IR 05000528/1979001
| ML17296A426 | |
| Person / Time | |
|---|---|
| Site: | Palo Verde  |
| Issue date: | 04/25/1979 |
| From: | Haynes R, Hutson T, Vorderbrueggen NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V) |
| To: | |
| Shared Package | |
| ML17296A422 | List: |
| References | |
| 50-528-79-01, 50-528-79-1, 50-529-79-01, 50-529-79-1, NUDOCS 7908140397 | |
| Download: ML17296A426 (16) | |
Text
Report No.
Docket No.
50-528/79-01 50-529/79-01 CPPR-141 License No.
CPPR-142 50-529 Arizona Public Service Company U. S.
NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT
REGION V
Safeguards Group P. 0.
Box 21666 Phoenix AZ 85036 ar o
Inspectors:
L.
. Vorder ueggen, Re r Inspector
.Facility Name:
Pal d
Inspection at:
Palo Verde Construction Sit Inspection conducted:
February 12-15, and 28, 1979 Wwa Date igned T.
j<. Hutson, Reactor Inspector G.
r andez, React Inspector Approved By:
.C.
RE C. Haynes,
, Projects, Projects Section, Construction and Engineering Support Br'anch
.
d Ins ection on Februar 12-15 and
1979 Re ort No.
'0-529/79-01 Date Signed V/AB '7 ate Signed
" Date igned Reactor 50.-528 79-'Q1, A~I d:
F b
y.12-15 R
,
d i p
construction activities including:
Follow-up of enforcement and unresolved
. items; site tour; cadwelding and cadwel.d test records; concrete placement records; containment post-tensioning system component storage, protection and installation; reactor coolant and other. safety related piping installation; containment liner component records.-
'The inspection involved 71 inspector-hours on site by 3 NRC inspectors.
On February 28,. a tour of the Palo Verde site was made by NRC-Commissioner R. T. Kennedy.
Results:.
One item of noncompliance was identified in regard to drawing control.
No items of noncompliance or deviations were identifi.ed in the other areas inspected.
RV Form 2'19 (2)
'I
DETAILS 1.
Persons Contacted Arizona Public Service Com an APS
- E
- W
- J.
- Ri
- R.
- J G.
R.
L.
E.
Van Brunt, Jr.,
Vice President/Project Director M.'etro, ANPP'onstruction Manager A. Roedel, ANPP Quality Assurance Manager L. Hand, Site Quality Assurance Supervisor L. Robb, Manager Nuclear Services E. Cook, Quality Systems Engineer Pankonin, Quality Assurance Engineer D. Forrelter, Quality Assurance Engineer Ruiz, Quality Assurance Engineer Bechtel Power Cor oration Bechtel-
- C. Betzhold, Project Quality Assurance Supervisor
". J.
E. Pfunder, Quality Assurance Engineer T. S. Patel, Field Engineer R. J.
Casey, Civil Engineer P. A. Albertson, Lead Surveyor G. V. Johnson, Survey Field Engineer D.
G. Murphy, Surveyor D. J.
Shipman, Level II Inspector G. Evans, Lead Electrical Engineer A. Anderson, Assistant Field Engineer H.
H. Burgess, Assistant Field Engineer R. L. Lykens, Lead QC Engineer - Civil/Structural B.
R. Canaban, QC Engineer T. L. Horst, Lead Field Engineer - Civil J. Black, Resident Engineer V. Matson, Lead QC Engineer - Welding and NDE U.
S. Nuclear Re ulator Commission
- Richard T. Kennedy, Commissioner
- C. Seifert, Administrative Assistant
- J. C. Guibert, Technical Assistant Arizona Atomic Ener Commission
- D. Gilbert, Executive Director
- Exit Interview Attendees
- February 28 Site Tour Only
2.
Construction Status The licensee 'reported that as of February 15, the approximate incompletion status of Unit 1 was 34%,. Unit 2 was 12.5%,
and Unit 3 was still 0.5%.
The overall project was consid'ered to be 22%
complete.-
=3.
Licensee Action.on Previous Ins ection Findin s a.
b.
(Closed).Noncompliance (50-528/78-08/03)
Marking of reinforcing bar for cadwelding was performed after placing and, pinning the cadweld sleeve rather than before.
The corrective action identified in the licensee's response dated January 22, 1979 was examined.
The inspector verified that Bechtel supervision had been instructed to assure that all procedural requirements were being followed, and that the cadwelding crews had been reinstructed on the proper sequencing of cadwelding operations.
The inspector also observed cadwelding activities on the exterior wall of Unit 2 containment to ascertain compliance with Section 10.0 of Specification No. 13-CM-375, Placing of Reinforcing Steel; WPP/gCI 56.0 Cadweld Splicing of Reinforcing Steel; and the recommended procedures in Erico, Catalog RB10M-974, Cadweld Rebar Splicing.
Two crews were observed cadwelding horizontal T-Series splices on No.
and No.
11 rebar.
The inspector noted. that the bars were permanently marked 12" + 1/4" from the bar ends by the. use of a light file mark before pinning the splice sleeve in-position.
The craftsmen also appeared knowledgeable in the sequence of the other procedural steps.
This item is'losed.
(Closed)
Open Item (50-528/78-09/05)
questionable segregation control of discrepant electrical cable in storage at the large materials warehouse.
The licensee had established a separate, fenced storage yard for acceptable electrical cable, and only discrepant cable is now "quarantined" in the large materials warehouse.
The inspector found the new cable storage yard satisfactorily organized and under the control of a full-time custodian.
Also the cable at the warehouse was observed to be adequately tagged as being on "hold".
This item is close c.
(Closed)
Unresolved (50-528/78-09/03)
Adequacy of segregration of nonconforming post-tensioning trumplate assemblies in outdoor storage.
The inspector examined the tr umplate assemblies in the storage yard and found that each nonconforming unit had been adequately marked and "red-tagged" so as to preclude inadvertent use.
Also, each item removed from the materials storage yard must be identified on a signed Released For Installation (RFI) form and must be transported through a single access gate which is under continuous control by receiving department personnel.
The inspector concluded that nonconforming trumplates in storage were being adequately controlled.
This item is closed.
4.
Structural Concrete The subject of chloride content in concrete was again discussed with cognizant Bechtel personnel during this inspection.
(Ref:
50-528/78-06, Par. 5.a).
Specification 13-CH-101, Section D.7.3, limits total chloride content to 0.35 pounds of chloride ion per cubic yard of concrete.
According to Bechtel, this is equivalent to 400 ppm, the limit specified in ASME. code case 1811 pertaining to Section III, Division 2 construction.
After discussion of the method used to calculate chloride content with the Bechtel resident engineer, the inspector questioned its validity.
The licensee was informed that this item would remain open pending further review of the calculational technique by the HRC.
(50-528/79-01/01)
The inspector examined B series cadweld sleeves welded to embed plates located in the outdoor storage yard.. Host of the sleeves were observed to be partially filled with water, though they were taped shut as required by the manufacturer (Erico)
and'echtel Specification 13-CM-375.
Discussion with licensee personnel and a review of Specification 375 (Section 10.5.2)
disclosed that provisions exist for determining the adequacy of the sleeves at the time of installation.
Since the specificiation addresses the situation and the licensee plans to provide additional protection by cleaning and covering the sleeves, the inspector had no further questions on this item at this time.
The inspector reviewed the quality records for Unit 2 concrete place-ments 2C100-Exterior Ring Wall, and 2C036 - Main Steam and Feedwater Shield Wall for compliance with procedures WPP/gCI 53.0, Concrete placement, and WPP/gCI 54.0, Concrete Postplacement.
Cadweld sampling records for approximately 30 welders were also reviewed.
The records were reviewed for compliance with Specification 13-CH-375, Section 11.0 - Testing Mechanical Splices, and Regulatory Guide 1.10-
Mechanical (Cadweld) Splices in Reinforcing Bars.
No deviations from acceptance criteria. were noted in any of the records reviewed.
5.
Containment Liner The inspector selected at random four Unit 1 liner plate segments for review of the documentation furnished by the fabricator.
The segments selected were those containing penetration sleeves P-47, 1-I-l, P-21 and the personnel access hatch.
The records included the Bechtel Documentation Requirements Form 6-321.-D (~which had been filled out as required by Bechtel and supplier personnel),
material certification sheets listing chemical and. physical test data, material traceabi lity data sheets, heat treatment charts, fabrication process sheets, detail drawings, welder identification sheets, and nondestructive examination reports.
No deviations from the applicable acceptance criteria were identified'y the inspector.
6..
Containment Post-Tensionin Installation The inspector examined the completed installation of tendon sheathing extending above placement 2C100-0 in Unit 2, and observed the layout of line and grade by surveyors for the installation of the horizontal tendon sheathing above placement 2C100-0.
The examination of the sheathing installation included tiedown, alignment, splicing, freedom from abrupt change of direction, tolerances between sheaths and penetrations, and the protection from entry of foreign materials.
In addition, the storage of trumplate assemblies, rigid extensions and sheathing both in the controlled yard and in Unit 2 containment laydown areas.was observed.
The inspector did not identify any deviations from PSAR commitments, or the requirements of the installation specification (13-CM-371)
and inspection plan (LJPP/QCI 66.0).
During the observation of line and grade layout for the horizontal sheathing, the inspector noted that the surveyors were working from a drawing file marked "Information Only."
The specific drawing which was being used at the time was Western Concrete Structures (MCS) draw ng PS-ill, Rev.
4.
A check of the controlled drawing file in the Field fngineer's office showed that the latest revision of that drawing approved for construction was Rev.
4.
The inspector questioned
"
why the latest revision of a drawing was marked "Information Only" was being used for construction.
Cognizant Bechtel personnel stated that they had been told by Bechtel Quality Assurance that drawings should not be removed from a controlled stick file to be used in the
,field.
They also stated that this required taking an entire stick file of drawings to the field when only a few of the drawings were needed.
Discussions with the survey crew disclosed that they would
I
I l
obtain the drawings they needed from the document control center and mark them "Information Only." The surveyors stated that by using this technique they did not have to take many drawings to the work location.
The inspector found that marking the drawings "Information Only" removed the drawings from the document control system and that the drawings would not be subject to gA audits.
Furthermore, since such drawings are not controlled and audited, they are not collected when a later revision is issued, and are not available for attaching DCN's which may be issued.
Thus, the practice of using completed and approved drawings for construction that are marked
"Information Only" is contrary to the licensee's document control requirements and is an item of noncompliance.
(50-528/79-01/04)
The inspector also reviewed the quality records associated with the tendon sheathing installation and material control.
Included were six Material Receiving Reports and their associated Receiving Inspection Planning Sheets; Material Certifications for trumplates, rigid extensions, tubing extensions, insert assemblies, vent and drain valves and galvanizing; Construction Inspection Planning for Walls, Buttress'es and Dome; Installation and Inspection records for Unit 2 placement 2C100-0; Personnel gualification for two gC Inspectors; and four nonconformance reports on trumplate assemblies.
No items of noncompliance or deviations were noted.
7.
Reactor Coolant Pressure Boundar Pi in At the time of the inspection, automatic machine welding was in progress on the 30-inch outlet nozzles on both steam generators in Unit 1.
Weld No. P-15 on No.
2 generator outlet to pump No.
2B was selected for examination to ascertain compliance with the governing weld procedures (PI-AT-LH-CVN for fit-up tacking and Pl (62)-T-I-o (ITP) for the automatic machine).
The associated drawing.was.
13PC-ZCG-103, Rev. 0.
The actual welding operation was observed and the workmanship looked good.
The Field Welding Check List was noted to be properly filled out with hold points identified.
The variable parameters of arc voltage, current, travel and wire feed speed, etc.,
were compared and found to be within the ranges specified in the procedure.
The procedure qualification and the welders'ualification records were also examined.
No items of noncompliance or deviations were identified.
The inspector also reviewed the specified post-weld stress relief procedure, PHT -501, Rev.
5.
The=-procedure appeared adequate except for needing clarification in two areas:
a.
Section 5.1.2 specifies a, maximum temperature differential of 150o F. during the holding period.
It is not clear whether -this is the permissible deviation of the average temperature of the material or the permissible differential through the pipe wall-thickness.
The latter might allow the inside of the pipe to be below the minimum specified heat treatment temperature.
(1100o F.)
b.
Section 8.2 briefly addresses the possibility of air currents being established inside the pipe, and the procedure appears to provide. for'hermocouple attachment and temperature measurement only on the exterior of the pipe.
Without i.nside temperature measurement, it is not, clear how it can be assured that the weld region on the inside of the pipe reaches and is held at the specified heat treatment temperature.
These points were brought to the licensee's attention during the exit interview andi,this procedure will be reexamined.
(50-528/79-01/05)
The inspector also examined the reactor outlet pipe spool to steam generator No.
2 and the cold leg return spoolpiece (-902) from coolant pump No.
2A, both of which had been rigged into their approximate positions for installation.
Both spools appeared to be properly supported using ring-clamps and chainfalls from temporary overhead supporting structures.
All openings were properly capped.
No deviations from the Combustion Engineering Company Instruction Manual for Reactor Coolant Pipe'and Fittings (CE Book No. 78473)
were igentified.
8.
Electrical Com onents and S stems The equipment placement, installation welding, and in-place.
storage of safety related 480 volt, motor control centers (MCC's)
E-PHB-M34, E-PHB-M36 and E-PHB-M38 in Unit 1 was examined by the inspector.
The in-place storage of the MCC's appeared adequate and the space heaters were energized.
Although the MCC's were.
covered, considerable buildup of dust inside the panels was noted due. to some of the doors being left ajar.
This was called to the licensee's attention.
While the welding of the MCC's to the floor plates conformed to the specified AWS Dl.l requirements, the irispector observed that an additional fillet weld had been added at the ends of the MCC's.
-The welding details as shown on Bechtel drawing 13-10407-E-018-564-1 does not call for a weld on the ends of the MCC's.
Consequently, this item is considered unresolved.
(50-528/79-01/02)
o
The inspector also examined the installation and in-storage maintenance records for t1CC's identified above and the in-storage maintenance records for the pump bowl and drive motor for reactor coolant pumps 1B and 1C.
The installation inspection records for the t1CC's had not been signed by the gC inspectors for work that had been accepted up to the present 'status of installation.
Bechtel personnel stated that
~ the gC ins'pectors had performed the required inspections and logged that fact in their field notes, but had not yet signed off the inspection record card.
The documentation of the inspection performed will be reviewed during a future inspection.
(50-528/79-01/03)
The storage of electrical equipment in the warehouse was also observed.
The main control room panel space heaters were not energized and section 801 was not covered.
Discussion with personnel indicated that the panels had just been moved from another area of the warehouse and the space heaters would be energized and section BOl.covered.
No items of noncompliance.or deviations were identified.
9.
Site Tour b
NRC Commissioner On February 28, 1979, the inspector accompanied Commissioner Richard T.
Kennedy and two members of his staff of a tour of the PVNGS site.
The tour highlighted the outdoor storage yard, concrete batch plant, water reservoir and treatment plant areas, auxiliary building, turbine building, containment building, and large-warehouse.
Licensee personnel also made a brief presentation director to construction status and progress, and a description of the project organization.
10.
Unresolved Items Unresolved items are matters about which more information is required in order to ascertain whether they are acceptable items, items of noncompliance, or deviations.
One unresolved item was identified during this inspection and is discussed in Paragraph 8.
ll.
Exit Interview At the conclusion of the inspection, a meeting was held with the licensee and contractor representatives denoted in paragraph 1.
The areas covered during the inspection.
and the observations and conclusion of the inspectors were reviewed.
The licensee stated that prompt consideration would be given and appropriate action taken on the items which were called to their attentio vw
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