IR 05000440/2009008
| ML110530144 | |
| Person / Time | |
|---|---|
| Site: | Perry, 07200069  |
| Issue date: | 02/17/2011 |
| From: | Christine Lipa Division of Nuclear Materials Safety III |
| To: | Bezilla M FirstEnergy Nuclear Operating Co |
| References | |
| IR-09-001, IR-09-008 | |
| Download: ML110530144 (11) | |
Text
ary 17, 2011
SUBJECT:
NRC INSPECTION REPORT NOS. 072-00069/09-01(DNMS) and 050-00440/09-08(DNMS) - PERRY NUCLEAR POWER PLANT
Dear Mr. Bezilla:
On January 7, 2011, the U.S. Nuclear Regulatory Commission (NRC) completed its inspection of the dry cask storage pad construction activities at the Perry Nuclear Power Plant. The purpose of the inspection was to determine whether the dry cask storage pad design and construction activities were conducted safely and in accordance with NRC requirements and design specifications. At this time, the inspection of the construction phase is complete.
However, the inspection of the dry cask storage pad design and haul path is ongoing. This inspection will be completed prior to placing spent fuel on the pad and documented in a separate report. The preliminary results of the construction phase of this inspection were provided with members of your staff during an exit meeting on January 21, 2011. The enclosed report presents the results of this inspection.
The inspection was an examination of the dry fuel storage pad construction activities as they relate to safety and compliance with the Commissions rules and regulations and with the conditions of your license. Specifically, the inspectors observed placement of structural fill, reinforcement, and concrete for the storage pad. Areas examined during the inspection are identified in the enclosed report. Within these areas, the inspection consisted of selected examinations of procedures and representative records, observations of activities, and interviews with personnel.
Based on the results of these inspections, the inspectors did not identify any violations of NRC requirements. The storage pad construction activities were conducted in accordance with applicable regulations and license conditions.
In accordance with Title 10 of the Code of Federal Regulations (CFR) 2.390 of the NRCs Rules of Practice, a copy of this letter and its enclosure will be available electronically for public inspection in the NRC Public Document Room or from the NRC's Agencywide Documents Access and Management System (ADAMS), accessible from the NRC Web site at http://www.nrc.gov/reading-rm/adams.html. We will gladly discuss any questions you may have regarding this inspection.
Sincerely,
/RA/
Christine A. Lipa, Chief Materials Control, ISFSI, and Decommissioning Branch Division of Nuclear Materials Safety Docket Nos.: 72-069 and 50-440 License No.: NPF-58
Enclosures:
NRC Inspection Reports 072-00069/09-01(DNMS) and 050-00440/09-08(DNMS)
REGION III==
Docket Nos.72-069; 50-440 License No. NPF-58 Report Nos. 072-00072/09-01(DNMS) and 050-00440/09-08(DNMS)
Licensee: FirstEnergy Nuclear Operating Company Facility: Perry Nuclear Power Plant, Unit 1 Location: Perry, OH Inspection Dates: On-site: October 14 - 16, 2009; November 10 - 12, 2009; April 5 - 7, 2010; December 1 - 3, 2010 In-office review completed January 7, 2011 Inspectors: Jeremy Tapp, Health Physicist Rhex Edwards, Reactor Inspector Approved by: Christine A. Lipa, Chief Materials Control, ISFSI, and Decommissioning Branch Division of Nuclear Materials Safety Enclosure
EXECUTIVE SUMMARY Perry Nuclear Power Plant, Unit 1 NRC Inspection Report Nos. 072-00069/09-01(DNMS) and 050-00440/09-08(DNMS)
The purpose of the inspection was to observe and evaluate the licensees activities associated with construction of a new Independent Spent Fuel Storage Installation (ISFSI) pad. The design inspection of the new pad and haul path is ongoing and will be completed prior to storing fuel on the pad. The design inspection will be documented in a separate inspection report.
ISFSI Pad Construction
- The licensees site characterization was adequate and the soil compaction activities were performed in accordance with specifications, design drawings, and industry standards. (Section 1.1)
- The inspectors concluded that the construction activities for the ISFSI concrete storage pad complied with specifications contained in the licensees approved Engineering Change Package, design drawings, Civil Construction Specifications, and applicable industry standards. (Section 1.2)
2 Enclosure
Report Details 1.0 Independent Spent Fuel Storage Installation Pad Construction (60853)
1.1 Excavation and Soil Compaction Activities a. Inspection Scope The inspectors evaluated the licensees site characterization, and observed soil and engineered fill compaction activities for the new dry cask storage pad to verify the licensees compliance with its specifications, design drawings, and industry standards.
b. Observations and Findings The licensee constructed a reinforced concrete ISFSI storage pad east of the Fuel Handling Building (FHB) between the unfinished Unit 2 Plant and the Unit 2 cooling tower. The licensee excavated the soil, ensuring removal of topsoil, organic, and all undesirable material within approximately the top five feet. Rolling of the underlying in-situ material ensured that a suitable subgrade existed under the pad area. Following receipt of satisfactory compaction results for the subgrade, the licensee backfilled the area under the pad with approximately 14 inches of non-frost susceptible structural fill (engineered fill consisting of sand and gravel) and compacted it to a minimum of 95 percent of the maximum dry density as indicated in American Society for Testing and Materials (ASTM) D1557.
The inspectors observed certified personnel perform field tests to verify that each layer of structural fill met the minimum compaction, maximum dry density, and moisture content as specified in the design specifications. Field tests included both nuclear moisture density gauge methods described in ASTM D6938 and Sand-Cone methods described in ASTM D1556. All wet and dry density, moisture content, and layer thicknesses were performed correctly and within the frequencies required by the appropriate ASTM standards.
No findings of significance were identified.
c. Conclusion The licensees site characterization was adequate and the soil compaction activities were performed in accordance with specifications, design drawings, and industry standards.
1.2 Pad Construction Activities a. Inspection Scope The inspectors evaluated whether construction activities for the ISFSI concrete storage pad complied with specifications contained in the licensees approved Engineering Change Package (ECP), design drawings, and applicable industry standards. The inspectors also reviewed select material records and concrete documentation (batch plant tickets).
3 Enclosure
b. Observations and Findings The dry cask storage system selected is the Holtec International HI-STORM 100S vertical cask storage overpack and the Holtec MPC-68 multipurpose canister. The storage pad is a reinforced concrete slab 347 feet long, 75 feet wide, and 2 1/2 feet thick designed to provide a storage capacity for 80 storage casks. The storage pad is supported by a 4 inch thick concrete mat foundation set on top of approximately 14 inches of structural fill.
Placement of Reinforcing Steel After placement and satisfactory compaction of the engineered fill, the licensee placed a 4 inch concrete mat (mud mat) which provided a work surface to facilitate reinforcement bar (rebar) installation and concrete placement. The licensee then installed forms and placed rebar. The reinforced concrete was designed for a nominal compressive strength between 3,000 pounds per square inch (psi) and 4,200 psi at 28 days and the rebar conformed to ASTM A615 Grade 60 steel.
The licensee built the storage pad in five different sections, beginning with section number 5. After the forms were placed and the rebar installed, the licensee performed an inspection of the area prior to concrete placement. The inspectors reviewed the design drawings and performed an independent walk down of the proposed section 5 of the pad. The pad area was free of debris and excessive moisture. The rebar was placed in two upper and lower layers joined by U-shaped bars and the correct size of rebar was verified to be installed. The inspectors measured the spacing between the rebar and around embedments and found all measurements within the design specifications and applicable standards of American Concrete Institute (ACI) 117 and 349.
Placement of Concrete for Storage Pad The storage pad was constructed in accordance with ACI 301 and 349. The proposed ISFSI storage pad was constructed in five sections allowing five separate continuous placements of concrete. The inspectors observed concrete placement for section 5 of the main storage pad. The licensee deposited concrete in this section in one continuous placement. The licensee checked the concrete batch tickets for every truck to confirm that each concrete batch was mixed as specified in the mix design and the mixing time and number of drum revolutions satisfied code requirements to ensure the concrete was suitable for placement. The inspectors checked a random sampling of batch tickets to independently confirm the batches were mixed as specified in the mix design and the mixing time and number of drum revolutions satisfied code requirements. The inspectors observed that the concrete was transported by conveyor belt and deposited in the areas of placement as indicated by the forms. The inspectors noted that the contractor staff maintained careful control of the discharge hose and ensured that concrete had an unrestricted vertical drop to the point of placement to prevent segregation of the aggregate. The contractor used a systematic pattern of vibration to ensure proper consolidation, thereby preventing voids in the concrete slab. The licensee applied a broom finish to the pad, as required by the design, in order to achieve the appropriate surface friction factor.
4 Enclosure
Concrete Field Tests The licensees contractor obtained concrete samples approximately every 50 cubic yards for the first 300 yards, then every 100 yards thereafter in accordance with the design specification. With each concrete sample, the licensee tested air content, temperature, and slump. The inspectors observed the conduct of the field tests and noted that they were performed satisfactorily and in accordance with ASTM standards.
During testing of ISFSI Storage Pad section 5, one slump and one air content measurement were outside the acceptance criteria. The licensee documented this non-compliance in Condition Report (CR) 09-67691, 525 YARD POUR FOR SFDS PAD
- 5 HAD 2 TEST RESULTS IN NON-COMPLIANCE WITH SPECS. Since the associated concrete was placed as a top lift, the licensee visually evaluated for non-conforming appearance during curing. The licensee also took cylinders from this batch truck and performed strength testing to verify it was in compliance with the concrete strength specifications. The results for these test cylinders were within specification. In addition, during testing of ISFSI Storage Pad section 4, one slump test was outside the acceptance criteria. The licensee documented this in CR 09-68563, 510 YARD POUR FOR ISFSI PAD #4 HAD 1 TEST RESULT IN NON-COMPLIANCE WITH SPECS.
Since the associated concrete was placed as a bottom lift, the contractor made adjustments to the target initial slump values to ensure this condition would not occur again. The licensee also took cylinders from this batch truck and performed strength testing to verify it was in compliance with the concrete strength specifications. The results for these test cylinders were within specification.
In addition to the field tests, the contractor collected concrete samples in cylinders for the concrete strength tests. The cylinders were adequately stored in accordance with ACI and ASTM standards. The cylinders were cured and tested after 28 days by an independent laboratory to measure the compressive strength of the concrete. The inspectors reviewed the 28 day concrete compressive strength test results to ensure they met the minimum strength of 3,000 psi and maximum of 4,200 psi as specified by the design requirements. All results were in accordance with the design certification and applicable code requirements.
In addition to field observations, the inspectors reviewed documentation regarding the batch plant certification which was certified for production in accordance with the National Ready Mixed Concrete Association.
No findings of significance were identified.
c. Conclusion The inspectors concluded that the construction activities for the ISFSI concrete storage pad complied with specifications contained in the licensees approved ECP, design drawings, civil construction specifications, and applicable industry standards.
5 Enclosure
2.0 Exit Meeting Summary On January 21, 2011, the inspectors conducted an exit teleconference to present the results of the inspection. The licensee acknowledged the findings presented and did not identify any information discussed as being proprietary in nature.
ATTACHMENT: SUPPLEMENTAL INFORMATION 6 Enclosure
SUPPLEMENTAL INFORMATION PARTIAL LIST OF PERSONS CONTACTED Licensee Neil Bonner - Engineering Lead, Dry Cask Storage Jeff Fox - Project Manager, Dry Cask Storage Pete Roberts - Project Manager, Dry Cask Storage Ben Spiesman - Fleet Regulatory Affairs Paul Wilson - Engineering, Dry Cask Storage Lloyd Zerr - Regulatory Compliance INSPECTION PROCEDURES USED IP 60853 Construction of an Independent Spent Fuel Storage Installation ITEMS OPENED, CLOSED, AND DISCUSSED Opened Type Summary None Closed None Discussed None LIST OF DOCUMENTS REVIEWED CR 09-67691; 525 YARD POUR FOR SFDS PAD #5 HAD 2 TEST RESULTS IN NON-COMPLIANCE WITH SPECS; November 12, 2009 CR 09-68563; 510 YARD POUR FOR ISFSI PAD #4 HAD 1 TEST RESULT IN NON-COMPLIANCE WITH SPECS; December 4, 2009 Drawing No. 498-0004-00000; SFDS Project ISFSI Cask Storage Pad Plan, Sections & Details; July 23, 2009 ECP No. 04-0278-003; ISFSI and Cask Fabrication Area; Revision 0 Attachment
LIST OF DOCUMENTS REVIEWED (continued)
G58-S-R-G-010; Geotechnical Design Report for the Proposed Independent Spent Fuel Installation ((ISFSI); August 18, 2009 Construction Engineering Consultants, Inc; Cask Storage Pad Concrete Slab Perry Nuclear Power Plant - South of Electric Vaults 68 &69; January 15, 2010 LIST OF ACRONYMS USED ACI American Concrete Institute ADAMS Agencywide Documents Access and Management System ASTM American Society for Testing and Materials CFR Code of Federal Regulations CR Condition Report DNMS Division of Nuclear Material Safety ECP Engineering Change Package FHB Fuel Handling Building ISFSI Independent Spent Fuel Storage Installation NRC U.S. Nuclear Regulatory Commission psi pounds per square inch 2 Attachment