IR 05000528/1979005
| ML17296A484 | |
| Person / Time | |
|---|---|
| Site: | Palo Verde  |
| Issue date: | 09/19/1979 |
| From: | Dodds R, Haist D, Vorderbrueggen NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V) |
| To: | |
| Shared Package | |
| ML17296A480 | List: |
| References | |
| 50-528-79-05, 50-528-79-5, 50-529-79-05, 50-529-79-5, NUDOCS 7911080456 | |
| Download: ML17296A484 (16) | |
Text
50-'528/79-05 Report No.
50-529/79-05 Docket No.
50"528, 50-529 V. S.
NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION, V License No.
CPP -
142 Safeguards Group Licensee:
Arizona Public Service Com an P. 0.
Box 21666 Phoenix, Arizona 85036 Facility Name:
Palo Verde Units 1 and
Inspection at:
Palo Verde Site, Harico a Count Arizo Inspection conducted:
Jul 31 - Au ust
1979 Date Signed Date Signed Date Signed D te Signed Results:
One item of noncompliance was identified concerning noncon-formance of pipe hanger and support we'Ids in design drawings.
Ho items of noncompliance or deviations were identified in the other areas inspected.
Inspectors:
L.
. Yorderhrueggen, Reactor Inspector q -gg-gc a'st, Reactor Inspector I
G.
He and z
~ Reacto Inspector.
Approved By:
/~
Wpc R. T. Dodds, Chief, Reactor Engineering Support Section, Reactor Construction and Engineering Support Branch.
Ins ection on Jul 31 - Au ust 3, -1979 Re ort Hos.
50-528 79-05 and 50-529/79-05
'~AI d:
Rti,'i p
. activities including:
followup of open and unresolved items, fuel pool cooling water heat exchangers, pipe supports and restraints. in Unit l.
containment and safety-related steel structures and supports for Unit 2 reactor and.auxiliary buildings, and Unit 1 steam generator supports.
The inspection involved 42 inspector-hours onsite by three HRC inspectors.
7911080
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DETAILS 1.
Persons Contacted a
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Arizona Public Service Com an b.
- E. E.
Yan Brunt, Jr., YicePresident/Project Director
- J. A. Roedel, Manager, Quality Assurance
- R. L. Hand, Si te QA Supervi sor
- L. W. Price, Site Construction Manager
+B. S.
K pl n, Quality Systems Superv sor R.
L. Robb. Manager, Nuclear Services R.
D. Forrester, Quality Assurance Engineer N.
E. Wibel, Quality Assurance Engineer G. Pankonin. Quality Assurance Engineer Bechtel Power Cor oration co
- D. W. Hawkinson, Project Quality Assurance Supervisor
- C. E. Gaither, Project Field Engineer T. L. Horst.
Lead Field Engineer - Civil S. Boenzi, Lead Field Engineer - Civil A. E. Moore, Lead QC Receiving Engineer R.
E. Guitierres, Mechanical Quality Control Engineer R. Hedzik, Lead Discipline Field Engineer T.
E. Sonnemann, Discipline Field Engineer T.
F. Heiser, Mechanical Field Engineer D. J. Jacks, Quality Control Field Inspector - Mechanical H. Hear, Assistant Project Quality Control Engineer M. Patterson, Pipe Support Group Leader R. Condie, Quality Assurance Engineer Combustion En ineerin CE S.
N. Mager, Site Manager Interviews were also held with two individuals regarding allegations of faulty construction work.
- Denotes attendance at the exit interview on August 3, 1979.
2.
Construction Status The licensee reported that as of July 31, 1979,, the approximate completion status of Unit
was 44..5I, Unit 2 was 19.1/,
and Unit 3 was 1.8X.
The overall project was considered to be 23.4X complet J I
3.
Licensee Action on Previous Ins ection'indin s
a.
Closed 0 en item: t1aterial certifications for A449 Diesel Generator foundation bolts were not available for review.
50-528 79-04/01 A review of the material certification determined that the chemical, physical, and hardness analysis appeared to conform to the requirements of ASTtl A449-68, Standard Specification for quenched and Tempered Steel Bolts and Studs.
This item is closed.
b.
0 en Unresolved item:
Undersize fillet weld on i e su ort No. ISI-079-H-005 sadd;e :" saddle
"ase late.
50-529 79-04 02 As a result of an NRC inspection on June 11-15, 1979.
Bechtel performed an unscheduled audit of 49 installed and accepted hangers during the week of June 29, 1979.
The audit disclosed that a generic problem exists regarding welds not meeting drawing requirements.
The inspector examined licensee and Bechtel correspondence and-the following quality assurance documents resulting from this audit.
(1)
NCR-P-A-534 addresses pipe.support No. ISI-079-H-005.
(2)
NCR-P-A-568 addresses installed pipe supports with
'nacceptable Bechtel welds.
(3)
NCR-P-A-567 addresses installed pipe supports with un-acceptable Harathon l<elds.
(4)
NCR-P-A-566 addresses installed pipe supports with un-acceptable Pullman Welds.
" (5)
CAR No.
OAF UA-79-'S-35A - Bechtel Melds.
(6)
CAR No.
OAF UA-79-S-35B - Supplier Welds.
(7)
DER 79-10 - Deficiency Evaluation Report addressing weld defects passed through the system and installed and
CFR 50.55(e) significance.
Corrective Action Requests (CAR) listed above had not been dispositioned.
Bechtel stated that they were awai ting disposi-tion of DER 79-10 by project engineering prior to dispositioning
'he CARs, and that the gC engineers responsible for inspecting pipe support welds have been made aware of the subject deficiencies and documentation to that effect was in their training file l
In connection with this previously unresolved item the inspector examined additional pipe supports as described in Paragraph BB.
c.
Closed 0 en item:
Construction Ins ection Plannin CIP records for i e su ort 13SI-144-H-005 indicated both lu weld Nos.
1 and 2 received ll used enetrant LP teston
LP test re ort did not indscate that a
LP test was er ormed on we d No.
2.
50-528 79-04/03 NCR No. P-A-535 was issued to perform LP test on both weld Nos.
2 and 3.
Examinations were acceptable and a new LP test report was prepared.
Bechtel has increased surveillance of NDE contractor's field activities.
This item is closed.
4.
Unit 1 Steam Generators - Shim Movement Each steam generator is fitted with 4 slides which support and provide for movement of the sliding base.
The licensee has recently discovered that a random shifting has taken place in the shim
"stacks" located under each slide on both steam generators.
Shifting has occurred in both the N-S and the E-W directions.
In one location on steam generator No. 2, shim mov'ement was sufficient to cause cracking of the 1/4-inch fillet veld which fastens the 2-inch x 6-inch x 21-inch shim restraint bar to the embedded beari ng plate.
The inspector examined the shifted shims under steam generator No.
2 and observed the cracked weld and slightly bent restraint bar.
The movement is thought to be associated with the preheat and welding of the generator/vessel hot legs.
The. exterior welding of the hot leg lines has been completed.
The internal backing rings have been ground off in preparation for internal welding and surface cladding.
The licensee is having the condition of the generators evaluated and is considering the 50.55(e) reportability aspects of the matter.
5.
Fuel Pool Coolin Water Heat Exchan ers Subsequent to the discovery of the longitudinal weld defects in ASNE SA-312 pipe manufactured by Youngstown Welding and Engineering Company, (Ref:
IE Bulletin 79-03), the Struthers-Wells Company notified the licensee that nozzles on the fuel pool cooling water heat exchangers had been fabricated from Youngstown SA-312 material.
Inasmuch as the two exchangers had already arrived on the job site,
-Bechte'l issued Stop Work Notice 79-SW-3 on June 22, 1979 and had the testing laboratory perform a radiographic examination of the suspect nozz'les.
Radiography Repot ts 4899, 4900, 4901 and 4902 documented the examination and were reviewed by the inspector.
The weld seams were found to contain no discernible defects.
6.
Safet -Related Pi e Su orts and Restraints a.
Review of ualit Assurance Im 'lementin Procedures The following pipe support and restraint documents were reviewed for conformance to licensee and code requirements:
(1)
Specification 13-PM-209, "Specifications for Nuclear Pipe Supports."
(2)
WPP/gCI-201.1,
"Nuclear Pipe Hangers and Supports In-stallation."
(3)
Specification 13-PM-201, "Specification for Shop Fabrication of Nuclear Service Piping."
No items of noncompliance or deviations were identified.
The inspector noted that FACE verification and documentation of mechanical snubber cycling is not a requirement of WPP/gCI 201.1.
The pipe support area field engineer (PSAFE)
performs this functional check and then records the serial number of the acceptable snubber on the CIP.
The licensee agreed to review the need for FACE verification and documentation of snubber cycling.
b.
Observation of Work and Work Activities (1)
The folio>/ing safety-related mechanical snubbers, not yet installed, were selected for examination:
~Sstem Restraint Number Load Classification Chemical and Volume Control 13-CH-028-h-OOM '00>
Main Steam 13-SG-045-H-012 456408 Spray Pond 13-SP-079-H-001 13-SP-025-H-001 38245'8248 All snubbers were checked for smooth shaft travel and for unit activation by sudden movement.
All snubbers conformed to drawings and had the correct hot and cold settings indicated on attached stainless steel tags.
No items of noncompliance or devations were identified.
(2)
The following safety-related fixed pipe supports were selected for examination:
~Ss tern Essential Chilled Water Su ort Number 1EC-01 0-H-023 1EC-001-H-'006 1EC-069-H-008 Essential Cooling Water 1EW-026-H-034 IEW-026-H-009 IEW-023-H-023
'EW-023-H-033
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Chemical and Volume Control 1CH-027-H-00Y 1CH-027-H-00A Reactor Coolant Safety Injection 1RC-068-H.-005 1SI-129-H-003 (Spring Hanger)
The supports were all of fixed design, quality Class g, seismic category 1 and ASME Class 1,
2 or 3.
The supports were examined to ascertain conformance to the applicable drawings and specifications.
A11 of the supports had received gC acceotance inspection on or after June 15, 1979.
The inspector identified the following deficiencies:
~SN b
~Ofi i 1EW-023-H-033 IEC-069-H-008 (1)
Field weld attaching item A to existing vertical column is specified as 3/8-inch fillet 2-4; actual condition is 3/8-inch fillet 2-6.
(2)
Field welds attaching top and bottom of brace (item D)'o item B and existing column, respectively is specified as 3/8-inch fillet, one side, both legs; actual condition is 3/8-inch fillet, both sides, one leg Shop weld attaching item B to item A is specified as 3/16-inch fillet 4-12; actual condition is 3/16-inch fillet 2-7.
-
Dummy pipe shop weld to saddle base is specified as 1/4-inch fillet; existing weld is 3/16-inch,fil'let.
The inspector examined the Construction Inspection Planning (CIP) reports for the three supports and found welding FACE signoff on Hay 22, June 22, and June 28, 1979, respectively.
WPP/gCI 201:1 was revised on July 20, 1979 to require ACE verification of vendor welds on pipe hangers and supports.
The failure to weld pipe hangers and supports in accordance with the applicable drawings is considered to be an item of noncomplianc c ~
Review of ualit Assurance Records The Construction Inspection Plans (CIP) for the three deficient
.
pipe supports listed in Paragraph b'were reviewed for conformance with procedural requirements.
All records appeared satisfactory with the exception of the deficiencies identified in Paragraph Bb.
7.
Containment - Steel Structures and Su orts
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a 0 Observation of Work and Work Activities The insoector examined work activities associated with Unit
pressurizer supports for compliance with WPPgCI 375.0, Revision 1.0, Pressurizer Storage, Handling, and Installation, and Bechtel Civil Drawing No. 13-C-ZCS-604, Revision 4.0.
The'xamination included verifying that the support was of the type specified, installed in the proper location, critical dimensions were adhered to, anchor bolts and nuts were of the type and grade specified, instruments were properly cali-bratedd, and bolts properly tensioned to procedural requirements.
The inspector further determined that the cognizant quality control personnel performed inspections and verification reviews of all final alignments and orientations of the pres-surizer vessel.
All inspection results appeared to be adequately documented on applicable Construction Inspection Plans (CIP).
Review of ualit Records The quality records associated with the pressurizer support were reviewed for compliance with applicable procedures and specifications.
This included a review of material certifi-fications.
anchor bolt installation, grouting, tensioning, receipt inspection, nondestructive examination and noncon-formance reports.
No items of noncompliance or deviations were identified..
8.
Safet -Related Structures Structural Steel and Su orts a ~
Observation of Work and Work Activities The inspector examined structural steel supports for two Low Pressure Safety Injection Pumps, Nos.
2M-51A-P01 and 2N-SlB-P01, and two Containment Spray Pumps, Nos.
2M-SlA-P03 and 2N-SlB-P03, located at the 40-foot elevation of the Auxiliary Building of Unit 2.
The structures were examined for compliance to the requirements of Specification 13-CM-320, Revision 5.0 and WPP/gCI 58. 0, Revision 6.0 Erection of Structural and Hiscellaneous Steel, and Bechtel Civil Drawing No. 13-C-ZCS-242, Revision 4.0.
The structural steel supports were observed
-7-to be installed and located as specified in the drawings, and quality control inspections performed in accordance with the above procedures and specifications.
One item of concern, as indicated below, was identified during examination of the structura'l steel support of the pumps.
Bechtel specification 13-CU-320 identifies the requirements for bolting of structural steel supports for the Containment Spray and LPSI pumps.
It was observed by the inspector that one A325 bo'lt and nut for Containment Spray Pump Ho. 2H-SlB-P03 on the west side of the support was loose.
The construction work in this area'as considered complete and a review of the CIP indicat d that quality control had verified and accepted the work.
The licensee took immediate action to have the bolt retorqued, and documented this condition on nonconformance report Ho. C-A-,1483.
b.
Review of ualit Records The quality records associated with the structures identified in Paragraph 10a above were reviewed.
This review included:
material certifications, grouting.
compressive strength for grout specimens, inspection reports, calibration, receipt inspection, nondestructive examination, and nonconformance reports.
While no items of noncompliance were identified, the following items were brought to the attention of the licensee:
{1)
The Construction Inspection Plan (CIP) for LPSI Pump Ho.
2N-SlB-POl was not available for review.
Bechtel repre-sentatives stated that the CIP could not be located, although the support had been inspected and accepted.
HCR Ho. C-A-1484 was issued to document this situation and a program started to reinspect the structure and
,establish a replacement CIP.
(2)
For Containment Spray Pump Ho. 2H-S1B-P03 the CIP in-dicated, that two items that should have been verified and accepted by the quality control inspector were marked
"not applicable" in both instances.
Licensee repre-sentatives stated that discussions with the cognizant engineer indicated that the "H/A" marks were an oversight.
on the part of the inspector and items had been verified and accepted at the time the inspection was performed.
The licensee then asked the inspector to correct, sign and date the CIP.
9.
Exit Interview At. the conclusion of the inspection a meeting was held with the licensee and contractor representatives denoted in Paragraph 1.
The scope and findings of the inspection, including the items noted in Paragraphs 8b and 10a were discussed.
The licensee stated that prompt consideration would be given and appropriate action taken on the items called to their attentio C
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