IR 05000528/1982002
| ML20041C822 | |
| Person / Time | |
|---|---|
| Site: | Palo Verde  |
| Issue date: | 02/10/1982 |
| From: | Bishop T, Burdoin J, Eckhardt J, Hernandez G NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V) |
| To: | |
| Shared Package | |
| ML20041C789 | List: |
| References | |
| 50-528-82-02, 50-528-82-2, 50-529-82-01, 50-529-82-1, 50-530-82-01, 50-530-82-1, NUDOCS 8203020586 | |
| Download: ML20041C822 (9) | |
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U. S. NUCLEAR REGULATORY COMMISSION
REGION V
50-528/82-02 50-529/82-01 P. port No.
50-530/82-01 CPPR-141, -142, Docket No. 50-528, 50-529, 50-530 License No.
-143 Safeguards Group Licensee:
Arizona Public Service Company P. O. Box 21666 Phoenix, Arizona 85036 Facility Name:
Palo Verde Nuclear Generating Station - Units 1, 2. and 3 Inspection at:
Palo Verde Construction Site, Wintersburg, Arizona
Inspection conducted:
January 25-29, 1982
[
J//d/82 Inspectors:
e H. Eckhardt, Reactor Inspector Oat 6 Signed h
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)Y obt 67//p/g2 F. Burdoin, Reactor Insp'ector
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[ l / $ / u 4 tlW d2/ta/bg-G ernandez,ReactojInspector-Date Signed j
Approved by:
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T. W. Bishop, Chi 8f, Reactor Projects.Section_1 Date Signed Summary:
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Inspection on January 25-29, 1982 (Report Nos. 50-528/82-02,-50-529/82-01, and 50-530/82-01)
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Areas Inspected:
Routine, unannounced inspection by regional based inspectors of activities associated with licensee action on previous inspection findings, Unit 1 instrumentation cable installation, Unit I structural steel welding nondestructive examination, Unit 1 as-built configuration, and Unit 3 structural steel installation.
The inspection involved 90 inspector hours on-site by three NRC inspectors.
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Results:
One item of noncompliance was identified in the area of structural steel welding (paragraph 5).
RV Form 219(2)
8203020586 820211 PDR ADOCK 05000528 PDR
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DETAILS 1.
Persons Contacted a.
Arizona Public Service Company (APS)
- E. E. Van Brunt, Jr., Vice President, Nuclear Projects Management
- J. A. Roedel, Corporate QA Manager
- D. B. Fasnacht, Nuclear Construction Manager
- A Carter Rogers, Nuclear Engineering Manager
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- W. E. Ide, Site QA Supervisor
- B. S. Kaplan, Quality Systems Supervisor L. Souza, QA Engineer R. Forrester, QA Engineer P. J. Moore, QA Engineer D. Wittas, QA Engineer b.
Bechtel Power Corporation (Eachtel)
S. M. Nickell, Project Superintendent A. K. Priest, Project Field Engineer W. G. Bingham, Project Engineer
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- D. R. Hawkinson, Project QA Supervisor
- R. M. Grant, Project QC Supervisor R. Roehn, QA Engineer M. A Rosen, Assistant Project QC Engineer M. E. Williams, Discipline Field Civil Engineer P. M. Snider, Discipline Field Civil Engineer G. l Grover, Area Field Civil Engineer
- Denotes those attending exit meeting.
2.
Licensee Action on Previous Inspection Findings i
The inspector examined the action taken by the licensee on the following items:
(Closed) Noncompliance (50-528/81-12/01 and 50-529/81-10/01)
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a.
Access control to fuel pool areas The licensee's written response (December 14, 1982) to the item of noncompliance was reviewed and is considered satisfactory.
The specified corrective action included revising Bechtel WPP/QCI-13.0, " Housekeeping," to more clearly define the control and implementation requirements-of cleanliness zones
for both personnel and materials.
In addition to reviewing this revised procedure, the inspector reexamined the access controls to both the' Unit 1 and Unit 2 fuel pool areas and found the controls to be in accordance with the revised procedure. This item is considered closed.
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-2-b.
(Closed) Noncompliance (50-529/81-10/02) Moisture control for low hydrogen welding electrodes The licensee's corrective action included adding a new paragraph to Bechtel WPP/QCI-100.0, " Weld Filler Material Control,"
emphasizing that the "... filler material holding ovens are to be used for welding electrodes only..." and "...it is strictly forbidden to place foreign objects such as food or liquid items, etc. in the holding ovens." Bechtel also issued a memo to this affect to all rod room attendants.
To verify that surveillances in this area are being performed, the inspector reviewed three APS and six Bechtel QA surveillance reports of weld rod rooms. No similar problems were identified, and the inspector is satisfied that the licensee's corrective action has been effective. This item is closed.
c.
(Closed) Noncompliance (50-529/81-10/03) Structural steel bolting The licensee's corrective action included reinspection of the entire Unit 2 containment elevation 149' platform. The bolting discrepancies identified in IE Inspection Report No. 50-529/81-10 and Bechtel's reinspection were documented on Nonconformance Report Numbers CC-2837 and CC-2840, respectively, and have been corrected. The inspector reexamined the Unit 2 platform at elevation 149', verified that the items had been corrected, and did not identify any additional problems. The inspector also examined the Unit 1 platform at elevation-149' and did not identify any bolting problems. Additional corrective action specified by the licensee included inspection of the remaining accessible platforms in Unit 2 containment. The inspector reviewed records of these inspections. QC Engineers involved in structural steel inspections were given one hour of refresher training in WPP/QCI-58.0, " Erection of Structural and Miscellaneous Steel" and the AISC Standard bolting requirements.
This was documented on a Training Session Report dated September 1, 1981. The inspector also reviewed ten Bechtel QA surveillance reports of surveillances performed during the last few months for structural steel bolting.
Based on the. verification of the licensee's corrective action and examination of bolting for Unit 3 structural steel during this inspection, as dis-cussed in paragraph 6 this item is considered closed.
3.
Instrumentation Cables 'and Terminations - Unit 1 a.
Observation of Work Activities The installations of 15 safety related instrument cables from the oh nt protection systems and plant control system, were
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-3-inspected and reviewed for conformance with the FSAR and the following procedures:
(1) WPP/QCI-251.0, " Raceway Installation" (2) WPP/QCI-254.0, " Cable Installation"
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.(3) WPP/QCI-255.0, " Cable Terminations" The inspection of cable raceway installation included examina-tion of location, routing, separation, identification, grounding, supports, and raceway loading.
The cable installation was inspected for storage, handling, identification, size and type of cable, terminations, and work performance.
No items of noncompliance or deviations were identified.
b.
Review of Quality Records A detailed review of the installation records and quality records for six of the above instrument cables was performed.
The cable records included cable installation cards, cable termination cards, and cable nonconformance records.
No items of noncompliance or deviations were identified.
4.
NDE for Structural Steel and Equipment Support Welds - Unit 1 A review of performance and quality records for nondestructive examination (NDE) of nine structural steel welds and nine equipment support welds was conducted to determine compliance with the following applicable procedures:
WPP/QCI-102.0, " Nondestructive. Examination Control" Specification 13-MM-501A, " Technical Specification for Field Nondestructive Examination" Drawing No.13-C-00A-050, " Welding and Nondestructive Testing Requirements" The review included three containment liner welds that had been examined by the radiographic process, and six welds (three in containment and three in the auxiliary building) that had been tested by the liquid penetrant process.
Six structural steel welds (three in the auxiliary building and three in the control building) and three equipment support welds in the control building required only visual examination.
Consequently, no NDE process was utilized on these welds.
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The NDE records and weld records for the above identified welds were reviewed for accuracy, thoroughness, legibility, and complete-ness.
Twelve welds (six in the control building and six in the auxiliary building) were visually examined.
No items of noncompliance or deviations were identified.
5.
Review of As-Builts a.
Review of Quality Assurance Implementing Procedures The inspector reviewed the site-specific Bechtel procedures governing the generation and completion of as-built design documents. The procedures were reviewed to determine the method used to ensure that design documents accurately reflect the as-built condition of the plant, and how changes from the original design are reviewed and approved and incorporated into the design. The following sections from the Palo Verde Bechtel Internal Procedures Manual were reviewed:
(1)
Internal Procedure 4.20, Revision 12, " Design Calculations" (2)
Internal Procedure 4.27, Revision 1, " Engineering Design Change Control Program" (3)
Internal Procedure 4.33, Revision 4, "As-Built Records" (4)
Internal Procedure 4.34, Revision 7, " Design Change Package" (5)
Internal Procedure 4.37, Revision 0, " Final Design Verification for Safety-Related Piping Systems" The licensee at the present time is verifying as-built conditions for all safety related systems and expects to complete this verification prior to fuel load.
No items of noncompliance or deviations were identified.
b.
Observation of Work and Work Activities - Unit 1 Representative final design documents were selected and compared with the actual installation to determine whether the final design documents reflected as-built conditions for each of the items indicated below.
(1) Piping Systems For each of the selected piping runs, the inspector verified that the type, configuration, size, and location
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-5-for the pipe spools, valves, and pipe supports were as indicated in the design drawings. The following safety related piping runs were examined:
System Isometric Drawing Hanger Drawing Chemical &
13-P-CHF-212 13-CH-166-H001 Volume Control 13-CH-166-H002 13-CH-166-H003 13-CH-166-H004 Chilled Water 13-P-ECF-302-13-EC-070-H00A System 13-EC-070-H008 13-EC-070-H00E 13-EC-070-H00F MSSS Downcomer 13-P-SQF-156 13-SG-200-H006 Feedwater 13-SG-200-H007 13-SG-200-H008 13-SG-200-H010 Safety Injection 13-P-SIF-202 13-SI-033-H001 System 13-SI-033-H002 13-SI-033-H003
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13-SI-033-H004 All items examined were found to conform to the design documents.
No items of noncompliance or deviations were identified.
(2) Electrical Raceways and Conduit Runs At the 100' elevation of the Unit 1 auxiliary building, the inspector selected sections of electrical raceway and conduit runs to verify the as-installed condition with design documents. The raceways and conduits were also examined for compliance with site procedures and industry standards relative to routing, identification, protection /
isolation, and separation requirements.
The following raceways and conduit runs were examined:
Drawing Nos.
Conduit Nos.
Electrical Raceway Nos.
13-E-ZAC-017 IEZA1CARG07 IEZA1CATKAC 13-E-ZAC-036 1EZA1CARG09 1EZAICATKAD 13-E-ZAC-043 1EZA1CARG12 1EZAICATKAE 13-E-ZAC-047 IEZAICARG13 13EZAC048 All electrical raceways and conduit runs examined conformed to the design documents.
No items of noncompliance or deviations were identified.
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-6-(3) Structural Steel Assemblies Inside of Unit 1 containment, two Seismic Category I structural steel assemblies were selected and compared to the as-built design documents.
The first assembly examined, located just above the northside steam generator at the 168' elevation and identified on drawing No.13-C-ZCS-652, was found to conform to the design documents.
The second assembly, located at the 149' elevation and identified on area drawing No.13-C-ZCS-650, was found to have three columns which did not conform to the weld detail as specified in Section G of drawing No.13-C-ZCS-655.
Section G of the weld detail specifies 1/2" fillet welds on the outside of the column flange to base plate intersec-tion. Three columns were found to lack the required welds. The discrepant structural steel columns were fabricated, inspected, and accepted in Marathon Steel Company's shop prior to shipment to the site.
The failure to fabricate structural steel beams in accordance with prescribed drawings is considered an apparent item of noncompliance with 10 CFR 50, Appendix B, Criterion V,
" Instructions, Procedures, and Drawings."
(50-528/82-02/01)
Upon notification of the above discrepancies, the licensee immediately issued Nonconformance Report No. C-C-3186 to effect corrective action.
6.
Structural Steel Installation - Unit 3 a.
Observation of Work Activities Unit 3 structural steel installation was examined to ascertain compliance with the following procedures:
(1) WPP/QCI-58.0, Rev.11, " Erection of Structural and Miscellaneous Steel" (2) WPP/QCI-101.2, Rev. 6, " Stud Welding" (3) AWS D1.1-72, " Structural Welding Code" (4) Specification No.13-CM-320, " Installation Specification for Erection of Structural and Miscellaneous Steel" (5) AISC Standard
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-7-The following work was examined:
(1) Auxiliary building elevation 120', areas A2A, A2B, A2C, and A2D. The inspector observed in-process welding, weld electrode control, in-process bolting, and rigging of structural steel into place; and examined completed bolting, fillet welds, and stud welds. The configuration was compared with Bechtel drawings 13-CZAS-530, 531, 532, and 533.
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(2) LPSI pump support in room A-C15 of the auxiliary building -
examination of completed welds and bolting.
(3) Control building elevation 140',153', and 160' - examination of completed welds and bolting.
(4) Control building elevation 120' - cable tray supports.
The inspector examined welds and bolting for partially completed structural steel to support cable trays. The configuration and details.were compared with Bechtel drawings 13-E-ZAC-053 and 13-E-ZJC-042.
(5) Containment building, platform at elevation 92' - examination of completed welds and bolting.
(6) Containment building elevation 120' areas C2B and C2D.
The inspector examined partially completed structural steel for the lateral support of the top of two safety injection tanks.
The configuration was compared with Bechtel drawings 13-C-ZCS-532 and 533.
(7) Containment building elevation 140' areas C3B and C3D.
The inspector examined partially completed structural steel installation including welding and bolting.
The configuration was compared with Bechtel drawings 13-C-ZCS-534 and 535.
In addition, the inspector observed the rigging into place of a reactor vessel pedestal.
Three pedestals had previously been placed and were adequately protected.
No deviations or items of noncompliance were identified.
b.
Review of Quality Records Quality records of six structural steel beams (supplied by Marathon Steel Company) were examined to determine that the material is as specified by the designer.
During inspection of the Unit 3 structural steel laydown area, the inspector
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-8-selected structural steel members QM31ZJS-530-6721, QM15ZJS-530-6721, QM3ZJS-530-6721, QM7ZJS-530-6721, X6711-88-Load 920, and X6711-88-Load 921.
The\\ first four of these beams are to be installed in the auxiliary building (120' elevation) and the last two'in the diesel generator building. The inspector reviewed applicable Bechtel drawings 13-C-ZJS-538,13-C-ZJS-552, and 13-C-ZGS-500, which specified the' material.to be A36 ca-bon steel.
Applicable purchase orders 10407-13-CM-131 and 19; were reviewed, and they also.specified A36 material. The inspector then examined the receipt inspection documents for the beams. The material certifications were reviewed and the physical and chemical properties were within the limits specified in ASTM A-36.
No deviations or items of noncompliance were identified.
7.
Exit Meeting On January 29, 1982, the inspectors met with the licensee representative identified in paragraph 1 and summarized the scope of the inspection
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activities and reviewed the inspection findings, as described in
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