IR 05000428/2006029

Insp Repts 50-528/85-17,50-529/85-19 & 50-530/85-13 on 850428-0629.No Violation or Deviation Noted.Major Areas inspected:as-built Configuration & Documentation of Unit 2 Main Steam Supply Sys

ML20133P099
Person / Time
Site:	Palo Verde, 05000428
Issue date:	07/19/1985
From:	Ball J, Hernandez G, Miller L NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V)
To:
Shared Package
ML20133P088	List: IR 05000428/2006029 ML20133P086
References
50-528-85-17, 50-529-85-19, 50-530-85-13, NUDOCS 8508140144
Download: ML20133P099 (12)

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U. S. NUCLEAR REGULATORY COMMISSION

REGION V

Report No /85-17, 50-529/85-19, and 50-530/85-13 Docket No , 50-529, and 50-530 License N NPF-34 Construction Permit Nos. CPPR-142 and 143 Licensee: Arizona Nuclear Power Project Post 0ffice Box 52034 Phoenix, Arizona 85072-2034 Facility Name: Palo Verde Nuclear Generating Station Unit Nos. 1, 2, and Inspection Conducted: Apr,il 8 - J 1e 29, 1985

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Inspectors: 1 7'[ f-b G. U ernandez. Sen Resident Inspector Date Signed h '

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J . R' Ball, Res' ent Inspector Date Signed Approved By: 7-/f-75 L(/ F. Miller, Chief Date Signed Reactor Projects Section No. 2 Summary:

Inspection from April 28 - June 29, 1985 (Report Nos. 50-528/85-17, 50-529/

85-19 and 50-530/85-13).

Areas Inspected: A routine, onsite inspection by the Construction Resident Inspectors of activities related to the as-built configuration and documenta-tion of the Unit 2 Main Steam Supply System, observation of Unit 2 work activities related to safety related components and piping, review of quality records related to safety related components, investigation of Allegation N RV-85-A-006 and close out of NRC Temporary Instruction No. 2512/1 The following I.E. Manual Chapters were utilized during this inspection:

Module Nos. 37501, 49065, 50074B, 50075B and 5007 The inspection involved 468 inspector hours on site by two NRC Resident Inspector Results: In the areas inspected, no deviations or violations of NRC require-ments were identifie %6 G

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DETAILS t i

1. Persons Contacted Arizona Nuclear Power Project (ANPP)

E. E. Van Brunt, Jr., Executive Vice President J. G. Haynes, Vice President, Nuclear Production D. B. Karner, Assistant Vice President, Nuclear Production

• J. R. Bynum, Plant Manager W. E. Ide, Corporate Quality Assurance Manager D. B. Fasnacht, Nuclear Construction Manager W. F. Quinn, Licensing Manager A. C. Rogers, Nuclear Engineering Manager

• L. A. Souza, Assistant Corporate Quality Assurance Manger

• C. N. Russo, Quality Assurance-Audits / Monitoring Manager D. E. Fowler, Quality Control Manager T. A. Shriver, Quality Systems Engineering Manager R. J. Burgess, Field Engineering Supervisor S. G. Penick, Quality Assurance Monitoring Supervisor J. C. Sherrin, Quality Document Review Group Supervisor A. T. Ramey, Quality System Supervisor r K. R. Daley, Quality Assurance Engineer M. L. Provost, Quality Assurance Engineer

• W. W. Montefour, Quality Assurance Engineer D. M. LeBoeuf, Quality Assurance Engineer H. L. Green, Quality Assurance Engineer W. J. Gratza, Quality Assurance Engineer

• T. J. Bloom, Licensing Enginear Bechtel Power Corporation (Bechtel)

W. J. Stubblefield, Project Manager S. M. Nickell, Project Superintendent W. G. Bingham, Project Engineering Manager

• J. L. Black, Chief Resident Engineer T. L. Horst, Project Field Engineer

• D. R. Hawkinson, Project Quality Assurance Manager

• H. A. Foster, Project Quality Control Engineer H. A. Hear, Assistant Project Quality Control Engineer J. Waddington, Assistant Project Quality Control Engineer R. Ruff, Lead Electrical / Instrumentation Quality Control Engineer G. Griffin, Lead Civil Quality Control Engineer  :

• W. A. Miller, Construction Engineer >

• W. P. Murphy, Project Superintendent The Waldinger Corporation (TWC)

R. R. Strait, Project Engineer

• Denotes personnel attending the NRC Exit Management Meeting conducted on June 28, 1985.

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The inspectors also talked with other licensee and contractor personnel

during the course of the inspectio . Plant Status Unit One: Testing is in progress with Unit I at the 20% power plateau.

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Unit Two: Unit 2 is undergoing precore Hot Functional Testing. Fuel Load for Unit No. 2 is scheduled for December 198 Unit Three: All major components and equipment have been installe ,

Unit 3 has a scheduled fuel load date of March 1987, i

Construction completion of Unit 3 is estimated at 95% by l the license . Review of As-Builts - Unit No. 2 As-Built Verification This inspection compared the as-built condition of portions of the Unit No. 2 Main Steam Supply System, with design, installation and quality assurance document Areas Reviewed: Piping System Installation I

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The following documents and areas were reviewed: piping and instrumentation diagrams, piping and instrument sensing line plans and isometrics, large and small pipe installation control cards, valve installation records and completed construction inspection plans for instrumentation installations. The physical inspection of the piping and sensing line runs includ-ed location, size and configuration, support type and location,

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and valve location and orientation. The installation of the l

following pipe spools and associated pipe supports (totaling approximately 300 feet of piping for the Main Steam Supply System located in the MSSS Building) was examined:

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2-SGE-206-S001 28" Main Steam Line 2-SGE-207-S001 28" Main Steam Line 2-SGE-208-S001 28" Main Steam Line 2-SGE-209-S001 28" Main Steam Line l 2-SGE- 95-S003 through S006 4" Main Steam Bypass Line i 2-SGE-100-S003 through S006 4" Main Steam Bypass Line 2-SGE-192-N00A through NOOD and NOAA 1" Main Steam Line

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2-SGE-194-N00A through NOOD and NOAA 1" Main Steam Line Drain i

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The installation of the following valves was examined:

Valve Numbers Description 2JSGE-UV-170, 171, 180, 181 Main Steam Isolation Valvea

.2JSGE-UV-169 and-183 Main Steam Isolation

., Bypass Valves 2JSGE-UV-ll35A and B Main Steam Drain

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Isolation Valves j 2JSGE-PSV-554 through 561, 572 Main Steam Safety j through 579, 691, 692, 694 and 695 Relief Valves The installation of sensing lines for the following instruments l was also examined:

Instrument Tag Number Description 2JSGA-PT-1023A Steam Generator #2 Pressure -Channel A 2JSGB-PT-1023B Steam Generator #2 Pressure -Channel B 2JSGC-PT-1023C Steam Generator #2 Pressure -Channel C l 2JSGD-PT-1023D Steam Generator #2 Pressure -Channel D 2JSGB-LT-1023B Steam Generator #2 Wide Range Level-Channel B

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2JSGB-LT-1024B Steam Generator #2 Narrow Range Level ;

i-Channel B 2JSGD-LT-1123D Steam Generator #2 Wide Range Level-Channel D

! 2JSGD-LT-1124D Steam Generator #2 Narrow Range Level j -Channel D I No deviations or violations of NRC requirements were identified.

, Electrical System Installation

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j The following documents and areas were reviewed: elementary and I i cable block diagrams, instrument loop diagrams, cable code and '

{ cable scheme numbers, single line diagrams, cable type and identification, including separation color and cable markers

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i 580 computer program sorts for routing, identification of

! cables at tray points, and size and type of cable, physical separation criteria, including raceway and tray designations, conduit and tray arrangement drawing, raceway installation cards, cable installation cards, and cable installation spec-

ifications. The physical inspection of the cable runs included a determination of size, type, routing, protection, separation, identification, loading, cable supports and cable spacing. The

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actual cable installation and routing was compared to the l design as determined from the E580 computer program and the

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cable installation card ,

I The installation of the following power, control and instrument cables for the Main Steam Supply System were examined:

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i Cables Equipment / Instrument To Location i 2ESG23ACIRD Main Steam Isolation Valve Main Steam and

, (MSIV) 2JSGE-UV-170 Feedwater Isola 2ESG23AC2RD MSIV 2JSGE-UV-171 tion Actuation 2ESG23AC3RD MSIV 2JSGE-UV-180 System (MSFIS)

l 2ESG23AC4RD MSIV 2JSGE-UV-181 Cabinet 2JSGAC01 2ESG23BCIRD Main Steam Isolation Valve Main Steam and (MSIV) 2JSGE-UV-170 Feedwater Isola-

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2ESG23BC2RD MSIV 2JSGE-UV-171 tion Actuation 2ESG23BC3RD MSIV 2JSGE-UV-180 System (MSFIS)

2ESG23BC4RD MSIV 2JSGE-UV-181 Cabinet 2JSGBC01

2ESG23AC MSFIS Containment Engineered Safety l 1 to 4 RG 2JSGAC01 Features Actuation (ESFAS) Auxiliary Relay Cabinet 2JSAAC01 2ESG23BC MSFI Containment ESFAS Auxiliary 1 to 4 RG 2JSGBC01 Relay Cabinet i 2JSABC01 2ESG58ACI XA MSIV 2JSGE-UV-170 instrument Cabinet and XE Accumulator Pressure ZJA-C02B

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A-PT-229

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2ESG58ACI XA MSIV 2JSGE-UV-171 Accumulator Pressure i A-PT-233

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2ESG58ACI XB MSIV 2JSCE-UV-180 Accumulator Pressure A-PT-231

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2ESGS8AC2 XB MSIV 2JSGE-UV-181 and XF Accumulator Pressure i

A-PT-235

! 2ESG72BC1 XA MSIV 2JSGE-UV-170 Instrument Cabinet and XE Accumulator Pressure ZJB-C02A

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A-PT-230

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2ESG72BC2 XA MSIV 2JSCE-UV-171 and XE Accumulator Pressure A-PT-234

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2ESG72BC1 XB MSIV 2JSGE-UV-180 and XF Accumulator Pressure A-PT-232

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2ESG72BC2 XB MSIV 2JSGE-UV-181 and XF Accumulator Pressure A-PT-236 2ESG63DCl XA Steam Generator #1 Electrical Pene-and XB Pressure Channel D- tration Assembly D-PT-1013D 2ESPDZ771

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2ESG63DCI XA Steam Generator #2 and XB Pressure Channel D-D-PT-1023D No deviations or violations of NRC requirements were identifie Applicable Specifications and Procedures The following specifications and Work Plan procedures / Quality Control Procedures (WPP/QCI) governing the installation of piping, instrumentation and electrical cables were reviewed during this inspection:

. 13-PM-204 Specification for Field Fabrication and Installation of Nuclear Piping Systems

. WPP/QCI 202.0' Piping-Systems Installation

. 13-EM-300 Installation Specification for Electrical Cables in Cable Trays

. 13-EM-301 Installation Specification for Electrical Cables in Conduit and Duct Banks

. 13-EM-303 Installation Specification for Electrical Cables and Raceway Identification

. WPP/QCI 251.0 Raceway Installation

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WPP/QCI 254.0 Cable Installation

. 13-JM-702 Installation Specification for Electrical Instruments and Controls WPF/QCI 302.0 Instrument Installation

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WPP/QCI 2 Field Change Request

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WPP/QCI 2 Design Change Package No deviations or violations of NRC requirements were identifie Findings The inspector reviewed three design change packages (DCP's) as they related to documenting the as-built condition of the plan The following DCP's were reviewed:

DCP 2SMSG-069 Installation of Additional Main Steam Line Drain Lines DCP 2SJSB-021 Revised Condensate Pot Installation for Safety-Related Instrument Sensing Line DCP 2SESB-033 Cable Splices inside Containment Penetrations for Post-Accident Monitoring Instrumentation The inspector'found the as-built condition of the plant did reflect the implementation of the approved changes. The inspector noted, however, that DCP 2SMSG-069 had not been reviewed by the Project Quality Assurance Engineer prior to its implementation as require The change did affect safety-related piping and instrumentation .

diagrams. The licensee informed the inspector that this problem had )

been previously identified and corrective action was

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currently being taken under Corrective Action Request (CAR)

PVH52/85-09A dated April 22, 1985. The inspector stated that this corrective action appeared adequate to resolve this discrepanc The inspector also reviewed nonconformance reports (NCR's) and field change request (FCR's) as they related to documenting the as-built condition of the plant. Note 10 of piping isometric 13-P-SGF-155 required specific clearances be maintained around the main steam isolation valves to accommodate the thermal and seismic movements of these valves. FCR 85463-C dated November 9, 1984, was written to notch a W12x40 structural beam which was found to interfere with the movement of main steam isolation valve 2JSGE-UV181. Startup Field Report (SFR) number 25G-6014 was written May 24, 1985, and indicated that the interference still existed. FCR 91167-M was written to increase the size of the notches to alleviate this proble Although the interference problem was eventually resolved satisfactorily, the licensee failed to document this problem using a nonconformance report. This should have been done since the installation of the valve had been accepted by Quality Control on September 9, 1983, as having been installed in accordance with piping isometric 13-P-SGF-155. The use'of FCR's in lieu of NCR's has been previously addressed in NRC inspection report 50-528/84-3 The inspector reviewed the current status of the licensee's actions relating to a commitment made by the licensee to assess the current use of FCR's and the effectiveness of past corrective action (Re Followup Item 50-528/84-39-01). Corrective Action Request, CAR PVH 4/84-26A was written December 14, 1984, and addresses this concern over the current use of FCR's. As of this report, the above CAR l remained open awaiting additional investigation into the extent of '

this problem and definition of corrective: action which may'still be required. Followup item 50-528/84-39-01 remains open until the licensee has completed act-ions relate'dt to close out of this CA ; ., w *

No deviations or violations of'NRCirequirements were4 identifie . Safety Related Components - Unit No. 2 ;

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s Observation of Work and Work Activities'

The inspector observed completed work on nine components within the reactor coolant pressure boundary and on four components located outside the_ reactor coolant pressure boundary. The inspection determined that the components selected met the applic'able require-ments for storage, handling, installation and protection after installation. The following components were selected: Reactor Coolant Loop Piping and Valves.

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Valve Number Loop Number Serial Number o 2PCHEV431 009 28632 o 2PCHVAM41 520 4903AAL o 2JCHAHV205 520 4 o 2JCHBHV203 521 3 s

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Piping Subassembly o 2CH009N00A-0 o 2CH520N00A-1 o 2CH520N00B-1 o 2CH520N00C-0 o 2CH520N00A-5 Other Safety System Components Valve Number Line Number Serial Number o 2JCHAHV524 2CH-003 26978 o 2PCHEVM70 2CH-015 74379 o 2PCHEVM76 2CH-015 NAK-62 o 2PCHBV331 B259 51321 No deviations or violations of NRC requirements were identifie Review of Quality Related Records The inspector reviewed the pertinent records for these safety related components to assure that the records reflected work accomplishment consistent with NRC requirements and SAR commitment The inspector reviewed the following records for each of these component o Code Data Packages o Construction Inspection Plans (CIP)

o Nonconformance Reports (NCR)

o Modification Change Notices (MCN)

o Certified Material Test Reports (CMTR)

o Field Change Requests (FCR)

o NDE Reports o Torquing Sheets o Records of Internal Cleanliness Checks o Receipt Inspection Records o Storage Inspection Records No deviations or violations of NRC requirements were identifie Review of Quality Assurance Audits Three of the licensee's most recent audits associated with safety related components were reviewe The following audits were

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examine o Quality Assurance Audit Report Number 84-034 l

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o Unscheduled Project Quality- Audit Number UA-84-56 o Joint Bechtel/APS Audit Number 62-S-85-10 The audits were found to appropriately identify and resolve audit findings in accordance with the licensee's audit program.

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No deviations or violations of NRC requirements were identified.

Qualification of Quality Control Inspe,ctors The qualification of eight mechanical, three receiving, and nine welding Quality Control Inspectors were reviewed. The records were reviewed for education, work experience prior to certification, eye

examinations, training received and other pertinent dat In all cases, the qualification of the inspectors met or exceeded the qualification requirements of ANSI N45.2.6-197 No deviations or violations of NRC requirements were identifie . Safety Related Piping - Unit No. 2 Review of Quality Records

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The inspector reviewed the pertinent records for the following safety related piping components to assure that the records reflect work accom-plishment consistent with NRC requirement and SAR commitment Drawing Number Spool Number Hanger Number 13-P-SIF-103 5005 2-SI-193-H017 13-P-SIF-105 5004 2-SI-193-H007 13-P-SIF-105 5006 2-SI-240-H007 13-P-SIF-105 5007 2-SI-240-H010 13-P-SIF-201 5007 2-SI-307-H003 13-P-SIF-201 5038 2-SI-307-H014

, 13-P-SIF-201 5001 2-CH-424-H006 13-P-SIF-201 5009 2-SI-307-H005 13-P-SIF-201 5008 2-SI-307-H006 13-P-SIF-201 5006 2-SI-307-H002 13-P-SIF-202 5002 2-CH-425-H008 13-P-SIF-202 5001 2-CH-425-H006 13-P-SIF-202 5013 2-SI-308-H010 13-P-SIF-202 5011 2-SI-308-H008 The inspector reviewed the following records for each of the above piping componen .

o Construction Installation Plans (CIP)

o Certified Material Test Reports (CMTR)

o Nonconformance Reports (NCR)

o Field Change Requests (FCR)

o Pressure Test Records o NDE Reports o Welding Field Checklist o Valve Installation Checklists o Valve Flange Torquing Data Sheets No deviations or violations of NRC requirements were identified.

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6. Allegation No. RV-85-A-006 (0 pen)

l l Cha racterization:

On January 22, 1985, an alleger contacted the NRC Resident Inspector's office by telephone and related the following concerns:

1) During installation of the 42" Containment Purge Valves, the valves were found to exhibit rust damage due to improper storage.

I 2) During installation of a Unit No. 2 Heating, Ventilating and Air Conditioning (HVAC) safing plate, the plate was cut without obtain-ing the proper reviews and approval On May 30, 1985, the alleger called the NRC Resident Inspector's office and related a number of concerns including that he believed that HVAC pressure tests had been falsifie Implied Safety Significance to Plant Design, Construction or Operations:

The failure of the 42" Containment Purge valves to function as designed could cause the 10 CFR Part 100 limits to be exceeded during accident conditions. The failure to obtain the proper engineering approvals prior to cutting of the HVAC safing plate could effect the proper function of the components and may indicate a problem with personnel training and failure to follow procedural requirements. The failure of the HVAC system to function as design could effect the safe operation or the safe shut down of the plant during an emergenc Assessment of Safety Significance:

Containment Purge Valve Allegation In order to resolve this allegation, the inspector examined the contain-ment purge valve receipt inspection, the storage inspection, the ware-house requisition and installation records for all three units. The inspector also examined the storage requirements as specified by the manufacturer and as contained in Specification No. 13-JM-605, and examin-ed all Nonconformance Reports (NCR) written on discrepancies identified during the receipt, storage and installation activitie Additionally, because the alleger had also stated that he had called the APS Hot-line on the containment purge valves on or about June 1984, the inspector examined the APS Hot-line and Special Hot-line log books dating back to the program inception, November 17, 1982 and August 28, 1984, i respectivel l The inspector's investigation found that none of the Nonconformance Reports written against the containment purge valves during receipt, storage or installation concerned or addressed a problem with rust damage to the valves. The inspector's review of the APS Hot-line and Special Hot-line log determined that the APS Hot-line logs did not have a record of a concern regarding rust damage to the containment purge valves. On May 21, 1985, the inspector contacted the alleger to obtain further l

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information on his concerns. At this time the alleger stated he had never made a phone call'.to the NRC on problems with the containment purge valves or the HVAC safing plate. The alleged alleger stated his belief that somebody had apparently used his name to discredit him with the company. This individual stated that the problem with the containment purge valves occurred over four years ago and at that time the contain-ment purge valves were requisitioned from the warehouse by Bechtel and stored next to the Waldinger lay down area for over a year. The indivi-dual reported the improper storage and rust on the valves to his super-visors. The valve problems were corrected in accordance with the licensee's procedures and the individual was satisfied with the action The inspector (to further assure that containment purge valves would function as designed), reviewed the local leak rate tests for Units 1 and The test date indicated that all valves were found to pass the leak tightness criteria as required by the FSAR. The local leak rate tests had not been performed on the Unit No. 3 containment purge valves, at the time of this inspectio HVAC Safing Plate Allegation The concern regarding the cutting of the HVAC safing plate was also alleged to be a concern of this individual, however the individual stated problem was addressed in accordance with the licensee's procedures and the individual was satisfied that everything was taken care of as re-quired by the quality progra To further assure that the problem had been handled in accordance with the licensee's program, the inspector reviewed the Nonconformance Report (Waldinger NCR No. 1068 F/II), the Bechtel Field Change Request (FCR N .254-P), and the Supplier Deviation Disposition Request (SDDR N ), which documented the craft error of trimming more of the safing plate then was allowed by the requirements. All the documents appeared to have been prepared and dispositioned in accordance with the applicable requirement HVAC Pressure Test Allegation A preliminary review of the HVAC pressure tests referred to by the alleger do not indicate that the tests were improperly performe However, the investigation into whether persons knowingly falsified the pressure tests is continuing with the aid of the NRC Office of Investigation Other Related Allegations (RV-85-A-034, RV-85-A-040) i The alleger in his May 30, 1985 phone call to the NRC made certain other '

allegations related to other licensee contractor personnel. The alleger stated that he has made Bechtel aware of all these allegations. The '

inspector confirmed that Bechtel is aware of all the allegations made by I this alleger, and is actively pursuing resolution of these allegation These allegations will be reviewed during a future inspectio ,_, ,_ _ _

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Staff Position The two allegations related to the containment purge valves and the HVAC safing plate are considered by the staff to be resolved, and are close The investigation into the allegations related to HVAC Pressure Tests is continuing and will be discussed in a future inspection repor The licensee is pursuing the other allegations and the NRC's conclusions regarding whether these allegations effect or impact on safety will be reported in a future inspection repor NRC Temporary Instruction (TI) 2512/11

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1 On February 21, 1984, the NRC issued Temporary Instruction (TI) 2512/11 to increase inspection coverage in areas of nuclear plant construction found by past experience to be in-need of improved licensee performanc The areas that were targeted for increased inspection effort were Heating Ventilating and Air Conditioning (HVAC) Systems, Pipe Supports, "As-

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built" Systems Inspections, and Craftsmen Qualifications and Training Programs. For Palo Verde, the regional and resident inspection program has performed a number of inspections in these areas. The inspection scope and results are documented as follows:

Type of Inspection: NRC Inspection Report Number:

o Pipe Supports 50-528/83-34, 84-38, 84-45 and 84-48 o HVAC Systems 50-528/83-34, 84-10, 84-21, 84-25 and 84-45 o As-built Systems 50-528/83-34, 84-38, 84-45, 84-48, 85-16 and 85-17 o Craftsmen Qualification and Training 50-528/85-02 Based on the above referenced inspection effort, Temporary Instruction (2512/11) is close No deviations or violations of NRC requirements were identified.

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8. Inspection Tour of Site On a weekly basis, the inspector and licensee representatives tour the site to observe general housekeeping conditions, care and preservation of equipment, handling of components, tagging and identification of materia No violations or deviations with NRC requirements were identifie . Exit Interview The NRC inspectors met on June 28, 1985, with licensee management repre-sentatives denoted in paragraph 1. The scope of the inspection and inspection findings as noted in this report were discussed.