IR 05000528/1981004
| ML17297A469 | |
| Person / Time | |
|---|---|
| Site: | Palo Verde  |
| Issue date: | 04/29/1981 |
| From: | Burdoin J, Eckhardt J, Kirsch D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML17297A466 | List: |
| References | |
| 50-528-81-04, 50-528-81-4, 50-529-81-04, 50-529-81-4, 50-530-81-04, 50-530-81-4, NUDOCS 8106080153 | |
| Download: ML17297A469 (18) | |
Text
50-528/81-04 50-529/81-04 Report No.
50 530/81
U. S.
NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT
REGION V
Docket No 50"530/81-04 License No CPPR-141 s-142>-143Sateguards Group X
Arizona Public Service Company P.
0.
Box 21666 Phoenix, Arizona 85036 Feei] ity Name Pal o Verde Nucl ear Generating Station - Units 1, 2 and
Inspection at Pal o Verde Constructi on Si te, 1lintersburg, Arizona Inspection conducted:
Harch 24-27, 1981 Inspectors; J.
H. Eckhardt, Reactor Inspector
. Kir, Re tor Inspector Da e Signed zN g/
Dat Signed Approved By:
F.
Bu doin, eactor Inspector Date Signed Summary:
D.
F.
'rsch, Acting Chief, Reactor Construction '<<e sign~~
Projects Section
Ins ection on Harch 24-27 1981 Re ort Nos.
50-528 81-04, 50-529/81-04, and 50-530/81-04
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~A<<d:
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by g'b db p
of activities relating to electrical cable installation, pipe welding, electrical penetration installation, containment post-tension)ing, and attachment welding to structural steel.
The inspection involved 69 inspector-hours onsite by three NRC inspectors.
Results:
One item of noncompliance was identified in the area of temporary attachment removal from structural steel (paragraph 3.c).
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RV Form 219 (2)
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1.
Persons Contacted DETAILS a
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Arizona Publi.c Service Com an APS b.
- E.
E.
Van Brunt, Jr., Vice President, Nuclear Projects
- D. B.
Fas nacht, Si te Cons tructi on Manager
- G. Pankonin, gA Engineer R.
D. Forrester, gA Engineer L. Souza, gA Engineer
- D. E. Fowler, gA Engineer
- R. J.
Kimmel, FE Supervisor
- Bruce S.
Kaplan, guality Systems Supervisor
~J. Solakiewicz, Operations gA Engineer Bechtel Power Cor oration Bechtel C.
d.
- W. J. Stubblefield, Field Construction Manager
- R. M. Grant, Project gC Supervisor
- D. R. Hawkinson, Project gA Supervisor
- S.
M. Nickell, Project Superintendent
- A. K. Priest, Project Field Engineer J.
Robinson, Field Engineer J.
Crawford, gC Engineer A. Robertson, gC Engineer P.
Mong, Civil Engineer H. Seckinger, Preservice Field Coordinator Western Concrete Structures, Inc."
WCS K. Guffey, Project Superintendent K. Jacobsen, gA/gC Manager Lumbermans Mutual Casualt
,
Comnan J.
Keenan, Authorized Nuclear Inspector
- Denotes those attending exit interview.
2.
Containment Post-Tensionin a.
Review of ualit Im lementin Procedures The inspector reviewed the following documents effecting the purchase, testing, receipt, installation, tensioning and lubrication of the Unit 1 tendons f'r compliance with PSAR and specification requirements.
(1)
Bechtel Contract Specification 13-CM-158, Section D:
Technical Specification (2)
Western Concrete Structures Company, Inc.
(WCS) Field Installation and Inspection Manual e ~:
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Procedure PTP-4:
Base Mat Component Installation Procedure PTP-5:
Wall, Buttress and Dome Component Installation Procedure PTP-6:
Tendon Installation Procedure PTP-7:
Installation of Field Anchor Head and Field Button Heading Procedure PTP-8:
Tendon Stressing and Installation of shims and Tendon Grease Caps Procedure PTP-9:
Greasing Tendons Procedure OCP-2:
Base Mat Installation Inspection Procedure gCP-4:
Tendon Installation Inspection Procedure (jCP-5:
Inspection of Field Anchor Head Installation and Field Button Heading Procedure gCP-6:
Inspection of Tendon Stressing and Installation of Grease Caps Procedure gCP-7:
Inspection of Greasing Operations No i tems of noncompliance or deviations were identified.
b.
Observation of Work and Work Activities c ~
The inspector observed the cleanliness and protective conditions of tendons H32-030 and H32-032 being prepared for installation in the Unit 1 containment for compliance with procedural requirements, and discussed the installation and inspection sequencing and performance with WCS and Bechtel supervision and quality control personnel.
No items of noncompliance or deviations were identified.
Review of ualit Records The inspector examined the below listed quality records for compliance with specification and procedural requirements.
(1)
Tendons H32-030 and H32-032:
Wire tensile test reports, certificates of inspection of tendons and wire coil test result (2)
Tendons H13-040, H21-040 and H32-040 (these tendons had recently been tensioned and greased):
Wire tensile test reports; receiving inspection, certificate of tendon inspection; wire coil test results; certificates of inspection for tendon installation, installation of field anchor head and button heading, tendon stressing and installation of shims and grease caps, tendon stressing and greasing tendons; and test report of sheathing filler material.
Tendons H13-040, H21-040 and H32-040 were tensioned utilizing a procedure titled "Demonstration Program for Verification of Friction Factors".
The normal procedure PTP-8, for WCS use in production tensioning, was not utilized for these three tendons.
Discussions with cognizant Bechtel and WCS personnel indicated that the tensioning of these first three tendons was conducted as a test program to more accurately determine the associated friction factors and establish a technique suitable for production use.
The tensioning operations had been witnessed by engineering and supervisory personnel from Bechtel and WCS.
Procedure PTP-8 was being revised to incorporate suitable production tensioning techniques.
Examination of the tendon tensioning data sheets indicated the following:
(1)
The data sheets used were not those presented by the approved procedure PTP-8.
(2)
The WCS Field gC Inspector had signed the data sheets indicating that the tendon was acceptable and acceptance criteria had been met even though:
The measured elongations for tendons H21-04Q and H32-040 exceeded that calculated by greater than 5/
of the calculated value, f1easured and calculated elongations for tendon H13-04Q were not recorded for both buttresses 1 and 3, and The recorded measured elongation for Tendon H21-040 at buttress 1 and had been incorectly computed.
PTP-8 requires that if the measured elongation is not within 5%
of that calculated, the WCS Engineer shall be notified and an investigation made to determine the disposition of the tendon.
These tendons were under evaluation by WCS engineering.
However, the procedure does not specify how the engineer's investigation results are to be incorporated in the final tendon documentation package.
Further examination of the WCS procedure PTP-8 indicated an apparent need for consideration of the following:
Providing the gC inspectors with appropriate instructions as to the necessary criteria which must be met prior to the affixing of the gC signature for tendon acceptability, Specific instructions as to what measures the qC inspector is to take if the acceptance criteria are not met, and Appropriate methods for documenting the WCS engineering evaluations of tendons which do not comply with the stated acceptance criteria.
The licensee agreed to evaluate and resolve the above programmatic concerns and resolve the tendon data record discrepancies.
This area will be examined during a future inspec6on (528/81-04/01).
J'lo items of noncompliance or deviations were identified.
3.
Attachment Welds to Thick Section Structural Steel
~kkdd During the site tour the inspector observed a large number of temporary and permanent attachment welds made to 1 5/8" and 2 1/4" thick structural steel columns within Units 1, 2 and 3 containment buildings.
For permanent attachment welds, the beam protective coating was removed for 1" to 1.5" in preparation for welding while on most temporary attachments it was observed that the beam protective coating had not been removed prior to welding.
The inspector, further, did not observe any indications of'reheat traditionally evidenced by resistance heaters/blankets o} smoke/flame discoloration of the material protective coatings.
The licensee reported by telephone on April 3, 1981, that the protective coa$ ing will not be discolored until some temperature in excess of 15Q F is reached.
The A'IJS Structural Welding Code contains specific requirements for preheating members, whose thickness is in excess 1.5 inches, prior to welding.
The licensee's system for controlling the welding of attachments to existing structural steel was examined for compliance with
CFR 50, Appendix B, ANSI-N45.2 and the PSAR, Chapter ]7.
In particular, the following documents were examined, which specify the controls to assure compliance to AWS Dl.)-72 (Structural lJelding Code)
and ANSI N45.2.5:
Specification 13-CN-320:
Installation Specification for Erection of Structural and Miscellaneous Steel WPP/OCI-100:
Weld Rod Control Drawing 13-C-OOOA-050.
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b.
~Findin s The licensee's system for issuing of weld rod assures that, by completion of the
!JR-6 form:
approval is obtained prior to welding the correct welding procedure specification (WPS) is specified the proper welding electrode is utilized the wel der i s qualified, and the WPS specifies the necessary preheat.
However, the WR-6 form for the temporary attachment weld is not retained as a part of the licensee's record system.
While AWS Dl. 1-72 does not require the maintenance of such documentation and records of inspections the inspector noted that
CFR 50, Appendix B, Criterion 17; ANSI N45.2 and the licensee's PSAR, paragraph 17.1A.17 requires that records be provided and maintained to furnish documentary evidence of activities affecting the quality of items.
The welding of temporary attachments to existing quality class
structural steel appears to be an activity affecting quality.
The licensee agreed to evaluate their practices regarding:
(a) compliance to 10 CFR 50, Appendix B, Criterion 17; ANSI N45.2; and the PSAR, paragraph 17. 1A. 17 and (b) compliance with the preheat requirements specified by AWS D1.1-72.
This item is unresolved and will be examined again during a future inspection.
(528/529/530/81-04/02)
c.
Removal of Tem orar Attachments Specification 13-CH-320 paragraph 14.3 requires that when removing construction aids from structural steel the permanent member shall not be damaged.
The inspector observed two gouges approximately 1/2 inch deep on the flange of column number
at the 100 foot elevation in Unit 2 containment.
The gouges appeared to be due to improper removal of attachments.
This is an apparent item of noncompliance (529/81-04/03).
4.
Pi e Weldin Activities The inspector examined welding activities in Units 2 and 3 to ascertain compliance with aoplicable specifications, codes, and procedures.
The activities examined were:
Unit 2 Cladding of weld W002 i'n 30 inch NSSS pipe spool RC-093.
The cladding was being applied to this cold leg pipe by a Dimetrics machine.
Welding by a Dimetrics machine of weld H002 in 30 inch NSSS cold leg pipe spool RC-034.
Preheat was being applied and the weld was completed through approximately 100 passes.
Cleanliness check of weld HOOC of 1 inch pipe 13PGRF126(2).
Surveillance of rod room numbers 4 and 6.
Examination of completed welds FW300 and FlJ301 on 10 inch pipe spool SI-008-GCBC.
These welds were ready for radiographic examination (RT.).
Un1t 3 Examination of weld W008 on 4 inch pipe spool SI-B-114-CCBA.
This weld had just been completed. and was ready for surface conditioning in preparation for liquid penetrant (PT) and RT examination.
Examination of weld W005 on 14 inch pipe spool SI-B-135-FCBA.
This weld was ready for PT and RT.
Held W009 on 20 inch pipe spool SI-B-123-FCBA was ready for fit up.
Dissolvable purge dams were installed.
Surveillance of rod room number 13.
Tacking of 36 inch flued head containment penetration number 20.
This was for 12 inch line SI-220.
In addition to observing the specific activities in progress, the weld filler metal withdrawal records and field weld checklists for the above welds were examined.
Also, the welder qualification records for the above welds were examined.
No i tems of noncompliance or deviations were identified.
5.
Preservice Examination The inspector discussed, with Bechtel and APS personnel, preservice examination activities including examination and system tracking methods, calibration block control, UT instrument calibration, data recording and discrepancy resolution.
No items of noncompliance or deviations were identifie Electrical Racewa and Cable Installation Electrical raceway and cable installations in the Unit 1 control room and the upper and lower cable spreading rooms were examined to ascertain compliance with the applicable procedures 9LJPP/gCIs and specifications.
Particular attributes checked included tray bolting, separation, cable condition, cable tyedowns, edge protectors, tray cleanliness, cable end caps, and cable identification.
In the lower cable spreading room, ten cases were identified where rubber protective edge protectors were missing from the lip of horizontal trays where the cable was routed from a horizontal tray to a vertical tray.
Some of these missing edge protectors had been previously identified by Bechtel during area surveillances and were documented on surveillance reports.
In one case, cables lESB03DClRS and 1ESB03DC1RT appeared to have been bent beyond their minimum bend radius where they roll out of horizontal tray lEZJ2ADTREL (with the edge protector missing)
and go up vertical tray 1EZJ2ADTRVB.
No other damaged cable was identified.
A nonconformance report was written concerning the two identified cables.
Based of the fact that the licensee and Bechtel were aware of the missing edge protector problem and were in the process of obtaining a different type of edge protector that would stay in place more securely after cable installation, this item will be reexamined during a future inspection (50-528/80-04/03).
Electrical Penetration Installation The electrical penetrations (GONAÃ type) installed in Unit 2 containment were inspected to determine compliance with applicable procedures, specifications and standards.
Electrical penetration numbers 46, 47, 49, 53, 55, 57, and 59 were examined.
Penetrations 46, 47, and 49 were completed.
The installation of penetrations 53 and 57 had just been completed (less the terminal box enclosure)
and were being stabilized under 60 pounds pressure of dry nitrogen gas.
Penetrations 55 and 59 are spare units for future use.
Particular aspects. reviewed included; torquing of flanges, welding, wrapping of conductor termination for field protection, purging/stabil'izing penetration with dry ni trogen, penetration leak testing, and maintenance of penetration and nitrogen gas pressure after acceptance.
It was observed that there were no welding slag protection covers oyer the terminal box enclosures for penetrations 46 and 47.
This was pointed out to the Bechtel O.C.
Engineer who took action to have covers installed.
No items of noncompliance or deviations were identifie Unresolved items are matters about which more information is required to ascertain whether they are acceptable items, items of noncompliance or deviations.
An unresolved item disclosed during the inspection is discussed in paragraph 3.b.
9.
Exit Interview On March 27, 1981, the inspectors met with licensee representatives identified in Paragraph 1 and summarized the scope and findings of the inspection.
The licensee acknowledged the apparent i tem of noncompliance identified in paragraph 3.c.