ML19326A806
| ML19326A806 | |
| Person / Time | |
|---|---|
| Site: | Crystal River  |
| Issue date: | 05/01/1969 |
| From: | Bryant J US ATOMIC ENERGY COMMISSION (AEC) |
| To: | |
| Shared Package | |
| ML19326A798 | List: |
| References | |
| 50-302-69-02, 50-302-69-2, NUDOCS 8003040763 | |
| Download: ML19326A806 (6) | |
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U. S. ATOMIC ENERGY COMMISSION REGION II DIVISION OF COMPLIANCE Report of Inspection C0 Report No. 50-302/69-2 Licensee:
Florida Power Corporation License No. CPPR-51 Category A Date of Inspection:
April 17-18, 1969 Date of Previous Inspection:
January 23 -24, 1 % 9 V/36' 6+
Inspected By:
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,/ J. C. BrffMt, Rea'ctor Inspector
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Revieved By:
W. C. Seidle, Senior Reactor Inspector (Date) j Proprietary Infor.ution:
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
Safety Items - None Noncomoliance Items - None i
Status of Previously Renorted Problems - None Other Significant Prob 1 ps_ - None r%
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Manneement Interview - The exit interview was held with Bennett, and the following items were discussed:
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1.
Site Precaration
. Bennett felt that the overall construction schedule would not be affected by eroded areas found in foundation rock (see Section B).
2.
Backfill When asked what action would be taken as a result of low j
compressive strength of backfill concrete, Bennett replied j that it would be justified in the FSAR (see Section C).
3 Batch Plant Bennett expects difficulties to be eliminated by the time structural placements begin (see Section E).
4 Quality Assurance g
The inspector emphasized to Bennett the need of having required quality control measures specified in contracts.
Bennett produced documents from Chicago Bridge and Iron, who will fab.-icate the containment lines, detailing QC measures. The inspector pointed out that no mention was made of control of the low hydrogen electrodes specified.
Bennett stated that the documents had not been accepted, and that he would make this addition.
DETAIIS A.
Persons Contacted:
H. L. Bennett, Florida Power Corporation, Construction Manager W. R. Zimmeman, Florida Power Corporation, Assistant Construction Manager E. E. Froats, Florida Power Corporation, Quality Superviser
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C. Pachos, Florida Power Corporation, Structural Construction Supervisor E. P. Shows, J. A. Jones Construction Company, Construction
- Manager R. Fleck, Gilbert Associates, Inc., Resident QA Engineer J. Harris, Gilbert Associates, Inc., Geologist R. Boyd, Consulting Geologist to Gilbert Associates O)
W. Hurst, Pittsburgh Testing Laboratory,. Resident QC Chief i
Inspector R. Parrish, Florida Board of Conservation J. Moore, Florida Boani of Conservation
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~3-B.
Site Precaration - Excavation The method of site preparation, as described in C0 Report No.50-302/69-1 is to excavate to competent rock then back-fill with a lean (1500 psi) concrete mi:t to form the foundation.
for base mat construction. Backfilling has been delayed somewhat by the discovery of weathered areas adjacent +n "e=" - in the_ f rock. The areas were determined by passing a Vibrapaktor over
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sthe' exposed limerock surface. All soft areas found have been excavated and either grouted or filled with lean concrete, depending on the size of the area.
Discovery of these soft spots has resulted in additional coring in areas still to be excavated to provide more precise planning f1 M "
of work. The inspector asked Bennett, Shows, Harris, and Boyd
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if this discovery created any doubts as to the competence of the foundation. Each expressed confidence that the only effect 1
it would have would be to create more work and delay, and that eg e
the methods of excavation, backfill, and grouting are sound.
Some difficulty is being experienced with water coming through (Q")
the grout curtain in the area of excavation for the sea water service sump. Pachos feels that this may necessitate the use,
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to some extent, of compacted, grouted rock fill, prior to placement of concrete fill.
C.
Site Precaration - Backfill Difficulties have been encountered with compressive strength of the lean concrete used for backfill. Florida Power Corporation (FPC) epecifications call for all concrete to conform to ASTM C150 for Type II, moderate heat of hydration cement. ASTM C150 states that if moderate heat of hydration is required and tests for heat of hydration are not specified, the sum of tricalcium silicate and tricalcium aluminate shall not exceed 580 Florida Portland Cement Company, the vendor, supplies a commercial Type II which exceeds this value and a moderate heat Type II which does not.
Florida Portland Cement Company furnished commerci4 Qpe for l the design mbces and for the first concrete plaev 4tich went into the mud sill under the tendon gallery.
Ir.A E.inepring l Testing Company analyzed the cement, and rea @ ; ; as con-forming to ASTM 150 Type II, and FPC persom 2
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that the 58% value for moderate heat was err neded.
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[3, When the discrepancy was noted, the proper cement was substituted.
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Concrete placed for the lower part of the containment backfill
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conformed to the specifications for moderate heat. Twenty-eight-day break tests for this lot averaged 1503 psi with a low previous five average of 1255 psi, and with 52 7% breaking below 1500 psi.
It was then decided to return to the commercial type for the remainder of the backfill. This concrete averaged, for 28-day tests, 2036 psi, and with no cylinders breaking under 1500 psi.
Note: ASTM C150 Table II, Note "e" states that when moderate heat of hydration is required, the strength requirements of mortar test cubes should be 80% of the values listed in the tables for Type II.
h3ennett was asked what action would be taken concerning the low 28-day strength of the concrete. He said that Gilbert Associates, Inc. was preparing justification for the FSAR, and that no action would be taken. He pointed out that the design load of the containment building was 16,000 psf, which gives a safety factor of 10 using the 1255 psi value of the low previous five average.
The_insoector offered no objection to this, but cointed ont-need for quality vigilance, _since the Law report was available fiefore the first concrete was placed.
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Bennett was asked what cement would be used for construction.
He replied that only Type II moderate heat would be used, and that new mixes were being designed using the correct cement.
D.
Quality Control 1.
Personnel The quality assurance organization onsite has Froats with the title of Quality Supervisor; Fleck is the Gilbert Associates' resident quality assurance engineer whose mission is to audit quality control; Hurst is Pittsburgh Testing Laboratory's (PFL) resident chief inspector who actually supervises quality control. Hurst has five resident inspectors, and at the time of this visit had two temporary inspectors from the Tampa office. According to
. Froats, Hurst has on call as many inspectors as may be needed.
2.
Observation of Performnce The inspector observed part of a 200 yard concrete placement.
Slump, air entrainment, temperature, and revolutions were i
checked on each truck at the site, and no concrete was placed from the truck until approved by PTL. The first two loads were stiff and had water added at the site after sliap j (A) l and batch records were checked. Hurst stated that PIL and v
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' the batch plant operator had obtained different values for moisture of the aggregate that day, and he then ordered the batch plant operator to use the PIL moisture values. Sub-sequent loads had the desired slump. Hurst also ordered that one truck not be used again at the site, since, as he informed the AEC inspector, the blades were worn and he considered the truck unreliable.
3 Placement Records An evamhtion of Froats' reconis revealed the following on each placement:
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A drawing showing the exact location of the placement.
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A pour slip with all applicable signatures, description of placement, and drawing reference.
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A PIL report of batch plant operations for the placement with specifications, source of materials, design sieve analysis, moisture, batch weights, and other batch
[s information.
D) d.
A PIL gradation analysis for aggregate actually used.
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PTL onsite reports for each truck.
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PTL daily reconi of batch plant control giving ingredient weights and time on each batch, and cause for rejection I
when applicable. Records for each placement were together and easily recoverable.
4 Testine A concrete block building of approximately 3000 square feet was built to house PTL facilities. PTL is equipped for sieve analysis of fine and course aggregates and for cylinder breaking. They are also capable of chemical analysis should FPC desire it. A decision has not been reached about rebar testing, but equipment may be added at the site to do this.
All equipment appeared to be in good condition, and calibration reconis on scales were up to date.
E.
Batch Plant Oceration Westcoast Concrete Company has had some difficulties in begirming O.
operations. The earlier difficulties were due, primarily, to
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getting accustomed to the new plant. Difficulties were encountered at first in getting the desired slump in the lean concrete without exceeding the allowable water-cement ratio. This was overcome by obtaining per 'ssion to increase the amount of cement, thus anowing more water tc ~ e used. Westcoast has rented delivery equipment from two - other concrete vendors. This equipment was inspected by PIL and FPC.
The PTL temporary hispectors were brought onsite due to the breakdown of Westcoast Concrete's quality control. Records showed that on April 12, 48 yands (6 loads) of concrete were rejected. Three were rejected for excessive slump, and the other three because of appearance, even though air entrainment, slu=p, and batch plant records were all right.
Investigation revealed that a new materials man at the plant had loaded sand into a coarse aggregate hopper and vice versa. The new man was there since the experienced man was fired the previous day for refusing to work on Saturday. As a result of this, FIL put two inspectors at the batch plant. Bennett stated that he had just taken the batch plant manager to task, and insisted that j
he pay more if necessary to obtain better workers.
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F.
Construction Status d
i Zi= merman gave the following tentative schedule:
Consolidation grouting of subsurface rock using a 25% concrete, 20%
fly ash, and 55% limerock flour mix should begin April 28.
i Tendon gallery walls should be placed in September, the base mat for containment in October, and the bottom liner plate in December.
G.
Environmental Survey l
The Florida Board of Conservation has two meniat the sits who -
have been in residence since January 1969. / These men, R.- Parrish and J. Moore, had numerous samples of sea creatures taken>'froni.
the Gulf of Mexico up to 13 miles from thei plant effluent. ',\\
Parrish expressed regret that surveys had not begun befoie\\
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Crystal River Unit 1, a 350 Mwe coal-fired unit, becanib.
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~j operational.. He said that extensive surveys would be.cdn-ducted at present and in the future as Unit 2, 500.Mwe coal fired, and Unit 3 become operational.
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