer (NDT) J. T. Moore - Supervisor Technician (Welding) A. R. Hollins - Assistant Field Engineer (Welding) M. Curtis - Design Engineering (Mechanical) B. Reactor Vessel The Oconee Unit No. 2 reactor vessel is in transient from near Augusta, Georgia, where it arrived by barge f rom the Babcock and Wilcox Company (B&W) Mt. Vernen, Indiana, manufacturing facility. Installation of the vessel vill be delayed until the arrival and installation of the two s team generators. One stean generator was shipped via railcar f rc= the Mt. Vernon facility January 6,1971. The second s team generator is not scheduled to arrive at the site until February 1971. The reactor vessel and steam generators will be installed in accordance with the B&W installation procedures. The reactor vessel and steam generator sole plates are being installed in preparation for the arrival of the vessels. The reactor vessel handling and installation procedures appear to be adequate and, if properly followed, we can expect to see the vessel saf ely ins talled according to the design intent.
- Present at the Management Exit Interview.
C0 apt. Nos. 50-2 70/ 71-1 50-287/71-1 Documents Reviewed B&W Specifications: FS-ll-1 Storage Requirements for NSS Ccaponents and Ecuipment. ES-11-3 Housekeeping During Erection of NSS Primary and Auxiliary Systems. FS-lll-13 Ecceipt, Inspection, Handling, Storage and Installation of the Reactor Pressure Vessel. FS-lll-lb Receipt, Inspection, Handling, Stc mge and Installation cf the Reactor Vessel Closure Head. FS-lll-lc Receipt, Inspectien, Handling, Storage and Installation of the Centrol Rod Drive Service Structure and Accessories. FS-lll-22 Receipt, Inspection, Handling, Storage and Installation of Once Through Concercial Steam Generator. CS-3-28-1 Pressurizer Relief Valves for Reactor Coolant Systems. Duke Specifications: J.1 Reactor Vessel Foundation Anchor Bolt Tensioning ?rocedure. 0S-139-3 Shop Inspecticn of Reactor Building Liner Plate and Assembly Steel 0S-139-4 Reactor Building Suppleaental Spec fication for the Erection of Inspection of Liner Plate. Attachment J - Reactor Vessel (Unit 2) The receiving, handling and ins tallation procedures cere reviewed to verify that preliminary arrangements have been made and site personnel are prepared to receive the vessel according to the procedures. 4900 - Mechanical Campenents 1905.03 - I=clenentatica cf lA Prezram The Duke QA program has been satisf actorily evaluated and it has been determined that Duke's procedures are adequate and QC forms contain s uf ficient information that if properly executed vill provide documented-verificatica cf the di=ensions and tolerances of the installed conpenents.
CO Rpt. Nos. 50-270/71-1 30-287/71-1 4903.04 - Review of OC System b.2 - Receipt insoection and Handline The reactor also.-ill be shipped by barge and supported by a special shipping rig. The reactor vessel will be shipped from the 36% facility in Mt. Vernon, Indiana, with an internal cleanliness of Class C as defined in the 3&'d reference specification. Cleanliness will be assured by the use of plugs, caps, covers, and with desiccants with or without nitrogen pressure. Upon receipt of the reactor vessel, nuclear steam supply compenent inspection report (PDS31581) nus t be completed making certain that the following specific inspections are perforned: 1. If nitrogen overpressure is used, check and record reading of pressure gauges. Open valves to assure a positive pressure of the nitrogen system. 2. If desiccants are used, either alone or in conjection with the nitrogen overpressure, exanine the hunidity indicator in the vessel top. 3. Check shipping f race, lugs, tie rods, cables, protection covers, steels, etc., for shipping damage or any indication of vessel novement. b.6 - Special Handling and Storage Precautions The vessel vill be unloaded from the barge in accordance with Section 3 of B&W Specification FS-lll-la, the vessel will be s tored en its shipping rig and up-ended. ith all covers in place. Preins tallatien S to rate Recuirerents 1. All openings mus t remain closed or covered when not in us e. 2. Humidity control is not a storage requirement; however, if elected by the cus terer, desiccants or clean-heated, circulating air shall be provided. The circulating air cus t be filtered as required by the field cleanling specification (FS-ll-2). 3. Periodic in-s torage inspections shall be made at intervals not greater than 30 days. Report of inspecticas shall be made en fo rm NSS, Cc=ponent Inspection Report, PDS-313Sl. l i f
C0 Rpt. Ne s. 50-270/71-1 50-287/71-1 c.1 - Ins tallation Specifications and Procedures B&W and Duke specifications and procedures for installation, leveling, torquing anchor bolts, and cleaning the reactor vessel have been tes ted and proven during the installation of Unit 1 vessd and will be followed for Units 2 and 3. The following specificatione were reviewed: - Housekeeping During the Erection of NSS Primary and Auxiliary Sys tens - FS-11-3. - Receipt, Inspection, Handling, Storage, and Ins tallatien of the Reactor Pressure Vessel - FS-lll-la. - Leveling of the Reactor Vessel - Drawing PC-19082. - Receipt, Inspection, Handling, Storage and Installation of the Reactor Vessel Closure Head - ES-lll-lb. - Reactor Vessel Foundation Anchor Bolt Tensicning Procedure - J.l. c.2 - Use of Expertise in Installation The same supervisory people used in the installation of the Unit 1 reactor vessel are scheduled for the installation of Unit 2. These qualified engineers will utilize their years c f construction experience in ins talling heavy equipment plus the experience obtained during the recent installation of Unit 1. c.3 - Installation Insoection Visual inspection of the installed reactor vessel will be perforced by 3&W and Duke engineers The installed dimensions and tolerances will be re viewed and approvs! by B&W and Duke. 4905.05 - Followup Record Review This section will be ccapleted at a later date. 4905.06 - Follocup Cbservations of Work This section will be completed at a later date. 5500 - Cleanliness This section will be completed at a later date.
C0 Rpt. Nos. 50-270/71-1 50-287/71-1 C. Containment Building Liner Plate Unit 2 containment liner has been completed. Final cleaning and forming preparations were being nade for placemeat of the eight-inch working slab. The erection of the Unit 3 containment building liner plate has progressed through the seventh course, which includes the personnel air lock and other penetrations. The inspectors reviewed QC records, dimensional tolerance check data and radiogt,ah records for a segment (10*-90*) of containment liner Nos. 2 and 3. Additionally, the inspectors performed a work pe r fo rmance review of the equipment hatch installation for Unit No. 3 ina callation. Duke is ascessed to be cons tructing in sccordance with the plans, specifications and QA program. With the exceptian of poor house-keeping practices, the erection of the Unit 3 liner plate and concrete walls is proceeding according to the cons truction schedule in a satisf actory manner. 4800 - Welding 4805.05 - Followup Record Review a.3, 4 - NDT Records and Repair The inspectors reviewed the liner plate procedure, 211.1, " Procedure for Checking Erecticn Tolerances of Reactor Building Liner Plate," and the Liner Plate Erection Specification, 05-139-4 Work performance records reviewed were: 1. Radiographs of all courses by a 60-degree segment (39*-90*) on Units 2 and 3. 2. QC Daily Welding Inspection Record. 3. QC Daily Record of Welcing Defects. 4. QC Radiographic Inspection Report. 5. G Radius Deviation Forms (all courses).
C0 Rp t. Nos. 50-270/71-1 50-287/71-1 Tes ting Tes ting shall be perforced in accordance with Section VIII of the ASME Pressure Vessel Code and the Duke specifications for reactor building liner plate and accessory steel. All welds on the containment building liner plate will receive 100% visual inspection. All welds shall be vacuc2 box tested. However, where the vacuum box cannot be used due to the configuration of the weld, the weld shall be dye pene trant tested. For quality control purposes, a radiograph 12 inches in length shall be taken in the first ten feet of the completed horizontal, vertical, and overhead welds for each veldor. No further welding shall be permitted until radiographic inspection has been completed and the welding found to be acceptable. A ninitum of 2% of welding shall be progressively spot examined as the welding is performed using 12-inch length film, wherein the basis is to be spr.cified by the inspector in such a mannar, that approximately an equal number of spot radiographs shall be tcda of each weldor. The inspectors reviewed the radiographs taken for all courses (1-16) of Unit No. 2 between 30*-90*. Total number of radiographs taken equalled 63. Total rej ects equalled 31. The inspectors selected 23 of the total number of radiographs for review. Seven of the 23 radiographs were rejected. The review of the rejected radiographs included the review of the tracer shots and weld repair shot. The radiograph quality and traceability of weld, radiograph, weldor, repair and tracer shots are acceptable. The review of radiographs for Unit No. 3 included twelve shots for courses one through six. One reject was neted. Qualification of weldors was checked through 31aisdell's current records. Duke maintains current qualificction records on a 30-day basis. Erection Tolerances Radial Tolerances The radial location of any point on the cylinder wall liner plate will not vary from the design radius by more than 11-1/2 inches or i,3 inches in total diameter ceasured at 10* increments around t I L
C0 Rpt. N^s. 50-270/71-1 50-287/71-1 the inside periteter of the liner plate at the top of each lift before welding the horizontal seam and at the bottom of each lif t af ter welding the horizontal seam. The radial dimensien will be measured by using a vertical-reading theodolite set on a predetermined baseline on the reactor building floor to read a scale held radially to the liner plate. This offset dimension will be added to the radial baseline dimensicn to determine the radius at 10. Eac; radius dimensien ceasured should not deviate from the design radius by more than the tolerances given above. The radial tolerances will be measured by the survey party af ter a complete ring of liner plate is welded into place and af ter concrete is placed against the plate. The survey party chief will record the final radius deviations on Form G-1A for each lift of liner plate. The completed Form G-1A will be submitted to the field of fice engineer for transmittal to the engineering depar tment. Local Deviations A 15-foot-long template curved to the design radius will be used to check local deviations at each 10* around the periteter of the liner plate. The template will be pl aced not closer than 12 inches f rom the top or botton of each section ,f liner plate nor within 12 inches of a vertical velded seas. The template shall not show deviations of more than three-fourths inch when placed agains t the completed surf ace of the liner plate. The effect of change in plate thickness or veld reinforcement shall be excluded when determining deviations. When the tenplate is placed across one or core welded seans, the deviations sha:1 not exceed one inch. The =aximum inward deflection toward the center of the structure of the one-fourth inch plate between the angle stiffeners will be measured at each 10* around the perimeter of the liner plate at the vertical quarter points in each lift of plate will be one-eighth inch relative to a 15-inch straight edge placed hori-
- ontally agains t the plate.
Sharp bends or local deviations in the horizontal welded seans measured relative to a 15-inch vertical straight edge shall not of fset by more t?an one-half inch. These deviations will be ceasured at each 10* around the periceter of the liner plate. Local deviations will be checked by the survey party af ter a con-plete ring of liner plate is welded into place but before concrete is placed against the liner plate. Any local deviation which f ails
C0 Rpt. Nos. 50-270/71-1 30-237/71-1 to meet the specified tolerance will be marked en the plate locating the area of the deviation and the size of the deviation. The survey party chief will notify the field engineer, who will deter =ine the method of correction. The inspectors reviewed all Forms G-13, " Radius Deviation Reports," for Unit No. 2 lif ts 1-16. No areas of discrepancy were noted except at the thickened portica at the ecuipment hatch, a.5 - Material Control The inspectors performed a review of weld material control. Receipt, issue and use records are censidered to be adequate and maintained in accordance with the QA program requirements. 4805.06 - Followup Observations of Work a.1 - Weld Procedures a.3 - Identification of Weld, Weldor, Inspector a.5 - Control of Ueld Materials 4 The inspectors selected the equipment hatch for Unit No. 3 as the tes t sample. The inspectors reviewed the installation, talked to weldors, selected weldor symbols and checked records for current status, and performed saterial control observations. No significant areas of concern were detected. Duke is performing and maintaining records in accordance with the plans and specificaticns. One area of concern noted during the review was that housekeeping practices were negligent to the extent that disregard for Class I ccmponent protection was evident. A soda water can was removed from a tendon trumpet, reinforcing steel was removed from a tendon trumpet .d the steam generator ambedments were being used as trash collect s. This was brought up at the management exit interview and management prcaised corrective action. D. Pressurizer-Safetv Valves The inspector reviewed the B&W Purchase Order No. 80 404 Z, dated Feb rua ry 22, 1968, and the B&W Technical Specificaticas for pressurizer relief valves for Reactor Coolant Sys tem Se rvices, CS-3-28-1, date d September 29, 1967. l Curtis provided input and review information pertaining to the relief l valves. l l i W-
C0 Rg t. Nos. 50-270/71-1 50-287/71-1 B&W Purchase Order No. 80 404 Z Ihe purchase order was for eight each pressurizer safety valves size 2-1/2" x 6" in accordance with B&W Specificatien No. CS-3-28-1 dated September 29, 1967, and Dresser Quotation No. Q.S.V. - 17896 Revisica 1 dated December 27, 1967, as amended by Dresser letter, dated January 23, 1968. Valve description is as follows: Special consolidated pressurizer safety valve, enciesed spring with packed lifting, liner, s tainless s teel forged through seat bushing, Inconal "X" Thermodisc, s tainless steel bellows for maximun variable back pressure of 700 pounds at 500'F, auxiliar; balancing pis tens. Inlet Flange 2500 lb. ASA Outlet Flange 300 lb. ASA i Set Pressure 2500 lb. Orifice Area 2,545 sq. in. Capacity 311,733 lb/hr sat. steam at 10% accumulation, 90% rating Paragraph 4.0 of the purchase order requires that ND1 of the equipment shall consist of: 1 1. Class 2 - E71 radiograph of the body only. 2. UT inspection of the seat bushing. 3. PT of the seat bushing and disc. 4. All other inspection procedures required to IAW 3&S 3pecificatien No. CS-3-28-1 and/or USAS Draft Specificaticn 331.7. B&W Purchase Specification C3-3-28-1 Section 3.0, " General Requirements," requires that the valves shall be flanged and the flange specifications described in the code (ASA 316.5) shall be follcwed. The valves shall have an inle: design tamperature - pressure rating of 670*F - 2500 psig - Class 5, as specified in the code (ASA 316.5). Dcwnst ream portion of valve to be designed to 500*F - 700 psig. Section 6.0, " Inspection Requirements," requires thac each valve shall 1 meet the inspection requirements and acceptance standards of Devision 1-724 of USAS B31.7. l 2 1 l
C0 Rpt. Nos. 50-270/71-1 50-287/71-1 Section 7.0, "Tes ting Requirements," requires that all valves shall be given hydrostatic shell pressure tests as required in the latest edition of the code (ASA 3-16.5). Valves shall show ne leakage or permanent deformation at any point. Hydrostatic Shell Test Pressure The inspector asked what would be the shop shell hydrestatic test pressure. Curtis stated that the test pressure would be 1-1/2 times system design pressure or 3 753 psi. The inspector informed Curtis that the test pressure did not teet the requirements of the FSAR requirement (USAS 316.5), the purchase order or purchase specification requirement (USAS 316.5). Curtis s tated that he would check into the area of discrepancy. The valves are not to be shipped from the supplier until February 19, 1971. Subsequent information received from W. Owens (telecon) indicates that Duke will attempt to amend the FSAR, purchase order and pur-chase specification requirement pe rmit testing of the valves at 'm the lower pressure. Compliance will follcw this area of concern. i i ~ l J}}