IR 05000528/1976003
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U. S. NUC1. EAR REGULATORY CCW.ISSION OFFICE OF' INSPECTION AND ENFORCE..:.NT
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REGION V
IE Inspection Report No.
50-528. 50-529, 50-530/76-03 50-528 Licensee Arizona Public Service Ccmcany Docket No.
50-529, 50-530
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P. O. Box 21666 License No. CPPR-141, la2, 443 Phoenix, Arizena 85036 Priority
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racility Palo Verde Units 1-3 category A
Location Buckeve, Arizona Type of Facility PWR's (CE)
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Type of Inspection Routine, Unannounced Dates of Inspecti:n Sectember 21-24, 1976 Dates of Previous Inspection Aoril 28-30, 1976
/ !f!'7d Principal Inspector
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/ D'at e R. J/ Pate, Reactor I spector
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Accompanyir.g Inspecters N' [ ;
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/ Date W F~.Mrrsch, Reactor Inspecter Date lione Other Accc=penying Personnel:
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Reviewed by
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Date G.S. Spencer,dief,ReactorConstructionandEngineering Support Branch IE:V Form 219 8508150513 050703 (b CH$
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SUT'.APY OF FINDINGS
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Enforcenent Acticn
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1.
The qualification records of the Engineers Testino Laboratory personnel did not conferm to the requirements of ASME Section III, Division 2, Appendix VII, referenced in the Specificatien No.
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13-CM-191.
(Paragraph 13.b.(3) of Details)
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The Engineers Testing Laboratcry equipnent calibration records for the equipmen: used to develop the design mixes for the Palo Verde plant were not maincained as required by Criterion XVII of 10 CFR 50, Appendix B, and Section 7.4 of the Engineers Testing Laboratcry Quality Assurance Manual.
(Paragraph 13.b.(3)ofDetails)
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Licensee Action on Previcusly Identified Enforcement Items Not applicable.
Other Sionificant Findinos
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A.
Current Findines
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.1.
A soft rust was noted on the rebar for the auxiliary building
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(Paragraph 6 of Details)
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The licensee idertified that the training' records of field engineers had not been maintained as required.
(Paragraph 7 of Details)
3.
The licensee has not determined what provisions will be made to preclude unplanc.ed cold joints.
(Paragraph 13.a.(1) of Details)
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4.
Special cre:autions for concrete curing in hot weather (Per
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ACI 205-72) have r:t been included in the construction specification.
(Paragraph 13.a.(3)ofDetails)
5.
The constructicn s:ecification and procedures recuired that the slump measurement sample be taken at the discharge of the truck instead of at the discharge of the punp line.
(Paragraph 13.a.(3)and(4)ofDetails).
6.
The Champion, Inc. QA program appeared to be deficient in the following areas:
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-2-(a) The duties of the QC engineer were not. clearly.
established.
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(b) A training program had not been established.
(c) An audit program had not been established.
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(d)
Sufficient numbers of qualified personnel had not been provided.
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(Paragraph 13.b.(1)ofDetails)
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The United-Metro, Inc., QA program appeared to be deficient in the following areas:
(a) The qualification records of inspection personnel had
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not been maintained.
(b) Appropriate corrective action was not documented when nonconforming material was identified.
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Conforming and nonconforming materials were not uniquely c
identified.
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(Paragraph 13.b.(2) of Details)
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B.
Status of Previcusiv Reported Unresolved Items The followine items which were identified durino the orevious inspections (F.eportNos. 50-528/76-01 and 50-525/75-O') have been l
closed.
1.
APS audit schedule of major contractors.
(Paragraph 4.a.(1)ofDetails)
2.
Site construction procedures.
(Paragraph 4.a.(4)ofDetails)
3.
Audit of NUS Corporation.
(Paragraph 4.a.(3)ofDetails)
4.
APS review of the documents in QAD 5.0, Attachment A.
(Paragraph 4.a.(2)ofDetails)
Manaccrent Incerview The results of the inspection were discussed with Mr. Van Brunt and other
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The following items summarize the discussion at the exit meeting.
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The status cf previcusly idertified unresolved items was reviewed.
The inspector noted that all the items identified.by the NRC inspectors were clescd. However, an item on improper filing identified by APS was held cpen pending completion cf the records review and verification of the effectiveness of the corrective action.
(Paragraph 4.bofDetails)
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B.
The need for provisions to meet the requirement of Regulatory Guide 1.55 to preclude unplanned cold joints in concrete place-
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nents was discussed. The licensee's management personnel stated that the methcd of.eeting the requirement of Regulatory Guide 1.55 had not been resolved but that the requirement would be met.
(Paragraph 13.a.(1)).
C.
The need for special precautions for hot weather curing conditions in the specificaticn and procedures for preplacement, placement and postplacement of concrete was discussed. The licensee's management personnel stated that the aporopriate specification and procedures would be revised to include special precautions for hot weather conditions.
(Paragraph 13.a.(3) of Details)
D.
The rea'uirement to sample pumped concrete at the pump line discharge was discussed.
The licensee's management personnel stated that the appropriate specifications and procedures would be revised to include this requirement. ~~(Paragraph 13.a.(3) and (4) of Details)
E.
The deficiencies in the QA programs.of Champion, Inc., United-Metro Inc., and Er.gineers Testing Laboratory were discussed.
The licensee's management stated -hat an audit of each of these programs has been planned. The cceplete CA system of each of the contractors will be included in these audits.
The items identified by the NRC inspector will be reviewed and a:propriate corrective action will be initiated.
(Paragraph 13.b of Details)
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-4 DETAILS 1.
Persons Contacted Arizona Public Service Cccoany (APS)
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E. E. Van Brunt, Jr., Vice President, Construction Projects and AtlPP Director
J. A. Roedel, Quality Assurance Manager R. Hand, Site QA Supervisor B. S. Kaplan, Quality Systems Supervisor Bechtel Power Corcoration (Bechtel)
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C. Betzhold, Project QA Engineer R. W. Herrman, Field Contracts Administrator D. C. LaValla, Lead Civil QC Engineer W. F. Sturm, Civil GC Engineer J. A. Packard, Field Construction Manager A. K. P.riest, Project Fiela Engineer
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R. E. Ramsey, Office Engineer H. P. Smith, Project Field QC Engineer R. L. Lyknes, QC Engineer L. L. Blackburn, Decument Control Engineer B. Hamilin, Warehouse Supervisor
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J. Beers, QA Engineer P. A. Albertson, Survey Supervisor Chamoion, Inc. (Chamoion)
P. Schmanski, Plant Supervisor K. C. Holman, QC Engineer United-Metro, Inc. (UM)
R. Morrison, Vice Presicent, Special Products R. Stearman, OC Cirector G. Hunt, QC Technician Encineers Testine Laboratory (ETL)
J. G. Bennitt, Executive Vice President J. J. Danielski, Project Coordinator D. J. Hams, Chief Engineer, Quality Assurance
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Organization Mr. Van Brunt has been given additional responsibilities within APS. He is now responsible for all APS construction projects including the Palo Verde Nuclear Generating Station.
Mr. Van Brunt's title has been changed to Vice President and AMPP Director, Construction Projects. This change appears to have no affect on the
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Palo Verde Nuclear Power Station.
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Two additions have been nade to the OA organization.
Mr. S. S. Kaplan has joined the Nuclear Services staff as Quality Systems Supervisor; Mr. D. D. Webster has joined the site QA staff as the Site QA Engineer.
3.
Project Status The project is reported to be five percent complete.
This is divided as follows:
Engineering & Procurement - 47%
Construction 1%
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4.
Followuo of Prev'icusly Identified Unresolved Items a.-
The following concerns, identified during previous inspections, were examined and closed out.
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(1) The audit schedule for audits conducted by APS QA was reviewed.
The implementation of the audit schedule appears to be satisfactory.
(2) The list of documents in OAD 5.0, Attachment A, has been reviewed by APS, and the documents which require review and acceptance by APS have been delineated.
APS personnel stated that the list may be removed frem CAD 5.0 but will be available for future NRC review.
(3) APS perscnnel stated that an audit of the NUS Corporation after October 15, 1974 was not required as NUS was not involved in any activities affecting quality after that time.
(4) The construction procedures for PVNGS were reviewed and found to be acceptable.
The procedures ap; eared ade:uate to govern the activities in progress or planned for the near tern.
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One item will remain open from previous inspections. APS management identified that some of the Palo Verde documents
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had been improperly filed and corrective action had been
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initiated. A review of the corrective action records indicated the dccuments received by APS during October,
November and December of 1975 were not checked for filing errors; although, this period was included in the time interval
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in which impreper filing was suspected to have occurred.
Also, it was determined that a followup audit had not been conducted to verify the effectiveness of the corrective action.
5.
Audits by APS The audits of the Bechtel site organization, conducted by APS site,
QA, were reviewed.
The audit scope, planning, and results appeared to be adecuate.
Procedures were implemented for initiating corrective action, but corrective action was not required or was not due for the audits reviewed.
The records of the audits conducted by AP5 on Bechtel and Combustion Engineering were examined.
The audit planning, scope and required
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corrective actions appeared to be satisfactory.
6.
Site Dewaterina
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The excavations for the auxiliary building sumps were observed to contain water up to the first level of rebar. The rebar was coated with a very soft rust.
The plans for removing the water from the sump excavations were discussed with the Bechtel site construction management.
The Sechtel management personnel stated that an engineer had been assigned to develop a plan for removing the water frc the sump excavations. Also, excavation of the Unit 2 site was being dene early to determine the scope of the dewatering program for Unit 2.
7.
Traininc of Construction Personnel The training records for QC engineers and field engineers were reviewed.
The records for the QC engineers appeared to be adequate. The records for the field engineers had not been maintained.
The deficiencies in the training program which are contrary to the requirements of Criterion XVII of 10 CFP, 50, Appendix B, were identified in an audit by APS site OA. No additional inspection of this area will be made until the APS audit, including the followup audit, has been completed.
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Qualification of CC Encireers The qualification records for the QC engineers were examined and found to be in ccmpliance with ANSI N45.2.6.
The QC engineers appeared to have the appropriate education, training, and experience to support the certifications.
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9.
Placing of Reinforcino Steel The specificatien for placing reinforcing steel (No.13-CM-315) was examined. No inspectica criteria for determining the proper overlap for rebar splices were included, except Paragraph 8.1 referenced Drawing 13C-00A-001, " Civil Structural General Notes." Note 1 on Drawing 13C-COA-001 referenced ACI 315-74. The NRC inspector was advised that there was not a copy of ACI 315-74 on site, but that a copy had been ordered.
The Bechtel QC personnel stated that lap spiic-
- ing criteria would be made available to the QC engineers before QC acceptance of quality related rebar placements.
10.
Receiving Inscection TheProcedureWP/P-CCINo.4,"ReceivingknspectionPlanningfor Permanent Plant Itens," was reviewed and the receiving storage facilities
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wer'e toured. The receiving procedure and storage facilities appeared to be adequate for the current status of the project.
The inspector noted that the warehouse was under construction. No material that
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required inside storage was observed on site.
11.
Document Control The procedures governing field drawing control were reviewed. The method of drawir.g control was discussed with Bechtel document control personnel.
The ir.structions for receiving, reproducing and distributing drawings are included in Procedure WP/P No. 3, " Field Control of Design Documents." The cbserved method of handling the field drawings appeared to be in accordance with the Procedure WP/P No. 3, except that the
" Drawing Issue Revision ';otification" was not posted as required by Paragraph 11.3 cf WP/P Nc. 3.
Document control personnel advised the inspector that tne notifications have been delivered to a person in the area of each centrolled drawing file instead of being posted.
12.
Procure ent The procurerent records for reinforcing steel were examined. Areas of examination consisted of document review and approval from specification formulation through award of contract.
No deficiencies were noted.
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Containment (Structural Concrete)
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Bechtel Ouality Assurance Implementina Procedures l
The specifications for placing reinforcing steel; furnishing
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and delivering concrete; preplacement, placement and post-placement of concrete and testing concrete, materials and l
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reinforcing steel were examined.
The specifications appeared I
to be satisfactory, except as discussed below.
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(1) Soecification No.13-CM-101, Furnishina and Deliverina Concrete This specification requires an option for provision of a backup concrete batch plant. This option has not been
exercised.
Regulatory Guide 1.55 requires that provisions be made to preclude unplanned cold joints due to primary equipment loss or breakdown. The licensee has not resolved
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how the requirements of Regulatory Guide 1.55 will be met.
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This is an open item.
(2) Soecification No.13-CM-191, Testino of Concrete, Materials and Reinforcine Steel
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Bechtel representatives had noted that this specification
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requires a maximum of 400 ppm chloride ion content in the j
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concrete mixing water, whereas the ASME Code,Section III,
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Division 2, recuires a maxinum chloride ion content of 250,
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ppm.
Bechtel has submitted a request for code case to the ASMS allowing 400 ppm in the concrete mixing water. The licensee's representatives stated that studies are under-way to determine the feasibility of trucking water to the site and/or installing a reverse osmosis unit to ensure that the concrete mixing water conforns to code pending
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resolution of the request for code case.
This item is
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open.
(3) Specification No.13-CM-305, Concrete Preolacement, Placement and Postolacement t
The NRC inspector noted that this procedure and the
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associated forms did not address the special precautions i
for concrete curing in hot weather as identified in l
Pare. graph 4.4.2 of ACI 305-72. The site is located in an j
arid region and special precautions for hot weather conditions appear appropriate. This item is open.
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Also, the inspector noted that this specification did not contain a requirement to samole pumped concrete at the pump line discharge as required by A!!SI t;45.2.5-1974,
Paragraph 4.8 (See discussien of Specification tio.
13-CM-191, Item {4) below).
(4) Specification No.13-CM-191, Testina Concrete. Materials
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and Reinforcino Steel This specification and Specification 13-CM-305 did not contain a requirement to sample pumped concrete for slump measurement at the pump line discharge as required by AfiSI fl45.2.5, Paragraph 4.8.
Both of these specifications require the samples to be taken at the truck discharge (the pump inlet) instead of the pump line discharge. As the slump is generally lower at the pump line discharge,'
it appears the recuirement to sample at the pump line discharge is appropriate. This item is open.
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Contractor Quality Assurance Precrams and Imolementatien (l') Chamofon, Inc.
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The Champicn QA program and its implementation were examined.
Champion is the concrete supply contractor to Bechtel and is responsible for furnishing and delivering
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concrete for the Palo Verde fluclear Generating Station.
i As such, Chanpion is obligated to perform in-process en-site materials testing of moisture content, aggreca:e sieve
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analysis and material finer than flo. 200 sieve.
seentel approved the Champion QA manual on April 28, 1976. The QA program, specified in Subcontract No.13-CM-101, Appendix DII, is governed by 10 CFR 50, Appendix B, and is to conform to the applicable provisions of A'ISI ??45.2-1971,
" Quality Assurance Program Requirements for Nuclear Power
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Plants."
Examination of the Champion QA program manual and implementa-tion disclosed the following:
(a) The duties of.the QC engineer were not clearly established to delineate the responsibility and authority, as required by 10 CFR 50, Appendix B, Criterion I, and AriS! f;45.2, Paragraph 2.
The QC engineer job description merely states "Perfoms quality assurance and quality control at the plant site."
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I-10-(b) A training program as required by 10 CFR 50, Appendix B, Criterion II, and AtlSI !.145.2, Paragraph 2, has not been established.
l (c) The Champion Plant Supervisor is required to visit the aggregate subcontractor facilities with a frequency specified as " frequent." flo comprehen-l
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sive systen of planned and periodic audits has been established, as required by 10 CFR 50, Appendix B,
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Criterion XVIII, and AftSI ft45.2, Paragraph 19.
(d) Champion has only one QC engineer qualified to Level II to perform and evaluate the results of the aforenentioned on-site, in-process materials testing.
It is required by AtlSI t:45.2.5-74 that resources be sufficient to accomplish the scheduled construction -
without degradation of cuality. ArtSI !!45.2.6, as referred to by Regulatery Guide 1.58, requires train-ing an adequate number of personnel to perform the required inspections and tests.
It was also noted that Appendix B to the Champion QA
manual required equipment reeertification every six
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months whereas the specification for furnishing and delivering concrete (flo.13-CM-101) requires
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recertification every six months or 25,000 cubic yards,
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whichever occurs first.
i Champion representatives stated that a revised QA manual will be submitted to Bechtel for approval and would resolve the items noted.
Other areas of examination consisted of handling, storage, document ~ control, management audit and review, records and nonconforming materials. f;o further deficiencies were noted. The inspector observed that Class I concrete production had not started and that certification and checkout of the batch plant was in progress.
(2) United-Metro, Inc. (UM)
The QA program and procedures of United-Metro were exanined.
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United-Metro has contracted to supply sand and aggregate to Char.picn for use in batching concrete.
The contract requires
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Uli to perform certain testing with Engineers Tes. ting Laboratory (ETL) perfoming other required tests.
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l Materials testing under UM cocnizance is perforced by
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a quality e.ontrol technician located at the Buckeye,
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Arizona facility. Materials are required to be certified l
by UM quality control and certification delivered to
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l Champion prior to delivery to the job site.
Likewise,
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I ETL is required to certify copies of ETL cognizant test results and submit them to UM and Champion. The inspector
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observed that sand and aggregate production for the Palo Verde project began on August 24, 1976 and is stockpiled l
according to aggregate size at the Uti Buckeye facility.
Examination of the UM QA program disclosed the following:
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(a) A!!SI ft45.2.5, Paragraph 2.4, recuires that personne1'
performing field inspection and testing activities l
be certified for Level I capability, and A!;SI t:45.2.6 requires that the individual evaluating tests and inspections be certified for Level II capability.
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Pursuant to such certifications, A!!SI fi45.2.6,
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Paragraph 5, requires that records of personnel qualifications and certifications be established and maintained.
In addition, Regulatory Guide 1.58
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promulgates the position that the requirements of ANSI lt45.2.6 are applicable to inspection, examina-
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tion and testing activities during fabrication prior to receipt at the construction site. United-Metro
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had not established the required personnel qualifica-l tions, and qualification records had not documented certification of personnel responsible for performing and evaluating tests and inspections.
(b) On August 27, 1976, a fineness modulus of 2.41 was recorded, and on August 24, 1976 the one inch sieve passed 62f' of 1.5 inch aggregate. The construction specification for furnishing and delivering concre:c (flo. 13-CM-101) requires a fineness modulus of not less than 2.5 and an acceptability range of 20'; to 55';
of 1.5 inch aggregate passing a one inch sieve.
The test result documents, signed by the Uti QC technician, noted that the production superintendent was notified and did not specify additional corrective action. The inspector was unable to detemine if the nonconfaming aggregate was separated from confoming material, as required by UM QA manual. Appendix B, Criterion XV of 10 CFR 50 requires that nonconfgrming items be reviewed
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and appropriate action taken to resolve the non-confomity.
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(c) Aggregate piles destined for Palo Verde, which have j
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been tested and inspected, are not marked or identified uniquely in order to preclude inadvertent
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introduction or shipping of nonconforming material
as required by 10 CFR 50, Appendix B, Criterion XV.
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(d) The sieve and fines test documentation for Palo Verde material was intemixed with the documentation l
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for production material which need not meet Palo j
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Verde quality requirements.
In addition, the test result documentation for Palo Verde destined material
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was identified as " stockpile" and not specifically categorized as quality material in contrast to
" production" material.
f Other areas of examination consisted of organizations l
management audit and review, test standards and acceptance criteria, and test equipment control.
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j further deficiencies were noted. The inspector
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i observed that no aggrecate or sand, for use in Class I (
concrete, had been deliver,ed to the PVMGS site.
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(3)
Engineers Testing Laboratorv The QA mariual for ETL was examined. ETL is contracted to
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I United-Metro and Bechtel to provide certain testing services, i
i ETL was conductina tests on cadwelds performed by Bechtel
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forcadwelderqualifications.
The preliminary results were
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excmined by the inspector and appeared to contain no
deficiencies.
Engineers Testing Laboratory had completed the concrete mix
l designs and had submitted the results to Bechtel for j
approval.
The batch plant uniformity tests had been
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completed; however, the results had not been analyzed at the time of inspection.
The examination of these documents
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will be conducted pending Bechtel approval.
e The monthly internal QA audits were examined and noted to l
be satisfactory as to planning, scope and finding resolution.
The results of cadwelder qualification tension
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tests were examined and appeared to be satisfactory.
An examination of personnel qualifications disclosed that
qualification records of ETL personnel did not confom to
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the requirements of ASME, Section !!!, Division 2 Code for Concrete P.eactor Vessels and Containments. Appendix VII,
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-13-Paragraph 22:0, in that qualification records did not
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conform to forr.at and content specified.
ETL representatives stated that this deficiency will be
corrected.
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The calibration records for the equipment used to develop the design mixes for the Palo Verde plant were examined.
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Some of the records could not be found. This is contrary
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to Criterion XVII of 10 CFR 50, Appendix B, and the ETL
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QA manual, Section 7.4 that states in part that the calibration of equipment, as listed on the Summary of Standards and Equipment requiring calibration, shall be performed at the frequencies indicated on the list. The
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Summary of Standards and Equipment Requiring Calibration list could not be found. The ETL management personnel l
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the calibratier, records in the proper order.
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