IR 05000528/1985023

Insp Repts 50-528/85-23,50-529/85-24 & 50-530/85-18 on 850630-0806.No Violation or Deviation Noted.Major Areas Inspected:Observation of Work Re Electrical Cable Installation & Terminations in Unit 3

ML20137H595
Person / Time
Site:	Palo Verde
Issue date:	08/13/1985
From:	Ball J, Hernandez G, Miller L NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V)
To:
Shared Package
ML20137H588	List: IR 05000528/1985023 ML20137H585
References
50-528-85-23, 50-529-85-24, 50-530-85-18, NUDOCS 8508290300
Download: ML20137H595 (12)

Text

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U. S. NUCLEAR REGULATORY COMMISSION

REGION V

Report No /85-23, 50-529/85-24, and 50-530/85-18 Docket No , 50-529, and 50-530 License N NPF-41 Construction Permit Nos. CPPR-142 and 143 Licensee: Arizona Nuclear Power Project Post Office Box 52034 Phoenix, Arizona 85072-2034 ' Facility Name: Palo Verde Nuclear Generating Station Unit Nos. 1, 2, and Inspection Conducted Ju 3 - gust 6, 1985 Inspectors: b h G. f. IIernan .'Senic Resident Inspector Date Signed

 '$l[[v Eqs' OftGD inspector VW Dfte Signed J. l{f ' Bal
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Approved By: f/ L. F. (igler, Cly6f Da'te Signed Reactor Projects Section No. 2 Summary: Inspection from June 30 through August 6, 1985 (Report Nos. 50-528/85-23, 50-529/85-24 and 50-530/85-18).

Areas Inspected: A routine, onsite inspection by the Construction Resident Inspectors of activities related to licensee action on an NRC identified followup item, observation of work related to electrical cable installation and terminations in Unit No. 3, record review of electrical cable and termination in Unit No. 2, work activities related to pipe support and restraint systems in Unit No. 2, use of Superstrut material in cable trays, and closure of Allegation No. RV-85-A-00 The inspection involved 397 inspector hours onsite by two NRC Resident Inspector The following IE Manual Chapters were utilized during this inspection: Module Nos. 30703, 50090B, 51064B, 51065B, 51065, 70370B and 92706 Results: In the areas inspected, no deviations or violations of NRC requirements were identifie PDR ADOCK 05000528 G PDR

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  , DETAILS Persons Contacted Arizona Nuclear Power Project (ANPP)
 *E. E. Van Brunt, Jr., Executive Vice President D. B. Karner, Assistant Vice President, Nuclear Production
 *E. Ide, Corporate Quality Assurance Manager D. B. Fasnacht, Nuclear Construction Manager W. F. Quinn, Licensing Manager A. C. Rogers, Nuclear Engineering Manager
 *L. A. Souza, Assistant Corporate Quality Assurance Manger
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 *C. N. Russo, Quality Assurance Audits / Monitoring Manager D. E. Fowler, Quality Control Manager T. A. Shriver, Quality Systems Engineering Manager R. J. Burgess, Field Engineering Supervisor S. G. Penick, Quality Assurance Monitoring Supervisor J. C. Sherrin, Quality Document Review Group Supervisor A. T. Ramey, Quality System Supervisor K. R. Daley, Quality Assurance Engineer M. L. Provost, Quality Assurance Engineer W. W. Montefour, Quality Assurance Engineer D. M. LeBoeuf, Quality Assurance Engineer H. L. Green, Quality Assurance Engineer W. J. Gratza, Quality Assurance Engineer Bechtel Power Corporation (Bechtel)

W. J. Stubblefield, Project Manager

 .S. M. Nickell, Project Superintendent W. G. Bingham, Project Engineering Manager J. L. Black, Chief Resident Engineer
 *T. L.' Horst, Project Field Engineer
 *D R. Hawkinson, Project Quality Assurance Manager
 *H. A. Foster, Project Quality Control Engineer H. A. Hear, Assistant Project Quality Control I..gineer J. Waddington, Assistant Project Quality Control Engineer R. Ruff, Lead Electrical / Instrumentation Qualit y Control Engineer G. Griffin, Lead Civil Quality Control Engineer The Waldinger Corporation (TWC)

J. A. Ciminski, Project Manager R. R. Strait, Project Engineer D. J. Wheeler, Quality Assurance Manager D. R. Lanham, Quality Control Supervisor

* Denotes personnel attending the NRC Exit Management Meeting conducted on
. August 6, 198 The inspectors also talked with other licensee and contractor personnel during the course of the inspectio u

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2. Plant Status Unit Two: Unit 2 has a scheduled fuel load date of December 198 Construction completion of Unit 2 is estimated at 99.5% by the license Unit Three: All major components and equipment have been installe Construction completion of Unit 3 is estimated at 96% by the license . Licensee Action on NRC Identified Followup Item - Unit 1 (Closed) Followup Item No. 50-528/84-48-03, " Weld Inspector's Knowledge of Weld Symbols" During a pipe' support walkdown performed by the NRC and NRC consultants, a weldment was identified that was not in accordance with the design documents. The weldment was subsequently determined to be able to perform as intended, however the consultants subsequently raised the question of whether Quality Control Inspectors were accurately interpreting weld symbols as shown on design drawing The licensee, in order to resolve this question, interviewed eight Bechtel Welding Quality Control Engineers on December 4, 1984, to determine their knowledge and understanding of AWS weld symbols. The individuals were found to be very knowledgeable regarding AWS weld symbols. Additionally,' on December 6,1984, eighteen Quality Control Engineers were given a weld symbol test to assure that all weld > inspectors were consistently interpre*.ing the symbols correctly. The - test indicated that all weld inspectors were knowledgeable, and consistently interpreting the standard AWS weld symbols and the symbols as detailed on the Bechtel design documents. Subsequently, the Project Quality Control Engineer made the weld symbol test mandatory for all Welding Quality Control Engineers on sit Based on the results of the tests, the licensee believes that they have taken sufficient action to assure that all weld inspectors interpret drawing requirements consittently. Additionally, the weld inspectors have been instructed that any questions regarding weld symbols interpretation should be brought to the attention of the cognizant welding enginee Based on examination of the tests results, the test material, and a review of the training record conducted on weld symbology, the inspector considers this item close F

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4. Electrical Cables and Terminations - Unit No. 3 Observation of Work and Work Activities The inspector selected in process electrical cable installation . activities in Unit No. 3 to observe installation and inspection ' activities relative to Class IE cable pulls and cable termination activities. 'For the cable pull, the inspector examined each of the cable

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runs to ascertain compliance with applicable design criteria relative to size, type,- location, routing, bend radii, protection, separation, identification and support. For the terminations, the inspector examined both in process and completed terminations using applicable design and installation documents, for such items as lug size and type, proper termination, proper termination point, configuration, correct identification of cable and conductors, proper crimping of lugs or connectors, the absence of insulation or jacket damage, and correct performance of nondestructive tests (continuity, high potential, etc): Cable Pulls Cables Location Conduits

 . 3EPE01BCICA Diesel Generator high voltage 3EZJ1BBRC11 cabinet to 4160 V Switchgear to 3EPBBSO4B
 . 3EAF01BCICA Auxiliary Bldg. to Control Bld EZJ1BBTCAB from Auxiliary Feedwater Pump B 3EZJ1BBTCAA 3EZAIDBTCAA 3EZAIDBTCAB 3EZAIDBTCAC 3EZAIDBTCAD 3EZAIDBTCAE
 . 3EPE02BCICB Diesel Generator high voltage 3EZG1ABRC12 cabinet via embedded conduit Terminations Cable Number  , Location
 . 3ERCBOAC1XA2  Penetration No. 3ESAAZ471
 . 3ESG63DC1XA2  Penetration No. 3EZFDZ77I
 . 3EAF01BCICA2  Auxiliary Feedwater Pump B No deviations or violations were identifie Corrective Action The inspector also examined five nonconformance reports to determine whether procedures were being followed relative to identification, evaluation and disposition of deficiencies identified during the installation of electrical components. The following Nonconformance Reports were reviewed, EC-6168, EC-6146, EC-6167, EJ-6236, and
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EJ-5893.=JAll reports were found to be documented,; evaluated an dispositioned _in accordance with :the licensee's procedures,

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f ' No devi5tions' or violations were identifie' >-

    . . .~ ; . As-Built / Final Design Electrical 'Insta11ations Drawings     i Six as-built / final-design electrical installation drawings.were

_g . selected and compared.to the actual installation. The installations

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.. s  were found to conform.to the drawings, the documents'were found-Lg "

_ to be properly controlled in accordance with' licensee's procedures

   .  .and any. changes were found to be. supported by' engineering. review,s Lapproval,~ including as necessary supporting calculations. . Th'e'
 -#     following installations were examined:
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Raceway ~ Identification Design Document

3EZAZCNTFAK FCR 93204-E

.~       3EZAZCNTKAK     FCR 93206-E
   ' ~    '3EZAZCNTRCK-      7

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3EZAZCNTFAL- ?CR 93204-E 3EZAZCNTKAL FCR'93206-E 3EZAZCNTRCL

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3EZAZCNTFAJ FCR 93038-E FCR 93204-E

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3EZAZCNTXCJ

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      '.3EZJZANTRAP  ,
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3EZAZDBKXJ04 ~FCR 65825-E

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3EZAIDARR18 SKETCH 3-A-18-09-R

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No violations or4 deviations were identifie ElectricalCable'andTerbinationsReviewofQualityRecords-Unit 2;,

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    : . Areas Reviewed:      ,
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1The inspector rev'iewed receiving inspection documentation for.5 KV p power cable, 600 V_ power cable and 600:V instrumentation and control L* Lcable. The inspector also reviewed receiving inspection

     ~ documentation for cable termination material. Installation and'
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  - verification' test records'for the 30 cables and associated terminations. listed in Table A were examined including cable pull cards,. termination cards.. insulation resistance and DC Hi-Pot test
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record . TABLE A

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CABLE NUMBER- DESCRIPTION

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2ESIO1ACICA "5KV Power to HPSI Pump A

  ' 2ESIO1BCICA  5KV Power to HPSI Pump B 2ESIO2ACICA  5KV Power to LPSI Pump A 2ESIO2BCIC SKV Power.to'LPSI Pump B
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2ESIO3ACICA ~SKV Power.to Containment Spray Pump A 2ESIO3BCICA , SKV Power to Containment Spray Pump B

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2EAF03BCICA

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    . SKV Power to Auxiliary Feedwater Pump
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. t a , 2EPE01ACICA/CB/CC " SKV Power- from DG to 4160 V Switchgear (' 2EPE01BCICA/CB/CC. ,5KV Power from DC to 4160 V Switchgear *

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2EPH01ACIFA, - 480qV. Power to 480 V Motor Control Center

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2EEC03AC1KA 480 V Power to' Essential Chilled Water. Pump A 2EEC03BC1KA' , 480 V Pow'er to= Essential Chilled Water Pump B

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IESIO5AC1KB 480 V' Power to SI Tank Isolation Valve 2JSIA-UV-634

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2ESIO5AC2KB 480 V Power to SI Tank Isolation Valve

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2JSIA-UV-644

  :2ESIO6BC1KB  480 V Power-to SI. Tank Isolation Valve'
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2JSIA-UV-614 2ESIO6BC2KB 480 V Power to.SI Tank Isolation Valve 2JSIA-UV-624 2ESIO5AC1RE ~ Low Voltage. Control to SI Tank Isolation Valve 2JSIA-UV-634 2ESIO5AC2RE Low Voltage Control to SI. Tank Isolation

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Valve 2JSIA-UV-644 2ESIO6BCIRE Low Voltage Control to SI. Tank Isolation Valve 2JSIA-UV-614

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2ESIO6BC2RE Low Voltage Control to SI Tank Isolation

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Valve 2JSIA-UV-624 12EPK01ACIFA DC Power from Battery "A" to Positive. Terminal 2EPK01ACIFB fDC Power'from Battery "A" to Negative Terminal-

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2EPK01ACIFC DC Power from Battery "A" Rack Interconnection

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2EPK01BC1FA _DC Power from Battery "B" to Positive Terminal 2EPK01BC1F DC Power from Battery "B" to Negative Terminal

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  ~2EPK01BC1FC  DC Power from Battery "B" Rack Interconnection
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     .The" records were reviewed to determine whether they reflect.that

_ _ items were-installed in accordance with specification requirements using proper materials and. that required inspections were properly performed recorded, reviewed and evaluated by qualified personne : The inspector evaluated the licensee's handling of nonconformances !. ,

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or deviations related to cables, terminations and' cable system

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installations by reviewing 20 nonconformance reports. - The inspector

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     =also looked at.five design'and field changes. Audits performed by the' licensee'and the licensee's contractor were reviewed asiwel ~
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No deviations or violations'were identifie ,

    -b.' Ap'plicable Specifications and Procedures       ^
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lThe following specifications"and Work' Plan Procedures / Quality

 . Control Procedures.(WPP/QCIs) governing the installation of
    ^ . electrical cables were utilized during this inspection:
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     . ' 13-EM-300, '

Installation Specification for Electrical Cables .:Ln

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       -Cable Trays
     -. -. 13-EM-301,  Installation Specification for Electrical Cables
       ~in Cond' tit and Duct Banks
     . 13-EM-306,  Installction Specification for" Cable Splicing

 ;       Terminations and Supports
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     .: WPP/QCI 254.0; Cable Installations:
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     ' . WPP/QC1.255.0, Cable Installations

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     . WPP/QCI 256.0, Insulation Resistance and Hi-Pot Testing
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     .. 93EG-0ZZ01,Conbrol'andIPowerCableInstallation
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       , fVerification--
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     'The following!materiallspecifica'tibus~were also reviewed:
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     . ,' 13-EM-029 Quality, Class'"Q" 5 and 15 KV Power Cable
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     . ' ~13-EM-057 ' Quality Class".'Q" 600 V Copper Control Cabl '.
     .- 13-EM-058 Quality' Class "Q" 600 V Copper Control Cable
     .. 13-EM-1061Qu'ality Class "Q" Cable Terminating Material
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c.; Findings n, %

- ' _The inspector observed that ' cable'. pulling tension calculations

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     . performed--by field engineering did lnot appear to be handled in the
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     (same manner as other records'related to the' installation of cable, in that they were.found to be temporarily stored in fire proof
  ,   . cabinets.withinthe. contractor field offices. Specification l      13-EM-301fInstalla' tion Specification for Electrical Cables in Conduite and Duct Banks required that calculations be performed for
,     certain cable pulling operations to assure maximum allowable' cable
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tension was not' exceeded. On the basis of these calculations the-

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field engineer determined whether the pull could be made as planned _ :or if a tension monitcring device had~to~be used during the cable

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_ WPP/QCI 2'5410. Cable" Installation required _that the assigned cable l: pull calculation number and. maximum allowable: tension, as determined K,

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by'the calculation, be recorded =on the cable installation recor ; ,' ,

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c maintained for the life of the plant. The inspector inquired as.to

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the licensee's intention with regard to maintaining the calculation

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   <  ~ records. The licensee informed the inspector.that the calculation
    - records'would be maintained as permanent records,'and provisions
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     .would be made for' transfer of the records.from the contractor field e     -_ offices to a more permanent f acility. -
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'. The inspector also investigated ~the manner in which these calculations were performed. The inspector reviewed a small sample
#:      .of calculations to determine if the calculations were receiving-the 4      proper review prior to use. ,The inspector'found that the records indicated that the calculations had been verified by an individual <

other than the'one performingLt he calculation. However, the

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     -licensee ^ stated that these calculations were considered to be an aid
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to construction calculations, and not~ design calculations.. The (inspector intends;to perform a more in' depth review of the calculated method used, and determine whether'these calculations should'be considered more-than aid to construction calculations-

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during a further inspection. -(Followup, item 50-529/85-24-01)

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No violations.or' deviations were' identifie W ,

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   , Safety-Related Pipe Supports and Restraints --Observation of Work
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and Work Activities - Unit 2 4 - Areas Examined:' L-L- ,

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    : The'inspectoi examined 20 dynamic pipe support installations in Unit'2 prior to and enbsequent'to the start of Hot Functional Testing. The       ,

supports examined are listed in' Table +. t f . 4 -

         ~ TABLE 1
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Steam Generator'#1 Main Feedwater Line

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2SG-002-H004 , Q' 2SG-002-H006 ,

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    'SteamGenerator#1DowncommedFeedwaterLine      :2SG-008-H003
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2SG-008-H020;

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Steam Generator'#2 Blowdown Line 2SG-048-H003 > i, '

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Steam Supp'ly Lines to Auxiliary,Feedwater Pump Turbine 2SG-082-H002 2SG-082-H003

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2SG-082-H011 2AF-030-H001 2AF-030-H004 Reactor Coolant System Charging Line 2CH-005-H0AA 2CH-005-H006 2CH-005-H010 2CH-005-H026 2CH-005-H041 The inspector visually examined the installations to determine that:

. Components were free from corrosion or other signs of deterioratio . Connecting joints, moving parts, piston shaf ts, etc. were free f rom foreign materials that might obstruct proper operatio . Support plates, extension rods and connecting joints were not bent, deformed or loos .. All bolts, nuts, washers, locking devices, and fasteners were tight
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and secur . The snubber was~the specified size and stroke length and was properly oriente . The support was properly located in accordance with drawings relative to piping, and no interferences appeared to exist which would restrict pipe or snubber movemen The inspector observed the supports in both cold and hot positions to determine if the initial cold piston setting and snubber stroke length provided for the associated design movements (with the resulting hot piston position neither overextending nor compressing the snubber).

The inspector also reviewed the licensee's snubber preservice examination records for accuracy and completenes The following specifications and procedures were referred to during this inspection:

. 13-PM-204 Specification for Field Fabrication and Installation of Nuclear Piping System
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. WPP/QCI 201.1 Nuclear Pipe Hangers'and Supports' Installation
. 73TI-9ZZO3 Snubber.Preservice Examination Procedure
. 91HF-2ZZ08 BOP Piping Thermal Expansion Test No violations or deviations were identifie %

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. 9 7. Allegation No. RV-85-A-006 (Closed)

Background In NRC Inspection Report No. 50-528/85-17 the staff determined the only remaining safety related issues related to this allegation concerned whether persons knowingly falsified HVAC pressure tests referenced by the alleger and whether other allegations made concerning Bechtel personnel impacted on plant safety. These two issues are addressed belo Falsification of HVAC pressure tests Examination of the referenced tests indicated that the tests had been properly performed. However, the inspector noted that one of the pressure tests referenced by the alleger does not exist. The alleger had referenced test Nos. CP01, CP02 and HA01. Pressure test No. CP02 does not exis The alleger had also provided the name of an individual who was alleged to have tampered with the pressure tests in order to assure that the HVAC system passed test requirements. This individual was placed under oath by an investigator of the Office of Investigations and questioned regarding the alleged' tampering. The individual denied any wrongdoing, and indicated that it would not be in his company's interest to tamper with the pressure test, because an independent contractor has responsibility for assuring that the HVAC system can be balanced as required by design. Any discrepancies found with the HVAC system would immediately be turned back to his company for correction, thus reflecting on his company's product. ~ The inspector's review of documentation by the

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independent contractor who performed the final flow balance for the HVAC system indicated that the HVAC for Unit I was balanced as required by design. Units 2 and 3 HVAC systems had not been balanced ye Based'on the interview of'the named individual, the review of the

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pressure tests, and the fact that final test of the system is conducted by an independent contractor, the inspector considered that this allegation was not substantiated, and is close Other Allegations * The inspector revi'eved the report issued by the Bechtel internal audit

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team examining other allegations made by the alleger, and determined that only one of.the individuals named by the alleger had any responsibility over safety related work performed by the contractor involved. However, the Bechtel internal audit found no improprieties with the conduct of this individua The inspector concluded that the other allegations were outside NRC's purview, and did not have any apparent impact on plant safety. This allegation is considered closed.

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.8. Use of Superstrut Material in Cable Tray Supports As a consequence of allegations in 1982 regarding the quality of welding and materials on superstrut material, the Region IV Vendor Program Branch (VPB) conducted an inspection of the Midland-Ross Superstrut manufacturing facility during December 6 - 8, 1982. The VPB inspector found that materials supplied by Midland-Ross prior to 1980 may not be adequate for use in seismic Category I structures due to lack of quality assurance procedures in material procurement, manufacturing and fabrication of the Superstrut materials. Superstrut materials have been used in the' construction of Class IE raceway supports at Palo Verde. In December of 1979 while the licensee craft were assembling a raceway support, a vendor weld on a piece of back-to-back spot welded channel separated. NCR EX-342 was initiated to document this occurrence. As a result of this event, the licensee instituted a program to investigate the quality of welded channel supplied by both Superstrut And Unistru This program included an analysis of installed strut material consisting of both destructive and nondestructive testing and review of vendor test records of all previously supplied material. The licensee concluded that the material being supplied was adequate and that additional testing on site was not necessary. The 1icensee did, however, instruct all
  ~

electrical personnel to maintain an awareness of failure of the vendor spot welds and to report any future occurrence The inspector considers the licensee's actions to be appropriate wit regard to the identified nonconformance and alleged concerns. This issue is considered close No violations or deviations were identifie . Inspection Tour Weekly, the inspector and licensee representatives toured the site to observe general housekeeping conditions, care and preservation of equipment, handling of components, tagging and identification of material. During a tour of the Unit 3 Control Room, the inspector observed a number of small clamps used to support small electrical conduits (approximately one inch conduit) that contain safety related cables. The clamps were apparently used for support and maintaining separation criteria requirements. These clamps were also found in the control room panels for Units I and The inspector questioned whether the clamps were seismically qualified in this application, since they were held in place by a screw that bore on the supporting structur Discussion with licensee personnel indicated that the clamps appeared to be part of the vendor supplied equipment for the control room panel . Licensee personnel stated that they would contact the vendor of the panels to provide assurance that his clamps had been seismically qualifie Generally, a vendor had initially qualified each of the panels and all vendor installed equipment inside the panels to assure that the panel can perform as designed during a seismic even This item is considered unresolved pending review of the vendor supplied documentation (Unresolved Item No. 50-530/85-18/01) f

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,c  ~ 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. An unresolved item disclosed during the  inspection is discussed in Paragraph .
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as . 1 Exit Interview The NRC inspectors met on' August 6, 1985, with the licensee managemen representatives denoted in paragraph 1. .The scope of.the. inspection and

   ' inspection findings ~as noted in this report were discusse k
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