IR 05000528/1981020
| ML17297B208 | |
| Person / Time | |
|---|---|
| Site: | Palo Verde  |
| Issue date: | 01/14/1981 |
| From: | Bishop T, Burdoin J, Eckhardt J, Wagner W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML17297B207 | List: |
| References | |
| 50-528-81-20, 50-529-81-15, 50-530-81-15, NUDOCS 8201290346 | |
| Download: ML17297B208 (26) | |
Text
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50-528/81-20 50-529/81-15
"'eport No 50-530/81-15 U. S.
NUCLEAR REGULATORY COMMISSION
,OFF ICE OF INSPECTION AND ENFORCEME'aaT
REGION V
Docket No.
50-528/529/530 License No.
CPPR-141, 142, 143Sa feguards Group I
Licensee:
Arizona Public Service Company P. 0.
Box 21666 Phoenix, Arizona 85036 Facility Name:
Palo Verde Nuclear Generating Station - Units 1, 2, and
Inspection at:
Palo Verde Construction Site, Wintersburg, Arizona Inspection condu ted: October 5-9 and 26-30, 1981 Inspectors'.
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eac or nspec or rz gz D te Signed er ea nspec or Date Signed
"'..""Approved J.
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rdoin Reactor nspec or I.l'v(i 'L T.
W. Bishop, Chief, Reactor rogec s
ec son o.
Date Signed l ill/S2.
Date Signed II tet Summary:
Ins ection on October 5-9 and 26-30 1981 Re ort Nos. 50-528/81-20 50-529/
and 50-30 8 -
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di of activities associated with pipe installation, structural steel installation, component installation, concrete records, pipe welding, instrumentation cables, electrical cables, and preservice examination.
The inspection involved 128 inspector hours on-site by three NRC inspectors.
Results:
No deviations or items of noncompliance were identified.
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DETAILS 1.
Persons Contacted a ~
Arizona Public Service Com an APS b.
C.
- E. E.
Van Brunt, Jr., Vice President, Nuclear Projects
- D. B. Fasnacht, Nuclear Construction Manager
- W. E. Ide, Site QA Supervisor
- B. S. Kaplan, Quality Systems Supervisor G. Pankonin, QA Engineer L. Souza, QA Engineer R. Forrester, QA Engineer..
D. Wittas, QA Engineer
'.
C. Sterli,ng, Instrumentation Engineering Supervisor P. J. Moore,'A>Engineer r'
Bechte1 'Power.'Cor orati on Bechte1 S.
M. Nicfell,'Pr'oject Sup'erintendent
- D. R.
Hawkinson,, Pr'oject QA'upervisor
Herman, Lead',Discipline Egg'ineer', Electrical J. T..Hayes, Lead 'Fie'ld Engineer,,Cable/Terminations W. Sturm,'est-L'ab-Coorcfinator'"
H. Seeking'er,,
Preservice Examination Coordinator G.
Stam, Welding. Enganee'r"
-";,
R. Barton; Welding QC Engineer
~r tl Combustion En ineerin CE Management E. Presbie, Project Engineer G. Bloomquist, QA Engineer,
- Denotes those attending exit-'eetings.
2.
Pi e Installation Activities Piping activities were examined to ascertain compliance with applicable construction specifications and work plan procedure/quality control instructions.
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Observation of Activities The following activities were observed:
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(1)
Unit 1 Containment (a)
Protective covers on check valve openings for safety injection piping.
(b)
Protection of piping from work being performed above piping.
(c)
Grinding of attachment weld of dummy pipe to 12" safety injection piping for pipe hanger SI-220-H029.
(d)
Grinding of attachment weld of dummy pipe to 14" safety injection piping for pipe hanger SI-206-H-005.
(e)
Protection, condition, cleanliness, and orientation of the following installed piping:
Pressurizer surge line 1-RC-028-BCAA-12", spool S-001.
Pressurizer spray line 1-RC-018-BCAA-3", spool S-001.
Pressurizer relief valve line 1-RC-001-BCAA-6", spool S-001.
Safety injection tank 2B line 1-SI-178-GCBB-14", spool S-001.
(2)
Unit 2 Control Bui ldin (a)
Pipe storage'nd capping of pipe openings.
(3)
Unit 3 Containment (a)
12" safety injection piping installed on temporary hangers.
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Safety injection piping being'igged into place.
(c)
Capping of pipe openings.
b.
Review of ualit Records
'
'V The following qualityr'ecords for the Unit 1 piping spools listed in paragraph 2.a(1)(e)
were reviewed:
ASME form NPP-1 data report, quality, verification documentation list, weld history records, nondestructive examinati'on records, material physical and chemical properties data, certificate of compliance, and installation records.
No deviations or items of noncompliance were identifie e
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3.
Structural Steel Installation Structural steel installation activities were examined to ascertain compliance with applicable construction specifications and work plan procedure/quality control instructions.
The following activities were inspected:
a ~
Unit 2 Containment Liner Weldin In-process welding of liner plate being installed in the Unit 2 containment construction opening was observed.
The welding status on different seams included fitup, tacking, in-process welding, and completed welds.
In addition to inspection of the actual-in-process work, weld filler metal control and field weld checklists were examined.
b.
Unit 2 Containment Interior Structural Steel co Steel structure 13-C-ZCS-597(2)
being erected inside the Unit 2 containment at elevation 141-166 feet was examined.
Particular attributes considered included fillet weld size and contour, control of weld filler material, use of proper weld procedure, high strength bolting, evidence of turn of the nut method for nut installation, and proper installation of washers.
Unit 3 Containment Interior Structural Steel No A steel structure at the 90 foot elevation in Unit 3 containment was examined for proper fillet welding and bolting.
deviations or items of noncompliance were identified.
4, Com ao onent Installation Unit 1 Examination of Installed Com onents I+
The following"components installed in Unit I containment were examined:
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pressuriz'er;. spray,l,ine check va]ve V-'244 (2)
safety-'.injection'heck'valve,V-,.227 (3)
pressurize spray valve V-,2'42 ",.,
(4)
pressurizer re'lief valve"V-202-,
5)
pressurizer, ',,',.
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(6)
steam',generator
'number I (7)
reactor<<'coolant pdmp'1A,including'orizontal supports (8)
safety, injectiontank for'oop '2A "
(9)
upper personnel lock',
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Specific items checked included component protection during construction, installed orientation, cleanliness, and component supports.
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b.
Review of ualit Records The following quality-records associated with the above identified components were reviewed:
(1)
Installations records for pressurizer spr ay line check valve V-244, pressurizer spray valve ~V-242, and pressurizer relief va.l ve. V-202. "'=-,
(2)
Manufacturers "data report', special construction inspection planni'ng -(CIP,') for ~(SSS-equipmen't";(WPP/gCI-350.0),
and CIP for rigging ofequipment,',(WPP/QCI'-15.0) for pressurizer.
(3)
Manufaoture'rs. data'report,:and'spec'ial CIP for NSSS equipment for steam,"generator number 1.:This-included shim stacks, slidin'g'-,bhs'e~ plate',"~,and stud tensioning data.
(4)
Manufactur'ers,data>report~for.,
reactor'oolant pump lA including horizontal supports. '
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'5)
Manufactur'ers data report,'nd -special CIP for NSSS equipment for loop 2A safety injection tank.", This including hold down bolt torquing data.
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(6)
CIP for containment liner penetr ation installation (WPP/gCI-61.0) including,,survey data, certification of conformance, code data report, NDE, records, shop leak test, and material property records for upper personnel lock.
No deviations or items of noncompliance were identified.
5.
Concrete ualit Records Review Units
2 and
The following concrete records were reviewed to ascertain compliance with applicable construction specification and work plan procedure/
quality control instructions:
a.
Unit 1 s ra ond placement no.
1Y444, placed June 19, 1981 33 yd.
Preplacement, placement, post-placement, cadwell rebar splice, and 28 day compressive strength records.
b.
Unit 2 containment dome placement no.
2C123, placed July 10, 1981-1395 yd.
Preplacement, placement, post-placement, delivery tickets, sheathing installation, cadweld r ebar splicing, cadwelder qualification, and 7 and 91, day compressive strength record C L k( g cA c'
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Unit 3'imar shield'wall placement rio. 3C042A, placed August 12,
8 yd.
I Preplacement, placement*," post-pl acement, delivery tickets, cadweld rebar splicing, 'and'7 day compressive strength records.
d.
Unit 3 containment exterior wall placement no.
3C107, placed June 9, 198
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7 yd.
Preplacement, placement, plost-placement, delivery tickets, sheathing installation, cadweld rebar splicing, and 7 and 91 day compressive strengths.
e.
Material test records for fine and coarse aggregate received October 19-
No deviations or items of noncompliance were identified.
6.
Pi e Weldin Activities a ~
Observation of Work In-process welding activities were observed to ascertain compliance with ASME Section III Code requirements.
The following activities were examined:
(1)
Unit 1 reactor coolant line RC-091 weld OBH-C pipe to fitting weld.
Weld fit-up, argon purge, and gC verification of fit-up and purge prior to releasing the joint for welding were observed.
(2)
Unit 1 safety injection pipe spool SI-220-S-001 weld 005.
Observed grinding of weld in prepar ation for NDE.
(3)
Unit 2 cooling water pipe spool NC-E-135-HLBB-10" weld 004 (R-2) pipe to penetration no. 33.
Examined completed weld.
(4)
Unit 2 safety injection pipe spool SI-E-223-BCAA-14" weld 007.
Weld was fit-up, tacked, and purge was in progress.
Observed ANI inspect fit-up.
(5)
Unit 2 safety injection pipe spool SI-E-223-BCAA-14" weld 006 and 008.
Observed in-process welding.
(6)
Unit 2 chemical and volume control pipe spool CH-563-CCBA-1',", weld OOT.
Observed in-process weldin I l
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Unit 2 safety. injection'ipe spool SI-160-BCAA-14" weld 301.
Examined weld prep, area and cleanliness.
(8)
Unit 2 cooling water 'pipe spool'C-E-137-HLBB-10" weld 004(C)
pipe to penetration no. 34.
This was ready for fit-up.
(9)
Unit 2 containment spray piping.
Lugs welded on piping for hangers SI-326-H-OOB; OOC, and 000.
Examined completed lug to pipe fillet welds.
(10) Unit 3 penetration number 19 for line SI-202-12".
Observed grinding of 36" flued head weld.
For the above welds, the inspector reviewed the filler metal withdrawal forms and field weld checklists.
Also, the welder and OC inspection personnel qualifications for weld (1) were reviewed.
No deviations or items of noncompliance were identified.
b.
S ecial Weldin A
lications (1)
Repair weld records review - Unit 1.
The inspector reviewed the repair records of three weld repairs for the Unit 1 reactor coolant system.
These were for RC-034 NSSS, RC-084 (W-002)
and RC-084 (W-003).
The inspector is satisfied that the repairs were performed in accordance with applicable code requirements.
The repair procedure included all the special requirements as specified in the original welding process, such as weld procedures and NDE requirements.
The inspector reviewed the qualification records of the six welders involved in these repair activities and verified that all were qualified on the date the weld repairs were made.
(}C verification and ANI signoffs were evident on the field weld checklist.
The radiographs taken of these weld joints indicated that the weld repairs were acceptable.
The inspector reviewed two weld procedure specifications used in the repair welding process.
The weld procedures were Pl Clad 0 and Pl(G2)-T-I-0(ITP).
These procedures and the P(R's were reviewed to determine compliance with requirements of ASME Section IX and III.
No items of noncompliance or deviations were identified.
(2)
Weld cladding - Unit 2.
Cladding of the following Unit 2 reactor coolant system welds was observed:
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RC-033-NSSS-30" weld 004
'C-073-NSSS-30" weld 004 The cladding was being performed with a Dimetrics machine.
No 'deviations or items of noncompliance were identified.
c.
Weldin Material Control The inspector examined the activities of control, issue, return and storage of weld filler materials for compliance with procedural requirements.
These activities were inspected in rod room numbers 7 and 10A serving Unit 1 and rod room numbers 6, 8, and 16 serving Unit 2.
The holding ovens were calibrated and operating within the required temperature range.
All filler material located in holding ovens and in opened containers were correctly identified.
The receiving and storage area was inspected for identification of acceptable weld material and segregation of nonconforming material.
No items of noncompliance or deviations were identified.
7.
Instrumentation Cables and Terminations Unit 1 a.
Review of ualit Im lementin Procedures The quality assurance plan was r eviewed to determine whether plans, instructions, and procedures have been established relative to safety-related instrument cables and terminations.
The following Work Plan Procedures/Quality Control Instructions (WPP/QCIs) applicable to the installation, inspection, identification, separation, testing, termination, and handling of design changes of instrument cables were examined:
WPP/QCI 251.0
-
Raceway Installation WPP/QCI 254.0
-
Cable Installation WPP/QCI 254.2
-
-- Copper and Aluminum Sheathed Cable Installation WPP/QCI 254. 1
-
,Electrical Cable Repair WPP/QCI 255.0
-
Cable Terminations WPP/QCI 256.0
-
Insulation Resistance and 8i-Pot Testing II The listed'rocedures were reviewed '-in-detai'1 and found to be acceptable
- in their plans, instructions, ".and requirements for the installation,"'identification, separation, testing, and termination of instrument cable's.",
No items of noncompliance. or deviations~wer'e..identified.
b.
Review of'alit
.Records (:,
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A review of'.quality"records>of instrument cab'les and terminations was conducted."-
Eleven 'instrument cables'were selected; three in the engineered safetyfeatures system,'ive in the reactor trip system, and three,. in the. plant control system.
The following instrument cable records were examined
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Cable Install ation Cards Cable Termination Cards Cable Nonconformance/Deviation Records gA Audits for Installation of Cable Trays/Conduit and Cables.
The above records for the selected instrument cables were examined in detai l.
No items of noncompliance or deviations were identified.
8.
Electrical Cables and Terminations Unit 1 a ~
Observation of Work Activities The installations of ten electrical cables important to safety, five power and five control cables, were inspected and reviewed for conformance with the FSAR.
b.
The inspection areas for cable raceway installation included location, routing, separation, grounding/bounding, supports, and r aceway loading.
The cable installation was inspected for size and type of cable, terminations, work performance and adherence to the following procedures:
WPP/gCI 251.0 Raceway Installation WPP/gCI 254.0 Cable Installation WPP/gCI '255.'0>Cable Terminations
,
I pr While inspecting the installation of trays and cables, the following isolated di,screpancies were observed:
the terminal box cover was mis'sing"from the,di.ive ~motor of motor operated valve '1JSIAUV-635, three, aluminu'm'drink c'ans were <found, in a 'cable tray, and the cable'identification was missing from the'ower cable at Train B
LPSI pump motor.
Immediate action was taken by the licensee to correct these 'discrepancies.'o deviations or items of noncompliance were identified.
Review of ualit Records A review of the installation records and quality records for the above ten electrical ca6les,was conducted.
The following electrical cable records were examined:
Cable Installation Cards Cable Termination Cards Cable Nonconformance Records gA Audits for Installations of Cable Trays/Conduit and Cables The above records for the ten electrical cables were examined in detail.
No items of noncompliance or deviations were identified.
9.
Preservice Ins ection Baseline a ~
Preservice Ins ection Pro ram The inspector reviewed the licensee's preservice inspection (PSI)
plans and schedules for compliance with the requirements of the
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SAR and ASME Section XI, 1977 Edition through Summer 1978 Addenda.
CE is the prime contractor for the nondestructive examination (NDE) portion of the program.
CE subcontracts part of their NOE activities to NES.
The CE preservice inspection program for Units 1,
2 and 3 is described in Document No. TR-ESS-069, Rev. I of 2/1/80.
Volume 1 of this document describes the program plan and volume 2 contains -the NDE procedures.
The PSI program adequately described the number of;.items to be inspected, and the method and extent of the examinations.
The hydrostatic tests will be performed by Bechtel in accordance with Bechtel's ASME Section III quality assurance program.
.PSI-activities at Unit I is approximately 95K complete,'
Observation of. Work"A'ctivities - Unit 1 The inspectorobserved the follow'in'g volumetric and surface examinations for compliance,wi,th.,.the approved~ NDE:procedures and ASME Section XI requ,irement's (1)
Edd current~examination of. reacto'r", ressure vessel RPV c osure.'at.
nut'sY <', e approve eddy'urrent proce ure 9678-ISI-05
,was avai lab)e,'t'he work 'location.
NDE personnel appeared to'e knowledgeable of,the examination method and operation of the equipment.. lhe,following attributes were evaluated and found,,'to be'atisfactory by the inspector:
proper equipment, sensitivity, equipment calibration, method of examination (single amplitude), recalibration frequency, and acceptance criteria.
(2)
Ultrasonic examination of RPV closure heat nuts.
Ultrasonic examination was performed on the closure head nuts that were previously examined by the eddy current technique.
Attributes evaluated by the inspector were type of apparatus used, extent of coverage, scanning technique, calibration size and frequency of search units, beam angle, DAC current, transfer mechanisms, limits for evaluation and recording of indications, and determination of acceptance limits.
(3)
Automated ultrasonic examination of steam enerator sta p
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f the automated ultrasonic equipment.
Five transducers were utjlized durin~ this examina$ ion, two with beam angles at
, two at 60 and one at 0
.
In addition to the attributes evaluated as described in par agr aph b.(2), the inspector was satisfied that the following requirements were met:
program procedure is being followed, NOE personnel were familiar with the inspection system, test equipment permitted continuous observation of scanning pattern to achieve 100/ volumetric coverage, five DAC curves were generated for each of the transducers used, recording of data was continuous and meaningful, and couplant type (water).
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Demonstration of li uid enetr a t techni ue and ultrasoni examination on LPSI header loo 1A Preservice inspection activities of components and piping systems were not in process during this inspection.
However, CE demonstrated to the inspector, their LP and UT technique on previously inspected LPSI header loop 1A, Weld No. 01-076-024.
This demonstration was performed by NDE personnel knowledgeable and experienced in the NDE examinations and methods employed in Unit 1 PSI activities.
Attributes evaluated by the inspector observing surface examination using liquid penetrant technique are as follows:
examination consistent with LP procedure, penetrant materials analyzed for sulfur and halogen content, surface preparation, penetrant application, penetrant dwell time, removal of solvent, technique for evaluation of indications, and reporting of examination results.
Attributes of the UT examination were as described in paragraph b(2).
This demonstration revealed no reportable indications which is consistent with the PSI records the inspector reviewed.
c.
NOE Personnel ualifications The qualifications and certifications of each of the NDE persons involved in the NDE activities observed during this inspection were reviewed by the inspector.
This included the qualification records of SNT-TC-lA Levels I, II and III NOE individuals from both CE and NES.
The review revealed that these people were qualified to perform NOE activities for the 'flDE process (UT, PT, ET) of their.respective certification level.
The certification statements of the certifying Level III were on file.
Review of the vision test records,'indicated that the annual"visual acuity and color vision examinationare stil'1'alid.
I d.
Review of Preservice Ins ection'Procedures I
The inspector'reviewed.the fol,lowing" examination procedures for conformance'to,t5e
-'ASME Code, Section 'XI', 1977 Edition through Suraner 1978 Addenda",'ASME Co'de Section, and licensee committments:
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Procedure No.
'itTe't 9678-ISI-057 Procedure for the'reservice and Inservice Eddy Rev.
0 of Current Examination of Reactor Pressure Vessel 7/24/81 Nuts in Accordance with Section XI of the ASME Boiler and Pressure Vessel Code NIP 941 Rev.
1 of 6/11/80 Ultrasonic Ex'amination Procedure for RPV Closure Head Studs and Nuts
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-11-Procedure No.
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2 of 9/25/80 Automated Ultrasonic Examination Procedure for Steam Generator Stay Cylinder Welds NIP 955 Rev.
5 of 6/10/80 Ultrasonic Examination Procedure for Primary Coolant Pipe Circumferential, Longitudinal and Branch Pipe Nozzle Welds 525115-ESS-Liquid Penetrant Examination Procedure for Preservice 093 Rev.
0 of and Inservice Inspection 1/16/78 e.
~Re airs The inspector.examined the, records, of,.three welding repairs made as a result of,the pr'eservi'ce "inspection, to ascertain that the repairs were made under the licensee'
quality assurance program.
The PSI indications and the resulting repair welds wer e dispositioned on Bechtel NCR's, No.- PC-2177,'C-2092 and PC-2177.
The welding and NDE procedures used for the repairs were consistent with the original welding "and NDE; qequirements.
l'he inspector verified that the welder was qualified, on the date'he weld repair was made, and that subsequently NDE'as performed by certified personnel.
Review of the. radiographic report indicated that the repaired weld quality was acceptability.
Post-repair PSI data review showed no indications.
f.
Data Review and Evaluation (1)
Class
Com onents The inspector examined the UT records of three Class 1 components to ascertain whether the following documents were provided:
examination results and data sheets, examination equipment data, calibration data sheets, examination evaluation data, extent of. examination, disposition of findings and identification of NDE material.
Records were examined from the following areas:
(a)
Pressurizer Area Desi nation Area Descri tion 01-005-003 Lower Shell Longitudinal Weld at 90 (b)
Steam Generator No.
01-004-009 Out 1 et Nozzle-to-Head at 315
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Reactor Coolant Pum 01-SN2-004 Pump Casing Girth Weld (2)
Pressure Retainin Pi e'Welds The inspector examined the preservice inspection records of three piping systems to ascertain whether the following requirements were met:
initial and final calibration show no major deviations; examination data properly reported, evaluated and documented; evaluation of data performed by a Level II or Level III examiner; procedural compliance of evaluated data; evaluation of indications in compliance with NDE procedure and ASME Section XI requirements.
The following piping systems were examined:
(a)
Hot Le Steam Generator No.
1 to Reactor Vessel Area Desi nation Weld Descri tion Examination Method 01-006-010 Surge Nozzle-to-Safe End UT (b)
Loo 1B - Saf et In ection Line 01-024-022
"
12" Sch 160 Pipe-to-Elbow UT.
(c)
Main Feedwater Steam Generator No.
2 Inside Containment 01-055-045 24" Sch 80 Pipe-to-Valve UT, PT The inspector reviewed CE's records system utilized for maintaining evidence of PSI activities, The organization, filing, maintenance and ease of retrieving these records is satisfactory.
No items of noncompliance or deviations were identified for the preservice inspection activities examined.
10.
~Ei On October 9 and 30, 1981, the inspectors met with the licensee representatives identified in Paragraph 1 and summarized the scope and findings of the inspection as discussed in this repor J
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